Still STED forklift Tow tractor LTX70 LTX80 LTX-T08 Workshop Manual

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Workshop literature

Tow tractor LTX70 LTX80 LTX-T08

(€ oeo8 0509 0610 0688 0689 0590

11918012101 EN - 09/2019

first in intralogistics

History of changes

Edition 11/2014 First edition

Edition 11/2015 Chapter 11: Replacing the rear axle added Chapter 11: Replacing the traction motor bearing added Chapter 23: Replacing the transmission seal Chapter 30: Changing the seat contact Chapter 30: Replacing the windscreen wiper motor Chapter 30: Replacing the windscreen Chapter 50: Changing the accelerator Chapter 50: Replacing the front brake drum Chapter 50: Replacing the front brake assembly Chapter 50: Blue-Q option added Chapter 60: Changing the fan Chapter 60: Replacing the ABE 2 display Chapter 60: FleetManager option added

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Chapter 60: On-board charger option added Chapter 60: Opportunity charging option added Chapter 60: Electric coupling option added Chapter 60: Liftrunner option added Chapter 90: Heating option added

Edition 11/2016 Chapter 00: Safety guidelines added Chapter 01: Service plans added Chapter 42: Addition of the functional diagram for the brake circuit Chapter 60: Addition of Liftrunner characteristics Chapter 60: Addition of the location of Liftrunner components

Edition 09/2019 Addition of the new type carriers

11918012101 EN - 09/2019

I

Table of contents

00 Product information Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 -1 Technical description

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

Safety guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-2 Slinging the tow tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-2 Jacking the tow tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-4

01 Service Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 -1 1000-hour maintenance schedule

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 -1

3000-hour/two-year maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 -1

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 -3 Standardised tightening torques for standard-pitch threads and fine-pitch threads . . . . 01 -3 Measuring and testing equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 -4

02 Diagnostic Diagnostic tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02 -1 STEDS-Navigator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02 -1

Truck diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-2 CAN box diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-5 Connecting a laptop to the USB CAN Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02 -6 CAN bus network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02 -7

Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02 -9 Reading and deleting the error list TRACTION fault codes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02 -9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-11

11 Motor Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -1 Shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -3 Cleaning and checking the gearbox breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -4 Replacing the rear axle

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -5

Traction motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -10 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -10 Replacing the bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -10

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III

Table of contents Checking the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -12 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 -12

Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 -12

Traction motor winding test

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -12

Rotor testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the motor

11 -12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -13

Motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -14 Location of motor cables

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -14

Power module connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 -14

Motor sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 -15 Rev sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 -15

Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 -17

23 Transmission Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1 Replacing the transmission seal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1

30 Chassis, bodywork and fittings Driver's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1 Changing the seat contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30-1

Driver's cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2 Replacing the windscreen wiper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30-2

Replacing the windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30-4

Battery compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5 Installing and adjusting the battery door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30-5

42 Steering, braking and wheels Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-1 Steering angle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering column

42-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-2

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-3 Functional diagram of the brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42-3

50 Control devices Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1

IV

Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50-1

Changing the accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50-3

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Table of contents Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 -5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 -5 Electrical braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 -6 Electromagnetic brake Y1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 -6 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 -8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 -9 Hydraulic brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 -9 Hydraulic braking

Brake drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10 Replacing the front brake drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11 Replacing the front brake assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-14

Blue-Qmode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-18 Energy-saving mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-18 Parameterising Blue-Q mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-19

60 Electrics/electronics General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 -1 Safety guidelines for electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 -1 Cleaning the electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 -2 Insulation testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 -4 Electromagnetic compatibility

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

Traction controller 1A 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 -6 LAC traction controller (1A 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 -6 Functions of the "Inputs/Outputs" of the LAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 -8

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10 Changing the fan

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-12

Electric components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-13 Emergency off switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-13 Voltage converter U1 (75 W)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-14

Voltage converter U2 (500 W)

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

Main fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-16 Line switch 1 KO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-17

ABE2 display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-18 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-18 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20 Replacing the ABE 2 display

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-22

Maintenance interval indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-23 Display of the remaining travel time

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-24

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Table of contents Discharge indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-25

CPP control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-26 Functions of CPP (Can Power Port) control boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-26 CPP 1 (front lighting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-27 CPP 2 (rear lighting)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-28

CPP 3 (cab option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-29 CPP 4 (electric hook and additional hydraulics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30 CPP 6 (top rear lighting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31

FleetManager (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-32 FleetManager description

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-32

Access control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-33 FleetManager options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-34

On-board charger (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-35 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-35 Charger operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-37 Parameterising the charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-38

Opportunity charging (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41 Description of opportunity charging

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41

Electric coupling (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-42 Description of the coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-42

Liftrunner (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-43 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-43 Location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-46 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-47

90 Special equipment Battery holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1 Changing the battery with the Fork Off tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1 Changing the battery with the Roll Off tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4

Heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-6 Electric heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-6

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Product information a

Foreword Technical description Introduction

Electrical equipment

The tow tractor and the carrier have been developed to meet the most arduous application requirements. They comply with all current European directives. The tow tractor and the carrier have a nominal towing capacity of 6.2 to 8 tonnes and an unladen traction speed of up to 20 km/h.

These tow tractors are tted with advanced 48 V microprocessor-based high-frequency control systems.

There are three different models: The 7-tonne model The 8-tonne model

Steering The single front wheel steering is both light and responsive to reduce driver fatigue. This system ensures excellent manoeuvrability and improves overall handling ef ciency.

The carrier model

Brakes Driver's compartment and controls For optimal ergonomics, a low step facilitates access to the driver's compartment. Adjusting all the controls and the seat contributes to optimum driver comfort and ef ciency.

The arrangement of the pedals, controls and steering wheel (automotive), together with the electronic control, provides smooth handling.

The accurate recording of the tow tractor's shift time, the hour meter and battery discharge indicator allow: Better management of maintenance intervals Minimised risk of battery damage. The truck can be equipped with an electrolyte level sensor

Hydraulic drum brakes on all three wheels Automatic parking brake Lift off braking. The tow tractor brakes electrically and comes to a standstill when the accelerator pedal is released

Tow coupling and carrying compartment The tow tractor has provision for various towing couplings at the rear and an optional tow coupling at the front.

The carrying compartment behind the driver's seat has a load capacity of 150 kg.

Carrier

Chassis The chassis is designed for maximum strength and rigidity. A low centre of gravity ensures safe road handling, and its compact size ensures excellent manoeuvrability. The traction motor and electronic control are protected within the chassis but remain easily accessible for servicing. The battery is located between the two axles to obtain maximum stability and to allow quick and easy removal.

The carrier version is also available.

This allows you to carry a load of 800 kg.

Equipment available as standard or as an additional option - Side access to batteries - Fork Off system for battery removal and a suitable tool for this use - Roll Off system for battery removal

Drive and transmission A powerful 4.5-kW traction motor (AC technology) is mounted transversely on the drive axle.

Power is transmitted to the rear wheels through a reduction gearbox as well as a differential.

STILL

The tow tractor has three independent braking systems:

- Wheels or tyres - Different cab types - Different seat types - On-board charger etc.

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Sharp edges can damage the harnesses. Protect the harnesses from sharp edges.

Only use harnesses with adequate load capacities.

Refer to the truck type/capacity plate to determine the weight of the tow tractor and battery.

Never lift the truck using the tow coupling.

Only use the tow coupling for towing.

Sling only at the corresponding connecting points.

Risk of tow tractor damage if the harnesses are incorrectly adjusted Pressure from the harnesses can damage or destroy attachment parts when the tractor is lifted.

Secure harnesses so that they do not touch any attachment parts.

Harnesses can damage the tractor's paintwork.

Harnesses can damage paintwork by cha ng and pressing on the surface of the tractor. Particularly hard or sharp-edged harnesses, such as wires or chains, can damage the surface.

Use textile harnesses, for example, lifting straps, with edge protectors or similar protective devices, if necessary

Observe the following instructions: Immobilise the tow tractor.

Switch off the ignition, and remove the key.

Press the emergency stop button.

Remove any items that could fall.

Ensure that the battery is properly locked and that the battery compartment door is closed Protect all parts that come into contact with the lifting device.

Attach the lifting device as illustrated.

Lift the tow tractor slowly and carefully.

-2

11918012101 EN - 09/2019

When lifting the tractor, make sure that no one is in the vicinity.

11918012101 EN - 09/2019

-3

Refer to the tow tractor or carrier capacity plate to determine the weight of the truck and battery.

Always chock the raised tow tractor securely after jacking.

Before lifting the tow tractor, ensure that the load has been removed.

Only raise the tow tractor at lifting points (1) and (2).

-4

11918012101 EN - 09/2019

a

Depending on the application, environmental conditions and driving style, the following procedures should be carried out every 1000, 2000, 4000, 5000, 7000, 8000 and 10,000 hours

Cleaning the truck Checking the error codes using the diagnostic tool Checking and lubricating the driver's seat Checking and lubricating the automatic tow coupling Checking and lubricating the latches and hinges Cleaning and checking the gearbox breather Checking and lubricating the steering chain Checking the front suspension Lubricating the front suspension Checking and lubricating the front wheel bearing Checking the brake uid level Checking the condition of the front and rear brake shoes Checking the drive axle rubber shock mounts Checking the drive axle suspension bushes Checking the steering stops (wear and tightness) Checking and adjusting the battery compartment door latch Checking the battery acid level and electrolyte density Checking the traction controller Checking the oil level in the Liftrunner system equipment Checking the condition of the motor brushes for the Liftrunner system equipment Checking the condition of the mounting for the Opportunity Charging equipment .

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

Carry out all 1000-hour maintenance work Changing the brake uid Checking the electromagnetic brake Draining and lling the drive axle

11918012101 EN - 09/2019

-1

Draining then re lling the Liftrunner system equipment with engine oil Visually checking the condition of the air lter for the agitation pump (on board charger). Cleaning the lter with water if necessary. .

-2

11918012101 EN - 09/2019

Thread

Grade 4.6

Grade 4.8

Grade 5.8

Grade 6.8

Class 8.8

M4

1

1.3

M5

2.1

2.7

M6

3.6

M8

8.5

M10 M12 M14

47

62

M16

73

100

M20

145

192

M24

250

330

M30

510

M36

880

Thread

Grade 4.6

M8x1

9.5

Grade 10.9 Grade 12.9

1.7

2

2.7

3.8

4.6

3.4

4.1

5.5

8

9.5

4.7

5.9

7.1

9.5

13

16

11

14

17

23

32

39

17

23

29

34

46

64

77

30

40

50

60

80

110

135

78

94

125

180

215

122

146

195

275

330

240

289

385

540

650

410

495

660

930

1110

675

840

1000

1350

1850

2250

1170

1470

1760

2350

3300

3900

Grade 4.8

Grade 5.8

Grade 6.8

Class 8.8

12

16

19

25

35

.

Grade 10.9 Grade 12.9 42

M10x1

20

26

32

39

52

72

95

M10x1.25

18

24

30

37

49

68

82

M12x1.25

33

44

55

66

88

125

150

M12x1.5

31

41

52

62

83

115

140

M14x1.5

52

70

87

105

140

195

235

M16x1.5

79

105

130

157

210

295

350

M18x1.5

115

150

190

230

305

425

510

M20x1.5

160

210

265

320

425

600

720

M22x1.5

215

285

355

425

570

800

960

M24x1

270

360

450

540

720

1000

1200

M27x1

395

525

655

785

1050

1500

1800

M30x2

540

725

905

1085

1450

2050

2500

M36x3

930

1250

1560

1870

2500

3500

4100

.

11918012101 EN - 09/2019

-3

USB CAN Box, unit with cables

50983605401

USB CAN Box 50983605400 Adaptor cable, CAN Box for diagnostics on the truck, diagnostic 0171381 connector, 7-pin .

STILL multimeter with measurement leads

0009418737

Test adaptor, SAAB, 42-pin

8426527

.

.

Replacement MetraHit measuring lines, pair of red and black Measuring tips, pair of red and black

0143426

Crocodile clips, pair of red and black

0143427

Measurement cables, pair of red and black

0143425

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

Hahn&Kolb 77200910

.

.

-4

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a

1 2

3 4 5

Document category Document language

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

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

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

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

Select the required document category (1).

Select the required truck series (4).

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

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

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

Enter the required type carrier and con rm by pressing Start .

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

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-1

1 2 3 4

ABE2 display Traction controller 1A1 CPP enclosures Laptop equipped with "STEDS Navigator" software

-2

5 6 7 8

Connection (serial or USB port) between the laptop and the CAN box CAN box Connecting the CAN box to the diagnostic connector Diagnostic connector

11918012101 EN - 09/2019

The truck diagnostics are carried out using a laptop, on which the "STEDS Navigator" diagnostic software and the corresponding "Service Base" for the truck are installed. The "STEDS Navigator" software must be registered with Still and is then activated by Still AC (Application Control).

The serial CAN box (3) is connected to the laptop's serial port (5) via the connecting cable (4).

The connecting cable (2) is inserted between the CAN box (3) and the truck's diagnostic connector (1).

The laptop (4) is connected via the CAN box (6) to the truck's diagnostic connector (8).

There is an input connection from the diagnostic connector (8) to the display (1), and output connections from the diagnostic connector to the 1A1 traction controller (2) and the CPP control boxes via the CAN bus.

Depending on the type of CAN box used (serial or USB), the connection to the laptop can be made using a Sub-D plug or USB cable, although the diagnostic options are always identical.

The diagnostic connector is located on the dashboard.

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

The USB port of the CAN box (3) is connected to the USB port of the laptop (4). The connecting cable (2) is inserted between the CAN box (3) and the truck's diagnostic connector (1).

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-3

The interface adaptor USB plug (4) is connected to the laptop's USB port (5). The serial CAN box (3) is connected to the interface adaptor

-4

serial connection (4). The connecting cable (2) is inserted between the CAN box (3) and the truck's diagnostic connector (1).

11918012101 EN - 09/2019

The serial CAN box is equipped with a 4-pin round plug (1) on the left-hand side that is connected to the truck diagnostic connector.

A 9-pin Sub-D plug (5) is provided on the right-hand side. This plug is connected to the notebook.

A reset button (6) for restarting the CAN box is tted on the left-hand side.

The USB CAN box is equipped with three connections on the left-hand side. The top connection is a 4-pin round connector (1), which is connected to the diagnostic connector on the truck. The bottom connection is a USB cable (8), which is connected to the notebook. The centre connection is not currently used.

Three LEDs indicate the communication status of the CAN box: The LED (2) lights up once the CAN box is supplied with voltage via the diagnostic connector when the truck is switched on The LED (4) indicates the status between the notebook and the CAN box The LED (3) indicates the status between the CAN box (CAN 1) and the truck The LED (7) indicates the status between the CAN box (CAN 2) and the truck. This LED is not used.

Applies only to the USB CAN box: If all of the LEDs (2,3,4,7) are ashing, the CAN box is in programming mode. In this case, the CAN box must be restarted.

Switching the truck off and on again will trigger a reset of the CAN box. The supply to the CAN bus is interrupted when the truck is switched off.

RX50 (5060-5066): The CAN box must be disconnected from the truck (diagnostic connector) in order to be reset. It is not suf cient to switch off the truck.

11918012101 EN - 09/2019

-5

1 2

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

3 5

USB CAN Box Laptop

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

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

1 2 3 4a

4b

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

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

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

5

Connecting line, serial serial and serial converter Laptop

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

The laptop (5) is connected to the CAN Box via the connecting line. The type of connection

-6

11918012101 EN - 09/2019

119100_00-003 1X1:14 CAN1 high (traction) 1X1:28 CAN1 low (traction) 1X1:24 CAN2 high (traction) 1X1:34 CAN2 low (traction) 6X2:3 CAN2 high (display) 6X2:4 CAN2 low (display) 6X7 Diagnostic connector 6X7:1 CAN1 high (diagnostic) 6X7:2 CAN1 low (diagnostic)

6X7:5 6X7:6 6X10 1A1 6P4 CPP1 CPP2 U2

The truck is equipped with two CAN bus networks:

Each CAN network is composed of:

CAN1 (500kb): Used for parameterising the truck by the After Sales Service Centre and used for the current sensor and LFM option CAN2 (250kb): Used for communication between the display, the LAC controller and the different CPPx control boxes.

CAN2 high (diagnostic) CAN2 low (diagnostic) LFM connector LAC 03/81 traction controller ABE2 display Front lighting Rear lighting 500W voltage converter

The "CAN high" The "CAN low" Two 120- "Rt" terminating resistors tted in parallel in the circuit: CAN1 network: One on the 6X10 connector and one on the LAC controller CAN2 network: One on the display and one on the LAC controller Checking the CAN Bus 1 network: Using an ohmmeter, the measured value of the diagnostic connector (6X7) between terminals (1) and (2) is approximately 60 ; the value is

11918012101 EN - 09/2019

-7

measured between the CAN high and the CAN low when the truck is not under voltage.

Using a voltmeter, the measured value of the diagnostic connector (6X7) between terminals (1) and (4) and between terminals (2) and (4) is approximately 2.5 V when the truck is under voltage.

Checking the CAN Bus 2 network:

(5) and (6) is approximately 60 ; the value is measured between the CAN high and the CAN low when the truck is not under voltage.

Using a voltmeter, the measured value of the diagnostic connector (6X7) between terminals (5) and (4) and between terminals (6) and (4) is approximately 2.5 V when the truck is under voltage.

Using an ohmmeter, the measured value of the diagnostic connector (6X7) between terminals

-8

11918012101 EN - 09/2019

1 2 3

F2: Diagnostics Jobs Execute

4 4 4

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

F2: Diagnostics

Read error list Delete error list Read error ring buffer

Different types of error list can be selected: 1

Current errors Details all errors that are currently active

Jobs

2

Details all errors that have occurred since the truck was switched on

Select job (4) 3

Execute

Errors since the last start-up

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

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

11918012101 EN - 09/2019

-9

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

-10

11918012101 EN - 09/2019

The traction fault codes are described in the diagnostic software in the of the truck.

11918012101 EN - 09/2019

-11

-12

11918012101 EN - 09/2019

a

1 2 3 4 5

Electromagnetic brake Breather Filler cap Axle mountings Identi cation plate

6 7 8 9 10

11918012101 EN - 09/2019

Traction motor Brake drums Shock absorbers Differential housing Traction motor temperature gauge

-1

The rear axle identi cation plate (5) is in the following location:

-2

11918012101 EN - 09/2019

A B C

Force Characteristic curve Distance

01 02 03

Load 320 kg

Diameter (±20%)

900 kg

136 mm

Force measurement Distance measurement Rigidity measurement

119.5 mm

Adjustment speed: 20 mm/min Load adjustment up to: 56 kN

11918012101 EN - 09/2019

-3

Park the tow tractor safely Switch off the ignition and remove the key Press the emergency stop button Open the battery compartment door Disconnect the battery connector Remove the cover Remove the breather from the gearbox (1) Clean the breather with clean fuel then check for correct operation Re t the breather on the gearbox Re t the cover Reconnect the battery connector. Lock the battery Close the battery compartment door Restart the tow tractor

-4

11918012101 EN - 09/2019

Immobilise the truck.

Switch off the ignition and remove the key.

Pull the emergency off switch.

Open the battery compartment door (1), (2).

Disconnect the battery connector (3).

Remove the screws (4) located at the ends of the cover plate.

Remove the cover plate (5).

11918012101 EN - 09/2019

-5

Put chocks (6) on the front wheel.

Raise the truck using jacks (7) at the front and the rear of the truck.

When the truck is lifted: Place axle stands (8) at the front and at the rear of the truck.

Remove the chocks (6).

Loosen the nuts on the rear wheels (9) and remove them (tightening torque: ).

Remove the two rear wheels (10).

Bleed the brake circuit.

Remove the axle from the bottom.

-6

11918012101 EN - 09/2019

Loosen the three terminals U, V, W of the traction motor (11) (tightening torque: ).

Remove the cable ties.

Disconnect the connector (1X2) of the rev sensor (12).

Remove the connector (13).

Remove the sealing ring (14).

Loosen the screws of the parking brake (15).

Remove the parking brake (16).

Remove the armature (17).

Remove the plate (18).

Loosen the locking ring of the gear (19).

Remove the gear (20).

11918012101 EN - 09/2019

-7

Risk of injury.

Risk of injury from heavy components.

Act with a suf cient degree of safety.

Use a suitable device.

Loosen the screw of the traction motor (21).

Sling the traction motor with a suitable lifting device (22).

Remove the traction motor (23).

Disconnect the brake pressure switch (23).

Disconnect the rear brake hose (24).

Remove each damper (25).

Remove the remaining screws and nuts.

Remove the drive axle (26).

Remove the cable ties (27).

Remove the bleeder valves (28).

Remove the brake hose (t-pipe union) (29).

-8

11918012101 EN - 09/2019

The rear axle is completely disassembled.

At the end of the operation, ll the brake system and carry out a full bleed.

To install the rear axle: Repeat the operations in reverse order.

11918012101 EN - 09/2019

-9

Nominal data of traction motor Model Battery voltage

Three-phase AC asynchronous motor

Effective voltage

28 V

Nominal power

4.5 kW

Current Speed

119 A 2630 rpm

Insulation class Protection type

F

Connection Mode of operation

Delta S2 (60 min)

Nominal frequency

90 Hz

48 V

IP54

.

Refer to chapter 11 (Replacing the rear axle, up to the extraction of the traction motor).

-10

11918012101 EN - 09/2019

Once the traction motor is removed, carry out the following operations: Remove the parallel key (1) .

Remove the O-ring (2) .

Remove the locking ring (3) .

Remove the rotor (4) .

Remove the snap ring (5) .

Remove the grooved ball bearing (6) .

For replacement, carry out the operations in reverse order.

11918012101 EN - 09/2019

-11

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

These components should be rst checked before testing the motor.

The following points must be checked if a motor operating fault is detected: External check: corrosion, contamination, cracks, correct mounting of the following components:

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

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

connections U, V, W of the traction motor temperature sensor connector

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

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

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

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

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

exposure to excessive heat or local heat build-up.

This may be identi ed by discolouration of the rotor.

-12

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

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

However, brown discolouration of the rotor is normal.

11918012101 EN - 09/2019

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

The outside of the drive axle can be cleaned thoroughly. The best cleaning agent is compressed air. If the outside of the axle housing is very heavily soiled, a high-pressure cleaner can be used. However, depending on the level of contamination, it is recommended that the air ducts and power modules are removed.

Special care should be taken to ensure that the spaces between the cooling ns on the motor are free from contamination, so as to ensure correct cooling of the motor. Only water may be used for this. Under no circumstances should chemical cleaning agents be added when using a high-pressure cleaner. Chemical cleaning additives may attack the plastic parts of the motor. Suf cient distance must be maintained between the jet lance and the motor.

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

Intensive cleaning with a high-pressure cleaner should be avoided around the motor connections.

No moisture should be allowed to enter the motor. If despite all precautions, moisture does penetrate the motor, the truck must be driven for

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

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

The rotor can be cleaned with conventional cleaning methods .

PCB polychlorinated biphenyls PCT polychlorinated terphenyls CHCs chlorinated hydrocarbons CFCs chloro uorocarbons

11918012101 EN - 09/2019

-13

U

Phase U connection

V

Phase V connection

W

Phase W connection Temperature sensor and rev sensor connector Rev sensor Temperature sensor KTY83-140

1X2 1B2 1B6 .

The power supply for the power module is provided by two main power lines (L+) and (L-).

The connections of the traction motor are connected to the LAC 1A1 power module (terminals U, V, W).

These connections are secured with a nut (tightening torque for hexagon nut: 9 Nm).

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

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

1 2 3 4 5 6 7

-14

U power cable for the traction motor (connection U of the LAC) V power cable for the traction motor (connection V of the LAC) W power cable for the traction motor (connection W of the LAC) Li terminal: not used + supply cable for the battery after 1K0 contactor (+ connection of the LAC) - supply cables for the battery and different options (- connections of the LAC) 1X1 connector of the LAC

11918012101 EN - 09/2019

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

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

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

11918012101 EN - 09/2019

-15

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

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

The direction of rotation is only analysed for the two traction motors. A 4-pin plug (3) is used to connect the rev sensor with the power module 1A1.

Rev sensor connector

2

Power supply + 12 V Output signal A

3

Battery negative

Black

4

Output signal B

Blue

1

Brown White

.

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

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

Traction motor rev sensor signal

The rev sensor can be tested using the diagnostic tool. If the signal is incorrect, the supply voltage, connector and connection must be checked.

-16

11918012101 EN - 09/2019

The (1B6) temperature sensor is located on the traction motor. It is connected to the traction motor power module.

The temperature sensor is type

.

Supply: approx. 1.7 mA It is dust-proof and splash-proof.

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

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

11918012101 EN - 09/2019

-17

Check the resistance between pins 5 and 6 of the 7X6 connector: Reference values for the temperature measurement:

-40

355

-30

386

-20

419

-10

455

0

493

10

533

20

576

25

598

30

621

40

668

50

718

60

769

70

824

80

880

90

939

100

1000

110

1063

120

1129

130

1197

140

1268

150

1340

160

1415

170

1493

180

1572

190

1654

200

1739

210

1825

220

1914

.

-18

11918012101 EN - 09/2019

a

Refer to chapter 11 (Replacing the rear axle, up to the extraction of the traction motor).

Once the traction motor is removed, carry out the following operations: Remove the transmission seal (1).

Grease the transmission seal (2).

For replacement, carry out the operations in reverse order.

11918012101 EN - 09/2019

-1

-2

11918012101 EN - 09/2019

a

Switch off the truck power supply.

Disconnect the battery.

Remove the seat backrest (1).

Loosen the cushioning (2).

Remove the cover (3).

Disconnect the plug 1X10 (4).

Remove the cable ties.

Disconnect the seat switch (5).

Remove the screws (6).

Remove the seat contact (7).

11918012101 EN - 09/2019

-1

Immobilise the truck.

Switch off the ignition and remove the key.

Pull the emergency off switch.

Open the battery compartment door (1).

Disconnect the battery connector (2).

Move the driver's seat forwards (3).

Remove the 2 screws (4) Remove the rear cover (5).

-2

11918012101 EN - 09/2019

Disconnect the plug from the windscreen wiper motor (6).

Place a container under the windscreen wiper motor (7).

Disconnect the hose from the windscreen wiper motor (8).

Remove the windscreen wiper motor from the tank (9).

Take a new windscreen wiper motor (10).

Place the new motor on the tank (11).

Connect the hose to the motor (12).

Remove the container (13).

Connect the plug of the windscreen wiper motor (14).

Re t the rear cover in the cab (15).

Insert the two screws (16).

Position the driver's seat (17).

Open the cover of the tank (18).

Fill the water tank (19).

Carry out a functional test.

11918012101 EN - 09/2019

-3

Immobilise the truck.

Switch off the ignition.

Press the emergency off switch.

Remove the button head screws of the cab cowling (1).

Raise the cowling a few centimetres (2).

Position the wiper arm on the side of the windscreen (3).

Remove the four protective caps from the four ends of the outer windscreen (4).

Remove the four protective caps from the four ends of the inner windscreen (5).

Remove the four hexagon head screws on the outer windscreen (6).

Remove the four supports from the outer windscreen (7).

Remove the four hexagon head screws on the inner windscreen (8).

Remove the windscreen (9).

Apply adhesive to the rubber pro le (10).

Af x the pro le to the windscreen (11).

Repeat the operations in reverse order.

Carry out a functional test.

-4

11918012101 EN - 09/2019

1 2 3

M10 screw 5-mm wedge Alignment area

Position the door and start to screw the two M10 screws (1) of the hinge support onto the chassis.

Do not torque the screws straight away.

Close the door to align it with the loose screws.

Chock the door with a 5-mm wedge (2) at the bottom right of the door.

Check that the upper section of the door (3) is aligned with the chassis.

Check that the lower section of the door (4) is touching the chassis.

The lines of the door and the chassis must be as closely aligned as possible.

Tighten the two screws ( ).

Remove the wedge.

Check that the door is no longer touching the chassis.

11918012101 EN - 09/2019

-5

Move the latch as far as possible towards the truck front and torque tighten (1.7 Nm).

Fully tighten the tapered buffer (4) so that it is offset from the welded point on the door (5) only by the thickness of the nut (6).

Close the door normally (without excessive force) and check that: The latch of the handle protrudes (7a) beyond the thickness of the battery tunnel.

If the latch does not protrude (7b) beyond the thickness of the battery tunnel, remove the nut behind the tapered buffer and fully retighten the buffer.

Risk of the battery door opening Repeat the opening/closing operation several times (at least three times) in order to check the adjustment.

Check that when you start to open the latch (20°), the door starts to open.

Then check that when the latch (8) is released the door returns to its position.

-6

11918012101 EN - 09/2019

a

1 2 3 4 5 6

Enclosure Magnet support Magnet Connecting part Seal Cover

Pin

7 8 10 11 12

1

Red

Function Supply voltage

2

Blue

Signal 1

3

Black

4

White

GND Signal 2

Colour

Printed circuit board assembly Bundling Cap Interface Cutting screw

.

11918012101 EN - 09/2019

-1

The steering column (1) is used to operate the front steering controller (steering wheel) of the tractor.

The upper part is attached to the steering wheel and the lower part is attached to the pinion gear (2).

The pinion gear (2) drives the steering arm via the chain (3).

The upper part of the steering column is attached to the chassis at the points marked (4) with four nuts and washers.

The lower part is attached to the plate with the pinion gear (2) by two screws (5).

-2

11918012101 EN - 09/2019

Axle

119100_42-003

11918012101 EN - 09/2019

-3

-4

11918012101 EN - 09/2019

a

The accelerator is located underneath the steering wheel of the truck.

The accelerator consists of the accelerator pedal (1) and a redundant potentiometer (1B1) The accelerator contains a dual potentiometer with an 8-pin male connector (X16) that is connected to the LAC controller.

The dual potentiometer 1B1 comprises a guide potentiometer and a monitoring potentiometer.

The guide potentiometer (C1) controls the direction of rotation and the number of revolutions of the traction motor 1M1, and the monitoring potentiometer (C2) electrically veri es the guide potentiometer.

The accelerator is supplied with +10 V (1X1:27) by the traction controller 1A1 and -10 V by the battery negative (1X1:42).

The two traction setpoint potentiometers are mechanically connected to one another. The sum of the output signals must be approximately 10 V. In the event of a failure, the voltage between the two slider points changes and the truck traction controller detects an error.

X16:1

N/A

N/A

X16:2

Black

Signal C2

X16:3

Red

Signal C1

X16:4

Yellow

GND accelerator

X16:5

N/A

N/A

X16:6

N/A

N/A

X16:7

N/A

N/A

X16:8

Green

10 V accelerator

.

11918012101 EN - 09/2019

-1

Pedal at rest Pedal actuated

C1

C2

4.80 5.40

4.70 5.30

8.70 9

1.10 1.40

.

The two output signals can be checked using the STEDS Navigator diagnostic tool.

Go to the following menu:

To calibrate the pedal, connect to the truck using the STEDS Navigator diagnostic tool.

Go to the following menu:

-2

11918012101 EN - 09/2019

Immobilise the truck.

Switch off the ignition and remove the key.

Pull the emergency off switch.

Open the battery compartment door (1).

Disconnect the battery connector (2).

Remove the oor mat (3).

Raise the front of the truck using a hydraulic jack (4).

Place axle stands under the truck (5).

Risk of injury Ensure that the hydraulic cylinder of the jack is in the correct position.

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-3

Remove the button head screw (6) located under the accelerator pedal.

Remove the screw from the pedal box (7).

Remove the pedal box (8).

Disconnect the connector (9).

Remove the accelerator (10).

Repeat the operations in reverse order.

Start the diagnostic software.

Adjust the accelerator Carry out a functional test.

-4

11918012101 EN - 09/2019

The truck has two independent brake systems: A hydraulic drum brake An electromagnetic parking brake The electrical brake (without current) is activated when the driver releases the accelerator pedal. It is controlled by the LAC traction controller.

The hydraulic brake is activated by pressing the brake pedal. It controls the drums at the front and at the rear of the truck.

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-5

Nominal voltage:

42 V

Nominal capacity:

53 W at 20°C

Inrush current:

1.26 A

The truck is not braked when the parking brake is released.

Before releasing the brake, it is necessary to check that the truck is parked on a level surface or that the brake pads are available to prevent the truck from rolling.

Turn the switch key S1, press the emergency off switch 7S1 and disconnect the battery connector.

Remove the engine cover.

Insert two M6 x 55 mm screws in the two holes and tighten thoroughly to mechanically release the parking brake.

Turn the switch key S1, press the emergency off switch 7S1 and disconnect the battery connector.

Remove the engine cover.

Use a feeler gauge to measure the distance between the coil housing and the pressure disc.

The nominal distance = 0.3 mm ± 0.1 mm The maximum distance = 0.7 mm

The distance cannot be adjusted. If the distance is greater than 0.7 mm, the lining must be replaced.

-6

11918012101 EN - 09/2019

Turn the switch key S1, press the emergency off switch 7S1 and disconnect the battery connector.

Remove the engine cover.

Disconnect the 1X2 plug connectors of the brake coil.

Check the resistance between 1X2:9 and 1X2:10 using a suitable multifunction measuring device.

The resistance should be 33.3

± 2.5 .

If the measured value is not within the tolerance range, the coil must be replaced.

With the parking brake applied, check the currents and voltages at 1X2:9 and 1X2:10.

Current draw Approximately 1.26 A

Holding current Approx. 0.29 A (R = 33.6 )

The voltage drop and the current drop occur after approximately one second.

When there is no power supply to the coil, the parking brake is applied.

When the parking brake is released, output 1X2:10 is switched on.

The coil is then supplied with the full battery voltage (48 V). From this point, the current increase is progressively measured. This ends when a current of 0.9 A is supplied, after 0.5 seconds or when the brake disc hits the armature. When the brake disc hits the armature, the current is interrupted.

To prevent the coil overheating and to save energy, the coil control is pulsed with a PWM signal (frequency = 16 kHz) after applying the battery voltage of 48 V.

11918012101 EN - 09/2019

-7

1: Brake pedal action 2: Spring tension 3: Piston of the master cylinder activated 4: Supply to the brake uid reservoir 5: Release of pressure

-8

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1 2 3 4 5

Brake pedal Front wheel exible hose Master cylinder Bleeder screw (quantity: 3) Rear brake hose

6 7 8 9 10

11918012101 EN - 09/2019

Distributor of the rear brake circuit Front lights pressure switch Brake uid reservoir Brake uid supply to the master cylinder Rear brake hose

-9

1 2 3 4

Linings Adjustment cam Retaining spring Compression springs

5 6 7 8

Each brake is equipped with a slave cylinder (8) mounted at the top of the brake support plate.

Diameter of the drum 180 mm Alignment width of the 40 mm brake Diameter of the cylinder 22.22 mm

When the brake pedal is actuated, pressure is exerted on the brake uid in the hydraulic brake system.

The brake uid pressure, exerted in each slave cylinder, causes the brake shoes to press against the brake drums of the load wheels.

Each brake shoe rotates around a xed point, which means that the shoe of the front brake is pressed against the brake drum in the direction of rotation, and the shoe of the rear brake is pressed in the opposite direction to rotation. This produces virtually the same braking effect in both directions of travel.

-10

Return springs Bleeder screw Brake hose union Slave cylinder

Brake oil DOT 3/4 Maximum pressure 120 bar Brake torque (with 1400 Nm 80 bar) Maximum brake torque 2100 Nm (with 120 bar) .

11918012101 EN - 09/2019

Immobilise the truck.

Switch off the ignition and remove the key.

Pull the emergency off switch.

Open the battery compartment door (1).

Disconnect the battery connector (2).

Loosen the ve bolts from the front wheel (3).

Raise the front of the truck using a hydraulic jack (4).

Place axle stands under the truck (5).

Risk of injury Ensure that the hydraulic cylinder of the jack is in the correct position.

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-11

Remove the bolts from the front wheel (6).

Remove the wheel from the truck (7).

Unscrew the brake shoe (8).

Remove the hubcap (9).

Unscrew the hexagon nut (10) (tightening torque: 185 Nm).

Remove the washer (11).

Remove the inner ring of the tapered roller bearing (12).

Remove the brake drum (13).

Push in the brake drum using a drift punch (14).

Place the outer ring of the tapered roller bearing in the brake drum (15).

Push in the brake drum using a drift punch (19).

Place the outer ring of the tapered roller bearing in the brake drum (16).

Lubricate the inner ring of the tapered roller bearing (17).

Place the inner ring of the tapered roller bearing in the brake drum (18).

Push in the brake drum again (19).

Place the gasket in the brake drum (20).

-12

11918012101 EN - 09/2019

Place the brake drum on the truck (21).

Lubricate the inner ring of the tapered roller bearing (22).

Risk of injury Wear protective equipment

Risk of damage Use the consumables speci ed.

Place the inner ring in the brake drum (23).

Position the washer (24).

Tighten the hexagon nut (tightening torque: 185 Nm) (25).

Lubricate (26) and position the hubcap (27).

Position the brake shoe (28).

Re t the wheel (29).

Re t the wheel bolts (30).

Carry out a functional test.

Remove the axle stands.

Tighten the wheel bolts (tightening torque: 195 Nm) (31).

Carry out a test drive.

11918012101 EN - 09/2019

-13

Immobilise the truck.

Switch off the ignition and remove the key.

Pull the emergency off switch.

Open the battery compartment door (1).

Disconnect the battery connector (2).

Loosen the ve bolts of the front wheel (3).

Remove the screws from the cover plate (4).

Remove the cover plate (5).

Raise the front of the truck using a hydraulic jack (6).

Place axle stands under the truck (7).

Risk of injury Ensure that the hydraulic cylinder of the jack is in the correct position.

-14

11918012101 EN - 09/2019

Remove the bolts from the front wheel (8).

Remove the wheel from the truck (9).

Unscrew the brake shoe (10).

Remove the hubcap (11).

Unscrew the hexagon nut (12).

Remove the washer (13).

Remove the inner ring of the tapered roller bearing (14).

Remove the brake drum (15).

Remove the clamping spring (16).

Remove the two socket head screws (17).

Remove the support (18).

Place a container under the brake system (19).

Disconnect the brake hose (20).

Risk of injury Wear protective equipment

11918012101 EN - 09/2019

-15

Remove the three remaining socket head screws (21).

Remove the brake (22).

Risk of injury Wear protective equipment

Remove the brake hose (23).

Take the new brake (24).

Position the hose (25) .

Place the brake on the truck.

Position the socket head screws (tightening torque: 100 Nm).

Connect the brake hose.

Remove the container under the brake system.

Position the support.

Attach the support using the two socket head screws.

Position the clamping spring.

Place the brake drum on the truck (26).

Lubricate the inner ring of the tapered roller bearing (27).

Risk of injury Wear protective equipment

Risk of damage Use the consumables speci ed.

Place the inner ring in the brake drum (28).

Position the washer (29).

-16

11918012101 EN - 09/2019

Tighten the hexagon nut (tightening torque: 185 Nm) (30).

Lubricate (31) and position the hubcap (32).

Position the brake shoe (33).

Re t the wheel.

Re t the wheel bolts.

Risk of injury Wear protective equipment

Risk of damage Use the consumables speci ed.

Remove the ller cap from the tank (34).

Connect the lling device (35) to the tank (36).

Connect the hose (37).

Open the bleeder valve (38).

Bleed the brake.

Close the bleeder valve (39).

Disconnect the hose (40).

Remove the lling device (41).

Fill the tank (42).

Re t the ller cap (43).

Carry out a functional test.

Remove the axle stands.

Tighten the wheel bolts (tightening torque: 195 Nm).

Re t the cover plate.

Re t the button head screws.

Carry out a test drive.

11918012101 EN - 09/2019

-17

1

Blue-Q function activated

2

Display on start-up

allows you to: Limit the performance of the truck (motor, speed) Reduce the power consumption of the tow tractor Switch off options to save the battery There are two levels of energy consumption with three possible uses:

1

Standard (default)

2

Blue-Q: Mode FIXED

3

Blue-Q: Mode FIXED-FLEX

Blue-Q function deactivated on start-up.

The operator can activate or deactivate the function multiple times.

Blue-Q function activated on start-up.

The operator cannot deactivate the function.

Blue-Q function activated on start-up.

The operator can deactivate or activate the function multiple times.

.

-18

11918012101 EN - 09/2019

Blue-Q mode regulates the switching on and off of electrical equipment.

A

B

C

Working lights Main beam headlights Cab roof light Defrosting Windscreen wipers

front rear

Cab heating Seat heater A: Switches off after 10 seconds if the forklift operator is not sitting down. Switches back on once the operator is sitting down.

B: The forklift operator is sitting down and is driving at more than 3 km/h in reverse travel.

C: The forklift operator is sitting down and is driving at more than 3 km/h in forward travel.

Connect the diagnostic PC to 6X7.

Launch Navigator and go to the following menu:

Connect the diagnostic PC to 6X7.

Launch Navigator and go to the following menu:

11918012101 EN - 09/2019

-19

Standard mode Blue-Q mode activated Level 2

Acceleration/deceleration limit

Acceleration/deceleration level vDown Levels

Acceleration/deceleration limit

2.2

9

aLevel 3 dLevel 3

2

7

aLevel 1 dLevel 3

1.3

2

aLevel 2 dLevel 1

1

1

aLevel 1 dLevel 1

Notes: Acceleration can be adjusted to between 1 and 3 m/s² Deceleration can be adjusted to between 0.6 and 2 m/s² Acceleration and deceleration levels can be independently adjusted to between 1 and 3 m/s²

-20

Acceleration/deceleration level vDown Levels

11918012101 EN - 09/2019

a

Damage to electrical components due to working on live parts.

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

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

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

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

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

On no account open the control module.

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

Opening it may invalidate the warranty.

Operating units can be damaged by electrostatic discharge.

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

11918012101 EN - 09/2019

-1

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

Moisture must not enter the electrical components.

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

However, if moisture does enter the components, they must be dried by heating (hot air blower, heating system) to prevent corrosion damage.

-2

Electrical components can be destroyed by overtemperature.

Observe the maximum temperature when using a hot air blower.

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

PCB polychlorinated biphenyls PCT polychlorinated terphenyls CHCs chlorinated hydrocarbons CFCs chloro uorocarbons

11918012101 EN - 09/2019

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-3

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

Measurement 1 from battery female connector + to chassis

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

Measurement 2 from battery female connector - to chassis

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

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

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

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

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

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

Different regulations may apply in other countries.

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

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

Test the - terminal of the truck connector and a threaded stud of the chassis Test the + (red) terminal of the LAC controller and a threaded stud of the chassis

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

Test the - (blue) terminal of the LAC controller and a threaded stud of the chassis

Do not touch the insulation measuring device terminals during testing.

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

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

-4

11918012101 EN - 09/2019

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

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

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

Ensuring suf cient resistance to external electromagnetic interference.

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

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

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

The EMC regulations for the truck must be observed.

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

Do not remove ferrites.

Position all the bundling in their original locations.

11918012101 EN - 09/2019

-5

1 2 3 4 5

U phase L1 of the traction motor

6

W phase L3 of the traction motor

7

+ positive terminal of the +48 V power supply for the power unit

8

V phase L2 of the traction motor Li terminal not used

- negative terminal of the +48 V power supply for the power unit - negative power supply terminal for the various electrical consumers 1X1 control module connector

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

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

If an error occurs, it is immediately detected and the control system puts the truck in safety mode.

The control module is equipped with a 42-pin connector.

-6

11918012101 EN - 09/2019

11918012101 EN - 09/2019

-7

1

Contact switch positive

48 V/LAC safety relay

2

Fan control

4

Right-hand slow speed (optional) Brake pedal

5

Right turn indicator

6

Upper trailer cut-out

3

7 8 9 10 11

13 14

CAN high 500 kb

-8

Output

LAC/PWM signal

Digital

Output

48 V/0 V via 1S10

Digital

Input

48 V/0 V via 1S3

Digital

Input

48 V/0 V via 4S1

Digital

Input

48 V/0 V via 2S19

Digital

Input

Digital

Input

Digital

Input

Digital

Input

Digital

Input

Digital

Input

Analogue

Input

Analogue

Input

Forward inching mode 48 V/0 V via 1S35 and (optional) 1S36 Variable signal Motor speed track B 0 V-6 V/1B2 Left-hand slow speed 0 V/48 V via 1S11 (optional) Operator seat 48 V/0 V via 1B9 presence Brake uid Actual value track 2 (optional) Converter supply

12

Analogue

48 V/0 V via 7S6 Voltage between 0 and 10 V/3B3 12 V/+Ub via S5 Approximately 2.5 V

11918012101 EN - 09/2019

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 32 33 34 35 36 37 37 38 39 40 41 42

Control circuit opening 48 V/+Ub via 7S5 control positive Left-hand slow speed 48 V/0 V via 1S11 (optional) Contact switch LAC/PWM signal via negative 1K0 Customer option Customer option

Analogue

Input

Digital

Input

Digital

Output

Customer option

Customer option

Digital

Input

Digital

Input

Analogue

Input

Digital

Input

Digital

Input

Analogue

Input

Analogue

Input

Analogue

Output

Analogue

Output

Analogue

Input

Digital

Output

Digital

Input

Digital

Input

Digital

Input

Analogue

Output

Digital

Input

Digital

Input

Digital

Input

Digital

Input

Analogue

Input

Analogue

Input

Digital

Input

Analogue

Output

Left turn indicator 48 V/0 V via 4S1 Forward inching mode 0 V/48 V via 1S35 and (optional) 1S36 Motor temperature %/1B6 Variable signal Motor speed track A 0 V-6 V/1B2 Presence pedal 48 V/0 V via 1S9 (optional) CAN high 250 kb Approximately 2.5 V Voltage between 0 and Traction setting track 2 10 V/1B1 Actual value track 1 Voltage between 0 and (optional) 10 V/3B3 Supply to 1B1 and 3B3 10 V/LAC Approximately 2.5 V CAN low 500 kb Brake 0 V/LAC Electrolyte level PWM signal/via S6 (optional) Presence pedal 0 V/48 V via 1S9 (optional) Rear left-hand inching 0 V/+Ub via 1S33 and mode (optional) 1S34 Electric coupling 0 V/+Ub via 9B25 unlocked (optional) Operator seat 0 V/48 V via 1B9 presence Approximately 2.5 V CAN low 250 kb Pre-charging circuit 48 V/0 V via 1A6 supply Right-hand slow 0 V/48 V via 1S10 speed (optional) Rear inching mode 48 V/0 V via 1S33 and (optional) 1S34 Electric coupling 48 V/0 V via 9B24 locked (optional) Forwards drive 48 V/0 V via 1S3 direction Traction setting track 1 Voltage between 0 V and 10 V via 1B1 Pre-charging circuit 48 V via 1A6 supply Reverse drive 48 V/0 V 1B6 direction 0V 0 V/LAC

.

11918012101 EN - 09/2019

-9

The truck is equipped with the 9M1 fan. It cools the LAC traction controller, and is positioned next to the LAC power module.

The fan is driven by an external rotor motor with fully-integrated commutation electronics. It is connected to the truck wiring harness with a 3-pin plug (see details below).

During inspection and maintenance work, it is advisable to test the operation of the fan using the diagnostic tool and clean the fan as required in order to prevent the motor and the LAC power module from overheating.

The best cleaning agent is compressed air. Particular care should be taken to clean the spaces between the fan blades to ensure ef cient cooling of the components.

9X1:1

Battery voltage

red

9X1:2

PWM (Pulse Width Modulation) fan control signal

violet

9X1:3

Battery negative

blue

.

-10

11918012101 EN - 09/2019

Characteristic curve of the 9M1 fan: The fan is powered by a 48 V direct current via the control fuse F3 when the LAC controller is supplied and the 7S1 emergency off switch is deactivated.

The fan speeds are regulated in accordance with the cooling air ow required for the LAC controller.

This is implemented via the PWM (Pulse Width Modulation) signal from the LACcontroller.

The fan must be checked for correct operation during inspection and maintenance work.

Testing: Start the diagnostic tool.

Test the fan using the diagnostic tool.

11918012101 EN - 09/2019

-11

Refer to chapter 11 (Replacing the rear axle, up to disassembly of the cover plate).

Once the cover plate has been removed: Locate the fan positioned next to the LAC controller.

Disconnect the plug 9X1 (1) .

Remove the hexagon head screw (2) .

Remove the fan (3) .

Position the replacement fan (4) .

For replacement, carry out the operations in reverse order: Fit the fan (3) .

Re t the hexagon head screw (2) .

Connect the plug 9X1 (1).

-12

11918012101 EN - 09/2019

The standard version of the truck is equipped with an emergency off switch 7S5 positioned to the right of the driver.

When it is activated, it cuts off the controller LAC, the safety relay and the switch coil 1K0 at the same time.

There are two emergency off switches (7S9 and 7S10) at the rear of the truck for the inching mode option (inching).

It activates the electromagnetic brake Y1 (braking by lack of current) and cuts off the truck traction.

Pin

In addition, it cuts off the power supply to the pre-charging circuit 1A6.

7X9: 3

Function Normally open contact (not used) Normally open contact (not used) Normally closed contact

7X9: 4

Normally closed contact

7X9: 1 7X9: 2

There are two emergency off switches (7S5 and 7S8) on each side of the truck for the slow travel option (pedestrian).

.

11918012101 EN - 09/2019

-13

Technical data: Input voltage 48 V Output voltage 12 V Power rating 75 W Protection type IP65 The voltage converter U1 uses the battery voltage to produce a stabilised supply voltage of 12 V for the electrical and electronic components connected: Traction controller 1A1 Diagnostic socket 6X7 Speed sensor 1B2 Display 6P4 Current sensor (optional) LFM (option) Pre-charging circuit The voltage converter has a maximum output power of 75 W and it is galvanically isolated. It is connected to the electrical equipment by a 6-pin plug (X22).

When in operation, the voltage converter is cooled by the aluminium baseplate. To prevent the baseplate from overheating, it must have good metal-to-metal contact with the electrical plate.

The voltage converter U1 is protected by a 15 A fuse.

1

Input voltage

48 V-80 V

2

Earth Output voltage

0V

3 4 5

Earth Input voltage

6

Not connected

12 V 0V 48 V 80 V

.

-14

11918012101 EN - 09/2019

Technical data: Input voltage 48 V Output voltage 12 V Nominal power 500 W Protection type IP65 The voltage converter U2 uses the battery voltage to produce a stabilised supply voltage of 12 V for the electric and electronic components connected: CPP supply units The voltage converter has a maximum output power of 500 W. It is connected to the electrical equipment by 2 plugs (X26) and(X27).

When in operation, the voltage converter is cooled by the aluminium baseplate. To prevent the baseplate from overheating, it must have good metal-to-metal contact with the contactor support.

The converter U2 is protected by a 30 A fuse.

11918012101 EN - 09/2019

-15

The fuse holder comprises the following fuses: Marking

Fuse

Intensity

1

9F3

30 A

2

F6

30 A

3

F3

4A

4

F4

15 A

5

F5

3A

6

9F1

35 A

7

9F2

3A

8

5F1

30 A

Function Protects the converter for additional customer options Protects the U3 cab converter Protects the emergency stop system Protects the U1 voltage converter Protects the LAC controller Protects the heating Protects the 12 V lighter socket Protects the U2 lighting converter

The truck is also equipped with the 1F1 (355 A) power fuse.

-16

11918012101 EN - 09/2019

1 2 3 4

Coil + supply Coil - supply + Terminal from the fuse 1F1 + Terminal after switch to the LAC

5 6 7 1F1

+ Supply to the discharge module 1A6 + Supply of the converter U1 + Terminal after fuse 1F1 Power fuse 355A

Technical data:

Cut-off current: 1500 A

Nominal voltage: 48 V DC (direct current)

Coil resistance: 54

Current: 250 A

Coil power: 6 W

Max. contact current: 350 A

11918012101 EN - 09/2019

-17

Parking brake

17

Speed limit

2

Wait

18

Speed limit exceeded

3

Maintenance Motor temperature

19

ESC

20

Enter

Battery

21

OK

6

Electrical problem

22

7

23

Cancel Up arrow

8

Question Warning

24

Right arrow

9

Fast speed

25

Down arrow

10

Hours

26

11

27

12

Odometer Hour meter, day

Left arrow Up/down arrows

28

Defroster activated at the rear

13

Speed sensor

29

14

Steering angle

30

15

Odometer, day RFID (Radio Frequency Identi cation) symbol

Defroster deactivated at the rear Headlight activated Headlight deactivated

1

4 5

16

-18

31 .

11918012101 EN - 09/2019

11918012101 EN - 09/2019

-19

This button allows you to trigger the hazard warning lights (Warning) to warn other users of a potential danger.

Press the button brie y to start the front windscreen wiper .Press the button brie y a second time to stop the front windscreen wiper .Press and hold the button (for more than 2 seconds) to activate the button windscreen washer system. Hold the button down. Operating the button in this way engages the windscreen washer systems for the front and rear wipers.

Press the button brie y to start the rear windscreen wiper Press the button brie y a second time to stop the rear windscreen wiper Press and hold the button (for more than 2 seconds) to activate the button windscreen washer system. Hold the button down. Operating the button in this way engages the windscreen washer systems for the front and rear wipers. button Allows you to activate the work lights.

Allows you to work in battery-saving mode. Decreases the speed of button the tow tractor or carrier. Disables particular functions (e.g., heating).

Press once to switch sidelights on.

Press twice to switch dipped beams on. button Press three times to switch sidelights on and dipped beams off.

Press four times to switch sidelights off and dipped beams off.

0

button

1

2

3 4 5

-20

11918012101 EN - 09/2019

6 7 8 9 10

Allows you to reduce or increase the speed of the tow tractor. button Button for changing the To access additional options. display Press and hold the button to display menu 2. menu Allows you to demist the rear window. button Button light

11 12 13 14

indicator light indicator light light

15

16

Start-up screen

Allows you to switch on the cab's rotating beacon.

Provides access to options (if enabled).

This light signals that the parking brake is applied. It also signals that errors are present.

When this indicator light is on, the truck is moving forwards.

When this indicator light is on, the truck is moving backwards.

When this indicator light is on, the forklift truck driver is preparing to turn right.

When this indicator light is on, the forklift truck driver is preparing to light turn left.

Menu 1: A / Battery charge status B / Gradient of the slope C / Speed D / Time Menu 2: A / Hour meter B / Number of hours before the next service inspection C / Drive programme mode selection D / Number of daily kilometres

If the time is no longer displayed, please contact the after-sales service department.

11918012101 EN - 09/2019

-21

Immobilise the truck.

Switch off the ignition.

Push the display forwards in order to remove it from its unit (1).

Risk of injury.

Wear gloves to protect hands.

The plastic surface is fragile.

Do not use tools to remove the display.

Disconnect the plug 6X2 (2) and remove the display.

Connect the plug 6X2 (3).

Attach the display to the mounting unit (4). The springs (5) engage.

-22

11918012101 EN - 09/2019

When the key switch is switched on, the display shows the hours of use (1) until the next service.

The number of kilometres left to run (2) and the total number of kilometres travelled by the truck are shown (4).

The hours of use until the next service are counted down synchronously with the operating hours.

The maintenance interval time is set to 1000 operating hours and can be adjusted using the diagnostic tool.

When the counter for the maintenance interval time reaches zero, the symbol (3) is activated when the truck is started up.

The display shows the time exceeded as a negative value (5).

The symbol (3) will ash when the truck starts if the set maintenance time has been exceeded.

The service interval counter can be reset using the diagnostic tool.

11918012101 EN - 09/2019

-23

The following information is displayed: The remaining travel time in hours (1) Driving speed (2) The remaining battery charge (in bars and time) (3)

-24

11918012101 EN - 09/2019

The battery discharge status is shown in bars and time on the LED display unit (1).

The display is activated when starting the truck up. The battery charge is rst displayed in bars and then in time after 10 seconds.

When the battery is 75% discharged, the truck automatically goes into Blue Q mode (ef ciency mode) (2). Driving speed is automatically reduced.

Damage to equipment Deep discharge of the battery can cause irreparable damage. The battery must be charged in accordance with the manufacturer's instructions to avoid damaging it. The battery must not remain discharged for a lengthy period of time.

11918012101 EN - 09/2019

-25

Name

CPP1

CPP2 Rear lighting, top lighting without cab, licence plate lighting (STVZ0 option)

CPP3 Cab, rotating beacon, working light with cab

CPP4 CPP6 Electric hook, seat heater without Top lighting cab, rotating with cab, rear beacon without cab, window wiper additional hydraulics

Functions

Front lighting

Reference

56323602607

51523602606

56323602606

56323602605

51523602610

CAN node

0x40

0x43

0x45

0x49

0x4D

The CPPs supply and control the various optional electric components on the truck.

The location and number of the CPP in the truck varies. It depends on the truck equipment.

The rst digit shows the CPP number (1 6) and the second digit shows the channel number (OUTPW1 9).

-26

11918012101 EN - 09/2019

X51 X52

CAN bus Supply voltage

X53

2 x 2-pin plugs, 1 variable switching output, 1 xed switching output

X54

10 x 2-pin plugs with 7 variable switching outputs

X53:1-2 X54:1A X54:2A X54:1B X54:2B X54:9A X54:10A X54:9B X54:10B

OUTPW 1, 2, 10

Earth OUTPW 3 Earth OUTPW 9

Front left-hand main beam headlights 60 W (bulb)

Front right-hand main beam headlights 60 W (bulb)

X54:3A X54:4A X54:3B X54:4B

OUTPW 4

X54:5A

Earth

X54:5B

OUTPW 6

X54:6A

Earth

X54:6B

OUTPW 5

X54:7A

Earth

X54:7B

OUTPW 8

X54:8A

Earth

X54:8B

OUTPW 7

Front left-hand direction indicator 21 W (bulb) / 3 W (LED) Front left-hand lights 7 W (bulb) / 1 W (LED) Front right-hand lights 7 W (bulb) / 1 W (LED) Front right-hand direction indicator 21 W (bulb) / 3 W (LED)

.

11918012101 EN - 09/2019

-27

X51 X52

CAN bus Supply voltage

X53

2 x 2-pin plugs with 2 permanently assigned switching outputs

X54

5 x 2-pin plugs with 5 permanently assigned switching outputs

X53:1-2

OUTPW 1, 2, 10

X54:1A X54:1B X54:2A X54:6A X54:9A X54:4A X54:8A

OUTPW 3 OUTPW 6 Earth OUTPW 5

X54:9A

Earth

X54:2B

OUTPW 4

X54:10A

Earth

X54:5A

Earth

X54:5B

OUTPW 8

X54:5A

Earth

X54:7B

OUTPW 8

X54:3A

Earth

X54:8B

OUTPW 11

X54:3A

Earth

X54:4B

OUTPW 11

.

-28

11918012101 EN - 09/2019

Rear left-hand direction indicator 21 W (bulb) / 3 W (LED) Rear right-hand direction indicator 21 W (bulb) / 3 W (LED) Right-hand reversing lights 21 W (bulb) and reversing beep Rear left-hand brake lights 21 W (bulb) / 3 W (LED) Rear right-hand brake lights 21 W (bulb) / 3 W (LED) Rear right-hand lights 7 W (bulb) / 1 W (LED) + number plate light (STVZo option) Rear left-hand lights 7 W (bulb) / 1 W (LED)

X51 X52

CAN bus Supply voltage

X53

2 x 2-pin plugs, 1 variable switching output, 1 xed switching output

X54

10 x 2-pin plugs with 7 variable switching outputs

X53:1-2 X54:1A X54:2A X54:1B X54:2B X54:3A X54:4A X54:3B X54:4B

OUTPW 1, 2, 10

Earth OUTPW 3 Earth OUTPW 4

X54:5A

Earth

X54:5B

OUTPW 6

X54:6A

Earth

X54:6B

OUTPW 5

X54:7A

Earth

X54:7B

OUTPW 8

X54:8B

OUTPW 7

X54:9B

OUTPW 9

X54:10A

Earth

X54:10B

OUTPW 9

Front windscreen wiper

Seat heater 100 W

Rotating beacon 55 W (bulb) / 15 W (LED) Washer system 15 W Rear defroster relay 4.4 W Working lights 15 W (bulb)

Blue Q 3 W relay option and 15 W roof light (bulb)

.

11918012101 EN - 09/2019

-29

X51 X52

CAN bus Supply voltage

X53

2 x 2-pin plugs with 2 permanently assigned switching outputs

X54

6 x 2-pin plugs with 6 permanently assigned switching outputs

X53:1-2

OUTPW 1, 2, 10

X54:1A

Earth

X54:1B

OUTPW 4

X54:2A

Earth

X54:2B

OUTPW 6

X54:3A

Earth

X54:3B

OUTPW 5

X54:4A X54:4B

OUTPW 8

Electric hook Seat heater Hydraulic relay Solenoid valve relay 15 W working lights

X54:5A X54:5B

OUTPW 7

X54:6A X54:6B

OUTPW 9

.

-30

11918012101 EN - 09/2019

55 W rotating beacon

X51 X52

CAN bus Supply voltage

X53

2 x 2-pin plugs with 2 permanently assigned switching outputs

X54

6 x 2-pin plugs with 6 permanently assigned switching outputs

X53:1-2

OUTPW 1, 2, 10

X54:5B

OUTPW 8

X54:5A

Earth

X54:7B

OUTPW 8

X54:5A

Earth

X54:2A X54:6A X54:9A X54:4A X54:8A X54:9A X54:2B X54:6B

OUTPW 6 Earth OUTPW 5 Earth OUTPW 4

X54:10A

Earth

X54:4B

OUTPW 11

X54:3A

Earth

X54:8B

OUTPW 11

X54:3A

Earth

Rear window wiper Left-hand brake lights, 21 W Right-hand brake lights, 21 W Left-hand direction indicator, 21 W Right-hand direction indicator, 21 W

Right-hand reversing light, 21 W Rear left-hand lights, 7 W Rear right-hand lights, 7 W

X54:1A X54:1B X54:3B

OUTPW 3

X54:7A X54:9B

OUTPW 7

X54:10B

OUTPW 9

.

11918012101 EN - 09/2019

-31

The FleetManager eet management system allows access control and transmission of truck data.

This system consists of two reading device versions for access control.

Access control and GPRS module Access control, shock sensor and GPRS module This system and the additional options are tted on trucks from:

Additional options:

EXD:

Shock sensor

LTX:

Tools for wireless data management:

GPRS radio module (1) with GSM antenna (2)

The variants available on the truck are: Access control

SXD and SXH: (1)

GPRS: General Packet Radio Service

(2)

GSM: Global System for Mobile Communication

Access control and shock sensor

-32

11918012101 EN - 09/2019

1 2 2A 2B 3

Reading device with a keypad RFID reading device * RFID transponder card RFID transponder TDU connector 6X16

The TDU (Truck Data Unit) access control is available in two versions: Reading device with a keypad (1) OR RFID (Radio Frequency IDenti cation) reading device with truck access by:

The only way to nd out the access control version is by connecting it.

(3)

RFID transponder card, 13.56 MHz (2A)

Battery voltage

RFID transponder, 13.56 MHz (2B)

0V Shock signal

Some of the data is transferred via Bluetooth.

Relay 1

Parameterising is carried out with the of the After-Sales Service.

Relay 1 CAN 2 High

*Contact the After-Sales Service to obtain the following versions of transponders:

CAN 2 Low CAN 1 High

RFID transponder, 125 kHz

CAN 1 Low

RFID transponder card, 125 kHz .

11918012101 EN - 09/2019

-33

This sensor allows you to record the shocks received by the truck.

If the truck receives a shock, its speed can be reduced.

Some settings can only be changed by the eet manager.

If the sensor is faulty, replace it.

There are two reference numbers for shock sensors. One reference number when the sensor is tted alone and another when it is tted with the GPRS unit.

This is composed of a communication unit, also called a "radio module"(4) and a GSM antenna (5).

The GPRS unit allows: Access truck information remotely Locate the truck This data is located on a server.

The status of the diodes indicates the status of the communication unit.

-34

11918012101 EN - 09/2019

The on-board charger is positioned at the rear of the truck.

It allows you to recharge the battery easily by connecting to the mains socket.

The status of the on-board charger is represented by a diode (4) positioned on the outside of the enclosure (A).

1 2 3 4

On-board charger Electrolyte agitation pump (option) Fan Outer diode

The green (5) and red (6) diodes are located on the on-board charger (B).

Remove the enclosure for access.

Battery not connected Phase 1 (constant current) Phase 2 (voltage check)

GREEN (5)

RED (6)

Off

OFF

OFF

Orange

ON

ON

Orange

Phase 3 (overload)

Flashing orange

ON Flashing

ON Flashing

Phase 4 (stand-by)

Green

ON

OFF

Phase 5 (equalisation) Phase 6 (variable charge)

Green

ON

OFF

Green

ON

OFF

Alarm CAN connection/Mode button programming Battery fan error

Red

OFF

ON

Flashing green

Flashing

OFF

Flashing red

OFF

Flashing

.

11918012101 EN - 09/2019

-35

The switch (7) is connected to the truck power supply.

The truck will not start if: The power cable (8) is stored incorrectly OR The access panel (9) is not closed properly OR There is a switch fault.

The electrolyte agitation pump is a system that allows air to be blown into the battery to agitate the electrolyte inside.

If the air lter (13) is blocked: Open the lter.

Clean the foam by rinsing under water.

The fan (14) starts at the same time as the on-board charger starts charging.

10 11 12 13 14

-36

Electrolyte agitation pump Electrolyte agitation pipe 6-way connector for the electrolyte agitation pump Air lter Fan

11918012101 EN - 09/2019

As soon as you connect the charger to a mains socket, it summarises these parameters in the following order: 1 - "Fir" followed by a number => Software version (for information) 2 - "BAt" followed by a number => Battery voltage (for information)

They indicate in real time and in the order below: 1 - The voltage (1) 2 - The current (2) 3 - Time since the start of charging (3) 4 - Number of ampere hours (Ah) that it has transferred to the battery (4)

3 - Battery type 4 - Type of mains power 5 - "Ah" followed by a number => Battery capacity 6 - Battery charging time (for information) 7 - "Air" followed by ON or OFF => Presence of electrolyte agitation or not During charging, the lights (5) ash.

Disconnect and store the mains power cable at the end of charging.

If the access panel is not properly closed, the truck will not start. : These parameters are described in detail in the section "Parameterising the charger"

11918012101 EN - 09/2019

-37

9X12

2

1

X7

6X20

9X27

119100_60-021

1 2 9X12 X7

Power supply connector C20 On-board charger Fan connector Connector for the outer diode

6X20 9X27

CAN connector (not used) Connector for parameterising OR for the electrolyte agitation pump

The following procedure is to be followed when changing the battery or parameterising the charger.

All parameters are reset to zero

Unscrew the four screws (7) (three screws on the outside and one screw on the inside of the access panel).

Remove the enclosure (8) from the on-board charger.

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11918012101 EN - 09/2019

If the charger is equipped with an electrolyte agitation pump, the connector (9) must be disconnected.

Use a 6-way connector (10).

Make a shunt between pins 2 and 6 and connect.

Hold the "Mode" button (11) and connect the mains power cable.

Then release the button.

Parameterising can then begin.

To scroll to a parameter, press the "Mode" button.

Press the "Mode" button for two to three seconds to con rm a parameter and go to the following menus.

1

2

Battery type

Type of mains power

Lead battery

Pb Gel

Gel battery

CU1

CU1 = 10 A

Used in Switzerland

CU2

CU2 = 13 A

Used in the UK

CU3 = 14 A Used in the rest of the European Union Choose the capacity according to the battery type Lead [Ah] Gel [Ah]

CU3

3

Battery capacity

4

Battery charging time

5

Operation of the electrolyte agitation pump

default battery

Ah

ON OFF

240

210

345

225

375

300

400

330

575

500

625 550 Value cannot be changed ON: Activates the electrolyte agitation pump OFF: Deactivates the electrolyte agitation pump

.

11918012101 EN - 09/2019

-39

A01

Internal error

A07

Excess current

A08

High charger temperature

A09

Insuf cient voltage (Polarity reversal)

A10

Charging too long (Time)

A13

Battery disconnected

A23

Error in the power circuit

A24

Incorrect input voltage

A25

Short circuit at the output

A27

No mains voltage

A28

Low temperature

A55

Battery fan alarm

Output current out of range YES 1) Restart charging 2) Replace the on-board charger Excess current TEMPORARY 1) Restart charging 2) Replace the on-board

charger High charger temperature TEMPORARY Ventilate the charger and/or check that the fan is working and then restart charging Battery voltage sensor error TEMPORARY (Blown fuse) 1) Restart charging 2) Replace the on-board charger Maximum time of phase 1 YES exceeded 1) Check the condition of the battery 2) Check that the charger parameters are consistent with the battery 3) Restart charging Poor battery connection TEMPORARY Reconnect the battery Error in the current sensor YES circuit of the charger 1) Restart charging 2) Replace the on-board charger Supply voltage out of range YES 1) Check the mains voltage 2) Check the power cable 3) Restart charging Short circuit on the charger YES output circuit 1) Check the wiring at the charger output (towards the battery) 2) Restart charging 3) Replace the on-board charger No voltage on the mains input TEMPORARY 1) Check the mains voltage 2) Check the power cable The temperature of the charger TEMPORARY is less than -30°C 1) Check that the temperature is higher than -30°C 2) Restart charging The fan is blocked or there is a YES connection problem (cut wire) 1) Check the wiring of the fan 2) Restart charging 3) Replace the fan

.

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11918012101 EN - 09/2019

A socket (1) is available at the rear of the truck.

It allows you to connect an external charger to charge the battery.

The two switches (2) on the socket are connected to the truck power supply.

The truck power supply is cut when the charger is connected to the socket.

Replace the switches in the event of a fault.

Leave the socket on the truck during the replacement.

If the socket is equipped with an air mixing pipe, also leave this pipe on the truck.

11918012101 EN - 09/2019

-41

1 2

Electric coupling Coupling in the closed position (on the display) Electric coupling closed Coupling in the open position (on the display) Electric coupling open

3 4 5

6 7 8 9

Control button Lower position sensor (open coupling detection) Upper position sensor (closed coupling detection) Geared motor

The electric coupling (1) is positioned at the rear of the truck.

The operator can attach or detach trailers from the driver's compartment.

The electric coupling system is tted with: A control button (6) Two position sensors (7) and (8) A geared motor (9) A relay The system can be opened electrically or manually.

The system closes automatically.

Details on operation are available in the operating instructions (chapter: Trailer coupling)

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11918012101 EN - 09/2019

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

O-ring Pump motor Coupling Coil Flow limiter Pump Tank Plug Fasteners Pipe Pipe Suction lter Sealing plug

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

11918012101 EN - 09/2019

Valve Tank label '3/8-1/4-BSPP adaptor Manostat Adaptor Seal Min./max. oil level label Valve holder Pressure cut-off Non-return valve Screw plug 'G1/8-V80-A3C '3/8 seal Seal

-43

1 2 3 4 5

Pressure switch (set to 195 bar) Solenoid valve Flow limiter Pressure cut-off (set at 280 bar) Non-return valve

6 7 8 9

Power Voltage

Tank

Pump

-44

2 kW

Speed

48 V 2500 rpm

Current S2 mode of operation

2.6 min.

Motor

Operation cycle

Pump Pump motor Oil lter Tank

125A

S3 mode of operation

7%

Nominal capacity

4.5 l

Working capacity

3l

Max.

lling volume:

3.2 l

Min.

lling volume:

2.9 l

Moving off

1.6 cc/rev

Maximum pressure

350 bar

11918012101 EN - 09/2019

Hydraulic system

Pressure relief valve setting

280 bar

Pressure switch setting

195 bar

Flow limiter Hydraulic uid

Mineral oil

12 l/min DIN 51524 part 2

Recommended oil

Titan H46 Fuchs

46 cST

.

11918012101 EN - 09/2019

-45

1A13 1F1 1K0 2F1

-46

CPP4 unit 355 A power fuse Line contact switch 100 A pump-motor unit fuse

2K1 2K10 2Y11 6B2

Pump-motor unit contactor Load retaining solenoid valve relay Load retaining solenoid valve Current sensor

11918012101 EN - 09/2019

The operation of the Liftrunner function is described in the operating instructions.

Maximum traction speed in forward travel: 15 km/h.

Components required to use this option: CPP4 control box (see details in Chapter 60: Electrical/electronic equipment, CPP control box) Current sensor (see details in Chapter 60: Electrical/electronic equipment) A pressure switch is used to position the trailers in the raised or lowered position.

Pin 1X1: 6: If 1X1: 6 open: the trailers are not in the raised position

F3:Setup Jobs Tugger Train Execute Connect to the truck using the diagnostic tool.

Go to the following menu: The following time settings can be modi ed: Time before activation of lifting once the forklift operator is sitting on the seat (default: 1 s, can be adjusted to between 0 and 6 s) Time before activation of trailer lowering (default: 3 s, can be adjusted to between 0 and 10 s) Additional time for pumping: Ensure that the trailers are raised when the pressure switch is engaged (default: 5 s, can be adjusted to between 0 and 10 s) Additional pumping at start-up: re-pressurisation of the pump-motor unit when restarted (default: yes, can be deactivated) Condition: The trailers must be in the raised position

It is possible to x the trailers in the raised position

11918012101 EN - 09/2019

-47

If there is a pressure drop, the truck stops (error code T152 = pressure drop during operation) If code T150 is displayed: The pressure is greater than or equal to the maximum pressure after 10 s.

If code T151 is displayed: The pressure is lower than the maximum pressure.

Check the pressure switch Check if there is a leak Check the condition of the electrical connections

-48

11918012101 EN - 09/2019

a

Risk of trapping ngers It is recommended that you wear gloves when changing the battery.

When changing the battery, it is essential that you use the Fork Off tool sold with the battery by the Fenwick-Linde Group.

Proceed as follows: Immobilise the tractor in a suitable open area, on even, horizontal ground Switch off the ignition and remove the key or turn the turning knob Press the emergency off switch Open the battery compartment door Position the Fork Off tool as shown. Adjust the feet of the tool so that it is centred and parallel to the forks. Position the tool correctly under the battery

11918012101 EN - 09/2019

-1

Position the tool up to the stop (1) Unplug the battery connector (2). Place it in the location provided for this purpose

Unlock the battery (3)

Using the Fork Off tool, gently lift the battery and remove it from the battery compartment (4) Align the battery and the chassis in accordance with the visual marking (5) Change the battery Using the tool, push the new battery down to the bottom of the battery compartment (4)

Risk of pinching of the cables Take care not to pinch the battery connector cable.

Align the battery and the chassis in accordance with the visual marking (5) Lock the battery Reconnect the battery connector

-2

11918012101 EN - 09/2019

Close the battery compartment door Driving with the battery compartment door open is not permitted.

Restart the truck

11918012101 EN - 09/2019

-3

Risk of trapping ngers It is recommended that you wear gloves when changing the battery.

It is possible to change the battery using a Roll Off tool. The spare battery is on the tool already.

Proceed as follows: Immobilise the tow tractor in a suitable open area, on even, horizontal ground.

Switch off the ignition and remove the key or turn the turning knob.

Press the emergency off switch.

Open the battery compartment door.

Position the tool near the tow tractor. The empty slot is level with the battery compartment.

Disconnect the battery connector.

Unlock the battery.

Pull the battery towards the roll holder. Remove the battery completely.

Connect the battery connector to the second battery, which is located on the Roll Off tool.

Pull the emergency off switch and restart the tow tractor.

Move the tow tractor forwards slowly and carefully with the battery compartment door open.

This is the only manoeuver where it is permitted to drive while the battery door is open.

Immobilise the truck at the second battery.

Switch off the ignition and remove the key or turn the turning knob.

Press the emergency off switch.

Disconnect the battery connector.

Push the second battery to the bottom of the battery compartment.

-4

11918012101 EN - 09/2019

Risk of pinching of the cables Take care not to pinch the battery connector cable.

Lock the battery.

Reconnect the battery connector.

Close the battery compartment door.

Restart the truck.

11918012101 EN - 09/2019

-5

The electric heating system is designed to heat the cab. It is located below the display.

It consists of: A 48-V axial blower with a wiring harness of 56 resistance A PTC HR20 11/14 heating device with a wiring harness A bimetallic switch to 100°C for the PTC A grille that draws in air (A) Two Ø50-mm ttings for the air outlet (B)

The fuse is faulty or not connected properly The cables are faulty The fan is not working

The axial blower motor is faulty

Check the connection of the fuse Replace faulty fuses Test the cables Replace the blower

The controls are faulty

Check the controls and replace if necessary

The resistor is faulty

Replace the resistor

The connector is not connected Check the connection of the power supply connector properly The contacts are dusty Carefully clean the contacts of the connector The power of the heater is reduced

The cables are not suitable The air lter is dusty or worn

Install the recommended cable section Clean or replace the lter

The air intake area is blocked The PTC temperature sensor has fallen

Check the air intake area Check the fan

.

-6

11918012101 EN - 09/2019

X100: 1

Grey

Thermal protection

X100: 2

Grey

Thermal protection

X100: 4

Orange

Heating circuit

X100: 5

Orange

Heating circuit

X100: 6

Orange

Heating circuit

X100: 7

Orange

Heating circuit

X100: 10

Brown

0V

X100: 11

Brown

0V

X100: 12

Brown

X102: 1

White

0V Fan speed 1

X102: 2

Red

Fan speed 2

X102: 3

Brown

X102: 4

Blue

0V

.

11918012101 EN - 09/2019

-7

-8

11918012101 EN - 09/2019

ABE 2 display Replacing the ABE 2 display . . . . . . .

Display . . . . . . . . . . . . . . . . . . . . . . . . .

-20

Display of the remaining travel time . .

-24

Maintenance interval indicator . . . . .

-23

-22

Accelerator Changing the accelerator . . . . . . . . . .

-3

Function . . . . . . . . . . . . . . . . . . . . . .

-1

Accelerator pedal

Drive and transmission General description . . . . . . . . . . . . . .

-1

Drive axle

Connector assignment X16 . . . . . . . .

-1

Shock absorbers . . . . . . . . . . . . . . . .

-3

Driver's cab Battery Discharge indicator . . . . . . . . . . . . .

-25

Battery compartment Installing and adjusting the battery door . . . . . . . . . . . . . . . . . . . . . . .

Replacing the windscreen . . . . . . . . .

-4

Replacing the windscreen wiper motor . . . . . . . . . . . . . . . . . . . . . .

-2

Driver's compartment General description . . . . . . . . . . . . . .

-5

-1

Driver's controls

Brake drums

General description . . . . . . . . . . . . . .

-1

Technical features . . . . . . . . . . . . . .

-10

Brake pedal . . . . . . . . . . . . . . . . . . . . . . .

-8

Functional description . . . . . . . . . . . .

-8

Electric coupling (option) Description . . . . . . . . . . . . . . . . . . .

-42

-1

Electric heating . . . . . . . . . . . . . . . . . . . .

-6

Brakes General description . . . . . . . . . . . . . .

Braking

Electrical equipment

Brake drums . . . . . . . . . . . . . . . . . .

-10

General description . . . . . . . . . . . . . .

-1

Functional diagram . . . . . . . . . . . . . .

-3

General . . . . . . . . . . . . . . . . . . . . . . .

-5

Checking the coil . . . . . . . . . . . . . . . .

-7

Hydraulic brake circuit . . . . . . . . . . . .

-9

Checking the distance of the lining . . .

-6

Functional check . . . . . . . . . . . . . . . .

-7

Electromagnetic brake

Mechanical release . . . . . . . . . . . . . .

-6

CAN bus network . . . . . . . . . . . . . . . . . . .

-7

Electromagnetic brake Y1 . . . . . . . . . . . .

-6

Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing the battery with the Fork Off tool . . . . . . . . . . . . . . . . . . . . . . .

-1

Electromagnetic compatibility . . . . . . . . . .

-5

Emergency off switch . . . . . . . . . . . . . . .

-13

Changing the battery with the Roll Off tool .

-4

Energy-saving mode . . . . . . . . . . . . . . .

-18

-1

Chassis General description . . . . . . . . . . . . . .

-1

Cleaning the motor . . . . . . . . . . . . . . . . .

-13

CPP (Can Power Port) control boxes Functions of CPP control boxes . . . .

-26

CPP 1 (front lighting) . . . . . . . . . . . . . . .

-27

CPP 2 (rear lighting) . . . . . . . . . . . . . . . .

CPP 3 (cab option) . . . . . . . . . . . . . . . . .

-28 -29

CPP 4 (electric hook and additional hydraulics) . . . . . . . . . . . . . . . . .

-30

CPP 6 (top rear lighting) . . . . . . . . . . . . .

-31

Error codes Reading and deleting the error list . . . .

-9

Changing the fan . . . . . . . . . . . . . . .

-12

Function . . . . . . . . . . . . . . . . . . . . .

-10

Fan

FleetManager Access control . . . . . . . . . . . . . . . . .

-33

FleetManager

description . . . . . . .

-32

FleetManager

options . . . . . . . . . .

-34

GPRS unit . . . . . . . . . . . . . . . . . . . .

Shock sensor . . . . . . . . . . . . . . . . . .

-34 -34

11918012101 EN - 09/2019

1

Front brake drum

Motor

Removing . . . . . . . . . . . . . . . . . . . .

-15

Functions of the Inputs/Outputs of the LAC . . . . . . . . . . . . . . . . . . . . . . .

-8

Gearbox breather Cleaning and checking . . . . . . . . . . . .

Rotor testing . . . . . . . . . . . . . . . . . .

-12

Visual inspection . . . . . . . . . . . . . . .

-12

Motors Cleaning . . . . . . . . . . . . . . . . . . . . .

-13

Testing . . . . . . . . . . . . . . . . . . . . . .

-12

-4 On-board charger (option)

Hydraulic braking Replacing the front brake assembly .

-14

Replacing the front brake drum . . . . .

-11

Inner part of the new drum . . . . . . . . . . .

-12

Installing the brake drum . . . . . .

-13,

-16

Installing the new accelerator . . . . . . . . . .

-4

Installing the new windscreen . . . . . . . . . .

-4

Installing the windscreen wiper motor . . . .

-3

Insulation testing . . . . . . . . . . . . . . . . . . .

-4

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

-35

Electrolyte agitation pump . . . . . . . .

-36

Features of the diodes . . . . . . . . . . .

-35

Operation . . . . . . . . . . . . . . . . . . . .

-37

Parameterising . . . . . . . . . . . . . . . .

-38

Opportunity charging Description of opportunity charging . .

-41

Outer part of the drum . . . . . . . . . . . . . .

-12

Parameterising Blue-Q mode . . . . . . . . .

-19

Power module Connections . . . . . . . . . . . . . . . . . .

Jacking the tow tractor . . . . . . . . . . . . . . .

-4

KTY84-130 sensor Description . . . . . . . . . . . . . . . . . . .

LAC traction controller (1A1) . . . . . . . . . . .

-17

-6

Liftrunner Features . . . . . . . . . . . . . . . . . . . . .

-43

Hydraulic circuit diagram . . . . . . . . .

-44

Location of components . . . . . . . . . .

-46

Liftrunner (option) Description . . . . . . . . . . . . . . . . . . .

-47

Parameterising . . . . . . . . . . . . . . . .

-47

Line switch 1K0 . . . . . . . . . . . . . . . . . . .

-17

Preparing the truck . . . . . . . . . . . .

-4, -3, -11, -14

-2,

Raising the truck . . . . . . . .

-11,

-14

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

-1

Replacing the rear axle . . . . . . . . . . . .

-5

-3,

Rear axle

Removing the accelerator . . . . . . . . . . . . .

-4

Removing the brake assembly . . . . . . . .

-15

Removing the front brake drum . . . . . . . .

-12

Removing the windscreen . . . . . . . . . . . .

-4

Removing the windscreen wiper motor . . .

-3

Rev sensor . . . . . . . . . . . . . . . . . . . . . .

-15

Safety guidelines Electrical equipment . . . . . . . . . . . . . .

Main fuses . . . . . . . . . . . . . . . . . . . . . . .

-16

Maintenance plan 3000 hours . . . . . . . . . . . . . . . . . . . . .

-1

Maintenance schedule 1000 hours . . . . . . . . . . . . . . . . . . . . .

2

-1

-14

-1

Seat Changing the seat . . . . . . . . . . . . . . .

-1

Shock absorbers Test speci cations . . . . . . . . . . . . . . .

-3

Slinging the tow tractor . . . . . . . . . . . . . . .

-2

STEDS Navigator . . . . . . . . . . . . . . . . . .

-2

11918012101 EN - 09/2019

Steering

Traction motor

General description . . . . . . . . . . . . . .

-1

Location of motor cables . . . . . . . . . .

-14

Steering angle sensor . . . . . . . . . . . . . . .

-1

Replacing the bearing . . . . . . . . . . .

-10

3X2 connector assignment . . . . . . . . .

-1

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

-10

Steering column . . . . . . . . . . . . . . . . . . . .

-2

Winding test . . . . . . . . . . . . . . . . . . .

-12

Symbols

Transmission

Display . . . . . . . . . . . . . . . . . . . . . .

-18

Replacing the transmission seal . . . . .

-1

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

-1

Voltage converter U1 (75 W) . . . . . . . . . .

-14

Temperature sensor . . . . . . . . . . . . . . . .

-17

Voltage converter U2 (500 W) . . . . . . . . .

-15

Tow coupling and carrying compartment

Voltage converter U2 (75 W)

General description . . . . . . . . . . . . . .

-1

TRACTION fault codes . . . . . . . . . . . . . .

-11

Pin assignments for connector X22 . .

11918012101 EN - 09/2019

-14

3

STILL GmbH 11918012101 EN 09/2019