51 18 3617 1 en PDF

Workshop literature
Lithium-ion batteries
48-V version
BG 2.1, 2.2
50988012057 EN - 12/2017
History of changes
g
Edition 2017/12
• Version 1
• First edition for battery group 2
• This version 1 is continually being extended
and replaced by updated versions.
50988012057 EN - 12/2017 I
Header
g
List of abbreviations
NOTE
The list of abbreviations provides an overview of

the abbreviations used in this document and their
definitions. The explanations refer only to their
use in this document.
Abbreviation Meaning Explanation
AC Alternating Current Alternating current
Accord européen relatif

au transport international European convention for the international carriage of
ADR
des marchandises hazardous materials by road
Dangereuses par Route
Rechargeable
Rechargeable battery Storage medium for electrical energy
battery
BCM Brake Chopper Module Brake chopper module
Battery Management
BMC Battery master controller
Control
Battery Management
BMS Battery management system
System
BOL Begin Of Life Battery operating life
CAN Controller Area Network Serial bus system (CAN bus)
Confirms conformity with product-specific European
CE Communauté Européenne
directives (CE labelling)
Commission on the Rules
International Commission on the Rules for the Approval
CEE for the Approval of the
of Electrical Equipment
Electrical Equipment
Comité Européen de
CEN European committee for standardisation
Normalisation
CSC Cell State Controller Battery module controller (slave controller)
CVS Current Voltage Sensor Current/voltage sensor
DC Direct Current Direct current
Transducer for potential-free measurement of DC volt-
DC/DC Voltage transformer
age
Deutsches Institut für
DIN German organisation for standardisation
Normung
Depth of discharge (energy extracted in relation to ca-
DOD Deep Of Discharge
pacity
EN Europäische Norm European standard
EOL End Of Life End of the battery service life
Fédération Européene de European Federation of Materials Handling and Storage
FEM
la Manutention Equipment
ID-Nr. Identification number Unique ID of the object in question
International Electrotechni-
IEC International Electrotechnical Commission
cal Commission
IP International Protection Protection type for electrical operating materials
LCD Liquid Crystal Display Liquid crystal display (battery display)
50988012057 EN - 12/2017 III

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Abbreviation Meaning Explanation

LED Light Emitting Diode(s) Light emitting diode(s)
max. Maximum Greatest value of an amount
min. Minimum Smallest value of an amount
Negative Temperature
NTC Negative temperature coefficient
Coefficient
Persönliche Schutzausrüs-
PSA Personal protective equipment
tung
Règlement concernant le
transport international fer- Regulations concerning the international carriage of
RID
roviaire de marchandises hazardous materials by rail
Dangereuses
Parameter for the charging state of a battery (battery
SOC State Of Charge
charge level)
SOF State Of Function Battery function/performance capability
Parameter for the health of a battery = residual capacity
SOH State Of Health
of an old battery (battery degradation)
Steuer-Spannungs-
SSV Control voltage supply
Versorgung
Technische Regeln für Ordinance on hazardous materials applicable in the
TRGS
Gefahrstoffe Federal Republic of Germany
The handling of hazardous materials is determined
UN United Nations by the United nations (UN) and indicated by the UN
identification number for hazardous materials.
Verband der Elektrotech-
VDE nik Elektronik Information- German technical/scientific association
stechnik
.
IV 50988012057 EN - 12/2017
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Units
Unit symbol Unit name Explanation

°C Degree Celsius Unit of temperature
°F Degree Fahrenheit Unit of temperature
A Ampere Unit of electrical current
Unit of electrical charge storage capacity (nominal ca-

Ah Ampere hour
pacity)
dB Decibel Unit of sound intensity

cm Centimetre Unit of length (1 cm = 10 mm)
cm3 Cubic centimetres Unit of volume
g Gram Unit of mass
h/d Hours per day Hours driven per day
kg Kilogram Unit of mass (1 kg = 1000 g)
kg/m3 Kilograms per cubic metre Unit of density (ratio of the mass of a body to its volume)
km/h Kilometres per hour Unit of speed
kN Kilonewton Unit of force (1 kN = 1000 N)
kW Kilowatt Unit of electrical power
kWh/h Kilowatt hour/hour Energy consumption
l Litre Unit of volume
l/h Litres per hour Unit of consumption
l/min Litres per minute Unit of consumption
m Metre Unit of length (1 m = 100 cm)
2 Metres per second squared Unit of acceleration
m/s
min Minute Unit of time (1 min. = 60 s)
rpm Revolution(s) per minute Unit of revolution speed
mm Millimetre Unit of length (1 mm = 10-3 m)
N Newton Unit of force (1 N = 10-3 kN)
Nm Newton metre Unit of torque
s Second Base unit for time
t Tonne Unit of mass (1 t = 1000 kg)
V Volt Unit of electrical voltage
W Watt Unit of electrical power
W/kg Watt/kilogram Performance by mass (power density)
Wh Watt-hours Unit of electrical work (nominal energy)
Wh/kg Watt-hours/kilogram Stored energy per kilogram of mass (energy density)
.
Glossary
Rechargeable battery
A rechargeable battery can store electrical en-
ergy by converting it into chemical energy and
then output this energy by reconverting it. This is
how all rechargeable cells or batteries work.
50988012057 EN - 12/2017 V
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Active materials
Materials in the electrodes in which the chemical
alteration processes (charging, discharging) take
place are active materials. These are lithium
metal oxide and carbon in lithium-ion batteries.
Battery
A battery consists of multiple cells that are elec-
trically connected by permanent means, and
including housings, connectors and labels.
Examples of batteries:
• 9 V monobloc battery
• 48 V traction battery
• 200 to 800 V hybrid battery (car)
Battery Management System

The battery management system (BMS) mon-
itors the discharge and the temperature of the
battery. When charging, the BMS ensures bal-
anced charging of the battery cells. It protects
the cells and determines the charging state. The
BMS consists of the battery module controllers
(CSC) within the modules, and the battery master
controller (BMC) for the battery.
C-rate
The C-rate is the standardised charge current
and discharge current in amperes. The C-rate
corresponds to the nominal capacity divided by
one hour.
Example of 240 Ah nominal capacity:

Charge/dis-
C-rate Charging time
charge current
1 240 A 1h
0.5 120 A 2h
0.2 48 A 5h
.
Electrodes
The electrodes consist of the active material
and the conductors (connections). These are
aluminium and copper in lithium-ion batteries.
Energy density
The energy density is the ratio of available energy
from the battery to its volume or weight.
VI 50988012057 EN - 12/2017
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Final discharged voltage

The final discharged voltage is the voltage at
which the discharge of a battery or a recharge-
able battery is terminated.
During discharge tests, the final discharged
voltage is defined as the voltage below which no
usable energy can be extracted for the respective
application. In rechargeable batteries, it is the
lower limit of the cell voltage for deep discharge.
Rechargeable battery system Typical final discharged voltage for single cells
Lithium polymer battery 3.30 V
Lithium-ion battery 2.50 V
Lead-acid battery 1.75 V
Nickel-zinc battery 1.20 V
Alkaline manganese battery (rechargeable) 1.0 to 1.10 V
Nickel metal hydride battery 1.00 V
Nickel-cadmium battery 0.85 to 1.00 V
.
Final charged voltage

The final charged voltage is a parameter for
rechargeable batteries. It describes the voltage
applied to the battery terminals as a terminal
voltage during the charging process when the
battery charger is connected.
The final charged voltage is higher than the
nominal voltage.
Charging cycle
Charge cycles are the number of discharges
followed by re-charging. They are a parameter
for rechargeable batteries. A charging cycle
corresponds to time it takes for a battery to
recharge from the permissible discharge limit
of the battery to full charge. The full charge
corresponds to an SOC of 100 %. The number of
charging cycles always has the same ratio to the
number of discharge cycles and is the principal
factor determining the ageing of the battery.
Important factors for the number of charge cycles:

• Discharge current
• Discharge time
• Depth of discharge (DOD)
• Temperature
Nominal energy
The nominal energy (Wh) is the energy in watt-
hours that a battery can output under defined
conditions.
50988012057 EN - 12/2017 VII

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The nominal capacity (Ah) multiplied by the

nominal voltage (V) gives the energy content.
Example: 240 Ah x 48.75 V = 11,700 Wh
(11.7 kWh)
Nominal capacity
The nominal capacity (Ah) is the stored quantity
of electricity (current value x time) in a fully
charged battery that can be extracted during
discharge under defined conditions.
For example: A battery with 240 Ah could output
a current of 240 A for one hour or a current of 1 A
for 240 hours.
Nominal voltage
The nominal voltage (V) is the characteristic
operating voltage of the battery.
Example:
Battery type Nominal voltage
Lead-acid cell 2.0 V
Nickel-cadmium cell 1.2 V
Zinc-carbon cell 1.5 V
Lithium-ion cell 3.7 V
.
Memory effect
The reduction in capacity caused by frequent
partial discharge of nickel-cadmium batteries is
known as the memory effect.
Power source parallel connection

Parallel connection increases the capacity and
the maximum discharge current. Only power
sources with the same output voltages can be
connected in parallel.
386_000-001
VIII 50988012057 EN - 12/2017

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Primary cell
Primary cells (1) are not rechargeable and can be
discharged only once.
Power source serial connection

The serial connection of power sources increases
the total voltage. The capacity remains the same.
386_000-002
Regenerative braking (recuperation)

The term recuperation (derived from the Latin
recuperare = regain) describes a technical pro-
cedure for energy recovery.
Secondary cell
Secondary cells are rechargeable.
50988012057 EN - 12/2017 IX
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Cell
The cell is the smallest element of a battery. The
size and the voltage produced by the material
combination of the electrodes determines its
capacity.
A cell consists of an anode, cathode, separator
and electrolyte.
Examples of cells:
• 1.5 V/3 V button cells
• 2 V lead-acid cells
• 3.7 V lithium-ion cells
• Mono cells (D)
• Baby cells (C)
• Mignon cells (AA)
• Micro cells (AAA)
• Mini cells (AAAA)
X 50988012057 EN - 12/2017
Table of contents
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00 Product information
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
Overview of the battery groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
Nameplate of a lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-2

Special safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-2
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-4
Dangerous misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-4
Procedure in the event of a battery-related accident . . . . . . . . . . . . . . . . . . . . . . . . . . 00-5
Lithium-ion battery: First-aid measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-5
Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-6

Battery transport with crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-6
Transport directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-6
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-7
Description of lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-8

Structural principle of the battery cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-8
Charging/discharging - operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-8
Advantages of lithium-ion technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-9
Structural principle of the battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-10
Temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13
Battery module LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13
Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-14
Battery display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-14
Battery management system (BMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-16
01 Service
Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
Cleaning the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
Operating materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2

Tools, insulated up to 1000 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
Personal protection equipment (PSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
Special tool for lithium-ion technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
Attaching/removing the lifting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4
Battery charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5

Battery discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5
Course of action for a deeply discharged battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
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Function checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12

Checking that the battery male connector is de-energised . . . . . . . . . . . . . . . . . . . . . 01-12
Insulation testing the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-13
21 Battery group 2.1

Design BG 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1
Technical data for battery group 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1
Diagnostic set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-2
Design - Battery group 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-3
Technology compartment - Battery group 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-4
De-energised state BG 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-5

Measuring the insulation resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-5
De-energising the technology compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-6
Checking that the technology compartment is de-energised . . . . . . . . . . . . . . . . . . . . 21-9
Restoring operating status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-9
Components BG 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-13

Tray cover - Battery group 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-13
Removing/fitting the tray cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-13
Battery display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-15
Removing/installing the battery display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-16
Schocksensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-19
Pressure compensation element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-20
Removing/installing the module holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-21
Removing/installing the positive power connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-27
Removing/installing the battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-29
CAN bus terminating resistor (120 Ω) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-32
Technology compartment BG 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-33

Opening/closing the technology compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-33
Current/voltage sensor (CVS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-35
Removing/installing the current/voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-35
Brake chopper module (BCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-38
Removing/installing the brake chopper module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-40
Brake resistor 105 mΩ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-43
Removing/installing the brake resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-43
Battery master controller (BMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-46
Removing/installing the battery master controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-46
Control voltage supply (SSV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-48
Removing/installing the control voltage supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . 21-48
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Contactor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-50

Removing/installing the contactor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-50
Voltage transformer (DC/DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-56
Removing/installing the voltage transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-56
Electrical fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-58
Replacing electrical fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-59
Wiring BG 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-62

Removing/installing the power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-62

Design BG 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1
Technical data for battery group 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1
Design - Battery group 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-2
Technical compartment - battery group 1.1 / 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-4
De-energised state BG 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-5

Measuring the insulation resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-5
Spannungsfreiheit im Technikraum herstellen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-6
Spannungsfreiheit im Technikraum prüfen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-8
Beriebszustand wiederherstellen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-8
Components BG 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-11

Tray cover - Battery group 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-11
Trogdeckel Abbau/Anbau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-11
Battery display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-13
Batterie-Display Ausbau/Einbau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-14
Schocksensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-18
Pressure equalising element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-19
Leistungsverbinder Plus Ausbau/Einbau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-20
Temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-23
Batteriemodul Ausbau/Einbau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-23
CAN bus terminating resistor (120 Ω) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-26
Technology compartment BG 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-28

Technikraum öffnen/schließen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-28
Current/voltage sensor (CVS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-30
Removing/installing the current/voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-30
Brake chopper module (BCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-34
Removing/installing the brake chopper module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-36
Brake resistor 105 mΩ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-38
50988012057 EN - 12/2017 XIII

Table of contents
g
Removing/installing the brake resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-38

Battery master controller (BMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-42
Removing/installing the battery master controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-42
Control voltage supply (SSV) with reset button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-44
Removing/installing the control voltage supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . 22-44
Contactor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-46
Removing/installing the contactor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-46
Voltage transformer (DC/DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-52
Removing/installing the voltage transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-52
Electrical fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-55
Replacing electrical fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-56
Wiring BG 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-59

Removing/installing the power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-59
XIV 50988012057 EN - 12/2017

Product information 00
Foreword
Overview of the battery groups
Available Tray dimensions [mm]
Truck energy Circuit Tray no.
Capacity Length Width Height
Battery group 2
13.1 kWh
2.1 1030 529 350
268 Ah
RX20 14-20 48 V B 315
48.9 kWh
2.2 1030 529 627
1005 Ah
.
Nameplate of a lithium-ion battery

1 Manufacturer
2 Nameplate
3 Address of manufacturer
4 Safety information
5 Data matrix code
6 Transportation notes
7 General operating notes
8 CE labelling
9 Data/technical data
50988012057 EN - 12/2017 00-1

Safety information
Special safety regulations
Special safety regulations must be observed Special safety instructions
for lithium-ion batteries. An industrial truck with
lithium-ion-battery must be identified accordingly DANGER
with a lithium-ion label. Risk of explosion!
All lithium-ion batteries are essentially associated External temperatures of >80 °C can cause the battery
with the risk of a fire starting, of the battery to explode.
exploding and of the battery causing chemical – Never heat the battery to over 80 °C or expose it to
naked flames.
burns. The escape of dangerous substances
from the enclosed battery tray can be excluded
only by correct use and safe handling. The risk DANGER
of contact with toxic or corrosive substances
exists only in cases of improper handling leading Risk of injury!
to safety valves being opened or the housing The battery may be damaged or deformed in the event
being breached. These can result in electrolyte of an accident (impact, fall, collision). A strange smell,
an abnormal rise in temperature to >80°C, a change in
escaping, electrode materials reacting with
shape or any other anomaly may occur.
moisture and water, or fire and explosion.
– Establish a safety zone of five metres around the
The following guidelines must be observed: battery.
– Ensure sufficient ventilation.
– Observe the manufacturer’s information on
Linde lithium-ion technology. – If necessary, contact the emergency services
and inform them that there has been an accident
– Only work on the battery in areas that can be involving a lithium-ion battery.
easily ventilated in the event of an emergency.
– Use only the special tools, test equipment and
spare parts specified by the manufacturer. Other applicable standards and directives
– Only competent persons who have been DIN VDE 0100-410 voltage range I (for batteries
trained in how to work with Linde lithium-ion in battery groups 1 to 4)
technology may work on the batteries. DIN VDE 0105-100:2009-10
– Before carrying out any work on the battery,
put on personal protective equipment and NOTE
disconnect the battery.
Comply with the national laws and regulations of
– Never short-circuit the battery connectors.
the country in which the battery is used!
– Do not connect the battery with the polarity
reversed.
Personnel qualifications
– Do not subject the battery to excessive me-
chanical loads. According to the general principles for safe
operation, all persons involved in work with or
– Water can be used to cool down the incipient in the vicinity of electrical systems must be given
fire. instruction on the following subjects:
• Safety requirements
NOTE • Safety regulations
Before extinguishing fires, position yourself on • Operating instructions
the side of the fire from which the wind is blowing. Requirements for qualified personnel:
This will prevent inhalation of toxic fumes.
• Personnel must be approved according to
the current requirements of IEC 60449 or
DIN VDE 0100-410
• Observe instructions, regulations and require-
ments
• Wear suitable clothing for the work place
00-2 50988012057 EN - 12/2017

Safety information
• Wear personal protective equipment when

opening the battery or the technology com-
partment
• The person responsible for the work must
ensure compliance with these requirements
before starting work and during the work.
50988012057 EN - 12/2017 00-3

Safety information
Intended use
The battery must be used only in accordance with Charge the battery using only the battery charger
the following documents: for lithium-ion batteries approved by the manu-
• The original operating instructions for the facturer.
industrial truck
NOTE
Use the battery only when it is in good working
order: If the charging state is less than 10%, charge the
• The battery must not be damaged and must battery as soon as possible. Leaving the cells
not indicate any errors discharged for several days negatively affects
• The cables to the battery charger must not be the service life of the battery.
damaged
• The cables to the industrial truck must not be NOTE
damaged.
When taking the battery out of operation for a
The battery must only be used in a suitable prolonged period (e.g. for company holidays),
industrial truck. The nominal voltage of the always ensure the battery is charged (50% -
battery must correspond to the operating voltage 100%).
of the industrial truck (see "Technical data").
Dangerous misuse
DANGER DANGER
Improper handling can lead to an The penetration of water can cause short circuit and
explosion or cause a fire! fire!
– Never use the battery in areas where – Prevent liquids from penetrating the battery.
there is a risk of fire or a risk of
explosion.
– Never heat the battery to over 80°C or DANGER
expose it to an open flame.
A short circuit can destroy the battery and start a fire!
– Do not short circuit the battery.
DANGER – Keep the pin contacts away from metallic objects.
Improper handling or causing intentional damage to
the battery can result in serious injuries!
– Use the battery only in accordance with the manu-
facturer's instructions.
– Do not improperly dismantle the battery.
– Do not disassemble, bridge or bypass the safety
systems.
00-4 50988012057 EN - 12/2017

Safety information
Procedure in the event of a battery-related accident

WARNING
NOTE
Escaping gases can lead to breathing difficulties!
When used properly the battery will not catch – Immediately ventilate the area or go out into the
fire and there is no possibility of contact with fresh air; in more serious cases, call a doctor imme-
toxic substances. When the battery is handled diately.
correctly there is no possibility of an electric – Do not move the battery.
shock.
WARNING
Procedure in the event of a fire
Leaking chemicals can irritate the skin and the eyes!
DANGER – Immediately wash affected areas of skin thoroughly
with soap and water.
Risk of poisoning by inhalation of vapours.
– Thoroughly irrigate eyes with clean water.
If the battery catches fire, toxic vapours will be relea-
sed. – Seek medical assistance immediately.
– Position yourself on the side of the fire from which
the wind is blowing.
– Immediately clear the area around the battery, NOTE
retreating to a minimum distance of 5 m.
– Use respiratory protection. The battery must be moved to a safe area (5 m
– Call the fire brigade. away from buildings) by specially trained person-
– Water can be used to cool down the incipient fire. nel.
Procedure in the event of electric shock

DANGER
Risk of fire due to the battery overheating! DANGER
The battery can become very hot when in use. Tempe- Providing incorrect first aid to the injured person can
ratures in excess of 80°C must always be avoided. create additional risks!
If the battery reports a temperature that is too high, cool – Do not touch the injured person before ensuring the
the battery from the outside. Water can be used to cool power supply has been disconnected.
down an incipient fire. – Move exposed live cables away from the injured
– Make sure that the temperature limits are not person using non-conductive objects.
exceeded. – Ensure the injured person is breathing and has a
– Cool the battery to below the temperature limits. heartbeat.
– Cool the outside of the battery tray with water. – Treat burns injuries appropriately.
– Consult a doctor immediately.
Lithium-ion battery: First-aid measures

Measures required if gases or liquids escape: – Immediately rinse eyes thoroughly with water
for 15 minutes, then consult a doctor.
Escaping gases can lead to breathing difficulties.
Measures required in the event of electric shock:
– Immediately ventilate the area or go out into
the fresh air; in more serious cases, call a – 1. Ensure that the system is disconnected from
doctor immediately. the power supply. Do not touch the injured
person until this has been done!
Skin irritation can occur in the event of contact
with the skin. – 2. Move exposed live cables away from the
injured person using non-conductive objects.
– Thoroughly wash the skin with soap and water.
– Call an ambulance.
Eye irritation can occur in the event of contact
with the eyes. If the person is unconscious:
– Begin first-aid measures.
50988012057 EN - 12/2017 00-5

Transport and storage

Battery transport with crane
2
DANGER
If the load is dropped, the consequences
could potentially be fatal!
– Never walk or stand underneath
suspended loads.
1
– Ensure there is sufficient distance between the
truck and any obstacles so that the truck is not
damaged when the crane is used.
To avoid short circuits, batteries with open ter-
minals or connectors should be covered with a
rubber mat.
– Attach battery (1) to suitable lifting gear (2).
6210_003-012
Observe the operating instructions for the lifting

gear.
The lifting gear should be vertical when lifting, so
that no lateral pressure is applied to the tray.
– Lift the battery from the roller channel. Ensure
that there is sufficient distance from the battery
door.
– Set the battery down carefully.
– Do not place or allow slack lifting gear to fall on
the battery cells.
Transport directives
CAUTION
For transportation purposes, lithium-ion
batteries are classified as class 9
dangerous goods (UN 3480 for individual
batteries and UN 3171 for a battery-
powered truck/device) and assigned to
packing group II.
The batteries are carefully packed to minimise

the likelihood of any damage during transport.
However, the batteries must still be thoroughly
inspected for damage after any transportation.
The load must be carefully secured against
falling, tipping or slipping during transportation.
Only suitable means of transport may be used.
Only competent persons may perform trans-
portation and the necessary preparations.
Lithium-ion batteries are always hazardous
materials and are subject to the current version
00-6 50988012057 EN - 12/2017

Transport and storage
of the following hazardous materials regulations

and exceptions.
For further information on the transport guide-
lines, see the document entitled "STILL lithium-
ion technology properties, storage, transporta-
tion and processes".
NOTE
Please contact the person in your organisation

trained for this purpose.
Storage
For information about the storage of lithium-ion
batteries, see the document entitled "STILL
lithium-ion technology properties, storage, trans-
portation and processes".
50988012057 EN - 12/2017 00-7

Description of lithium-ion battery

Structural principle of the battery cell
A lithium-ion cell consists primarily of the follo- The electrolyte is an anhydrous solution. The
wing four components: electrolyte used is assigned to hazardous sub-
• Anode stances class "Carc. Cat. 3, C, R10-34-40-43".
• Cathode The separator physically separates the anode
• Separator from the cathode to prevent a short circuit. The
separator is permeable for ions to convert the
• Electrolyte
stored chemical energy into electrical energy.
The anode is mainly a compound of lithium-
nickel-manganese-cobalt oxide. Typical separators used in lithium-ion cells are:
• Polymers foils
The cathode consists mainly of graphite (carbon).
In addition, binders such as polyvinylide difluoride • Ceramic-coated membranes
and thin metal carrier foils such as aluminium foil • Microporous ceramics
and copper foil are used.
Chemical equation
NOTE Oxidation: LixC6 → Li1-xC6 + x Li+ + x e-
The same electrode acts either as anode or ca- Reduction: Li1-xNiaMnbCocO2 + x Li+ + x e- →
thode depending on the charging or discharging LiNiaMnbCocO2
procedure. I.e., the anode can function as the po-
sitive or negative electrode, as can the cathode.
Charging/discharging - operating principle
1 Graphit 2 LiCoO2 Graphit

LiCoO2
Li + Li +
Li + Li +
Li + Li +
A B A B
386_000-011
1 Charging A Cathode
2 Discharging B Anode
NOTE
The same electrode acts either as anode or ca-

thode depending on the charging or discharging
procedure. The anode can function as the posi-
tive and negative electrode, as can the cathode.
Charging process
During charging, lithium ions flow from the pos-
itive electrode (cathode) through the separator.
Lithium graphite is produced at the negative elec-
trode (anode); cobalt manganese and nickel
00-8 50988012057 EN - 12/2017

oxide are created at the positive electrode (cath-

ode) → chemical energy.
Discharging process
During discharging, lithium ions flow from the
negative electrode (cathode) through the sepa-
rator.
Graphite is produced at the negative electrode
(cathode); lithium metal oxide (CO, Mn, Ni)
is created at the positive electrode (anode)
→ electrical energy.
Advantages of lithium-ion technol-

ogy
Advantages:
• Very high energy density
• High efficiency of up to 95% (ratio of discharge
current quantity/charge current quantity)
• Same capacity with less volume and less mass
• Discharge to 5% residual capacity possible
• Very long service life (2 or 3 times as long as
conventional batteries)
• High number of charge cycles (at least 2500
cycles at 80% SoH, "second battery life"
possible)
• "Balancing": load balancing of cells connected
in series for maximum capacity utilisation
• No negative effects caused by partial charging,
no memory effects
• Short charging time
• Fast intermediate charging
• Very low energy loss when charging compared
to lead-acid batteries
• Energy costs can be lowered by up to 40%
• Low self-discharge rate
• Eliminates need for battery replacement or
replacement batteries
• No maintenance, e.g. topping up water
• Reduced energy and handling costs
• No leaking battery gas or battery acid
• Environmentally friendly (do not contain any
toxic substances such as cadmium, lead or
mercury) → Raw materials easy to recycle
50988012057 EN - 12/2017 00-9

Structural principle of the battery module
1 Battery cells (13 pieces) 8 Microcontroller

2 Battery modules 9 Voltage of the battery cells
3 Power supply 10 Temperature
4 Battery module controller (CSC) 11 CAN bus
5 Balancing controller 12 Monitoring signal
6 Balancing battery cells 13 Battery master controller (BMC)
7 Voltage of the battery module 14 Temperature sensors
The battery module consists of a sheet steel

enclosure and contains several components.
Within the battery module, the battery cells are
connected to each other by cell connectors.
There are 13 battery cells arranged in series,
thereby achieving a nominal voltage of 48 V.
The positive connection and negative connection
are designed as plug contacts on the battery
module. There is a 200 A fuse in the negative
side of the circuit. For vertically mounted battery
modules, the positive connection is at the top and
the negative connection is at the bottom of the
battery module.
At the top of the battery module there are two plug
connectors for connecting the battery module to
the battery CAN bus and supplying the battery
module with voltage. The battery module is
also connected to a monitoring signal (Fault
Line Signal) via the plug connector. It is then
connected to the next battery module in each
case via the two plug connectors. A terminating
resistor (120 Ω) for the CAN bus is fitted on the
last battery module.
The battery module is monitored by the battery
module controller (CSC). The CSC monitors each
00-10 50988012057 EN - 12/2017

individual cell voltage and the overall voltage of

the battery module. Parallel to each battery cell
there is a balancing unit. This is activated by
the CSC during the charging process in order to
maintain equality of the cell voltages.
Main components
10 1
9
5 4
386_000-003
1 Cell connector 6 Module housing

2 200 A module fuse 7 Battery module controller (CSC)
3 Negative terminal 8 Positive terminal
4 Cell voltage measurement 9 LED display
5 Cell 10 Module connector
50988012057 EN - 12/2017 00-11

Exploded view
6 5
386_000-004
1 Module cover 5 Module housing

2 Cell connector 6 Housing insulation
3 Cell cover 7 End plate
4 Cells (13 units) 8 Battery module controller (CSC)
00-12 50988012057 EN - 12/2017

Temperature sensors
1 NTC 1 3 NTC 3
2 NTC 2 4 NTC 4
Battery module LED display
1 LED display
Time 1s 1s 1s 1s 1s 1s 1s 1s 1s 1s 1s 1s
Red/green LED Red Green
OFF/quiescent state (off) (off)
Battery reset 1x 1x
Module not detected by
master
Error
Flash procedure active 3x 3x
Normal operation - no
faults
.
50988012057 EN - 12/2017 00-13

Balancing
Balancing refers to equalisation across a battery
module. This ensures an even voltage level
between the cells. It is a continuous internal
process.
The voltage value is displayed in the diagnostics.
Passive balancing
Resistors connected in parallel that discharge
the cells in a targeted manner during the charging
process.
Advantage
• Low-cost variant
• Low component requirements
• Small footprint
Disadvantage
• Energy is converted into heat
1 Rext1
2 I-balance
3 Battery cell
Battery display
1
Charging state LEDs
The battery display is switched on when the
battery is communicating with the truck, the
battery charger or the diagnostic device. The
charging state LEDs (3) indicate the charging
state of the battery. All charging state LEDs (3)
light up green in sequence when the battery is
charging.
Charging state
Display Comment
(%)
First charging
state LED
flashes red: 3 2
0-2
the truck can
386_609-007
no longer be
moved. 1 Service LED
First charging 2 Temperature LED
state LED lights 3 Charging state LED
up red: drive to
> 2 - 10
the charging
station
immediately
00-14 50988012057 EN - 12/2017

Charging state
Display Comment
(%)
> 10 - 20
> 20 - 30
> 30 - 40
> 40 - 50
> 50 - 60
> 60 - 70
> 70 - 80
> 80 - 90
> 90 - 100
.
Service LED
If the service LED (1) lights up, battery function
is significantly restricted or operation is not
possible. The service LED goes out as soon
as the fault is no longer present.
Temperature LED
The temperature LED (2) indicates an increased
battery temperature. Battery power is reduced or
switched off. The temperature LED remains
active for the run-on time or until the normal
temperature range is reached again.
LED status Temperature Result

Slightly
Power
Flashing yellow increased (>
reduction
60°C)
Increased (>
Solid yellow Shut-off
65°C)
Significantly
Flashing red increased Shut-off
(> 70°C)
Greatly
Solid red increased Shut-off
(> 75°C)
.
50988012057 EN - 12/2017 00-15

Battery management system (BMS)
1. Technology compartment 2. Battery tray

BMC Battery controller CSC Battery module controllers
BCM Brake chopper module
3. Interfaces
CVS Current/voltage sensor
X34 Communication plug
CS Shock sensor and battery display
X33 Diagnostic connector
SSV Control voltage supply
The battery management system (BMS) contains • Operating the battery module via the internal
various controllers that communicate with one CAN bus
another via CAN bus systems. The battery • Permanent Balancing
controller (BMC) is the main processor in this
system. Each battery module has its own battery The BMS contains independent CAN bus sys-
module controller (CSC). The BMS is powered by tems for data transfer between the controllers
the battery itself. and for communication with the truck.
Tasks of the battery controller (BMC) Internal CAN bus (CAN 2.0, 500 kB/s)
• Controlling and monitoring all battery functions • A CAN star circuit connects the controllers in
the technology compartment
• Communicating with the truck
• A CAN series circuit connects the battery
• Collecting all battery data and formatting it for
module controllers in the battery tray
the truck
• Recording all operating and diagnostic data External CAN bus (CANopen, 500 kB/s)
relating to the battery • Communication with the truck
• Processing the data supplied by the truck
Task of the battery module controllers (CSC):

• Monitoring the individual battery cells in a
battery module
• Sending data to the BMC and retrieving data
from the BMC
00-16 50988012057 EN - 12/2017

Service 01
Maintenance and repair

Service plan
Every 3 months
NOTE
• Fully charge the battery
The lithium-ion battery requires no special mai-
Every 1000 hours / every year
ntenance work. However, there are some tasks
outside the service plan that must be taken into • Visually inspect all components
account. • Visually inspect the labelling points (marking
and adhesive label)
At delivery and after 40 days in storage
• Visually inspect the tray lid and battery tray for
• Fully charge the battery damage
Regular tasks • Check the strength of the power connection
• Clean the battery pins
• Check the battery connections and battery • Check the strength of the battery male connec-
cables tor and cables
• Visually inspect the covers • Check the strength of the diagnostic connector
• Charge the battery
Cleaning the battery
DANGER – Cleaning electrical system parts with water is

forbidden!
Dangerous electrical voltage!
– Do not wear jewellery or metal objects when working – Do not spray electrical components or their
directly on batteries. covers directly with water.
CAUTION
CAUTION
Risk of fire!
Risk of short circuit!
Flammable fluids can be ignited by hot components.
The battery is located in an enclosed
– Do not use flammable fluids for cleaning.
and splash-proof battery tray. Excessive
water pressure or water and steam that – Follow the instructions of the cleaning material
are too hot can damage components. manufacturer.
Water ingress can cause a short circuit – Never clean brake resistors with cleaning materials,
and damage the battery. only clean them of dust without applying liquids.
– Always switch off the electrical system before Lithium-ion batteries do not require any special
cleaning. maintenance work. Regular cleaning according
to usage is recommended.
– Make sure that all openings of the battery that
can be closed are closed correctly. – Switch off the industrial truck and secure it
against being switched back on.
– Only use high-pressure cleaners with a
maximum output power of 50 bar and at a – Clear access to the battery in the industrial
maximum temperature of 85°C. truck.
– When using high-pressure cleaners, make – Check the condition of the connections.
sure there is a distance of at least 20 cm – When cleaning, wear protection goggles and a
between the nozzle and the object being dust mask if required.
cleaned.
– Blow out dust and dirt with low-pressure
– Do not aim the cleaning jet directly at adhesive compressed air or a vacuum cleaner.
labels or decal information.
50988012057 EN - 12/2017 01-1

01 Service
Operating materials
Tools, insulated up to 1000 V
DANGER
Risk to life due to short circuit.
– Do not use tools with damaged or worn insulation.
– Use only genuine bits with a maximum length of
25 mm.
– Do not use a tool if the bit locking system is loose.
Bits could fall out of the support mounting and cause
a short circuit between live components.
Designation Part number

Service case with tools insulated up to 1000 V, fully equipped 0009416021
1 Torque wrench, insulated, reversible, 3/8", 2.5–25 Nm 0009419915
2 Reversible ratchet, insulated, 3/8", 32-tooth 0009419916
3 Extender for socket, insulated, short, 3/8", 125 mm 0009419917
4 Extender for socket, insulated, long, 3/8", 250 mm 0009419918
5 Socket, insulated, 3/8", 7 mm 0009419919
12 Hexagon hole screwdriver, insulated, 2.5 mm 0009419926
13 Hexagon hole Allen key, insulated, 3 mm 0009419927
18 Open-ended spanner, insulated, 10 mm 0009419932
19 Open-ended spanner, insulated, 17 mm 0009419933
20 Long-nosed pliers, insulated, 230 mm 0009419934
21 Tweezers, insulated, bent, 11.5 mm 0009419935
22 Extender for bit, insulated, short, 3/8", 125 mm 0009419936
23 Extender for bit, insulated, long, 3/8", 250 mm 0009419937
24 Bit set for hexagon hole and Torx, 24-piece 0009419938
25 Insulated grommet with clamping cap, 17.5 mm, x4 0009419939
26 Insulated grommet with clamping cap, 26 mm, x4 0009419940
.
01-2 50988012057 EN - 12/2017

Service 01
Operating materials
Personal protection equipment (PSA)

Electricians' protective gloves in line with EN 60903:2003 or CEI 60903:2003 (gloves made from natural
rubber)
A half-yearly visual inspection is specified for class 00
Size 08 7654200078
Size 09 7654200079
Size 10 7654200080
Size 11 7654200081
Protective visor in accordance with EN 50365 Acquire independently
Lithium-ion workwear. Protection against sparks and welding spatter See STILL catalogue
.
Special tool for lithium-ion technology

STILL multimeter, including measurement leads 0009418737
2-pole voltage detector, e.g. DUSPOL-analog Acquire independently
Adhesive labels, service seals 50984391300
Insulating mat 80 x 120 cm Acquire independently
Protection against contact for positive rail in the technology compartment,
Number not yet known
insulated
SSV-Dongle 0009750855
Module removal tool Number not yet known
Kit module packaging Number not yet known
Balancing-Tool Number not yet known
.
50988012057 EN - 12/2017 01-3

01 Service
Operating materials
Attaching/removing the lifting tool

Attaching
– Insert the lifting tool (1) with the detent cams
under the socket head screws (4) and into the
bores (3) of the module.
– Slide the lifting tool so that the rear latches
engage with the slots (2).
NOTE
The detent cams underneath the socket head

screws (4) each have a recess. When they are
moved into the bores, the detent cams engage
under the module plate.
– Push the locking plate (6)outwards into the
recess of the surrounding crosspiece.
NOTE
The locking plate prevents the movement of the

lifting tool, therefore preventing the latches and
indexing bolt from slipping out of the module.
– Insert the Perspex plate with the eye bolt (7)
into the lifting tool.
The locking plates are now fixed in place and the
lifting tool is firmly attached to the module.
– Attach the hoist to the module and to the
bracket (8) of the lifting tool.
Removing
– Remove the Perspex plate with the eye bolt (7)
from the lifting tool.
– Push the locking plate (6) inwards from the
recess of the all-round lip.
– Push the lifting tool away from the rear engage-
ment slots (2) until the detent cams under the
socket head screws (4) hook onto the bores (3)
and the rear latches are exposed.
– Remove the lifting tool (1) from the module.
01-4 50988012057 EN - 12/2017

Service 01
Battery charge
Battery discharge
Cell voltage Status of the battery

The charging state of the battery is
100%
The last LED lights up red:
Connect the charger
The charging state of the battery is >2%
immediately
to 10%
The last LED flashes red:
3.0 V The charging state of the battery is <2%
It is no longer possible to drive the truck. Deep discharge begins from
The battery display is OFF. The service 3.0 V
LED lights up red Battery discharge takes
The control voltage supply unit (SSV) approximately 8 to 10 days
2.97 to 2.28 V has switched off the BMC. It is still possible to charge
It is still possible to establish CAN bus the battery using the charger
communication between the battery and
the charger
Battery discharge takes
The battery display and the LEDs are approximately 87 days
OFF. The battery must be put back
2.28 V to 2.0 V
It is not possible to establish CAN bus into service by a service
communication with the charger technician qualified to work
with high-voltage equipment.
Battery discharge takes
approximately 10 days
The battery or cells are deeply dis-
2.0 V to 1.5 V The battery can only be
charged
put back into service by the
manufacturer.
The battery is broken. It may
Below 1.5 V Battery cell damage be possible to replace faulty
cells.
The battery management system (BMS) is pow- eight to ten days for the battery to self-discharge
ered by the battery itself. The BMS cannot be from 3 V to 2.28 V.
switched off. For this reason, the battery dis-
After a further 87 days, the battery will have
charges slowly but continuously even while it is in
discharged to approximately 2.0 V. Deeply
storage.
discharged lithium-ion batteries may only be
The discharge limit is 3.0 V, which corresponds charged by service technicians who are quali-
to a battery capacity of < 2%. Discharging the fied to work with high-voltage equipment. The
battery below the discharge limit is known as technology compartment of the battery must be
deep discharging. opened for charging.
The control voltage supply unit (SSV) switches After another ten days, the cell voltage falls below
off the lithium-ion battery at 2.97 V. CAN bus 2.0 V. The battery can now only be put back into
communication between the battery and the service by the battery manufacturer. Irreparable
charger can still be established until the level cell damage occurs when the cell voltage falls to
reaches 2.28 V. The customer can charge the 1.5 V.
battery using the charger. It takes approximately
50988012057 EN - 12/2017 01-5

01 Service
Battery charge
Course of action for a deeply

discharged battery
Battery charging performed by the customer
Truck status:
• The truck is switched off and cannot be
switched on.
• The battery display is off.
• The service LED on the battery lights up red.
• The control voltage supply unit (SSV) of the
battery is switched off.
• Communication with the battery via diagnostic
connector X33 is possible.
• The battery is able to establish communication
with the charger.
– Park the truck securely.
– Disconnect the battery male connector.
– Connect the charger to the battery.
The charging process starts automatically. The
No control voltage warning message
appears in the display on the charger.
NOTE
The battery male connector must not be discon-

nected before the charger has completed the
charging process or before the STOP button on
the charger has been pressed.
– If the charging process does not start automat-
ically, pull out the battery male connector and
wait 5 minutes.
Usually, the battery master controller (BMC)
changes back to the quiescent state during this
time. The quiescent state is not visible.
– Connect the charger again.
Battery charging performed by an authorised

service technician
Requirements:
• The truck is switched off and cannot be
switched on.
• The battery display is off.
• The service LED on the battery does not light
up.
• Communication with the battery via the diag-
nostic connector X33 is not possible.
• The battery is not able to establish communi-
cation with the charger.
– Park the truck securely.
01-6 50988012057 EN - 12/2017

Service 01
Battery charge
– Disconnect the battery male connector.

– Check for control voltage at the battery male
connector.
If there is a control voltage at the battery male
connector, the battery has a different fault. The
battery is not deeply discharged.
If there is no control voltage at the battery male
connector, you may continue with the remaining
work steps:
– Carry out an insulation measurement.
– Check the battery voltage at the battery male

connector.
If there is a battery voltage at the battery male
connector, this means that the contactors are
jammed. The battery has a different fault.
If there is no battery voltage at the battery male
connector, you may continue with the remaining
work steps:
DANGER
Touching live components can lead to an electric
shock, which can have thermal or paralysing effects.
– Wear personal protective equipment.
– Use insulated tools.
– Open the maintenance cover of the technology

compartment.
– Remove the fuse F2 from the fuse holder (1).
– In the technology compartment, measure the
battery voltage between the main fuse F1 and
battery negative.
UNominal UMeasured
48 V 26 to 39 V
80 V 48 to 72 V
If the value measured is UNominal, the battery

has a different fault. The battery is not deeply
discharged.
If the value measured is UMeasured, you may
continue with the remaining work steps:
50988012057 EN - 12/2017 01-7

01 Service
Battery charge
– Depending on the battery group, it may be

necessary to remove components in order
to make the plug X52 on the control voltage
supply unit (SSV) accessible.
– Disconnect the plug X52 from the control
voltage supply unit (SSV).
X52
– Attach the SSV-Dongle(4) to the plug X52 on

the cable harness.
The SSV-Dongle bridges Pin 2 and Pin 4. 4
– Insert the fuse F2 back into the fuse holder (1).
01-8 50988012057 EN - 12/2017

Service 01
Battery charge
– Check the function of the battery master

controller (BMC). The blue LEDs and the white
LEDs must be flashing.
The battery master controller (BMC) is active
again. The battery display is on.
– Connect the battery to the charger. The
charging process starts automatically.
NOTE
In some cases, the charging process stops again

after a few seconds. In this case, the battery
male connector must be disconnected from the
charger.
• Wait until all LEDs on the BMC have gone out.
The BMC is in the quiescent state.
• Now connect the charger again. This process
can be repeated up to five times.
If the charging process does not start automati-
cally, then there is a serious fault. The battery can
neither be charged on site nor repaired. Read out
any error messages that appear on the charger.
NOTE
The battery male connector must not be removed

during the charging process. The charging
process may only be terminated prematurely
via the STOP button on the charger.
Charge the battery until at least three green bars
light up in the battery display. This is equivalent to
a charging state (also known as state of charge,
or SOC) of > 20%.
– End the charging process. Press the STOP
button on the charger.
– Disconnect the battery from the charger.
50988012057 EN - 12/2017 01-9

01 Service
Battery charge
– Remove the fuse F2 from the fuse holder (1).
– Disconnect the SSV-Dongle (4) from the plug

X52 on the cable harness.
– Connect the plug X52 to the control voltage 4
supply unit (SSV).
– Insert the fuse F2 back into the fuse holder (1).

Removing the fuse F2 interrupts the power supply
to the components. Even after the fuse F2 has
been re-inserted, the battery master controller
remains in the quiescent state. A reset must
be carried out to wake up the battery master
controller.
01-10 50988012057 EN - 12/2017

Service 01
Battery charge
– Press the reset button (5) on the control

voltage supply unit (SSV).
The batter master controller is active again. The
battery display is on.
– Check the function of the battery master

controller. The blue LEDs and the white LEDs
must be flashing.
– Reinstall all components that needed to be
removed based on the battery group back into
the technology compartment.
– Put the maintenance cover back in place to
close off the technology compartment.
The personal protective equipment can now be
removed.
– Connect the charger to the battery.
The charging process starts automatically.
NOTE
The battery male connector must not be removed

during the charging process. The charging
process may only be terminated prematurely
via the STOP button on the charger.
– If the charging process does not start automat-
ically, pull out the battery male connector and
wait 5 minutes.
Usually, the battery master controller (BMC)
changes back to the quiescent state during this
time.
– Connect the charger again.
If the charging process does not start again, there
is a serious fault. The battery can neither be
charged on site nor repaired.
50988012057 EN - 12/2017 01-11

01 Service
Function checking
Checking that the battery male
connector is de-energised
Measuring equipment
• 2-pole voltage detector
Measuring at the battery male connector

– If the battery is still in the truck, disconnect the
battery male connector.
Battery voltage is present at the pilot contact
(Batt+) even after the battery male connector has
been disconnected.
– Disconnect the plug X34 on the battery.
– Measure from the pilot contact (Batt+) to
the negative terminal (-) of the battery male
connector.
Test result: 0 V; no electrical voltage is present.
– Measure from the positive terminal (+) to

the negative terminal (-) of the battery male
connector.
Test result: 0 V; no electrical voltage is present.
If there is a battery voltage at the battery male
connector, this means that the contactors are
jammed.
CAUTION
If battery voltage is present at the plug, the contactors
are not open. The contactors are jammed.
– All subsequent work on the battery must be perfor-
med by a service technician qualified to work with
high-voltage equipment.
01-12 50988012057 EN - 12/2017

Service 01
Function checking
Insulation testing the lithium-ion

battery
Measuring equipment
• STILL MetraHit ISO multimeter
Test values
Recommended Nominal voltage
Component Measurements Test values
test voltage UBatt
24 volts
Batt+
Battery 500 VDC Battery tray 48 volts 2.8 GΩ to 1 MΩ
Batt-
80 volts
.
Performing battery measurements

– If the battery is still in the truck, disconnect the
battery male connector.
– Set the measuring device to the recommended
test voltage.
– Measure from the positive terminal (L+) of the
battery to an electrically conductive point on
the battery tray.
– Measure from the negative terminal (L-) of the
battery to an electrically conductive point on
the battery tray.
NOTE
The bare screws on the cover of the technology

compartment are suitable conductive points.
DANGER
The insulation resistance measured is below 1 MΩ.
The battery is unsafe and must not be used again.
Switch off the battery. Contact the authorised service
centre immediately.
50988012057 EN - 12/2017 01-13

01 Service
Function checking
01-14 50988012057 EN - 12/2017

Battery group 2.1 21
Design BG 2.1
Technical data for battery group
2.1
Parameter Unit Value

Cell connection Serial/parallel 13 / 4
Nominal energy kWh 13.1
Nominal capacity Ah 268
Nominal voltage V 48.75
Final charged voltage V 53.6
Final discharged voltage V 35.1
Discharge current (maximum) A 400
Discharge power (maximum) kW 18
Dimensions and weights Unit Value

Length mm 1030
Width mm 529
Height mm 350
Weight kg 850
Safety
Protection class IP6K9K
Fire protection rating External housing/13S cell module A2/B2
.
50988012057 EN - 12/2017 21-1

Design BG 2.1
Diagnostic set-up
The diagnostic connector can be used to enter
and read out battery data with a laptop and the
diagnostic program.
– Unscrew the lid (2) in an anti-clockwise
direction.
– Connect a laptop to the diagnostic
plug X33 (1).
NOTE
After completing diagnostics, screw the lid (2)

back onto the diagnostic connector (1). This
prevents the ingress of moisture.
NOTE
The diagnostics can also be accessed via the

diagnostic connector of the truck while the battery
is still installed. If the battery is in the truck, the
battery male connector must be disconnected
from the truck in order to carry out diagnostics.
21-2 50988012057 EN - 12/2017

Design BG 2.1
Design - Battery group 2.1
50988012057 EN - 12/2017 21-3

Design BG 2.1
1 Metal rail 6 Technology compartment

2 Tray cover 7 Maintenance cover
3 Module cover 8 Brake resistor
4 Module holder with positive/negative power 9 Connections for power, communication and
connector diagnostics
5 Front weight package 10 Tray
Technology compartment - Battery group 2.1
A Power cables H Main fuse

B Auto plug-in fuse I Contactor assembly
C Battery master controller (BMC) J Diagnostic plug X33
D Control voltage supply unit (SSV) K Communication plug X34
E Voltage transformer (DC/DC) L Positive power connection (+)
F Pressure compensation element M Negative power connection (-)
G Brake chopper module (BCM)
21-4 50988012057 EN - 12/2017

De-energised state BG 2.1

Measuring the insulation resis-
tance
The insulation measurement steps described
below must be carried out on the battery before
and after any repair work.
DANGER
Special tools
• Personal protective equipment
• Insulation measuring device
Measuring the insulation resistance

– Disconnect the battery male connector from
the industrial truck.
– Set the insulation tester to U = 500 V DC.
During the test, the BMS must be connected
and the contactors must be open (perform the
insulation testing anyway if the contactors are
stuck).
– Connect the insulation tester to an unpainted
socket head screw (1) on the maintenance
cover (2), and to the negative terminal of the
truck plug (3).
– Measure the insulation resistance.
The insulation resistance (Riso) must be > 1 MΩ.
cover (2), and to the positive terminal of the
truck plug (3).
50988012057 EN - 12/2017 21-5

De-energising the technology

compartment
DANGER
Special tools
• Hexagon socket wrench AF 4
• Fuse puller
• Torque wrench AF 15
• Two-pole voltage detector in line
with DIN VDE 0682-401:2011-02
(DIN EN 61243-3)
• Insulating mat in accordance with DIN VDE
0682-511 [EN/IEC 61112], 1000 V
• Safety device (part number: 0009418815)
Removing the front module cover

– Measure the insulation resistance, see the
section entitled "Measuring the insulation
resistance".
– Remove the power cable, see the section
entitled "Removing/installing the power cable".
– Remove the tray cover; see the section entitled
"Removing/attaching the tray cover".
– Mask the lift hole on the front module cover (1).
21-6 50988012057 EN - 12/2017

– Unscrew the M10x20 screws (1).

– Remove the adhesive label from the lift hole.
WARNING
Risk caused by lifting heavy loads!
Manual lifting and handling is permitted only up to a
maximum weight of 25 kg.
– Use a suitable hoist or transport vehicle for items
above 25 kg.
– Remove the front module cover (2).

Weight: 10.5 kg
– Cover live parts in the battery tray (2) with an

insulating mat (1).
Pulling out auto plug-in fuse F2

WARNING
When pulling out a fuse that is connected to a live
voltage, a small arc fault may occur.
– Remove the fuse using a fuse puller.
– Pull out the auto plug-in fuse F2 (1).
50988012057 EN - 12/2017 21-7

Opening the technology compartment

WARNING
above 25 kg.
– Remove the maintenance cover (2).

Weight: 9 kg
Removing the main fuse

DANGER
Voltage is still present at the positive fuse input.
– Pull out the protective caps (if present) (1).

– Unscrew the M10x20 ratchet screws (2)
– Remove the main fuse (3).
DANGER
Prevent accidental touching or short-circuiting of the
input side of the main fuse, which is still live.
– When making repairs in the technical compartment
of the battery, the insulated safety device must be
attached after removing the main fuse.
21-8 50988012057 EN - 12/2017

– Cover the conductor rail (1) with the safety

device (2).
Checking that the technology

compartment is de-energised
DANGER
– Touch the two-pole voltage detector to the

CVS negative (3) and the positive fuse input
(1).
Test result: electrical voltage present.
– Test the two-pole voltage detector on the CVS
negative (3) and the positive fuse output (2).
Test result: no electrical voltage present.
It is now safe to replace the components in the
technology compartment.
Restoring operating status
DANGER
50988012057 EN - 12/2017 21-9

Special tools
• Fuse puller
• Two-pole voltage detector in line
with DIN VDE 0682-401:2011-02
(DIN EN 61243-3)
Installing the main fuse

– Remove the safety device (2) from the conduc-
tor rail (1).
– Fit the main fuse (3).

– Tighten the M10x20 ratchet screws (2).
Tightening torque: 18 Nm
– Fit the protective caps (if available) (1).
21-10 50988012057 EN - 12/2017

Closing the technology compartment

WARNING
above 25 kg.
– Fit the maintenance cover (2).

Weight: 9 kg
– Tighten the M6x10 screws (1) crosswise.
Inserting auto plug-in fuse F2

– Insert the auto plug-in fuse F2 (1).
NOTE
If the SSV does not start automatically after

reinserting the auto plug-in fuse F2, the SSV
must be restarted manually. To do this, press the
reset button on the SSV.
– Remove the insulating mat (1) from the battery

tray (2).
50988012057 EN - 12/2017 21-11

Assembling the front module cover

WARNING
above 25 kg.
Weight: 10.5 kg
– Place the front module cover in position and
mask the lift hole (1).
– Tighten the M10x20 screws (1).

– Remove the adhesive label from the lift hole.
– Fit the tray cover; see the section entitled
"Removing/fitting the tray cover".
– Fit the power cable; see the section entitled
"Removing/installing the power cable".
– Measure the insulation resistance; see the
resistance".
21-12 50988012057 EN - 12/2017

Components BG 2.1
Tray cover - Battery group 2.1
Unit Value
Length mm 1030
Width mm 529
Height mm 22
Screw joint Piece 25
NOTE
The different types of cover design are not inter-

changeable.
1 Battery tray cover

2 Bore for cover screw joint
3 Recess for lifting eyes
4 Duct for battery cable
5 Cover seal
Removing/fitting the tray cover

Special tools required:
Removing
resistance".
– Remove the power cable and communication
cable (3); see the section entitled "Remov-
ing/installing the power cable".
– Unscrew the M6x25 socket head screws (1)
along with the washer.
– Repeat the procedure on the opposite side of
the cover.
– Unscrew the M6x25 socket head screws (2).
the cover.
– Remove the cover rail (4).
– Lift off the tray cover (5).
– Take care not to damage the seal on the
underside of the tray cover when lifting off
the tray cover.
50988012057 EN - 12/2017 21-13

Components BG 2.1
Fitting
Before fitting the tray cover, make sure:
• The cover seal is in perfect condition and is
positioned correctly in the seal groove on the
underside of the tray cover
• The cable inlet of the tray cover is located
above the cable channel for the power and
communication connections
• The sealing face of the battery tray is clean and
free of objects
– Place the tray cover (5) in position.
– Make sure that the tray cover fits flush all
around and that there is nothing lodged
between the cover seal and the sealing face of
the battery tray.
CAUTION
Such objects may cause damage to the component or
leakage around the tray cover.
If the mounting screws are tightened unevenly, this
may distort the tray cover and cause the cover seal to
leak.
– First, tighten all mounting screws by hand until the
screw heads are seated.
– Always start by tightening the centre mounting
screws and work outwards from there.
– Observe the different tightening torques.
– Screw in the M6x25 socket head screws (1)

along with the washer.
the cover.
– Place the cover rail (4) in position.
– Screw in the M6x25 socket head screws (2).
the cover.
– Starting from the middle and working out-
wards, tighten the M6x25 socket head
screws (2).
– Starting from the middle and working out-
wards, tighten the M6x25 socket head
screws (1).
– Install the power cable and communication
cable (3); see the section entitled "Remov-
ing/installing the power cable".
21-14 50988012057 EN - 12/2017

Components BG 2.1
Battery display
1
Charging state LEDs
charging.
Charging state
Display Comment
(%)
First charging
state LED
flashes red: 3 2
0-2
the truck can
386_609-007
no longer be
up red: drive to
> 2 - 10
the charging
station
immediately
> 10 - 20
> 20 - 30
> 30 - 40
> 40 - 50
> 50 - 60
> 60 - 70
> 70 - 80
> 80 - 90
> 90 - 100
.
Service LED
Temperature LED
50988012057 EN - 12/2017 21-15

Components BG 2.1

Slightly
Power
reduction
60°C)
Increased (>
65°C)
Significantly
(> 70°C)
Greatly
(> 75°C)
.
Removing/installing the battery

display
DANGER
– De-energise the system.

• Personal protective equipment (PSA)
Removing
– Ensure that the electrical system is de-ener-
gised; see the section entitled "De-energising
the system".
– Disconnect the plugs X1 (1) and X2 (2) and the
battery display/display electronics connecting
cable (3).
along with the lock washer.
– Remove the display electronics (4).
21-16 50988012057 EN - 12/2017

Components BG 2.1

– Push the cradle (2) inwards along with the
battery display (1) and remove these compo-
nents.
– Disconnect the battery display/display elec-

tronics connecting cable (3) from the battery
display (1).
– Leave an intact seal (2) on the battery display,
do not remove it.
CAUTION
Damage to the seal may occur.
The seal is attached to the battery display with its own
adhesive strip. If the strip is pulled off, the seal may be
damaged or destroyed, and the adhesive strip will lose
its adhesive properties. Remove the seal only if it is
damaged and a new seal is available for fitting.
– Leave an intact seal on the battery display.
– If the seal has been removed or damaged, replace
it with a new seal.
Installing
the system".
When reinstalling a battery display that has pre-
viously been removed, the following procedure
must be followed:
50988012057 EN - 12/2017 21-17

Components BG 2.1
– Check that the battery display seal (2) is

undamaged and can be reused. If not, then
the seal must be replaced with a new seal.
When replacing a battery display that has pre-
viously been removed, the following procedure
must be followed:
– Pull off the protective film from the front of the
new battery display (1).
– Pull off the protective film from the adhesive
backing of the new seal (2).
– Position the new seal at an even circumference
on the front face of the battery display and
press the seal gently onto the glass casing.
– Connect the battery display/display electronics
connecting cable (3) at the back of the battery
display (1).
– Push the cradle (2) along with the battery
display (1) and adhesively bonded seal into
the recess.
– Screw on the M4x6 socket head screws (3)
Tightening torque: 2.5 Nm
– Align the display electronics (4) with the plug

connections (1, 2) facing upwards on the tray
wall.
– Route the battery display/display electronics
connecting cable (3) upwards between the
display electronics (4) and the tray wall.
– Connect the battery display/display electronics
connecting cable to the plug connection (6).
– Screw on the M4x10 socket head screws (5)
– Connect the plugs X1 (1) and X2 (2).
– Restore operating status; see the section
entitled "Restoring operating status".
21-18 50988012057 EN - 12/2017

Components BG 2.1
Schocksensor
G
Der Schocksensor teilt sich die Platine mit dem
(m/s²)
Display und ist mechanisch starr an den Batteri-
etrog angebunden.
Ein Schockereignis während der Ruhephase
(Lagerung oder Transport) wird ebenfalls reg- 15 G
istriert und gespeichert.
10 G
Batterie im Flurförderzeug verbaut
Schocklevel Reaktion
t
Ergebnis wird nicht
≤ 10 G im Fehlerspeicher der (min)
Batterie gespeichert. 386_609-012
Speichern des
Ereignisses im
Fehlerspeicher der
Batterie,
10 G - 15 G Senden von CAN-
Nachricht an das
Fahrzeug,
Reduzierung der
Fahrgeschwindigkeit
Starten der Batterie
nicht möglich,
>15 G
Reset durch
Servicetechniker nötig.
Transport der Batterie

nicht möglich,
Reset durch
>15 G Servicetechniker nötig.
Fehler kann über
die Diagnose nicht
zurückgesetzt werden.
.
50988012057 EN - 12/2017 21-19

Components BG 2.1
Pressure compensation element 1

The pressure compensation element is part of
the safety concept of the battery system.
In normal operation, the membrane (3) equalises
internal and external pressures.
The pressure cap (2) is connected to the hous-
ing (1) by a bayonet catch. If a critical over pres-
4
sure (4) is reached, the pressure cap is pushed 2
from the housing and the over pressure escapes.
386_691-024
1 Housing
2 Pressure cap with bayonet catch
3 Membrane
4 Pressure "P"
Visual inspection
DANGER

resistance".
– Unscrew the M6x10 screws (1) from the
maintenance cover (2).
– The pressure compensation element (3) is
located behind the maintenance cover.
21-20 50988012057 EN - 12/2017

Components BG 2.1
– Check that the pressure cap (1) is securely

attached.
Pressure cap secure:
If the pressure cap is firmly seated in the bayonet
catch, no critical over pressure has occurred
within the battery.
– Place the maintenance cover (2) into the

recess in the tray.
Pressure cap loose:
If the pressure cap is loose, a critical over pres-
sure has occurred within the battery. A critical
over pressure is caused by a serious defect within
the battery. In the event of this happening, the
battery must be tested by the manufacturer and
repaired.
– Do not place the battery back in service; inform
the battery manufacturer.
Removing/installing the module

holder
NOTE
The battery modules are located in a module

holder and are not immediately accessible.
DANGER
Battery voltage is present between the POSITIVE
power connectors and the NEGATIVE power connec-
tors.
50988012057 EN - 12/2017 21-21

Components BG 2.1

• M8 lifting eyes
• Suitable harnesses
• Suitable hoist
• Insulating mats in accordance with DIN VDE
0682-511 [EN/IEC 61112], 1000 V
• Spanner AF 10
• Spanner AF 12
Removing
resistance".
– Ensure that the system is de-energised;
see the section entitled "De-energising the
system".
– Cover live parts in the battery tray (2) with an
insulating mat (1).
WARNING
above 25 kg.
– Put on personal protective equipment.

– Remove the rear module cover.
Weight: 8 kg
– Remove the insulating mat from the battery
tray.
– Loosen the M16 hexagon nuts (1) and remove
them, along with the washers, from the guide
rods.
– Screw the lifting eye into the internal thread (3)
of the tie rod.
Thread size: M8
– Remove the weight package (2) from the
battery tray by hooking it onto a suitable hoist
using the lifting eye (3).
Weight: approx. 100 kg
21-22 50988012057 EN - 12/2017

Components BG 2.1
– Loosen the M12x30 clamping bolts (1).
– Remove the protective cap and unscrew the

M6x20 hexagon head screw (1) (negative
power connector).
– Unscrew the M8 self-securing nut (2) from the
decoupler threaded bolt.
– Unscrew the M10x25 mounting screws (1)

from the module holder.
50988012057 EN - 12/2017 21-23

Components BG 2.1
– Screw the lifting eyes into the module holder

(1).
DANGER
Voltage is present between the POSITIVE power
connectors and the NEGATIVE power connectors.
– Secure the POSITIVE power connector against
inadvertent contact.
– Secure the positive power connector (3)

against inadvertent contact.
WARNING
above 25 kg.
– Lift the module holder (1), along with the

negative power connector (2) and the positive
power connector (3), out of the battery tray.
Weight of module holder including modules:
approx. 200 kg
– Place the module holder (1) on a suitable
surface, e.g. a europallet.
Installing
DANGER
Battery voltage is present between the POSITIVE
power connectors and the NEGATIVE power connec-
tors.
WARNING
above 25 kg.
21-24 50988012057 EN - 12/2017

Components BG 2.1
– Screw the lifting eyes into the module holder

(1).
– Place the module holder (1), along with the
negative power connector (2) and the positive
power connector(3), in the battery tray.
Weight of module holder including modules:
approx. 200 kg
– Remove the device securing against inadver-
tent contact from the positive power connector
(3).
– Tighten the M6x20 hexagon head screw (1)

(negative power connector) and attach the
protective cap.
– Screw the M10 self-securing nut (2) to the
decoupler threaded bolt.
– Tighten the M10x25 mounting screws (1) of

the module holder.
50988012057 EN - 12/2017 21-25

Components BG 2.1
– Tighten the M12x30 clamping bolts (1).

Tightening torque of the clamping bolt: 10 Nm
Tightening torque of the lock nut: 40 Nm
WARNING
above 25 kg.
– Place the weight package (2) into the battery

tray by hooking onto the M8 lifting eye(3).
Weight: approx. 100 kg
– Secure the M16 nuts (1), along with the
washers, to the guide rods.
– Unscrew the lifting eye from the internal thread
of the tie rod (3).
– Place the module covers (1) on the battery

tray.
21-26 50988012057 EN - 12/2017

Components BG 2.1
Removing/installing the positive

power connector
DANGER
Voltage is present at the positive power connector.
Removing
– Remove the module holder; see the section
entitled "Removing/installing the module
holder".
(x18).
– Remove the front module guide plate (2).
50988012057 EN - 12/2017 21-27

Components BG 2.1
– Disconnect the plugs (1) from the plug connec-

tions of the respective modules and pull out the
CAN bus cable (2).
NOTE
The positive power connector is inserted into

the module connecting plug and can easily be
removed without using any further tools.
– Pull the positive power connector (3) together

with the plugs (2) forwards out of the plug
connections (1) on the modules.
Installing
– From the front, plug the positive power con-

nector (3) together with the plugs (2) into the
plug connections (1) on the modules.
21-28 50988012057 EN - 12/2017

Components BG 2.1
– Insert the CAN bus cable (2) into the adjoining

plug connections (1) of the adjacent modules.
– Insert the terminating resistor at the cable end
of the CAN bus into the plug connection on the
module.
NOTE
The 50 Ω terminating resistor of the CAN bus

is not included in the scope of delivery for the
new battery module and must be taken from the
removed module.
– Position the front module guide plate (2) in

front of the module holder.
– Tighten the M6x12 socket head screws (1).

module
DANGER

• Lifting tool
• Spanner AF 10
50988012057 EN - 12/2017 21-29

Components BG 2.1
Removing
– Remove the positive power connector; see
the section entitled "Removing/installing the
positive power connector".
– Remove the power distributor plate (1) from
the positive side of the battery module.
WARNING
above 25 kg.
– Fit the lifting tool to the relevant battery mod-

ule(1) and pull the module forwards out of the
module holder.
Battery module weight: approx. 30 kg
– Set the battery module down, ensuring that it
is stable.
– Remove the lifting tool.
Installing
NOTE
After installing a new battery module, pack the

old battery module that you have removed in the
packaging used to deliver the new battery module
to ensure that it can be safely transported back to
the battery module manufacturer.
– Fit the lifting tool.
WARNING
above 25 kg.
21-30 50988012057 EN - 12/2017

Components BG 2.1
– Bring the battery module to the battery tray and

lift it until the battery module (1) is positioned
horizontally in front of the battery tray.
– Push the battery module into the module
holder from the front.
The centring pins (1) in the battery tray ensure

that the plug for the negative power connector (2)
engages securely in the plug connection on the
underside of the battery module.
The centring holes (2) on the underside of the

battery module ensure that the plug connection
for the negative power connector (1) engages
securely in the plug in the battery tray.
– Check the position in which the respective
plug of the negative power connector and the
centring pins in the battery tray can be seen.
– Carefully push the battery module horizontally
into the tray until it sits firmly in the module
holder.
– Make sure that the battery module engages
securely and is centred in the installation
position.
– Remove the lifting tool.
50988012057 EN - 12/2017 21-31

Components BG 2.1
– Place the power distributor plates (1) on the

battery modules.
– Install the positive power connector; see
– If a defective battery module has been re-
placed, pack the defective battery module in
the battery module packaging.
CAN bus terminating resistor (120

Ω)
The CAN bus is equipped with a terminating
resistor (120 Ω). The terminating resistor is
plugged into the last plug connector on the
CAN bus. Uninterrupted operation cannot be
guaranteed without a terminating resistor.
– Pull the terminating resistor (1) out from the
plug connection on the removed module.
– Place the terminating resistor (1) at the cable
end of the CAN bus into the plug connection on
the new module.
21-32 50988012057 EN - 12/2017

Technology compartment BG 2.1

Opening/closing the technology
compartment
Opening
resistance".
WARNING
above 25 kg.

Weight: 9 kg
Closing
Before fitting the maintenance cover, ensure that:
• The cover seal in the battery tray wall is in
perfect condition and is positioned correctly in
the seal groove
• The sealing face of the maintenance cover is
clean and undamaged
WARNING
above 25 kg.
50988012057 EN - 12/2017 21-33

– Position the maintenance cover (2) in front of

the technology compartment.
Weight: 9 kg
– Make sure that there are no cables between
the maintenance cover (2) and the mounting
surface.
– Fit the maintenance cover.
resistance".
21-34 50988012057 EN - 12/2017

Current/voltage sensor (CVS)

The CVS measures the current and voltage
and supports the BMS in evaluating the power
requirements of the truck.
Tasks in detail:
• Measuring the battery current (Messshunt)
• Measuring the battery voltage
• Temperature measurement Messshunt
• Galvanic isolation of 48 V control voltage
supply
• Measured value transmission to BMC via CAN
Voltage measurements:
1 Battery module connection
• Measurement of voltage + modules directly 2 Battery male connector connection
after 450 A fuse (S1-) X71 Connection BMC
• Measurement of voltage after connected X72 Voltage measurement
contactor K1 (K1+)
• Measurement of output voltage after con-
nected contactor K2 (K2-)
Removing/installing the cur-

rent/voltage sensor
DANGER

• Spanner AF 10
• ISO grommet sleeve (insulated grommet,
clamping cap)
50988012057 EN - 12/2017 21-35

Removing
the system".
– Disconnect the plugs X71 (2) and X72 (3).
– Remove the protective caps (5).
– Unscrew the M6x20 hexagon head screws (4,
6).
– Remove the current/voltage sensor (1).
Securing the CVS conductor rails

– Push ISO grommet sleeves onto the positive
(1) and negative (2) conductor rails.
Removing the CVS support

– Unscrew the M6 ratchet screw (1).
– Remove the CVS support (2).
Installing
the system".
21-36 50988012057 EN - 12/2017

Installing the CVS support

– Insert the CVS support (2).
– Tighten the M6 ratchet screw (1).
Installing the current/voltage sensor
– Remove the ISO grommet sleeves from the

conductor rails.
– Insert the current/voltage sensor (1).
– Tighten the M6x20 hexagon head screws (4,
6).
– Attach the protective caps (5).
50988012057 EN - 12/2017 21-37

Brake chopper module (BCM)

Functional description
The BCM monitors battery voltage during truck
operation. If the battery voltage exceeds the
value of 53.9 V in a 48 V lithium-ion system
due to recuperation, the system is automatically
activated.
It connects a resistor in parallel with the battery
using power electronics. The resistor absorbs
the average regenerative power, which keeps
the battery voltage constant at approximately
53.7 V.
The housing of the BCM includes three LEDs.
1 Connection R+ on brake resistor (+)
These indicate the current status of the compo- 2 Connection R- on brake resistor (-)
nent independently of the BMC. 3 X42 (2-pin) connection on brake resistor NTC
temperature sensor
4 BAT- connection
5 X41 (6-pin) connection on brake resistor BMC
6 Status LED
7 BAT+ connection
Status LED
1 "enable" LED (enabled by master)

2 "ready" LED (temperature monitoring/perfor-
mance)
3 "pre-charge" LED
LED on/off BCM operating mode Function

All Off Switched off
Release available, must be performed by the
"enable" On Ready
BMC
Temperature monitoring of the NTC resistance
"ready" On Active on the brake resistor within the specified temper-
ature range
Active - is then switched
"ready" Off on the brake resistor outside the specified tem-
off
perature range
Internal pre-charging of the BCM pre-charge
"pre-charge" On Pre-charging active relay by the BMC (must be charged for 200 ms
before the main contactors close)
21-38 50988012057 EN - 12/2017

Enabled by master
The "enable" LED (1) indicates the enable
status signalled by the BMC. If the LED is
illuminated, the enable signal is present.
The BMC can disable the BCM component
depending on the truck condition/battery
status.
Temperature monitoring/performance
The BCM monitors the temperature of the
power electronics internally and monitors the
temperature of the brake resistor externally
with an additional open circuit detector. The
two temperature monitors are standardised
into a single "performance" parameter. This is
transmitted to the BMC via pulse width modu-
lation using PIN "feedback" and indicated by
the "ready" LED (2). The pulse width modula-
tion frequency is approx. 10 Hz. The LED is
illuminated constantly when the component is
performing at 100%. If the LED flashes briefly,
this indicates increased performance. If the
LED flashes slowly, this indicates decreased
performance. If performance is at 0% or if
there is a cable break in the external tempera-
ture sensor, the LED is off.
Pre-charging
The BCM has an internal pre-charge circuit
for the intermediate circuit of the BCM. Pre-
charging is controlled by the BMC. The status
of the pre-charge path is indicated by the
"pre-charge" LED (3). If the LED lights up,
pre-charging is active.
Status description
There are three internal testing and measure-
ment circuits that function independently of each
other. All measurement, detection and control is
analogue (performed without software):
• Continuous testing for line breakage of the
external temperature sensor
• Continuous measurement of the performance
electronics temperature and the brake resistor
as well as adaptation of the feedback signal
• Testing the battery voltage and generating
switching signals for the power transistors
BCM self-protection
The BMC uses the feedback signal from the BCM
to adjust the maximum permissible recuperated
power to keep the BCM system within the per-
missible temperature range. If the truck does not
adhere to this value, the BCM system switches
off automatically to protect itself.
50988012057 EN - 12/2017 21-39

Removing/installing the brake

chopper module
DANGER

• Hexagon key AF 10
Removing
NOTE
The BCM must be removed together with the

carrier plate. Otherwise, not all of the screw joints
that connect the BCM to the assembly baseplate
will be accessible.
resistance".
the system".
– Disconnect the plug for the NTC temperature
sensor at connection X42 (1).
– Disconnect the plug for the BMC signal at
connection X41 (4).
– Unscrew the socket head screw (5) from the
BAT+ connection and remove the cable from
the BMC.
– Unscrew the M10x12 (2) socket head screw.
– Remove the BCM/CVS cable (3) from the
BCM.
– Remove the BMC/negative brake resistor
cable from the BMC.
– Remove the BMC/negative brake resistor
cable (9) from the BMC.
– Remove the BMC/contactor assembly cable
(8) from the BMC.
21-40 50988012057 EN - 12/2017

– Unscrew the M6 flanged nuts (1).

– Remove the tensioning stabilisers (3).
– Remove the BCM (2) together with the carrier
plate (4).
– Remove the BCM from the carrier plate.
Installing
the system".
– Place the BCM (2) on the carrier plate (4).
– Insert the BCM together with the carrier plate.
– Fit the tensioning stabilisers (3).
– Tighten the M6 flanged nuts (1).
– Place the BCM/CVS cable (3) on the BAT-

connection.
CAUTION
Incorrect assembly can damage the battery!
Incorrectly routed cables can be crushed and cause a
short circuit.
– Route cables safely and ensure that they are held in
position.
– Tighten the M10x12 socket head screw (2).

– Place the BAT+ cable (5) on the BAT+ connec-
tion and tighten the screw.
– Place the BMC/negative brake resistor cable
on the BMC.
50988012057 EN - 12/2017 21-41


– Place the BMC/negative brake resistor cable
(9) on the BMC.
– Place the BMC/contactor assembly cable (8)
on the BMC.
– Connect the BMC signal plug to the X41
connection (4).
– Connect the NTC temperature sensor to the
X42 connection (1).
21-42 50988012057 EN - 12/2017

Brake resistor 105 mΩ

1
WARNING
Danger of burns from the hot brake resistor!
The temperature of the brake resistor can rise to
>100 °C during operation. It can take several hours
for the brake resistor to cool down to a low hazard
temperature. Thermal radiation can also affect other
components in and around the technical compartment,
which then become hot.
– Do not touch hot surfaces with bare hands.
– Wear protective gloves.
The brake resistor is used to absorb recovered

energy (braking energy) if the brake current 4 3 2
exceeds the generator voltage of the traction
motor. 386_609-001
The NTC resistor monitors the temperature and 1 Brake resistor 105 mΩ
provides feedback to the brake chopper module. 2 Connection to BCM "R-"
3 Connection to BCM "R+"
Technical data 4 Connection to contactor connectors "K1"/"K2"
Resistance value 105 mΩ
Resistance value
±10%
tolerance
Insulation resistance >50 MΩ
Operating voltage UMAX = 54 V (48 V)
Nominal voltage Unominal = 13 x 3.75 V
Final charged voltage 13 x 4.12 V
Test voltage (1 minute) UP = 1200 V DC
NTC resistance 10 kΩ
Dimensions (length / 503 mm / 100 mm /
width / height) 50 mm
.

resistor
DANGER
50988012057 EN - 12/2017 21-43

WARNING
Risk of burns from the hot brake resistor!
>100°C during operation. It can take several hours
for the brake resistor to cool down to a temperature
at which it poses a low risk. The heat can also radiate
to other components in and around the technology
compartment, which then become hot.

Removing
resistance".
the system".
– Remove the brake chopper module; see the
section entitled "Removing/installing the brake
chopper module".
from the holding plate (2).
– Remove the holding plate (2).
– Carefully remove the brake resistor (3).
CAUTION
Risk of damage as a result of the forces applied to
cable glands!
Pulling on the connecting cables can cause damage to
the cable glands of the brake resistor.
– Remove the brake resistor by pulling directly on the
cable glands.
21-44 50988012057 EN - 12/2017

Installing
– Insert the brake resistor (1) in the right-hand
side of the guide (2).
– Push the brake resistor (3) all the way in.

– Place the holding plate (2) in front of the brake
resistor.
– Install the brake chopper module; see the
section entitled "Removing/installing the brake
chopper module".
50988012057 EN - 12/2017 21-45

Battery master controller (BMC)

The BMC determines the charge and overall
condition of all the battery cells. It communicates
with the industrial truck via the CAN bus and with
the CSC via the internal CAN bus.
Tasks in detail:
• Activation of the main contactors, K1 and K2
• Monitoring of the battery modules
• Safety monitoring function of the battery
modules
• Communication with the truck control unit
• Communication with the battery display and
the shock sensor 1 LEDs (x2), BMC main processor
• Communication with the BCM 2 BMC
3 LEDs (2 pieces) BMC monitoring computer
X11 Diagnostics, CAN, contactors, BCM, SSV
X12 CSC
X13 Battery display / shock sensor
X14 Power supply
LED codes BMC

LEDs Computer BMC Operating status
Main processor and monitoring
Off Quiescent state
processor
Flashing white Ready, charging or driving
processor
Self testing, emergency opera-
Flashing white + blue Main processor
tion, error with error analysis
Malfunction (with error, including
Solid white + blue Main processor
up to shut-off 1)
Solid blue Monitoring processor Feedback signal deactivated
Normal operation, feedback
Flashes blue once Monitoring processor
signal test
.

master controller
DANGER

• Spanner AF 10
21-46 50988012057 EN - 12/2017

Removing
resistance".
the system".
– Disconnect the plugs X11 (5), X12 (4), X13 (3)
and X14 (6).
– Unscrew the M6x16 ratchet screws (1).
– Remove the battery master controller (2)
together with the carrier plate (7).
Installing
– Fit the battery master controller (2) together
with the carrier plate (7).
– Connect the plugs X11 (5), X12 (4), X13 (3)
and X14 (6).
50988012057 EN - 12/2017 21-47

Control voltage supply (SSV)

The SSV supplies the truck electrics before the
battery is switched on, and ensures a continuous
power supply to the DC/DC converter. The power
transmission path used to supply control units
with power has a 20 A fuse on the output side.
X51 - pin assignment:

• PIN 1
Blocking signal from BMC
• PIN 2
Negative

• PIN 1
Negative connection
• PIN 2
F50 20 A fuse
Battery positive connection before switch-on X51 Plug connection
contactor X52 Plug connection
• PIN 3
Control voltage to truck
• PIN 4
Battery positive connection to battery voltage
transformer
Tasks in detail:
• Supplies the truck electrics before the battery
is switched on
• Switches the power supply off after the battery
is switched off
• Switches off the battery supply voltage in the
event of under voltage
• Switches off the battery supply voltage from
BMC
• Switches off the complete power supply
• Limits the control current to the truck
• Prevents battery charging from the control
voltage (voltage feedback protection)
Removing/installing the control

voltage supply unit
DANGER
21-48 50988012057 EN - 12/2017


• Spanner AF 10
Removing
resistance".
the system".
– Remove the battery master controller (BMC);
see the section entitled "Removing/installing
the battery master controller".
– Disconnect the plug X52 (1) and the plug
X51 (2).
– Remove the control voltage supply unit
(SSV) (4).
Installing
– Insert the control voltage supply unit (SSV) (4).
– Tightening torque: 9 Nm
– Connect the plug X52 (1) and the plug X51 (2).
– Install the battery master controller (BMC); see
battery master controller".
50988012057 EN - 12/2017 21-49

Contactor assembly
When commissioning the truck, the contactors
are enabled as long as the battery is ready for
operation.
1 Contactor K1
2 Connector plug X94
3 Contactor K2
Removing/installing the contactor

assembly
DANGER

• Spanner AF 10
• Spanner AF 15
21-50 50988012057 EN - 12/2017

Removing
the system".
– Remove the protective cap (1).
– Disconnect the plug X94 (2).
Removing the connector between contac-

tor K1/contactor K2
– Unscrew the M10 flanged nut (2).
– Remove the connector between the brake
resistor/contactor bridge (4) from the threaded
bolt (2).
– Remove the connector between contac-
tor K1/contactor K2 (3) from the threaded bolt.
The electrical connection between contactor
K1 (5) and contactor K2 (6) is now broken.

tor K1/main positive connection
tor K1/main positive connection (3) from the
threaded bolt (2).
K1 (1) and the main positive connection is now
broken.
50988012057 EN - 12/2017 21-51


– Remove the protective cap and unscrew the
M10 flanged nut (3).
tor K2/main positive connection (4).
K2 (1) and the main positive connection is now
broken.
Removing the contactor bridge

– Unscrew the M6 hexagon nuts (1).
– Remove the contactor bridge (2) with contac-
tors.
21-52 50988012057 EN - 12/2017

Removing contactor K1 and contactor K2

– Remove contactor K1 (3) and contactor K2 (4)
from the contactor bridge (1).
Installing
Fitting contactor K1 and contactor K2

– Fit contactor K1 (3) and contactor K2 (4) to the
contactor bridge (1).
Installing the contactor bridge

– Place the contactor bridge (2) on the rear wall
of the technology compartment.
– Tighten the M6 hexagon nuts (1).
50988012057 EN - 12/2017 21-53

Installing the connector between contac-

– Fit the connector between contactor K2/main
positive connection (4) onto the threaded
bolts (2) at the contactor K2 (1).
bolts (3) at the main positive connection (3).
– Tighten the M10 flanged nut (3).

bolts (2) at the contactor K1 (1).
– Align the connector between contactor
K1 /positive main connection with the threaded
hole on the positive main connection.
– Tighten the M10x20 hexagon head screw (2).

tor K1/contactor K2
– Fit the connector between contactor K1/con-
tactor K2 (3) onto the threaded bolts (1) above
contactor K1 (5) and contactor K2 (6).
– Fit the connector between the brake resis-
tor/contactor bridge (4) onto the threaded
bolts (2) on the connector between contac-
tor K1/contactor K2.
21-54 50988012057 EN - 12/2017

– Connect the plug X94 (2).

– Attach the protective cap (1).
50988012057 EN - 12/2017 21-55

Voltage transformer (DC/DC)

The DC/DC voltage transformer ensures a per-
manent power supply to the BMC and the diag-
nostic interface.
• Input voltage 48 V from SSV
• 12 V output voltage
• Supply from:
BMC
CSC
CVS
Battery display / shock sensor
1 DC/DC voltage transformer

2 Plug connection
Removing/installing the voltage

transformer
DANGER

• Spanner AF 10
Removing
resistance".
the system".
21-56 50988012057 EN - 12/2017

– Disconnect the connector plug (3) from the

voltage transformer (2).
– Remove the voltage transformer (2).
Installing
– Position the voltage transformer (2) on the rear
wall of the technology compartment.
– Connect the connector plug (3) to the voltage
transformer (2).
50988012057 EN - 12/2017 21-57

Electrical fuses
Main fuse
The main fuse on the positive power distribution
side has a rating of 450 A.
1 Fuse holder
F1 Main fuse (450 A)
Control current fuses

The control current is protected by blade fuses in
the fuse holder.
1 Fuse holder
F2 BMC / SSV (20 A)
F3 CVS voltage measurement S1- (3 A)
F4 CVS voltage measurement S2+ (3 A)
F6 Pre-charging for the brake chopper (3 A)
21-58 50988012057 EN - 12/2017

Blade fuses on the SSV
1 F20
386_609-015
1 SSV
F50 Control units supply (20 A) power transmis-
sion path (output side)
Replacing electrical fuses
DANGER

• Fuse puller for auto plug-in fuse
50988012057 EN - 12/2017 21-59

Replacing the main fuse

CAUTION
Risk of damage to the contactors by triggering the main
fuse.
Triggering the main fuse may cause "short-circuit
current" that can damage the contactors.
– After the main fuse has been triggered, the contac-
tors must be replaced.

resistance".
the system".
1 Fuse holder
– Remove the protective caps (1).

– Remove the main fuse (3).
– Insert a new main fuse with the same nominal
current.
21-60 50988012057 EN - 12/2017

Replacing the control current fuses

Control current fuses in the fuse holder
resistance".
the system".
– Locate any defective auto plug-in fuses (F2-
F6) and remove them from the fuse holder (1)
using a fuse puller.
– Insert a new auto plug-in fuse with the same
nominal current.
1 Fuse holder
F2 BMC / SSV (20 A)
50988012057 EN - 12/2017 21-61

Wiring BG 2.1
Removing/installing the power
cable
DANGER

• Spanner AF 22
1 Battery male connector for the industrial truck

2 Tray cover
3 Communication connection
4 Positive power connection
5 Negative power connection
Removing
resistance".
– Unscrew the M10x47 terminal bolt (1) from the
positive power connection (6).
negative power connection (5).
– Pull out the communication plug (7).
– Pull the positive power cable (2), the negative
power cable (3) and the communication cable
(7) upwards and out of the cable channel.
Installing
(7) into the cable channel from above.
– Screw the M10x47 terminal bolt (1) along with
the positive power cable (2) onto the positive
power connection (6).
the negative power cable (3) onto the negative
21-62 50988012057 EN - 12/2017

Wiring BG 2.1
– Insert the communication plug (7).

resistance".
50988012057 EN - 12/2017 21-63

Wiring BG 2.1
21-64 50988012057 EN - 12/2017

Design BG 2.2
Technical data for battery group
2.2
Parameter Unit Value

Cell connection Serial/parallel 13 / 15
Nominal energy kWh 48.99
Nominal capacity Ah 1005
Nominal voltage V 48.75
Final charged voltage V 53.6
Final discharged voltage V 35.1
Discharge current (maximum) A 400
Discharge power (maximum) kW 18
Dimensions and weights Unit Value

Length mm 1030
Width mm 529
Height mm 627
Weight kg 839
Safety
Protection class IP6K9K
Fire protection rating External housing/13S cell module A2/B2
.
50988012057 EN - 12/2017 22-1

Design BG 2.2
Design - Battery group 2.2
1 2
11
10
9 5
8
6
7
386_691-002
22-2 50988012057 EN - 12/2017

Design BG 2.2
1 Metal rail 7 Space for power and communication connec-

2 Tray cover tions
3 Module 8 Tray
4 Technology compartment 9 Negative side power connector
5 Connections for power, communication and 10 Power cables
diagnostics 11 Positive side power connector
6 Service flap
The batteries are divided into three main assem-

blies:
• Tray structure with cover, modules and power
connector
• Power and communication connection struc-
ture
• Technology compartment and service flap
structure
Battery safety
Battery safety is ensured by the following proper-
ties:
• 25-mm steel housing
• Master controller collects measured data from
the slave controller CANs
• Two main contactors
• Main current fuse in the positive circuit
• LCD status display
• Brake resistor, brake chopper
• High-pressure relief valve on battery base
50988012057 EN - 12/2017 22-3

Design BG 2.2
Technical compartment - battery group 1.1 / 1.2
386_691-001
A Brake resistor I Contactor K2

B Brake chopper module (BCM) J Main fuse
C Current/voltage sensor (CVS) K Control current fuses
D Battery master controller (BMC) L Pressure equalising element
E Control voltage supply (SSV) M Diagnostic plug X33
F Voltage transformer (DC/DC) N Communications plug X34
G Battery display O Positive power connection (+)
H Contactor K1 P Negative power connection (-)
22-4 50988012057 EN - 12/2017


Measuring the insulation resis-
tance
The insulation measurement steps described
below must be carried out on the battery before
and after any repair work.
DANGER
Special tools

– Disconnect the battery male connector from
the industrial truck.
– Set the insulation tester to U = 500 V DC.
During the test, the BMS must be connected
and the contactors must be open (perform the
insulation testing anyway if the contactors are
stuck).
cover (2), and to the negative terminal of the
truck plug (3).
cover (2), and to the positive terminal of the
truck plug (3).
50988012057 EN - 12/2017 22-5

Spannungsfreiheit im Tech-
nikraum herstellen
DANGER
Gefährliche elektrische Spannung!
Durch Berührung stromführender Bauteile kann es zu
einem elektrischen Schlag kommen, der thermische
oder muskellähmende Auswirkungen haben kann.
– Persönliche Schutzausrüstung anziehen.
– Isoliertes Werkzeug verwenden.
Spezialwerkzeuge
• Persönliche Schutzausrüstung
• Innensechskantschlüssel SW 4
• Sicherungszieher
• Drehmomentschlüssel SW 15
• Zweipoliger Spannungsprüfer nach DIN VDE
0682-401:2011-02 (DIN EN 61243-3)
• Sicherheitsvorrichtung (Teilenummer:
0009418815)
Technikraum öffnen
– Isolationswiderstand messen, siehe Abschnitt
"Isolationswiderstand messen".
– Schrauben M6x10 (1) herausschrauben.
WARNING
Gefahr durch Heben schwerer Lasten!
Das Heben und Tragen von Hand ist nur bis zu einem
Gewicht von max. 25 kg zulässig.
– Oberhalb 25 kg geeignete Hebezeuge oder Förder-
mittel verwenden.
– Servicedeckel (2) abbauen.

Gewicht: 17 kg
22-6 50988012057 EN - 12/2017

Flachstecksicherung F2 ziehen
WARNING
Beim ziehen der Sicherung unter Spannung kann ein
kleiner Störlichtbogen entstehen.
– Sicherung mit Sicherungszieher entfernen.
– Flachstecksicherung F2 (1) ziehen.
Hauptsicherung ausbauen
DANGER
Am Plus-Sicherungseingang liegt weiterhin Spannung
an.
– Schutzkappen (wenn vorhanden) (1)

abziehen.
– Sperrzahnschrauben M10x20 (2) herauss-
chrauben
– Hauptsicherung (3) entfernen.
DANGER
an.
Verhinderung von versehentlichem Berühren oder
Kurzschließen der noch spannungsführenden Ein-
gangsseite der Hauptsicherung.
– Bei Reparaturen im Technikraum der Batterie
muss nach dem Entfernen der Hauptsicherung
die isolierte Sicherheitsvorrichtung angebracht
werden.
50988012057 EN - 12/2017 22-7

– Stromschiene (1) mit Sicherheitsvorrichtung

(2) abdecken.
Spannungsfreiheit im Tech-
nikraum prüfen
– Zweipoliger Spannungsprüfer an CVS-Mi-
nus (3) gegen Plus-Sicherungseingang (1)
anlegen.
Prüfergebnis: Elektrische Spannung anliegend.
– Zweipoliger Spannungsprüfer an CVS-Mi-
nus (3) und Plus-Sicherungsausgang (2)
prüfen.
Prüfergebnis: Keine elektrische Spannung
anliegend.
Beriebszustand wiederherstellen
DANGER
Spezialwerkzeuge
• Isolationsmessgerät
22-8 50988012057 EN - 12/2017

• Sicherungszieher
• Drehmomentschlüssel SW 15
• Zweipoliger Spannungsprüfer nach DIN VDE
0682-401:2011-02 (DIN EN 61243-3)
Hauptsicherung einbauen
DANGER
an.
– Sicherheitsvorrichtung (2) von der Strom-

schiene (1) abnehmen.
– Hauptsicherung (3) anbauen.

– Sperrzahnschrauben M10x20 (2)
festschrauben
Anzugsdrehmoment: 18 Nm
– Schutzkappen (wenn vorhanden) (1) auf-
stecken.
50988012057 EN - 12/2017 22-9

Flachstecksicherung F2 einsetzen
– Flachstecksicherung F2 (1) einstecken.
NOTE
Wenn die SSV nach wiedereinsetzen der Flach-

stecksicherung F2 nicht automatisch startet,
muss die SSV manuell neu gestartet werden.
Dazu den Reset-Taster auf der SSV drücken.
Technikraum schließen
WARNING
mittel verwenden.
– Servicedeckel (2) anbauen.

Gewicht: 17 kg
– Schrauben M6x10 (1) über Kreuz
festschrauben.
22-10 50988012057 EN - 12/2017

Components BG 2.2
Tray cover - Battery group 2.2
Unit Value
Length mm 1030
Width mm 502
Height mm 22
Screw joint Piece 29
NOTE
The different types of cover design are not inter-

changeable.
1 Battery tray cover

2 Bore for cover screw joint
3 Cover seal
4 Recess for lifting eyes
5 Duct for battery cable
Trogdeckel Abbau/Anbau
Benötigte Spezialwerkzeuge:
Abbau
– Leistungskabel und Kommunikationskabel
ausbauen siehe Abschnitt "Leistungskabel
Ausbau/Einbau".
– Zylinderschraube M6x25 (1) herauss-
chrauben.
– Deckelschiene (3) abnehmen.
– Vorgang auf der gegenüberliegenden Deckel-
seite wiederholen.
– Zylinderschraube M6x25 (5) mit Unterlegblech
herausschrauben.
seite wiederholen.
– Zylinderschraube M6x25 (2) mit Unterleg-
blech-Kabelschacht herausschrauben.
– Trogedeckel (4) abheben.
50988012057 EN - 12/2017 22-11

Components BG 2.2
– Sicherstellen, dass beim Ablegen des

Trogdeckels die Deckedichtung unterhalb
des Trogdeckels nicht beschädigt wird.
Anbau
Vor dem Auflegend es Trogdeckels sichterstel-
len:
• Die Deckeldichtung ist einwandfrei und sitzt
korrekt in der Dichtungsnut auf der Unterseite
des Trogdeckels.
• Die Kabeldurchführung des Trogedeckels
liegt über dem Kabelschacht der Anschlüsse
Leistung und Kommunikation.
• Die Dichtfläche des Batterietrogs ist sauber
und frei von Gegenständen.
– Trogedeckel (4) auflegen.
– Sicherstellen, dass der Trogdeckel umlaufend
bündig abschließt und sich nichts zwischen
der Deckeldichtung und der Dichtfläche des
Batterietrogs befindet.
CAUTION
Bauteilbeschädigung oder Undichtigkeit des Trog-
deckels möglich!
Der Trogdeckel kann durch ungleichmäßiges Anzie-
hen der Befestigungsschrauben verziehen und die
Deckeldichtung undicht werden.
– Zuerst alle Befestigungsschrauben von Hand bis
zur Kopfauflage hineinschrauben.
– Befestigungsschrauben immer von der Mitte begin-
nend nach außen festschrauben.
– Unterschiedliche Anzugsdrehmomente beachten!
– Zylinderschraube M6x25 (2) mit Unterleg-

blech-Kabelschacht hineinschrauben.
– Zylinderschraube M6x25 (5) mit Unterlegblech
hineinschrauben.
seite wiederholen.
– Deckelschiene (3) auflegen.
– Zylinderschraube M6x25 (1) hineinschrauben.
seite wiederholen.
– Zylinderschrauben M6x25 (1) von der Mitte
beginnend nach außen festschrauben.
– Zylinderschrauben M6x25 (5) von der Mitte
beginnend nach außen festschrauben.
– Zylinderschraube M6x25 (2) festschrauben.
22-12 50988012057 EN - 12/2017

Components BG 2.2
– Leistungskabel und Kommunikationskabel
einbauen, siehe Abschnitt "Leistungskabel
Ausbau/Einbau".
Battery display
1
Charging state LEDs
charging.
Charging state
Display Comment
(%)
First charging
state LED
flashes red: 3 2
0-2
the truck can
386_609-007
no longer be
up red: drive to
> 2 - 10
the charging
station
immediately
> 10 - 20
> 20 - 30
> 30 - 40
> 40 - 50
> 50 - 60
> 60 - 70
> 70 - 80
> 80 - 90
> 90 - 100
.
Service LED
Temperature LED
50988012057 EN - 12/2017 22-13

Components BG 2.2


Slightly
Power
reduction
60°C)
Increased (>
65°C)
Significantly
(> 70°C)
Greatly
(> 75°C)
.
Batterie-Display Ausbau/Einbau
DANGER
– Spannungsfreiheit herstellen.
• Isoliermatte nach DIN VDE 0682-511 [EN/IEC
61112], 1000 V
• Berührungsschutz Stromschiene
• Persönliche Schutzausrüstung (PSA)
Ausbau
– Sicherstellen, dass die elektrische Anlage
spannungsfrei ist, siehe Abschnitt "Span-
nungsfreiheit herstellen".
– Trogdeckel abbauen, siehe Abschnitt
"Trogdeckel Abbau/Anbau".
– Leistungsverbinder Plus ausbauen, siehe Ab-
schnitt "Leistungsverbinder Plus Ausbau/Ein-
bau".
22-14 50988012057 EN - 12/2017

Components BG 2.2
– Spannungsführende Teile im Batterietrog (1)

mit Isoliermatte (3) abdecken.
– Entkopplerbolzen (2) gegen unbeabsichtigtes
Berühren sichern.
– Spannungswandler ausbauen, siehe Ab-
schnitt "Spannungswandler Ausbau/Einbau".
– Stecker X1 (1), X2 (2) und Verbindungskabel

Batterie-Display/Displayelektronik (3) tren-
nen.
– Zylinderschraube M4x10 (5) mit Sicherungss-
cheibe herausschrauben.
– Displayelektronik (4) entnehmen.

cheibe herausschrauben.
– Haltebrücke (2) mit Batterie-Display (1) nach
innen drücken und entnehmen.
50988012057 EN - 12/2017 22-15

Components BG 2.2
– Verbindungskabel Batterie-Display/Dis-
playelektronik (3) vom Batterie-Display (1)
trennen.
– Eine einwandfreie Dichtung (2) auf dem
Batterie-Display belassen, nicht abziehen!
CAUTION
Beschädigung der Dichtung möglich!
Die Dichtung ist mit dem dichtungseigenen Klebestrei-
fen auf dem Batterie-Display fixiert. Beim Abziehen
kann die Dichtung beschädigt oder zerstört werden
und der Klebestreifen verliert seine Haftfähigkeit. Die
Dichtung nur abziehen, wenn diese beschädigt ist und
eine neue Dichtung zur Montage vorliegt.
– Einwandfreie Dichtung auf dem Batterie-Display
belassen.
– Abgezogene oder beschädigte Dichtung durch eine
neue Dichtung ersetzen.
Einbau
nungsfreiheit herstellen".
Beim Wiedereinbau des vorher ausgebauten
Batterie-Displays gilt:
– Prüfen, ob die Batterie-Displaydichtung (2)
unbeschädigt und wiederverwendbar ist. An-
sonsten durch eine neue Dichtung ersetzen.
Beim Ersetzen des ausgebauten Batterie-Dis-
plays durch ein neues Batterie-Display gilt:
– Schutzfolie von der Vorderseite des neuen
Batterie-Displays (1) abziehen.
– Schutzfolie von der Klebefläche der neuen
Dichtung (2) abziehen.
– Dichtung auf der Vorderseite des Batterie-
Displays umlaufend gleichmäßig ausrichten
und leicht auf dem Glaskörper andrücken.
playelektronik (3) auf der Rückseite des Bat-
terie-Displays (1) anschließen.
22-16 50988012057 EN - 12/2017

Components BG 2.2
– Haltebrücke (2) mit Batterie-Display (1) und

aufgeklebter Dichtung in die Ausfräsung
hineinschieben.
cheibe festschrauben.
Anzugsdrehmoment: 2,5 Nm
– Displayelektronik (4) mit den Steckeran-

schlüssen (1, 2) nach oben an der Trogwand
ausrichten.
playelektronik (3) zwischen der Displayelek-
tronik (4) und der Trogwand nach oben führen.
playelektronik an den Steckeranschluss (6)
anschließen.
cheibe festschrauben.
Anzugsdrehmoment: 2,5 Nm
– Stecker X1 (1) und X2 (2) anschließen.
– Spannungswandler einbauen, siehe Abschnitt
"Spannungswandler Ausbau/Einbau".
– Berührungsschutz vom Entkopplerbolzen (2)
entfernen.
– Isolliermatte (3) vom Batterietrog nehmen.
– Leistungsverbinder Plus anbauen, siehe Ab-
bau".
– Trogdeckel anbauen, siehe Abschnitt
– Betriebszustand wiederherstellen, siehe
Abschnitt "Beriebszustand wiederherstellen".
50988012057 EN - 12/2017 22-17

Components BG 2.2
Schocksensor
G
Der Schocksensor teilt sich die Platine mit dem
(m/s²)
Display und ist mechanisch starr an den Batteri-
etrog angebunden.
Ein Schockereignis während der Ruhephase
(Lagerung oder Transport) wird ebenfalls reg- 15 G
istriert und gespeichert.
10 G
Batterie im Flurförderzeug verbaut
t
Ergebnis wird nicht
≤ 10 G im Fehlerspeicher der (min)
Batterie gespeichert. 386_609-012
Speichern des
Ereignisses im
Fehlerspeicher der
Batterie,
10 G - 15 G Senden von CAN-
Nachricht an das
Fahrzeug,
Reduzierung der
Fahrgeschwindigkeit
nicht möglich,
>15 G
Reset durch
Servicetechniker nötig.
Transport der Batterie

nicht möglich,
Reset durch
>15 G Servicetechniker nötig.
Fehler kann über
die Diagnose nicht
zurückgesetzt werden.
.
22-18 50988012057 EN - 12/2017

Components BG 2.2
Pressure equalising element 1

The pressure equalising element is part of the
safety concept of the battery system.
In normal operation, the membrane (3) equalises
internal and external pressures.
The pressure cap (2) is connected to the hous-
ing (1) by a bayonet catch. If a critical over pres-
4
sure (4) is reached, the pressure cap is pushed 2
from the housing and the over pressure escapes.
386_691-024
1 Housing
2 Pressure cap with bayonet catch
3 Membrane
4 Pressure "P"
Visual inspection
– Unscrew the M6x12 countersunk screws (2)
from the maintenance cover (1).
– Remove the maintenance cover.
– Check that the pressure cap (1) is securely

attached.
Pressure cap secure:
If the pressure cap is firmly seated in the bayonet
catch, no critical over pressure has occurred
within the battery.
50988012057 EN - 12/2017 22-19

Components BG 2.2
– Place the maintenance cover (1) into the

recess in the tray.
– Tighten the M6x12 hexagon head screws (2).
Pressure cap loose:
If the pressure cap is loose, a critical over pres-
sure has occurred within the battery. A critical
over pressure is caused by a serious defect within
the battery. In the event of this happening, the
battery must be tested by the manufacturer and
repaired.
– Do not place the battery back in service; inform
the battery manufacturer.
Leistungsverbinder Plus Aus-

bau/Einbau
DANGER
Am Leistungsverbinder Plus liegt Spannung an.
• Schraubenschlüssel SW 17
Ausbau
– Spannungsfreiheit herstellen, siehe Abschnitt
"Spannungsfreiheit herstellen".
22-20 50988012057 EN - 12/2017

Components BG 2.2
– Stecker (3) aus den Steckeranschlüssen

(2) der betreffenden Module lösen und das
CAN-Bus Kabel (1) abziehen.
– Selbstsichernde Mutter M10 vom Entkoppler-

Gewindebolzen (1) abschrauben. 1
– Kontaktzunge Leistungsverbinder Plus(2)
vom Entkoppler-Gewindebolzen (1) abheben. 2
NOTE
Der Leistungsverbinder Plus ist in die Modul-

Verbindungsstecker gesteckt und kann ohne
weiteres Werkzeug entnommen werden.
386_691-011
– Leistungsverbinder Plus (1) mit den Steck-

ern (3) nach oben aus den Steckeran-
schlüssen (2) der Module ziehen.
Einbau
50988012057 EN - 12/2017 22-21

Components BG 2.2
– Leistungsverbinder Plus (1) von oben mit den

Steckern (3) in die Steckeranschlüsse (2) der
Module stecken.
– Kontaktzunge Leistungsverbinder Plus (2) auf

den Entkoppler-Gewindebolzen (1) stecken. 1
– Selbstsichernde Mutter M10 auf dem Entkop-
pler-Gewindebolzen (1) festschrauben. 2
386_691-011
– CAN-Bus Kabel (1) in die zueinander liegen-

den Steckeranschlüsse (3) benachbarter Mod-
ule stecken.
Über die Steckeranschlüsse (2) weitere Nach-
barmodule verbinden.
Abschnitt "Betriebszustand wiederherstellen".
22-22 50988012057 EN - 12/2017

Components BG 2.2
Temperature sensors
1 NTC 1 3 NTC 3
2 NTC 2 4 NTC 4
Batteriemodul Ausbau/Einbau
DANGER
– Spannungsfreiheit herstellen.
• Aushebewerkzeug
• Schraubenschlüssel SW 10
• Schraubendreher Torx (T10)
50988012057 EN - 12/2017 22-23

Components BG 2.2
Ausbau
nungsfreiheit im Technikraum herstellen".
– Leistungsverbinder Plus ausbauen, siehe Ab-
bau".
– Leistungsverteilerplatte (3) vom defekten

Batteriemodul abnehmen.
– Sechskant-Sperrzahnschraube M6x567 (1)
aherausschrauben.
– Niederhalter (2) abnehmen.
– Aushebewerkzeug anbauen.
WARNING
mittel verwenden.
Gerwicht Batteriemodul: ca. 30 kg

– Hebezeug an das Batteriemodul bringen und
am Aushebewerkzeug befestigen.
– Batteriemodul (1) senktrecht nach oben
heben, bis das Batteriemodul frei über dem
Batterietrog (2) hängt.
– Batteriemodul (1) vom Batterietrog (2) entfer-
nen und standsicher abstellen.
– Hebezeug vom Aushebewerkzeug lösen.
– Aushebewerkzeug abbauen.
Einbau
NOTE
Für den sicheren Rücktransport zum Batteriemo-

dul-Hersteller ist nach dem Einbau eines neuen
Batteriemoduls, das ausgebaute alte Batteriemo-
dul in die verbliebene Batteriemodulverpackung
des neues Batteriemoduls zu packen.
22-24 50988012057 EN - 12/2017

Components BG 2.2
– Aushebewerkzeug anbauen.
– Hebezeug an das Batteriemodul bringen und
am Aushebewerkzeug befestigen.
WARNING
mittel verwenden.
Gerwicht Batteriemodul: ca. 30 kg

– Batteriemodul zum Batterietrog bringen und
anheben, bis das Batteriemodul senkrecht und
frei über dem Batterietrog hängt.
NOTE
Die Steckeranschlüsse des Leistungsverbinders

Plus auf der Oberseite und des Leistungsver-
binders Minus auf der Unterseite des Batterie-
moduls sind deckungsgleich. Beim Einbau des
Batteriemoduls muss der Steckeranschluss für
den Leistungsverbinder Plus senkrecht über dem
Stecker des Leistungsverbinders Minus im Trog
zu sehen sein.
Die Zentrierbolzen (3) im Batterietrog sorgen
für ein passgenaues Einrasten des Steckers
Leistungsverbinder Minus (4) in den Steckeran-
schluss auf der Batteriemodulunterseite.
Die Zentrierbohrungen (2) auf der Batteriemodu-

lunterseite sorgen für ein passgenaues Einrasten
des Steckeranschlusses Leistungsverbinder Mi-
nus (1) in den Stecker im Batterietrog.
– Prüfen, in welcher Stellung der entsprechende
Stecker des Leistungsverbinders Minus und
die Zentrierbolzen im Batterietrog zu sehen
sind.
– Batteriemodul mit dem Steckeranschluss
Leistungsverbinders Plus und den Zentrieb-
bohrungen über der Einbauposition aus-
richten.
50988012057 EN - 12/2017 22-25

Components BG 2.2
– Vorsichtig das Batteriemodul (1) senktrecht in

den Trog (2) absenken, bis dieses fest auf dem
Trogboden steht.
– Prüfen, ob das Batteriemodul sicher
eingerastet und in der Einbauposition zentriert
ist.
– Hebezeug vom Aushebewerkzeug lösen und
von der Batterie entfernen.
– Aushebewerkzeug abbauen.
– Sechskant-Sperrzahnschraube M6x567 (1)

mit Niederhalter (2) einschrauben und über
vier zueinander stehenden Batteriemodulen
ausrichten.
– Sechskant-Sperrzahnschraube (1)
festschrauben.
– Leistungsverteilerplatte (3) auf das Bat-
teriemodul legen.
– Leistungsverbinder Plus einbauen, siehe Ab-
bau".
Abschnitt "Betriebszustand wiederherstellen".
– Wurde ein defektes Batteriemodul ausge-
tauscht, das defekte Batteriemodul in die Bat-
teriemodulverpackung einpacken.
CAN bus terminating resistor (120

Ω)
The CAN bus is equipped with a terminating
resistor (120 Ω). The terminating resistor is
plugged into the last plug connector on the
CAN bus. Uninterrupted operation cannot be
guaranteed without a terminating resistor.
– Pull the terminating resistor (1) out from the
plug connection on the removed module.
22-26 50988012057 EN - 12/2017

Components BG 2.2
– Place the terminating resistor (1) at the cable

end of the CAN bus into the plug connection on
the new module.
50988012057 EN - 12/2017 22-27


Technikraum öffnen/schließen
Öffnen
– Zylinderschrauben M6x10 (1) herauss-
chrauben.
WARNING
mittel verwenden.
– Servicedeckel (2) abbauen.

Gewicht: 17 kg
Schließen
Vor dem Anbauen des Servicedeckels sichter-
stellen:
• Die Deckeldichtung in der Batterietrogwand
ist einwandfrei und sitzt korrekt in der Dich-
tungsnut.
• Die Dichtfläche des Servicedeckels ist sauber
und unbeschädigt.
WARNING
mittel verwenden.
22-28 50988012057 EN - 12/2017

– Servicedeckel (2) vor den Technikraum

stellen.
Gewicht: 17 kg
– Sicherstellen, dass sich keine Kabel zwischen
Servicedeckel (2) und Anschraubfläche
befinden.
– Servicedeckel anbauen.
– Zylinderschrauben M6x10 (1) festschrauben.
50988012057 EN - 12/2017 22-29

Current/voltage sensor (CVS)

The CVS measures the current and voltage
and supports the BMS in evaluating the power
requirements of the truck.
Tasks in detail:
• Measuring the battery current (Messshunt)
• Measuring the battery voltage
• Temperature measurement Messshunt
• Galvanic isolation of 48 V control voltage
supply
• Measured value transmission to BMC via CAN
Voltage measurements:
1 Battery module connection
• Measurement of voltage + modules directly 2 Battery male connector connection
after 450 A fuse (S1-) X71 Connection BMC
• Measurement of voltage after connected X72 Voltage measurement
contactor K1 (K1+)
• Measurement of output voltage after con-
nected contactor K2 (K2-)
Removing/installing the cur-

rent/voltage sensor
DANGER

• AF 10 spanner
22-30 50988012057 EN - 12/2017

Removal
– De-energise the technology compartment;
technology compartment".
– Disconnect the plugs X71 (2) and X72 (1).
– Remove the protective caps and unscrew the

M6x20 hexagon head screws (1).
– Unscrew the M6x20 hexagon head screws (2)
and remove the BCM/CVS connecting cable.
– Pull out the current/voltage sensor (2) from

under the conductor rails (1) and remove it.
50988012057 EN - 12/2017 22-31

Removing the support for the current/voltage

sensor
– Unscrew the M6 nut (1).
– Remove the support for the current/voltage
sensor (2).
Installing
– Insert the support for the current/voltage
sensor (2).
– Tighten the M6 nut (1).
Install the current/voltage sensor

– Slide the current/voltage sensor (2) under the
conductor rails (1).
22-32 50988012057 EN - 12/2017

– Fit the BCM/CVS connecting cable on the

M6x20 hexagon head screw (2) and tighten it.
– Fit and tighten the M6x20 hexagon head
screws(1).

50988012057 EN - 12/2017 22-33

Brake chopper module (BCM)

Functional description
The BCM monitors battery voltage during truck
operation. If the battery voltage exceeds the
value of 53.9 V in a 48 V lithium-ion system
due to recuperation, the system is automatically
activated.
It connects a resistor in parallel with the battery
using power electronics. The resistor absorbs
the average regenerative power, which keeps
the battery voltage constant at approximately
53.7 V.
The housing of the BCM includes three LEDs.
1 Connection R+ on brake resistor (+)
These indicate the current status of the compo- 2 Connection R- on brake resistor (-)
nent independently of the BMC. 3 X42 (2-pin) connection on brake resistor NTC
temperature sensor
4 BAT- connection
5 X41 (6-pin) connection on brake resistor BMC
6 Status LED
7 BAT+ connection
Status LED
1 "enable" LED (enabled by master)

2 "ready" LED (temperature monitoring/perfor-
mance)
3 "pre-charge" LED
LED on/off BCM operating mode Function

All Off Switched off
Release available, must be performed by the
"enable" On Ready
BMC
"ready" On Active on the brake resistor within the specified temper-
ature range
Active - is then switched
"ready" Off on the brake resistor outside the specified tem-
off
perature range
Internal pre-charging of the BCM pre-charge
"pre-charge" On Pre-charging active relay by the BMC (must be charged for 200 ms
before the main contactors close)
22-34 50988012057 EN - 12/2017

Enabled by master
The "enable" LED (1) indicates the enable
status signalled by the BMC. If the LED is
illuminated, the enable signal is present.
The BMC can disable the BCM component
depending on the truck condition/battery
status.
Temperature monitoring/performance
The BCM monitors the temperature of the
power electronics internally and monitors the
temperature of the brake resistor externally
with an additional open circuit detector. The
two temperature monitors are standardised
into a single "performance" parameter. This is
transmitted to the BMC via pulse width modu-
lation using PIN "feedback" and indicated by
the "ready" LED (2). The pulse width modula-
tion frequency is approx. 10 Hz. The LED is
illuminated constantly when the component is
performing at 100%. If the LED flashes briefly,
this indicates increased performance. If the
LED flashes slowly, this indicates decreased
performance. If performance is at 0% or if
there is a cable break in the external tempera-
ture sensor, the LED is off.
Pre-charging
The BCM has an internal pre-charge circuit
for the intermediate circuit of the BCM. Pre-
charging is controlled by the BMC. The status
of the pre-charge path is indicated by the
"pre-charge" LED (3). If the LED lights up,
pre-charging is active.
Status description
There are three internal testing and measure-
ment circuits that function independently of each
other. All measurement, detection and control is
analogue (performed without software):
• Continuous testing for line breakage of the
external temperature sensor
• Continuous measurement of the performance
electronics temperature and the brake resistor
as well as adaptation of the feedback signal
• Testing the battery voltage and generating
switching signals for the power transistors
BCM self-protection
The BMC uses the feedback signal from the BCM
to adjust the maximum permissible recuperated
power to keep the BCM system within the per-
missible temperature range. If the truck does not
adhere to this value, the BCM system switches
off automatically to protect itself.
50988012057 EN - 12/2017 22-35


chopper module
DANGER

• Hexagon socket key AF 10
Removing
4 3 11 12 1 2 3 4
NOTE
The BCM (1) must be removed together with

the carrier plate (2). Otherwise, not all of the
screw connections that connect the BCM to the
mounting plate will be accessible.
• The tensioning stabiliser (3) behind the con-
nectors for the brake resistor (5) is accessible
only once the brake resistor has been removed
the technology compartment".
– Disconnect the NTC temperature sensor at the
X42 connector (9). 10 9 8 7 6 5 386_609-029
– Remove the brake resistor; see the section en-

titled "Removing/installing the brake resistor".
– Disconnect the BMC signal plug at the X41
connector (12).
– Unscrew the socket head screw (6) at the
BAT+ connection.
– Remove the BAT+ (7) cable from the BCN.
– Remove the BCM/CVS cable (10) from the
BCM.
– Remove the tensioning stabilisers (3)
– Remove the BCM (1) together with the carrier
plate (2).
– Remove the BCM from the carrier plate.
22-36 50988012057 EN - 12/2017

Installing
4 3 11 12 1 2 3 4
– Place the BCM (1) on the carrier plate (2).
– Insert BCM together with the carrier plate.
– Fit the tensioning stabilisers (3) .
– Place the BCM/CVS cable (10) on the BAT-
connector. 10 9 8 7 6 5 386_609-029
– Place the BAT+ cable (7) on the BAT+ connec-
tor.
– Tighten the socket head screw (6).
– Connect the BMC signal plug to the X41
connector (12).
NOTE
When the brake resistor is being installed, the

right-hand tensioning stabiliser is covered by the
brake resistor connector (5). Before installing the
brake resistor, make sure the flanged nuts (4) are
fully tightened.
– Install the brake resistor; see the section enti-
tled "Removing/installing the brake resistor".
– Connect the NTC temperature sensor to the
X42 connector (9).
50988012057 EN - 12/2017 22-37

Brake resistor 105 mΩ

1
WARNING
>100 °C during operation. It can take several hours
for the brake resistor to cool down to a low hazard
temperature. Thermal radiation can also affect other
components in and around the technical compartment,
which then become hot.
The brake resistor is used to absorb recovered

energy (braking energy) if the brake current 4 3 2
exceeds the generator voltage of the traction
motor. 386_609-001
The NTC resistor monitors the temperature and 1 Brake resistor 105 mΩ
provides feedback to the brake chopper module. 2 Connection to BCM "R-"
3 Connection to BCM "R+"
Technical data 4 Connection to contactor connectors "K1"/"K2"
Resistance value 105 mΩ
Resistance value
±10%
tolerance
Insulation resistance >50 MΩ
Operating voltage UMAX = 54 V (48 V)
Nominal voltage Unominal = 13 x 3.75 V
Final charged voltage 13 x 4.12 V
Test voltage (1 minute) UP = 1200 V DC
NTC resistance 10 kΩ
Dimensions (length / 503 mm / 100 mm /
width / height) 50 mm
.

resistor
DANGER
22-38 50988012057 EN - 12/2017

WARNING
During operation, the brake resistor temperature can
rise to >100°C. It can take several hours for the brake
resistor to cool down to a low hazard temperature.
Thermal radiation can also affect other components
in and around the technical compartment, which then
heat up.

Removal
and (4) on the BMC (5).
The connectors (1) and (3) remain on the brake
resistor.
– Pull out the NTC plug (6).
50988012057 EN - 12/2017 22-39

– Remove the protective cap from the M10

flanged nut (1) on the contactor bridge (4).
– Unscrew M10 flanged nut (1).
– Remove the ring terminal (3) from the M10
threaded bolt (2).
– Unscrew the M8x35 socket head screw (2)

– Remove the retaining key (1).
– Lift the brake resistor (3) and remove it.
Installation
– Insert the brake resistor (1) from above.
– Ensure that the brake resistor slides into the
lower latch (2).
22-40 50988012057 EN - 12/2017

– Fit the retaining key (1) at the top of the brake

resistor (3).
– Screw on the M8x35 socket head screw (2)
– Insert the ring terminal (3) on the M10 threaded

bolt (2) of the contactor bridge(4).
– Place a protective cap on the flanged nut (1).
– Fit the brake resistor connector (1, 3) on the

BMC (5).
– Screw the M10x12 socket head screws (2, 4)
along with the lock washer onto the BMC.
– Attach the NTC plug (6).
50988012057 EN - 12/2017 22-41

Battery master controller (BMC)

The BMC determines the charge and overall
condition of all the battery cells. It communicates
with the industrial truck via the CAN bus and with
the CSC via the internal CAN bus.
Tasks in detail:
• Activation of the main contactors, K1 and K2
• Monitoring of the battery modules
• Safety monitoring function of the battery
modules
• Communication with the battery display and
the shock sensor 1 LEDs (x2), BMC main processor
• Communication with the BCM 2 BMC
3 LEDs (2 pieces) BMC monitoring computer
X11 Diagnostics, CAN, contactors, BCM, SSV
X12 CSC
X13 Battery display / shock sensor
X14 Power supply
LED codes BMC

LEDs Computer BMC Operating status
Off Quiescent state
processor
Flashing white Ready, charging or driving
processor
Self testing, emergency opera-
Flashing white + blue Main processor
tion, error with error analysis
Malfunction (with error, including
Solid white + blue Main processor
up to shut-off 1)
Solid blue Monitoring processor Feedback signal deactivated
Normal operation, feedback
Flashes blue once Monitoring processor
signal test
.

master controller
DANGER

• Spanner AF 10
22-42 50988012057 EN - 12/2017

Removal
– Disconnect plugs X11 (5), X12 (4), X13 (3) and
X14 (6).
– Unscrew ratchet screws M6x16 (1).
– Remove the battery master controller (2)
together with the carrier plate.
Installing
– Fit the battery master controller (2) together
with the carrier plate.
– Tighten ratchet screws M6x16 (1).
– Connect plugs X11 (5), X12 (4), X13 (3) and
X14 (6).
50988012057 EN - 12/2017 22-43

Control voltage supply (SSV) with

reset button
The SSV supplies the truck electrics with power 1 2 3
before the battery is switched on and ensures a
continuous power supply to the DC/DC converter.

• PIN 1
X51 X52
Blocking signal from BMC

• PIN 2
Negative

• PIN 1
Negative connection
386_609-122
• PIN 2
Battery positive connection before switch-on 1 Plug connector X51
contactor 2 Reset button
3 Plug connector X52
• PIN 3
Control voltage to truck
• PIN 4
Battery positive connection to battery voltage
transformer
Tasks in detail:
• Supplies the truck electrics with power before
the battery is switched on
• Switches the power supply off after the battery
is switched off
• Switches off the battery supply voltage in the
event of under voltage
• Switches off the battery supply voltage from
BMC
• Switches off the complete power supply
• Limits the control current to the truck
• Prevents battery charging from the control
voltage (voltage feedback protection)
Removing/installing the control

voltage supply unit
DANGER
22-44 50988012057 EN - 12/2017


• AF 10 spanner
Removal
– Remove the battery master controller; see
– Disconnect the plug X51 (2) and the plug
X52 (1).
– Remove the SSV.
Installing
– Insert the SSV.
– Tightening torque: 9 Nm
– Connect plug X51 (1) and plug X52 (2).
– Install the battery master controller; see the
section entitled "Removing/installing the
50988012057 EN - 12/2017 22-45

Contactor assembly
When commissioning the truck, the contactors
are enabled as long as the battery is ready for
operation.
1 Contactor K1
2 Connector plug X94
3 Contactor K2
Removing/installing the contactor

assembly
DANGER

• Spanner AF 10
• Spanner AF 15
22-46 50988012057 EN - 12/2017

Removal
– Remove the protective cap (1).
Remove the connector between contac-

tor K1/contactor K2.
– Remove the connector between the brake
resistor/contactor bridge (3) from the threaded
bolt (1).
tor K1/contactor K2 (8) from the threaded
bolt (4) .
K1 (6) and contactor K2 (7) is now broken.
Remove the connector between contactor K1/po-

sitive main power connection.
– Unscrew M10x20 hexagon head screw (3).
tor K1/positive main power connection (4)
from the threaded bolt (6).
K1 (1) and positive main power connection (2) is
now broken.
50988012057 EN - 12/2017 22-47

Remove the connector between contactor K2/po-

sitive main power connection.
tor K2/positive main power connection (2).
K2 (6) and positive main power connection (5) is
now broken.
Remove the contactor bridge.

– Remove cable tie (4).
– Unscrew M6 long nut (5).
– Unscrew M6 hexagon nut (2).
– Remove the contactor bridge (1) with contac-
tors.
22-48 50988012057 EN - 12/2017

Remove contactor K1 and K2.

– Remove contactor K1 (3) and contactor K2 (4)
from the contactor bridge (1).
Installing
Attach contactor K1 and K2.

– Connect contactor K1 (3) and contactor K2 (4)
to the contactor bridge (1).
Install contactor bridge.

– Place the contactor bridge (1) on the rear wall
of the technical compartment.
– Tighten the M6 hexagon nut (2).
– Tighten the M6 long nut (5).
– Tighten the M6x16 hexagon head screw (3)
with cable ties (4).
50988012057 EN - 12/2017 22-49

Install the connector between contactor K2/posi-

tive main power connection.
– Fit the connector between contactor K2 /pos-
itive main power connection (3)onto the
threaded bolt (2) at the contactor K2 (6).
K2 /positive main power connection with the
threaded hole on the positive main power con-
nection (5).
Install the connector between contactor K1/posi-

tive main power connection.
– Fit the connector between contactor K1 /pos-
itive main power connection (4)onto the
threaded bolt (6) at the contactor K1 (1).
K1 /positive main power connection with the
threaded hole on the positive main power con-
nection (2).
Install the connector between contactor K1/con-

tactor K2
– Fit the connector between contactor K1/con-
tactor K2 (8) onto the threaded bolt (4) above
contactor K1 (6) and contactor K2 (7).
– Fit the brake resistor/contactor bridge (3) onto
the threaded bolt (1) on the connector between
contactor K1/contactor K2.
22-50 50988012057 EN - 12/2017

– Attach plug X94 (2).

– Attach plug X14 (3).
– Attach the protective cap (1).
50988012057 EN - 12/2017 22-51

Voltage transformer (DC/DC)

The DC/DC voltage transformer ensures a per-
manent power supply to the BMC and the diag-
nostic interface.
• Input voltage 48 V from SSV
• 12 V output voltage
• Supply from:
BMC
CSC
CVS
Battery display / shock sensor
1 DC/DC voltage transformer

2 Plug connection
Removing/installing the voltage

transformer
DANGER

• AF 10 spanner
Removal
22-52 50988012057 EN - 12/2017

– Disconnect the connector plug (4) from the

voltage transformer.
– Unscrew the M5x10 countersunk screw (5).
– Slide the upper cradle (1) off the clamping
sleeve (6) and the threaded bolt (3), and
remove the upper cradle.
– Pull the voltage transformer (1) with the base

plate (3) upwards and remove it.
– If necessary, remove the clamping sleeve (2).
The voltage transformer and the base plate are

loosely plugged into the recess (2) of the lower
cradle (1).
– To remove the lower cradle (1), unscrew the
flanged nut (3) and remove the lower cradle.
50988012057 EN - 12/2017 22-53

Installation
– Ensure that the recess in the lower cradle (1)
faces the wall of the technical compartment.
– Check the tightness of the M6 flanged nut (3).
– Push the voltage transformer (1) with the base

plate (3) from above into the recess in the lower
cradle.
– Ensure that the clamping sleeve (2) is present
and is correctly installed.
– Push the upper cradle (1) onto the clamping

sleeve (6) and threaded bolt (3).
– Tighten the M5x10 countersunk screw (5).
– Connect the connector plug (4).
22-54 50988012057 EN - 12/2017

Electrical fuses
Main fuse
The main fuse on the positive power distribution
side has a rating of 450 A.
1 Fuse holder

The control current is protected by blade fuses in
the fuse holder.
1 Fuse holder
F2 BMC / SSV (20 A)
50988012057 EN - 12/2017 22-55

Blade fuses on the SSV
1 F20
386_609-015
1 SSV
Replacing electrical fuses
DANGER

• Fuse puller for auto plug-in fuse
22-56 50988012057 EN - 12/2017

Replacing the main fuse

CAUTION
Risk of damage to the contactors by triggering the main
fuse.
Triggering the main fuse may cause "short-circuit
current" that can damage the contactors.
– After the main fuse has been triggered, the contac-
tors must be replaced.

the system".
1 Fuse holder
– Remove protective caps (1).

– Unscrew ratchet screws M10x20 (2).
– Remove main fuse (3).
– Insert new main fuse with the same nominal
current.
– Tighten ratchet screws M10x20 (2).
50988012057 EN - 12/2017 22-57

Changing control current fuses

Control current fuses in the fuse holder
the system".
– Locate defective auto plug-in fuses (F2-F6)
and remove from the fuse holder (1) using a
fuse puller.
nominal current.
1 Fuse holder
F2 BMC / SSV (20 A)
F6 Pre-charging of brake chopper (3 A)
Control current fuse on the SSV

the system".
– Remove BMC.
– Pull out the auto plug-in fuse (F20) using a fuse
puller.
nominal current.
– Install BMC.
1 F20
386_609-015
1 SSV
22-58 50988012057 EN - 12/2017

Wiring BG 2.2
Removing/installing the power
cable
DANGER

• Spanner AF 22
Removing
resistance".
positive power connection (6).
negative power connection (5).
– Pull out the communication plug (7).
(7) upwards and out of the cable channel.
Installing
(7) into the cable channel from above.
– Place the tab for the positive power cable (2)
onto the M10x47 terminal bolt (1).
the positive power cable (2) onto the positive
– Place the tab for the negative power cable (3)
onto the M10x47 terminal bolt (4).
the negative power cable (3) onto the negative
50988012057 EN - 12/2017 22-59

Wiring BG 2.2
– Insert the communication plug (7).
22-60 50988012057 EN - 12/2017

Index
g
A Battery transport with crane . . . . . . . . . . . 00-6

BCM . . . . . . . . . . . . . . . . . . . . . 21-38, 22-34
Anode . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-8
Betriebszustand wiederherstellen . . . . . . . 22-8
B Flachstecksicherung F2 einsetzen . . 22-10
Batterie-Display Hauptsicherung einbauen . . . . . . . . . 22-9
Ausbau . . . . . . . . . . . . . . . . . . . . . . 22-14 Spezialwerkzeuge . . . . . . . . . . . . . . . 22-8
Einbau . . . . . . . . . . . . . . . . . . . . . . . 22-16 Technikraum schließen . . . . . . . . . . 22-10
Batteriemodul 2.2 Brake chopper module . . . . . . . . 21-38, 22-34
Ausbau . . . . . . . . . . . . . . . . . . . . . . 22-24 Functional description . . . . . 21-38, 22-34
Einbau . . . . . . . . . . . . . . . . . . . . . . . 22-24 Installing . . . . . . . . . . . . . . . 21-41, 22-37
Battery cell Removing . . . . . . . . . . . . . . 21-40, 22-36
Structural principle . . . . . . . . . . . . . . . 00-8 Self-protection . . . . . . . . . . . 21-39, 22-35
Battery display . . . . . . . . . 00-14, 21-15, 22-13 Status description . . . . . . . . 21-39, 22-35
Charging state LEDs . 00-14, 21-15, 22-13 Status LED . . . . . . . . . . . . . 21-38, 22-34
Installing . . . . . . . . . . . . . . . . . . . . . 21-17 Brake resistor
Removing . . . . . . . . . . . . . . . . . . . . 21-16 105 mΩ . . . . . . . . . . . . . . . . 21-43, 22-38
Service LED . . . . . . . . 00-15, 21-15, 22-13 Installation . . . . . . . . . . . . . . . . . . . . 22-40
Temperature LED . . . 00-15, 21-15, 22-13 Installing . . . . . . . . . . . . . . . . . . . . . 21-45
Battery group 1.1 Removal . . . . . . . . . . . . . . . . . . . . . 22-38
Technical compartment . . . . . . . . . . . 22-4 Removing . . . . . . . . . . . . . . . . . . . . 21-43
Battery group 1.2
C
Technical compartment . . . . . . . . . . . 22-4
Cathode . . . . . . . . . . . . . . . . . . . . . . . . . 00-8
Battery group 12.1
Charging
Design . . . . . . . . . . . . . . . . . . . . . . . . 21-3
Operating principle . . . . . . . . . . . . . . . 00-8
Battery group 2.1
Cleaning the battery . . . . . . . . . . . . . . . . . 01-1
Technology compartment . . . . . . . . . . 21-4
Connector between contactor K1/contac-
Tray cover . . . . . . . . . . . . . . . . . . . . 21-13
tor K2
Battery group 2.2
Installing . . . . . . . . . . . . . . . 21-54, 22-50
Design . . . . . . . . . . . . . . . . . . . . . . . . 22-2
Removing . . . . . . . . . . . . . . 21-51, 22-47
Tray cover . . . . . . . . . . . . . . . . . . . . 22-11
Connector between contactor K1/main
Battery master controller . . . . . . 21-46, 22-42 positive connection
Installing . . . . . . . . . . . . . . . . . . . . . 22-43 Installing . . . . . . . . . . . . . . . . . . . . . 21-54
Removal . . . . . . . . . . . . . . . . . . . . . 22-43 Removing . . . . . . . . . . . . . . . . . . . . 21-51
Tasks . . . . . . . . . . . . . . . . . 21-46, 22-42 Connector between contactor K1/positive
Battery master controller 2.1 main power connection
Removing . . . . . . . . . . . . . . . . . . . . 21-47 Removing . . . . . . . . . . . . . . . . . . . . 22-47
Battery module Connector between contactor K2/main
Exploded view . . . . . . . . . . . . . . . . . 00-12 positive connection
Main components . . . . . . . . . . . . . . . 00-11 Removing . . . . . . . . . . . . . . . . . . . . 21-52
Removing . . . . . . . . . . . . . . . . . . . . 21-30 Connector between contactor K2/positive
main power connection
Structural principle . . . . . . . . . . . . . . 00-10
Installing . . . . . . . . . . . . . . . . . . . . . 22-50
Battery size 2.1
Removing . . . . . . . . . . . . . . . . . . . . 22-48
De-energising the technology
compartment . . . . . . . . . . . . . . . . 21-6
50988012057 EN - 12/2017 1
Index
g
Contactor assembly . . . . . . . . . . 21-50, 22-46 CVS

Installing . . . . . . . . . . . . . . . 21-53, 22-49 Securing the conductor rails . . . . . . . 21-36
Removal . . . . . . . . . . . . . . . . . . . . . 22-47 CVS support
Removing . . . . . . . . . . . . . . . . . . . . 21-51 Installing . . . . . . . . . . . . . . . . . . . . . 21-37
Contactor bridge Removing . . . . . . . . . . . . . . . . . . . . 21-36
Installing . . . . . . . . . . . . . . . 21-53, 22-49
Removing . . . . . . . . . . . . . . 21-52, 22-48
D
Contactor K1 Dangerous misuse . . . . . . . . . . . . . . . . . . 00-4
Attaching . . . . . . . . . . . . . . . . . . . . . 22-49 De-energised technology compartment
Fitting . . . . . . . . . . . . . . . . . . . . . . . 21-53 Checking . . . . . . . . . . . . . . . . . . . . . . 21-9
Removing . . . . . . . . . . . . . . 21-53, 22-49 De-energising the technology compart-
Contactor K2 ment
Attaching . . . . . . . . . . . . . . . . . . . . . 22-49 Battery size 2.1 . . . . . . . . . . . . . . . . . 21-6
Fitting . . . . . . . . . . . . . . . . . . . . . . . 21-53 Opening the technology compart-
ment . . . . . . . . . . . . . . . . . . . . . . 21-8
Removing . . . . . . . . . . . . . . 21-53, 22-49
Pulling out auto plug-in fuse F2 . . . . . . 21-7
Removing the front module cover . . . . 21-6
Changing . . . . . . . . . . . . . . . . . . . . . 22-58
Removing the main fuse . . . . . . . . . . . 21-8
Replacing . . . . . . . . . . . . . . . . . . . . 21-61
Special tools . . . . . . . . . . . . . . . . . . . 21-6
Control voltage supply . . . . . . . . . . . . . . 21-48
Definition of terms . . . . . . . . . . . . . . . . . . . . V
Functions . . . . . . . . . . . . . . . 21-48, 22-44
Design
Pin assignment . . . . . . . . . . 21-48, 22-44
Battery group 2.1 . . . . . . . . . . . . . . . . 21-3
Removal . . . . . . . . . . . . . . . . . . . . . 22-45
Battery group 2.2 . . . . . . . . . . . . . . . . 22-2
Reset button . . . . . . . . . . . . . . . . . . 22-44
Diagnostic set-up 2.1 . . . . . . . . . . . . . . . . 21-2
Control voltage supply unit
Discharging
Installing . . . . . . . . . . . . . . . . . . . . . 21-49
Operating principle . . . . . . . . . . . . . . . 00-8
Removing . . . . . . . . . . . . . . . . . . . . 21-49
Control voltage supply unit 9.1 / 9.2 E
Installing . . . . . . . . . . . . . . . . . . . . . 22-45
Electrical fuses . . . . . . . . . . . . . 21-58, 22-55
Current/voltage sensor . . . . . . . . 21-35, 22-30
Changing control current fuses . . . . . 22-58
Functions . . . . . . . . . . . . . . . 21-35, 22-30
Control current fuses . . . . . . 21-58, 22-55
Installing . . . . . . . . . . 21-36 – 21-37, 22-32
Main fuse . . . . . . . . . . . . . . . 21-58, 22-55
Removal . . . . . . . . . . . . . . . . . . . . . 22-31
Replacing . . . . . . . . . . . . . . 21-59, 22-56
Removing . . . . . . . . . . . . . . . . . . . . 21-36
Replacing the control current fuses . . 21-61
Voltage measurements . . . . 21-35, 22-30
Replacing the main fuse . . . . 21-60, 22-57
Electrolyte . . . . . . . . . . . . . . . . . . . . . . . . 00-8
2 50988012057 EN - 12/2017
Index
g
G Lithium-ion battery
Balancing . . . . . . . . . . . . . . . . . . . . 00-14
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . V
First-aid measures . . . . . . . . . . . . . . . 00-5
Active materials . . . . . . . . . . . . . . . . . . . VI
LED display . . . . . . . . . . . . . . . . . . . 00-13
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . VI
Pressure compensation element . . . 21-20
Battery Management System . . . . . . . . . VI
Pressure equalising element . . . . . . 22-19
C-rate . . . . . . . . . . . . . . . . . . . . . . . . . . VI
Technological advantages . . . . . . . . . 00-9
Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Temperature sensors . . . . . . 00-13, 22-23
Charging cycle . . . . . . . . . . . . . . . . . . . VII
Electrodes . . . . . . . . . . . . . . . . . . . . . . . VI M
Energy density . . . . . . . . . . . . . . . . . . . . VI
Main fuse
Final charged voltage . . . . . . . . . . . . . . VII
Replacing . . . . . . . . . . . . . . 21-60, 22-57
Final discharged voltage . . . . . . . . . . . . VII
Memory effect . . . . . . . . . . . . . . . . . . . VIII
Special tools . . . . . . . . . . . . . . 21-5, 22-5
Nominal capacity . . . . . . . . . . . . . . . . . VIII
Module holder
Nominal energy . . . . . . . . . . . . . . . . . . VII
Installing . . . . . . . . . . . . . . . . . . . . . 21-24
Nominal voltage . . . . . . . . . . . . . . . . . . VIII
Removing . . . . . . . . . . . . . . . . . . . . 21-22
Power source parallel connection . . . . . VIII
Power source serial connection . . . . . . . IX N
Primary cell . . . . . . . . . . . . . . . . . . . . . . IX
Nameplate of a lithium-ion battery . . . . . . . 00-1
Rechargeable battery . . . . . . . . . . . . . . . V
Recuperation . . . . . . . . . . . . . . . . . . . . . IX O
Regenerative braking . . . . . . . . . . . . . . . IX
Operating principle
Secondary cell . . . . . . . . . . . . . . . . . . . . IX
Charging/discharging . . . . . . . . . . . . . 00-8
I
P
Insulation resistance
Pin assignment
Measuring . . . . . . . . . . . . . . . . 21-5, 22-5
X51 . . . . . . . . . . . . . . . . . . . 21-48, 22-44
Intended use . . . . . . . . . . . . . . . . . . . . . . 00-4
X52 . . . . . . . . . . . . . . . . . . . 21-48, 22-44
L Positive power connector
Installing . . . . . . . . . . . . . . . . . . . . . 21-28
Leistungsverbinder Plus
Removing . . . . . . . . . . . . . . . . . . . . 21-27
Ausbau . . . . . . . . . . . . . . . . . . . . . . 22-20
Power cable
Einbau . . . . . . . . . . . . . . . . . . . . . . . 22-21
Installing . . . . . . . . . . . . . . . . . . . . . 21-62
Lifting tool
Removing . . . . . . . . . . . . . . . . . . . . 21-62
Attaching . . . . . . . . . . . . . . . . . . . . . . 01-4
Power cable 2.2
Removing . . . . . . . . . . . . . . . . . . . . . 01-4
Installing . . . . . . . . . . . . . . . . . . . . . 22-59
List of abbreviations . . . . . . . . . . . . . . . . . . . III
Removing . . . . . . . . . . . . . . . . . . . . 22-59
Lithium-ion batteries
Procedure in the event of a battery-related
Nameplate . . . . . . . . . . . . . . . . . . . . . 00-1
accident . . . . . . . . . . . . . . . . . . . . 00-5
Passive balancing . . . . . . . . . . . . . . 00-14
Technical data 2.1 . . . . . . . . . . . . . . . 21-1
Technical data 2.2 . . . . . . . . . . . . . . . 22-1
50988012057 EN - 12/2017 3
Index
g
R Technikraum 2.2
Öffnen . . . . . . . . . . . . . . . . . . . . . . . 22-28
Restoring operating status . . . . . . . . . . . . 21-9
Schließen . . . . . . . . . . . . . . . . . . . . 22-28
Assembling the front module cover . . 21-12
Technology compartment
Closing the technology compart-
ment . . . . . . . . . . . . . . . . . . . . . 21-11 Battery group 2.1 . . . . . . . . . . . . . . . . 21-4
Inserting auto plug-in fuse F2 . . . . . . 21-11 Technology compartment 2.1
Installing the main fuse . . . . . . . . . . . 21-10 Closing . . . . . . . . . . . . . . . . . . . . . . 21-33
Special tools . . . . . . . . . . . . . . . . . . 21-10 Opening . . . . . . . . . . . . . . . . . . . . . 21-33
Terminating resistor
S CAN bus . . . . . . . . . . . . . . . 21-32, 22-26
Schocksensor . . . . . . . . . . . . . . 21-19, 22-18 Transport directives . . . . . . . . . . . . . . . . . 00-6
Separator . . . . . . . . . . . . . . . . . . . . . . . . 00-8 Tray cover
Service plan . . . . . . . . . . . . . . . . . . . . . . . 01-1 Battery group 2.1 . . . . . . . . . . . . . . . 21-13
Spannungsfreiheit im Technikraum Battery group 2.2 . . . . . . . . . . . . . . . 22-11
Prüfen . . . . . . . . . . . . . . . . . . . . . . . . 22-8 Tray lid 2.1
Spannungsfreiheit im Technikraum Fitting . . . . . . . . . . . . . . . . . . . . . . . 21-14
herstellen . . . . . . . . . . . . . . . . . . . 22-6 Removing . . . . . . . . . . . . . . . . . . . . 21-13
Flachstecksicherung F2 ziehen . . . . . 22-7 Trogdeckel 1.1 / 1.2
Hauptsicherung ausbauen . . . . . . . . . 22-7 Anbau . . . . . . . . . . . . . . . . . . . . . . . 22-12
Spezialwerkzeuge . . . . . . . . . . . . . . . 22-6 Trogdeckel 2.2
Technikraum öffnen . . . . . . . . . . . . . . 22-6 Abbau . . . . . . . . . . . . . . . . . . . . . . . 22-11
Special safety regulations . . . . . . . . . . . . . 00-2
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 00-7 U
Support for the current/voltage sensor Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Installing . . . . . . . . . . . . . . . . . . . . . 22-32
Removing . . . . . . . . . . . . . . . . . . . . 22-32 V
Voltage transformer . . . . . . . . . . 21-56, 22-52
T
Installation . . . . . . . . . . . . . . . . . . . . 22-54
Technical compartment Installing . . . . . . . . . . . . . . . . . . . . . 21-57
Battery group 1.1 . . . . . . . . . . . . . . . . 22-4 Removal . . . . . . . . . . . . . . . . . . . . . 22-52
Battery group 1.2 . . . . . . . . . . . . . . . . 22-4 Removing . . . . . . . . . . . . . . . . . . . . 21-56
4 50988012057 EN - 12/2017
STILL GmbH
50988012057 EN – 12/2017

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Workshop literature

The list of abbreviations provides an overview of

Abbreviation Meaning Explanation

AC Alternating Current Alternating current

Accord européen relatif

50988012057 EN - 12/2017 III

Abbreviation Meaning Explanation

Unit symbol Unit name Explanation

Unit of electrical charge storage capacity (nominal ca-

dB Decibel Unit of sound intensity

Battery Management System

Example of 240 Ah nominal capacity:

Final discharged voltage

Final charged voltage

Important factors for the number of charge cycles:

50988012057 EN - 12/2017 VII

The nominal capacity (Ah) multiplied by the

Power source parallel connection

VIII 50988012057 EN - 12/2017

Power source serial connection

Regenerative braking (recuperation)

Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-2

Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-6

Description of lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-8

Operating materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2

Battery charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5

Function checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12

21 Battery group 2.1

De-energised state BG 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-5

Components BG 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-13

Technology compartment BG 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-33

XII 50988012057 EN - 12/2017

Contactor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-50

Wiring BG 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-62

22 Battery group 2.2

De-energised state BG 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-5

Components BG 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-11

Technology compartment BG 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-28

50988012057 EN - 12/2017 XIII

Removing/installing the brake resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-38

Wiring BG 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-59

XIV 50988012057 EN - 12/2017

Nameplate of a lithium-ion battery

50988012057 EN - 12/2017 00-1

00-2 50988012057 EN - 12/2017

• Wear personal protective equipment when

50988012057 EN - 12/2017 00-3

00-4 50988012057 EN - 12/2017

Procedure in the event of a battery-related accident

Procedure in the event of electric shock

Lithium-ion battery: First-aid measures

50988012057 EN - 12/2017 00-5

Transport and storage

Observe the operating instructions for the lifting

The batteries are carefully packed to minimise

00-6 50988012057 EN - 12/2017

of the following hazardous materials regulations

Please contact the person in your organisation

50988012057 EN - 12/2017 00-7

Description of lithium-ion battery

Charging/discharging - operating principle

1 Graphit 2 LiCoO2 Graphit

The same electrode acts either as anode or ca-