https://truckmanualshub.

com/

 
  
     

 

 

                
      
                 
https://truckmanualshub.com/
 https://truckmanualshub.com/

  

  

  

   
    
   
    
     
      

     

    
      
    
    
        

    

    
      
    
      
      
    

      

    
     
     
    
     
     
    
    
   
    
   
   
    
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  

  
    
  
     
    
        
         
    
       
         
        
         
          
   
     
      
        
      
                
   
            
        
      
        
        
     
   
       
     
       
         
      
          
   
           
            
           
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  

  

   

    
       
   
     
      
      
         
       
          
        
     
     
   
       
          
          
        
       
             
    
    
     
     
      
      
    
       
       
      
      
        

    

    
     
      
 https://truckmanualshub.com/

  

  
 https://truckmanualshub.com/

 
  



             

   

               
      
              
        

     

       
         

         

  
  
   

      

         

   

            

    

   
   

    

              
               

                 
       
 https://truckmanualshub.com/

 
  


          
     











 



              
              
               
  
           

 











         


            



            



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 
  

          










              


             
















              
                
               
               
         
              
 
                
           
             
  
         
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 
  
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Section 1
Service Training Page 1

1 TRACTION MOTOR
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Section 1
Päge 2 Service Training
1.1 DESCRIPTION



 






Asynchronous traction motor (AC) mounted vertically on

the reduction gear, which is fixed on the motor unit
support.

Electrohydraulic brake mounted directly on the motor

shaft.

Motor without maintenance controlled by:

- 1 speed sensor (1B2)
- 1 temperature probe (1B6).

1.2 TECHNICAL DATA

Asynchronous motor (AC) 24 volts

Power consumption 3 KW
Maximum speed 4,865 rpm
Torque at max. speed 5.2Nm
Max. torque 35 Nm (590 rpm)
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Section 1
Service Training Page 3

1 2 3 4 5 6 7 8

15

14

Oil level in reduction gear

13 12 19 20 11 10

1 Flange  
2 Circlips - 30 x 1.5 FST - DIN 471  
3 Key - 8 x7 x 20 DIN 6825  
4 Circlips -25 x 1.2 FST - DIN 471  
5 Ball bearing - 6006 2 RS1/ C3GJN  
DIN 625  
6 Circlips 55 x 2 FST - DIN 472 
7 Crown wheel (for measuring the speed)  
8 Screw D M 6x25-St-A2E - DIN 7500  
9 Rotor  
10 Ball bearing ICOS-D1B04 TN9
 
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Section 1
Päge 4 Service Training
1.3 REMOVAL OF TRACTION MOTOR



 






1 Traction motor
2 Temperature probe connector (1X25) 1B6
3 Speed sensor connector (1X2) 1B2
4 Screw CHC M6 X 20 (quantity 8)
Tightening torque 9.5 Nm
5 O-ring
6 Electrohydraulic brake
7 Brake mounting bolt (quantity 3)
Tightening torque 9.5 Nm
8 Reduction gear

U, V, W Power cable terminals

for motor supply
Tightening torque 9 Nm
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Section 1
Service Training Page 5

Note:
To remove the traction motor, it is recommended to first
remove the motor unit (see section 2.1.1 Removal/ins-
tallation of motor unit)

On clearing the chassis, the motor unit can be

manipulated more easily:

- Unscrew the 8 motor / reduction gear mounting bolts

(4).
- Sling the motor (1).
- Extract the traction motor from the top carefully and by
using appropriate equipment.

WARNING
Dangerous handling. The motor is heavy,
proceed with caution to remove the reduction
gear motor. It is recommended to wear gloves.

Installing the traction motor

- To install the traction motor, proceed in the reverse

order as for removal.

- Replace the O-ring (5) and grease it before refitting

the motor (1) in the reduction gear (8).

- Check the tightening torque of all the joints and con-

nections of the motor (see section 2).

CAUTION
- To prevent a short-circuit, it is important to
clamp the 3 terminals U, V, W of the traction
motor supply cables (tightening torque
9 Nm ).

- It is always possible to use an open-end

wrench to hold them while tightening.

- Make sure that all the fixtures are tightened at the

correct torque of 9.5 Nm

- Check the electrohydraulic brake air gap setting (see

section 4).
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Section 1
Päge 6 Service Training
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Section 2
Service Training Page 1

2 DRIVE - TRANSMISSION
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Section 2
Page 2 Service Training
2.1 DRIVE UNIT

7
8

3
4

3
6

Drive unit mounted on a turntable (4); steering ensured by

an electrical gear motor (7), which positions the turntable.

Motor wheel (6) powered by a single-stage reduction gear

(5) and a conical ring gear.

Asynchronous 3 kw traction motor (1) mounted vertically

on the reduction gear (5).

CAUTION
For a rubber or unbranded rubber motor wheel ,
a shim (3) is added.
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Section 2
Service Training Page 3

2.1.1 Removing/replacing the drive unit

CAUTION
Compulsory lifting potentiometer

- Sling the truck at least 60 cm from the ground and brace

it on platforms to extract the drive unit and its support
from the bottom.
- Turn the variator plate and the handlebar plate to the
back.
- Dismantle the left stabiliser (see section 4). 11
- Disconnect the steering potentiometer (8), the steering
motor (7) and the traction motor (1).
- Disengage the electrohydraulic brake (2) (see section 10
4).

CAUTION
To prevent hydraulic leaks on the brake linings,
don’t dismantle the brake hydraulic hose pipe.

- Screw on a slinging ring (10) at the end of the motor

spindle.
- Fasten 1 sling (11) and stretch it slightly with the hoist.
- Unscrew the 4 fixing screws (9) of the motor/ chassis
support unit.
- Extract the entire drive unit carefully from the bottom
(80 Kg).

WARNING
Dangerous handling. The drive unit is heavy,
proceed with caution to disengage it from the
chassis.
It is recommended to wear gloves.

To reinstall the drive unit, proceed in the reverse order as

for removal.

CAUTION
To prevent a short-circuit, it is important to clamp
the 3 terminals U, V, W of the traction motor
supply cables (tightening torque 7.5 Nm).
- It is always possible to use an open-end wrench
to hold them while tightening.

- Check the electrohydraulic brake air gap setting (see

section 4)
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Section 2
Page 4 Service Training
2.2 REDUCTION GEAR

33 28
34 29 2 27 3 5
7
8
6 12
10
6
18 17

1 11
9
32 22 13
25 14
16
15
21 19
30

23
26
20
15

Motor wheel powered by a single-stage reduction The type and serial number are identical on a sign
gear and a conical ring gear. plate fixed on the reduction gear.

Reduction gear in rotation by a slew ring fixed on

the chassis.

Maintenance:
Permanently greased slew ring.

2.2.1 Technical data

Reduction gear T20 / T24

Load on the drive wheel 1.5 T maxi
Number of teeth: slew ring 108
Speed reducing ratio 19.67
Oil volume 1.5 litres
Maximum torque at the wheel (static) 1,375 Nm
Maximum torque at the wheel (dynamic) 916 Nm
Torque at wheel: 229 Nm
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Section 2
Service Training Page 5

35 1
2
34
33
32 3
31
30 4
29 5
28 6
7
27
8
26
9
10
25 11
12
24
13

23 14
22 15

21 16
17
20
18
19

1 Grease duct 17 Drain plug

2 Headless screw M8X1.8 18 Drain plug joint
(for special applications, 2 lubricators can be 19 Trolley with tapered rollers
mounted in place of the screws). 20 Cover
3 Tightening torque 170 Nm 21 Wheel shaft
4 Lock nut 22 Trolley with tapered rollers
5 Right pinion 23 Spacer (60 / 7.5)
6 Trolleys with tapered rollers 24 Shim
(internal bushes mounted with loctite 603) 25 Seal ring (mounted with loctite 574)
7 Spacer 26 Wheel bolt (tightening torque 35 Nm)
8 Shim 27 Input pinion
9 O-ring 28 CHC M8X30 fixing screws toothed ring (see
10 Tapered pinion with tail tightening torque mark 31)
11 Cover 29 Centring bolt
12 CHC M8X16 screws (tightening torque 23 Nm) 30 Reduction gearbox case
13 H ISO 4017 M16x45 screws - 8.8-A2C 31 Tightening torque 23 Nm
(Tightening torque 290 Nm) 32 Steering toothed ring (z=108; m=2.5)
14 Lock washer 33 CHC M8X60 mounting screws, pivot bearing
15 Control shim (see tightening torque mark 31)
16 Conical ring gear 34 Slew ring
Note: Lifetime lubrication
35 Shim mounting tapped holes
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Section 2
Page 6 Service Training
2.2.2 Removal / reinstallation of reduction gear

1 2 3

10

9 6
4

1 Steering motor reducer

2 Traction motor
3 Electrohydraulic brake
4 Reduction gear
5 Screw CHC M6 X 20 (quantity 8)
Tightening torque 9.5 Nm
6 Screws Chc M10X30 (quantity 8)
Tightening torque 64 Nm
7 Screws Chc M10X35 (quantity 4)
Tightening torque 64 Nm
8 Drive unit support plate
9 Shim (for rubber or non-branded rubber drive wheel ).
10 Screws Chc M10X30 (quantity 3)
Tightening torque 64 Nm
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Section 2
Service Training Page 7

Note:
To remove the reduction gear, it is recommended to first
remove the drive unit (see section 2.1.1 Removal/instal-
lation of motor unit)

On clearing the chassis, the motor unit can be

manipulated more easily:

- Drain the reduction gear (4)

- Remove the steering motor reducer (1)
- Remove the traction motor (2)
- Pull out the support plate (8)

CAUTION
The traction motor and the reduction gear are
heavy. Use handling gloves to disengage the
motor and the reduction gear from the chassis.

To reinstall the reduction gear, proceed in the reverse

order as for removal.

Note:
In the chassis, the position of the drive wheel is at the
left and the reduction gear is at the right.

- Fill the reduction gear with the stipulated oil quality (SAE
80 W 90, API, GL5, MIL.L 21DSC quantity 1.5 l ).

CAUTION
Following this operation, it is absolutely
necessary to check the electric steering
control.
(see section 4.5: steering motor reducer).
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Section 2
Page 8 Service Training
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 
  

 
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 
  
  

    

         
     

          
        
   

         
   
       


          
 

           


  
          
        

  

             
 
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 
  

 

         

 

         

   
   
                  
         
         
       
            
              
   

    
    
          
 
      
  
  


         
 

       

  
           
   
         
         
       
    
      
       
 https://truckmanualshub.com/

 
  
  








 

 
   
 
  

 
 

 

           

     
  
       
     
    
   
             
                  
     
          
       
    
   
                
          
    
           
      
       
          
   
              
 
   
  
    
  
 
   
 https://truckmanualshub.com/

 
  



     

      
       
  

       

   
     

         

  

      

          
   
      

         


     
          
      

 
           

        
    
 https://truckmanualshub.com/

 
  
    

      

       

 

     

    
      
     
         


     
    
   


     
   
  


   
         
 
         
 https://truckmanualshub.com/

 
  

 



    

   

   
         
                
    
    
       
           
       
         
        


 

        


     
     
            
 

       

      
 https://truckmanualshub.com/

 
  
 https://truckmanualshub.com/

 
  

 
 https://truckmanualshub.com/

 
   







 






 

   

   
   
   
  
    
   
   
 https://truckmanualshub.com/

 
  

  

           

      

      
              

        
           
          

     

           
               

                 
                
                  

       

 https://truckmanualshub.com/

 
   
 

 









 











  

        

        
    
                 
     
         
           
           
     
                 
      
   

       
        
  
        
    
         
       
 
         
   
    
  
   
 https://truckmanualshub.com/

 
  

 

    

     
          
     
      
     
      
        

 

     
     
     
       
 
       
         

     





        


        


     

        
    
          
         
   
      
         
   

        


 https://truckmanualshub.com/

 
   
 


 

 


   













 

         

     
   
            
      
        
           
      
      
 
       
    
   
  
    
        
    
         
     
       
        
                    
            
        
     
   
   
 https://truckmanualshub.com/

 
  

        

      
        
     




     

       
  
       
 
       
      
       
   
     
      
    
     

         


          
      

  

            
  
      
         
         
    
        

        

  

 
 https://truckmanualshub.com/

 
   
 

          

            


        

        
       
     
       
                  
               
  

          
 
 https://truckmanualshub.com/

 
  



   

 
  
     
    
    
 
    
   
   
    
     
  
     
    
  
     
  
    
    
   
   
   
    
 https://truckmanualshub.com/

 
   
 






          
    
      
             
            
     
                  
        
  
    
 https://truckmanualshub.com/

 
  



    

       
       
  
         
  

         


        
  
      

      

  
        
       
     
 




       
   

 

       

       
    

       

   
      

    


 

 
 

 
   
 https://truckmanualshub.com/

 
   
 
 

        
        
        
       
      

        

      
      
    

  




     
    
          
 
         
        
    
     
      

 
 https://truckmanualshub.com/

 
  



         

     

    
          
         



       
             
     

            
      
           
    



 
          
         

           
         
    
      
     
      


         


 
  

 
 https://truckmanualshub.com/

 
   
  










      


       
           
        
  
          
              
  
    
        
      
   
    
         
  
         
 https://truckmanualshub.com/

 
  



      

      
    
     
    
               
  
  



         
           
 

           

            
          
         


            

     
      
      
           

      
      
         
          
     


          
       

     

 https://truckmanualshub.com/

 
   
 



       

     
           
       
   
            
      
    
 https://truckmanualshub.com/

 
  

 



     

 
           
        
      



    

          
    
        
    
          
 
        
   
           
 https://truckmanualshub.com/

 
   
 



 


 
  




 
















      

     

    
     
            
           
         
     
   
       
   
   
   
 
  
          
      
  
   
        
 
          
         
  
  
   
   
    
        

 https://truckmanualshub.com/

 
  

   


          

          

       

        
         

     




   
       

        
 
       
       
            
        
  
     
          
    
        

         


      
 





      
      
      



      


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 
   
 







 

      

        
    
         
               
   
     
     




    

          
    
       
     
           

     
    

     


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 
  

 

 





 



        


     
            
     
            
         
      
    
   
  

    
    
          
 
   
    




         
    
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 
   
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Section 6
Service Training Page 1

6 ELECTRICAL EQUIPMENT
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Section 6
Page 2 Service Training
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Section 6
Service Training Page 3

6.1 TRACTION

6.1.1 Description and operation

ATTENTION: Before starting any work on the control system, always disconnect the battery connector. Non-
compliance with this procedure could damage the CAN interface controls. DO NOT remove or replace the
components when the truck is switched on.

6.1.1.1 Speeds / reduction of speeds

Stand-on pallet stacker speed => lowered platform and raised guard rail / SP version => 10Km/h
Stand-on pallet stacker speed => lowered platform and lowered guard rail => 8Km/h
Pedestrian pallet stacker speed => raised platform and lowered guard rail => 6Km/h

Speed reduced on turning => 6Km/h

Speed reduced / anti-crush 1S3 activated => 4Km/h
Speed reduced / battery unlocked => 2Km/h
Speed reduced / stabiliser oil level too low => 2Km/h

6.1.1.2 Tiller rear safety control – 1S3

By activating the tiller safety contact, the truck moves in the direction of the fork arms at reduced speed while the tiller
safety switch is not released. Once released, the truck is in safety and can restart only if the accelerator throttle moves
back to neutral position. The anti-crash safety can be activated or deactivated with the lowered platform (stand-on).

6.1.1.3 Control for lowering fork arms - 2S7

In SP and AP versions, in the lowered platform configuration, the lowering of the fork arms is possible only if the driver
is present on the platform.
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Section 6
Page 4 Service Training
6.1.2 Electric plate
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Section 6
Service Training Page 5

No. Description

1. Line contactor LES - 3K1

2. Line contactor LAC – 1K2
3. Hour meter indicator - 6P1
4. Inclinometer - 1A8
5. Steering controller LES – 3A1
6. Inclinometer support
7. Horn - 4H1
8. 29-track connector for LES -3X1
9. Connector support
10. LAC fans - 9M1 9M2
11. Power cables for traction motor and pump motor
12. Traction and hydraulic controller LAC - 1A1
13. Key switch - S1
14. Emergency stop button -7S1 / 7S5
15. Power fuse LES - 3F1
16. Power fuse LAC - 1F1
17. Control fuse - 1F3

Inclinometer support

A1 connector 1X3 (tiller panel card)

1A8 connector 1X26 (inclinometer)

1B6 connector 1X25 (T° motor 1M1)

Y1 connector 7X5 (electrobrake)

7A5 connector X13 (wheel brake)
Fuse support 1F3
Connector support LAC side

Connector 9X1 for 9M1/9M2 (fans)

1S9 connector 1X9 (operator presence)

1S15 connector 1X20 (platform)

Stopper for 1S15 on 131 SP

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Section 6
Page 6 Service Training
6.1.3 A.C. control – Operating principle

6.1.3.1 Traction and hydraulic power module - 1A1

For an asynchronous motor with typical three-phase current, the conducting path in the three windings is
controlled by a “bridge” of six MOSFETS. By controlling when each of the six MOSFETS is activated or
deactivated, it is possible to control in one direction then in the other, the current in each of the three motor
windings (phases).

MOTOR WINDING (PHASE) – ONE

First active Second

pair of active pair
MOSFETS of
MOSFETS

MOTOR WINDING (PHASE) – TWO

First active Second

pair of active pair
MOSFETS of
MOSFETS

MOTOR WINDING (PHASE) – THREE

First active Second

pair of active pair
MOSFETS of
MOSFETS
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Section 6
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Moreover, by varying the time during which each MOSFET is on, it is possible to control the average voltage applied
to each motor winding at any moment. In this manner, an almost sinusoidal voltage is applied to each winding when
the motor is running.

The frequency at which the six MOSFETS are activated and deactivated ON and OFF is much faster than that of the
AC supply seen by the motor. Typically, the traction motor will see an AC frequency of 180 Hz at the maximum speed,
while the MOSFETS will be switched at ON and OFF status at 8 KHz.

MOTOR RUNNING AT SEMI-SPEED (A SINGLE PHASE SHOWED FOR REASONS OF CLARITY)

90 Hz seen by the
motor
First active pair of Second active pair
MOSFETS of MOSFETS

12 V
8.5 V EFF

0V

8.5 V EFF 0% 50% 0%

12 V Percentage of time during which the
MOSFETS are on

MOTOR RUNNING AT FULL-SPEED (A SINGLE PHASE SHOWED FOR REASONS OF CLARITY)

180 Hz seen by the motor

First active pair Second active

of MOSFETS pair of MOSFETS

24 V

17 V EFF

0V

0% 100% 0%
Percentage of time
during which the
17 V EFF
MOSFETS are on
24 V
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Section 6
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High speed calculation microprocessors are used to make complex mathematical calculations required to arrange this
operation in sequences. It generates a revolving magnetic field variable at three phases. The synthesised AC supply
applied to the motor windings is thus an AC supply with variable frequencies and voltages. The motor rpm and the
available torque are controlled very accurately during the drive and also while braking through recovery.

6.1.3.2 Speed control and direction of travel

The truck speed is proportional to the frequency of the power supply applied to the motor. The direction of travel depends
on the conducting path through the three motor windings, one with relation to the other.

When the AC frequency applied is low, the average AC voltage applied to the motor windings is also low. On pressing
the accelerator initially, the voltage and the AC motor frequency will be low. Gradually, as the truck speed grows, the
frequency and AC voltage also grow simultaneously.

With the AC asynchronous type of motors used in the truck 131, the maximum torque is obtained when the motor
rotating speed is slightly less than what is determined by the AC voltage generated by the controller, i.e. the
“synchronous speed”. The minor difference is called “creep speed”. The controller regulates the voltage and the motor
frequency to ensure that this creep speed is maintained at the optimum value to have efficient performances.

The controller monitors the motor current and to ensure that it does not become excessive, it automatically assumes
priority on the accelerator loading to reduce the frequency and the AC voltage when necessary.
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Section 6
Service Training Page 9

6.1.4 Fuses - 1F1 - 1F3 - 3F1

The power circuit fuses are located on the LAC plate under the emergency stop.
The small control fuse is located on a bracket below the controller of the LES, it protects the entire control harness (LAC
and LES).

1. The nominal power of the fuse 3F1 (steering) is 100 A

2. The nominal power of the battery main fuse 1F1 is 225 A
3. 1F3 7.5A Key switch, traction/hydraulic and steering control circuits

NOTE: Although this control fuse might be interchangeable with the fuses with automobile type plate,
the USE OF AUTOMOBILE FUSES IS FORBIDDEN. Only original Linde fuses have the adequate capacity to
enable proper functioning with the voltages present in the truck.

POWER FUSE LES 3F1

POWER FUSE LAC 1F1

CONTROL FUSE 1F3

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Section 6
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6.1.5 Traction and hydraulic controller - LAC / 1A1

6.1.5.1 Description

The 1A1 controller, the LAC (Linde Asynchronous Control), comprises of a control card LTC (Linde Truck Control)
and a power stage for the traction and the hydraulics.

The transistors' control is performed by an electronic circuit called DRIVER, forming the interface between the power
and control parts.

The numeric control module LTC uses two microprocessors (Traction and Hydraulic) that are auto-controlled. If a fault
occurs, it is detected instantly and the control system puts the truck in safety, which can be a reduction in performance
or the halting of a controller, depending on the type of fault. The control module is equipped with a connector 1X1 of
70 pins.

µP Main for TRACTION µP Main for RAISING

AND AND
Safety for RAISING Safety for TRACTION

1X1

1
2

3 4 5 6

Control circuit connector 1X1

Traction
hydraulic
Traction and hydraulic
unused
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Section 6
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6.1.5.2 Main circuit terminals

1 :U the phase L1 of the traction motor

2 :+ positive power supply terminal +24V for the power unit
3 :V the phase L2 of the traction motor
4 :W the phase L3 of the traction motor
5 :- negative power supply terminal for the power unit
6 :Lift control terminal of the lift motor

6.1.5.3 Connector terminal functions 1X1

TERMINALCOLOUR TRAC/HYD. FUNCTION ASSOCIATED WITH

1 BU(329) Traction/hyd. Positive +24V for internal relay of LAC Provided by the internal relay of the steering LES
2 YE(2) Traction/hyd. Connected to the traction contactor coil Battery negative 0V
7 WH(7) Traction Tiller base Connected to the battery negative 0V
8 WH(8) Traction Operator presence Connected to the battery negative 0V
9 WH(9) Traction Speed sensor track A Variable signal 0V-6V
10 WH(10) Traction Speed sensor track B Variable signal 0V-6V
11 RD(11) Traction/hyd. Push button control Connected to the battery positive 24V
12 WH(12) Traction/hyd. Locking battery Connected to the battery negative 0V
14 YE(14) Traction Anti-crash safety Connected to the battery negative 0V
16 WH(16) hydraulic Cut-off of the LI on top Connected to the battery negative 0V
17 WH(17) Hydraulic Traction speed reduction LI low Connected to the battery negative 0V
21 WH(21) Hydraulic CAN high (elevation) Connected to the bus CAN high (elevation) LAC
22 YE(22) Traction Accelerator supply Connected to the +8.2V
23 RD(23) Traction/hyd. Supply voltage LAC Connected to the battery positive +24V
24 RD(24) Traction/hyd. Power supply to external components Connected to the battery positive +24V
25 GY(25) Hydraulic Lowering valve negative supply Connected to the battery negative via internal transistor
27 YE(27) Traction Left stabiliser negative supply Connected to the battery negative via internal transistor
29 BK(29) Traction Traction speed reduction no. 1 Connected to the battery negative 0V
30 BK(30) Traction Seat Connected to the battery negative 0V
31 WH(31) Traction Platform Connected to the battery negative 0V
33 WH(33) Traction Stabiliser oil level Connected to the battery negative 0V
35 BU(308) Traction Signal status of the LES Connected to the battery negative 0V via LES
36 YE(36) Hydraulic Lift control LI Connected to the battery positive +24V
37 YE(37) Traction Accelerator signal Variable signal 1V-4.1V-7.1V
38 PK(54) Traction Accelerator micros Connected to the battery positive +24V
43 WH(43) Traction CAN high (traction) Connected to the bus CAN high (traction) LAC
44 BN(44) Traction CAN low (traction) Connected to the bus CAN low (traction) LAC
45 BN(45) Hydraulic CAN low (elevation) Connected to the bus CAN low (elevation) LAC
46 YE(46) Traction Speed sensor supply Connected to the +8.2V
48 BK(48) Traction/hyd. Negative supply LAC Connected to the battery negative 0V
49 YE(49) Traction Electric brake negative supply Connected to the battery negative via internal transistor
50 YE(50) Traction Right stabiliser negative supply Connected to the battery negative via internal transistor
53 WH(53) Traction Guard rails Connected to the battery negative 0V
55 GN(55) Hydraulic Battery discharge status signal Connected to the battery negative 0V via indicator
56 YE(56) Traction Anti-crash safety Connected to the battery positive +24V
57 BK(57) Traction Traction speed reduction no. 2 Connected to the battery negative 0V
59 YE(59) Hydraulic Lower control LI Connected to the battery positive +24V
60 WH(60) Traction Traction motor temperature signal Variable signal
61 BU(317) Traction Steering angle signal Signal coming from the steering 6V in right line
64 WH(64) Traction Inclinometer signal Signal from 4.1V truck flat
68 YE(68) Traction Supply 0 V for accelerator Supply 0 V for accelerator
69 WH(69) Traction Speed sensor supply 0V Speed sensor supply 0V
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6.1.5.4 Starting the controller LAC - 1A1

- Emergency stop is made => The positive +24V arrives at the input of the line contactor 1K2 and the key switch.

- The key is turned => the positive +24V pass through the key and the auxiliary microswitch of the emergency stop
7S5. 7S5 ensures the complete halt of the truck if the operator activates the push button (it is an auto feed of the
electronics when the traction motor is generator).

- The LAC is then fed => +24V terminals 1X1:23/11, and terminal direct negative 1X1:48.

- An internal voltage regulator provides the +8.2V => accelerator potentiometer supply in terminals 1X1:22/68,
and supply of the speed sensor and the inclinometer terminals 1X1:46/69.

- The 2 microprocessors for traction and hydraulic are supplied in +5V by a second regulator. The two controllers
start and launch the LAC internal test program.

- If there is no serious internal fault at the LAC => the start-up conditions are consolidated.
The internal safety relay is then controlled. Its contact is connected between the terminals 1X1:1/24.
This relay provides the supply positive +24V for => the line contactor 1K2, the electrobrake Y1, the lowering valve 2Y2
and the two valves of the left and right stabilisers 2Y8 and 2Y9.

- The line contactor 1K2 is supplied to negative terminal 1X1: 2 => after closing 1K2, the power stage is supplied +24V
in terminal:+.

EMERGENCY CIRCUIT BREAKER -7S1 / 7S5

ATTENTION: Always make sure that the emergency circuit-

breaker is pressed before disconnecting or reconnecting
the battery.

7S1

7S5

TRACTION / HYDRAULIC LINE CONTACTOR 1K2

Characteristics of the contactor coil:

Resistance (20° C) 44 Ohms
Coil interference Only free wheel diode.
No series resistance.
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Section 6
Service Training Page 13

SUPPLY AFTER THE KEY AND 7S5

+24V

+24V

Safety relay

EMERGENCY STOP -7S1 / 7S5

Connector 7X9
Terminal Colour Function
1 BN Microswitch input 7S5
2 GY Microswitch output 7S5
Auxiliary
Power

MECHANICAL LINK
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Section 6
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6.1.6 Traction start-up conditions (Validation)

The LAC needs some information to start the traction. This information is associated with the operating
status of the electric steering and the driver’s position in the truck.

- The first LAC validation condition is an LES electric steering in good condition, controlled by the traction
in terminal 1X1:35. The signal sent by the steering is a negative coming from the terminal 3X1:8.

- The second condition, to obtain the traction, is linked to the Platform/ guard rail/operator presence / tiller
base (inputs of terminals 1X1: 31 / 53 / 8 / 7 of the LAC).

In the table:
- Value 1 means that the input is linked to the battery negative
- Value 0 means that the input is disconnected
- A "-" means that the value can be 1 or 0

Operator Tiller base Reaction of the truck Status

Platform Guard rails
presence
1X1: 31 1X1: 8 1X1: 53 1X1:7
- 0 0 0 No traction 1
0 0 0 1 Walkie mode (AP) 2
- 0 1 - No traction 3
0 1 - - Stop +Error :1X1:31/8 incompatible 4
1 0 - - No traction 5
1 - - 0 No traction 6
1 1 0 1 Speed 6Km/h (AP) 7
1 1 1 1 Speed 10Km/h (AP + SP) 8
1= 1= 1= 1=
Low position Activated Position High Position
Steering

Reaction of the truck when you go from one status (from 1 to 8 in the table) to another:

Truck status Action Reaction

- The truck moves to status 2, 7 or 8 release the tiller - apply the electrobrake.
(1X1:7=0)

- The truck moves to status 7 raise the guard rail - if the accelerator is released in neutral position then
(1X1:53=1) reactivated move to status 8.

- The truck moves to status 8 lower the guard rail - move to status 7.
(1X1:53=0)

- The truck moves to status 7 or 8 leave the presence - the motor brakes, then when the truck halts, the brake (1X1:8=0) is
applied, you go back to status 5.

- The truck moves to status 7 or 8 raise the platform - the motor brakes, then when the truck halts, the brake (1X1:31=0)
is applied, you go back to status 4.
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Section 6
Service Training Page 15

TILLER BASE MICROSWITCHES IN VERSION AP

The tiller base is equipped with two microswitches, 1S4 and 1S4A, mounted in series. When the tiller is
in vertical position, 1S4 is open and disconnects the terminal 1X1:7 of the LAC (rest position of the truck
electrobrake applied). While moving, if the driver has to brake in an emergency, it is enough to press the
tiller downwards in horizontal position. The microswitch 1S4A opens and disconnects the terminal 1X1:7.
The tiller base microswitches are replaced by a wire to the connector 1X3 between the terminals :10
and :12 in version 131 SP.

PLATFORM AND GUARD RAIL

The platform and guard rail microswitches are replaced by a wire to the connector 1X20 between the
terminals :1 and :2, and 1X3 between the terminals :15 and :14 in version SP.

1X1:31= 0V => Platform low

1X1:53= 0V => Guard rail high

1X1:8 = 0V => Active presence

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6.1.7 Control module – tiller in version AP- Handlebar in version SP - A1

6.1.7.1 Description

The control unit is identical to the old range of trucks and is common to the two versions, AP and SP. Only
the traction potentiometer 1B1 can be and must be regulated while changing the control unit or a
replacement of the LAC. The potentiometer value must be regulated precisely and this precision can only
be obtained by using the PathFinder software.
The anti-crash safety microswitch 1S3 for the operator is located behind a red button that can be activated
in the AP version, and behind a black cover in the SP version forbidding the use of this safety (the driver
is protected by the outer hull of the truck).

Throttle
Electronic circuit

Potentiometer

Anti-crash button

Connector 1X5
Terminal Colour Function
1 PK Horn output positive
2 VT Initial lift output positive
3 WH Initial lowering output positive
4
5 WHRD Anti-crash switch output positive
6 GY Accelerator potentiometer supply negative
7 OG Link potentiometer (mid point)
8 YE Supply +10 V accelerator potentiometer
9 BU Forward / reverse movement switch output positive
10 RD Card supply input positive A1
11 BK Anti-crash switch input negative
12 BK(801) Output negative to tiller base microswitch
13 GN Tiller base input negative
14 WHBU Anti-crash signal output negative
15 GY(802) Input negative via tiller base
16 BN Tiller base signal output negative
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Section 6
Service Training Page 17

VIEW OF THE TILLER ELECTRONIC CARD

Potentiometer Horn
1B1 4S1

Front switch.
Lower
1 S 21
2S7

LBS-C screws 2.9x6.5-DIN7981

Raise
2S6

Connector
(16 channels)
1X5 Rear switch.
Green wire 1 S 22

Red wire Safety

1S3
Yellow wire
Circuit A1

PRINTED CIRCUIT PROVIDED

+24V
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Section 6
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6.1.7.2 Potentiometer 1B1 and microswitches 1S21 - 1S22 of the accelerator

The accelerator is controlled by a radiometric value, a % of the supply voltage. This control mode always
helps to be at the important values for carrying out the acceleration and the regulation of the potentiometer.
The radiometric values are always true regardless of the variations in the supply voltage. They can be
displayed with the PathFinder application. The accelerator must be calibrated with the diagnostics
software.

% Action
47 to 53 Neutral position
47 to 43 // 53 to 57 Close 1S21 or 1S22. Brake control Y1
43 to 15 // 53 to 85 Acceleration of the truck up to normal speed
15 to 2 // 85 to 98 Truck moves at maximum speed
2 to 0 // 98 to 100 Power supply harness breaks / outside range

0% 50% 100%

2% 15% 1S21 Neutral 1S22 85% 98%

Mechanical stop Mechanical stop
47% 53%

6.1.7.3 Tiller rear safety control – 1S3

The anti-crash is available in the AP version. This safety works when the truck is in walkie configuration,
with raised platform and lowered guard rail. With the PathFinder software, you can also activate this safety
in stand-on configuration.

While moving, the action on the tiller rear safety control causes the following reaction:
- action on the tiller safety contact, the truck moves in the direction of the fork arms at reduced speed while
the tiller safety switch is not released.
- on releasing the tiller safety contact, if the accelerator is still activated, the truck moves with free wheel
until it stops.

Note 1: To retrieve the full drive, it is necessary to release the accelerator at zero and to
reaccelerate.
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Section 6
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6.1.8 Electrohydraulic brake – Y1

This brake is an electromagnetic brake with no current with hydraulic assistance.

The electrohydraulic brake is used as parking brake and also for emergency braking.
The hydraulic piston helps increase the brake torque according to the load on the fork arm, the hydraulic
pressure in the lifting jacks activate the piston and increase the braking.

The brake release is done by the action of the accelerator, to enable start-up on side without the truck
moving. The brake is reapplied if the accelerator is released and if the truck speed is zero.

The air gap setting must be between 0.2 mm and 0.6 mm.

ELECTROMAGNETIC BRAKE

Gap setting screw

(three)

Connector 7X6
Terminal Colour Function
1 BU Positive +24V of Y1
2 BK Negative -Ub of Y1
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6.1.9 Traction motor speed sensor – 1B2

A sensor 1B2 is mounted on the traction motor. This sensor is controled by the cog wheel mounted on the
rotor.

The sensor is supplied with +8.2V (outputs terminals 1X1: 46 / 69 of the LAC) and provides two pulse
outputs with dephased time slots of 90°. These signals are transmitted to the traction control module
(inputs terminals 1X1:9 / 10 of the LAC) as well as to the controller LES where they are processed to
determine the speed and the direction of rotation of the traction motor. No regulation is provided for the
speed sensor.

CAUTION: If the sensor is not mounted properly or if the connector 1X2 is disconnected, it will be followed
by a traction speed of 0.2Km/h and the motor effective current will increase to the Imax current of 270A
(with a standard factory truck parameterisation).
TRACTION SPEED SENSOR

Towards
LES

Connector 1X2
Terminal Colour Function
1 YE(152) Supply +8.2 V
2 WH(101) Output channel A
3 YE(176) Negative
4 WH(102) Output channel B
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Section 6
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6.1.10 Traction motor temperature control – 1B6

A resistance probe 1B6 integrated in the stator windings controls the temperature and reduces the
performances when it is too high.
- If the motor temperature exceeds 160°C, the truck speed is reduced to 2Km/h.
- If the temperature probe is defective or if the harness is disconnected, the LAC controller will reduce
its speed to 4Km/h.

TRACTION MOTOR TEMPERATURE SENSOR

LAC

Connector 1X25
Terminal Colour Function -UB
1 WH(60) Temperature signal
2 YE(151) Temperature probe
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6.1.11 Truck hydraulic stabilisers

6.1.11.1 Description

The new stabiliser system is mounted to compensate the wear of stabiliser wheels, to increase the
motoricity of the truck and to get a high stability while turning.
The stabilisers work as vehicle dampers with an oscillating movement very limited by the hydraulic oil.
However, when the truck takes a curve, the external stabiliser spring crashes at the turn and the truck
bends. This tilt is detected by an inclinometer, the LAC controls the closing of the valve that blocks the
stabiliser and gives support to the truck.

The stabiliser valves are marked by a colour code:

- Right yellow stabiliser, pump side
- Left green stabiliser, LAC side

If the oil level is too low, the maximum speed of the truck is 2km/h.

Oil level sensor

Tank

Block valve 2Y7 for 2 stabilisers

2Y8 2Y9
Left stabiliser

Stabiliser valves

Right stabiliser
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Section 6
Service Training Page 23

6.1.11.2 Stabiliser valves 2Y8 and 2Y9

The stabiliser valves are supplied in positive after the internal safety relay, and in negative by the Mosfet
transistors.
- When the valves are not fed, the stabilisers are free.
- When a valve is fed, the corresponding stabiliser is blocked.

Connector 2X20
Terminal Colour Function
1 RD(73) Power supply +24V
2 YE(50) Negative supply

Connector 2X21
Terminal Colour Function
1 RD(72) Power supply +24V
2 YE(27) Negative supply
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Section 6
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6.1.11.3 Inclinometer - 1A8

The inclinometer is a bubble level that transmits the inclination degree of the truck to the LAC.
The values displayed in % are ratios of the supply voltage. The inclinometer must be calibrated if it is
changed or if the LAC is changed. No mechanical regulation is possible.
A 50% value corresponds to a horizontal truck. The stabiliser blocking and unblocking thresholds can be
controlled with the PathFinder software.
Turn left
Blocked right stabiliser
0%

50% 0°

-10°

Turn right
Blocked left stabiliser 10°

50% 0°

100%

Connector 1X26
Terminal Colour Function
1 YE(153) Positive supply
2 WH(64) Signal
3 YE(175) Negative supply
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Section 6
Service Training Page 25

6.1.12 Battery locking sensor – 1S19

1°) For trucks equipped with a side battery outlet, battery locking sensor B1 is mounted to ensure that the
battery box is firmly locked in place.
- If the battery is not locked, the traction is reduced to 4Km/h and the left and right stabilisers are blocked
by the supply to the valves 2Y8 and 2Y9 to prevent the truck from bending when charging the battery.
- If the truck supply is cut off, the valve 2Y7 (closed without supply) will block the stabilisers.

2°) If the side output function of the battery is not mounted:

- 2Y7 is replaced by a stopper
- 1S19 is replaced by a wire to the connector X2 between the terminals :1 and :2.
- On stopping, supply cut off, the stabilisers are free.

The battery locking sensor B1 is supplied by a direct positive. A negative output signal is added to the
control card when the battery is locked (input in terminal X1:12).

KEY

Connector X2
Terminal Colour Function
1 WH(12) Signal
2 BK(88) Negative supply
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6.1.13 L.A.C. cooling fans - 9M1, 9M2

The 24V DC fans without brush, equipped with highly durable bearings are used to cool the LAC traction
and hydraulic controller.
The L.A.C. controls the fans when the internal temperature of the power stage exceeds 50°C, and stops
them when the temperature drops below 40°C.

LAC

9M1-9M2 ON =LAC > 50°C

9M1-9M2 OFF =LAC < 40°C

Connector 9X11
Terminal Colour Function
1 WH(47) +24V variator output signal
2 BK(83) Negative supply
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Section 6
Service Training Page 27

6.1.14 Horn operation – 4H1

The horn circuit is supplied directly from the emergency stop contact. The push button 4S1 is above
the control panel. Pressing 4S1 applies a voltage +24V to the horn 4H1.

HORN

Connector 1X3
Terminal Colour Function
8 BK(80) +24V Signal
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6.1.15 Speed limitation no. 1 and no. 2 (options)

The LAC controller is equipped with two speed limitation inputs that will be parameterised with the
diagnostics software. In the truck standard configuration, these speed limitations are deactivated by the
controller when the terminals 1X1: 29 / 57 are permanently connected to the battery negative.
Deleting one of the negatives activates the corresponding speed limitation.

Speed limitation No. 1 => 1X1: 29

Speed limitation No. 2 => 1X1: 57
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Section 6
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6.2 LIFTING

6.2.1 Operating the initial lift of the truck – 2M1

The motor pump is supplied in positive +24V by the line contactor 1K2, and in negative by the MOSFET
power transistor mounted inside between the terminals”: Li “ and”:- “.
A free wheel diode that helps free the stored energy by the armature during the FET transistor passing
phases, is connected between the terminals “ :+ “ and “ : Li “.
The motor start-up then is gradual, which prevents current surges and extends the life of the motor.
Note: Putting the traction in safety stops the hydraulic function.

MOTOR PUMP UNIT

6.2.2 Operating the lowering of the truck initial lift – 2Y2

The lowering function is realised by controlling the valve 2Y2.

The supply positive +24V is direct after the LAC internal relay, the negative is controlled, when you press
the button 2S6, through a FET transistor in output 1X1 : 25.
The lowering speed fixed by the flow restrictor diameter: in the T20AP/SP-2.2 mm diameter, and in the
T24AP/SP- 2.4 mm diameter.

VALVE 2Y2

Connector 2X9
Terminal Colour Function

1 RD(24) Positive supply +24V

2 GY(25) Negative supply 2Y2
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6.2.3 Raised forks position sensor – lift stop - 1B4

The 1B4 sensor, mounted on all the trucks, stops the lift before the mechanical stop of the elevator system
to limit the pressures in the circuit and to handle the pump motor.
It also has the function of preventing too high pressure in the brake hydraulic system (forced braking
without load).

Operation

- The lift is controlled via 2S6 => The fork arms climb.
- Arrives in high position => The sensor 1B4 is activated.
- The lift is stopped via 1B4 => The lowering function is engaged (controlling 2Y2).
- The fork arms lower => They leave the high position.
- The sensor 1B4 is deactivated. => The lowering function is stopped.
- The lift is no longer authorised. => The motor is no longer supplied, even if 2S6 is activated
- To retrieve the lifting function => Activate the lowering button once 2S7.

LAC

LIFT STOP 1B4

Connector 2X14
Terminal Colour Function
1 WH(16) Signal
2 BK(84) Negative supply
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6.3 STEERING

6.3.1 LES steering – Operating principle

Steering power part – 3A1

The new electric steering system is equipped with a motor with permanent magnets. The armature is
controlled by 4 MOSFET transistors that controlled 2 by 2 turn the motor in the 2 directions of rotation, left
and right. The steering motor rotation speed depends only on the difference between the position of the
set value potentiometer and the position of the wheel potentiometer.
The motor stops turning when this difference is zero (with a certain tolerance range, to prevent permanent
steering correction, and to push the motor too much).
The use of a motor with permanent magnets helps have a larger power, for a smaller size than the old
system.

ATTENTION : Before opening the motor, mark the position of the bodywork, this position is adjusted in
the factory to optimise switching (brush setting). Only a service hatch is provided for blowing the brushes.

STEERING MOTOR REDUCER

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6.3.2 Steering controller LES / 3A1

6.3.2.1 Description

The LES (Linde Electrical Steering) steering controller is composed of a control card with two
microprocessors, a main “CP” and a safety “CS”, and a power stage with 4 Mosfet transistors. The
transistors are controlled by an electronic circuit called DRIVER (optocoupled for galvanic insulation)
located in the power stage.

If a fault appears, it is detected instantly and the control system is put in safety and controls the truck stop.
The control module is equipped with a connector 3X1 of 29 terminals.

Control circuit connector 3X1

3X1

µP M µP S
Main for LES Main for LES
Master Safety

:+

:- :M2 :M1
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6.3.2.2 MAIN CIRCUIT CONNECTIONS

1 :+ Positive connection for the power unit via the line contactor 3K1, the power fuse 3F1 and the
circuit-breaker button.
2 :- Power part negative supply
3 :M1 Connection coming from the motor armature.
4 :M2 Connection coming from the motor armature.

6.3.2.3 CONNECTOR TERMINAL FUNCTIONS 3X1

TERMINALCOLOUR FUNCTION ASSOCIATED WITH

1 RD(301) Control card supply positive +24V after key switch
2 BU(302) Potentiometer negative supply Battery negative 0V for set value
3 BU(303) Set value signal track 1 Variable signal between 0V- 8.2V
4 BU(304) Set value signal track 2 Variable signal between 0V- 8.2V
5 WH(305) Speed sensor track A Variable signal 0V-6V
6 WH(306) CAN 2 high (steering) Connected to the bus CAN 2 high (steering) LES
7 BN(307) CAN 2 low (steering) Connected to the bus CAN 2 low (steering) LES
8 BU(308) Traction signal go Battery negative 0V if LES OK
9 BU(309) Contactor control 3K1 Negative for steering motor contactor
10 RD(310) Positive supply for 3K1 positive +24V after internal relay for 3K1
11 BK(311) Negative supply of the card Connected to the battery negative 0V
12 BU(312) Potentiometer negative supply Battery negative 0V for current value
13 BU(313) Current signal value track 1 Variable signal between 0V- 8.2V
14 WH(314) Speed sensor track B Variable signal 0V-6V
16 WH(316) CAN 1 high (steering) Connected to the bus CAN 1 high (steering) LES
17 BU(317) Steering angle signal Signal for traction speed reduction
18 RD(318) Positive supply for internal relay Positive +24V towards 3K1 via the internal relay A
19 RD(319) Positive input for internal relay Positive +24V towards the LAC via the internal relay B
20 BU(320) Stabilised power supply +10V for set point potentiometer
21 BU(321) Stabilised power supply +10V for wheel potentiometer
22 BU(322) Current signal value track 2 Variable signal between 0V- 8.2V
27 BN(327) CAN 1 low (steering) Connected to the bus CAN 1 low (steering) LES
29 BU(329) Positive output of internal relay Positive +24V towards the LAC via the internal relay B
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6.3.3 Starting the controller LES

The LES steering is the main safety unit, if it has broken down, the truck is stopped and no more operation
is authorised (lifting included).
Procedure for start-up: (the steps written enable quick diagnostics during breakdown)

- Starting the LES after the key in inputs 3X1: 1 / 18 / 19 =>+24V.

the supply negative is directly in input 3X1: 11 => -Ub

- The LES generates a stabilised voltage on the outputs 3X1: 20/21 => +8.2V for the positive and for the
outputs 3X1: 2/12 => -Ub for the negative

- The steering controls the proper operation of the 2 set value and wheel potentiometers by the double
signals (redundant potentiometers) in inputs 3X1: 3/4 and 3X1: 13/22 => 4.1V (voltages measured
when the set value and the wheel are in the alignment of the fork arms).

- The LES controls a first safety internal relay (A), this relay provides the supply positive in output 3X1
: 10 =>+24V (for the line contactor 3K1) and a negative via a Mosfet transistor in output
3X1: 9 => -Ub (for the line contactor 3K1)

- The steering contactor 3K1 and the wheel brake system coil (F.V.) 7A5 are then fed.
The power stage is controlled, motor at stop, outputs:M1 and :M2 => 12V
The brake pivot is then controlled in current (between 5 and 750 mA), if the harness breaks, the truck
is brought to a halt by the CAN BUS link.

- The LES gives the two traction operation activation signals:

The steering controls the second safety relay (B) giving the positive for the traction (input positive 1X1:
1 for the internal relay contact to the LAC) in output 3X1:29 => +24V and a negative signal of “OK”
controlled by a Mosfet in output 3X1: 8 => -Ub

6.3.4 Validation of the traction and the hydraulic

For safety reasons, the validation of the traction and the hydraulic is done with two different signals, one,
positive coming from the safety relay B of the LES that supplies the line contactor of the traction and
hydraulic, the other, negative is controlled by a transistor giving the steering status to the LAC controller.
Then a final traction authorisation is sent by the LES via the CAN BUS, this authorisation only pertains to
the traction.
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STEERING LINE CONTACTOR 3K1 AND TRACTION AUTHORISATION

+24V

+24V
:19
0V

Safety relay B Safety relay A

LAC LES

3K1 Characteristics of the line contactor coil:

Resistance (20° C) 44 Ohms

Coil interference Diode
No series resistance.
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6.3.5 Speed reduction on turning

The truck is equipped with a safety system, the controller reduces the translation speed during turns. The
electric steering calculates the steering angle according to the position of the set value potentiometer in
the form of a voltage in 3X1:17.
The LAC receives this signal in terminal 1X1 : 61, then, according to the pre-regulated values, it reduces
the truck speed during turns.
The traction speed reduction is controlled when the set value reaches or exceeds a steering angle AC+hAC,
on either side of the midpoint of the steering. The speed limitation is suppressed when the set value
returns to a position less than or equal to the angle AC. Beyond 45°, the translation speed is automatically
reduced regardless of the control values. The AC and hAC points can be controlled with the PathFinder
software. The signal in 1X1:61 is a percentage of the supply voltage stabilised from the set value
potentiometer.

Signal In 1X1: 61 Movement of the handlebar/tiller from 0° to 45°

80% of 8.2V

Normal speed

Reduced speed

0° AC AC+hAC +45°

Signal In 1X1:61 Movement of the handlebar/tiller from 45° to 0°

80% of 8.2V

Normal speed

Reduced speed

0° AC AC+hAC +45°
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6.3.6 Steering brake pivot – wheel brake (f.v.)- 7A5

An electromagnetic device helps create and adjust the resistant torque at the handlebar/tiller level.
The resistant torque increases or decreases according to the truck traction speed, the handlebar/tiller
rotation speed and the steering angle.
It is a brake system with propellant controlled by a coil. This coil is supplied by a current between 5mA for
an almost negative torque and 750mA for the maximum torque. The current generated by the LES steering
varies according to the different parameters described above, the internal series resistance with the wheel
brake coil is 18 ohms.
The brake pivot box also contains the set value potentiometer.

WHEEL BRAKE SYSTEM (LORD)

LES
Connector X13
Terminal Colour Function
5 BU(330) Positive supply +24V
6 BU(328) Square signal according to hardness
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6.3.7 Set value potentiometer (handlebar/tiller) – Wheel potentiometer

The electric steering is equipped with two potentiometers,

- a potentiometer placed in the brake pivot called set value potentiometer, without mechanical control.
- a potentiometer placed in the steering reduction gear called wheel potentiometer, without mechanical
control.

The operating principle is simple, the LES controls the motor to bring the wheel to an angular value
corresponding to the one requested by a handlebar or the tiller. The steering potentiometers provide a
voltage enabling the LES to calculate this steering angle. Each potentiometer is double (2 tracks, to obtain
redundancy, for safety reasons)

The steering permanently controls the status of each potentiometer by the total of the values of link
voltages no. 1 + no. 2, this total must correspond to the supply voltage.

The value of the stabilised voltage (potentiometer supply) as well as that of the links are converted
into % : "radiometric voltage".
- The stabilised voltage is 100%
- The links are in “right line” position: the values are 50%
- Thus no.1 + no.2 = stabilised voltage ==> 50% +50% = 100%

SET VALUE POTENTIOMETER

Connector X13
Terminal Colour Function
1 BU(320) Supply +8.2 V
2 BU(302) Negative
3 BU(303) Set value (link) no.1 calculates the angle
4 BU(304) Set value (link) no.2 redundancy

WHEEL POTENTIOMETER (CURRENT VALUE)

Connector 3X3
Terminal Colour Function
1 BU(313) Link no.1 calculates the angle
2 BU(312) Link no.2 redundancy
3 BU(321) Supply +8.2 V
4 BU(312) Negative
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LES

4.1V + 4.1V = 8.2V

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6.3.8 LES OFF mode

To prevent premature wear of the steering motor and a wasted current consumption during the phases
when the truck is not used, the LES is put in off mode. It disconnects the power stage but verifies the control
card input information to reactivate the motor if necessary.

This power reset information comes from:

- either a movement of the set value potentiometer (variation of the two links in inputs 3X1:3/4)

- or detection of a truck traction movement by the speed sensor signals in inputs 3X1:5/14)

- or a major movement of the motor wheel corresponding to a variation of the two links of the real value
potentiometer in inputs 3X1: 13/22.

If all the reset conditions are met, if there are no more steering responses after a timeout of 30 seconds.
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6.4 MULTIFUNCTION INDICATOR TlN Version 1

(Not linked to the truck Can-Bus)

6.4.1 Description

6 2

5 3
4

Figure 1

1 Alphanumeric display
2 Control buttons
3 Accumulator cap
4 Fork rod
5 Connector (22 channels)
6 Control indicators

CHARACTERISTICS
General protection: IP 66 Frontal and
IP 54 lateral and rear
Nominal power supply: 24 V

DESCRIPTION
Raised instead of and in place of the ILDB on the speed control plate cover, the TNL multifunction indicator
has the following functions:
- Battery discharge indicator with low level alarm and lifting cut off

Important: - Full load: 100% displayed

- Discharged: 0% displayed corresponds to the limit of 80% of battery discharge
(recharge mandatory)
- Date, time
- Truck operation hours (hour meter)
- Display of information messages and tips
- Wheel position indicator
- Service interval indicator with service alarm to be provided
- Truck operator presence indicator
- Alarms with messages indicators
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Main screen

13 14 1 2 3

4
12 5
11
10 6

9 8 7

Description Meaning Remarks/

Screen messages
1 Battery charge level in % Full load: 100%
- Weak load: 10% -> Recharge to be provided
- Discharged: 0% -> Recharge mandatory

2 Charge level of - Full load: 100%

battery represented by 5
bars - Weak load: 10%

- Discharged: 0% Note:0 % corresponds to 80% max

discharge to protect the battery.

3 Egg-timer (flashing) - Indicates hour meter operation

4 Control button - to display another screen Other function: setting key

5 Control button - to display the previous screen Other function: setting key

6 Control button - to access the control screens

7 Marking of active buttons

8 Display of date ->For setting, see page

9 Display of time ->For setting, see page

10 Alarm STOP (red) - Speed control fault: Truck stop Message: "Engine fault..."
- Restart attempts by resetting con-
tact key
- Alarm always active: Call service
technician

11 Alarm BATTERY (red) - Blinking:charging < or = at 10% -> Recharge to be provided

Message: Weak battery charge level

-> Lifting cut

- Fixed: battery discharged -> Recharge mandatory
Message: "Battery level=0%
lift qualified"
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13 14
Hour meter screen

12
15
Next service :

Information messages screens

16

Wheel position screen indicator

17

Remarks/
Description Meaning Screen messages

12 Alarm T ° (red) - Fixed: speed control overheating -> Truck stop

Message: " T° abnormal..."
In general, wait few minutes
before proceeding.
13 T ruck o pe rato r pre sen ce - Flashing: presence non-activated
indicator
(Green) - fixed (lasting 10 s): truck operator
present

14 Alarm Maintenance (red) - Flashing: service required in:... -> Message: "Next visit in X days or
in Y hours."
- fixed: service required -> Message: "Maintenance visit
today"

15 Hour meter - Truck operating hours

16 Display of information messages

17 Wheel position indicator Position of steering wheel Only for trucks equipped with a
steering wheel.
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6.4.2 Alarms and linking of multifunction indicator screens

x1
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6.4.3 Setting parameters for multifunction indicator / Factory settings

ON TRUCK OPERATION IN FACTORY

The parameters must be customized: The default parameters on leaving the factory are:

THE DISPLAY (see menus 2 and 5):

- Homepage screen logo (Linde - Lansing) -> Truck delivery country logo
- The menu language (French, English, German, -> The delivery country language
Spanish, Italian, Dutch)
- Date format (DDMMYY or MMDDYY)
- Time
- Service Point contact details

PROGRAMMING NEXT MAINTENANCE VISIT

(see menu 2):
- Enabling or disabling the service reminder -> Enabled
- Choosing the enable mode in hours or in days -> at 500 hours
- Alarm Service X days or Y hours before enabling -> 50 hours before

DISCHARGE INDICATOR (see menu 4):

- Setting parameters according to the characteristics ->Truck delivered with a battery:
of the battery mounted on the truck indicator set according to battery equipment
->Truck delivered without battery:
by default set on the curve Varta – 2.09V - 20%
- 0 mn.

6.4.4 Setting the multifunction indicator after a service visit

The technician must activate the next visit reminder (see menu 3) and
through the same operation reset the service alarm.

The technician can open the Bloc Note (see menu 6-6) to store useful information for future interventions.

The technician can also edit the multifunction indicator parameters (see menu 7).
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6.4.5 PC connection for multifunction indicator settings

- All the operating parameters are stored in the multifunction indicator memory.
- The multifunction indicator is programmable by using the Linde parameterisation software, Truck
doctor version V1.1 P7 or later.

- Battery disconnected and contact cut-off

- Connecting the PC wire to the programming connector
for multifunction indicator 6X4
- Connect the battery
- Start Truck doctor
- Select "TNL - Dashboard" (p) in the main menu
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6.4.6 Selection of multifunction indicator menus in TRUCK DOCTOR

Truck Doctor
A
Z

1 "Electric truck" (E)

2 "Thermal truck"(V)

3 "Trans-pallet stacker" (L)

4 "Transpalet"(T)

"Commands
5 preparator"(N+V)
"Truck with retractable
6 mast"(R)
MENUS

7 "Tractor" (P)

8 "Linde speed control" 1 Programming initialisation

9 "TNL Multifunction
indicator"
P 2 Service option
"TNL Multifunction
indicator" SUB-MENUS
3 Display option
U "Accessories"
4 Battery parameters
X "End"
1 Programming initialisation
5 Accessories

2 Regulate hour meter

6 Edit parameters
3 Service Point Address
Setting tool
7 Battery discharge curve 4 Set date

5 Set hour
B Return

6 Bloc Notes
Wheel position indicator
7 calibration

B Return
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6.4.7 Using the Truck Doctor to set parameters for the multifunction indicator

MENU 1: Programming initialisation

- Open this menu so that the multifunction indicator goes to display mode in programming mode.

TRUCKDOCTOR

Program

MENU 2: Service Options

The service indicator can be Enabled(*) or Disabled

Service indicator Enabled:

The next service visit can be enabled with a given hour meter on a precise date.

- On the screen choose: the hour meter (*) or the date.

- Enter the hour meter or the date of activation.

By the hour meter By the date

Example: Example:
Next service visit activated at 1,050 hours Next service visit activated on 200802
(20 August 2002)
(*) By default: at 500 hours

The service alarm can be triggered few days or few hours before the service visit.

- In the screen enter: the number of hours or the number of days before activating the visit.

Alarm by the hour meter Alarm by the date

Example: Example:
The service alarm will ring 20 hours before the The service alarm will ring 10 days before the
service service

(*) By default: 50 hours before (*) By default: 7 days before

Delete service reminder alarm:

- Carry out programming of next service visit.

(*) By default
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Menu 3: Display options

This menu helps select and parameterise the information visible on screen:

- The display format for date and time Choose: European(*) / Anglo-Saxon
- The choice of display of the hour meter Choose: Displayed (*) / Non-displayed
- The choice of display of error messages Choose: Enabled(*) / Disabled
- The choice of language and logo Choose: - English Linde
- English Lansing
- French Fenwick
- French Linde
- German Linde
- Spanish Linde
- Italian Linde
- Dutch Linde
- Wheel position screen indicator Choose: Enabled(*) / Disabled

Menu 4: Battery parameters

The discharge indicator must be compulsorily parameterised according to the battery characteristics.

1) CHOICE OF BATTERY TYPE

Various discharge curves are stored in the multifunction indicator memory:

1 Battery model: Lead acid standard battery (Varta, Fulmen, Oldham, Fenwick) (*)
- Standard control for lead acid battery.

2 Battery model: Battery PZs (Deta)

- Setting for the Hawker leak proof batteries (gel).

3 Battery model: Battery with increased capacity (PZs)

- To reserve for the trucks equipped with large capacity battery, with a long discharge duration

4 Battery model: Battery without service (Gel)

- Preferably use the model no. 2 or
- Consult the battery manufacturer to get the characteristics.

2) RESET VOLTAGE/CHARGED BATTERY NO-LOAD VOLTAGE

Possible choices:
2.00 – 2.03 – 2.06 – 2.09 (*) – 2.12 – 2.15 – 2.18 – 2.21 – 2.24 – 2.27 – 2.3 V.

(*): Standard setting

Note:
- The battery no-load voltage must be greater than the value selected to unblock the multifunction
indicator.
- The reset voltage can be slightly lowered if the indicator does not reset for a charged battery.

(*) By default
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3) LIFTING CUT-OFF

To protect the battery from too high discharge, set the residual capacity value (in %) at which the hoist cut
is produced: 20(*) - 25 - 30 - 35 - 40%.

- (*) Standard control for an open lead battery.

- Setting recommended for a leak proof battery (gel): 30%

TIPS TO ADJUST THE HOIST CUT

After checking the real status of the battery on the cut, gravity and voltage on an open lead battery, voltage
on a gel battery, it is possible to fine-tune the setting according to real use of the battery:

- If the indicator cuts too early, reduce the residual capacity value (E.g.: 25% to 20%)
- If the indicator cuts too late, increase the residual capacity value (E.g.: 25% to 30%)

Remarks: - Minimum gravity, battery 80% discharged; 1,14

- Maximum gravity, battery 100% charged; 1.29 to 1.32 according to models.

4) RESET TIME

After cutting the discharge indicator, it can be reset only after a period of:
0(*) - 1 - 2 - 3 - 4 - 5 - 6 - 7 - 8 minutes.

(*): standard setting

MENU 5-1: Programming initialisation

Same as menu 1

Menu 5-2: Initialisation of an hour meter after replacement

On a new multifunction indicator, it is possible to program the hour meter from the old one.

NOTE:
The hour meter can be reinitialised only if there are less 2.9 hours.

Menu 5-3: Service Point Address

This menu shows the Service Point address closest to the truck user:
- Company
- Telephone No.
- Name of person to contact

Menu 5-4: Setting the date

Example: 011102 means 01.11.02

Menu 5-5: Setting of time

Example: 161202 means 16 hours 12 minutes and 2 seconds

(*) By default
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Menu 5-6: Bloc Note

This menu records or accesses the information concerning the truck. (example: change the traction motor
brushes on the next visit)

Menu 5-7: Reset

Do not use

Menu 6: Printing the multifunction indicator setting parameters

The setting parameters are displayed on the screen and can be saved in a file.

Menu 7: Setting tool table for battery parameters

To set the discharge indicator, this table can guide the technician while making the settings.
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6.5 DIAGNOSTICS CONCEPT

NOTE: The Linde test module can no longer be used in 131 type of trucks. Only the portable PCs
equipped with the PathFinder software can be used.

The diagnostics system uses the Linde diagnostics program for portable PC. The portable PC is now
connected to the truck with the help of a cable/interface adapter (CANBOX) of version 2.00 minimum.

The diagnostics equipment is connected to a single connector 6X7 located in front of the truck after the
key switch. This diagnostics connector offers an interface with the CAN bus and enables diagnosing all
the modules.

Traction Hydraulic Main steering Safety steering Display screen

(future)

CAN bus
Truck

CANBOX cable
adapter Portable PC

- Before starting the software, the truck must be started and connected to the PC.
- On starting the PathFinder software, a truck type selection table is displayed.
- Choose the type 131 and click Continue.
- The software now connects to all the controllers present on the truck.
- The start page is displayed.
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The CAN BUS network between the different controllers is equipped with two lines «CAN HIGH», «CAN
LOW» and two resistances of 120 Ohms mounted in parallel and located in the LAC (start of CAN
network) and in the display (end of CAN network).
The ohmic value measurable on the diagnostics connector is 60 Ohms, the value is measured between
the CAN high and the CAN low.

Display PC
connector

LAC LES
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6.6 ERROR CODES:

The diagnostic system uses error codes between 1 and 499.

- The codes between 1 and 99 are the information codes.

They are never stored in the controller memory, hence can be displayed only in the [inputs/
outputs]=>[current error codes].

- The codes between 100 and 199 are the warning codes.
They are stored, they do not pertain to faults that can be repaired, but that need truck servicing: example,
electrobrake air gap setting.

- The codes between 200 and 499 are the error codes.
They are grouped into 3 parts:
1- From 200 to 299: fault in a controller input or output (external component fault, internal transistor
to control the output defective).
2- From 300 to 399: fault in controller power part.
3- From 400 to 499: internal fault between two microprocessors.
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6.6.1 Traction error codes:

Information codes
1 Initial condition not yet satisfied: butterfly not in neutral position and / or belly switch on and / or potentiometer
supply too low (< 7,5V)
2 Butterfly in neutral position (according potentiometer signal or redundant switch signal)
3 Tiller in neutral position (according input signal)
4 Booster function active
5 Butterfly, platform, guardrail and foot signals correspond whether to pedestrian nor ride on mode
6 Butterfly, platform, guardrail and foot signals correspond to pedestrian mode (=WALK)
7 Butterfly, platform, guardrail and foot signals correspond to ride on mode without guardrail (=FLY)
8 Butterfly, platform, guardrail and foot signals correspond to ride on mode with guardrail (=RIDE)
9 Power save on: if all switch inputs released and standstill the power module is deactivated
10 Analog steering angle signal and / or CAN steering angle value exceed threshold (default: 15°)
11 Speed reduction commanded by input X1:29 (reduction active when input connected to GND)
12 Speed reduction commanded by input X1:57 (reduction active when input connected to GND)
15 Speed reduction commanded by battery interlock at input X1:12 (reduction active when input connected to GND)
19 No speed signal though torque applied
reasons may be: speed sensor problem, motor / wheel / truck blocked
20 Belly function activated by platform, tiller and belly switches
In trucks without platform: Belly function activated by tiller and belly switches
21 Belly function active, reset not yet performed (for reset turn butterfly into neutral position)
27 Truck immobilization due to simultaneous activation of creep function forwards and / or creep function backwards
and / or turning butterfly out of neutral position
28 Creep function backwards active (inputs X1:28 and X1:52 connected to GND)
29 Creep function forwards active (inputs X1:05 and X1:06 connected to GND)
30 Monitoring of rotor field according motor model
35 Battery voltage too low (< 12V)
40 High MOS temperature (> +95°C AND < +200°C)
45 High motor temperature (> +160°C AND < +200°C)
60 Truck immobilization because ok status signal from LES (X1:35) not set
61 Speed reduction requested from LES via CAN
70 Discharging of power module capacitors for test purposes is being performed
71 Switching on of main contactor contact could not be performed
80 [2] The Forks are down (Truck N20)
81 [2] The load is over 1 ton (Truck N20/4W)
82 [2] Creep Speed Buttons are active
83 [3] The Forks are over 1.5m
90 Teaching procedures have not been performed yet
91* Incorrect truck identification from traction controller
92* Incorrect CAN truck identification from steering controller LES
93* Incorrect truck identification from lift controller

Warning codes

110 Brake actuator failure (measured current rise when actuator switched on does not match with correct/ideal
current rise)
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 

200 Truck identification incompatible with actual state of unused digital inputs
201 Potentiometer supply voltage (8.3V) too high (> 11V)
202 Potentiometer supply voltage (8.3V) too low (< 7V)
203 Tiller ok status not set at input X1:34 (not implemented in [1])
204 Emergency signal activated (input X1:11 open)
205 Oil level too low (input X1:33 connected to GND)
207 Driving speed too high (> 18 km/h)
208 Perturbation of speed sensor signals detected (inputs X1:09 and X1:10)
209 Digital inputs (except butterfly) switched with unrealistically high frequency (> 10 Hz)
210 Analog and CAN - bus steering angle signals incompatible
211 Steering angle (PWM signal at input X1:61) out of tolerated range
(< -45° or > +45°)
212 CAN - bus steering angle signal out of tolerated range
(< -90° or > +90°)
215 Inclinometer signal out of tolerated range (< 0,5V or > 9,5V)
219 No production test
220 Analog belly signal (input X1:14) value out of tolerated range
(in trucks with belly switch: > 1V AND < 9V)
(in trucks without belly switch: < 4V or > 7V)
221 Positive supply voltage (24V) for belly switch not insured
222 Analog belly signal value (input X1:14) ok but belly switch not built in
223 Positive supply voltage (24V) applied on input X1:56 but belly switch not built-in
225 Analog butterfly signal (input X1:37) out of tolerated range
(< 0,5V or > 9,5V)
226 Analog butterfly signal (input X1:37) and digital butterfly signal (input X1:38) are in contradiction to each other
228 Redundant creep forwards signals (inputs X1:05 and X1:06) incompatible
229 Redundant creep backwards signals (inputs X1:28 and X1:56) incompatible
230 No deceleration torque when required
231 [2] Platform is enabled, but this truck has no Platform
232 [2] Creep Speed Buttons are enabled, but this truck has no Creep Speed Buttons
233 [3] Input Masthigh1 is enabled, but this truck has no Mast
240 MOS temperature signal out of tolerated range (< -50°C or > +200°C)
reasons may be: wire shortcut, wire open, sensor problem
241 MOS temperature signal too high (> +100°C AND < +200°C)
presumed MOS overheat
245 Motor temperature signal out of tolerated range (< -50°C or > +200°C) reasons may be: wire shortcut, wire open,
sensor problem
246 Motor temperature signal too high (> +170°C AND < +200°C)
presumed motor overheat
251 Safety relay transistor remains OFF whereas it is commanded to switch ON
252 Safety relay transistor remains ON whereas it is commanded to switch OFF
255 Safety relay remains OFF whereas it is commanded to switch ON reasons may be: contact oxidized or damaged
256 Safety relay remains ON whereas it is commanded to switch OFF reasons may be: contact welded or short circuit
to 24V
261 Main contactor transistor remains OFF whereas it is commanded to switch ON
262 Main contactor transistor remains ON whereas it is commanded to switch OFF
265 Main contactor remains OFF whereas it is commanded to switch ON
reasons may be: contact oxidized or damaged
266 Main contactor remains ON whereas it is commanded to switch OFF
reasons may be: contact welded or short circuit to 24V
271 Castor wheel left transistor remains OFF whereas it is commanded to switch ON
272 Castor wheel left transistor remains ON whereas it is commanded to switch OFF
281 Brake transistor remains OFF whereas it is commanded to switch ON
282 Brake transistor remains ON whereas it is commanded to switch OFF
283 No brake coil current whereas voltage applied
(applied voltage > 12V, coil current < 0,2A)
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Service Training Page 57

284 Brake coil current whereas no voltage applied

(voltage < 3V, coil current > 0,8A)
291 Castor wheel right transistor remains OFF whereas it is commanded to switch ON
292 Castor wheel right transistor remains ON whereas it is commanded to switch OFF311 Driver: Error
Phase U transistor side low
302 Current - sensor problem, phase U (offset - correction exceeds upper limit)
303 Current - sensor problem, phase U (offset - correction exceeds lower limit)
304 Current - sensor problem, phase W (offset - correction exceeds upper limit)
305 Current - sensor problem, phase W (offset - correction exceeds lower limit)
310 Error message driver Phase U High Side
311 Error message driver Phase U Low Side
312 Error message driver Phase V High Side
313 Error message driver Phase V Low Side
314 Error message driver Phase W High Side
315 Error message driver Phase W Low Side
320 Error message undervoltage driver
330 Permanently error message of driver (Error 340 could not be reset after 3 attempts. One of Error messages 302
... 320 should be shown now)
340 Internal driver error (one of error messages 302 ... 320 is set but not shown)
341 Capacitor Voltage too high (> 36V)
345 Measured voltage on phase U does not fit to voltage set by vector controller (not active in [1])
346 Measured voltage on phase V does not fit to voltage set by vector controller (not active in [1])
347 Measured voltage on phase W does not fit to voltage set by vector controller (not active in [1])
400 Monitoring of function processor: internal error
401 Monitoring of function processor: torque setpoint too high (traction control error)
402 Monitoring of function processor: torque setpoint too low (traction control error)
403 Monitoring of function processor: brake incongruously released (traction control error)
404 Monitoring of function processor: actual torque value too high (vector control error)
405 Monitoring of function processor: actual torque value too low (vector control error)
406 Cyclic disable test of relay, contactor and brake outputs failed
407 Internal serial communication disturbed
410 Internal serial communication disturbed
420 Binary inputs are different in main and safety controller
421 Butterfly signal (potentiometer) and / or belly signal and /or potentiometer supply voltage (8,3V) are different in
main and safety controller
422 States of voltages for safety relay (X1:24) and / or contactor (X1:2) and / or brake (X1:49) are different in main
and safety controller
423 LES steering angle and / or torque setpoint are different in main and safety controller
424 Actual motor speed is different in main and safety controller
425 Motor torque evaluation and / or motor voltage (stator) and /or motor frequency are different in main and safety
controller
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6.6.2 Lifting error codes:

Information codes

1 Start - Up - Tests not finished

4 Initial lifting OR initial lowering buttons pressed at start up
5 Initial lifting AND initial lowering signals are active at same time
(X1:36 > 16V and X1:59 > 16V)
8 Truck identification values are different on lift and drive controllers
9 not active in [1] and [2]
Mast Potentiometer in neutral position (X1:19 around 4,1V)
11 Truck in passive mode
13 Battery voltage low (< 12V) (detected by LAC03 internal supervision)
14 Battery discharged (detected by Battery Discharge Indicator = BDI)
16 Emergency STOP pressed
30 not active in [1] and [2]
Belly active (X1:14 > 16V)
35 not active in [1] and [2]
Foot switch not pressed (X1:8 > 16V)
36 not active in [1] and [2]
Platform down and foot switch not pressed (X1:8 > 16V, X1:31 < 1V)
40 not active in [1] and [2]
Mast over 1,5 m (X1:41 > 16V)
41 not active in [1] and [2]
Mast over 1,5 m (X1:41 > 16V)

Warning codes

Warnings not yet implemented

Error codes
220 No production test
225 Safety relay remains ON whereas it is commanded to switch OFF. Reasons may be: contact welded or short
circuit to 24V
226 Safety relay remains OFF whereas it is commanded to switch ON. Reasons may be: contact oxidized or
damaged
227 Contactor remains ON whereas it is commanded to switch OFF. Reasons may be: contact welded or short circuit
to 24V
228 Contactor remains OFF whereas it is commanded to switch ON. Reasons may be: contact oxidized or damaged
229 FET of contactor is closed while opening is ordered
230 FET of contactor is open while closing is ordered
241 FET of initial lowering valve closed while opening is ordered
242 FET of initial lowering valve is open while closing is ordered
243 FET of initial lowering valve is active while no action is ordered by the user
244 not active in [1]
Internal serial communication disturbed
251 Internal powerpart error
252 Lift - Powerpart is active while no action is ordered by the user
260 Motor temperature signal out of tolerated range (< -30°C or > +200°C) reasons may be: wire shortcut, wire open,
sensor problem
261 Motor temperature high (> 90°C)
262 MOS temperature signal out of tolerated range (< -30°C or > +200°C) reasons may be: wire shortcut, wire open,
sensor problem
263 MOS temperature high (> 90°C)
273 Potentiometer supply voltage (8.3V) high (> 9,5V)
274 Potentiometer supply voltage (8.3V) low (< 7,5V)
281 Error from driving controller via SSC: torque setpoint too high
282 Error from driving controller via SSC: torque setpoint too low
283 Error from driving controller via SSC: brake control error
284 Error from driving controller via SSC: actual torque evaluation too high
285 Error from driving controller via SSC: actual torque evaluation too low
286 Error from driving controller via SSC: cyclic disable test of relay, contactor and brake outputs failed
287 Internal serial communication disturbed
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Service Training Page 59

300 not active in [1] and [2]

Truck without belly function, but belly - switch signal is active
(X1:14 > 16V)
305 not active in [1] and [2]
Truck without platform, but foot - switch signal is active
(X1:8 < 1V)
306 not active in [1] and [2]
Truck without platform, but platform - switch signal is active
(X1:31 < 1V)
307 not active in [1] and [2]
Truck without platform, but guardrail - switch signal is active
(X1:53 < 1V)
310 not active in [1] and [2]
Truck without mast, but signal of mast - switch at 1,5 m is active
(X1:41 < 2,5V)
311 not active in [1], [2] and [3]
Truck without mast, mast potentiometer signal is active (X1:19 > 0,5V)
315 not active in [1], [2] and [3]
Mast potentiometer signal out of tolerated range: X1:19 < 0,5V reasons may be: wire cut or shortcut to GND
316 not active in [1], [2] and [3]
Mast potentiometer signal out of tolerated range: X1:19 > 9,5V reason may be: shortcut to supply voltage

6.6.3 Main steering error codes:

Information codes

1 Power-Up -Tests not finished

3 Controller set to Passivemode by CAN-Flasher
7 Unteached Potentiometer or corrupped EEProm
8 incorrect EEProm truckidentifer value
9 incorrect CAN traction truckidentifer
10 Message from Powerpart (pwm to motor voltage fault, but not critical),
monitors set steering value from logic part to current steering value at steering motor
11 Setpotentiometer to actpotentiometer value difference

Warning codes
no error implemented

Error codes
220 no Productiontest (--OK--sign missing in EEPROM)
223 Safetyrelay closed without demand
224 Safetyrelay open but should be closed
225 ext. Safetyrelay closed without demand
226 ext. Safetyrelay open but should be closed
227 Contactor closed without demand
228 Contactor open but should be closed
240 Fatal plant behaviour error: Steering angle varies in the opposite direction to the commanded one (PWM). One
of those components does not work properly: PWM unit, inverter, motor, gear or angle sensor or the steering
axle is externally actively moved (should not occur normally)
244 Error from internal communication between controllers (SSC Watchdog)
250 Errorsignal from Powerpart (1 time occured),
Internal error of powerpart logic chip due to following reasons: undervoltage, high current by short cut,
overtemperature
Note: LES tries to reset the powerpart chip up to three times to keep steering alive
251 Error from Powerpart (3 times errorsignal -> powerpart disabled),
see description of error 250
252 Error from Powerpart (capacitor voltage < Ubattery - 4V),
Measured capacitor voltage for steeringmotor reaches lower limit
254 Error from Powerpart (pwm to motor voltage fault),
Measured motor voltage does match to applied PWM duty cycle ratio and measured battery voltage whereas
motor voltage and current are not both equal to zero (relay contact closed). One of those components does not
work properly: PWM unit, inverter, voltage or current measurement.
255 Error from Powerpart (motorcurrent overrides limit),
Current sensor, motor voltage and steering angle signal courses do not suit to plant model. One of those signals
is erroneous - presumably current signal if no further trouble code generated. The aim of this monitoring function
is the detection of erroneous current signal.
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260 Error from Powerpart (MOSFETS temperature to high)
Measured temperature at power mosfets has reached critical value (>90°C)
264 SWB (steer wheel brake) connection with short cut
265 SWB (steer wheel brake) connection open
266 SRWS (speed reduction with steering), angle for traction differs from wheelangle
267 SRWS (speed reduction with steering) connection with short cut
268 SRWS (speed reduction with steering) connection open
269 EnableTraction voltage wrong
270 Battery voltage low (<100% from 8.3V)
272 Ratiometric sensor voltage high (>104% from 8.3V),
Measured supply voltage (real 8.3V) for potentiometers overrides upper limit
273 Ratiometric sensor voltage low (<89% from 8.3V),
Measured supply voltage (real 8.3V) for potentiometers underrrides lower limit
274 Ratiometric setpoti 1 voltage high (>98.5% from 8.3V)
275 Ratiometric setpoti 1 voltage low (<1.5% from 8.3V)
276 Ratiometric setpoti 2 voltage high (>98.5% from 8.3V)
277 Ratiometric setpoti 2 voltage low (<1.5% from 8.3V)
278 Ratiometric setpoti 1 to 2 voltage high (>105% from 8.3V)
279 Ratiometric setpoti 1 to 2 voltage low (< 95% from 8.3V)
280 Ratiometric actpoti 1 voltage high (>98.5% from 8.3V)
281 Ratiometric actpoti 1 voltage low (<1.5% from 8.3V)
282 Ratiometric actpoti 2 voltage high (>98.5% from 8.3V)
283 Ratiometric actpoti 2 voltage low (<1.5% from 8.3V)
284 Ratiometric actpoti 1 to 2 voltage high (>105% from 8.3V)
285 Ratiometric actpoti 1 to 2 voltage low (< 95% from 8.3V)
290 Error by Safety Controller (AD-setpoti 1 uC1 - uC2 difference )
291 Error by Safety Controller (AD-actpoti 1 uC1 - uC2 difference )
292 Error from Safety Controller (powerstages uC1 - uC2 differs)
293 Error from Safety Controller (dig. input uC1 - uC2 differs)
294 Error from Safety Controller (dig. output uC1 - uC2 differs)
295 Error from Safety Controller (srwsangle uC1 - uC2 differs)
296 Error from Safety Controller (Voltage Entraction uC1 - uC2 differs)
299 Common error by Safety Controller

6.6.4 Safety steering error codes:

Information codes

1 Power-Up -Tests not finished (ext. Safetyrelay open but should be closed)
2 Power-Up -Tests not finished (Safetyrelay open but should be closed)
3 Controller set to Passivemode by CAN-Flasher
7 Unteached Potentiometer or corrupped EEProm
8 incorrect EEProm truckidentifer value

Warning codes
No codes implemented

Error codes

220 no Productiontest (--OK--sign missing in EEPROM)

240 Fatal plant behaviour error: Steering angle varies in the opposite direction to the commanded one (PWM). One
of those components does not work properly: PWM unit, inverter, motor, gear or angle sensor or the steering
axle is externally actively moved (should not occur normally)
242 ext. Safetyrelay open but should be closed
243 Safetyrelay open but should be closed
244 Error from internal communication between controllers (SSC Watchdog)
245 EnableTraction voltage wrong
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Section 6
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6.7 ELECTRICAL DIAGRAMS

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Section 6
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6.7.1 T20/24 SP ET AP ( LAC )

POWER:

1A1 Traction speed control and initial lift 7-22 X2 Battery locking controller 72
3A1 Steering speed control 25-35 X13 Brake module connector (LORD) 117-113

1F1 Traction / elevation fuse 250A 9 1X1 Traction/hoist control connector

3F1 Steering fuse 100A 26 (LAC) 49-99
G1 Battery 1 1X2 Speed sensor connector 93-96
1X3 Control panel /unit interface connector (A1) 45-73
1K2 Traction/hoist switch 9 1X4 Steering programming box connector (LAC) 82-85
3K1 Steering switch 26 1X5 Control module connector 45-73
1X9 Driver presence connector 58
1M1 Traction motor 14-17 1X20 Platform position connector 53
2M1 Pump motor 20-22 1x25 Traction motor temperature connector 80
3M1 Steering motor 31-33 1X26 Stability module connector (inclinometer) 86-88
9M1 Fan motor 60
9M2 Fan motor 63 2X9 Lowering solenoid valve connector LI 84
2X14 High (1B4) and low (1B3) end of course
CONTROLS: connector of the LI. 77
2X15 Solenoid valve connector (2Y7)
A1 Control interface for stabiliser block 41
(moving, lifting, horn) 43-73 2X16 Stabiliser fluid level connector 65
1A1 Traction, initial lift speed control (LAC) 48-99 2X20 Right stabiliser electrovalve connector 53
1A8 Stability module 86-89 2X21 Left stabiliser electrovalve connector 89
3A1 Steering speed control (LES) 102-132
7A5 Brake module (LORD) 116-125 3X1 Electric steering connector 102-132
3X3 Wheel position potentiometer connector 128-131
1B1 Acceleration potentiometer 65-67
1B2 Traction speed sensor 92-96 6X2 Multi-function indicator connector 94-99
1B3 Lower fork detector 77 6X7 Diagnostics connector 103-106
1B4 High forks detector 75
1B6 Traction motor temperature sensor 80 7X6 Electromagnetic brake connector (Y1) 80-81
3B2 Steering potentiometer (set value) 118-123
3B3 Steering potentiometer (wheel position) 125-130 Y1 Electromagnetic brake 78-82
2Y2 Initial lift lowering solenoid valve 84
1F3 Control fuse 7.5 A 51 2Y7 Solenoid valve for stabiliser block
(only for trucks with battery with side outlet) 42
4H1 Horn 45 2Y8 Solenoid valve for right stabiliser block 86
2Y9 Solenoid valve for left stabiliser block 89
1K2 Traction contactor 9-76
3K1 Direction contactor 26-113 Z1 Interference circuit 45,53,
58,62
9M1 Electric plate fan 60 Z2 Anti interference diode 47
9M2 Electric plate fan 63 7Z1 Brake interference 79-81
7Z2 Interference contactors 77,114
6P4 Multifunction indicator 95-100

S1 Ignition key 52
1S3 Rear safety microswitch (belly switch)
at tiller (only for T20 AP) 47-50
1S4 Tiller base microswitch 69
1S4A Tiller base microswitch 70
1S9 Driver presence microswitch 58
1S19 Locking battery microswitch 72
1S21 Forward travel micro switch 51
1S22 Rear micro switch 55
2S6 Fork lowering control 57 Code Colour Code Colour
2S7 Fork lifting control 60
2S18 Oil level of stabilisers 66 BK Black GN Green
4S1 Horn 44 WH White VT Violet
7S5 Microswitch to open control circuit BU Blue RD Red
(controlled mechanically by 7S1) 52 OG Orange YE Yellow
BN Brown GY Grey
 Electrical diagram
power T20/24 SP and AP

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 Electrical diagram
Control T20/24 SP (LAC)

1318042401.0904
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 Electrical diagram
Control T20/24 SP and AP (LES)

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  




 

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        

        
   
          
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 
   

   

    

 




   



 

          

       
    
    
      
    
    
           
             
       
     
    

    
               
               
         
   
       
       
     
   
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 
   
   

 

 

 
 

 

 
 

 

 

 

              


 
   

  
   

  
   

  

   
  
     
  
 
 https://truckmanualshub.com/

 
   

   

    

   
          
        
            
         
        
         
    


       
   


           
        
           
    
       
          
 

   

   

    
         

   

           
        
            
           
        
         
    
      
          

    
   


        

       
 https://truckmanualshub.com/

 
   
   

 


 
 


  

 
 https://truckmanualshub.com/

 
   

    

 
 

           

               
    
     
               
     
       
              
    
                
     
     
  
  
  
  
 https://truckmanualshub.com/

 
   
https://truckmanualshub.com/
 https://truckmanualshub.com/

 
     

 
   

      