CS 20

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CS
Ident-Nr. 4 497 188 08.04
Workshop Manual
Order Picker Truck
71 1040 0 XXXXX CS 20
71 1041 0 XXXXX CS 10-M
71 1042 0 XXXXX CS 16-S
71 1043 0 XXXXX CS 30-Z
STILL
SEDS
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CS
Ident-Nr. 4 497 188 08.04
Workshop Manual
71 1040 0 XXXXX CS 20
71 1041 0 XXXXX CS 10-M
71 1042 0 XXXXX CS 16-S
71 1043 0 XXXXX CS 30-Z
STILL
CS 20
CS 10-M
CS 16-S
CS 30-Z
CS 20 Electric Pallet Truck
CS 10-M Electric Pallet Stacker
CS 16-S Electric Pallet Stacker with Scissors Lift
CS 30-Z Tractor
00 Workshop Manual CS
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Overview of assemblies
00 General
01 Frame
03 Gearbox
04 Wheels
05 Driving controls
06 Steering
07 Brakes
08 Electrical system
09 Options
10 Hydraulic system
11 Traction motor
20 Mast
22 Fork carriage
31 Diagnosis
32 Special tools
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Page
TabIe of contents
Foreword ........................................................ 1
Truck information............................................ 2
Approved applications .................................... 2
Special risks when using the truck and
attachments................................................ 2
ntroduction..................................................... 3
nformation on operation ................................. 4
CS 20 Description .......................................... 5
CS 10 M Description ...................................... 9
CS 16 S Description .................................... 12
CS 30 Z Description ..................................... 15
Manufacturer's identification plate ................ 18
Overview of options and models CS 10 M ... 18
Overview of options and models
CS 20 / CS 16 S....................................... 19
Overview of options and models CS 30 Z .... 20
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Foreword
GeneraI
STLL fork lift trucks comply with safety regulations. f your truck
is used on public roadways, it must be equipped as required by
local regulations. The driving permit must be obtained at the
appropriate office.
STLL fork lift trucks are equipped with the latest technology. t is
now important to operate your truck safely and to maintain its
operability.
To achieve this, STLL provides you with the necessary information
i n thi s manual . Read and fol l ow the i nstructi ons before
commissioning your truck! n this way you will avoid accidents,
save yourself trouble, and not void your guarantee.
Operating and maintenance instructions accompany each truck.
This manual must be stored carefully and kept within easy reach
of the driver and operator.
f the operating instructions are lost, the operator must immediately
order a replacement from STLL.
The operating and maintenance instructions are included in the
spare parts list and can be ordered like a spare part.
The staff concerned with the operation and maintenance of the
equipment must be made cognizant of these operating and
maintenance instructions.
The operator must ensure that all users have access to, have
read and understood these instructions.
We thank you for reading and following these instructions. Please
contact our Service if you have any questions, want to submit
improvement suggestions or have discovered an error.
Date of issue and version of manuaI
August 2004
STLL is constantly developing and improving their fork lift trucks.
Therefore, the manufacturer reserves the ri ght to make
modifications and he will not accept any liability claims based on
the information and illustrations contained in these operating and
maintenance instructions.
Your partner
STLL GmbH
Berzeliusstr. 4
D-22113 Hamburg
hopes you will be driving safely.
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Truck information
Truck identification
Type, serial no. and year built are contained on the identification
plate.
Approved appIications
The truck can be used for lifting and carrying loads. t is equipped
with forks and allows the fast transport of loads on the ground.
The truck may only be used as approved and described in this
manual.
f the truck is to be used in a way other than established in the
operating instructions, the written approval of the manufacturer
and, if necessary, of the responsible authorities must be obtained
beforehand to prevent any potential dangers.
The maximum load that can be lifted is specified on the load
capacity plate (load diagram). Do not exceed the maximum load
capacity.
Site of operation
The truck can be used in enclosed spaces or occasionally outside
except in bad weather. The service area must have a sufficient
ground load capacity. Contact your dealer for the data concerning
the wheel loads or specific ground pressure for your truck. The
ground must conform to our specifications.
The ground surface influences the braking distance of the truck.
When driving and braking, the driver must take the quality of the
ground on which he is driving into consideration.
Please observe local regulations.
The truck can be used in tropical and northern countries
(temperature range -20 C to +40 C). As an option the truck can
also be equipped for cold stores*.
Unapproved appIications
The manufacturer is not liable for any hazards arising from
unapproved applications.
Use for other purposes is prohibited. Riders are not allowed on
the truck.
Do not operate the truck in zones posing a fire or explosion risk or
in areas causing corrosion or in a very dusty environment.
Do not operate the truck on public roadways and in cold stores*.
SpeciaI risks when using the truck and
attachments
Each application not within the scope of the usual operations and
about which the driver is uncertain whether it can be performed
in an approved and safe manner requires the approval of the
manufacturer and, if necessary, of the responsible authorities. n
particularly difficult cases requiring the simultaneous use of two
trucks for the transport of heavy or bulky loads, the supervising
officer must be on the site and assume the responsibility and
supervision for this transport.
Modifications and retrofits
f your truck is to be operated, for example, in a cold store or in an
environment with an explosion hazard, the truck must be equipped
and approved for this application.
f your truck is to be used for work not specified in the guidelines
and has to be converted or re-equipped for such use, remember
that any alteration to the structural state can affect the driving
behaviour and stability of the truck and lead to accidents. You
shoul d therefore contact your di stri butor beforehand. No
modifications affecting the stability of the truck negatively may be
performed without our approval.
Retrofits are only allowed with our written approval. The approval
of the responsible authorities must also be obtained, if required.
Warning against using non-genuine
parts
Genui ne parts and accessori es are
specifically designed for our vehicles.
We expressly point out that parts and
accessories not supplied by us have also
not been tested and approved by us. The
installation and/or use of such products
can consequently adversely affect the
structurally predetermined properties of
your truck and thus reduce the active and/
or passive driving safety of your vehicle.
The manufacturer is not responsible for
any damage caused by the use of non-
genuine parts and accessories.
FueIs and Iubricants
Please refer to "Recommended Fuels and Lubricants" for the
required materials.
CAUTION: Fuels and lubricants can be hazardous. Please follow
the safety instructions when handling these materials.
Definition of directions
The references front, rear, forward, backward, etc. when
describing location are made relative to the tiller. The load is at the
rear.
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Introduction
Definition of terms used:
DANGER: For work procedures which
must be fol lowed exactl y to prevent
danger to the life and limb of persons.
WARNING: Indicates procedures which
must be fol lowed exactl y to prevent
personal injury.
CAUTION: Indicates procedures which must be followed exactly
to prevent damage to and/or destruction of the equipment.
NOTE: ndicates points of technical interest requiring special
attention.
ResiduaI hazards and risks
Despite working carefully and according to the standards and
regulations, residual risks cannot be excluded when operating
the truck.
The truck and all other system components conform to current
safety regulations. Nevertheless, even for approved applications
and with the observance of all safety notices, a residual risk
cannot be excluded.
A residual risk cannot be excluded even beyond the immediate
danger area of the truck, so that any persons standing in this area
must pay particular attention to the truck in order to be able to
react fast in case of an incident, failure, etc.
CAUTION: All persons standing in the
vicinity of the truck must be advised of
the hazards arising with the operation of
the truck. We also refer to additional
safety rul es i n these operati ng
instructions.
These hazards can be:
- Egress of fuels and lubricants due to
l eaks, breaki ng of pi pes and
containers, etc.
- Ri sk of dri vi ng acci dents due to
unfavourable ground conditions such
slope, ice, roughness or poor visibility,
etc.
- Falling off or down, etc. when moving
on the truck, particularly when wet.
- The stability of the truck has been
tested according to the state of the
art. Only the dynamic and static tipping
forces occurri ng duri ng the
determi ned regul ar operati ng
conditions and approved operations
were taken into consideration. The risk
of exceeding the tipping moment during
unapproved or incorrect operation
cannot entirely be excluded for difficult
stability conditions.
- Loss of stability due to displaced or
unstable load, etc.
- Fire and explosion hazard due to the
battery and electric power.
- Human error: non-observance of
safety rules.
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Information on operation
Operator
The operator is the natural or legal person using the truck or on
whose order the truck is used. The operator must ensure that the
truck is only used for approved applications. He is responsible for
the observance of the accident prevention rules and the safety
rules in these operating instructions. The operator must ensure
that all users understand the safety information.
Driver
The truck may only be driven by qualified persons at least 18
years of age or acc. to local regulations, trained in its operation,
and who have demonstrated to the operator or his representative
their driving and load-handling ability and have expressly been
entrusted with driving the truck. Observe national laws and
regulations.
Rights, obIigations and behaviouraI
ruIes for drivers
Drivers must be informed of their rights
and obligations. They must be accorded
the rights to which they are entitled. The
driver must wear safety gear according
to the conditions of his activities (protective
clothing, safety shoes, helmet, safety
glasses, protective gloves and other) as
required by his task and the load to be
handled.
The driver must be acquainted with the
operating instructions and they must be
available to him at all times.
Prohibition of use by unauthorized
persons
During the shift the driver is responsible for the truck. He must
ensure that it is not driven or operated by unauthorized persons.
When leaving the truck unattended, he must secure the truck
against unauthorized use.
Damage, deficiencies
The driver must immediately notify the supervisors of any damage
to the truck or of any faults. noperative and unsafe trucks and
attachments must not be operated until they have been properly
repaired.
Safety devices and switches must not be removed or disabled.
Fixed settings may only be changed with the approval of the
manufacturer.
EC conformity certificate,
EC conformity sign
With the EC conformity certificate, the
manufacturer certi fi es that the truck
conforms to the val i d standards and
requirements at the time of marketing.
The EC conformity sign is located on the
truck identification plate and it indicates
that the above-mentioned requirements are
met.
f the truck is modified or retrofitted without
the approval of the manufacturer, the
safety of the truck may be reduced so
that the EC conformi ty certi ficate i s
invalidated.
Copyright and property rights
These operating instructions - even excerpts thereof- may not be
reproduced, translated or made available to third parties without
the written permission of the manufacturer.
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CS 20
Description
TechnicaI Data
Definition of directions
Forwards
Backwards
Lift
Lower
to the right
to the left
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CS 20
Description
TechnicaI data
Dimensions
CS20_Ba_03_065
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CS 20
Description
TechnicaI data
n o i t a c i f i t n e d I
r e r u t c a f u n a M L L T S
n o i t a n g i s e d l e d o m s ' r e r u t c a f u n a M 0 2 S C
m r o f t a l P x i f
s n i a m , s a g P L , l o r t e p , l e s e i D , y r e t t a B : e v i r D y r e t t a B
r e k c i p r e d r o , d e t a e s r e v i r d , g n i d n a t s r e v i r d , e i k l a w , l a u n a M : n o i t a r e p O g n i k l a W - g n i d n a t S
d a o l d e t s i o h / y t i c a p a c d a o L ) g k ( Q 0 0 0 2
e r t n e c d a o L ) m m ( c 0 0 2 1
e c n a t s i d d a o L ) m m ( x 5 1 6 1
e s a b l e e h W ) m m ( y 3 4 8 2
s t h g i e W
t h g i e w d a e D 3 1 1 y a r t y r e t t a b h t i w g k 5 4 1 1
d a o l h t i w d a o l e l x A e d i s d a o l / e d i s s ' r e v i r d g k 5 9 8 1 / 0 5 2 1
d a o l t u o h t i w d a o l e l x A e d i s d a o l / e d i s s ' r e v i r d g k 5 6 2 / 0 8 8
s i s s a h c , s I e e h W
) V ( n a l l o k l l u V , ) P ( e n a h t e r u y l o p , ) L ( c i t a m u e n p , ) E S ( c i t s a l e r e p u s , s e r y T V
s n o i s n e m i d e r y T e d i s s ' r e v i r d 0 0 1 x 0 5 2
s n o i s n e m i d e r y T e d i s d a o l 0 8 x 5 8
l e e h w r e s i l i b a t s f o n o i s n e m i D e d i s s ' r e v i r d 0 5 x 0 5 1
) n e v i r d = x ( t n o r f r e b m u n , s l e e h W r a e r / t n o r f 4 / 1 - x 1
t n o r f , h t d i w k c a r T ) m m ( 0 1 b 5 7 4
r a e r , h t d i w k c a r T ) m m ( 1 1 b 8 4 3
s n o i s n e m i d I I a r e v O
t f i L ) m m ( 3 h 0 3 1
m r o f t a l p s ' r e v i r d f o t h g i e H ) m m ( 7 h 5 3 1
t h g i e h r e l l i T ) m m ( 4 1 h 5 6 1 1
t h g i e h k r o F ) m m ( 3 1 h 5 8
h t g n e l l l a r e v O ) m m ( 1 l 5 0 8 3
h t g n e L ) m m ( 2 l 5 2 4 1
h t d i w l l a r e v O ) m m ( 1 b 0 0 8
s s e n k c i h t k r o F ) m m ( s 1 6
h t d i w k r o F ) m m ( e 2 7 1
h t g n e l k r o F ) m m ( l 0 9 3 2
e c n a t s i d k r o f e d i s t u O ) m m ( 5 b 0 2 5
e c n a r a e l c d n u o r G ) m m ( 2 m 4 2
g n o l 0 0 2 1 x 0 0 8 s t e l l a p h t i w h t d i w e l s i A ) m m ( t s A 7 2 1 4
s u i d a r g n i n r u T ) m m ( a W 6 4 0 3
s e c n a m r o f r e P
. w r o f g n i v i r D d a o l h t i w h / m k 8
. w r o f g n i v i r D d a o l t u o h t i w h / m k 0 1
e m i t g n i t f i L d a o l h t i w s 1 . 2
e m i t g n i t f i L d a o l t u o h t i w s 4 . 1
e m i t g n i r e w o L d a o l h t i w s 7 . 1
e m i t g n i r e w o L d a o l t u o h t i w s 2 . 3
e c r o f e v i t c a r t d e t a R d a o l h t i w % 6
e c r o f e v i t c a r t d e t a R d a o l t u o h t i w % 6
) m 0 1 r e v o ( e m i t n o i t a r e l e c c A d a o l h t i w s 4 . 6
) m 0 1 r e v o ( e m i t n o i t a r e l e c c A d a o l t u o h t i w s 4 . 5
e k a r b e c i v r e S c i t e n g a m o r t c e l e
s r o t o m c i r t c e I E
n i m 0 6 = 2 S , e c n a m r o f r e p , r o t o m e v i r D W k 2
% 5 1 = 3 S , e c n a m r o f r e p , r o t o m t f i L W k 2 . 2
o n , C , B , A 6 3 / 5 3 / 1 3 5 3 4 N D o t . c c a y r e t t a B B ; 2 - 4 5 2 C E
e g a t l o v y r e t t a B ) V ( U 4 2
y t i c a p a c y r e t t a B ) h A ( 5 K 0 5 4
t h g i e w y r e t t a B r e i l p p u s n o g n i d n e p e d ) % 5 - / + ( g k 0 1 4
e l c y c D V o t . c c a n o i t p m u s n o c y g r e n E h / h W k 4 1 . 1
s n o i t a c i f i c e p s r e h t O
e p y t r e l l o r t n o C R C S
l e v e l e s i o N r a e s ' r e v i r d t a ) A ( B d 5 . 6 6
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TechnicaI data
Sound and vibration
The noise specifications in the technical data
were determined according to CE standard
"Noise measurement of industrial trucks, sound
level at the workplace and sound power level" (in
preparation). The sound power level at the driver's
station is 65 dB(A).
According to directive 86/188/EEC, however, the
specified truck noise levels cannot be used for
determining the noise emission at the workplace
(daily personal noise allowance). f required, these
must be determined directly at the workplace
under actually existing influences (further sources
of noise, special operating conditions, sound
reflections).
The vibrations were determined according to the
CEN standard "Vibrations measurements on fork
trucks" (in preparation). These data are truck
characteristics under defined conditions. The
requirements and values are met. The personal
vibration load on the driver for one work day must
be determined, if necessary, at the site of
operation in order to take all other influencing
factors such as road stretch, intensity of
operation, etc., into consideration.
Emissions
During charging, the drive battery emits a mixture
of oxygen and hydrogen (detonating gas). This
gas mixture is explosive and it must not be ignited.
The risk of explosion can be avoided through
sufficient ventilation and by avoiding naked
flames. Follow the safety precautions for handling
the drive battery.
WheeIs and tyres
Approved types of tyres
Only the specified types of tyres may be installed.
TabIe of fork dimensions (mm)
Dimension
b5 520 560 670
L
U
X
b
5
CS20_Ba_03_016
Dimension
L 1190 1450 1650 1650 1800 2150 2150 2390 2390 2900 3100
X 1005 1265 1105 1465 1615 1605 1375 1615 1845 2125 2125
U 185 185 545 185 185 545 775 775 545 775 975
Y 2233 2493 2333 2693 2843 2833 2603 2843 3073 3353 3353
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CS 10 M
Description
TechnicaI data
Dimensions
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CS
Description
TechnicaI data
n o i t a n g i s e d l e d o m s ' r e r u t c a f u n a M M 0 1 S C
r e k c i p r e d r o , d e t a e s r e v i r d , g n i d n a t s r e v i r d , e i k l a w , l a u n a M : n o i t a r e p O r e k c i p r e d r O
e r t n e c d a o L ) m m ( c 0 0 6
e c n a t s i d d a o L ) m m ( x 5 7 6
e s a b l e e h W ) m m ( y 6 0 9 1
s t h g i e W
t h g i e w d a e D y r e t t a b h t i w g k 8 1 2 1
d a o l h t i w d a o l e l x A e d i s d a o l / e d i s s ' r e v i r d g k 0 5 3 1 / 8 6 8
d a o l t u o h t i w d a o l e l x A e d i s d a o l / e d i s s ' r e v i r d g k 6 7 3 / 2 4 8
s n o i s n e m i d e r y T e d i s s ' r e v i r d 0 0 1 x 0 5 2
s n o i s n e m i d e r y T e d i s d a o l 0 8 x 5 8
l e e h w r e s i l i b a t s f o n o i s n e m i D e d i s s ' r e v i r d 0 5 x 0 5 1
d e r e w o l t s a m , t h g i e H ) m m ( 1 h 5 7 3 1
t f i L ) m m ( 3 h 0 0 7
d e d n e t x e t s a m , t h g i e h l l a r e v O ) m m ( 4 h 5 7 0 2
t h g i e h r e l l i T x a m / n i m ) m m ( 4 1 h 5 6 1 1
t h g i e h k r o F ) m m ( 3 1 h 6 8
h t g n e L ) m m ( 2 l 6 1 4 1
h t d i w k r o F ) m m ( e 4 8 1
h t g n e l k r o F ) m m ( l 0 9 1 1
h t d i w r e i r r a c k r o F ) m m ( 3 b 4 7 7
g n o l 0 0 2 1 x 0 0 8 s t e l l a p h t i w h t d i w e l s i A ) m m ( t s A 1 5 9 2
s u i d a r g n i n r u T ) m m ( a W 1 9 0 2
e m i t g n i t f i L d a o l h t i w s 5 3 . 5
e m i t g n i t f i L d a o l t u o h t i w s 5 4 . 3
e m i t g n i r e w o L d a o l h t i w s 6
e m i t g n i r e w o L d a o l t u o h t i w s 5 . 7
e c r o f e v i t c a r t d e t a R d a o l h t i w % -
e c r o f e v i t c a r t d e t a R d a o l t u o h t i w % -
n i m 0 6 = 2 S , e c n a m r o f r e p , r o t o m e v i r D W k 0 . 2
e l c y c D V o t . c c a n o i t p m u s n o c y g r e n E h / h W k -
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CS 10 M
Description
TechnicaI data
Sound and vibration
level at the workplace and sound power level"
(in preparation). The sound power level at the
driver's station is 73.3 dBA.
According to directive 86/188/EEC, however,
the specified truck noise levels cannot be used
for determining the noise emission at the
workplace (daily personal noise allowance). f
required, these must be determined directly at
the workplace under actually existing influences
(further sources of noise, special operating
conditions, sound reflections).
Emissions
flames. Follow the safety precautions for
handling the drive battery.
WheeIs and tyres
Dimensions
b
5
565
L 1185
X 675
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CS 16 S
Description
TechnicaI Data
Dimensions
452 420
x
y
c
y'
x'
100 l1
Ast
100
l2
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CS 16 S
Description
TechnicaI Data
n o i t a n g i s e d l e d o m s ' r e r u t c a f u n a M S 6 1 S C
r e k c i p r e d r o , d e t a e s r e v i r d , g n i d n a t s r e v i r d , e i k l a w , l a u n a M : n o i t a r e p O r e k c i p r e d r O
e r t n e c d a o L ) m m ( c 0 0 2 1
e c n a t s i d d a o L ) m m ( x 2 4 5 1 / * 1 8 3 1
e s a b l e e h W ) m m ( y 2 2 8 2 / * 1 6 6 2
s t h g i e W
t h g i e w d a e D y r e t t a b h t i w g k 6 7 4 1
d a o l h t i w d a o l e l x A e d i s d a o l / e d i s s ' r e v i r d g k 4 7 8 1 / 2 0 2 1
d a o l t u o h t i w d a o l e l x A e d i s d a o l / e d i s s ' r e v i r d g k 0 6 4 / 6 1 0 1
s n o i s n e m i d e r y T e d i s s ' r e v i r d m m 0 0 1 x 0 5 2
s n o i s n e m i d e r y T e d i s d a o l m m 4 3 x 2 8
l e e h w r e s i l i b a t s f o n o i s n e m i D e d i s s ' r e v i r d m m 0 5 x 0 5 1
d e r e w o l t s a m , t h g i e H ) m m ( 1 h 1 7 3 1
t f i L ) m m ( 3 h 0 0 7
d e d n e t x e t s a m , t h g i e h l l a r e v O ) m m ( 4 h 1 7 0 2
t h g i e h r e l l i T x a m / n i m ) m m ( 4 1 h 5 6 1 1
t h g i e h k r o F ) m m ( 3 1 h 5 8
h t g n e L ) m m ( 2 l 5 6 4 1
h t d i w r e i r r a c k r o F ) m m ( 3 b 4 8 7
h t d i w k r o F ) m m ( e 4 8 1
h t g n e l k r o F ) m m ( l 0 9 3 2
g n o l 0 0 2 1 x 0 0 8 s t e l l a p h t i w h t d i w e l s i A ) m m ( t s A 4 5 1 4 / * 1 4 1 4
s u i d a r g n i n r u T ) m m ( a W 7 0 0 3 / * 6 4 8 2
e m i t g n i t f i L d a o l h t i w s / m 0 . 8
e m i t g n i t f i L d a o l t u o h t i w s / m 1 . 4
e m i t g n i r e w o L d a o l h t i w s / m 6 . 5
e m i t g n i r e w o L d a o l t u o h t i w s / m 3 . 6
e c r o f e v i t c a r t d e t a R d a o l h t i w % -
e c r o f e v i t c a r t d e t a R d a o l t u o h t i w % -
n i m 0 6 = 2 S , e c n a m r o f r e p , r o t o m e v i r D W k 0 . 2
e l c y c D V o t . c c a n o i t p m u s n o c y g r e n E h / h W k -
p u d e t f i l r o s s i c S *
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CS 16 S
Description
TechnicaI data
Sound and vibration
level at the workplace and sound power level" (in
preparation). The sound power level at the driver's
station is 71.2 dBA.
According to directive 86/188/EEC, however, the
reflections).
Emissions
the drive battery.
WheeIs and tyres
L
X
b
5
CS 16_Ba-001
Dimensions
b
5
540
L 2887
X 1542
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CS 30 Z
Description
TechnicaI Data
Dimensions
CS30Z-Ba_001
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CS 30 Z
Description
TechnicaI Data
Identification
Manufacturer STILL
Manufacturers model designation CS 30 Z
Platform fix
Drive: Battery, Diesel, petrol, LP gas, mains Battery
Operation: Manual, walkie, driver standing,
driver seated, order picker
Standing-Walking
Load capacity/hoisted load Q (kg) 3000
Rated drawbar pull F (N) 600
Wheelbase y (mm) 1190
Weights
Dead weight with battery kg 1530
Axle load without load driver's side/load side kg 875/655
Wheels, chassis
Tyres, superelastic (SE), pneumatic (L),
polyurethane (P), Vullkollan (V)
V
Tyre dimensions driver's side 250 x 100
Tyre dimensions load side 250 x 80
Dimension of stabiliser wheel driver's side 140 x 50
Wheels, number front (x = driven) front/rear 1x -1/2
Track width driver's side b 10 (mm) 475
Track width load side b 11 (mm) 424
Overall dimensions
Height of drivers platform h 7 (mm) 136
Tiller height min/max h 14 (mm) 1165
Height of trailer coupling h 10 (mm) 290/345/400
Overall length l 1 (mm) 1667
Rear overhang l 5 (mm) 293
Overall width b 1 (mm) 800
Ground clearance m 2 (mm) 60
Turning radius Wa (mm) 1382
Performances
Driving with load km/h 7,5
Driving without load km/h 9
Maximum drawbar pull without load N 600
Drawbar pull with load N 3000
Rated tractive force with load % -
Rated tractive force max. without load % -
Service brake electromagnetic
Electric motors
Drive motor, performance, S2 = 60 min kW 2
Battery acc. to DIN 43531/35/36 A, B, C, no IEC 254 - 2;B
Battery voltage U (V) 24
Battery capacity C5 K 5 (Ah) 310
Battery weight depending on supplier kg (+/- 5%) 560
Energy consumption acc. to VDI cycle kWh/h 1,4
Other specifications
Controller type SCR
Noise level at drivers ear at drivers ear dB (A) < 70
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CS 30 Z
Description
TechnicaI Data
Noise emissions
The values were determined in a test cycle in
accordance with EN 12053 (noise measurement
on industrial trucks on the basis of EN 12001 and
EN SO 3744 and EN SO 4871 requirements).
This machine emits the following noise pressure:
Noise IeveI at driver's station .... < 70 dB(A)
According to directive 86/188/EC, however, the
reflections).
Frequency characteristics
The machine frequencies were determined on an
identical machine in accordance with prEN 13059
of CEN "Vibration Tests on ndustrial Trucks.
Weighted effective vaIue of acceIeration on
the human body
(feet or seat) .................................. < 1.6 m/s
2
Uncertainty K.................................... 0.5 m/s
2
Studies have shown that the frequency of hand and
arm vibrations at truck steering wheels or controls
is under 2.5 m/s. For this reason no test
specifications are available for these measurements.
The personal vibration load on the driver for one
work day must be determined, if necessary, at
the site of operation in order to take all other
influencing factors such as road stretch, intensity
of operation, etc., into consideration.
Emissions
the drive battery.
WheeIs and tyres
Performance Chart
Tractor speed and drawbar pull are programmed,
depending on the application.
The permissible haul per hour is the total distance
travelled, including the return journey and any
downhill gradients.
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Manufacturer's identification pIate
1 Type
2 Manufacturer
3 CE conformity sign
4 Year of manufacture
5 Dead weight (kg)
6 Battery voltage (V)
7 Admissible min. battery weight
8 Admissible max. battery weight
9 Load capacity kg
10 Serial number*
*NOTE: Please indicate this serial number for all
technical questions.
Still GmbH
22113 Hamburg Germany
Typ Nr.
Type
Modle
Gerte Nr/Baujahr
Serial no./year
No de srie/anne
Nenntragfhigkeit
Rated capacity
Capacit nominale
Batteriegew.
Battery mass.
Masse de batterie
max.
min.
Leergewicht
Unladen mass
Masse vide
Batt. Spannung
Battery-volt.
Tension batterie
kg
kg
kg
/
V
478208
s. Betriebsanl./ see Operating instructions /voir Mode d'emploi
CS20_Ba_03_020
1 2 3
4 5 6 7 8 9 10
Overview of options and modeIs CS 10 M
AMB 03 Fork lift
1 Cut-off of forks lowering while driving
AMB 05 Battery frame
450 Battery roller frame for 360/465 Ah, tray 97
AMB 09 Load wheel equipment
4 Single load wheels, Vulkollan85 x 80 mm
AMB 10 Traction wheel equipment
1 Vulkollan traction wheel 250 x 100
AMB 34 Bumpers
1 Rubber bumpers, height 165 mm, installed on powerhead
2 Metal-type bumper, height 545 mm, installed at powerhead
AMB 37 Backrest
1 Cushioned backrest
AMB 38 Step
1 Hinged step, height 400 mm over platform
AMB 40 Slow speed
1 Slow speed forward/reverse with throttle at cockpit
2 Slow speed forward/reverse
Throttle at the cockpit & slow speed, forward/reverse travel with buttons
on each side behind the backrest
3 Slow speed forward/reverse with buttons on each side behind the
backrest
AMB 49 Bracket for accessories at the powerhead
1 Bracket for accessories at the bottom of the powerhead
2 Bracket for accessories at the top of the powerhead
3 Bracket for accessories top with cross member at the powerhead
AMB 55 Cold store model
1 Cold store protection -30 C for intermittent duty.
AMB 59 Document holder
1 Rotatable Document holder DN-A4 installed on bracket for accessories
00
19
Workshop ManuaI CS
GeneraI
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Overview of options and modeIs CS 20 / CS 16 S
AMB 03 Fork lift
1 Cut-off of forks lowering while driving
AMB 08 Back panel
180 Load screen, height 1875 mm
Attention: AMB 50, item 2 or 3 brackets specified for accessories.
1 Single load wheels, Vulkollan 85 x 100 mm
Required for picking up pallets 800 mm across
2 Single load wheels, Vulkollan 85 x 80 mm, distance between the load wheels
approx. 5 mm
AMB 23 Fork tips
1 Fork tips with entry/exit shoes
AMB 34 Powerhead bumper
1 Rubber bumper, height 165 mm, installed on powerhead
2 Metal-type bumper, height 545 mm, installed at powerhead
AMB 37 Backrest
AMB 38 Step
1 Hinged step, height 400 mm from platform
AMB 68 Holding rod
1 Holding rod installed on bracket for accessories
Attention : AMB 50 item 2 or 3 brackets specified for accessories.
AMB 40 Slow speed
Throttle at cockpit & slow speed, forward/reverse travel with buttons on each
side behind the backrest
3 Slow speed forward/reverse with buttons on each side behind the backrest
AMB 48 Speed limitation
1 Speed limitation with forks lowered
3 Bracket for accessories with cross member at top of the powerhead
AMB 50 Bracket for accessories on fork end
1 Bracket for accessories at bottom on fork end
2 Bracket for accessories at top on fork end
3 Bracket for accessories with cross member at top on fork end
AMB 51 Elevating platform
1 Elevating platform, height 750 mm
1 Rotatable document holder DN-A4, installed on the bracket for accessories
00
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Workshop ManuaI CS
GeneraI
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Overview of options and modeIs CS 30 Z
AMB 40 Slow speed
Throttle at cockpit & slow speed, forward/reverse travel with buttons on each
side behind the backrest
3 Slow speed forward/reverse with buttons on each side behind the backrest
3 Bracket for accessories with cross member at top of the powerhead
1 Rotatable document holder DN-A4, installed on the bracket for accessories
1 Single load wheels, Vulkollan 85 x 100 mm
Required for picking up pallets 800 mm across
2 Single load wheels, Vulkollan 85 x 80 mm, distance between the load wheels
approx. 5 mm
AMB 32 Trailer coupling
1 Tow pin coupling, 1 level
1 Tow pin coupling, 3 levels
AMB 34 Powerhead bumper
1 Rubber bumper, height 165 mm, installed on powerhead
2 Metal-type bumper, height 545 mm, installed on powerhead
AMB 37 Backrest
AMB 38 Step
1 Hinged step, height 400 mm from platform
01
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Page
TabIe of contents
General ........................................................... 1
Fork carriage CS 20 ....................................... 1
Fork carriage CS 16 S.................................... 2
Fork carriage CS 10M .................................... 2
Rear cover CS 30Z ........................................ 3
Removal of counterweight parts CS 30 Z ...... 4
Covers............................................................ 5
Hinged seat .................................................... 6
Renewal of battery cover in CS with elevating
platform ...................................................... 7
01
1
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Workshop ManuaI CS
Introduction
GeneraI
The frame of these machines is wel ded
automatically.
1 Frame for motor compartment
2 Frame
(Steel quality: S355 J2 G3)
Fork carriage CS 20
1 Automatically welded unitized construction
2 Formed fork tip (3) welded on to fork
01
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Fork carriage CS 16 S
Automatically welded construction in one piece.
Welded-on formed fork tips.
Fork carriage CS 10M
01
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Workshop ManuaI CS
Rear cover CS 30Z
Counterweight consisting of stacked steel plates.
Automatically welded trailer coupling in one piece
01
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RemovaI of counterweight parts CS 30 Z
To remove the counterweight parts (1), remove
the screws (2), then remove the counterweight
plates individually.
01
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Workshop ManuaI CS
Covers
The covers are manufactured usi ng RM
technology with which polyurethane* is formed
using reaction-injection moulding. This makes the
covers enormously resistant to shock.
1 Motor compartment cover
2 Backrest
3 Battery cover
4 Mounting for rolls
5 Rear cover
6 Hinge
*NOTE:
With exception of CS H, whose self-supporting covers are made of steel.
01
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Hinged seat
To remove the hinged seat, remove the two nuts (1).
To replace the hinged seat fastening elements (2), remove the four screws (3).
01
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Workshop ManuaI CS
RenewaI of battery cover in CS with eIevating pIatform
The driver's platform must be raised, the truck must be turned off and the battery connector removed.
Remove the three steel screws (1) to make the battery cover accessible.
Attention: The enclosure is made of steel
and not of plastic; it is therefore very
heavy.
Lower the driver's platform again, then pull the battery cover out.
For the removal of the elevating platform covers (option) see Group 20, Page 31.
03
Workshop ManuaI CS
Gearbox
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Page
TabIe of contents
Technical Data for Service ............................. 1
Removing gearbox ......................................... 2
03
1
Workshop ManuaI CS
Gearbox
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Designation 5.53.313.1 (Kordel)

Mounting on frame
Phillister head screws DN 912 M10
Torque Ma = 42 Nm
Mounting gearbox on motor
Phillister head screws DN 912 M6
Torque Ma = 40 Nm
Gear oil SAW 80 1.5 l
Transmission ratio 1 = 15.18
TechnicaI Data for Service
03
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Gearbox
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Removing gearbox
1 Disconnect the battery plug.
2 Using blocks of wood, block up the pallet
truck 350 mm over the ground (1).
3 Remove the traction motor (see group 11)
4 Remove the steering motor (see group 06).
5 Remove the traction wheel (see group 04).
6 Drain the oil from the gearbox. Carefully
remove any particles of metal from the
magnetic oil drain plug (2).
7 Replace the two screws connecting the
reduction gearbox with the turntable by two
eyebolts (3).
8 Secure the gearbox with a lifting sling and
hoist (4).
9 Remove the six fastening screws on the
reduction gearbox (5) (torque 42 Nm).
10 Carefully lower the gearbox and remove it.
03
3
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Gearbox
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Removing gearbox
InstaIIation is in the reverse order of rem-
ovaI
Gear oil in gearbox: about 1.5 litres.
f the oil level is correct, the spur gear (6) should
be covered about 1/3 by the oil.
Avoid any excessive filling as this could destroy
the seals and possibly prevent the working
temperature from being maintained.
04
Workshop ManuaI CS
WheeIs
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Page
TabIe of contents
General ........................................................... 1
Removing traction wheel ................................ 1
nstalling traction wheel .................................. 1
Adjusting the stabiliser.................................... 2
Removing the stabiliser .................................. 2
nstalling ......................................................... 2
Removing the load wheels CS 20 .................. 3
Removing the load wheels: CS 16 S.............. 4
nstallation ...................................................... 4
Removing the load wheels CS10 M ............... 4
Removing the rear wheels CS 30Z ................ 5
Adjusting the height of the stabiliser CS 30Z .. 8
nstallation ...................................................... 8
04
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WheeIs
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Introduction
GeneraI
Dimensions of a new traction wheel:
250 mm x 100 mm
The traction wheel must be replaced if:
1 the running surface is heavily damaged or not
round.
2 the diameter of the tyre has been reduced by
over 10 %
Type of tyre:
Traction wheel: VULKOLLAN
Removing traction wheeI
2 Block up the truck 230 mm (1) on squared
timber blocks and secure it against rolling.
3 Turn the traction wheel so that the 5 wheel nuts
can be removed.
4 Set the traction wheel square to the truck.
5 Remove the wheel nuts and washers and
deposit them.
6 Remove the traction wheel.
InstaIIing traction wheeI
1 Before installing the traction wheel, clean its
running surface and check it for proper
condition.
2 Put the traction wheel in place.
3 nstall the washers (3) and tighten the 5 nuts
by hand.
4 Tighten opposite nuts (2) with a torque wrench.
5 Adjusting the stabiliser
Torque for the wheeI nuts:
140 Nm
04
2
Workshop ManuaI CS
WheeIs
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N
o

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m
a
y

b
e

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u
c
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d

i
n

a
n
y

f
o
r
m

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b
y

a
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y

m
e
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s
.
C
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.
StabiIiser
Adjusting the stabiIiser
Dimensions of a new stabiliser: 150 x 50 mm
1 Put the truck on a level surface.
2 Measure the distance between the ground and
the lower edge of the frame at the traction wheel
axle.
3 Loosen screw (1).
4 Turn screw (2) until the stabiliser axle has
reached the previously measured dimension.
5 Tighten screw (1) to a torque of 125 Nm.
6 Check the tightness of screw (2).
NOTE: After mounting, check the stabiliser for
proper operation. When changing the direction
of travel, the stabiliser should turn 180 after
driving a short distance.
Removing the stabiIiser
1 Remove the hex head screw (2).
2 Loosen the clamping screw (1) on the stabiliser
mount. Now the wheel can be removed with
the securing wires and sleeves. Deposit on a
workbench.
- Remove the cap (4).
- Drive out the cotter pin (6).
- Unscrew the nut (8).
- Remove the bearing (5) and sleeve (7).
These two parts must be removed with a
puller.
InstaIIing
nstallation is in the reverse order of removal.
When tightening the nut (8), tighten it until the
sleeve (7) can no longer be turned. Pretension
the conical bearing, then loosen the nut (8) a 1/4
of a turn and secure it with the cotter pin (6).
04
3
Workshop ManuaI CS
WheeIs
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.
N
o

p
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t

m
a
y

b
e

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d
u
c
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d

i
n

a
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y

f
o
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m

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b
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m
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.
C
o
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r
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.
Removing the Ioad wheeIs CS 20
1 Raise the forks to the maximum height.
3 Loosen the load wheel fastening screws (1)
with a torque of 85 Nm.
4 Using a jack, raise the forks until the load
wheels no longer touch the ground and then
secure the truck with squared timbers (2).
5 Remove both fastening screws (3).
6 Renew the load wheels.
InstaIIation is in the reverse order of removaI
Use a puller for the replacement of the bushings
(4). Then drive them out with a blow of the
hammer and replace them.
Do not grease the bushings (4)!
04
4
Workshop ManuaI CS
WheeIs
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N
o

p
a
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t

m
a
y

b
e

r
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d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
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b
y

a
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m
e
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.
C
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.
Removing the Ioad wheeIs: CS 16 S
1 Raise the forks and secure them.
2 Raise the scissors and put a block between
the ground and their end points.
3 Remove the four screws (1) on the load wheels
(2).
4 Remove the pins (3) and then the rollers (2).
InstaIIation
InstaIIation is in the reverse order of removaI.
Removing the Ioad wheeIs CS10 M
1 Raise the forks and secure them.
2 Raise the legs from the ground and block up
with squared timbers so that the load wheels
no longer contact the ground.
3 Remove both pins (5).
4 Remove the load wheels (2).
NOTE:
After installation do not forget to check the (4) the
see-saw.
Do not grease the Teflon bearing races.
04
5
Workshop ManuaI CS
WheeIs
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N
o

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m
a
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b
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d
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i
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f
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b
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a
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m
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.
C
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.
Removing the rear wheeIs CS 30Z
- To remove the two lateral service covers remove 2 x 2 screws (1) (Fig. 2).
04
6
Workshop ManuaI CS
WheeIs
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N
o

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m
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b
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.
- Remove the 2 x 5 fastening screws on the rear wheels rear (6) through the lateral service covers.
6
04
7
Workshop ManuaI CS
WheeIs
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C
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.
- Remove the wheel to the side and downwards (Fig. 4).
04
8
Workshop ManuaI CS
WheeIs
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N
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f
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C
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.
Adjusting the height of the stabiIiser CS 30Z
- To adjust the height of the stabiliser, loosen the screw (7) and adjust the wheel to the desired
height; then retighten the screw (7).
The entire procedure is carried out through the openings in the counterweight plates.
OId version New version
InstaIIation
- nstallation is step by step in the reverse order of removal.
- See the General Table for all torques.
7
06
Workshop ManuaI CS
Steering
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m
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b
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.
Page
TabIe of contents
ntroduction..................................................... 1
Overview power assist steering ..................... 2
Removing the steering motor ......................... 3
Replacing the potentiometer .......................... 4
06
1
Steering
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Workshop ManuaI CS
Technical data for Service
Motor Direct current with two windings
Manufacturer Schabmller
Type R 100/0.15 150W
Gearbox Planetary hub reduction gearbox MS
reinforced, gear reduction ratio 18 : 1
Gear reduction ratio of differential/pinion gear 1 : 4.15
Thermal class F
Protection class and S3 P20/S3 78 %
Winding resistance
Armature: 265.5 mOhm +/- 3 %
Field winding: 325.4 mOhm +/- 3 %
nduction: 8 mH
Potentiometer actual value Potentiometer connected with 2 x 22 KOhm
Potentiometer specified value Potentiometer connected with 2 x 22 KOhm
Introduction
06
2
Workshop ManuaI CS
Steering
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Overview power assist steering
M Motor
L.E.S. Digital controller
K6 Driving direction relay
P1 Potentiometer specified value
P2 Potentiometer actual value
bIue
white
bIack
key on
06
3
Steering
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.
Workshop ManuaI CS
Removing the steering motor
2 Block up the truck on squared timbers and
secure against rolling (see photo).
3 Disconnect the electric leads of the motor
(1) and potentiometer (2).
4 Remove the three motor fastening screws
(3).
5 Lift out the motor (do not damage
potentiometer (4) at the end of the shaft).
Before instal lati on, make sure that the
potentiometer is adjusted correctly (see Group
06, Page 4) and position the traction wheel (5) as
straight as possible.
Refit the electric steering motor. Take care not to
put the potentiometer out of adjustment.
After installation make sure that the potentiometer
is always in the acceptable adjustment range
(see Group 06, Page 4). f this is not the case,
repeat all the work steps.
06
4
Workshop ManuaI CS
Steering
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m
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.
RepIacing the potentiometer
RepIacing the potentiometer
For access to the potentiometer see the chapter
"Removing the steering motor, Group 06, Page
3, for the steps 1 to 5.
1 Loosen the locknut and socket head screw
at the end the motor shaft (1 and 2).
2 Remove both screws at the potentiometer
(3).
3 Remove the potentiometer.
4 Fit a new potentiometer in the centre and
measure the resistor with a multimeter at the
potentiometer terminal between pins 4 and 1
and pins 4 and 3.
ATTENTION:
Tightening the screws (3) too tightly can damage
the potentiometer.
A difference of 10 ohms maximum is allowed
between the readings at pins 4 and 1 and pins 4
and 3.
After installation of the potentiometer and motor
group, make sure that the reading is as close as
possible to this deviation of 10 ohms.
f this is not the case, remove the steering motor
again for the adjustment of the potentiometer.
NOTE:Take care that the traction wheel is
posi ti oned as straight as possi bl e before
installation of the motor.
ATTENTION :
A poor adjustment can lead to an abort of the
teach-in of the electric steering (See Group 31,
Page 4).
07
Workshop ManuaI CS
Brakes
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.
Page
TabIe of contents
Spring-loaded brake engaged when no
electrical power applied .............................. 1
General ........................................................... 2
Electromagnetic brake ................................... 3
Remove the coil in order to replace
the brake disc ............................................. 3
07
1
Workshop ManuaI CS
Brakes
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.
Spring-Ioaded brake engaged when no eIectricaI power appIied
Type: BFK 457 - 14
Manufacturer: Lenze
Brake torque: 60 Nm
Power consumption of the coil at 20C: 53 W 10 %
Voltage: 24 V
Weight: 8.6 kg
Min. air gap: 0.3 mm
Max. air gap: 0.8 mm
Wear of the brake disc: max. 0.5 mm
07
2
Workshop ManuaI CS
Brakes
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m
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b
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d
u
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f
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m
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GeneraI
The following diagram displays the brake system
when no electrical power is applied, i.e. the brake
is engaged.
The compression springs (2 and 3) push the brake
plate (6) axially against the brake pad (4) and this
in turn against the flange (5) fixed to the motor.
When the directional switch is moved from the
neutral position to drive, the brake coil (1) is
supplied with DC voltage. The magnetic circuit
between brake plate (6) and coil closes.
The brake plate lifts to the magnetised part and
the air gap a is reduced to zero, releasing the
brake pad (4).
The air gap of the brake is not adjustable.
The air gap is adjusted to 0.3 mm at the factory.
When the directional switch is returned to the
neutral position, the power to the coil is removed
after approx. 3 sec.
1 Coil
2 Compression spring
3 Compression spring
4 Brake pad
5 Motor flange
6 Brake plate
7 Non adjustable brake pad
8 Plate made from stainless
steel
NOTE: The stainless steel plate prevents the brake disc from sticking (especially under damp
conditions).
This is an eIectricaI brake system with no adjustment possibiIities.
07
3
Workshop ManuaI CS
Brakes
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m
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i
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f
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EIectromagnetic brake
Remove the coiI in order to repIace the
brake disc
1. Jack the truck onto blocks and prevent from
rolling.
2. Disconnect battery plug.
3. Remove plug (1) from electric brake.
4 nstall the two M6x60 or M6x65 (2) screws and
tighten by hand to keep the brake disc in position
upon actuation of the electric brake.
5. Remove the 3 socket head screws (3)
securing the electric brake (torque 25 Nm)
alternately and step by step. (3)
6. Lift off electric brake.
7. Remove worn brake disc.
8. Mount the new brake disc.
ovaI.
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Page
TabIe of contents
Technical data for Service .............................. 1
Location of components ................................. 2
Overview ........................................................ 2
Pallet truck ..................................................... 2
Control console .............................................. 3
Tiller ................................................................ 3
Removing control console.............................. 4
Entering a driver code .................................... 5
Hour meter ..................................................... 6
Battery charge ................................................ 6
Displays, settings,
operation of the Digicode control ................ 7
Driver code..................................................... 7
Master code ................................................... 8
Service code .................................................. 8
Error code ...................................................... 8
Adding a master code .................................... 9
Deleting a master code ................................ 10
Adding a driver code..................................... 11
Deleting a driver code .................................. 12
Replacing microswitches and rubber
mounts of dead man's pedal .................... 14
CS 20 ........................................................... 16
Removing, installing and adjusting height
sensor ...................................................... 16
CS 16 S........................................................ 17
Removal of lateral controls and end position
sensors .................................................... 17
CS 10 M ....................................................... 20
Removing ..................................................... 20
Removing steering controller ....................... 23
Removing traction and pump controller ....... 24
Plug assignments ........................................ 25
Page
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TechnicaI datfor Service
Electronic controller Digital controller SEM
Traction motor speed controller Controller 4 quadrants
Pump motor speed controller Controller 1 quadrant
Rated voltage 24 V
Current limiter for traction motor
Armature/field 300 A / 30 A
Pump motor 125 A
RPM range Adjustable with traction programmes
Max. speed: 12.5 km/h
RPM reduction Adjustable with traction programmes
Contactors K1, K2 24V (30 Ohm)
Relay K6 24 V ( coil 330 Ohm)
Fuses
- Power circuits fuses F1, F2 (125 A)
- Control circuits fuses F3, F4 (7 A)
F5 (15 A)
Traction battery G1 24 V 450 Ah
nsulation resistance
- Electrical system
- Electrical machines 1000 Ohm/V
- Traction battery G1
Protection class
- Electrical system P 64
- Controller
- Electric motors Traction motor P 22
Pump motor P 54
P 22
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Location of components
Overview
PaIIet truck
1 Battery plug
2 Tiller
3 Pedestrian mode button*
4 Steering controller
5 Operator place and dead man's switch
6 Traction battery
7 Brake
8 Traction motor
9 Steering motor
10 Pump motor
11 Fuse mount
12 Traction controller
13 Belly switch
* Option
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ControI consoIe
TiIIer
1 Lowering button
2 Lift button
3 Horn button
4 "Tortoise" button
5 "PRG " button (scrolling)
6 Numbers "123" button
7 Display
8 "" button (On)
10 "PRG " button (enter)
12 "Hare" button
13 Handle
14 Travel control
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Removing controI consoIe
1. Disconnect the battery plug.
2. Open the battery compartment cover.
3. Remove the 5 fasteni ng screws on the
protective plate (1).
4. Disocnnect the tiller head electrically at the two
connectors (2).
5. Remove the 3 fastening screws on the control
console (3).
6. Remove the control console. During the
installation of the new control console, pay
attention to the guide stop (4) engaging in the
centre receptacle (5).
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123 456 789
PRG
PRG
CS20_Ba_03_024
1 2 3 4
5
6 7
8
CS20_Ba_03_025
9
CS20_Ba_03_026
Entering a driver code
- Press the "" (ON) button (6).
The word "CodE" (8) appears in the display
(4) and disappears after approx. 1 sec.
This is the prompt to now enter a valid 4-digit
driver code.
The input is made in the same way as letters
are entered on a mobile telephone.
- Press the buttons (1, 2, 3) until the desired
number appears.
For:
code numbers 1-2-3 the "123" button (1)
After a number has been entered, the
cursor goes to the next digit.
A flashing line cursor (9) (example shown)
appears in the display.
NOTE: f you have entered an incorrect number,
you can delete it by pressing the PRG
(scrolling) button (7).
- The number is deleted and the flashing line
cursor (9) reappears.
You can repeat your input.
- After you have entered the 4th number, confirm
the input with the PRG button (5).
The word "STLL" will appear briefly in the
display.
The pallet truck is now operational.
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NOTE: The following information can be displayed
by depressing the PRG (scrolling) button
repeatedly.
Hour meter
The display changes approx. 4-5 s after power-
up to show the operating hours (1) and the hour-
glass symbol (2).
These are the total number of hours since the
commissioning of the pallet truck.
The meter always runs when the pallet truck is
driven or a load is raised.
t is also possible to have the service interval
displayed (only the service engineer can activate
this feature in the diagnostics, see Group 31,
Page 13).
NOTE: The meter goes to 9999.
Battery charge
- Press the PRG (scrolling) button to display
the available battery charge (3).
NOTE: After the battery is connected, the correct
state of charge appears only after about 1 minute.
- The charge is shown in per cent and changes
in steps of 5%.
NOTE: The factory setting of the battery charge
indicator is a lead battery. The indicator can also
be set to a gel battery. Please contact your Ser-
vice.
CS20_Ba_03_028
%
3
CS20_Ba_03_027
2
1
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- The display flashes if the available residual
charge of 5% (25% the indicated value) is
reached.
The battery must be charged soon.
- f the display shows a residual charge of 0%,
the lifting device switches off.
The battery must be charged
immediatel y as deep discharging sets in
now.Deep discharging damages the battery and
the electric units of the truck.
DispIays, settings, operation of the
Digicode controI
Access to the electronic controller is possible with
three different codes:
1. Driver code
2. Master code
3. Service code (service engineer)
Driver code
The driver code consists of four figures and must
be assigned by the pool manager.
t is used for normal utilisation and operation of
the truck by the driver and operator. The
knowledge of the code is like a key and should
not be misused. Do not tell third persons the driver
code without express order.
A maximum of 200 driver codes can be stored in
the control.
A driver code can be added or deleted with the
master code.
123 456 789
PRG
PRG
CS20_Ba_03_030
4
123 456 789
PRG
PRG
CS20_Ba_03_023
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Master code
The master code consists of four figures and is
reserved for the pool manager. The factory setting
of this code is "1234.
The pool manager is advised to replace this code
with a new master code, see "Deleting a master
code and "Adding a master code.
Like the driver code, it is intended for normal use
and operation of the pallet truck, but it also allows
a driver code to be added or deleted.
This control can store a maximum of five master
codes.
NOTE: f master codes or driver codes are
forgotten or get lost, please contact your STLL
Service Engineer for he alone can make the
stored codes visible again.
Service code
The service code is only intended for your Ser-
vice. t allows the diagnosis of the pallet truck
during an inspection and provides access to the
driver's and master code.
Error code
f an error code, eg "E380 (1), appears, the truck
must be stopped and the starting procedure
repeated. (see chapter: Starting up).
f the error code continues to be displayed, please
contact your STLL Service Engineer.
CS20_Ba_03_067
%
1
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Adding a master code
NOTE: The pallet truck is turned off, the battery
is connected.
- Press the " (ON) button (5).
- Enter the valid 4-digit master code with buttons
"123 (1), "456 (2) or "789 (3).
- Press the PRG (scrolling) button (6) until "Pin
(7) appears in the display.
- Press the PRG (enter) button (4) until "Add
- Confirm with the PRG (enter) button (4).
A flashing line cursor (8) appears in the display.
- Enter the desired new 4-digit master code with
button (1), (2) or (3) as above.
NOTE: The controller can store a maximum of
five master codes.
f you try to enter a sixth master code, the
message "Err appears in the display.
- Confirm with the PRG (enter) button(4) until
the new master code (9) flashes (code shown
is an example), then release the button.
"Add (10) reappears in the display.
123 456 789
PRG
PRG
CS20_Ba_03_057
1 2 3
4
5 6
8
CS20_Ba_03_059
9
CS20_Ba_03_060
10
CS20_Ba_03_061
10
CS20_Ba_03_061
7
CS20_Ba_03_068
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%
11
CS20_Ba_03_062
123 456 789
PRG
PRG
CS20_Ba_03_057
1 2 3
4
5 6
8
CS20_Ba_03_059
9
CS20_Ba_03_060
7
CS20_Ba_03_068
10
CS20_Ba_03_064
- Press the PRG (scrolling) button (6) until a
normal operating display (11) (eg battery
charge) appears.
The new master code is now entered.
DeIeting a master code
NOTE: The pallet truck is shut off, the battery is
connected.
"123 (1), "456 (2) or "789 (3).
- Press the PRG (scrolling) button (6) until "Pin
- Press the PRG (enter) button (4) until "dEL
- Enter the 4-digit master code to be deleted with
NOTE: When attempting to delete a wrong master
code, "Err appears in the display.
When only one master code remains, "None
appears in the display.
- Confirm with PRG (enter) button (4) until the
new master code (9) flashes (code shown is
an example), then release the button.
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123 456 789
PRG
PRG
CS20_Ba_03_057
1 2 3
4
5 6
8
CS20_Ba_03_059
10
CS20_Ba_03_061
7
CS20_Ba_03_069
%
11
CS20_Ba_03_062
10
CS20_Ba_03_064 The letters "dEL (10) reappear in the display.
charge) appears.
The master code is deleted.
Adding a driver code
NOTE: The pallet truck is turned off, the battery
is connected.
"123 (1), "456 (2) or "789 (3).
- Press the PRG (scrolling) button (6) until
"USEr (7) appears in the display.
- Press the PRG (enter) button (4) until "Add
- Enter the desired new 4-digit driver code with
NOTE: The control can store a maximum of 200
driver codes. f you try to enter a 201st driver code,
"Err appears in the display.
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9
CS20_Ba_03_060
10
CS20_Ba_03_061
%
11
CS20_Ba_03_062
123 456 789
PRG
PRG
CS20_Ba_03_057
1 2 3
4
5 6
8
CS20_Ba_03_059
7
CS20_Ba_03_069
10
CS20_Ba_03_064
- Confirm with the PRG (enter) button (4) until
the new driver code (9) flashes (code shown
"Add (10) reappears in the display.
charge) appears.
The new driver code is now entered.
DeIeting a driver code
NOTE: The pallet truck is shut off, the battery is
connected.
"123 (1), "456 (2) or "789 (3).
- Press the PRG (scrolling) button (6) until
"USEr (7) appears in the display.
- Press the PRG button (enter) (4) until "dEL
- Enter the 4-digit driver code to be deleted with
08
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9
CS20_Ba_03_060
%
11
CS20_Ba_03_062
10
CS20_Ba_03_064
NOTE: f an attempt is made to delete an incorrect
driver code, "Err appears in the display.
- Confirm with the PRG (enter) button (4) until
the new driver code (9) flashes (code shown
"dEL (10) reappears in the display.
charge) appears.
The master code is deleted.
08
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RepIacing microswitches and rubber
mounts of dead man's pedaI
1. Remove the load screen, see the appropriate
section under "Group 08, page 16.
2. Lower the forks completely.
4. Remove the two versions of the buttons at
the side of the rear cover. To do this, lift the
four corners of the label to gain access to
the fastening screws (1) (Bezels with 2 or 4
push-buttons possible, depending on the
model).
5. Disconnect the connectors at the push-
buttons and remove the rear cover after
dismantling the six fastening clamps (2).
6. Remove the floor mat of the dead man's
pedal.
7. Remove the guide stop of the dead man's
pedal by removing the two fastening screws
(3), and disconnect and remove the micro-
switches mounted on the guide stop (4).
8. The microswitches are installed in the
reverse order of removal.
9. Unscrew the nuts (5) of the rubber mounts
securing the dead man's pedal.
10. Open the battery cover and shove the battery
away to be able to remove the fastening
screws (6) for the battery cover hinges
(torque 25 Nm).
08
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11. Lift the battery cover slightly to be able to
remove and renew the pedals and the rubber
mount fasteners (7).
12. The installation of the dead man's pedal is in
the reverse order of removal.
08
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CS 20
Removing, instaIIing and adjusting
height sensor
1. Raise the forks to gain access to the 4 late-
ral fastening screws of the load screen (1).
2. Remove the screws (torque 25 Nm) and take
off the load screen.
3. Remove both height sensor fastening screws
and remove the height sensor (2).
4. nstall a new height sensor.
5. Adjust the height of the sensor so that the
pump unit cuts out when the forks have
reached a height of 200 mm (3) above the
ground.
6. nstallation is in the reverse order of removal.
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CS 16 S
RemovaI of IateraI controIs and end position sensors
- Truck turned off, battery disconnected.
- Remove the 2 x 2 CHC screws (1) on both sides of the truck in order to be able to take of the
protective screen.
- Remove the two fastening screws (3) at the protective plate on the upper mast cross member.
1
3
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- Under the cover, disconnect the electric connectors (Fig. 1) on each of the two lateral control
buttons for lifting/lowering/forward/reverse (4). Remove the 4 Phillips screws and the controls
upwards (mark the forward direction of travel of the truck good well to avoid an interchanging of the
direction of travel upon installation).
- Remove the 6 fastening screws on the back panel assy. (backrest and plastic housing) (5) on both
sides of the mast with the 6 cable ties bundling the electric cables.
4
5
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- Take off both sensors (6) (remove 2 screws each).
6
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CS 10 M
Removing
- Remove the 2 x 2 CHC screws (1) at the bottom of the protective screen on both sides of the
truck.
- Remove the screw (2), take off the mounting for the protective screen at the fork carriage upwards.
- Remove the two fastening screws (3) at the protective plate on the upper mast cross member.
1
2
3
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- Under the cover, disconnect the electric connectors (Fig. 1) on each of the two lateral control
buttons for lifting/lowering/forward/reverse (4). Remove the 4 Phillips screws and the controls
upwards (mark the forward direction of travel of the truck good well to avoid an interchanging of the
direction of travel upon installation).
- Remove the 6 fastening screws on the back panel assy. (backrest and plastic housing) (5) on both
sides of the mast with the 6 cable ties bundling the electric cables.
4
5
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- Take off both sensors (6) (remove 2 screws each).
6
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Removing steering controIIer
2. Disconnect the negative lead of the steering
controller at the traction controller (1).
3. Disconnect the steering motor leads (2).
4. Remove the two fasteners from the steering
controller (3).
5. Remove the locking plates (4) using a
screwdriver.
6. Disconnect the two steering control ler
connectors (5) and install a new steering
controller.
8. Teach the steering controller.
08
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Removing traction and pump controIIer
2. Disconnect the traction controller (1) and pump
(1) power cables.
3. Disconnect both control voltage connectors for
the traction and the pump controller.
4. Remove the battery to gain access to the
controller fastening screws (3).
5. Remove the 4 fastening nuts and remove the
controller.
6. Coat the new controller with heat conducting
paste (4).
8. Reactivate the optional equipment functions.
08
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.
Plug Functional Group Description Voltage Condition
A1-A1 Drive Power supply tiller to internal converter 24 V nput
A1-A2 Drive Power supply for external contact 24 V Output
A1-A3 Drive Lift limiter (S5) 24 V nput
A1-A4 Drive Presence area (S3) 24 V nput
A1-A5 Drive "Lift" button at load screen (S22-S23) 24 V nput
A1-A6 Drive "Lowering" button at load screen (S24-S25) 24 V nput
A1-A7 Drive Speed reduction (SlO) 24 V nput
A1-A8 Drive Common with B 0 V Output
A1-A9 Drive Negative lead of pump contactor (K2) 0 V Output
A1-A10 Drive Power supply after fuse (F4) 24 V nput
A1-A11 Drive Negative lead of "lowering" solenoid valve (Yi) 0 V Output
A1-A12 Drive Reduction of cornering speed (C24-C16) <2V or > 5V nput
A1-A13 Drive Negative lead of traction contactor (Ki) 0 V Output
A1-A14 Drive Enable of power steering (safety circuit 130K-C14) 24 V nput
A1-A15 Drive Negative lead of electric brake (Y2) 0 V Output
A1-A16 Drive Positive voltage for Y2 and Ki 24 V Output
A1-A17 Drive CAN L
A1-A18 Drive CAN H
A1-B1 Drive Power supply for external contact of option 24 V Output
A1-s2 Drive "Lift operator place" button (option) (S19) 24 V nput
A1-B3 Drive "Lower operator place" button (option) (S20) 24 V nput
A1-B4 Drive "Stop lift operator place" button (option) (S21) 24 V nput
A1-85 Drive Power supply for option 24 V Output
A1-B5 Drive Negative lead of lifting device solenoid valve (Y3) 0 V Output
A1-B7 Drive Negative lead of initial lift solenoid valve (Y4) 0 V Output
A1-BB Drive Negative lead of optional horn (4H1) 0 V Output
A1-89 Drive "Slow speed forward" button at load screen (S17-S18) 24 V nput
A1-B10 Drive "Slow speed reverse" button at load screen (S31-S32) 24 V nput
A2-D1 Control console Power supply after internal converter 24 V nput
A2-D2 Control console CAN H
A2-D3 Control console CAN L
A2-D4 Control console Power supply after internal converter 0 V
A2-D5 Control console Power supply after fuse F3 24 V nput
A2-D6 Control console Power supply for A3-C2 (safety circuit) 24 V Output
A3-C1 Steering Jumped at A3-C9
A3-C2 Steering Power supply after contact A2-D6 (safety circuit) 24 V nput
A3-C3 Steering Negative voltage of traction contactor (K6) 0 V Output
A3-C4 Steering Free
A3-C5 Steering Free
A3-C6 Steering Negative voltage for potentiometer 0 V Output
A3-C7 Steering Diagnostic plug for steering controller
A3-CS Steering Positive voltage for potentiometer 9 V Output
A3-C9 Steering Jumped at A3-Ci
A3-C10 Steering Free desired value of actual value potentiometer nput
A3-C11 Steering Free
A3-C13 Steering Diagnostic plug for steering controller
A3-C14 Steering Enable for power steering (Al-A14) (safety circuit) 24 V Output
A3-C16 Steering Traction wheel steered >10 <2 V or >5 V Output
(information for speed reduction)
A3-C19 Steering First desired value of desired value potentiometer nput
A3-C20 Steering Second desired value of the desired value potentiometer nput
A3-C22 Steering Second desired value of actual value potentiometer nput
A3-C24 Steering Traction wheel steered > 10 <2 V or >5 V Output
A3-C25 Steering Converter power supply 24 V nput
PIug assignments
10
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Page
TabIe of contents
Removing hydraulic unit ................................. 2
Hydraulic pump renewal ................................. 3
Removing hydraulic oil tank............................ 3
Removing solenoid valve................................ 4
Renewing brushes of the pump unit ............... 4
Removing ....................................................... 4
Replacing bearing .......................................... 5
Hydraulic circuit diagram CS 10 M, CS 16 S,
CS 20, CS 30 Z .......................................... 6
Hydraulic circuit diagram CS H ...................... 8
Discharging accumulator pressure ................ 9
10
1
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p
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m
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b
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d
u
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i
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f
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m

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b
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m
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Workshop ManuaI CS
Section 10
Pump unit
Type: K3.823.16.401
Manufacturer: Oil-System
Motor type: 4-pole series wound motor
Voltage (V): 24 V
Current (A): 134 A at 100 bar
Excitation: None
Power (kW): 2.2 kW
Duty cycle: S3 - 8 %
Protection class: P43
nsulation class: F
Brushes:
a) Length: 16 mm
b) Wear limit: 11 mm
c) Quantity (number): each 4
d) Motor brush monitor: None
Weight (kg): 11 kg
Breather filter: None
Pump:
Flow: 3.6 cm/rev
Oil quantity (for standard unit):
Suction filter and return filter: 250 and 300 micron
Oil change: annually
10
2
Workshop ManuaI CS
HydrauIic system
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Removing hydrauIic unit
1. Lower forks completely.
3. Disconnect electric cables of the motor and
solenoid valve (1).
4. Disconnect hydraulic lines to the unit (attention:
oil flows out) (2).
The fastening screws of the hydraulic unit are
accessible through the battery compartment.
5. Unclamp the battery (3).
6. Pull or push the battery slightly in order to pass
by the battery lock.
7. Move the battery lock back into position again,
it serves as a safety stop.
8. Screw out the screws (4) of the hydraulic unit
(torque 25 Nm).
ovaI.
10
3
HydrauIic system
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Workshop ManuaI CS
HydrauIic pump renewaI
Removing hydrauIic oiI tank
1. Screw out 4 socket head screws (total of 6,
torque: 10 Nm) (1).
2. Remove clamp (2) on the hydraulic oil tank.
3. Remove hydraulic oil tank.
4. Remove suction filter (3) including the plastic
connection.
5. Remove the two socket head screws (4) (8x90,
torque 25 Nm).
ovaI.
10
4
Workshop ManuaI CS
HydrauIic system
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Removing soIenoid vaIve
1. Remove the coil.
2. Screw out valve with a 24 mm socket extension
or an offset ring spanner (1) (torque: 45+5 Nm).
ovaI.
Renewing brushes of the pump unit
The replacement of the brushes is required, when
remaining length reaches 11 mm. Always replace
brushes (each 4) in sets.
Removing
2. Disconnect power cable of the motor.
3. Screw out the two screws (2) and remove the
cover.
4. Remove nuts on the terminals and pull off the
insulation (3).
5. Detach brush cables from the brush mounting
(4).
6. Pull out cylindrical brush mounting (5).
7. Replace brushes with mountings.
ovaI.
10
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HydrauIic system
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Workshop ManuaI CS
RepIacing bearing
n order to gain access to the bearings, proceed
as for renewing brushes of the pump unit up to
and including work step 6 (see previous page).
Pull off the bearing with an appropriate puller.
10
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HydrauIic system
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HydrauIic circuit diagram CS 10 M, CS 16 S, CS 20, CS 30 Z
Legend
1 Lift cylinder
2 Hydraulic unit
3 Lowering solenoid
4 Restrictor (orifice)
5 Hydraulic oil tank
6 Pump motor
7 Screen
8 Lift pump
9 Pressure relief valve
10 Check valve
11 Filter
10
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HydrauIic system
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Workshop ManuaI CS
Location of the hydrauIic system components
Y3 solenoid valve for lifting (ie scissors, mast, initial lift) (1).
Y5 (2) and Y6 (3) solenoid valves for lifting driver's platform. These
are connected in parallel to the controller (electric section) and Y6
cuts off the accumulator.
Y1 solenoid valve for lowering the driver's platform and load (4).
Hydraulic shock absorber for preventing jerky motions (steel cylinder
with diaphragm and nitrogen) allows end cushioning when lowering
the driver's platform (5).
10
8
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HydrauIic system
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HydrauIic circuit diagram CS H
NTAL LFT PLATFORM LFT
10
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HydrauIic system
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Workshop ManuaI CS
Discharging accumuIator pressure
ReIieving pressure
Perform before any servicing of the hydraulic system.
Depress the pushbutton for lowering the driver's platform and keep depressed at least 5 s after it has
reached its lowest position.
f the controller is down or there is a problem in the electrical system so that the platform is in the
topmost position, apply 24 V to the solenoid valves Y5 (3), Y6 (2) and Y1 (1) to lower the platform.
11
Workshop ManuaI CS
Traction motor
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Page
TabIe of contents
Removing traction motor ................................ 2
Renewing brushes of the traction motor ........ 3
Removing upper bearing ................................ 4
Removing lower bearing................................. 5
11
1
Traction motor
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Workshop ManuaI CS
TechnicaI data for Service
Section 11
Traction motor
Type: GF106-G3
Manufacturer: Juli
Motor type: separately excited
Voltage (V): 24 V
Current (A): 103 A
Excitation: 7.5 V (rated current 11.7 A)
Rated speed (rpm): 2800 rpm
Power (kW): 2.0 kW
Duty cycle: S2 - 60 minutes
Protection class: P00/00
nsulation class: F
Brushes:
a) Dimensions: 12.5x25x28 mm
b) Wear limit: 17 mm
c) Quantity (number): each 4
d) Motor brush monitor: None
Weight (kg): 27 kg
Ventilation: internal
11
2
Workshop ManuaI CS
Traction motor
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Removing traction motor
Removing
1. Jack truck onto blocks and prevent from rolling.
3. Disconnect electrical terminals (1) from the
motor.
4. Remove the 8 screws, which fix the motor to
gearbox, with a spanner for spherical collar hex
head screws (torque 10 Nm) (2).
5. Screw eyebolt (3) onto end of motor shaft.
6. Lift out the motor with a chain or rope and lever
(4).
ovaI.
11
3
Traction motor
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Workshop ManuaI CS
Renewing brushes of the traction
motor
Removing
1. Jack truck onto blocks and prevent from rolling.
3. Disconnect connection to the electric brakes.
4. Mark the position of the upper bearing at the
motor casing (1).
5. Remove the 4 socket head screws 8x20 of the
upper bearing of the motor (torque 25 Nm).
6. Disconnect both electrical connections from
the cylindrical brush mounting (2).
7. Rotate the upper bearing in order to gain
access to the 4 brushes.
InstaIIation is made in the reverse order.
11
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Workshop ManuaI CS
Traction motor
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Removing upper bearing
1 Remove electric brake as described in section
07.
2. Remove upper circlips (6).
3. Pull out the drive hub of the brake disc.
4. Remove lock key (16).
5. Remove the last two circlips (6).
6. Use an appropriate puller to pull off the upper
bearing of the motor casing.
7. To replace the roller bearing of the upper shaft
bearing, proceed as follows:
a) Pull off circlip (10).
b) Push out ball bearing (9).
11
5
Traction motor
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Workshop ManuaI CS
Removing Iower bearing
8. To remove the lower bearing of the traction
motor and of the cooling fan, proceed as
follows:
a) Remove knurled nut on shaft end (torque: 55
Nm).
b) Use an appropriate puller to pull out the pinion
gear and then remove lock key.
c) Pull off circlip (11).
d) Use a puller to pull out bearing with ball bearing (1
to 4).
e) Take out sealing ring from bearing (3).
f) Take out circlip (4).
g) Push out ball bearing (2).
h) Take out circlip (15).
i) Remove cooling fan.
20
Workshop ManuaI CS
Mast
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Page
TabIe of contents
CS 20 ............................................................. 2
Removing ....................................................... 2
CS 30 Z .......................................................... 3
Removing ....................................................... 3
nstalling ......................................................... 7
CS 10 M ......................................................... 8
Removing ....................................................... 8
nstallation .................................................... 14
CS 16 S........................................................ 15
nstalling ....................................................... 21
Removing the scissors joining pins. ............. 22
nstalling ....................................................... 25
nstalling ....................................................... 28
Removing ..................................................... 31
Remove the covers ...................................... 31
Removing the back panel ............................. 34
Removing the dead man's
sensor ...................................................... 35
Adjusting the guide rollers at the driver's
platform .................................................... 36
20
1
Mast
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Workshop ManuaI CS
TechnicaI data for Service
Group 20
Mast
Mast channel fastening screws
Tightening torque = 275 Nm (M16x700/10.9)
(M16x150/10.9)
Pipe safety valve (check valve) Tightening torque = 60 Nm 6 Nm
Chain Max. admissible elongation: 3 %
Lowering speed Max. admissible = 0.6 m/s
20
2
Workshop ManuaI CS
Mast
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
CS 20
Removing
1 Remove the load screen, see Group 08, page
15.
2 Fully lower the forks.
4 Remove the hydraulic fitting on the cylinder (1).
5 Screw out the setscrew in the bolt at the base
of the cylinder (2).
6 Remove the retaining pin at the end of the
piston rod (3).
7 Raise the forks slightly with a hydraulic jack to
be able to remove the pin at the base of the
cylinder.
8 Remove the cylinder.
9 nstall the cylinder after repair or replace with a
new one.
20
3
Mast
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
Workshop ManuaI CS
CS 30 Z
Removing
- Using a hoist, block up the truck on squared timbers about 25 cm high.
Block up the driver's stand securely (at least 3 resting points) before removing the
rear part of the truck.
20
4
Workshop ManuaI CS
Mast
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
- Disconnect the electric connectors (Fig. 1) under the cover at each of the two lateral traction
controls (1). Remove the 4 Phillips screws and traction controls upwards (mark the forward direction
of travel of the truck well to avoid an interchanging the direction of travel upon installation).
- Remove the 2 x 2 screws on the two lateral service covers and take them off (Fig. 2).
1
20
5
Mast
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
Workshop ManuaI CS
- Fasten both hooks symmetrically to the access openings, then tauten the sling lightly.
- Remove the 2 x 3 fastening screws on the back panel assy. (backrest + plastic housing) on both
sides of the truck (3) with the 6 cable ties bundling the electric cables (2).
3 2
20
6
Workshop ManuaI CS
Mast
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
- Remove the 5 fastening screws (4) at the rear section to separate it from the truck.
- Using a hoist, set the rear of the truck on squared timbers (Fig. 3).
4
20
7
Mast
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
Workshop ManuaI CS
- For the removal the trailer coupling, remove the 4 screws (5).
InstaIIing
- nstallation is in the exact reverse order of removal.
5
20
8
Workshop ManuaI CS
Mast
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
CS 10 M
Required equipment:
A hoist with a load capacity of at least 500 kg
An oil pan
Removing
- Remove the 2 x 2 CHC adjustment screws (7) (screw + lock screw) for the adjustment of the
lateral play of the inner mast (Fig. 2).
7
20
9
Mast
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
Workshop ManuaI CS
- Remove the 2 screws (17) at the chain anchor.
- Using a hoist, set the truck on squared timbers about 25 cm high (forks stay in lowered position).
17
20
10
Workshop ManuaI CS
Mast
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
Block up the driver's compartment securely (at least 3 resting points) before
removing the forks.
- Sling the forks and then tauten the sling lightly with the hoist (Fig. 3).
20
11
Mast
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
Workshop ManuaI CS
- Loosen the nut and locknut at the chain tensioner (8) to take the lift chains off the frame, then
detach the other chain end (fastened to the inner mast, see Fig. 4).
- Unscrew the stop (13) at the top of the inner mast.
8
13
20
12
Workshop ManuaI CS
Mast
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
- Using the hoist, remove the forks by pulling them up and then deposit them on the ground.
- Slide a container under the truck directly under the cylinder, then slowly screw out the hydraulic
fitting (10) and let the oil drain out of the cylinder. Then screw out the second hydraulic fitting (11)
of the cylinder.
10
11
The oil can be very hot after a
longer period of operation.
20
13
Mast
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
Workshop ManuaI CS
- Lash the inner mast (15), tauten the sling lightly, remove both pins (14) and then take off the inner
mast.
14
15
20
14
Workshop ManuaI CS
Mast
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
InstaIIation
- nstallation is exactly the reverse order of removal.
- Do not forget to fill oil to the correct level.
20
15
Mast
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
Workshop ManuaI CS
CS 16 S
DO NOT PUT YOUR HANDS IN THE SCISSORS CONSTRUCTION!
Required equipment:
A hoist with a load capacity of at least 500 kg
An oil pan
Truck turned off, battery disconnected.
- Remove the covers, lateral controls and transmitters (see Group 8, Pages 17 to 19).
- Remove the 2 x 2 CHC adjustment screws (7) (screw + lock screw) for the adjustment of the
lateral play of the inner mast (Fig. 2).
7
20
16
Workshop ManuaI CS
Mast
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
- Remove the 2 screws (17) on the chain anchor.
- Using a hoist, set the truck on squared timbers about 25 cm high (forks stay in lowered position).
17
20
17
Mast
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
Workshop ManuaI CS
removing the forks.
- Connect the forks and scissors with slings (Fig. 3), then the tauten the slings lightly with the hoist.
20
18
Workshop ManuaI CS
Mast
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
- Loosen the nut and locknut at the chain tensioner (8) to take the lift chains off the frame, then
detach the other chain end (fastened to the inner mast, see Fig. 4).
- Remove the 2 x 4 CHC screws (12) on the two anchor plates of the scissors.
8
12
20
19
Mast
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
Workshop ManuaI CS
- Unscrew the stop (13) at the top of the inner mast.
- Separate the forks from the scissors by pulling them up with the hoist and then depositing them on
the ground.
- Slide a container under the truck directly under the cylinder, then slowly screw out the hydraulic
fitting (10) and let the oil drain out of the cylinder. Then screw out the second hydraulic fitting (11)
from the cylinder.
The oil can be very hot after a
longer period of operation.
13
10
11
20
20
Workshop ManuaI CS
Mast
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
- Lash the inner mast (15), tauten the sling lightly, remove both pins (14) and then take off the inner
mast.
14
15
20
21
Mast
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4
(
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e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
Workshop ManuaI CS
InstaIIing
- nstallation is in the exact reverse order of removal.
- Do not forget to fill oil to the correct level.
20
22
Workshop ManuaI CS
Mast
D
a
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o
f

i
s
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A
u
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t

2
0
0
4
(
R
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p
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a
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i
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e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
Removing the scissors joining pins.
- Truck turned off, forks raised and battery disconnected.
- Remove the 2 screws retaining the chains in their mountings (17).
17
20
23
Mast
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4
(
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:

)
A
l
l

r
i
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h
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s

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s
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r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
Workshop ManuaI CS
- Using the hoist, put the truck on squared timbers (the forks and the scissors stay in the raised
position).
removing the forks.
- Place two squared timbers symmetrically across the scissors, then join the squared timbers with
a suitable means so that they can no longer be separated (Fig. 7).
20
24
Workshop ManuaI CS
Mast
D
a
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o
f

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s
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:

A
u
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2
0
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4
(
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:

)
A
l
l

r
i
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h
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s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
- Unhook the fork carriage chains. (To relax the chains, press on the head end of the cylinder piston
to start a lowering movement.)
- Lash the forks (without the scissors) (Fig. 8).
- Drive out the cotter pins in the lower and upper pins (Fig. 9).
20
25
Mast
D
a
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2
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4
(
R
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:

)
A
l
l

r
i
g
h
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s

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e
s
e
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v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
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r
e
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v
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d
.
Workshop ManuaI CS
InstaIIing
- Drive out the four upper pins (two on the right and two on the left side) towards the inside of the
truck (Fig. 10).
Do not forget to mark the shims (18) for the correct side play upon refitting.
- Remove the forks (Fig. 11) upwards.
18
20
26
Workshop ManuaI CS
Mast
D
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o
f

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A
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t

2
0
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4
(
R
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p
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a
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i
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:

)
A
l
l

r
i
g
h
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s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
- Attach each scissors individually to the inner mast (Fig. 12).
- Remove the squared timbers in the scissors (Fig. 13).
The scissors can drop a few centimetres abruptly until the full tension at the
connection to the inner mast is reached.
20
27
Mast
D
a
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2
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4
(
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:

)
A
l
l

r
i
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h
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s

r
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s
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v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
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g
h
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r
e
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d
.
Workshop ManuaI CS
- Drive out the lower pins (Fig. 14).
- Separate the scissor halves of the truck one after the other (Fig. 15).
20
28
Workshop ManuaI CS
Mast
D
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o
f

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A
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2
0
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4
(
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i
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:

)
A
l
l

r
i
g
h
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s

r
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s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
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r
v
e
d
.
InstaIIing
- Put the forks and scissors upside down.
- nstall bearing sleeves in the scissors.
There are two sleeve lengths: 16 mm and 20 mm.
Assemble two sleeves for each hole (16 mm & 20 mm for the upper pins and 16 mm & 16 mm for
the lower pins).
Lower Pins Lower Pins
- nstall each scissor individually in its fork.
20
29
Mast
D
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4
(
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:

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A
l
l

r
i
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h
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s

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s
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v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
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r
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.
Workshop ManuaI CS
- Connect the scissors to the forks with the upper pins, taking care to install the lateral spacers (1)
again. Then secure with cotter pins.
- Bind the scissors and forks together.
- Refit the forks-scissors unit with the hoist.
20
30
Workshop ManuaI CS
Mast
D
a
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o
f

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A
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2
0
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4
(
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i
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:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
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r
i
g
h
t

r
e
s
e
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v
e
d
.
- Using the hoist, refit the forks-scissors unit on the inner mast.
- Position the forks at the upper end of the mast (as high as possible and provided with a safety
device against pinching) so that the scissors can be connected more easily with the inner mast by
means of the lower pins. Do not forget to install the lateral spacers and to secure them with cotter
pins.
20
31
Mast
D
a
t
e

o
f

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4
(
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:

)
A
l
l

r
i
g
h
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s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
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.
Workshop ManuaI CS
Removing
Operate the emergency stop button to prevent
any movement.
Disconnect the battery.
Remove the covers:
Block up the truck on squared timbers, then raise
the driver's platform as high as possible.
Remove the 4 fastening screws (1) and then the
rear enclosure.
Then remove the panel over the driver's platform
lift cylinder by removing the 9 fastening screws
(2).
20
32
Workshop ManuaI CS
Mast
D
a
t
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o
f

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A
u
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t

2
0
0
4
(
R
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p
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a
c
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i
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:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
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v
e
d
.
Disconnect the 3 cable connectors at the driver's
platform:
- Lifting/lowering at X31
- Slow speed forward/reverse at X30
- Emergency stop at X29
Lash the driver's platform correctly with lifting
eyes (3) at the grips.
Remove the 4 fastening screws (4) on the back
panel and remove it.
20
33
Mast
D
a
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f

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2
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4
(
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:

)
A
l
l

r
i
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h
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s

r
e
s
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r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
Workshop ManuaI CS
Remove the nut on the cyl inder end (5)
completely.
Remove the stop screw. To do this, align the
opening in the back panel (6) with the screw head
(CHC flat head screw) .
Pull the driver's platform up.
20
34
Workshop ManuaI CS
Mast
D
a
t
e

o
f

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:

A
u
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t

2
0
0
4
(
R
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p
l
a
c
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s

i
s
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u
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:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
Removing the back paneI
Proceed as follows for the removal of the metal
back panel of the mast:
Disconnect the two cable connectors for the slow
speed controls on both sides of the mini-mast
(7).
Unscrew the two terminals of the emergency stop
button so that the pins can be removed.
Remove the six fastening screws (8) on the metal
back panel.
20
35
Mast
D
a
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o
f

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0
0
4
(
R
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p
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a
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s
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e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
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e
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d
.
Workshop ManuaI CS
Remove the metal back panel.
Removing the dead man's sensor
To gain access to the dead man's sensor,
proceed as follows:
Remove the two CHC screws (9) beside the two
sensors.
These two screws hold the sensor mounting (10),
which serves as a guidance to the dead man's
platform.
Remove the four nuts (11) on the rubber mounts
under the driver's platform.
20
36
Workshop ManuaI CS
Mast
D
a
t
e

o
f

i
s
s
u
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:

A
u
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s
t

2
0
0
4
(
R
e
p
l
a
c
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s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
Adjusting the guide roIIers at the
driver's pIatform
To adjust the guide rollers at the driver's platform
lifting device, proceed as follows:
Loosen both nuts (12) on the left at the lifting
device.
Using a key, turn the cam (13) until the lateral
play of the guide rollers on the lifting device is
adjusted. Then retighten the nuts.
Guide rollers (14) mounted on cam (13).
nstallation is in the reverse order of removal.
For all torques see the General Table.
22
Workshop ManuaI CS
Fork carriage
D
a
t
e

o
f

i
s
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:

A
u
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t

2
0
0
4
(
R
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p
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a
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i
s
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u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
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g
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.
Page
TabIe of contents
Removing the CS 20 fork carriage ................. 1
nstall .............................................................. 2
22
1
Fork carriage
D
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4
(
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:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
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r
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d
.
Workshop ManuaI CS
Removing the CS 20 fork carriage
1 Raise the forks.
2 Secure the truck with three squared timbers
(two under the forks and one where the fork
carriage is fastened to the frame) (1).
3 Remove the load screen, see Group 08, page
15.
4 Remove the retaining pin at the piston rod (2).
5 Depress the "lower forks" pushbutton and
press with the hand on the piston rod to remove
it from its mounting.
7 First remove the retaining pins, then the lever
pins (3).
8 Remove the rear cover (see Group 08, page
14) to gain access to the fastening screws in
the lever joint pins (4).
9 Remove the two pin fastening screws.
22
2
Workshop ManuaI CS
Fork carriage
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
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s

i
s
s
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InstaII
10. Drive the pins out of the lever joints with a
single blow of the hammer through the holes
in the frame (5).
Note the number and location of
the spacers.
11. Slide the fork carriage (6) on the squared
timbers.
To replace the bushes (7) in the lever joints, drive
them out with a blow of the hammer and then
replace them.
The bushes (7) should never be
greased.
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Page
TabIe of contents
System diagnosis ........................................... 1
mportant note on the use
of the service case ..................................... 2
mportant instructions ..................................... 3
Service case .................................................. 5
STEDS - CD-ROM......................................... 5
Models CS 10 M, CS 16 S, CS 30 Z, CS 20... 9
Model CS with liftable driver's platform ........ 10
Structure of CAN Bus ................................... 12
Truck start-up steps ..................................... 13
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System diagnosis
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Important note on the use of the service case
Before working with the service case on the eIectric components of the truck,
raise the traction wheeI from ground untiI it can turn freeIy. For safety reasons,
the frame of the truck must be supported with squared timbers to prevent
unintentionaI roIIing of the truck.
31
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Important instructions
These instructions concern testers and meters, the electric continuity checks and the installation of
the diagnostic software.
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The foIIowing meters and testers are required for the tests and, if required, eIimination of
fauIts:
A knowledge of how to use the meters and tools is assumed.
n any case, the operating instructions of the manufacturer must be observed.
The condition of the batteries in the meter must be checked before all tests and inspections. f
needed, the batteries must be replaced or recharged.
Description Part No. Manufacture
Service case STLL
METRSO 500D
nsulation resistance tester
(149 544) Gossen - Metrawatt
Connecting cables 8392452
8409550
Current pick-up (600 A) 0143920 Beckmann
Multimeter with digital display
Metra Hit
0158061 Gossen - Metrawatt
Test leads, pair, Metra Hit 0146344 Gossen - Metrawatt
Leads, pair 0143425
Alligator clips, pair 0143427
Probes, pair 0143426
Test probes, pairs 0143424
Desoldering tool 1675079
8052115
(France)
Crimping tool 144 087 AMP
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Service case
STEDS - CD-ROM
Connecting cabIe
Part No.: 8392452 (1)
Part No.: 8409550 (2) No longer available and replaced by
Part No.: 8430163 (3)
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Current pick-up
Part No.: 143 920
DigitaI MuItimeter Metra Hit
Part No.: 158 061
Leads
Part No.: 146 344
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Leads, pair
Part No.: 143 425
AIIigator cIips, pair
Part No.: 143 427
Probes, pair
Part No.: 143 426
Test probes, pair
Part No.: 143 424
DesoIdering tooI
Part No.: 1 675 079
Crimping tooI
Part No.: 144 087
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Connector, 2 pins: 4480621 4480385
Connector, 4 pins: 4478840 4478840
Connector, 6 pins: 4480261 4478839
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ModeIs CS 10 M, CS 16 S, CS 30 Z, CS 20
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ModeI CS with IiftabIe driver's pIatform
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A1 Traction controller General
Designations
All Battery charger S1 Key or Digicode X1 Cable connector, controller
A111 LED layout S2 Emergency isolator X2 Cable connector, display
A112 Socket bezel S3 Dead mans switch Sensor 1 X3 Cable connector, battery
A2 Controller enclosure S4 Sensor, tiller X4 Cable connector, other
A3 Steering controller S5 Sensor, initial lift height X5 Cable connector, other
2A3 Hydraulics module S6 Dead mans switch Sensor 2 X6 Cable connector, other
S7 Sensor, mast height X7 Negative pole
C1 Capacitor S8 Sensor, foot protector X8 Positive pole
S9 BP Enable pushbutton X9 Cable connector, other
F1 Fuse traction drive or main
current
S10 Transmitter, speed reduction X10 Cable connector, tiller cable
loom
F2 Pump fuse S11 Emergency isolator X11 Cable connector, other
F3 Control fuse S12 Emergency isolator X12 Cable connector, other
F4 Control fuse S13 Transmitter, hinged platform X13 Cable connector, other
F5 Fuse, steering S14 Transmitter, swing-up side
guards 1
X14 Cable connector, brake/tiller
switch
F6 Fuse, option S15 Transmitter, swing-up side
guards 2
X15 Cable connector, other
F7 Fuse, option S16 Emergency isolator X16 Cable connector, other
F8 Fuse, option S17 Forward pushbutton, right side X17 Cable connector, other
F9 Fuse, option S18 Forward pushbutton, left side X18 Cable connector, other
S19 Pushbutton, raise drivers
platform
X19 Cable connector, other
G1 Battery S20 Pushbutton, lower drivers
platform
X20 Cable connector, tiller
housing 1
S21 Transmitter, drivers platform X21 Cable connector, tiller
housing 2
4H1 Horn S22 Lift pushbutton, rear right of
backrest
H2 Indicator light or rotating
beacon
S23 Lift pushbutton, rear left of
backrest
Y1 Solenoid valve, lowering
S24 Lower pushbutton, rear right of
backrest
Y2 Brake
K1 Contactor, traction drive or
main current
S25 Lower pushbutton, rear left of
backrest
Y3 Solenoid valve, mast
K2 Pump contactor S31 Reverse pushbutton, right
K3 Brake relay S32 Reverse pushbutton, left Y5 Solenoid valve, drivers
platform
K4 Relay, option S33 Pushbutton, electronics
acknowledgement
Y6 Solenoid valve, disconnect
hydraulic accumulator
K5 Relay, option S34 Pushbutton, electronics
acknowledgement
K6 Relay, steering S82 Pushbutton, slow speed
S83 Pushbutton, slow speed
M1 Traction motor Traction drive
designations
M2 Pump motor 1S1 Throttle, forward or
forward/reverse
M3 Power steering motor 1S2 Throttle, reverse
1S30 Protective cover
P1 Traction potentiometer Hydraulic system
designations
P2 Potentiometer, hydraulic
system
2S1 Lowering button
P3 Desired value
potentiometer, steering
2S2 Lift button
P4 Potentiometer, Rekopie
steering
2S80 Pushbutton, initial lift up
6P20 Battery discharge indicator
and/or hour meter
2S81 Pushbutton, initial lift down
Designations for
RC Heating resistance 4S1 Horn button
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Structure of CAN Bus
The CAN bus network of the unit connects:
- the cockpit, which provides and powers communications
- the traction controller
- the steering controller
Cockpit -> traction controIIer:
- Specified values for traction drive
- Specified values for hydraulic system
- Specified values for horn
Traction controIIer -> cockpit:
- Error
- Hour meter
- Battery charge level
Steering controIIer -> cockpit:
- Error
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Truck start-up steps
1. Power supply for cockpit by connecting the battery connector.
2. Enter the code.
3. Power-up / activation of controllers.
3.a Power-up of the CAN bus
4. Feedback from the controllers (OK or not OK)
5. f the controllers are OK, the internal activation of the cockpit follows, then the activation of the
internal steering controller safety relay.
Contactor K1 is driven.
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15
Page
TabIe of contents
ntroduction..................................................... 1
Connection ..................................................... 1
Starting the software ...................................... 1
ntroduction..................................................... 2
Welcome screen (F2 Diagnosis) ................... 2
Display of the error list .................................... 2
Teach-in of the electric steering ..................... 4
1- Adjusting the wheelbase ............................ 5
ntroduction..................................................... 6
2- Read-out of the potentiometer value of the
handlebar with the cockpit in the "straight-
ahead position (reception) ......................... 6
ntroduction..................................................... 7
3- Readout of handlebar potentiometer value
with cockpit at the left stop (reception) ....... 7
4- Adjusting the position of the traction wheel in
straight-ahead position ............................... 7
5- Adjusting the position of the traction wheel at
the left stop ................................................. 8
ntroduction..................................................... 9
F3 Settings ................................................... 10
1- Errors ....................................................... 10
2- Hour meter ............................................... 12
3- Cockpit ..................................................... 13
4- Modes ...................................................... 13
5- Options .................................................... 14
6- Codes ...................................................... 15
6- Battery discharge indicator ...................... 16
7- Truck identification ................................... 17
Saving and retrieving parameters................. 17
F4 Screen .................................................... 19
ntroduction................................................... 20
Error list ........................................................ 21
A- Controller Error List .................................. 21
B- List of cockpit errors ................................ 25
Page
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Introduction
The fault diagnosis is a software which allows
various parameters to be made visible and to
change them.
Connection
The truck and Notebook are connected with the
following cables:
1- Part No.8392452.:
2- Part No. 8409550.: No longer available
replaced by
3- Part No.: 8430163.
Starting the software
Before starting the software, the Notebook must
be connected to the truck with the above cable.
To start the software:
- select CS20,
- click on "Continue" .
Then:
- enter the user code assigned to you.
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Introduction
WeIcome screen (F2 Diagnosis)
The following operations can be carried out with the software:
- display the error list,
- teach-in the electric steering,
- change parameters,
- to display various values,
- to store or print the configuration.
The software has three main menus:
-> F2 Diagnosis -> Teach-in of steering.
-> F3 Settings -> Configuration of the truck.
-> F4 Screen -> Test of the inputs / outputs.
These different functions are available on the welcome screen.
DispIay of the error Iist
n the window at the bottom left of the screen:
- Select "Teach-in electric steering,
- Click on "Ausfhren (execute).
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Then:
- click on the link "ft_frn.htm.
The error list will be displayed as shown below:
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Teach-in of the eIectric steering
The teach-in of the electric steering must be performed twice:
- Teach-in with the truck blocked up on squared timbers for the preliminary adjustment.
- Repeated teach-in, but this time with the truck on the ground for the fine adjustment
The teach-in of the electric steering is carried out in 5 steps:
1- Adjust the wheelbase.
2- Readout of the value of the steering potentiometer with the cockpit in the straight-ahead position.
3- Readout of the value of the steering potentiometer with the control console at the left stop (receive).
4- Adjustment of the traction wheel in the straight-ahead position.
5- Adjustment of the traction wheel at the left stop.
The start of the teach-in of the electric steering is carried out as follows:
- Select "Teach-in of the electric steering:
- Click on Execute.
- n response to the question "Do you want to start the teach-in-procedure? select "Yes.
- Click on Done.
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f the fault message "Fault in positioning of the steering. Steering is probably incorrectly positioned
appears:
- Re- initialise the cockpit.
- Restart the teach-in of the electric steering.
1- Adjusting the wheeIbase
f the value for the wheelbase shown on the screen is OK:
- Select "Okay.
- Click on Execute.
f the values for the wheelbase are not OK, you can adjust them:
- Select "more or "less
- Click on "Execute, when the correct value is shown and return to the previous step.
Depending on the fork length, 12 values are selectable for the wheelbase:
Y = Wheelbase
1200 1950 2075 2200 2325 2450 2575 2725 2825 2950 3075 3360
(mm)
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Introduction
f the error shown on the side appears after the
acknowledgement of the right values for the
wheelbase:
- Click on "gnore.
2- Read-out of the potentiometer vaIue of the handIebar with the cockpit in the
"straight-ahead position" (reception)
Follow the instructions in this window, then confirm:
- Select "Okay.
- Click on Execute.
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Introduction
3- Readout of handIebar potentiometer vaIue with cockpit at the Ieft stop
(reception)
- Move the cockpit to the left stop.
- Select "Okay.
- Click on Execute.
4- Adjusting the position of the traction wheeI in straight-ahead position
f the truck is driving perfectly straight ahead :
- Select "Okay.
- Click on Execute.
f an adjustment of the wheel is required:
- Select "Adjustment.
- Click on Execute.
- Adjust with the RGHT or LEFT arrow (with the truck stationary).
- Test the truck over a short distance.
- f the carried out adjustment is OK, press on the ENTER button.
- Select "Okay.
- Click on Execute.
NOTE: This wheeI adjustment step must be carried out in Iess than 60 s.
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5- Adjusting the position of the traction wheeI at the Ieft stop
- Move the cockpit to the left stop (forward travel not required)
- Select "Okay.
- Click on Execute.
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Introduction
NOTE:
f you skip this step, there is a risk of the electric
steering being unsymmetrical. This will lead to a
change in the angle for the reduction of speed
when driving in curves (this asymmetry can be
checked by jumping to "^F4 SCREEN / Electrical
steering / Steering input).
When the teach-in of the electric steering is
completed, click on "Done.
The teach-in can only be completed successfully
if all the steps were terminated correctly.
f the teach-in must be interrupted during one of
the 5 steps, it is absolutely necessary to proceed
as follows:
- Select Close.
- Click on Done.
Then:
- Select No.
- Click on Done.
Finally:
- Click on Reset.
NOTE:
f the teach-in was not interrupted properly,
- terminate the diagnosis and
- restart the truck.
f the teach-in was interrupted before completion, the steering controller will default to the initial values.
t is therefore necessary to repeat the teach-in from the start.
mportant The truck must be turned for the adjustment of the traction wheel position (level 4).
Possible cause for an unsuccessful teach-in: Poorly calibrated actual value potentiometer (see Group
6, Page 4), teach-in not completed, time allowed for the wheel adjustment ( > 60 s) exceeded.
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F3 Settings
To display or to change the truck parameters, proceed as follows:
- Click on "F3: Adjust.
The following window is displayed:
NOTE:
- The small round yellow buttons beside the settings indicate that the standard factory settings have
been modified.
- Click on "^F4:Load to load all the parameters of the truck connected.
1- Errors
This page is divided into three fields which represent the 3 sections of the CAN bus:
- cockpit errors,
- traction drive errors,
- steering errors.
By clicking on "Traction drive error " it is possible, for example, to display all the errors if this group:
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Click on the error no. to open the file with the fault description:
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To delete the error list, enter a 0 in "Number of errors.
NOTE:
The error list is updated automatically each time a new diagnosis version is installed.
2- Hour meter
On this page it is possible to:
- show the hour meter of the truck
- select the counting method.
- set the service intervals.
Setting the service intervals:
- For example, to set a service interval of 500 hrs enter the number 4.
Here a 5 was entered with the
result 6010 h = 600 h
Service interval 100 200 300 400 500 600 700 800 900 1000
(Service hours)
Number to be entered 0 1 2 3 4 5 6 7 8 9
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3- Cockpit
- configure the cockpit message texts.
- set the automatic shutdown of the truck.
NOTE:
Enter a fairly long period of
time to prevent the truck
from shutting down
automatically.
4- Modes
- activate the various types of programs.
- adjust the individual parameters for the various modes.
A certain range must be observed for each parameter. f this is not the case, the following message
is displayed:
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TabIe of the aIIowed range for individuaI parameters:
Parameter Range
Forward travel speed (%) 0-100
Reverse travel speed (%) 0-80
Acceleration time (100 ms) 4-200
Acceleration time (100 ms) 4-200
Brake function with regen braking) 4-200
Brake function in neutral (100 ms) 4-200
Starting threshold (%) 1-50
IMPORTANT:
n case the parameters are changed, do not forget to save to avoid all the changes from getting lost.
5- Options
This page allows the activation each of the following options and to set their speed:
- Pedestrian mode forwards with throttle (speed and duration of motion)
- Pedestrian mode forward with pushbutton (speed and duration of motion)
- speed limitation due to empty battery
- Speed limitation with forks lowered
- speed limitation due to steering angle
NOTE:
On the M and S models we have, for safety reasons, reduced the travel speed with raised forks at
heights >400 mm to 55 % of the rated speed and in all trucks to 80 % in curves and when reversing.
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The ranges must be observed for the adjustment of the speed (see following table).
* Trucks supplied until July 2004 have an accessible range of 0 to 65 %
6- Codes
With this page is possible to enter or delete a truck access code.
Factory code = 1111;With this code it is possible to move the truck at reduced speed for delivery.
Then the Pool Manager can the driver's code enter (see Group 8, Page 9).
Parameter Range
Pedestrian mode forward with
throttle speed (%)
0-50
Pedestrian mode forward with
pushbutton speed (%)
0-35
Speed limitation with forks lowered (%) 0-100
Speed reduction in curves (%) 0-85*
Speed reduction with raised forks
(M and S model) speed (%)
0-100
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6- Battery discharge indicator
Here it is possible to set the parameters for the reset (100 %) and the functional cut-out due to an
empty battery (20 %).
n the parameters:
- Select the field opposite to 100 % setting or 20 % setting.
- Enter a figure from 0 to 9 in the selected field (see Table of Correspondences below).
When setting the voltage, increase or reduce the values to obtain a battery voltage (readable in the
diagnosis, see figure above) closest to the actual battery voltage measured with the multimeter (the
multimeter must be connected to the power terminals of the controller to reduce losses). With each
adjustment the new value must be stored in the truck and then the parameters must be retrieved into
the computer again in order to be able to establish the congruence of both voltages.
The threshold of 100 % after retrieval makes an adjustment possible which allows the display of 100
% after retrieval, independent of the battery state of charge; see the table below:
Value 100 % Display 0 1 2 3 4 5 6 7 8 9
Voltage in V 24.53 24.68 24.82 24.97 25.12 25.27 25.42 25.57 25.72 26.01
Voltage for each cell 2.04 2.06 2.07 2.08 2.09 2.11 2.12 2.13 2.14 2.17
Value 20 % Display 0 1 2 3 4 5 6 7 8 9
Voltage in V 23.02 23.16 23.30 23.44 23.58 23.72 23.86 24.00 24.14 24.42
Voltage for each cell 1.92 1.93 1.94 1.95 1.97 1.98 1.99 2.00 2.01 2.03
Set value 0 1 2 3 4 5 6 7 8 9
Threshold 10 20 30 40 50 60 70 80 90 100
31
15-17
Workshop ManuaI CS
Diagnosis
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7- Truck identification
Shows the serial number of the truck and the program number.
Shows the serial number, software and hardware of the:
- cockpit,
- drive control,
- steering control.
Saving and retrieving parameters
For the truck to accept the changes made,
proceed as follows:
- Click on "^F5:Save,
- select "Device,
- Click on "OK.
The changed parameters marked with a yellow
point are now stored in the truck.
To store the parameters in a file, carry out the
following steps:
- Click on "^F5: Save,
- Select "Text file in the "Save parameters
window.
- Click on "OK.
31
15-18
Workshop ManuaI CS
Diagnosis
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n the window Save as:
- Select the file path.
- Enter the file name.
- Write explanatory comments.
- n the window "Parameters select the
parameters to be saved.
- Click on "Save.
n a similar manner it is possible to retrieve the
stored parameters into a file and then input them
into the truck.
To do this:
- Click on "^F4: Load.
- Select "Text file in the "Load parameters
window.
- Click on "OK.
n the Open window:
- Select the file and
- Click on "Load.
To enter the parameters into the truck:
- Click on "^F4: Load.
n the Save parameters window:
- Select "Device.
- Click on "OK.
The parameters of the truck will now be loaded.
31
15-19
Workshop ManuaI CS
Diagnosis
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F4 Screen
The various sections of the SCREEN menu allow a check of the individual CAN bus inputs and
outputs.
This menu displays various values on the screen dynamically:
- States of the various controller inputs and outputs and cockpit
- Readings like voltage and Ah, and temperatures
- Test values of the different controls.
To access these screens:
- Click on "F4:Screen.
- Click on the screen tab of the desired page.
Click on "^F3:Stop to stop the measurements.
To resume the measurements, click on "^F3:Measure.
31
15-20
Workshop ManuaI CS
Diagnosis
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Introduction
To determine if the electric steering is unsymmetrical, proceed as follows:
- Select the "Electric steering tab.
- Select "Steering control inputs.
- Carry out the various tests to determine if the truck steering is unsymmetrical (the rectangle turns
green when the speed reduction in curves becomes effective).
- f the rectangle changes to green far before or after the handlebar has reached an angle of 20 with
control console, the electric steering is unsymmetrical.
- n this case a teach-in of the electrical steering must be performed again.
NOTE:
The values are shown in steps of approx. +/- 10 %. An appropriately calibrated meter is required for
more exact measurements.
31
15-21
Workshop ManuaI CS
Diagnosis
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Error Iist
A- ControIIer Error List
E200: WATCHDOG
Communication problem in the master-slave allocation:
- Let the truck sleep.
- f the problem persists, replace controller A1.
________________________________________________________________________
E201: COIL INTERRUPTED
No voltage at the coils of main line contactor K1 and electromagnetic brake Y2:
- Check the wiring between C14 and A14.
- Check the control current lines of K1 and Y2.
- Check the continuity of coils of K1 and Y2.
________________________________________________________________________
E202: CAPACITOR CHARGE
Capacitors do not charge when voltage is applied:
- Check the voltage of battery G1.
- Check fuse F1.
- Check if contactor K1 closes correctly.
- Check the voltage at B+.
________________________________________________________________________
E203: CONTACTOR DRIVER
The driver of main line contactor K1 does not close; when voltage is applied, no voltage at A13:
- Replace controller A1.
________________________________________________________________________
E204: DRIVER SHORTED
Driver of main line contactor K1 shorted, permanent voltage at A13:
________________________________________________________________________
E205: COIL SHORTED
Coils of main line contactor K1 and/or the electromagnetic brake shorted:
- Check K1 and Y2.
________________________________________________________________________
E206: HIGH FIELD CUR
Field current too high, short in field winding of M1:
- Check fuse F1.
- Check the wiring of the field winding of M1.
- Check the field winding of M1.
31
15-22
Workshop ManuaI CS
Diagnosis
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________________________________________________________________________
E207: STBY I HIGH
Higher armature current in quiescent position, short in field winding of M1:
- Check fuse F1.
- Check the wiring of the armature of M1.
- Check the armature of M1.
________________________________________________________________________
E209: NO FIELD CUR.
Field current too low, field winding open:
- Check fuse F1.
- Check the wiring of the field winding of M1.
________________________________________________________________________
E210: EEPROM KO
Problem at the EEPROM test level:
________________________________________________________________________
E211: VFIELD NOT OK
Low voltage at the field winding, low impedance of the field winding.
- Check fuse F1.
________________________________________________________________________
E212: VMN LOW
Different voltages at + of battery G1 and at B+:
- Check fuse F1.
- Check the condition of contactor K1.
- Check the wiring between + of battery G1 and B+.
________________________________________________________________________
E215: VALVE COIL SHOR.
Short in the coil of solenoid valve Y1 or in pump contactor K2:
- Check fuse F4.
- Check the wiring of the power lead of the coils of Y1 and K2.
- Check the coils of Y1 and K2.
________________________________________________________________________
E216: FORW+BACK
Simultaneous forward and reverse traction requests. The simultaneous operation of the pushbuttons
for forward and reverse travel can trigger this error:
- Check the wiring of the slow speed pushbutton behind the backrest of the driver's platform.
- f the error occurs when actuating the throttle at cockpit A2, replace cockpit A2.
31
15-23
Workshop ManuaI CS
Diagnosis
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________________________________________________________________________
E217: INCORRECT START
An input desired value is set to "ON at power-up or wrong starting sequence:
- Shut the truck off and restart it.
- f the error persists, check the inputs at controller A1 (a pushbutton could be stuck or faulty).
________________________________________________________________________
E220: CHECK UP NEEDED
Maintenance required.
________________________________________________________________________
E221: LOGIC FAILURE #1
Main line contactor K1 and electromagnetic brake Y2 activated at power-up:
- Check control cables of Y1 and K2.
________________________________________________________________________
E222: LOGIC FAILURE #2
Coil of solenoid valve Y1 and pump contactor K2 activated at power-up:
- Check control cables of Y1 and K2.
________________________________________________________________________
E223: BATTERY LOW
Battery charge <= 10 %:
- Check the state of battery G1.
- Charge battery G1.
________________________________________________________________________
E224: SAFETY
Hardware problem:
E225: AUX1 OUTPUT KO
Problem in the supply voltage of electromagnetic brake Y2 and main line contactor K1, no voltage at
A16:
- Check if voltage is applied at A14.
________________________________________________________________________
Problem in the electric circuit of horn 4H1:
- Check fuse F4.
- Check if voltage is applied at A10.
- Check 4H1.
- Check the wiring of C4.
- f there is no voltage at B8 when the horn is operated, replace controller A1.
31
15-24
Workshop ManuaI CS
Diagnosis
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________________________________________________________________________
E227: CONTACTOR CLOSED
Main line contactor K1 is always closed:
- Check fuse F1 and replace it, if required.
- Check the wiring of K1.
- Check contactor K1 (sticking).
________________________________________________________________________
E228: VMN HIGH
Voltage at A1 of motor M1 higher than the voltage at B+:
- Check the wiring of steering motor M1.
- Check the connections at B+, T and B-.
- Replace controller A1 and/or motor M1.
________________________________________________________________________
E229: WRONG SET BATTERY
Wrong type of battery :
- Check the voltage of battery G1.
- f the voltage is OK, replace controller A1.
________________________________________________________________________
E230: KEY-OFF
Voltage at terminal A1 of motor M1, although K1 is closed:
E231: THERMIC SENS.
Temperature transmitter faulty:
- Let the truck sleep at ambient temperature.
- f the error persists, replace controller A1.
________________________________________________________________________
E232: CAN BUS KO
Problem in the CAN bus:
- Check the CAN bus loop.
________________________________________________________________________
E233: INPUT ERROR #1
Problem with the desired value setting of the throttle at cockpit A2:
- Restart the truck
- f the error persists, replace cockpit A2.
31
15-25
Workshop ManuaI CS
Diagnosis
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________________________________________________________________________
E234: UP+DOWN
Simultaneous lifting and lowering requests. A simultaneous operation of the pushbutton for lifting and
lowering at the backrest of the driver's platform can cause this error:
- Check the wiring of the pushbutton for the hydraulics controller behind the backrest of the
driver's platform.
- f the error occurs upon actuation of the pushbuttons in cockpit A2, replace cockpit A2.
________________________________________________________________________
E235: SLAVE IN ALARM
Alert of the secondary microprocessor:
- Restart the truck
________________________________________________________________________
E236: INCORRECT START
Wrong starting sequence. One input is active at power-up.
- Restart the truck.
- f the error persists, check the different inputs at controller A1.
________________________________________________________________________
E237: CAN BUS KO
Problem in the CAN bus:
Problem in the electric circuit of horn 4H1.
- Check the wiring of 4H1.
B- List of cockpit errors
Errors occurring with operation of the throttles
________________________________________________________________________
E300: Bad zero position
ncorrect neutral position:
- Restart and check the truck.
- f the problem persists, replace cockpit A2.
________________________________________________________________________
E301: Bad up/down detection
ncorrect position of forward / reverse travel:
31
15-26
Workshop ManuaI CS
Diagnosis
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________________________________________________________________________
E350: Bad initiaI position
ncorrect initial position:
- Check that the throttles can be rotated easily and do not stick.
Error at the emergency isolator button
________________________________________________________________________
E310: Power Iine error on
Voltage at D6 at power-up:
- Check the condition of the diode between D6 and C2.
- Check if D6 is not shorted.
________________________________________________________________________
E311: Secondary processor error detection
Error at the emergency isolator button detected wrongly by the secondary microprocessor:
________________________________________________________________________
E312: Main switch error on
Error at the emergency isolator button detected (main microswitch closed):
- Check that the emergency isolator button can be depressed properly and does not stick.
NOTE This error can occur occasionally if the emergency isolator button is operated. n this case
cockpit A2 does not have to be replaced.
________________________________________________________________________
E313: Secondary switch error on
Error detected at the emergency isolator button (secondary microswitch closed):
________________________________________________________________________
E314: Secondary switch error off
Error at the emergency isolator button detected (opening of the secondary microswitch):
31
15-27
Workshop ManuaI CS
Diagnosis
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________________________________________________________________________
E315: Short circuit on power transistor
Short on the power transistor:
- f there is no external short at D6, replace cockpit A2.
________________________________________________________________________
E316: Short circuit on reIay
Short at the internal relay level :
- f there is no external short at D6, replace cockpit A2.
________________________________________________________________________
E317: Power Iine error OFF
No voltage at D6:
- Check fuse F3.
- f no voltage is applied at D5, replace control console A2.
E318: Main switch error OFF
Error at the emergency isolator button detected (main microswitch open):
________________________________________________________________________
E360: Safe button activate on reset
Emergency isolator button activated at power-up:
NOTE This error can occur occasionally if the emergency isolator button is operated when the truck
is powered up. n this case it is not required to replace cockpit A2.
________________________________________________________________________
E361: Power faiI detection
Error in the power supply of cockpit A2:
- Check fuse F3.
- Check the voltage at D5.
- f +24V is applied at D5, replace cockpit A2.
Errors during actuation of the pushbuttons
31
15-28
Workshop ManuaI CS
Diagnosis
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________________________________________________________________________
E370: Left Iift
Left pushbutton for lifting at power-up activated:
- Check if a click can be heard when the appropriate button is depressed.
NOTE This error can occur occasionally when the appropriate button is operated when the truck is
powered up. n this case cockpit A2 does not have to be replaced.
________________________________________________________________________
E371: Left Iowering
Left lowering button activated at power-up:
________________________________________________________________________
E372: Left horn
Left horn button activated at power-up:
________________________________________________________________________
E373: TurtIe
Tortoise symbol button activated at power-up:
________________________________________________________________________
E374: 123
Button 123 activated at power-up:
31
15-29
Workshop ManuaI CS
Diagnosis
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
________________________________________________________________________
E375: 456
________________________________________________________________________
E376: 789
________________________________________________________________________
E377: PROG
left PRG button activated at power-up:
________________________________________________________________________
E378: VAL
Right PRG button activated at power-up:
________________________________________________________________________
E379: Hare
Hare symbol button activated at power-up:
31
15-30
Workshop ManuaI CS
Diagnosis
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
________________________________________________________________________
E380: Right horn
Right horn button activated at power-up:
________________________________________________________________________
E381: Right Iowering
Right lowering button activated at power-up:
________________________________________________________________________
E382: Right Iift
Right lift button activated at power-up:
CAN error message
________________________________________________________________________
E330: Bad CAN transmission
Faulty CAN transmission:
________________________________________________________________________
E331: E2p error
Problem with memory of cockpit A2:
Controller errors
________________________________________________________________________
E340: No controIIer heartbeat
Presence of controller A1 not detected:
- Check the ports of controller A1 at the CAN bus.
31
15-31
Workshop ManuaI CS
Diagnosis
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
________________________________________________________________________
E341: ControIIer emergency
Controller A1 in the safety state:
- Read the error list of controller A1 and process the shown errors.
________________________________________________________________________
E342: Bad controIIer init
ncorrect initialisation of controller A1:
- Read the error list of controller A1 and process the shown errors.
C- Electric steering
________________________________________________________________________
E421: Type change
Truck type changed:
- Check it there is a short at a free pin on cable connector C.
________________________________________________________________________
E427: Safety reIay init
The safety relay is closed at initialisation:
- Check if there is a short at C14 and C2.
________________________________________________________________________
E428: Safety reIay runtime
The safety relay opened during operation:
- Possible fault due to heavy impact.
________________________________________________________________________
E429: Cut-off reIay init
Relay K6 is closed at initialisation:
- Check K6.
________________________________________________________________________
E430: Cut-off reIay driver
Error in the relay driver for K6:
- Possible fault due to heavy impact.
- Check the wiring of coil K6.
- Check coil K6.
________________________________________________________________________
E431: Safety reIay off
Relay K6 does not close:
- Check the wiring of K6.
- Check K6.
31
15-32
Workshop ManuaI CS
Diagnosis
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
________________________________________________________________________
E432: Connection motor wires
Blue and white cable of steering motor M3 interchanged (sense of rotation):
- Check the wiring of steering motor M3.
________________________________________________________________________
E433: Motor power stage
Short in the power circuit of steering motor M3:
- Check for a short at the blue and white cable of steering motor M3.
- f there is no short in the wiring, replace steering controller A3.
________________________________________________________________________
E434: Poti suppIy voItage
ncorrect supply voltage of the steering potentiometers:
- Check the voltage between C6 and C8;if incorrect, replace steering controller A3.
- f the voltage between C6 and C8 is OK, check the voltage between L3 and L1 then between
E4 and 1.
- Depending on the result, check the wiring of the potentiometers or replace a defective
potentiometer.
________________________________________________________________________
E435: Set-poti cut
Short of the desired value potentiometer at + or at - :
- Check the wiring of the potentiometer.
- Check the desired value potentiometer.
________________________________________________________________________
E436: ActuaI-poti cut
Short at + or - of the actual value potentiometer:
- Check the actual value potentiometer.
________________________________________________________________________
E437: Temp. power stage high
Overheating at the power stage of steering controller A:
- Let the truck sleep at ambient temperature.
- Start and check the truck.
________________________________________________________________________
E438: Output steering dispIay shorted
Short at the +24V output of speed reduction:
- Check if C16 and C24 are properly connected to each other.
- Check if C16 and C24 are not shorted to a +24V power supply.
31
15-33
Workshop ManuaI CS
Diagnosis
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
________________________________________________________________________
E439: Set-point pots
ncompatible values the 2 tracks of the desired value potentiometer:
- Repeat the teach-in of the electric steering.
________________________________________________________________________
E440: ActuaI-point potis
ncompatible values of the 2 tracks of the actual value potentiometer:
- Check the condition and wiring of the potentiometer.
- Check the centring of the potentiometer.
- f the error persists, remove and re-install the actual value potentiometer and repeat the teach-
in of the electric steering.
________________________________________________________________________
E443: Bad actuaI vaIue
ncorrect values of the actual value potentiometer at key-on:
- Check the condition and wiring of the potentiometer.
- Check the centring of the potentiometer.
- f the error persists, remove and re-install the actual value potentiometer and repeat the teach-
in of the electric steering.
________________________________________________________________________
E444: Power reIay driver shorted
Output C3 shorted to +24V power supply:
- Check the wiring of C3.
________________________________________________________________________
E446: Power suppIy Iow
Power supply of the battery and the potentiometer low over a longer period:
- Measure the voltage between C6 and - of the battery.
- f the voltage is not 0 V, replace steering controller A3.
________________________________________________________________________
E450: Speed reduction
Error on the speed reduction in curves:
- Check if C16 and C24 are connected to each other.
- f yes, replace steering controller A3.
E451: Center point Iost
Loss of the centring of the speed-reduction-in-curves function:
- Teach-in the electric steering.
- f the problem persists, replace steering controller A3.
31
15-34
Workshop ManuaI CS
Diagnosis
D
a
t
e

o
f

i
s
s
u
e
:

A
u
g
u
s
t

2
0
0
4
(
R
e
p
l
a
c
e
s

i
s
s
u
e
:

)
A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.
N
o

p
a
r
t

m
a
y

b
e

r
e
d
u
c
e
d

i
n

a
n
y

f
o
r
m

o
r

b
y

a
n
y

m
e
a
n
s
.
C
o
p
y
r
i
g
h
t

r
e
s
e
r
v
e
d
.
________________________________________________________________________
E452: Wrong center position
ncorrect centring of the speed-reduction-in-curves function:
- Teach-in the electric steering.
________________________________________________________________________
E470: Uc2 reset faiIed
________________________________________________________________________
E471: Uc2 init faiIed
________________________________________________________________________
E472: Uc2 checksum faiIed
Communication problem between the two microprocessors:
________________________________________________________________________
E473: Uc1-Uc2 transmission faiIed
Faulty transmission between the two microprocessors:
________________________________________________________________________
E474: Uc1-Uc2 data exchange faiIed
Error with cyclical data exchange between the two microprocessors:

CS 20

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SEDS

Designation 5.53.313.1 (Kordel)

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