https://truckmanualshub.

com/

RX20-15 - 20, RX60-16 - 20

https://truckmanualshub.com/
https://truckmanualshub.com/

Chapter 22 - "Mechanical drive axle", chapter

has been restructured and drive axle AE18-07
has been added.
Various corrections and alignment with the Chapter 42 - "Steering axle", curve switch has
speci ed standards for workshop manuals been revised.
Chapter 50 - "Operating devices", "accelera- Chapter 49 - "Brake system", chapter has
tor, generation 2" integrated been restructured and brake adjustment for
Chapter 56 - "Travel direction selector and drive axle AE18-07 has been added.
indicator module, generation 2" integrated Chapter 60 - "Insulation testing" has been
revised
Chapter 60 - "Power cables" have been added
Chapter 64 - "MCU2" has been integrated
Chapter 69 "Maintenance guidelines for
Various corrections and enhancements attachment connectors" has been added
Chapter 00 "Product overview" revised
Chapter 01 "Harnesses and hoists" added
Chapter 42 "Steering system" restructured
Chapter 50 "Operating devices" revised;
"joystick 4Plus" added Various corrections and enhancements
Chapter 60 "Insulation testing on the drive Introduction rearranged.
battery" revised Chapter 00 maintenance and diagnostics
Chapter 60 "Temperature monitoring" added.
revised Chapter 42 CSC revised.
Chapter 69 "2014 discharge indicator" Chapter 49 electric parking brake revised.
added Chapter 60 insulation testing and intermedi-
Chapter 71 "Accumulator " added ate circuit summarised.
Chapter 81 "Lift masts" completely revised
Chapter 84 "Fork carriage" completely
revised

This workshop manual combines the truck

series RX20-15 - 20 and RX60-16 - 20.
All chapters have been revised.
Various corrections and enhancements Facelift integration, Step 1 and 2
Integration of type carrier 6209 (RX20-14).

50638042201 EN - 10/2017 I
https://truckmanualshub.com/
https://truckmanualshub.com/

This workshop manual contains all the informa-

tion required to assist a competent person with Display elements - display
all work, repairs and maintenance on this truck.
FleetManager
For the purposes of clarity and completeness,
some components have been deliberately ex-
cluded from this workshop manual and described
Error list
in their own speci c documentation. Changes
may be made at short notice and at any time, and Overview of truck software
are communicated via service information docu- Overview of consumables
ments. STILL Flasher
The documentation comprises operating instruc- FEM 4.004 test log book
tions, additional workshop manuals, special doc- Service information documents
umentation and circuit diagrams.

See Steds-Navigator
Original operating instructions for the truck
FleetManager 4.x

A quali ed person is de ned as a service engin-

eer or a person who ful ls the following require-
ments:
A completed vocational quali cation that
demonstrably proves their professional exper-
tise. This proof should consist of a vocational
quali cation or a similar document.
Professional experience indicating that the
quali ed person has gained practical experi-
ence of industrial trucks over a proven period
during their career During this time, this per-
son has become familiar with a wide range of
symptoms that require checks to be carried
out, such as based on the results of a hazard
assessment or a daily inspection
Recent professional involvement in the eld
of the industrial truck test in question and an
appropriate further quali cation are essential.
The quali ed person must have experience of
carrying out the test in question or of carrying
out similar tests. Moreover, this person
must be aware of the latest technological
developments regarding the industrial truck
to be tested and the risk being assessed

50638042201 EN - 10/2017 III

https://truckmanualshub.com/

The signal terms , , ,

and are used in this
document as hazard warnings or for unusual means that particular attention is drawn to the
information that requires special identi cation: interrelationship between technical factors that
may not be evident even to a specialist.

The instructions listed here must be strictly

observed in order to prevent damage to the
environment.
means that failure to comply involves risk of serious
injury and/or major damage to property can occur. Additional signs and symbols are used to illus-
trate the hazard warnings. These are printed to
the left of the hazard warnings.

means that failure to comply involves risk of material

damage or destruction.

If the truck is used for work not listed in the

guidelines or truck-speci c original operating
instructions and has to be converted or retro tted
accordingly, you should be aware of the following:
Any structural modi cation can affect the
handling and stability of the truck, and can
result in accidents.
Without authorisation from STILL, no changes
that affect the stability, the load capacity and
the safety systems may be carried out.
Operation of the truck without an overhead
guard at a lift height of over 1800 mm is
prohibited.
It is prohibited to install and use restraint
systems that are not approved by STILL.
It is prohibited to drill holes in the overhead
guard or to perform welding on it.
When carrying out welding on other parts of
the truck, it is essential that the battery and
all connections to the electronic controls are
disconnected.
It is prohibited
to drill holes in the area of the driver's seat into
the battery hood because hydrogen can enter
through the bores into the driver's cab.

IV 50638042201 EN - 10/2017
https://truckmanualshub.com/

With the CE declaration of conformity, STILL con-

rms that the truck complies with the standards
and regulations valid at the time of marketing.
The CE conformity mark is shown on the name-
plate and indicates compliance with the above
regulations.
A subsequent structural change or addition to the
truck can compromise safety, thus invalidating
the CE declaration of conformity. In this case,
a new CE declaration of conformity is essential
for the structural changes. The company that
was instructed by the truck operating company to
carry out the change is responsible for issuing a
new CE declaration of conformity.

The contractor of the operating company must CE-Symbol

also ful l the following prerequisites:

Construction documents, test documents
and assembly instructions associated with
the change must be archived and remain
accessible at all times.
Check that the capacity rating plate, decal in-
formation, hazard warnings and the operating
instructions are consistent with regard to the
changes and modify if necessary.
The change must be processed by a design of ce
that specialises in the area of industrial trucks.
The change must be planned, checked and
implemented in accordance with the standards
and directives valid at the time.

Original parts, attachments and accessories are

specially designed for this truck. We speci -
cally draw your attention to the fact that parts,
attachments and accessories supplied by other
companies have not been tested and approved
by STILL.

Installation and/or use of such products may therefore

have a negative impact on the design features of the
truck and thus impair active and/or passive driving
safety.
We recommend that you obtain approval from the
manufacturer and, if necessary, from the relevant
regulatory authorities before installing such parts.
STILL accepts no liability for any damage caused by
the use of non-original parts and accessories without
approval.

50638042201 EN - 10/2017 V
https://truckmanualshub.com/

It is not generally permitted to open controls.

STILL's liability and the warranty are no longer
applicable once the seal has been damaged.
In exceptional cases, personnel authorised by
STILL are allowed to open the controls.

VI 50638042201 EN - 10/2017
https://truckmanualshub.com/

......................................................... - 1
......................................... - 1
................................... - 3

................................................ . - 5
........................... - 5
....................................... - 6
........................................ - 6
......................................... - 8
............................................ - 9

...................................................... - 1
............................................. - 1
.................................... - 3
................................ - 5

.............................................................. - 6
............................. - 6
....................................... - 8
... - 9
............................ - 10

............................................. - 1
.................................................. - 1
.............................................. - 2
.................................................. - 3
................................................... - 4

............................................... - 5
............................................ - 5
.................................... - 6

............................................. - 7
..................................................... - 7
.................................................. - 9

50638042201 EN - 10/2017 VII

https://truckmanualshub.com/

..................................................... - 1
............................................... - 1
............................................... - 1
..................................................... - 2

................................................ .......... - 4
........................................................ - 4
........................................... - 5

................................................ - 1
............................................... - 1
........................................................ - 2
...................................... - 3
....................................................... - 7
................................ - 9
......................................... - 11
..................................................... - 14
.............................................. - 17
................................... - 18

................................................ - 22
............................................... - 22
................................................. - 23
......................................... - 24
............................. - 25
........................................... - 29
..................................... - 29
........................ - 31
...................................... - 33
.............................................. - 35
............................................... - 36
............................................... - 38
................................... - 41

........................................................... - 1
...................................................... - 1

VIII 50638042201 EN - 10/2017

https://truckmanualshub.com/

..................................................... - 2
..................................................... - 2

................................................... - 3
................................................... - 3
......................................... - 5
.......................................... - 11

................................................ . - 1
............................................... - 1
................................................... - 2
............................................ - 4
...................................................... - 5
........................................ - 7
...................................................... - 10

................................. - 12
................................................... - 12
........................................... - 14
..................... - 16
............................................... - 17

.................................................. - 20
...................................... - 20
........................................................ - 21
...................................................... - 21
...................................... - 22

........................................................ - 26
...................................... - 26
........................................................ - 27
.............................................. - 28
...................................... - 29
........................................................ - 31
..................................................... - 34
.......................................................... - 35
......................................................... - 36

50638042201 EN - 10/2017 IX
https://truckmanualshub.com/

........................................... - 1
.................................................... - 1
......................................... - 2
......................................... - 3
............................................ - 5
....................................... - 6
............................................. - 8
...................................................... - 9
........................................... - 10
...... .................................. - 12

.............................................. - 16
............................................... - 16
......................................................... - 17
................................................... - 19
......................................... - 21
............................................. - 23
................................................. - 24
......................................... - 26
...................................... - 29
................................................. - 32
...................................... - 34
.......................... - 36

........................................................ - 39
.................................... - 39
.................................. - 43

................................................. - 48
........................................................ - 48
..................................................... - 50
....................................... - 51
.............................................. - 53
....................................... - 55
...... .................................. - 57
........................................................ - 60
....................................... - 61
................................................ .......... - 62
.................................................. - 64

X 50638042201 EN - 10/2017
https://truckmanualshub.com/

.............................................. - 65
.................................. - 67

............................................................ - 69
.............................................. - 69

................................................ . - 1
....................................... - 1
..................... - 3
..................................... - 4

........................................................... - 6
...... ......................... - 6
......................................... - 8
............................ - 9
......................................... - 10

........................................................... - 1
........................................ - 1
........................................ - 3
............................................ - 4
................................................... - 5
............................................... - 5
............................ - 7
............................................... - 12
...................................................... - 13
............................................. - 14
...... .................................... .......... - 15
................................................ . - 16
...................................... - 17
.................................... - 19
.......................................... - 20
......................... - 23
......................... - 25
...................... - 26
.................................... - 27
....................... - 29
........................................... - 30

50638042201 EN - 10/2017 XI
https://truckmanualshub.com/

............................... - 30
....................................................... - 32

............................................................ - 34
................................................... - 34
............................................... - 36
..................................................... - 38
................................. - 39
............................................ - 39

.................................................. - 41
......................................................... - 41
........................................................... - 41
............................................ - 43
................................................ - 45
........................................................ - 46

.................................................... - 47
............................................. - 47
............................................... - 48
.......................................... - 50
................................. - 51
................................................. - 53
.................................... - 55

..................................... - 56
................................................ - 56
...................................................... - 57
.............................................. - 59
...................................................... - 59
................................................ .......... - 61
...................................................... - 62
........................................... - 62
.................................................. - 63

............................... - 1
............................................. - 1
............................................ - 2
.................................................. - 3
.......................... - 3

XII 50638042201 EN - 10/2017

https://truckmanualshub.com/

................................................... - 5
................................ - 7

......................................................... - 10
......................................................... - 10
........................................... - 10
.............................................. - 12
..................................... - 13

...... .................................... .......... - 1

.......................................................... - 1
............................................. - 3
................................................ . - 6
....................................................... - 7
...... ......................... - 9
................................. - 11
.......................................... - 12

........................................................... - 1
............................................... - 1
......................................... - 2
.............................................. - 4
......................................... - 4
.............................................. - 5

...................................................... - 7
............................................... - 7
................................................ . - 7
........................................ - 8

................................................... - 9
................................................... - 9
................................................ . - 10
................................................ . - 11
..................................................... - 12
...................................................... - 12
...... .................................... .......... - 13
..................................................... - 15
...................................................... - 16

50638042201 EN - 10/2017 XIII

https://truckmanualshub.com/

................................................. - 17
........................................... - 18
....................................................... - 18

......................................................... - 1
............................................... - 1
........................................................ - 2
............................................... - 4
...... .................................. - 4
............................................ - 5
....................................... - 6
................................................ - 8
.............................................. - 10
.................................................... - 13
................................. - 14

........................................................ - 18
................................................ .......... - 18
.................................... - 18
................................ - 20

................................................ - 23
...................................................... - 23
................................ - 24
............................ - 24
................................ - 26

...................................................... - 28
...................................................... - 28
............................................ - 29

........................................................ - 1
............................................... - 1
............................................... - 3
................................................ - 4
................................................ - 5
.................................... - 7

XIV 50638042201 EN - 10/2017

https://truckmanualshub.com/

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

.............. - 14
...................................... - 14
.................................. - 15
................................ - 17
.. .............................................. - 18
.................................................. - 19
...... .................................... .......... - 20

................................................... - 21
............................................... - 21
.......................................... - 22
................................................... - 23
......................................... - 24
............................. - 26

..................................................... - 1
............................................ - 1

.......................................................... - 1
............................................... - 1
....................................... - 2
....................................... - 5
.................................... - 6
...... .................................... .......... - 8
.. .............................................. - 9
................................................ . - 10
............................................... - 11

................................................ . - 14
...................................... - 14
................... - 15

...................................................... - 17
........................................... - 17

50638042201 EN - 10/2017 XV
https://truckmanualshub.com/

....................... - 19

.................................................... - 21
.......................................... - 21
............................... - 23
..................... - 26
...................................... - 28
....................................... - 30
................... - 32
.................. - 33

........................................................ - 35
................................................ .......... - 35
.............................................. - 36
..................................................... - 36
.............................. - 39
.................................................... - 41
............................. - 43
................................... - 46
...................................... - 47

...................................................... - 1
...................................................... - 1

......................................................... - 1
................................... - 1
................................... - 3
.................................................... - 5

XVI 50638042201 EN - 10/2017

https://truckmanualshub.com/

A Overhead guard C Battery sizes

a1 Standard overhead guard
a2 Container overhead guard (variant)
D Load lifting classes

B Chassis
E Steering axle
b1 Lower chassis
e1 3-wheel, fth-wheel
b2 Higher chassis
e2 4-wheel, swing axle

RX20 - 14 Low 48 V / 550 Ah 1.4 t 3-wheel 6209

RX20 - 15 Low 48 V / 550 Ah 1.5 t 3-wheel 6210
RX20 - 16 Low 48 V / 550 Ah 1.6 t 3-wheel 6211
RX20 - 16 Low 48 V / 550 Ah 1.6 t 4-wheel 6212
RX20 - 18 Low 48 V / 550 Ah 1.8 t 3-wheel 6213
RX20 - 18 High 48 V / 700 Ah 1.8 t 4-wheel 6214
RX20 - 20 Low 48 V / 550 Ah 2.0 t 3-wheel 6215
RX20 - 20 Low 48 V / 550 Ah 2.0 t 4-wheel 6216
RX20 - 20 High 48 V / 700 Ah 2.0 t 4-wheel 6217
.

These trucks are being replaced from calendar

week 35 onwards by the RX20 Facelift 2014.

50638042201 EN - 10/2017 -1
https://truckmanualshub.com/

Improved properties:
Enhanced discharge indicator and consump-
tion display

New components:
Joystick 4Plus
Push-up roof panel
Metal brand emblem
Lighting on top of the overhead guard
Diagnostic connector (Group connector) in the
front structure

New truck type RX20-14 (6209)

New components:
Generation 2 MCU
Drive axle AE18-07

Improved properties:
Ergonomic driver's workstation
Drive mode Blue-Q

New components:
Generation 2 mini-lever
Generation 2 display and operating unit
Electric parking brake
Load measurement
Mast vertical position
Hydraulics blocking function in accordance
with EN ISO 3691-1

-2 50638042201 EN - 10/2017
https://truckmanualshub.com/

A Overhead guard C Battery sizes

a1 Standard roof
a2 Container roof (variant)
D Load lifting classes

B Higher chassis
E 4-wheel, swing axle

RX60 - 16 High 80 V / 420 Ah 1.6 t 4-wheel 6311

RX60 - 18 High 80 V / 420 Ah 1.8 t 4-wheel 6313
RX60 - 20 High 80 V / 420 Ah 2.0 t 4-wheel 6315
.

Improved properties:
Enhanced discharge indicator and consump-
tion display

New components:
Joystick 4Plus
Push-up roof panel
Metal brand emblem
Lighting on top of the overhead guard
Diagnostic connector (Group connector) in the
front structure

New components:
Generation 2 MCU
Drive axle AE18-07

50638042201 EN - 10/2017 -3
https://truckmanualshub.com/

Improved properties:
Ergonomic driver's workstation
Drive mode Blue-Q

New components:
Generation 2 mini-lever
Generation 2 display and operating unit
Electric parking brake
Load measurement
Mast vertical position
Hydraulics blocking function in accordance
with EN ISO 3691-1

-4 50638042201 EN - 10/2017
https://truckmanualshub.com/

The truck must not be parked on a slope.

If necessary, use wedges to prevent the truck from
rolling away.

Before servicing, fully lower the unladen fork car-

riage.

Changes in the centre of gravity caused by attach-

ments can lead to additional hazards.
If attachments are tted, retract the working cylinders.
If necessary remove the attachment before performing
service work.

Apply the parking brake.

Lower the unladen fork carriage to the ground.
Tilt the lift mast forwards until the tips of the
fork arms rest on the ground.
If attachments (variant) are tted, retract
the unladen working cylinders; if necessary,
remove the attachment.
Turn the key switch to OFF.
If necessary, disconnect the battery male
connector or the starter battery.

50638042201 EN - 10/2017 -5
https://truckmanualshub.com/

Do not touch live contact points such as the positive

and negative connections of the power control units!
Before working on electrical power connections, al-
ways check the voltage between all contact points and
between the contact points and the truck chassis using
a suitable measuring device (capable of measuring up
to 1000 V/DC).
Discharge the intermediate circuit.

When jacking up the forklift truck, always secure it

with appropriate means (wedges, wooden blocks) to
prevent rolling or tipping.

The forklift truck has to be jacked up for various

maintenance tasks.

Always comply with the following:

Use only jacks with an adequate load capacity
Only jack up the forklift truck on a level surface
Secure the forklift truck against rolling and
dropping.

Risk of injury!
Apply the parking brake and disconnect the battery
male connector before jacking up the forklift truck.

Risk of injury!
Jack up the forklift truck to such a height that shoes
cannot be caught by turning wheels.

-6 50638042201 EN - 10/2017
https://truckmanualshub.com/

Park the truck securely on level ground.

Turn the key switch OFF.
Apply the parking brake.
Remove the forks or push them together in the
middle.
Lift the fork carriage so that the hydraulic jack
can be placed on the outer mast.
Jack up the truck until the wheels are no longer
in contact with the ground.
Insert supporting blocks under the chassis on
both sides.
Carefully lower the hydraulic jack until the truck
rests securely on the support blocks.

50638042201 EN - 10/2017 -7
https://truckmanualshub.com/

When jacking up the truck, always secure it with ap-

propriate means (wedges, wooden blocks) to prevent
rolling or tipping.

The truck has to be jacked up for various mainte-

nance tasks.

Always comply with the following:

Use only jacks with an adequate load capacity.
Jack up the truck only on a level surface
Secure the truck against rolling and dropping.

Risk of injury!
Apply the parking brake and disconnect the battery
male connector before jacking up the truck.

Risk of damage to the battery door!

Do not place jacks or square timbers under the battery
door.
Open the battery door and snap into place before
jacking up the truck.

Park the truck on a level surface.

Turn the key switch OFF.
Apply the parking brake.
Open the battery door and snap into place.
Place the hydraulic jack on a square timber
at the designated position (1) at the counter-
weight.
Jack up the truck until the wheels are no longer
in contact with the ground.
Place square timbers on both sides at the des-
ignated position (2) under the counterweight.
Carefully lower the truck until it rests securely
on the timbers.

Park the truck on a level surface.

Turn the key switch OFF.
Apply the parking brake.

-8 50638042201 EN - 10/2017
https://truckmanualshub.com/

Open the battery door and snap into place.

Right side of the truck:
Place the hydraulic jack on a square timber at
the designated position (3) at the chassis.
Jack up the truck until the square timber ts
under the chassis at the designated position
(2).
Place the square timber at the designated
position (4) under the counterweight.
Carefully lower the jack until the truck is resting
on the square timber.

Left side of the truck:

Place the jack at the designated position (1) at
the chassis
Jack up the truck until the wheel is no longer in
contact with the ground.
Place the square timber at the designated
position (2) under the counterweight.
Carefully lower the truck until it rests securely
on the timbers.

When working at the front of the truck, always secure

the fork carriage to prevent it dropping.

Use only chains with adequate lifting capacity to secure

the particular lift mast.

50638042201 EN - 10/2017 -9
https://truckmanualshub.com/

Potential damage to the ceiling!

Note the maximum lift height of the particular lift mast.

Extend the lift mast.

Route the chain along the cross traverse of the
outer mast (1) and connect it underneath the
cross traverse of the inside mast (2).
Lower inside mast until it strikes the chain.

Extend the lift mast to slacken the chain.

Extend the lift mast.

Route the chain along the cross traverse of the
outer mast (1) and connect it underneath the
cross traverse of the inside mast (2).
Lower lift mast until it sttrikes the chain.
Lower fork carriage down to the stop.

Extend the lift mast to slacken the chain.

-10 50638042201 EN - 10/2017

https://truckmanualshub.com/

Extend the lift mast.

Route the chain along the cross traverse of the
outer mast (1) and connect it underneath the
cross traverse of the middle mast (2).
Lower lift mast until it sttrikes the chain.
Lower fork carriage down to the stop.

Extend the lift mast to slacken the chain.

50638042201 EN - 10/2017 -11

https://truckmanualshub.com/

-12 50638042201 EN - 10/2017

https://truckmanualshub.com/

Maintenance work must be carried out in accor-

dance with the following maintenance intervals.
The intervals are designed for standard use.
Depending on the application conditions of the
truck, shorter maintenance intervals can be set,
on agreement with the operating company.

These factors may call for shorter maintenance

intervals:
Contaminated, poor quality roads
Dusty or salty air
High air humidity
Extremely high or low ambient temperatures,
or extreme changes in temperature
Multi-shift operation with a high duty cycle
Speci c national regulations for the truck or
individual components
For maintenance tasks, only use original spare
parts, and only use consumables that have been
prescribed in the overview of consumables.

50638042201 EN - 10/2017 -1
https://truckmanualshub.com/

-2 50638042201 EN - 10/2017
https://truckmanualshub.com/

Check chassis for cracks

Check overhead guard/cab and panes of glass for damage
Check controls, switches and joints for damage, and apply grease and oil
Check driver's seat for correct function and for damage
Check driver restraint system for correct function and for damage, and clean.
Check the signal horn
: Check the dual-pedal variant for damage and correct function, and lubricate

Check tyres for wear and check the air pressure if necessary
Check wheels for damage and check the tightening torques

Drive axle: Check mounting, check for leaks, and clean cooling ns
Drive wheel unit and multi-disc brake: Check the oil level
Change the gearbox oil (once after the rst 1000 hours)

Check steering system for correct function and for leaks

Check that the steering wheel is rmly attached and check the turning handle for damage
Steering axle: Check that it is rmly attached, check for leaks, and apply grease
Check steering stop

Check all mechanical brake parts for condition and correct function
Carry out brake test
: Check the electric parking brake variant for damage and correct function
: Electric parking brake: Check the relubrication device

Check all power cable connections

Check main contactor contacts
Test switches, transmitters and sensors for correct function
Check lighting and indicator lights

Check the lead-acid battery for damage and check the acid density; observe the manu-
facturer's maintenance instructions
: Lead-acid battery with electrolyte circulation: Replace the non-return valve
: Lithium-ion battery: Observe the manufacturer's maintenance instructions
Check the appliance plug and truck harness for damage
Check the battery male connector and battery harness for damage

Check that the battery door, and the sensor if necessary, is working correctly and check
for damage.
Check the battery lock for damage.
: Hydraulic battery carrier: Check all moving parts for wear, and oil or lubricate.
Observe the special maintenance schedule

50638042201 EN - 10/2017 -3
https://truckmanualshub.com/

: Hydraulic battery carrier: Check the oil level and check for leaks

Check hydraulic system for condition, correct function and leaks

Check the hydraulics blocking function (ISO valve)
Check oil level

Check mast bearings for damage, and lubricate. Check the tightening torque
Check mast pro les for damage and wear, and lubricate
Check load chains for damage and wear, adjust and lubricate
Check lift cylinders and connections for damage and leaks
Check guide pulleys for damage and wear
Check support rollers and chain rollers for damage and wear
Check the play between the fork carriage stop and run-out barrier
Check tilt cylinders and connections for damage and leaks
Check fork carriage for damage and wear
Check fork arm interlock for damage and correct function
Check fork arms for wear and deformation
Check that there is a safety screw on the fork carriage or on the attachment

Check the condition of the antistatic belt or antistatic electrode.

Check heating system for damage; observe manufacturer's maintenance instructions
Check attachments for wear and damage; observe manufacturer's maintenance instruc-
tions
Check trailer coupling for wear and damage; observe manufacturer's maintenance in-
structions

Read out error numbers and delete list

Reset maintenance interval
Check labelling for completeness
Test drive the truck

-4 50638042201 EN - 10/2017
https://truckmanualshub.com/

Perform all 1000-hour maintenance work

Drive wheel unit and multi-disc brake: Change the gearbox oil
Replace the bleeder screws on the drive wheel units

: Electric parking brake: Replace the actuation push button

Renew the hydraulic oil

Replace the return line lter and breather lter
: Replace the high-pressure lter
only: Replace the accumulator

50638042201 EN - 10/2017 -5
https://truckmanualshub.com/

USB service box, package group with wires 50983605401

USB service box 50983605400
BT service box, package group with wires and USB stick 50983605406
BT service box 50983605403
STILL Bluetooth USB stick 50983605405
Adaptor cable, service box on truck, diagnostic connector, 7-pin, 4
0171381
pins assigned
Adaptor cable, service box on truck, diagnostic connector, 7-pin, 6
3903820104
pins assigned, 50 cm
Adaptor cable, service box on truck, diagnostic connector, 7-pin, 6
3903820105
pins assigned, 200 cm
Adaptor cable, service box on truck, diagnostic connector, 4-pin 0625028
.

STILL multimeter including measurement leads 0009418737

Current probe 0156300
Temperature sensor, 20...320 C 0156299
Hydraulics test box 0147530
Hydraulics digital test box 0009416002
Accumulator test tting 0009418044
Spring force meter with up to 200 N
Refractometer
Testing of reduction agent DEF, coolant G12+, anti-freeze, battery
acid
.

Adaptor cable, SAAB, 42-pin 8426527

Adaptor cable, variable from 2-pin to 25-pin 0172204
Adaptor cable, SAAB, 16-pin 0172201
Adaptor cable, SAAB, 2-4-6-10-pin 0172202
Measuring adaptor, mark II, 2-4-6-8-pin 0149862
Adaptor cable, mark II - JPT, 4-pin, male connector 0157647
Adaptor cable, mark II - JPT, 4-pin, female connector 0157648
.

-6 50638042201 EN - 10/2017
https://truckmanualshub.com/

Replacement MetraHit measuring lines, pair of red and black

Measuring tips, pair of red and black 0143426
Crocodile clips, pair of red and black 0143427
Measurement wires, pair of red and black 0143425
.

AMP crimping tool 0144087

Ejector box 0172412
Crimping tool for wire cross-sections of 10...95 mm2 0009418107
.

50638042201 EN - 10/2017 -7
https://truckmanualshub.com/

Hydraulic jack, load capacity 5000 kg 0161527

Ratchet hoist, 800 kg Hahn&Kolb 77158080
.

Round sling 1000 kg, L= 1 m (purple) Hahn&Kolb 77200710

Round sling 1000 kg, L= 2 m (purple) Hahn&Kolb 77200910
Round sling, 2000 kg, L = 2 m (green) Hahn&Kolb 77200920
Safety chains up to 2000 kg 0155297
Truck hook, single, up to 2000 kg Hahn&Kolb 77185020
Shackle Hahn&Kolb 77174210
Lifting eye bolt M6 0148154
Lifting eye bolt M8 0148155
Lifting eye bolt M10 0148156
Lifting eye bolt M12 0148157
Adjustable screw clamp 0156303
.

Supporting block, 250x180x120 0146466

Supporting block, 250x180x38 0009315501
Supporting block, 250x180x58 0009315502
Wheel chock, braking wedge 0144267
.

-8 50638042201 EN - 10/2017
https://truckmanualshub.com/

Thread Grade 4.6 Grade 4.8 Grade 5.8 Grade 6.8 Class 8.8 Grade 10.9 Grade 12.9
M4 1 1.3 1.7 2 2.7 3.8 4.6
M5 2.1 2.7 3.4 4.1 5.5 8 9.5
M6 3.6 4.7 5.9 7.1 9.5 13 16
M8 8.5 11 14 17 23 32 39
M10 17 23 29 34 46 64 77
M12 30 40 50 60 80 110 135
M14 47 62 78 94 125 180 215
M16 73 100 122 146 195 275 330
M20 145 192 240 289 385 540 650
M24 250 330 410 495 660 930 1110
M30 510 675 840 1000 1350 1850 2250
M36 880 1170 1470 1760 2350 3300 3900
.

Thread Grade 4.6 Grade 4.8 Grade 5.8 Grade 6.8 Class 8.8 Grade 10.9 Grade 12.9
M8x1 9.5 12 16 19 25 35 42
M10x1 20 26 32 39 52 72 95
M10x1.25 18 24 30 37 49 68 82
M12x1.25 33 44 55 66 88 125 150
M12x1.5 31 41 52 62 83 115 140
M14x1.5 52 70 87 105 140 195 235
M16x1.5 79 105 130 157 210 295 350
M18x1.5 115 150 190 230 305 425 510
M20x1.5 160 210 265 320 425 600 720
M22x1.5 215 285 355 425 570 800 960
M24x1 270 360 450 540 720 1000 1200
M27x1 395 525 655 785 1050 1500 1800
M30x2 540 725 905 1085 1450 2050 2500
M36x3 930 1250 1560 1870 2500 3500 4100
.

50638042201 EN - 10/2017 -9
https://truckmanualshub.com/

The basis for these tables is works standard

WN 14031 "Tightening torques for union nuts
and threaded ends".

8-L 6 M14 x 1.5 17 12

10-L 8 M16 x 1.5 19 20
12-L 10 M18 x 1.5 22 28
15-L 12 M22 x 1.5 27 50
18-L 16 M26 x 1.5 32 75
22-L 19 M30 x 1.5 36 105
28-L 25 M36 x 1.5 41 150
.

10-S 6 M18 x 1.5 22 32

12-S 8 M20 x 1.5 24 45
14-S 10 M22 x 1.5 27 58
16-S 12 M24 x 1.5 30 70
20-S 16 M30 x 1.5 36 120
25-S 19 M36 x 1.5 46 170
30-S 25 M42 x 1.5 50 230
.

-10 50638042201 EN - 10/2017

https://truckmanualshub.com/

3 Document search by type carrier

1 Document category 4 Document search by truck series
2 Document language 5 Document selection

Start the notebook and double-click the icon

on the desktop.
The STEDS-Navigator opens with the home-
page (see above).
If necessary, change the document language
(2). We recommend that you select English as
the second language.
Select the required document category (1).
Select the required truck series (4).
In the document selection (5), select and
launch the required document by double
clicking.
It is also possible to search for documents directly
via the "Document search by type carrier" option.
Click the document search by type carrier
option (3).
Enter the required type carrier and con rm by
pressing Start .
All documents relevant for the type carrier in
question are listed and can be opened by double
clicking.

50638042201 EN - 10/2017 -1
https://truckmanualshub.com/

USB cable: the service box must be loaded

1 with the current software. The USB cable
will be omitted in later versions
Connection for the adaptor cable, 7-pin, 4
2
pins assigned
Connection for the adaptor cable, 7-pin, 6
3
pins assigned
The LED lights up once the service box
4 is supplied with voltage via the diagnostic
connector when the truck is switched on
The LED indicates the status between the
5
notebook and the service box
The LED indicates the status between the
6
service box (CAN 1) and the truck
The LED indicates the status between the
7
service box (CAN 2) and the truck
8 The LED indicates the Bluetooth status
9 Antenna
10 STILL Bluetooth USB stick

If all LEDs (3,4,5,6) are ashing, the service box

is in programming mode. In this case, the service
box must be reset.

USB cable: the service box is connected to

1
the notebook
Connection for the adaptor cable, 7-pin, 4
2
pins assigned
Connection for the adaptor cable, 7-pin, 6
3
pins assigned
The LED lights up once the service box
4 is supplied with voltage via the diagnostic
connector when the truck is switched on
The LED indicates the status between the
5
notebook and the service box
The LED indicates the status between the
6
service box (CAN 1) and the truck
The LED indicates the status between the
7
service box (CAN 2) and the truck

If all LEDs (3,4,5,6) are ashing, the service box

is in programming mode. In this case, the service
box must be reset.

Switching the truck off and on again will trigger a

reset of the service box. Switching the truck off
interrupts the CAN bus power supply.

-2 50638042201 EN - 10/2017
https://truckmanualshub.com/

1 Truck CAN bus (red) 5 CAN box, BT

2 Display and operating unit (ABE) 6 CAN box, USB
3 Truck control unit 7 Notebook
4 Diagnostic connector 8 STILL Bluetooth USB stick

The notebook is connected to the diagnostic

connector on the truck via a CAN box.
The "red" truck CAN bus connects the diagnostic
connector to the display and operating unit and
the truck control unit.
Depending on the type of CAN box used, the
connection to the notebook can be made using
a USB cable or via Bluetooth. In either case, the
diagnostic options are always identical.

The notebook is connected to the CAN box via

Bluetooth.
The CAN box is connected to the diagnostic
connector on the truck via the adaptor cable.
1 Diagnostic connector, 7-pin
2 Adaptor cable for diagnostic connector, 7-pin
3 CAN box, BT
4 STILL Bluetooth USB stick
The STILL Bluetooth USB stick must be used for 5 Notebook
the Bluethooth connection.

50638042201 EN - 10/2017 -3
https://truckmanualshub.com/

The notebook is connected directly to the CAN

box via the connecting line.
The CAN box is connected to the diagnostic
connector on the truck via the adaptor cable.
1 Diagnostic connector, 7-pin
2 Adaptor cable for diagnostic connector, 7-pin
3 CAN box, USB
5 Notebook
In the medium term the CAN box, USB will be
replaced by the CAN box, BT.

DiaMon starts a guided diagnostics process that

can be used to individually select and carry out
different diagnostic sequences and actions. The
user is guided by the program at all times. The
relevant speci cations stipulated must always be
followed!
Safely park the truck; see the chapter entitled
"Parking the truck so it is secured for service
work"
Jack up the truck on the drive side; see the
chapter entitled "Safety information"
Turn the key switch to ON.
Open the notebook and start STEDS-Naviga-
tor; see the chapter entitled "STEDS-Naviga-
tor" 1 F2: Diagnosis
2 Diagnosis Start Points
Connect the notebook to the truck; see the 3 Jobs
chapter entitled "Overview of diagnostic tools"
Select the required diagnostics in STEDS-
Navigator and double click to start.
It may take some time to establish the connection
with the truck and to launch the diagnostics.

-4 50638042201 EN - 10/2017
https://truckmanualshub.com/

All trucks are assigned a unique SERVICE

access code ex works. This access code is
created via a random generator in the truck
control unit (MCU, TCU).
The Fleet manager access code is set to an
invalid value ex works. The service engineer can
adjust the access code if required.
Connect the notebook to the truck and start
the truck diagnostics, see the chapter entitled
"Introduction to DiaMon":

F3: Setup

Truck

Access code

General

Read out the 4-digit numeric access code in

the "Service" eld and change if necessary.
Save the modi ed access code to the truck by
pressing ^F5: Save or the enter key .

Enter a 4-digit numeric access code in the

"Fleet manager" eld.
Save the access code to the truck by pressing
^F5: Save or the enter key .

50638042201 EN - 10/2017 -5
https://truckmanualshub.com/

Connect the notebook to the truck and start

the truck diagnostics, see the chapter entitled
"Introduction to DiaMon":

F2: Diagnosis

Jobs

Select action (4)

Execute 1 F2: Diagnosis

2 Jobs
3 Execute

4 Read error list

Various types of error lists are available for
4 Clear error list
selection: 4 Read error ring buffer
1 Active errors
Lists all errors that are currently active
2 Errors since the last reset
Lists all errors that have occurred since the
truck was switched on.
3 All stored errors
Lists all errors that have occurred since the
error list was last cleared
The relevant error list is then displayed, depend-
ing on the type of error list selected. All errors
from all control units are displayed in this list. It is
not possible to select individual controllers.

The error list for all controllers will be deleted. It is

not possible to select individual controllers.

The option to read out the error ring buffer de-

pends on the software version installed in the
truck. More information about this can be found
in the "Truck software overview" document
Error ring buffer: general
The latest 256 errors from the truck control unit
(MCU, TCU are displayed (error group A).
Error ring buffer: converter
The latest 256 errors from the converter are
displayed (error groups D and E).
For more information, see chapter "60 - Error ring
buffer"

-6 50638042201 EN - 10/2017
https://truckmanualshub.com/

Switch on the truck and wait until the standard

screen appears in the display.
Press buttons 6 and 7 simultaneously.

The display will change to the password

screen. Enter the password for the service
level and con rm by pressing button 9 .
Determine the unique password; see the
chapter entitled "Reading out access codes".

Once the password has been successfully

entered, the display will switch to the CON-
FIGURATION menu.
Press button 6 or 7 until ERROR LIST is
displayed in a framed eld. Con rm the entry
by pressing button 9 .

The display changes to the ERROR LIST

MODE menu.
Press button 6 or 7 until SERVICE is dis-
played in a framed eld. Con rm the entry by
pressing button 9 .
The display changes to the ERROR LIST
menu.

Selection of the relevant controller. For device IDs, see the chapter entitled "Overview
A .... Z, a ... z
of controllers"
* Errors for all controllers are displayed.

1 The active errors are displayed

2 All errors that have occurred since the last error reset are displayed
3 All stored errors are displayed
.

The framed eld DEVICE is activated. Use

button 6 or 7 to make the selection and
con rm by pressing button 9 .
The framed eld TYPE is activated. Make a
selection and con rm in this eld too.
The START display is activated. Press button
9 to start generating the error list.

50638042201 EN - 10/2017 -7
https://truckmanualshub.com/

It may take some time to read out the error list.

When the process is underway, the ashing
characters ? ?? ?? are displayed. When the
process is complete. the latest error in the list is
displayed.
X 00 00 indicates that the error list is empty.
X -- -- indicates an error with the process to
read out the error list. X stands for the device ID.
Press button 6 to scroll up the error list. It is
only possible to scroll one step at a time.
As soon as an error is repeated, this signals that
the start of the error list has been reached. All
errors in this error list have been displayed.
Press button 7 to scroll back down the list
As soon as an error is repeated, this signals that
the end of the error list has been reached. All
errors in this error list have been displayed.
Press button 0 to jump back to the TYPE and
DEVICE display elds.
Press button 8 to jump back to the CONFIG-
URATION menu.

-8 50638042201 EN - 10/2017
https://truckmanualshub.com/

Switch on the truck and wait until the standard

screen appears in the display.
Press buttons 6 and 7 simultaneously.

The display will change to the password

screen. Enter the password for the service
level and con rm by pressing button 9 .
Determine the unique password; see the
chapter entitled "Reading out access codes".

Once the password has been successfully

entered, the display will switch to the CON-
FIGURATION menu.
Press button 6 or 7 until ERROR RESET is
displayed in a framed eld. Con rm the entry
by pressing button 9 .
The display changes to the ERROR RESET
menu.

Selection of the relevant controller. For device IDs, see the chapter entitled "Overview
A .... Z, a ... z
of controllers"
* Error lists for all controllers are cleared.
.

The framed eld DEVICE is activated. Use

button 6 or 7 to make the selection and
con rm by pressing button 9 .
The framed eld RESET is activated.
Use button 6 or 7 to select either YES or NO
and con rm by pressing button 9 .
The selected error list is then cleared.
It may take some time to clear the list. The text
PLEASE WAIT is displayed to indicate that the
process is underway.
If the clearing process fails, the ashing message
ERROR is displayed.

Press button 0 to jump back to the RESET

and DEVICE display elds.

50638042201 EN - 10/2017 -9
https://truckmanualshub.com/

Resetting automatically activates the option NO

in the framed RESET eld. The error list is not
cleared.
Press button 8 to jump back to the CONFIG-
URATION menu.

-10 50638042201 EN - 10/2017

https://truckmanualshub.com/

Manufacturer
Designation AF-104-K1 AF-104-I4
Operating voltage 48 V 80 V
Motor type 4-pin AC motor with cage rotor
Connection Star Star
Design voltage (nominal) 3 x 28 V 3 x 48 V
Design current (nominal) 128 A 87 A
Design speed (nominal) 2000 rpm 2645 rpm
Maximum speed 4076 rpm at 16 km/h 5075 rpm at 20 km/h
Design output (nominal) 2 x 4.5 kW 2 x 5.5 kW

Mode of operation (nominal) S2 (60 min) S2 (60 min)

Protection type IP 54 IP 54
Insulation class F F
Weight Approx. 56 kg / motor Approx. 65 kg / motor

Cooling Surface / convection

Temperature sensor KTY84 - 130 KTY84 - 130

Rev sensor Pin sensor Pin sensor
.

1M2
U, V, W 1U07 converter, left
X12 Rev sensor, left
X13 Temperature sensor, left
1M1
U, V, W 1U06 converter, right
X10 Rev sensor, right
X11 Temperature sensor, right
.

50638042201 EN - 10/2017 -1
https://truckmanualshub.com/

1M2
U, V, W 1U07 converter, left
X12 Rev sensor, left
X13 Temperature sensor, left
1M1
U, V, W 1U06 converter, right
X10 Rev sensor, right
X11 Temperature sensor, right
.

X Travel direction 5 Right drive wheel

1 Right-hand traction motor (FM1) 6 Multi-disc brake
2 Left-hand traction motor (FM2) 7 Motor connections
3 Pump motor 8 Speed sensors
4 Left drive wheel 9 Temperature sensors

Both traction motors are fully integrated into the

drive axle. The drive axle also holds the pump
motor.
The traction motors are connected via the motor
housing. A wet-running multi-disc brake is lo-
cated between the motors.
On each side there is a drive wheel unit outside
the traction motors.
The motor connections U, V, W are fed upwards
out of the motors as screw connections.
The speed sensors are inserted in the axle from
the outside, sealed with an O-ring and secured
with a screw.

-2 50638042201 EN - 10/2017
https://truckmanualshub.com/

The temperature sensors are embedded into

the stator winding. The plugs are led out of the
motors.

The traction motors are three-phase AC asyn-

chronous motors that are equipped with short-cir-
cuit cage rotors.
Aluminium conductors are fused into the grooving
of the rotor core and connected at the ends with
short-circuit rings. The conductors with the
short-circuit rings form the cage rotor and hold
the rotor core together.
The stator consists of the 4-pole stator core and
the stator windings, which are pressed into the
motor housing as a unit.
The applied voltage is induced in the rotor bars
by the stator winding and causes a current to ow
in the rotor. The resultant rotor current and the
rotating eld acting on the stator generate the
torque.

The motors are each controlled by a converter.

The speed is changed by changing the frequency
and voltage of the applied AC voltage.
In the motor, each of the three phases is dis-
tributed to four poles in the stator, thereby gener-
ating the rotating eld. The motors are operated
in a star circuit and supplied with pulsating volt-
age by the converters.
The motors are controlled using pulse width
modulation at a frequency of approx 16 kHz.

50638042201 EN - 10/2017 -3
https://truckmanualshub.com/

Each traction motor has a two-track pin sensor

(2) as a rev sensor, which is tted from above into
the axle and scans the front-end gearing of the
brake disc (1).
The rev sensor is sealed with an O-ring and xed
in the motor housing by a screw.
The speed sensors have a 10 V supply from the
respective converter. The speed signals (A and
B) are connected to the Supply Unit (SU). The
sensor signals are forwarded by the SU to the
relevant converter and the Main Control Unit
(MCU).
The evaluation takes place in the converters,
whilst monitoring occurs in the MCU.

Model: Pin sensor

106 pulses per revolution
Phase shift: 90° ± 45°
Temperature range: -30 °C to +150 °C
Supply voltage: 10 V to 12 V, depending on the
converter type (LAC/SAC)

-4 50638042201 EN - 10/2017
https://truckmanualshub.com/

Red X10/1 X151/7 Supply

Blue X10/2 X44/24 Signal A
Black X10/3 X151/8 GND
White X10/4 X44/23 Signal B

Red X12/1 X152/7 Supply

Blue X12/2 X44/36 Signal A
Black X12/3 X152/8 GND
White X12/4 X44/37 Signal B
.

Insert the mark II test adapter into plug con-

nector X10 or X12
Use a digital multimeter with integrated duty
cycle (e.g. Metra Hit 16L)
Connecting the digital multimeter:
Adapter Pin 4 - Plus
Adapter Pin 3 - Minus
Then connect the digital multimeter:
Adapter Pin 2 - Plus
Adapter Pin 3 - Minus
Turn on key switch S1
Measuring range: duty cycle "V~Hz%"
At full speed, the duty cycle should be
.

If the sensor is not sending signals to the con-

verter, the traction motor is operating in creep
mode (creep speed).

Each traction motor is monitored by a tempera-

ture sensor.
The watertight temperature sensors are embed-
ded in the stator winding and are led out of the
motors through a removable terminal board.
The signals are evaluated in the inverters.

50638042201 EN - 10/2017 -5
https://truckmanualshub.com/

Type: KTY84-130.
Power supply: approx. 1.7 mA

Temp-
Red X11/1 X151/3
MCT+
Temp-
Blue X11/3 X151/4
MCT-

Temp-
Red X13/1 X152/3
MCT+
Temp-
Blue X13/3 X154/4
MCT-

An improperly conducted insulation test can destroy

the temperature sensor.
Before the insulation testing, jumper the temperature
sensor connections.

Insert test adapter into plug connector X11 or

X13
Compare the resistance value to the table

-40 355
-30 386
-20 419
-10 455
0 493
10 533
20 576
25 598
30 621
40 668
50 718
60 769
70 824
80 880
90 939
100 1000

-6 50638042201 EN - 10/2017
https://truckmanualshub.com/

110 1063
120 1129
130 1197
140 1268
150 1340
160 1415
170 1493
180 1572
190 1654
200 1739
210 1825
220 1914
.

A defective sensor can be exchanged with the

aid of a repair kit containing a temperature sensor
and two-component balancing mastic.
Knead both components (yellow and blue)
of the mastic together until the mass has a
uniform green colour
Continue kneading the green mass for at least
2 minutes until it is noticeably warm
Unscrew the terminal board with the main
power connections
Press the sensor against the side of the
winding using the balancing mastic

Make sure that no mastic gets between the sen-

sor and winding, as otherwise the temperature
measurement will be incorrect.
The balancing mastic is fully cured after
approx. 2.5 hours

50638042201 EN - 10/2017 -7
https://truckmanualshub.com/

-8 50638042201 EN - 10/2017
https://truckmanualshub.com/

Manufacturer Linde, Juli

Designation AE18 - 05AC
Weight 170 kg

5 x spherical collar bolts

Wheel nuts, per wheel
Tightening torque: 210 Nm
6 x hexagon head screws M20 x 40
Drive axle chassis screw joint, per side DIN 933, quality 8.8
Tightening torque: 385 Nm
4 x socket head screw M16 x 50
Traction motor screw joint, right/left DIN 912, Quality 10.9
Tightening torque: 195 Nm
16 x socket head screw M10 x 50
Drive wheel unit screw joint, per side DIN 912, Quality 10.9
Tightening torque: 64 Nm
M18 x 1.5
Screw plugs drive wheel unit oil lling
Tightening torque: 70 Nm
M10 x 1
Screw plugs drive wheel unit oil drain
Tightening torque: 20 Nm
M10 x 1
Screw plugs drive wheel unit oil-level check
Tightening torque: 20 Nm
M10 x 1
Screw plugs service brake oil lling
Tightening torque: 18 Nm
M10 x 1
Screw plugs service brake oil drain
Tightening torque: 18 Nm
M10 x 1
Screw plugs service brake oil-level check
Tightening torque: 18 Nm
1 x screw M16 x 45, ISO 4017
1 x screw M16 x 110 - 10.9 A2C, ISO 4017
Mast bearings, per side
2 x lock washer
Tightening torque: 275 Nm

SAE 80W-90, API GL4 + 5

Gearbox, drive wheel unit
0.3 litres per side
Shell Donax TX
Service brake
0.15 litres
.

50638042201 EN - 10/2017 -1
https://truckmanualshub.com/

X Travel direction 6 Multi-disc brake

1 Right-hand traction motor (FM1) 7 Motor connections
2 Left-hand traction motor (FM2) 8 Speed sensors
3 Pump unit 9 Temperature sensors
4 Left drive wheel 10 Brake actuator
5 Right drive wheel

Both traction motors are fully integrated into the

drive axle.
The traction motors are connected via the motor
housing. A wet-running multi-disc brake is lo-
cated between the motors.
On each side there is a drive wheel unit outside
the traction motors.
The drive axle also acts as a holding xture for
the pump unit. The pump unit is connected to
the drive axle at the top via two bearing bolts
in round bearing sockets. The pump unit is
supported below on two support bearings with
spring elements.

-2 50638042201 EN - 10/2017
https://truckmanualshub.com/

Removal of the individual units is described in

detail in the corresponding chapters.
The pump motor can remain in the truck during
removal of the drive axle.
Discharge the gearbox oil and brake oil at an
early stage so that the oil has time to drain off.
Park the vehicle safely.
Apply the parking brake.
Drain the gearbox oil if necessary.
Disconnect battery plug.
Release the wheel bolts, but do not unscrew
completely
Jack up the front of the truck, see chapter
"Safety instructions"
Remove the lift mast, see chapter "Lift mast -
installation / removal"
Remove the wheel bolts and take off the drive
wheels
Release parking brake
Remove oorplate.
For high chassis: Remove the cover sheet on
the front structure
Remove the brake control covering
Remove the ES bolts from parking brake (1)
and service brake (2) and detach the cables;
mark beforehand if necessary
The recuperating spring pulls the brake control
to the zero position and is not unhooked
Remove the guard plate for the speed sensors
(3)

50638042201 EN - 10/2017 -3
https://truckmanualshub.com/

Disconnect sensor connectors X10, X11

and X12, X13 from the traction motors; mark
beforehand if necessary
Unscrew the GND earthing cable from the
pump motor
Unscrew the power cable from the traction
motors; mark beforehand if necessary

Remove the retaining split pins from the

fastening bolts of the pump motor
Use a suitable belt to attach the pump motor to
the brake pedal; use a knob to hold in position

Remove the fastening bolts from the motor

mounts; push the bolts out of the bores if
necessary
Position a pallet truck with timbers beneath the
drive axle
Raise the forklift truck until the timbers are in
contact with the drive axle
On both sides, remove the six mounting
screws of the drive axle

-4 50638042201 EN - 10/2017
https://truckmanualshub.com/

Lower the drive axle and pull from beneath the

truck
Retain and reuse the support bearings' spring
elements

Installation of the individual units is described

in detail in the corresponding chapters.
Check screw quality and tightening torques.
Note the quality and quantity of gearbox oil,
brake oil
Place the spring elements on the support
bearings

Insert the drive axle into the truck and align

with the chassis and pump motor
Insert all screws on both sides between the
chassis and drive axle, and the fastening bolts
for the pump motor

50638042201 EN - 10/2017 -5
https://truckmanualshub.com/

Secure the fastening bolts of the pump motor

with retaining split pins
Remove the securing belt from the pump motor
Protect the mounting screws against corrosion
and tighten on both sides

Screw the power cables onto the traction

motors and assemble the clean splash guard
rims

Traction motors defective due to water

To guarantee the protection type of the traction motors,
the splash guard rims must be pulled correctly over the
power cables.

Attach sensor connectors X10, X11 and X12,

X13 to the traction motor
Screw the GND earthing cable onto the pump
motor
Screw on the guard plate (3) for the speed
sensors
Attach the brake cables and assemble the ES
bolts of the parking brake (1) and the service
brake (2)
Check the brake settings; see the chapter
entitled "Brake system"
Fit the covering on the brake control
For high chassis: Fit the cover sheet on the
front structure
Install the drive wheels and tighten the wheel
bolts
Fill with gearbox oil; see the chapter entitled
"Removal/installation of the drive wheel unit"
Attach the lift mast, see chapter "Lift mast -
installation / removal"
Re t oor plate.
Apply the parking brake.
Lower the truck.
Tightening check
Connect the battery plug

-6 50638042201 EN - 10/2017
https://truckmanualshub.com/

Carry out a function check on all traction and

hydraulic functions

The drive wheel units (1) are structurally identical

units. The drive wheel units are screwed directly
onto the axle housing (3) with socket head screws
(4).

The changing of shaft seals (6) at the wheel

hubs is the only repair work that is permissible.
The wheel gear can only be repaired using a
special tool and the corresponding tensioning
device.
If the wheel bearings are defective, the com- 1 Drive wheel unit
plete drive wheel unit must be changed. 2 Planetary transmission
3 Axle housing AE18
4 Socket head screw
5 O-ring
6 Shaft seal
7 Loctite

50638042201 EN - 10/2017 -7
https://truckmanualshub.com/

1 Snap ring 12 Locking ring

2 Planet gear carrier 13 Slotted nut
3 Planet gear 14 Tapered roller bearing
4 Angular roller bearing 15 Housing
5 Locking ring 16 Screw plug
6 Sun gear 17 O-ring
7 Socket head screw 18 Spacer ring
8 Washer 19 Shaft seal
9 Planet gear carrier 20 Wheel shaft
10 Planet gear 21 Screw plug
11 Cylindrical roller bearing 22 O-ring

The drive wheel unit consists of a housing (15)

with a reduction gearbox and a wheel shaft (20).
The wheel shaft is held in the housing by slotted
nut (13). The location of tapered roller bearings
(14) is determined by spacer ring (18) on the
wheel shaft. For precise adjustment, the spacer
rings are available in different sizes.

The reduction gearbox is a two-stage planetary

transmission:
Stage 1 consists of the planet gear carrier (2)
and three planet gears (3). The planet gears
are driven by the shaft stub in the traction motor
and move the planet gear carrier too.
Stage 2 consists of the planet gear carrier (9)
and four planet gears (10).

-8 50638042201 EN - 10/2017
https://truckmanualshub.com/

The sun gear (6) sits in the gearing of the planet

gear carrier (2) and drives the four planet gears
(10) of stage 2. The planet gears also move
the planet gear carrier (9).
The planet gear carrier (9) drives the wheel
shaft (20) via the gearing.

For simple installation and removal of the drive

wheel units, a conventional trolley jack from your
local building supplies store is suitable. The
U-pro le is welded onto the hydraulic jack.

Pro le parameter sets

140 x 60 x 60

For installation of the drive wheel unit, there are

two stud bolts that are to be screwed into the
traction motor housing to help as a guide.
Screw M10 x 100
Saw off the screw head

Park the truck safely on level ground

Apply the parking brake
Disconnect the battery male connector
Place a collection container for the gearbox oil
under the drive wheel unit
Drain the gearbox oil
Loosen the wheel bolts, do not unscrew
completely
Jack up the front of the truck; see the chapter
entitled "Safety information"
Release the parking brake
Remove the wheel bolts and remove the wheel

50638042201 EN - 10/2017 -9
https://truckmanualshub.com/

If necessary, use two M10 screws to push off

the drive wheel unit To do so, screw the screws
into the threaded holes provided (5 o'clock and
11 o'clock position)

Dispose of any remaining oil that escapes in an

environmentally friendly manner.
Remove the drive wheel unit with planetary
transmission
Insert a new shaft seal

The lips of the shaft seal must point towards

the outside of the axle
Check that the spring is properly seated
Lightly oil the shaft seal

Check tightening torques and screw quality

Check the quality and quantity of the gearbox
oil
For values, see "General technical data" in the
chapter entitled "Drive axle"
Place new O-ring in the groove
Fit the drive wheel unit to the traction motor
housing. The oil lling opening (1) must face
upwards. To aid assembly, screw two guide
pins into the traction motor housing.
Screw the drive wheel unit to the traction motor
housing, tightening the screws diagonally

-10 50638042201 EN - 10/2017

https://truckmanualshub.com/

Fill with gearbox oil via the oil lling opening (1)
until the oil ows out of the inspection opening
(3)

The oil level check is to be carried out when the

truck is on level ground.
Turn the wheel so that one of the two inspec-
tion openings is at 12 o'clock (2). The other
inspection opening (3) is then automatically at
the height of the maximum oil level.
When lling, always undo the top checking
screw so that air can escape.
Attach the wheel and tighten the wheel bolts
Lower the truck.
Check tightening torques
Connect the battery male connector
Function check

The following tools are necessary to disassemble

the drive wheel unit:
Vice
Slotted nut spanner (order no. 161538)
Brass pin
Loctite

50638042201 EN - 10/2017 -11

https://truckmanualshub.com/

1 Snap ring 12 Locking ring

2 Planet gear carrier 13 Slotted nut
3 Planet gear 14 Tapered roller bearing
4 Angular roller bearing 15 Housing
5 Locking ring 16 Screw plug
6 Sun gear 17 O-ring
7 Socket head screw 18 Spacer ring
8 Washer 19 Shaft seal
9 Planet gear carrier 20 Wheel shaft
10 Planet gear 21 Screw plug
11 Cylindrical roller bearing 22 O-ring

Fix the wheel shaft of the drive wheel unit in the

vice.
Pull planet gear carrier (2) with planetary gear
set (4) and sun gear (6) out of housing (15).
Unscrew socket head screw (7), washer (8)
remains in planet gear carrier (9).
Pull planet gear carrier (9) with planetary gear
set (11) out of housing (15).
Unscrew slotted nut (13) from wheel shaft (20).

The slotted nut is secured with Loctite.

-12 50638042201 EN - 10/2017

https://truckmanualshub.com/

Using a brass pin and hammer, carefully tap

the front end of the wheel shaft to release the
bearing halves of tapered roller bearings (14)
from one another.
Pull the wheel shaft out of the housing.
Insert a new shaft seal (19).

The lips of the shaft seal point towards the

outside of the axle.
Check that the spring is properly seated.
Lightly oil the shaft seal.
Lightly oil both roller cages.
Insert the wheel shaft into the housing.
Attach the roller cage of the internal bearing to
the wheel shaft.
Secure slotted nut (13) with Loctite and screw
tightly onto wheel shaft (20).

While tightening the slotted nut, rotate the wheel

shaft so that the bearing halves are evenly sea-
ted.
Insert planet gear carrier (9) with planetary
gear set (11) into housing (15).
Insert washer (8) and screw in socket head
screw (7) tightly.
Insert planet gear carrier (2) with planetary
gear set (4) and sun gear (6) into housing (15).

50638042201 EN - 10/2017 -13

https://truckmanualshub.com/

1 Right-hand traction motor (FM1) 6 Brake oil ller plugs

2 Left-hand traction motor (FM2) 7 Brake actuator
3 Wheel drive 8 Pump motor bearing pins
4 Drive wheel unit xing screws 9 Pump motor support bearings
5 Multi-disc brake

The two traction motors are almost identical to

each other in mirror image and, together with the
drive wheel units, form the drive axle.
The multi-disc brake is located centrally between
the traction motors. The drive wheel units are on
the left and right-hand sides.
To change a traction motor, the entire drive axle
must be removed from the truck and dismantled.

Removal of the individual units is described in

detail in the corresponding chapters.
The pump motor can remain in the truck during
removal of the drive axle.
Discharge the gear lubricant oil and brake oil at
an early stage so that the oil has time to drain
off.
Park the vehicle safely.

-14 50638042201 EN - 10/2017

https://truckmanualshub.com/

Apply the parking brake.

Draining the gear lubricant oil
Disconnect battery plug.
Remove the lift mast
Release the wheel bolts, but do not unscrew
completely
Remove the lift mast, see chapter "Lift mast -
installation / removal"
Jack up the front of the truck, see chapter
"Safety instructions"
Remove the wheel bolts and take off the drive
wheels
Release parking brake
Remove the drive axle; see the chapter entitled
"Removing/installing the drive axle"
Retain and reuse the support bearings' spring
elements
Before disassembling the left-hand traction
motor, the brake control must be removed: to
do so, release the two socket head screws

Once the connecting screws have been removed, the

drive axle splits into two parts.
Prevent the halves of the axles from rolling away

To separate the traction motors, release the

four M16 connecting screws

Screw the lower mast bearing screw on the

right-hand side back in again to act as a torque
damper when releasing the connecting screws.
Remove the individual parts of the multi-disc
brake and put them aside

50638042201 EN - 10/2017 -15

https://truckmanualshub.com/

Unscrew the drive wheel unit from the traction

motor housing

Installation of the individual assemblies is

described in detail in the corresponding
chapters.
Check tightening torques and screw quality.
Check gear lubricant oil and brake oil quality
For values, see "General technical data" in the
chapter entitled "Drive axle"
Screw the drive wheel unit onto the traction
motor housing
Insert the brake disc packages into the drive
axle in the order of installation
Insert the O-ring between both halves of the
axle
Join the halves of the axle in such a way that
the guide pins slot into the guide holes

Tighten the four connecting screws

To assemble the left-hand traction motor,
screw on the brake control using two socket
head screws
Place the spring elements on the support
bearings
Install the drive axle; see the chapter entitled
"Removing/installing the drive axle"
Fill both drive wheels with gear lubricant oil
Fill the multi-disc brake with brake oil
Attach the drive wheels
Attach the lift mast, see chapter "Lift mast -
installation / removal"
Lower the truck.
Connect the battery plug
Check the traction drive for correct operation

-16 50638042201 EN - 10/2017

https://truckmanualshub.com/

The wet-running multi-disc brake (2) is positioned

centrally between the traction motors.
The joint brake control (1) of the parking brake (4)
and the service brake (3) is located on top of the
left traction motor.

The disc pack consists of two brake discs that are

separated by discs.
The shim rings necessary to set the clearance of
the brake are located between the pressure plate
and the rst disc.
There are two variations of the armature stack.

has been in series production since

August 2005:
Two outer laminas with sintered brake lining
on one side (7)
A middle lamina with sintered brake lining on 1 Pressure plate
both sides (9) 2 Fit bolt
3 Shim ring
Two brake discs without brake lining (8) 7 Lamina, one-sided brake lining
Compression springs (10) ensure that there is 8 Brake disc
an equal distance between the discs when the 9 Lamina, double-sided brake lining
brake is not actuated 10 Compression spring
11 Guide pin
was in series production until August
2005 and was replaced by variant A: 1 Pressure plate
Two thin laminas without brake lining (4) 2 Fit bolt
3 Shim ring
One thick lamina without brake lining (6)
4 Lamina (thin)
Two brake discs with sintered brake lining on 5 Brake disc
both sides (5) 6 Lamina (thick)
No compression springs
The brake discs have gearing on the facing side
(1) and serve as the trigger wheel for the rev
sensors (2) of the traction motors.

50638042201 EN - 10/2017 -17

https://truckmanualshub.com/

In the brake control, the brake cables are con-

nected to the service brake (2) and the parking
brake (1) using ES bolts (3).
The pressure plate of the brake is actuated via an
eccentric (4) and the discs and brake discs are
pressed together.
The return spring (6) returns the brake control to
its initial position when the brake is not actuated.
In this case, the lever must rest on the adjustment
screw (5).
The adjusting screw of the actuation unit must not
be adjusted. 1 Parking brake
2 Service brake
3 ES bolts
4 Eccentric
5 Setscrew
6 Return spring

Removal of the individual units is described in

detail in the corresponding chapters.
The pump motor can remain in the truck during
removal of the drive axle.
Discharge the gear lubricant oil at an early
stage so that the oil has time to drain off.
Park the vehicle safely.
Apply the parking brake.
Draining the gear lubricant oil
Disconnect battery plug.
Release the drive wheel ball-seat nuts, but do
not unscrew completely
Remove the lift mast, see chapter "Lift mast -
installation / removal"
Jack up the front of the truck, see chapter
"Safety instructions"
Remove ball-seat nuts, remove drive wheels
Remove the drive axle; see the chapter entitled
"Removing/installing the drive axle"
Retain and reuse the support bearings' spring
elements

-18 50638042201 EN - 10/2017

https://truckmanualshub.com/

Once the connecting screws have been removed, the

drive axle splits into two parts.
Prevent the halves of the axles from rolling away

To separate the traction motors, release the

four M16 connecting screws

Screw the lower mast bearing screw on the

right-hand side back in again to act as a torque
damper when releasing the connecting screws.
The brake discs and laminas of the right and
left halves of the axle are exposed and can be
removed

On the left half of the axle, release the two

cylinder screws on the brake control and
remove the brake control

Release the two cylinder screws on the

pressure plate and remove the pressure plate

The clearance must be checked after the follo-

wing operations:
Installation of new brake spare parts
Brake discs
Discs
Thrust piece
Installation of a new traction motor
The clearance is set using the shim ring. The
clearance and the shim ring depth can be deter-
mined as follows:
Measure the depth on both clean, empty
traction motor housings using a slide gauge
or a depth gauge

50638042201 EN - 10/2017 -19

https://truckmanualshub.com/

To establish the depth of the left half of the

axle, two measurements are required:
and

Adding both measurements from the left half

of the axle gives

The depth of the right half of the axle gives

To establish the total depth of both halves of

the axle, add both measurements together

Pile up the complete armature stack and weigh

down with approx. 6 kg

For measuring the variation A armature stack,

pile them up without springs.
The height of the loaded armature stack mea-
sured with the sliding gauge gives

From these measurements, it is possible to

determine the shim ring depth:

Installation of the individual assemblies is

described in detail in the corresponding
chapters.
Check tightening torques and screw quality.
Check gear lubricant oil and brake oil quality
For values, see "General technical data" in the
chapter entitled "Drive axle"
Mounting the pressure plate

-20 50638042201 EN - 10/2017

https://truckmanualshub.com/

Screw the brake control onto the left half of the

axle using two cylinder screws

Mount the brake discs and laminas, checking

the variation and sequence

Mount armature stack variation A with springs.

Insert the O-ring between both halves of the
axle
Join the halves of the axle in such a way that
the guide pins slot into the guide holes
Tighten the four connecting screws
Place the spring elements on the support
bearings
Install the drive axle
Fill both drive wheels with gear lubricant oil
Fill the multi-disc brake with brake oil
Attach the wheels
Attach the lift mast
Lower the truck.
Connect the battery plug
Check the service brake and traction drive for
correct operation

50638042201 EN - 10/2017 -21

https://truckmanualshub.com/

Designation
Manufacturer Linde, Juli
Total weight [kg] 170.5
Permissible axle load [kg] 4870
Axle load for track width of
[kg] 5430
990 mm
Maximum speed [km/h] 16 20
Tyres (alternative) 18 x 7-8 (200/50 10)
Dynamic tyre radius [mm] 211 (229)
Track width [mm] 990 (942)
Driving torque [Nm] 2200 3100
Maximum wheel speed [rpm] 201 251
Gear ratio 20.8
Oil content per gearbox [l] 0.3
Gearbox oil SAE 80W-90 API-GL4
Oil change interval Once at 1000 hours, then every 3000 hours

Static braking torque [Nm] 4500

With force F1 [N] 2270
Dynamic braking torque [Nm] According to characteristic curve
With force F2 [N] According to characteristic curve
Oil content [l] 0.2
Brake oil Shell Spirax S4 ATF HDX
Oil change interval

Wheel nuts, per wheel [Nm] 210 5 x spherical collar bolts

Screw joint between drive axle 6 x hexagon head screw M20 x 40-8.8, DIN
[Nm] 385
and chassis, per side 933
Screw joint in traction motors, 4 x socket head screw M16 x 60-10.9, DIN
[Nm] 275
central 912
Screw joint in drive wheel unit, per 7 x socket head screw M16 x 50-10.9, DIN
[Nm] 275
side 912
Slotted nut on drive wheel unit [Nm] 65020
Oil ller on drive wheel unit [Nm] 70 M18 x 1.5
Oil drain on drive wheel unit [Nm] 20 M10 x 1
Oil level check on drive wheel unit [Nm] 20 M10 x 1
Oil ller on service brake [Nm] 20 M10 x 1
Oil drain on service brake [Nm] 20 M10 x 1
Oil level check on service brake [Nm] 20 M10 x 1
1 x screw M16 x 45, ISO 4017
Mast bearing, on each side [Nm] 275 1 x screw M16 x 110-10.9 A2C, ISO 4017
2 x lock washers
.

-22 50638042201 EN - 10/2017

https://truckmanualshub.com/

1 Right drive wheel unit 6 Counter bearing

2 Right traction motor 7 Temperature sensor X11
3 Temperature sensor X13 8 Left traction motor
4 Brake actuator 9 Left drive wheel unit
5 Speed sensors

The images of the drive axle differ somewhat from

the installed component in the truck! The devia-
tions in the images only relate to the external
contours. The technical descriptions correspond
precisely to the installed component.
The drive axle consists of the two traction mo-
tors (2) and (8) (three-phase AC asynchronous
motors) with the ange-mounted two-stage drive
wheel units (1) and (9).
Between the traction motors, there is an inte-
grated multi-disc brake that serves as the service
brake and parking brake.
The two traction motors are connected to the
output modules via the terminal boards. The
speed and direction of rotation of the traction
motors is reported back to the power module
by a speed sensor on each electric motor. Two

50638042201 EN - 10/2017 -23

https://truckmanualshub.com/

temperature sensors (3) and (7) monitor the

temperature in the coil ends.

In the drive direction of the axle, the traction motor

connecting boxes are facing upwards. The right
traction motor contains the actuating lever of the
brake.

The identi cation plate for the axle is located on

the front of the right traction motor.

The identi cation plate for the traction motors is

located on the respective connection box.

Park the truck safely on level ground.

Apply the parking brake.
Disconnect the battery male connector.
Loosen the wheel bolts; do not unscrew them
completely.
Jack up the front of the truck; see the chapter
entitled "Safety information".
Release the parking brake.
Remove the wheel bolts and remove the
wheel.

Secure the drive axle not mounted in the truck

with a suitable device to prevent it from turning.
Place a suitable collection container (> 1 l)
under the oil drain opening.
Unscrew the oil ller plug and oil drain plug.

-24 50638042201 EN - 10/2017

https://truckmanualshub.com/

Dispose of drained oil in accordance with regula-

tions.
Loosen and unscrew 7 screws from the drive
wheel unit. The upper screw acts as a guide;
do not unscrew it completely.
Remove the two plugs from the threaded holes
located opposite.
Screw 2 M14 screws (e. g. screws from the
drive wheel unit) into the threads. This will
separate the drive wheel unit from the motor
housing.
Pull the drive wheel unit out of the motor
housing.

Lift the rst planetary gear set out of the

annular gear.

Loosen and unscrew the mounting screw from

the second planetary gear set.

50638042201 EN - 10/2017 -25

https://truckmanualshub.com/

Pull the second planetary gear set out of the

housing.

Secure the drive wheel unit on a suitable

xture.
Warm the slotted nut to release the Loctite.

The hot slotted nut can cause burns.

Wear suitable protective gloves.

Loosen the slotted nut using a slotted nut

spanner and torque multiplier.
Remove the slotted nut.

Support the drive wheel unit in order to press

the wheel shaft out downwards.
Press out the wheel shaft.

-26 50638042201 EN - 10/2017

https://truckmanualshub.com/

Drill a hole in the shaft seal, cut the thread and

then pull it out using ejector rod WM109.

Coat the inside of the new shaft seal between

the sealing lip and the dust lip with lithium soap
grease. Fill the space to a maximum of 50%.

The grease must not be added to the spring

chamber.
Position the shaft seal on insertion
tool WM455.
Apply Loctite 243 to the outside of the shaft
seal.

Position the shaft seal on the wheel shaft with

insertion tool WM455.
Attach insertion tool WM455 to the wheel shaft
using three wheel screws.

The shaft seal is tted in the wheel shaft by

tightening the wheel screws. Tighten the wheel
screws alternately to prevent the shaft seal from
canting.
Remove the wheel screws and insertion tool
from the wheel shaft.
Remove Loctite residues from the slotted nut
and the thread of the wheel shaft. Use brake
cleaner if necessary.
Position the drive wheel unit on the wheel
shaft.
Insert the spacer ring.
Insert the tapered roller bearing.
Coat the thread of the slotted nut with Loc-
tite 270. Screw in the slotted nut and tighten by
hand.

50638042201 EN - 10/2017 -27

https://truckmanualshub.com/

Secure the drive wheel unit on a suitable xture

and tighten the slotted nut using the slotted nut
spanner and torque multiplier to a tightening
torque of 650 +20 Nm.
Turn the drive wheel unit by 10 revolutions and
retighten the slotted nut to a tightening torque
of 650 +20 Nm.

Insert the second planetary gear set.

Coat the second planetary gear set mounting

screw with Loctite 270; screw in and tighten
the mounting screw to a tightening torque of
23 Nm.

Insert the rst planetary gear set into the

housing.

-28 50638042201 EN - 10/2017

https://truckmanualshub.com/

Observe tightening torques and screw quali-

ties
Observe gearbox oil quality and quantities
See "general technical data" for values.
Oil and t a new O-ring (1).
Attach the drive wheel unit with ller plug (2)
facing upwards and screw in the 7 mounting
screws (3) on the drive wheel unit.
Tighten the mounting screws crosswise.
See the section on "Filling with oil" for instruc-
tions on lling with gearbox oil.
Attach the wheel and tighten the wheel bolts
Lower the truck.
Check tightening torques
Connect the battery male connector
Perform a function check.

The drive axle can remain in place when ex-

tracting the rotor from the traction motor. When
replacing the rear shaft seal, it is easier to remove
the drive axle completely.
When the rotor is pulled out, brake oil runs into
the traction motor. You must therefore either
completely drain the brake oil beforehand, place
the drive axle on a slight slope or jack up the truck
on one side. A height difference of 5...10 cm is
suf cient.
Drain the gearbox oil; drain the brake oil if
necessary.
Remove the drive wheel unit, see the chapter
entitled "Removing the drive wheel unit".

50638042201 EN - 10/2017 -29

https://truckmanualshub.com/

The locking screws of the rotor are positioned

opposite one another and are accessible even
in the installed position.
In order to access the M8x16 locking screws
(2) underneath, the threaded pins M8x8 (1)
must be removed. The screws are positioned
opposite one another (180°).

For the bearing shield installation, mark the

position of the rotation lock on the motor
housing. (may differ from the illustration)
Turn the locking screws (2) back into the
housing.

Slide 2 screwdrivers (≥ 1.2 x 8 mm) behind the

pinion and carefully extract the rotor.

Remove the washer and 2 shaft washers from

the motor housing.

-30 50638042201 EN - 10/2017

https://truckmanualshub.com/

If necessary, unscrew the pinion gear from the

rotor shaft (M8x20), so that the rotor can be
placed upright for any subsequent work.

Pull the rear bearing out of the rotor shaft using

a 2-claw extractor.

The bearing will be damaged as it is pulled out

over the outer ring. Use a new bearing.

Remove the shaft seal (1) from the bearing

ange. Use a screwdriver to lever out the shaft
seal or cut a thread in the shaft seal and then
pull it out.
If necessary, remove the drilling chips.

Remove the inner retaining ring (3) and outer

retaining ring (2).

50638042201 EN - 10/2017 -31

https://truckmanualshub.com/

Pull the rotor shaft out from the bearing ange

or press it out.

Knock the front bearing out of the bearing

ange.

The bearing will be damaged as it is knocked out

over the inner ring. Use a new bearing.

Press the new bearing into the bearing ange.

Press the bearing in over the bearing outer
ring, otherwise the bearing will be damaged.
Position the bearing ange with the bearing on
the rotor shaft and press on the bearing using
assembly sleeve WM451. Press the bearing
in over the bearing inner ring, otherwise the
bearing will be damaged.

Fit the inner retaining ring (3) and outer

retaining ring (2).

-32 50638042201 EN - 10/2017

https://truckmanualshub.com/

Wet the surface of the shaft with brake oil.

Press the new shaft seal (1) into the bearing
ange.

Press on the front bearing using assembly

sleeve WM451. Press the bearing in over the
bearing inner ring, otherwise the bearing will
be damaged.

First, insert the washer and then the shaft

washers (2 pieces) into the motor housing.
For the bearing shield installation, mark the
position of the rotation lock on the motor
housing.

Insert a new seal on the bearing ange. Insert

the rotor into the motor housing.

50638042201 EN - 10/2017 -33

https://truckmanualshub.com/

Place the bearing ange on the axle casing in

such a way that the position of the rotation lock
aligns with the notch on the bearing ange.
(may differ from the illustration)
Push the bearing ange into the housing.
Screw in the M8x16 threaded pin (2) (rotation
lock) and tighten.
Screw in the M8x8 threaded pin (1) (cover) and
tighten.

Fully screw in the M8x16 threaded pin(2). This

prevents the bearing shield from turning.
Wet the surface of the shaft with brake oil.
Install the shaft seal with handle WM170 and
universal sleeve WM449.
If necessary, screw the pinion onto the rotor
shaft (M8x20).
See the section on "Re tting the drive wheel
unit" for information on re tting the drive wheel
unit.

-34 50638042201 EN - 10/2017

https://truckmanualshub.com/

The wet-running multi-disc brake is positioned

centrally between the traction motors.
The brake actuator shared by the service brake
and handbrake is located on top of the traction
motor housing.

The disc pack consists of two brake discs that are

separated by discs.
The shim rings are used to adjust the brake
clearance.

1 Brake actuator
2 Pressure plate
3 Disc, one-sided brake lining
4 Brake disc
5 Disc, double-sided brake lining
6 Shim ring

The brake discs have gearing on the facing side

(1) and serve as the trigger wheel for the rev
sensors (2) of the traction motors.

50638042201 EN - 10/2017 -35

https://truckmanualshub.com/

The brake cables of the service brake (4) and

handbrake (5) are attached in the abutment (6)
and secured with locking plates.
The brake cables in the brake lever (3) are
attached and secured using s-bolts.

3 Brake lever
4 Service brake
5 Handbrake
6 Abutment

The entire drive axle must be removed from the

truck in order to carry out this repair.

Place a suitable collection container (> 0.5 l)

under the oil drain opening.
Unscrew the oil drain plug.

Dispose of drained oil in accordance with regula-

tions.

Secure the axle to prevent it from turning and

loosen and unscrew the 4 screws.
Remove plug X13 on the left side of the
housing.
Loosen and pull apart the housing halves with
a suitable tool.
2 brake discs fall out immediately.
Remove any remaining brake oil.

-36 50638042201 EN - 10/2017

https://truckmanualshub.com/

The rev sensor (1) can remain in the axle.

Remove the pressure plate (3) and two further
brake discs. Place the compression springs
(2) to one side.

Remove the retaining ring (4) using the

installation tool.
Carefully remove the cable tie (5). Do not
damage the dust protection cover in the
process; replace it if necessary.
Remove the dust protection cover (6).

Loosen and remove the screw plug.

Pull out the brake lever axle with a M6x80

screw. If necessary, use ejector rod WM109.

50638042201 EN - 10/2017 -37

https://truckmanualshub.com/

Remove the brake lever.

Take out the shaft seal.

Observe tightening torques and screw quali-

ties
Observe gearbox oil quality and quantities
See "general technical data" for values.

Insert the shaft seal.

-38 50638042201 EN - 10/2017

https://truckmanualshub.com/

Install the brake lever.

Screw in and tighten the screw plug.

Check the dust protection cover (6) for damage

and replace it if necessary.
Secure the dust protection cover using retain-
ing ring (5) and cable tie (5).

When replacing the brake discs, the brake lift play

must be inspected and, if necessary, adjusted.
Place the right traction motor upright.

Insert the pressure plate into the right traction

motor. Make sure that the guide pin engages
in the bore.
Remove the compression springs from the
middle brake disc support.
Insert the brake package into the traction motor
in the correct order.

50638042201 EN - 10/2017 -39

https://truckmanualshub.com/

Load the brake package with a weight of 6 kg.

Determine the height of the brake package
above the housing edge.

Determine the depth of the brake chamber in

the left traction motor housing.
The difference between the depth and height
measurements can be max. 0.8+0.2 mm.
If necessary, insert shim rings on the left.

Attach the compression springs to the brake

disc support.

Insert the pressure plate into the right traction

motor. Make sure that the guide pin engages
in the bore.
Insert the brake package into the traction
motor in the order shown. Ensure that all
compression springs are positioned and
aligned correctly. If necessary, secure the
brake package with a suitable cord or wire to
prevent it falling out.
Oil the new O-ring and insert into the right
traction motor housing.
Position the traction motors opposite one
another. Use suitable devices to align.
Screw the traction motors together with
four screws. Tighten the screws crosswise.
Insert the speed sensor. Insert the screw and
tighten to a tightening torque of 9.5 Nm.

-40 50638042201 EN - 10/2017

https://truckmanualshub.com/

Observe tightening torques and screw quali-

ties
Observe oil quality and quantities of oil
For the values, see the chapter entitled
"General technical data"
Do not reuse drained gearbox oil and brake oil.
Dispose of oil in an environmentally friendly
manner

Warm up the drive wheel unit

Park the truck so that the drive axle is horizon-
tal
Switch off the truck
Remove the drive wheel
Clean the area around the oil ller plug, the
checking screw and the oil drain plug
Place a suitable container beneath the wheel
gear
Unscrew the oil ller plug (1) from the drive
wheel unit
Unscrew the oil drain plug (2) from the drive
wheel unit
Collect the gearbox oil in the container
Clean, screw in and tighten the oil drain plug

If the oil volume is too great, it can damage the shaft

seal of the rotor shaft.
Pay close attention to the exact oil volumes on the
left-hand and right-hand side.

Unscrew the checking screw (3)

Turn the wheel so that one of the two inspec-
tion openings is at 12 o'clock (2). The other
inspection opening (3) is then automatically at
the height of the maximum oil level
Measure the gearbox oil into a measuring cup

50638042201 EN - 10/2017 -41

https://truckmanualshub.com/

Add the gearbox oil via the oil lling opening (1)
until the oil ows out of the inspection opening

The oil level check must be performed when

the truck is on level ground
When lling, always undo the upper checking
screw (2) so that air can escape
Screw in and tighten the oil ller plug (1).
Clean, screw in and tighten the oil ller plug
and the checking screw
Fit the drive wheel

Before checking the oil level, the truck must

be switched off and left for approximately ve
minutes so that the gearbox oil can drain out of
the planet gears.
Switch off the truck Wait for approximately ve
minutes
Remove the drive wheel
Unscrew the checking screw (2)
The oil level must reach the thread of the checking
screw opening.
Top up the gearbox oil if necessary

Drain any excess oil into a collection container

via the checking screw.
Check the oil level again
Clean, screw in and tighten the oil ller plug
Clean, screw in and tighten the checking screw
Fit the drive wheel

-42 50638042201 EN - 10/2017

https://truckmanualshub.com/

Screw in the drain plug with magnetic plug and

tighten.

Push back the dust protection cover.

If the oil lling quantity is too great, it can damage the

shaft seal of the rotor shaft.
Make sure you use the exact oil lling quantity for the
brake.

Measure out the brake oil into a measuring cup

and pour in through the brake lever opening.
Move the cover back so it is correctly seated.

Assemble the retaining ring (1) using the

installation tool. Note the position. Check
that it is correctly seated.
Assemble the cable tie (2). Check that it is
correctly seated.

50638042201 EN - 10/2017 -43

https://truckmanualshub.com/

-44 50638042201 EN - 10/2017

https://truckmanualshub.com/

Apply parking brake

Battery door open
Separate lock, loosen nut and remove screw

The lever by the frame is under spring tension. It shoots

towards the frame when released. Fingers can get
caught!
Firmly grip the lever with the ngers when separating
the lock.

Place jack under the battery door

Using the jack slowly lift the battery door and
unhook
Place battery door on available pallet

Hook on battery door

Connect lock

50638042201 EN - 10/2017 -1
https://truckmanualshub.com/

The counterweight is a massive cast component

that differs according to type carrier, dependent
on the load-bearing capacity, chassis and steer-
ing axle.
The counterweight is attached to the chassis with
mounting screws. The number, arrangement
and tightening torques of the mounting screws
are dependent on the type carrier, see the table.

Hexagon head screw

M20x70-10.9-A2C, ISO 4017
Washer
20-FST-A2C, DIN 6796

6214, 6217
Low 1 6 540 Nm
6311 - 6315
6210 - 6213
High 2 5 540 Nm
6215 - 6316
.

-2 50638042201 EN - 10/2017
https://truckmanualshub.com/

The overhead guard is an independent unit that is

connected to the chassis and the counterweight
via three bearings.
At the front, the overhead guard is supported on
the chassis on two bearings (1, 2), and at the
rear it is supported in the counterweight on one
bearing (3) on the bearing ange (4).
Depending on the truck type and chassis height,
the bearing ange (4) is either an individual part
or a component of the counterweight.
The bearings consist of spring elements that 1 Right-hand overhead guard bearing
protect the overhead guard against vibrations. 2 Left-hand overhead guard bearing
3 Rear overhead guard bearing
4 Bearing ange

The front bearings consist of two spring elements

(1) that are connected via washers and threaded
bushes.
Assemble the spring elements at a 90° rotation
to each other.
The spring elements in the overhead guard are
pre-loaded with the threaded bushes (4, 5).
Twisting the threaded bush (6) changes the
size of the gap between the overhead guard
and the chassis, as well as the gap between
the overhead guard and the trademark em-
blem. The bearings should be pre-assembled
with a setting dimension (X). 1 Spring element
2 Washer
3 Washer
4 Threaded bush
5 Threaded bush
6 Threaded bush
7 Lock washer
8 Tighten the screw
X Setting standard

1, 4, 5 Pre-load of the spring elements Threaded bushes 100 Nm

Hexagon head screw M10 x 90,
Connection between overhead
7, 8 8.8 46 Nm
guard and chassis
Lock washer
6 Gap, setting dimension X Threaded bush 6 mm
.

50638042201 EN - 10/2017 -3
https://truckmanualshub.com/

This bearing was tted until April 2007.

Only type carriers 6210 - 6217, 6311, 6313,
6315
The front bearings (1) are pre-assembled units
with a built-in spring element. The bearings are
connected to the overhead guard via two screws
(2-4).
Twisting the threaded bush (6) changes the 1 Bearing
size of the gap between the overhead guard 2 Undo xing screws
and the chassis, as well as the gap between the 3 Washer
4 Nut
overhead guard and the trademark emblem. The
5 Knurled nut
bearings should be pre-assembled with a setting 6 Threaded bush
dimension (X). 7 Lock washer
8 Tighten the screw
X Setting standard

Hexagon head screw M10 x 90,

Connection between overhead
7, 8 8.8 46 Nm
guard and chassis
Lock washer
6 Gap, setting dimension X Threaded bush 6 mm
.

The rear bearing consists of two spring elements

(3) that are loosely connected by bushes.
Above and below the spring elements there are
spacer washers (2). The spring elements are
pre-loaded by the overhead guard screws (4).

1 Bearing ange
2 Spacing washer
3 Spring element
4 Tighten the screw
5 Lock washer

Hexagon head screw M10 x 65,

Connection between overhead
7, 8 8.8 46 Nm
guard and chassis
Lock washer
.

-4 50638042201 EN - 10/2017
https://truckmanualshub.com/

Removal of the overhead guard varies according

to truck type and equipment version.
Signi cant differences are indicated in the re-
moval instructions.

For trucks with cabs:

Completely remove the cab doors and side
parts
Remove the roof window
Remove the heater

Tilt the lift mast fully forward

Removing the battery

The drive wheels do not need to be disas-

sembled, as overhead guard bearings can be
accessed freely
Prevent the truck from rolling away using
chocks
Remove the panelling between the chassis
and the overhead guard at the front right and
left

The drive wheels must be disassembled, as

overhead guard bearings be accessed
freely
Release ball-seat nuts
Jack up the front of the truck; see the chapter
entitled "Safety instructions". The drive wheels
should only be a few millimetres above the
ground
Remove ball-seat nuts and take out the drive
wheels

Remove oor plate.

Release parking brake
Remove trademark emblem, loosening the left
and right side screws but not unscrewing them
completely
Disconnect plug X57 from the light
strip
Remove the covering of the electronics

50638042201 EN - 10/2017 -5
https://truckmanualshub.com/

Detach the electrical connection between the

overhead guard and the counterweight

The number and location of the plug connections

vary according to the truck type and equipment
version. The control wiring harness (1) to the
supply unit is the standard design, and the roof
wiring harness (2) is a variant.
Detach plug X41 on the supply unit
Detach the connections from the
roof wiring harness
Heater XS6 and XS7
Plug X63, X65, X66, X67
Voltage converter wiring harness

Detach hoses LS and CF on the priority valve;

mark beforehand if necessary

Disconnect the return line of the steering unit

(1) at the return line lter
Disconnect the connection between the
steering hoses L and R (2) and the steering
cylinders

-6 50638042201 EN - 10/2017
https://truckmanualshub.com/

Tie up the ve loose hoses to the steering

column

Disassemble the hose guide from the solenoid

valve on the overhead guard

Remove the cover on

the brake actuation
Remove the ES bolts from the parking brake
(1) and service brake (2) and detach the
cables; mark beforehand if necessary
Remove the panelling from the front of the
directional control valve block
Release the panelling on the top of the direc-
tional control valve block

Detach plug X19 of the hydraulic sensor on the

directional control valve block

50638042201 EN - 10/2017 -7
https://truckmanualshub.com/

Detach plug X23 from the lift lever on the

directional control valve block

Detach the earthing cable at the directional

control valve block
Disconnect all the
plugs 2Y1 to 2Y11 and 2B5 on the directional
control valve block

Disconnect the earth

wires to the chassis and directional control
valve block at the front right of the overhead
guard

Disconnect the earth wires to the

directional control valve block on the hydraulic
tank

-8 50638042201 EN - 10/2017
https://truckmanualshub.com/

Detach the directional control valve block

holder from the overhead guard

From below, loosen the central screw (M8x90)

of the left and right front overhead guard
bearings

Do not change the setting of the threaded bushes

(see arrow in picture). The overhead guard height
changes according to the screw-in depth.

Release the two screws on the rear overhead

guard bearing

50638042201 EN - 10/2017 -9
https://truckmanualshub.com/

Secure the overhead guard with a lifting sling

and a crane or truck

The overhead guard may slip sideways

Check the fastening and position of the lifting sling

Unscrew all four screws on the overhead guard

bearings

Beware of damage!
Work slowly and carefully, with an assistant if possible
The solenoid valve must not remain hanging on the
overhead guard
Check the height of the ceiling

Carefully lift the overhead guard to a suf cient

height and remove it

Position the overhead guard with the rear

bearing on a suitable pallet stack

-10 50638042201 EN - 10/2017

https://truckmanualshub.com/

Installing the overhead guard varies according to

truck type and equipment version.
Signi cant differences are indicated in the re-
moval instructions.
The overhead guard is ready, placed separately
on a stack of pallets

Only assemble cab parts once the overhead

guard has been screwed onto the chassis:
Cab doors and side parts
Roof window
Heater

Secure the overhead guard with a lifting sling

and a crane or truck

The overhead guard may slip sideways

Check the fastening and position of the lifting sling

50638042201 EN - 10/2017 -11

https://truckmanualshub.com/

Position the overhead guard above the chassis

and lower it carefully

Beware of damage!
Work slowly and carefully, with an assistant if possible
The solenoid valve must not remain hanging on the
overhead guard
Check the height of the ceiling

Place the overhead guard on the front bearing

points and attach it to the chassis using screws
and conical spring washers

Position the lower spacer plate on the counter-

weight
Place the overhead guard on the rear bearing
points and secure screws and lock washer to
the counterweight
Remove the lifting sling

-12 50638042201 EN - 10/2017

https://truckmanualshub.com/

Screw the directional control valve block

holder onto the overhead guard

Connect plug X19 of the hydraulic sensor on

the directional control valve block

Connect plug X23 from the lift lever on the

directional control valve block

Connect the earthing cable on the directional

control valve block
Connect all the plugs
2Y1 to 2Y11 and 2B5 on the directional control
valve block

50638042201 EN - 10/2017 -13

https://truckmanualshub.com/

Connect the earth

wires to the chassis and directional control
valve block at the front right of the overhead
guard

Connect the earth wires to the

directional control valve block on the hydraulic
tank

Connect hoses LS and CF on the priority valve

Connect the return line of the steering unit (1)

to the return line lter
Connect the steering hoses L and R of the
steering cylinders (2)

-14 50638042201 EN - 10/2017

https://truckmanualshub.com/

Fit the hose guide from the solenoid valve on

the overhead guard

Attach the brake cable and assemble the ES

bolts of the parking brake (1) and the service
brake (2)
Check the brake settings; see the chapter
entitled "Brake system"
Fit the cover on the
brake actuation
Apply the parking brake.
Install the panelling on the front of the direc-
tional control valve block
Install the panelling on the top of the directional
control valve block
Attach the electrical connection between the
overhead guard and the counterweight
The number and location of the plug connections
vary according to the truck type and equipment
version. The control wiring harness (1) to the
supply unit is the standard design, and the roof
wiring harness (2) is a variant.
Connect plug X41 on the supply unit
Attach the connections from the roof
wiring harness
Heater XS6 and XS7
Plug X63, X65, X66, X67
Voltage converter wiring harness
Install and tighten the covering for the elec-
tronics
Install the trademark emblem
Connect plug X57 from the light strip
Check the gap between the overhead guard
and the chassis; adjust if necessary
Check the gap between the overhead guard
and the trademark emblem; adjust if necessary
Tighten all the screws on the overhead guard
bearings, check the tightening torques

50638042201 EN - 10/2017 -15

https://truckmanualshub.com/

Remove the panelling between the chassis

and the overhead guard at the front right and
left

Install the drive wheels and tighten the ball-

seat nuts
Lower the truck.
Tighten the spherical collar nuts; for tightening
torques, see Technical data in the chapter
entitled "Drive axle"

Battery reconnection
Re t oor plate.
Bleed the steering
Functional test

Check that the gap between the

is parallel.
Release the left front bearing screw
Adjust the gap by turning the threaded bush in
the left front bearing

6210 - 17
12.5 ± 2 mm
6311, 13, 15
6321 - 25
15 ± 2 mm
6327 - 30
.

Check that the gap between the

is parallel
Release the right front bearing screw
Adjust the gap by turning the threaded bush in
the right front bearing
Tighten all the screws on the overhead guard
bearings, check the tightening torques

-16 50638042201 EN - 10/2017

https://truckmanualshub.com/

Manufacturer Sauer Danfoss

Designation OSPF 50 LS EL 1, 50G5128
Delivery rate per rotation [cm3] 50
Pressure relief valve [bar] 135 140 bar
Shock valve [bar] 200 - 220

Connections P and EF [bar] 250

Connections CF and LS [bar] 140 - 145

Connections P, T, LS, R and L

Tightening torque [Nm]

Steering wheel revolution, stop to stop Min. 5.00

Steering wheel revolution, stop to stop Min. 4.25

Switching range 1.5 ± 0.2 bar

The diaphragm pressure switch is no longer evaluated in trucks with MCU 2 and software version 2.06
and is not tted in these trucks

Manufacturer Sauer Danfoss

Designation OLSP 80
Charging pressure [bar] 7
Load signal Dynamic

Pump P [Nm] 9+1 4 x DIN 912, M6 x 35, 8.8 socket head screws
Steering CF [Nm] +10
70 GE10-PL
Directional control valve EF [Nm] 90+10 GE18-PLR
Load Sensing LS [Nm] 35+5 GE10-LR-E
.

50638042201 EN - 10/2017 -1
https://truckmanualshub.com/

1 Steering angle sensors 6 Priority valve

2 Steering unit 7 Hydraulic pump
3 Return line 8 Induction hose
4 LS signal line 9 Directional control valve block
5 Pressure line 10 Steering cylinder connection

The steering system is equipped with power

steering that works according to the LS principle.
It affects the steering cylinder on the steering
axle.
"LS system"
"Load Sensing System"
Load Sensing System
A steering unit is ange-mounted to the lower end
of the steering column. It comprises a distributor
valve and a metering pump.
Upon actuating the steering wheel, an oil volume
is allocated to the steering system by the meter-
ing pump, which is proportional to the amount by
which the steering wheel is turned. The distribu-
tor valve guides this oil volume to the desired side
of the steering cylinder.

-2 50638042201 EN - 10/2017
https://truckmanualshub.com/

The oil volume for the steering is directed as a

priority to the steering unit by the priority valve in
all operating statuses.
If the working hydraulics are not actuated, the
pump speed for steering is proportional to the
rotational speed at the steering wheel (dynamic
steering). For slow steering wheel movements,
the hydraulic pump runs at a basic speed. Fast
steering wheel movements result in an increase
in the speed. The rotational speed of the steering
wheel is ascertained via the steering angle
sensor (3B01).

The pump motor is activated when the diaphragm

pressure switch (6S3) is opened. The hydraulic
pump runs at a basic speed.

Without the diaphragm pressure switch, the

pump motor always runs at > 0.1 km/h. A journey
of three minutes without a steering movement
produces an error.

For trucks equipped with two traction motors in

the drive axle, controlled driving is enabled via
the steering angle actual value.
Using the steering angle actual value, the truck
control unit (MCU) calculates the optimum num-
ber of revolutions for the traction motors. The
truck control unit constantly monitors all in u-
ences and generates errors messages in the
event of faulty or implausible values.

The steering angle actual value is calculated from

the following three in uences:
Speed actual values via the speed sensors in
the traction motors
Steering angle detection via the steering angle
sensor 3B01 on the steering column
Status of the cornering switches 3B28 and
3B29 on the steering axle

For trucks with one traction motor in the drive

axle, no steering angle actual value is required
for controlled driving.

50638042201 EN - 10/2017 -3
https://truckmanualshub.com/

Optionally, these trucks can be equipped with

steering angle detection for the "curve speed
control" variant. CSC is a component of the
comfort package (assistance system).

,
When the hydraulic pump is in Disconnect the steering unit from
operation, the steering actuates the steering column and check for
automatically. mechanical damage:
The hydraulic connections P, T, Without the steering unit, you
Mechanical fault in the steering
L, R are connected. must be able to turn the steering
unit.
column very easily (<10 Nm).
Assembly fault between
Check the steering unit for
The steering is tight (> 10 Nm) steering unit and steering axle.
contamination, clean the valves.
The hydraulic connections P, T,
Assemble the steering unit free
L, R are disconnected.
from distortion.
Change the oil as required.
Only in electric forklift trucks Check the steering angle sensor
Steering angle sensor defective
Insuf cient pump speed on the steering column

Clean the priority valve - even

better, change it.
Bleed the LS line at the priority
valve.
Air in the LS line.
Pressure measurement at
Steering overhaul Dirt in the hydraulic oil causes
the priority valve at P and LS. If
Pivoting problems when starting faulty oil ow in the priority valve.
there is no standby pressure or
to steer No volume ow rate from P to
pressure differential between P
CF.
and LS, change the priority valve.
Check the hydraulic oil for
contamination and change as
required.
.

-4 50638042201 EN - 10/2017
https://truckmanualshub.com/

The steering unit is secured to the steering

column ange via four mounting screws.

The following valves are tted in the steering unit.

Pressure relief valve
Shock valve
The shock valve has a damping function that
prevents major pressure uctuations being
transmitted from the hydraulic system to the
steering.

The values set by the manufacturer must not be

changed.

1 Steering unit
2 Steering column adjustment
Hydraulic oil may escape when loosening the 3 Steering column
hydraulic connections. 4 Undo the xing screws
5 Earth wire
Remove the steering column panelling. 6 Bearing axle
7 Diaphragm pressure switch
Remove the parking brake panelling on the
left-hand side.
Disconnect the plug contacts at the key switch.
Protect the bottom plate from oil by using a
cleaning cloth.
Preparation for swivelling
the steering column backwards:
Remove the steering wheel.
or:
Remove the battery from the truck.
Remove the driver's seat.

50638042201 EN - 10/2017 -5
https://truckmanualshub.com/

Remove the steering column adjustment

spring and securing bolt (1).
Unscrew the earth cable from one of the
mounting screws.

Unhook the steering column adjustment and

tip back.
Remove the diaphragm pressure switch, see
the chapter entitled "Diaphragm pressure
switch"

Unscrew all hydraulic connections and protect

them from contamination using sealing plugs;
mark if necessary.
Remove the steering column adjustment from
the mount.
Loosen the four M10 mounting screws and
take out the steering unit from below.

-6 50638042201 EN - 10/2017
https://truckmanualshub.com/

Tightly screw the steering unit onto the steering

column using the two front mounting screws.
Connect all hydraulic connections.
Insert the steering column adjustment into the
mount.
Swivel the steering column upwards and hook
on the steering column adjustment.

Fit the steering column adjustment spring and

securing bolt.

Using a cable tie makes it easier to t the tension

spring.
Tightly screw in the two rear mounting screws
with the earth wire.
Install the diaphragm pressure switch, see the
chapter entitled "Diaphragm pressure switch".

Attach the steering wheel.

or:
Install the driver's seat.
Install the battery in the truck.

Connect the plug contacts at the key switch.

Attach the panelling.
Clean the bottom plate as necessary; remove
any oil.
Carry out a functional test, steering from stop
to stop several times.

The diaphragm pressure switch is no longer

evaluated in trucks with MCU 2 and software
version 2.06 and is not tted in these trucks.

50638042201 EN - 10/2017 -7
https://truckmanualshub.com/

Activation and mode of the dynamic steer

0E1 03 1B
support
0E8 00 01 Steering switch not tted
0EF 00 20 Steering stop moment cut-off threshold

The diaphragm pressure switch is screwed to the

steering unit.
Pressure is built up in the steering unit by turning
the steering wheel. Once a speci c pressure has
been reached, the pressure switch opens and the
pump motor starts up.
For the switching range of the diaphragm pres-
sure switch, see chapter "General technical
data".

The switching range is set at the factory and must

not be changed.

Remove the steering column panelling

Unscrew the parking brake panelling on the
left-hand side
Disconnect the plug contacts at the key switch
Open the protective cap's cable ties and
remove the protective cap
Disconnect the plug contacts at the diaphragm
pressure switch
Unscrew the diaphragm pressure switch using
a long SW24 socket

Hydraulic oil can escape when unscrewing the

diaphragm pressure switch.

Screw on the diaphragm pressure switch using

a long SW24 socket
Connect the plug contacts at the diaphragm
pressure switch
Pull over the protective cap and secure with
cable ties
Connect the plug contacts at the key switch
Screw on the steering column panelling

-8 50638042201 EN - 10/2017
https://truckmanualshub.com/

Screw on the parking brake panelling on the

left-hand side
Carry out a functional test, steering from stop
to stop several times

50638042201 EN - 10/2017 -9
https://truckmanualshub.com/

The priority valve is screwed directly onto the

hydraulic pump.
The valve is a hydraulic control unit and ensures
that oil is supplied to the steering as a priority in
all operating conditions.

-10 50638042201 EN - 10/2017

https://truckmanualshub.com/

Steering sticks.
The slider in the priority valve
Steering overhaul Clean the priority valve - or
is prevented from moving in the
Pivoting problems when starting even better, change it
housing due to dirt particles
to steer.
.

Note the screw qualities and tightening torques.

Remove the priority valve
Release the screw plugs
Remove the pre-loading spring
Remove the slider
Clean all parts.
Check the sealing rings of the screw plugs
Insert the slider
Insert the pre-loading spring
Screw in the screw plugs

50638042201 EN - 10/2017 -11

https://truckmanualshub.com/

The steering column is screwed to the front

structure via the steering column support with
four rubber bearings.
The inclination of the steering column can be
adjusted in four different locking positions within
a 10° range.
The brake actuation components parking brake
lever and brake pedal are mounted on the
steering column support.

Hydraulic oil may escape when loosening the

hydraulic connections.
Remove the steering column panelling
Remove the parking brake panelling on the
left-hand side
Disconnect the plug contacts at the key switch
1 Steering column adjustment
Protect the oorplate against oil by using a 2 Four locking positions
cleaning cloth 3 Rubber mounts
Preparation for swivelling
the steering column backwards:
Remove the steering wheel
or:
Remove the battery from the truck
Removing the driver seat

Remove the steering column adjustment

spring and securing bolt (1)
Unscrew the earth cable from one of the xing
screws

-12 50638042201 EN - 10/2017

https://truckmanualshub.com/

Unhook the steering column adjustment and

tip back
Remove the diaphragm pressure switch, see
the chapter entitled "Diaphragm pressure
switch"
Remove the steering unit; see the chapter
entitled "Steering unit"
Remove the ES bolts of the service brake on
the front structure
Release the locknut for setting the brake cable
Push the brake cable forwards
Release the nut (SW19) on the bearing axle
and remove the bearing axle on the right-hand
side

Insert the steering column with bearing axle

into the front structure from the right-hand side
Screw on the bearing axle with nut (SW19)
Screw on the locknut for setting the brake
cable
Fit the ES bolts of the service brake on the front
structure
Install the steering unit; see the chapter
entitled "Steering unit"
Insert the steering column adjustment into the
mount
Move the steering column upwards and hook
on the steering column adjustment
Fit the steering column adjustment spring and
securing bolt

Using a cable tie makes it easier to t the tension

spring.
Tightly screw in the two rear xing screws with
the earthing cable
Install the diaphragm pressure switch, see the
chapter entitled "Diaphragm pressure switch"

Attach the steering wheel

or:
Driver's seat reconnection
Install the battery in the truck

50638042201 EN - 10/2017 -13

https://truckmanualshub.com/

Connect the plug contacts at the key switch

Install the panelling
Clean the bottom plate as necessary; remove
any oil
Carry out a functional test, steering from stop
to stop several times

The steering angle sensor is tted below the

steering wheel on the steering column and
comprises a two-track pulse generator and a
magnetic pole wheel. When steering is actuated,
the sensor delivers positive voltage pulses.
The pole wheel (4) is rmly connected to the
moving steering column. The pole wheel is xed
with Loctite and secured in place with a grub
screw.
The sensor (1) is set in its position in relation to
the pole wheel via two screws on the clamping
ring (5). To ensure its vertical position on the
steering column, the clamping ring is clipped to
the steering column using a cable clip (3). 1 Steering angle sensor
2 Mounting screws
3 Cable clip
4 Magnetic pole wheel
5 Clamping ring
Pulse generator
Supply voltage 9 13 V
Current draw <10 mA
Sensing distance ≤ 0.5 mm
Temperature range -40°C to 85°C
Protection type IP 64
.

3B01/1 (br) X46/38 12 V

3B01/2 (S1) X46/36 Track A signal
3B01/3 (bl) X46/23 GND_S
3B01/4 (S2) X46/35 Track B signal
.

In the event of implausible or missing values,

the truck control unit (MCU) generates error
numbers.
The truck then only travels in emergency mode at
2 km/h.

-14 50638042201 EN - 10/2017

https://truckmanualshub.com/

The driver sees the error STEERING in the

display.

Connect the multimeter between GND-S and

track A or track B
The displayed voltage must jump between
0.05 and 11 V during slow steering.
Fast steering results in an average DC of
approx. 5.6 V between GND_S and track A
or GND_S and track B.
Alternatively, the steering angle display ADJUST
can be activated in the display.

The sensor surface should rest gently on the

paper at the magnet ring.

50638042201 EN - 10/2017 -15

https://truckmanualshub.com/

In order to optimise drive comfort and operational

safety, trucks are tted with Curve Speed Control
(CSC). This function ensures that the driving
speed is reduced when steering. The effect
becomes more powerful at higher speeds and
is triggered when steering is actuated.
Depending on the truck type, CSC is either
standard equipment or a variant of the assistance
system.

The driving speed must generally be adjusted in such

a way that the CSC is not used.
When installed as standard equipment, CSC must not
be deactivated!

Traction motor rev

Series Series Series Series Series Series
sensor
Steering angle
Series Series Series Series Series Series
sensor 3B01
Curve switch 3B28, Only for Only for
Series Series Series
3B29 CSC CSC Not
Not Series until week 22/2010, available
Wiring with plug X29 Series Series
available then omitted
.

During operation, the speed is limited accord-

ing to the steering angle. This behaviour follows
characteristic curves that are individually calcu-
lated for each truck. Due to the different corner-
ing behaviour, different characteristic curves are
used for forwards and reverse travel.
If the driving speed is too high when cornering,
the drive is decelerated to the permissible speed
for the current steering angle. When driving in
a straight line, the maximum speed is enabled
V Speed [km/h]
again.
Steering angle [°]

-16 50638042201 EN - 10/2017

https://truckmanualshub.com/

The geometry of the truck is used as a basis upon

which the characteristic curve is calculated. For
this procedure, a secure stability triangle is used,
in the middle of which lies the centre of gravity of
the truck. All of the forces exerted on the truck
continuously affect its centre of gravity.

S Truck centre of gravity

Steering angle
R Curve radius
G Weight of truck
Z Centrifugal force
K Resulting force vector

When cornering, a centrifugal force (Z) is produ-

ced, which in uences the centre of gravity. The
greater the speed and the steering angle, the
greater the centrifugal force. The resulting force
vector (K) is generated from the weight and the
centrifugal force.
To calculate the maximum speed, it is assumed
that that the truck tips over as soon as the power
vector (K) attacking at the centre of gravity (S)
of the truck is directed at a point outside of the
stability triangle.

The CSC is an assistance system that is installed

as standard. It must not be deactivated.
The steering angle is recorded and calculated via
the following components:
Curve switch 3B28 and 3B29 at the steering
axle:
Steering angle monitoring
Steering angle sensor 3B01 at the steering
column:
Steering angle detection
Rev sensors for the traction motors
Accelerator
Brake sensor
Engine torque, calculated via the traction
converters

The steering angle is detected by steering angle

sensor 3B01 and the rev sensors. In addition, the

50638042201 EN - 10/2017 -17

https://truckmanualshub.com/

calculated steering angle is monitored using the

two curve switches 3B28 and 3B29.
The current cornering manoeuvre can be as-
sessed by means of the two speed signals from
the traction motors. The actuation of the vary-
ing engine speeds is calculated from the brake
sensor, accelerator, engine torque and current
engine speed, as well as using the truck statuses.
As a result of this procedure, CSC does not need
to be calibrated.

Park the truck on even ground.

Jack up the truck at the front, ensuring that the
drive wheels are not touching the ground.
Key switch ON
Show the steering angle and speed in the ABE
display.
Connect the notebook to the truck and start the
truck diagnostics:

F4: Monitor

Drive unit

Engine speed

When the truck is jacked up, the torques of the

traction motors do not match the values in actual
use, as the controller cannot correctly calculate
the steering angle. A trick can be used that
enables the controller to still display the steering
angle:
Maximum speed of the traction motors must
not exceed 5 km/h (<1290 rpm).
Move the steering wheel from the left steering
stop to the right steering stop and return the
steering wheel back into the centre position.
This will cause the system to initialise once. From
now on, the current steering angles will be shown
in the display. The following tables can be used
to check the values.

-18 50638042201 EN - 10/2017

https://truckmanualshub.com/

0 (18.00) 4640 0 (16.20) 4176

3 18.00 4640 3 16.20 4176
6 14.50 3738 6 13.05 3364
12 11.40 2939 12 10.26 2645
18 10.00 2578 18 9.00 2320
24 9.10 2346 24 8.19 2111
30 8.50 2191 30 7.65 1972
36 8.10 2088 36 7.29 1879
42 7.80 2011 42 7.02 1810
48 7.67 1977 48 6.90 1779
54 7.44 1918 54 6.70 1727
60 7.03 1812 60 6.33 1632
66 6.49 1673 66 5.84 1506
72 5.93 1529 72 5.34 1377
78 5.45 1405 78 4.91 1266
84 5.12 1320 84 4.61 1188
90 5.00 1289 90 4.50 1160
.

0 (20.00) 5156 0 (18.00) 4640

3 20.00 5156 3 18.00 4640
6 13.60 3506 6 12.24 3156
12 10.70 2759 12 9.63 2483
18 9.40 2423 18 8.46 2181
24 8.60 2217 24 7.74 1995
30 8.00 2062 30 7.20 1856
36 7.60 1959 36 6.84 1763
42 7.40 1908 42 6.66 1717
48 7.27 1874 48 6.54 1686
54 7.08 1825 54 6.37 1642
60 6.73 1735 60 60.6 1562
66 6.27 1616 66 56.4 1454
72 5.79 1493 72 5.21 1343
78 5.38 1387 78 4.84 1248
84 5.10 1315 84 4.59 1183
90 5.00 1289 90 4.50 1160
.

50638042201 EN - 10/2017 -19

https://truckmanualshub.com/

Manufacturer Linde
Designation LA 340
Weight

Steering angle 90°

Not adjustable
Steering angle limit
From centre position, 7 teeth to both the right and left
Push rods - lift from right to left 103.7 mm

5 x spherical collar nut A14-10

Wheel nuts, per wheel
Tightening torque: 195 Nm
1 x hexagon nut M14 x 1.5, DIN 980
Wheel hub, per side Tightening torque: 145 Nm
Secured with Loctite No. 243
3 x hexagon head screw M16 x 80, 8.8, DIN 931
Mounting of steering box / counterweight Tightening torque: 195 Nm
Secured with Loctite No. 243
1 x hexagon head screw M16 x 50, 10.9, DIN 933,
quality
Pivot bearing adjustment screw Equalisation of axial clearance using shim rings
Tightening torque: 195 Nm
Secured with Loctite No. 243
Tightening torque: 145 Nm
Cylinder pipe
Secured with Loctite No. 243

Lithium soap grease

Mounts in the steering box
DIN 51825 - KP2K-30
Greasing during operation Maintenance free
Greasing during assembly Fill the mounts until fresh grease escapes
.

-20 50638042201 EN - 10/2017

https://truckmanualshub.com/

The steering axle in the steering turntable version

is bolted with the steering box (6) from below to
the counterweight using three mounting screws
(5).
The steering cylinder pipes (11) are screwed to
the left and right in the steering box. The steering
cylinders' pistons actuate on a rack that performs
a turning movement via the gearing in the axle
casing (9).
The axle casing is tted at the top of the housing
(1) on tapered roller bearings. The axle casing
is connected to the steering box via the pivot
bearing adjustment screw (4). At the same 1 Plug X29
time and with the help of shim rings the axial 2 3B28 right curve switch
clearance of the pivot bearing is adjusted. 3 3B29 left curve switch
4 Pivot bearing adjustment screw
The wheel hubs (8) are placed and bolted onto 5 Undo the xing screws
both sides of the axle of the axle casing. The 6 Steering box
wheel hub nut is covered by the hubcap (7). 7 Hubcap
8 Wheel hub
The curve switches tted to the top of the housing 9 Axle body
(2, 3) calculate the steering angle actual value 10 Make hydraulic connection
and switch at a de ned steering angle. 11 Cylinder pipe

The curve switches are inductive proximity

switches that react to the proximity of iron.
At a de ned steering angle, curve switch 3B29
switches in left-hand curves, and curve switch
3B28 switches in right-hand curves.
Curve switches 3B28 (1) and 3B29 (2) are scre-
wed to the steering turntable via a retaining plate.
The cam disc (3) serves as a transmitter.

50638042201 EN - 10/2017 -21

https://truckmanualshub.com/

Switching range -40° to -20° +20° to +40°

Voltage jump From 0 V to 11 V
Max. steering angle of steering turntable -70° +70°
.

3B29 3B28
X29/1 X44/12 12 V X29/4 X44/13 12 V
(brown) (brown)
3B29 3B28
X29/2 X44/10 Signal X29/5 X44/27 Signal
(black) (black)
3B29
X29/3 X44/41 GND-L 3B28 (blue) X29/6 X44/42 GND-L
(blue)
.

In the event of implausible or missing values,

the truck control unit (MCU) generates error
numbers.
This does not restrict the handling characteristics.

Assembly tools:
Guide bolt, headless screw M16 x 100
Wooden plank, ideal size 190 x 30 x 820
Plug X29 for the curve switch is located in the
counterweight. In order to be able to lead the ca-
ble out downwards, the battery must be removed.

Actuate the parking brake.

Prevent the truck from rolling away using
chocks at the front wheels.
Remove the battery.
Loosen the sheet metal cover.
Disconnect connection assembly X29 of the
curve switch.
Lead the cable out downwards.
Place the steering in full lock to the left.
Loosen the wheel nuts.
Place the steering in full lock to the right.
Loosen the wheel nuts.

-22 50638042201 EN - 10/2017

https://truckmanualshub.com/

Jack up the truck on the right-hand side at the

chassis when the battery door is open.

Place a supporting block under the counter-

weight.
Jack up the truck on the left-hand side at the
chassis. Place a supporting block under the
counterweight.

Remove the wheels.

Return the steering to the neutral position.
Loosen the hydraulic connections on the
left-hand side and right-hand side of the
steering cylinders.

If the hydraulic connections are opened, hydrau-

lic oil may escape.

50638042201 EN - 10/2017 -23

https://truckmanualshub.com/

First loosen the front screw. Insert the guide

bolt.

The screws are secured with pourable plastics.

Place the wooden plank at an angle under the

steering turntable and prevent it from rolling
away with a wheel.
Loosen the two front screws.

Allow the steering turntable to slide slowly

downwards over the wooden plank.

Observe the screw quality and the tightening

torques
Observe the quality of pourable plastics
For values, see "General technical data" in the
chapter entitled "Steering axle"
Push the steering turntable upwards over the
wooden plank. Use the guide bolt in the front
thread as an aid to assembly.
Clean the screws of grease. Secure the
screws using pourable plastics.

-24 50638042201 EN - 10/2017

https://truckmanualshub.com/

Screw in the hydraulic connections on the

right-hand side and left-hand side of the steer-
ing cylinder. Follow the assembly instructions.
Screw in the screw joints up to the blue coating.
Then screw the screw joints into position using a
minimum of three to a maximum of four revolu-
tions. Do not unscrew the screw joints.
Mount the wheels.
Lower the truck.
Tighten the wheel nuts.
Guide the cable for plug X29 upwards into the
counterweight.
Connect plug X29.
Fit the sheet metal cover.
Install the battery in the truck.

Warm up the truck.

Then steer fully from stop to stop at least ve
times.

50638042201 EN - 10/2017 -25

https://truckmanualshub.com/

Manufacturer DANA
Designation LA 301
Weight approx. 80 kg
Steering angle 80 - 82°
Steering angle limit DIN 933, M12 x 40-8.8 stop screw

Wheel nuts, per wheel [Nm] 195 5 x spherical collar nuts A14-10
2 x DIN 933, M16 x 50-8.8 hexagon head
Screw joint between steering axle and
[Nm] 195 screws
counterweight
2 x lock washers VSK 16
Wheel hub, per side [Nm] 145 1 x DIN 980, M14 x 1.5 hexagon nut
4 x DIN 960, M16 x 1.5 x 100-8.8 hexagon
Steering cylinder [Nm] 210
head screws
M18 x 1.5 hexagon nut
Only insert oiled parts
Steering pivot pin
[Nm] 290 2200 - 3000 kg
[Nm] 310 3500 kg

Bolts tie rod on the cylinder side [kN] 1 - 21 Treated with MoS2
Bolts tie rod on the axle stub side [kN] 4 - 38 Treated with MoS2
Axle stub steering pivot pin [kN] 60 Oiled

Greasing 1000 operating hours

Fill with grease until a small amount of fresh grease

All joints
escapes

Wheel bearing, rotary shaft seal of wheel

bearing Fill with grease
Axle stub bearing
Grease all bearings until a small amount of fresh
Wheel hub, axle stubs, tie rod
grease escapes

Axle stub bearing, spherical bearing Aralub 4320

Wheel bearing, rotary shaft seal of wheel Lithium soap grease
bearing DIN 51825 KP2K-30
.

-26 50638042201 EN - 10/2017

https://truckmanualshub.com/

13 Buffer element
4 Axle casing 14 Mounting screws
5 Steering pivot pin 15 Joining plate
6 Wheel hub 16 Steering cylinder mounting
7 Axle stub
8 Tie rod
1 Plug X29
9 Steering cylinder
2 3B28 right curve switch
10 Piston rod
3 3B29 left curve switch
11 Hubcap
12 Stop screw

The steering axle in the swing axle version is The steering cylinder's piston rod (10) causes
inserted into the counterweight with two buffer a turning movement in the axle stubs via the tie
elements (13) and secured with joining plates rods (8). The steering angle is limited by the stop
(15) and mounting screws (14). screws (12) at the axle stub.
The steering cylinder (9) is screwed into the axle
casing (4) via four mounting screws (16).
The axle stubs (7) are tted on both sides in The curve switches tted to the left and right on
tapered roller bearings and secured with steering the steering cylinder (2, 3) serve to calculate the
pivot pins (5). steering angle actual value and switch at a de-
ned steering angle. The equipment depends on
The wheel hubs (6) are placed and bolted onto
the truck type; see the chapter entitled "Steering
the axle stubs on both sides. The wheel hub nuts
system".
(11) are covered by hubcaps.

50638042201 EN - 10/2017 -27

https://truckmanualshub.com/

Curve switches are inductive proximity switches

that respond to the proximity of iron. At a de ned
steering angle, curve switch 3B29 switches in
left-hand curves, and curve switch 3B28 switches
in right-hand curves.

Curve switches 3B28 (1) and 3B29 (2) are bolted

on to the left and right-hand side of the steering
axle respectively via angle plates. The connec-
ting pin (3) between the steering cylinder and
steering axle acts as a transmitter.

Switching range -40° to -20° +20° to +40°

Voltage jump From 0 V to 11 V
Max. steering angle 90° +90°

Switching range -20° to -12° +12° to +20°

Voltage jump From 11 V to 0 V
Max. steering angle of swing axle -70° +70°
.

3B29 3B28
X29/1 X44/12 12 V X29/4 X44/13 12 V
(brown) (brown)
3B29 3B28
X29/2 X44/10 Signal X29/5 X44/27 Signal
(black) (black)
3B29
X29/3 X44/41 GND-L 3B28 (blue) X29/6 X44/42 GND-L
(blue)
.

If values are implausible or missing, the truck

control unit (MCU) generates error numbers.
This does not restrict the handling characteristics.

-28 50638042201 EN - 10/2017

https://truckmanualshub.com/

The battery may need to be removed, depending

on the type of truck and equipment.
Plug X29 for the cornering switch is located in
the counterweight. The cable must be led out
downwards.

Operating the parking brake

Prevent the truck from rolling away using
chocks at the front wheels
Removing the battery
Release the sheet metal cover
Disconnect plug connector X29 of the corner-
ing switch
Lead the cable out downwards
Release the wheel nuts on both sides
Jack up the truck on the right-hand side when
the battery door is open
Place square timbers under the counterweight
Jack up the truck on the left-hand side at the
chassis and place square timbers under the
counterweight
Remove the wheels
Loosen the hydraulic connections on the left
and right of the steering cylinder

Hydraulic oil may escape when loosening the

hydraulic connections.
Position a forklift truck under the steering axle
and raise it to the stop
Unscrew the four M16 axle bearing screws and
remove the joining plates

50638042201 EN - 10/2017 -29

https://truckmanualshub.com/

The steering axle is retained by the forklift truck

Lower the steering axle, carefully tilt it forwards

and remove it sideways from the truck

Check screw quality and tightening torques

Check the quality of pourable plastics
For values, see "General technical data" in the
chapter entitled "Steering axle"
Position the steering axle under the truck from
the side

Lift the steering axle, taking care to keep it in a

straight position
Insert the buffer element, lightly greased with
multi-purpose oil in the bearing shells in the
counterweight

Screw in the joining plates using two M16 axle

bearing screws with spring lock washer for
each one
Screw in the hydraulic connections on the
right and left of the steering cylinder; follow the
assembly instructions
Screw in the screw joints up to the blue coating
and then put them into position using at least 3
or a maximum of 4 rotations. Do not unscrew the
screw joints.
Fit the wheels
Lower the truck.

-30 50638042201 EN - 10/2017

https://truckmanualshub.com/

Tighten the wheel nuts

Lead the cable for plug X29 upwards into the
counterweight
Connect plug X29
Fit the sheet metal cover
Install the battery in the truck
Carry out a functional test, steering from stop
to stop several times

1 Axle casing 7 Slotted spring pin

2 Axle stub 8 Dust cap
3 Radial seal ring 9 Nut
4 Tapered roller bearing 10 Washer
5 Wheel hub 11 Wheel nut
6 Tapered roller bearing 12 Wheel bolt

Apply the parking brake.

Prevent the truck from rolling away using
chocks at the front wheels.

50638042201 EN - 10/2017 -31

https://truckmanualshub.com/

Loosen the wheel nuts (11).

Jack up the truck at the counterweight.
Remove the wheel.
Take off the dust cap (8).
Unscrew the nut (9) and remove along with
washer (10), making sure that the slotted
spring pin (7) is properly seated while doing
so.
Take off the wheel hub (5).
Take off the radial seal ring (3).
Remove tapered roller bearings (4, 6) from the
wheel hub.
If necessary, drive out the outer rings of the
tapered roller bearings.

-32 50638042201 EN - 10/2017

https://truckmanualshub.com/

Check the quality of screws and lubricant, as

well as the correct tightening torques.
Values vary according to axle type; see
"General technical data" in the chapter entitled
"Steering axle".
Carefully grease the sealing lips of the radial
seal ring.
Pack the tapered roller bearing between the
inner ring and the cage with grease.
Pack the bearing chamber with grease at the
points indicated (x).
Press in the outer rings of the tapered roller
bearings.
Insert the tapered roller bearings (4, 6) into the
wheel hub.
Fit the radial seal ring (3).
Attach the wheel hub (5).
Insert the washer (10) into the slotted spring
pin (7) and attach the nut (9).

Installing the washer in the incorrect position and

attaching a nut that has already been used will cause
damage to the steering axle.
The self-securing nut must not be reused. It must
always be changed.
The washer should be installed with the chamfered
edge facing the axle.

Tighten the nut (9) by continuously turning the

wheel hub.
Fit the dust cap (8).
Fit the wheel.
Lower truck.
Tighten the wheel nuts (11).

50638042201 EN - 10/2017 -33

https://truckmanualshub.com/

The steering angle must be 80° 82°.

For easier measuring, a supplementary angle
can be used. This angle must be 98° 100°.

The steering angle is limited by a stop screw (1)

on each side.

The steering cylinder can be damaged.

It is important to ensure that the steering angle is clearly
limited by the stop screws. The stop must not take
place in the steering cylinder.

Set the left and right steering angles to 80° 82°

using the stop screws (1)
Check the opposite angle
Check for clearance at the points of constric-
tion
Check that the steering wheel stop does not
take place in the steering cylinder

-34 50638042201 EN - 10/2017

https://truckmanualshub.com/

A press is required to install the tie rod. For this

reason, the steering axle should be completely
removed beforehand; see the chapter entitled
"Removing and installing the steering axle".
Remove the steering axle; see the chapter
entitled "Removing and installing the steering
axle"
Knock out the slotted spring pins (4)
Press out the bolts (3)

Observe the press-in force of the bolts.

Values vary according to type of axle; see
"General technical data" in the chapter entitled
"Steering axle".
Lubricate and press-in the bolts (3)
Tap in the slotted spring pins (4)
Install the steering axle; see the chapter
entitled "Removing and installing the steering
axle"
1 Axle stub
2 Steering cylinder piston rod
3 Bolts
4 Slotted spring pin
5 Sealing ring
6 Spherical bearing
7 Conical lubricating nipple

50638042201 EN - 10/2017 -35

https://truckmanualshub.com/

A press is required to remove the axle stub.

For this reason, the steering axle should be
completely removed beforehand; see the chapter
entitled "Removing and installing the steering
axle".
Drive out the pin between the tie rod and the
axle stub
Slacken the hexagon nut (1)
Take out the washer (2)
Drive the steering pivot pin (3) out downwards
Take the axle stub (5) off the axle
Take the spacer washers, O-ring, wiper rings
and tapered roller bearings (8 - 15) off the axle
stub

Check the quality of screws and lubricant, as

well as the correct tightening torques.
Values vary according to type of axle; see
"General technical data" in the chapter entitled
"Steering axle".
Grease both tapered roller bearings (10, 12)
well and insert them
Carefully grease the sealing lips of the wiper
rings (9, 13)
1 Hexagon nut
Insert the wiper rings (9, 13), both spacer 2 Washer
washers (8, 15) and the O-ring (14) 3 Steering pivot pin
4 Sealing plug
Insert the axle stub (5) into the axle 5 Axle stub
6 Stop screw
Lightly oil the steering pivot pin (3) and insert it
7 Nut
from below 8 Spacing washer
Fit the washer (2) 9 Wiper ring
10 Tapered roller bearing
Fit and tighten the new hexagon nut (1) 11 Lubricating nipple
12 Tapered roller bearing
Drive in the pin between the tie rod and the axle 13 Wiper ring
stub, and secure it with slotted spring pins 14 O-ring
15 Spacing washer

-36 50638042201 EN - 10/2017

https://truckmanualshub.com/

1 Handbrake lever
2 Brake cable pull, handbrake 1S3 Handbrake switch
3 Brake pedal 1B2 Brake sensor
4 Brake cable pull, service brake

The multi-disc brake on the drive axle is activated

via two independent actuation elements:
Handbrake lever
The hand brake lever effects the brake actua-
tion of the multi-disc brake via the brake cable
pull (2)
Brake pedal
The brake pedal effects the brake actuation of
the multi-disc brake via the brake cable pull (4)

50638042201 EN - 10/2017 -1
https://truckmanualshub.com/

Park the truck safely and secure the truck

against rolling away.
Disconnect battery plug.
Remove oorplate.
Remove the panelling on the right-hand side of
the front structure
The position of the brake cable depends on the
equipment on the truck.

Remove the ES bolt (1) from the brake cable in

the front structure
Disconnect the brake pedal return spring (2)

Remove the ES bolt (1) from the brake cable in

the front structure
Disconnect the brake pedal return spring (2)
Loosen the adjustment nut on the brake cable
in the front structure and disconnect the brake
cable

Remove the brake control cover (3) on the

drive axle
Remove the ES bolt from the brake cable (2)
on the drive axle
Remove the securing clips from the brake
cable
Disconnect the brake cable and pull out and
down

Connect the brake cable to the drive axle

-2 50638042201 EN - 10/2017
https://truckmanualshub.com/

Fit the brake cable securing clips

Fit the ES bolt
Connect the brake cable in the front structure
Fit the ES bolt
Connect the brake pedal return spring
Adjust the brake cable at the adjustment nut
Fit the brake lever covering to the drive axle
Fit the panelling in the front structure
Insert the oorplate
Connect the battery plug
Check the service brake for correct operation

If the service brake is not actuated, the brake

lever (1) must rest on the adjustment screw (2).
The gap between the brake lever and adjustment
screw is .

Adjust the brake cable in such a way that there is

an actuation distance of at the pedal,
without the brake lever coming away from the
adjustment screw.

The presetting of the adjustment screw at the

brake lever must not be adjusted.

Park the truck safely and secure the truck

against rolling away.
Disconnect the battery male connector.
Remove the bottom plate

50638042201 EN - 10/2017 -3
https://truckmanualshub.com/

Remove the panelling on the right-hand side of

the front structure.

Remove and detach the s-bolt (1).

Detach the brake pedal return spring (2).
Loosen the adjustment nut on the brake cable
in the front structure and disconnect the brake
cable.

Remove the brake actuation assembly.

Remove the s-bolt (4) and detach from the
brake lever (3).
Loosen the adjustment nuts and detach the
brake cable from the abutment (6).

Connect the brake cable to the drive axle.

Fit the brake cable securing clips.
Fit the s-bolt.
Connect the brake cable in the front structure.
Fit the s-bolt.
Adjust the brake cable at the adjustment nut.
Fit the brake lever cover to the drive axle.
Fit the panelling in the front structure.
Insert the bottom plate.
Connect the battery male connector.
Check the service brake for correct operation.

-4 50638042201 EN - 10/2017
https://truckmanualshub.com/

When the service brake is not actuated, the brake

cable must be adjusted so that a distance of X
remains between the fork clevis and the brake
lever on the axle.

X 19 mm
.

3 Brake lever
4 Service brake cable
5 Parking brake cable
6 Abutment
X Setting dimension

Secure the truck against rolling away

Disconnect battery plug.
Remove oorplate.
Remove the panelling on the left-hand side of
the front structure
Remove the covering from the brake lever on
the drive axle

50638042201 EN - 10/2017 -5
https://truckmanualshub.com/

Loosen the brake cable fastening in the front

structure
Remove the retaining ring and drive out the
bolt (1) laterally from the fork clevis (2).
Loosen the adjustment nut (3) at the brake
cable and disconnect the brake cable

The s-bolt on the handbrake cable can only be

removed if the s-bolt on the service brake cable
has been removed beforehand.
Remove the s-bolt on the service brake cable
at the drive axle.
Remove the s-bolt on the handbrake cable at
the drive axle.
Remove the securing clips from the brake
cable
Disconnect the brake cables and pull out from
below

Connect the brake cable and gently screw in

the adjustment nut (3) at the brake cable
Drive the bolt (1) laterally into the fork clevis (2)
and secure with the retaining ring.
Attach the handbrake cable to the actuation
unit at the drive axle and secure using an
s-bolt.
Attach the service brake cable to the actuation
unit at the drive axle and secure using an
s-bolt.
Fit the brake lever covering to the drive axle
Adjust the brake cable.
Fit the panelling in the front structure
Insert the oorplate
Connect the battery plug
Test the handbrake function.

RX20-14-20,
AE18-05 8 85 ±8 91 to 110
RX60-16-20

-6 50638042201 EN - 10/2017
https://truckmanualshub.com/

RX20-14-20,
AE18-07 8 130 ±5 148 to 159
RX60-16-20
RX20-14-20
AE18-09 8 130 ±5 148 to 159
Facelift 2014
RX60-25-35 EC35 5 105 ±8 115 to 133
RX60-40-50 EC50 5 105 ±8 115 to 133

RX70-16-20 AD20E-02 8 100 ±8 109 to 128

RX70-22-35 8.20 4 125 ±8 138 to 157
RX70-40-50 EC50I 5 105 ±8 115 to 133

The handbrake lever must have a free travel of at

least without the brake lever detaching from the
stop screw. There is then no noticeable tension
in the cable. See the chapter entitled "Changing
the brake cable for the handbrake".
Adjust the handbrake cable to set the speci ed
actuating force.
The maximum actuating force is set at approx.
2
/3 to 3/4 of the actuation distance and then
decreases again.

Attach the spring force meter to the handbrake

lever using a cable tie. Lay the cable tie into
the groove beneath the movable handle.

Actuate the handbrake lever using the spring

force meter.

The direction of movement must be observed

in order for the actuating force to be displayed
correctly. See the diagrams.
Read off the maximum actuating force while
actuating the lever.
To increase the actuating force, adjust the lock
nuts in the direction of the brake lever.
To reduce the actuating force, adjust the lock
nuts in the opposite direction.

50638042201 EN - 10/2017 -7
https://truckmanualshub.com/

The cable tie prevents the handbrake from

engaging during the test.

The parking brake switch 1S3 is located on the

left-hand side in the front structure, behind the
parking brake lever.
The parking brake switch is an NO contact, i.e.
when it is not actuated it is open (normally open),
whereas when it is actuated it is closed.
The switch is closed when the parking brake is
not actuated. The traction drive is activated.

If the parking brake is actuated, the switch is

open. The traction drive is switched off.
The parking brake switch is set by loosening the
screws and moving the support.

If the parking brake is only slightly engaged, the truck

will roll as the electrical brake that keeps the truck in
place is not functioning.
If the truck is parked on a ramp, the parking brake must
be securely engaged

The parking brake switch 1S3 is connected

directly to the truck central control.

2-pin JPTimer 1S3

1S3/1 X46/3 Handbrake
1S3/2 X46/17 GND-S handbrake
.

-8 50638042201 EN - 10/2017
https://truckmanualshub.com/

The brake sensor 1B2 is tightly screwed to the

right side part of the operating unit and connected
to the truck control unit (MCU) via the plug (1).
The brake sensor is a potentiometer that is
adjusted by a tappet (2) on the brake pedal.

1B2/1 Yellow X46/41 +12 Volt-S

1B2/2 Red X46/13 Signal
1B2/3 Green X46/27 GND-S
.

When the brake pedal is in the inactive position,

the brake sensor must be adjusted so that the
output signal is within the valid value range.

RX20 1.3 V 1.0 1.6 V

RX60 1.3 V 1.0 1.6 V
.

A calibration must always take place after the

brake sensor has been replaced.
Connect the notebook to the truck and start the
truck diagnostics:

Action

Calibration

0. Sensors
Once calibration is complete, error messages
may be displayed.

50638042201 EN - 10/2017 -9
https://truckmanualshub.com/

The accelerator comprises the accelerator pedal

and a double-action potentiometer 1B1.
The accelerator pedal is tted on a permanently
greased, sealed shaft in the housing and is held
in place at the lower end in its inactive position by
a compression spring.
Driving speed is regulated by potentiometer 1B1
when the accelerator pedal is pressed.

Remove oor plate.

Disconnect plug X16 from the accelerator
Loosen the polystop nuts
Remove the accelerator from the oorplate
from below.

The con guration must be parameterised again

for all retro tting and conversions related to the
accelerator and drive direction.

This affects the following components:

Single pedal
Double pedal
Joystick, tip switch, mini-lever
Lift lever
Direction indicator module
Parameterisation takes place using the truck
diagnostics in the notebook.

Calibration must always take place after the

accelerator has been changed.
Connect the notebook to the truck and start the
truck diagnostics:

Job

Calibration

1. Accelerator
Once calibration is complete, error messages
may be displayed.

-10 50638042201 EN - 10/2017

https://truckmanualshub.com/

Operating error
Timeout during calibration
Value of accelerator's inactive position is
outside the valid range
Voltage increase does not lie within the valid
range

X16/1 Free
X16/2 1B1 - C2/sw Black Signal C2
X16/3 1B1 - C1/rt Red Signal C1
X16/4 1B1 - C1/C2/ge Yellow GND accelerator
X16/5 Free (Horn button)
X16/6 Free (Horn button)
X16/7 Free
X16/8 1B1 - C1/C2/gn Green 12 Volt accelerator
.

Supply voltage X16/4 - X16/8 11.05 - 12.05

Correction by turning the
C1 accelerator not actuated X16/4 - X16/3 5.5 - 6.5
potentiometer.
Correction by turning the
C2 accelerator not actuated X16/4 - X16/2 5.5 - 6.5
potentiometer.
Correction by turning the
C1 accelerator fully actuated X16/4 - X16/3 8.2 - 11.0
support.
Correction by turning the
C2 accelerator fully actuated X16/4 - X16/2 1.0 - 3.8
support.
GND breakdown detection 11.5
VCC breakdown detection 0.5
.

50638042201 EN - 10/2017 -11

https://truckmanualshub.com/

The difference in voltage between the transmit-

ter's inactive position (N) and maximum actuation
(max) is designated as the potentiometer voltage
increase.
At maximum actuation, the voltage must be at
least (up to maximum ) higher than
in the neutral position (N).

Voltage increase too small The maximum speed is not achieved

No problem for the evaluation
The maximum speed is reached but not exceeded.
Voltage increase too large
The end range of the voltage increase is ignored by the
controller (dead travel)
Voltage increase signi cantly too large Detection of breakdown with corresponding error message
.

The accelerator pedal consists of two plastic

parts, the pedal and the base, which are con-
nected to each other by an axle. The accelerator
pedal is attached to the bottom plate via two
screws.
Two compression springs hold the pedal in its
inactive position. The compression springs
contain different-coloured foam. The colour of
the foam provides information on the production
batch of the springs. For safety reasons, the
pedal should never be equipped with two springs
from the same product batch. In addition, the
foam also reduces noise made by the springs.
The foam has large pores so that it does not
become saturated with water.
The accelerator is a contactless inductive sensor.

The accelerator pedal will be included in the

current series from CW31/2017. As the wiring
harness has not been modi ed, an adapter cable
is required. 1 Pedal
2 Basis
Adapter cable without signal horn cable 3 Sensor 1B1
Adapter cable with signal horn cable 4 Fastening bushes
5 Adapter cable without signal horn cable
6 Springs with foam

Plug 6-pin MQS (AMP)

Supply voltage 12 V ± 8%

-12 50638042201 EN - 10/2017

https://truckmanualshub.com/

Protection class IP64

Temperature range -40° to +65°C
.

The con guration must be parameterised again

for all retro tting and conversions related to the
accelerator and drive direction.

The following components are affected:

Single pedal
Dual pedal
Joystick, ngertip and mini-lever
Hand lever
Turn indicator module for the drive direction
Parameterisation is performed using the truck
diagnostics in the notebook.

Calibration must always take place after the

accelerator has been replaced.
Connect the notebook to the truck. Start the
truck diagnostics:

Action

Calibration

1. Accelerator
Once calibration is complete, error messages
may be displayed.

Operating error
Timeout during calibration
Value of the transmitter's inactive position is
outside the valid range
Voltage increase is not within the valid range

50638042201 EN - 10/2017 -13

https://truckmanualshub.com/

1B1 - GND Pin 1 X16/4 GND accelerator

Unassigned Pin 2 X16/1 Unassigned
Unassigned Pin 3 X16/7 Unassigned
1B1 - signal A Pin 4 X16/2 Channel 2
1B1 - VCC Pin 5 X16/8 12 V accelerator
1B1 - signal B Pin 6 X16/3 Channel 1
Unassigned X16/5 Horn button (variant)
Unassigned X16/6 Horn button (variant)
.

Supply voltage X16/4 - X16/8 11.05 - 12.05 The sensor is adjusted for
C1 accelerator not actuated X16/4 - X16/3 5.5 - 6.5 the accelerator pedal by the
C2 accelerator not actuated X16/4 - X16/2 5.5 - 6.5 manufacturer. It is not possible
to perform a subsequent
C1 accelerator fully actuated X16/4 - X16/3 8.2 - 11.0
adjustment.
C2 accelerator fully actuated X16/4 - X16/2 1.0 - 3.8 In the event of a fault, the entire
GND breakdown detection 11.5 accelerator pedal must be
VCC breakdown detection 0.5 replaced.
.

The difference in voltage between the transmit-

ter's inactive position (N) and maximum actuation
(max) is referred to as the potentiometer voltage
increase.
At maximum actuation, the voltage must be at
least and up to a maximum of higher
than in the neutral position (N).

-14 50638042201 EN - 10/2017

https://truckmanualshub.com/

Voltage increase too small The maximum speed is not reached

No problem for the evaluation
The maximum speed is reached but not exceeded.
Voltage increase too large
The end range of the voltage increase is ignored by the
controller (dead travel)
Voltage increase signi cantly too large Detection of breakdown with corresponding error message
.

50638042201 EN - 10/2017 -15

https://truckmanualshub.com/

1 Cover
2 Actuation push button with LED
3 Hand wheel

The electric parking brake is available as a variant brake also offers automatic assistance and com-
for the following trucks: fort features, which apply the brake automatically
and release it again in certain situations.

6209 - 6217 12/2009

6311, 6313, 6315 12/2009
The driver's inattentiveness can be compen-
6321 - 6325,
12/2009 sated for by the automatic brake function.
6361 - 6364
6326 - 6330, Improved work ow, especially during order
12/2009 picking.
6367 - 6369
Automatic actuation of the electric parking
brake in de ned operating statuses (parking
assistant).
It is not recommended to retro t the electric Automatic release of the electric parking brake
parking brake because it takes a lot of effort. when setting off.
The driver can press the actuation button as
an alternative method of actuation.

The electric parking brake applies the mechanical Good integration into the overall safety and
comfort concept
brake to the axle, via a brake cable. It prevents
the brake from releasing again when the truck is Standard components for all trucks.
switched off. No unintentional, abrupt braking.
The brake can be released and applied by ac- More accurate detection of the brake condi-
tuating the push button. All of the necessary tion.
approvals, e.g. seat switch and switch lock, are Low energy consumption.
required for releasing the brake. The parking

-16 50638042201 EN - 10/2017

https://truckmanualshub.com/

The function of the electric parking brake is de-

pendent on the parameterised operating mode.
Parameterising takes place using the truck diag-
nostics. The function of the electric parking brake
cannot be derived from the operating mode des-
ignation.

The secure operating status of the electric parking

brake is dependent on the parameterised operating
mode and drive mode.
The electric parking brake must only be operated in
the "automatic applying/releasing" mode.
All drive programs must be set in the "speed-
controlled drive mode".
The StVZO option must not be adjusted.

Automatic applying/releasing
Only this mode is permitted for operation by
the customer!
Automatic applying/releasing with button
This mode is only permitted for test operation
by a service engineer.
Applying and releasing with button only
This mode is only permitted for test operation
by a service engineer.

If all the approvals required to drive the truck are present, the brake is
released when the accelerator is actuated.
Automatic releasing
: If it is absolutely necessary to release the brake via the button,
see below.
If the brake has been applied via the button, it must also be released on
this occasion via the button. Afterwards, automatic releasing is active
Releasing the brake via the again.
button Every time the electrical system is switched on via the switch lock or
emergency off, the brake must be released once via the button. After-
wards, automatic releasing is active again.
If the truck is at a standstill, the brake is applied after a set period of time,
Automatic applying
depending on the operating situation.
Pressing the button applies the brake if the truck is at a standstill.
Pressing the button has the same effect as releasing the accelerator.
This procedure can be parameterised.
Applying the brake via the : In speed-controlled handling performance mode, the drive
button brakes the truck with the dynamics of the set drive programme.
The request is saved while the truck is travelling unpowered. The brake
is applied as soon as the truck comes to a standstill.
: After the emergency off switch has been actuated
.

50638042201 EN - 10/2017 -17

https://truckmanualshub.com/

In emergency operation or during transport

without a battery, the electric parking brake can
be operated manually via the hand wheel.

Risk of injury from the moving parts in the electric

parking brake.
The electric parking brake must be operated via the
hand wheel only when in a voltage-free state.

Turn the key switch OFF. The display and

operating unit must be switched off.

Open cover (4), take hand wheel (3) and place

it upside-down on the tappet.
Press the hand wheel down against the spring
force and turn.
To apply the parking brake, turn the hand
wheel clockwise until the force is considerably
increased and the truck is held securely. The
required effort is not great.
To release the brake from the applied position,
turn a maximum of 5 revolutions in an anti-
clockwise direction, or until the limit position
switch is activated. The hand wheel can then
be turned smoothly. Do not release the hand
wheel to the stop, as this will trigger the central
lubrication device.

Order picking mode is always active as standard.

This mode reduces the mechanical stress on the
electric parking brake and therefore extends its
service life.
If the truck is left switched on or is at a standstill
for a prolonged period of time on level ground,
the electric parking brake is applied with reduced
power.
If the truck is on a slope or the enabling of the
switch lock or emergency off switch fails, please
apply the electric parking brake fully.

-18 50638042201 EN - 10/2017

https://truckmanualshub.com/

The behaviour of the LED indicates the current

operating status of the parking brake. The LED
illuminates with a steady light, ashes or does not
light up.

LED illuminates with a steady

Parking brake is applied correctly
light
Parking brake is released. The truck is ready for operation.
Unde ned parking brake status after being restarted
LED does not light up The controller cannot detect the parking brake status after the restart
Actuating the button causes the parking brake to release until the limit
position switch is activated reference position
Operating error caused by the driver
Error status with error code and message in the display
LED ashes
The electric parking brake has not registered correctly in the truck
parameters
.

ON OFF Unde ned After actuating the Reference drive:

(V engine accelerator: Release The parking brake
running, alternator the parking brake releases after the button is
engaged) pressed
ON Lights up Applied After actuating the Reference drive:
(V engine accelerator: Release The parking brake
running, alternator the parking brake releases after the button is
engaged) pressed
: Obsolete software
version 0.32

ON Flashing Released Apply the parking Parking brake was

(V engine brake released to the limit
running, alternator position switch
engaged) Truck is ready for
operation
LED goes out
immediately after start-up

50638042201 EN - 10/2017 -19

https://truckmanualshub.com/

ON after seat Flashing Released Apply the parking Start V engine

switch turned brake Parking brake was
actuated released to the limit
(V engine position switch
running, alternator Truck is ready for
engaged) operation
LED goes out
immediately after start-up
ON OFF Unde ned Short are-up: parking Parking brake was only
(V engine brake active released slightly
running, alternator Reference drive:
engaged) The parking brake
releases after the button is
pressed
.

The electric parking brake can only be automat-

ically released if it was previously automatically
applied.
If the electric parking brake was actuated via the
push button, it can also only be released via the
push button.

Truck is at a standstill The parking brake is applied after a parameterised time period
Key switch ON LED lights up with a steady light
Seat switch actuated
Accelerator not actuated
Truck is at a standstill The parking brake is applied after a parameterised time period
Key switch ON LED lights up with a steady light
Seat switch not actuated
Stopped on a slope The truck does not roll downhill and the setpoint value of 0 km/h
Seat switch actuated is maintained via the traction motor
Accelerator not actuated The parking brake is applied after a parameterised time period
LED lights up with a steady light
Key switch OFF The parking brake is applied immediately
LED is lit constantly until the electrical system switches off after
a time delay

Truck is at a standstill Parking brake releases audibly

Key switch ON LED goes out
Seat switch actuated
Single pedal: drive direction
selected, accelerator actuated
Dual pedal: accelerator actuated
.

-20 50638042201 EN - 10/2017

https://truckmanualshub.com/

Truck is driving Truck rolls to a stop

Emergency off switch actuated The parking brake is applied as soon as the setpoint value 0 km/h
is reached
Release emergency off switch Situation as if restarted
Release the parking brake via the push button
.

The electric parking brake consists of a drive unit

(3) that is integrated into the console (5) of the
operating unit (steering column, brake pedal).
The drive unit consists of an electric motor, a
spindle drive and an incremental transducer. The
spindle drive consists of a ball bearing-mounted
spindle nut and a trapezoidal spindle. The ten-
sion rod (6) is pin-jointed with the trapezoidal
spindle.
The electric motor turns the spindle drive, which
moves the tension rod in both directions. The
brake cable (9) is hooked onto the tension rod.
The incremental transducer sends pulses to the
controller once the electric motor is turning.
The electronic control (4) provides safety mon-
itoring and, depending on the parameterising, 1 Hand wheel
2 Tappet for hand wheel
automatic actuation of the parking brake.
3 Drive unit
The limit position switch (7) is used to reference 4 Controller
the zero position. 5 Console
6 Tension rod
The central lubrication device (8) lubricates the 7 Limit position switch
spindle drive with a small amount of grease after a 8 Central lubrication device
speci c number of cycles. The central lubrication 9 Brake cable
device is driven by the controller and is actuated
by the tension rod. During this process, the
tension rod moves a few millimetres beyond the
normal zero position and thus actuates the lever
for the central lubrication device.
The central lubrication device can also be actu-
ated manually via the hand wheel (1). This should
not take place unless necessary, as the grease
supply will otherwise be used up too quickly.

The described functions of the electric parking

brake are dependent on the software version.
Where possible, an up-to-date software ash
package must be loaded; see chapter entitled
"Software compatibility".

50638042201 EN - 10/2017 -21

https://truckmanualshub.com/

The StVZO (German Road Traf c Licensing

Regulations) and the torque-regulated handling
performance options are not supported in trucks
with an electric parking brake.

The controller consists of a control processor

SR and a monitoring processor UR. The con-
trol processor processes the incoming data and
activates the power module. The monitoring pro-
cessor tests the incoming data for plausibility and
monitors the motor movements. Both processors
can block the activation of power in the event of a
fatal error.
The controller ELF determines when the brake is
released or applied, and engages with the drive
unit via the CAN bus in order to brake the drive to a
standstill or to initialize the drive before releasing
the brake at the holding torque (smooth start-up).
The controller ELF also analyses CAN data from
the truck control unit and detects the respective
operating situation. The data analysed by the
controller includes the actual speed and the
actual torque of the drive unit.

-22 50638042201 EN - 10/2017

https://truckmanualshub.com/

The maintenance intervals relate to the

operating hours of the truck.
The operating hours of the electric parking
brake are counted separately and are the
speci cations used for the maintenance of the
central lubrication device.

If necessary, replace compo-

All movable components Visible wear
nents
If necessary, replace brake
Brake cable Visible wear
cable
Strong contamination that Clean the central lubrication
Central lubrication device
impairs function device; replace if necessary
Abnormalities such as large air
Lubrication hose and upper part Replace the central lubrication
bubbles or discolouration of the
of the grease cartridge device
grease
See the chapter entitled "Central
Rack rail position
lubrication device"

If necessary, perform the

Reading out the error memory For error codes, see error list measures according to the error
list
Carry out calibration
Check the repeatability of the Adjust brake cable if necessary
Read out the increments
values Adjust limit position switch if
necessary
Number of times the parking
100,000 actuations
brake is applied
Value can be read out via the If limit values are exceeded, the
Number of actuations of the diagnostics from mid-2013 components must be replaced.
actuation push button onwards.
5 years
Value can be read out via the
diagnostics from mid-2013
See the chapter entitled "Central
Number of relubrications onwards.
lubrication device"
20,000 operating
hours of parking brake
.

All maintenance steps for the 1000 and 2000 operating hour maintenance intervals must be carried out.

Actuation push button 5 years Replace actuation push button

.

50638042201 EN - 10/2017 -23

https://truckmanualshub.com/

Following maintenance work or during the course

of the regular security checks in accordance with
FEM 4.004, a brake test must be carried out on
the electric parking brake. This can be performed
in two different ways:
Check the holding power of the parking
brake at the maximum permissible gradient
for this truck. If there is not a slope with a
corresponding gradient on-site, tests must be
carried out on a gradient of at least 15%.
Brake the truck during travel using the parking
brake and measure the braking distance.
The two test methods are described below.

The permitted braking distances are summarised

in the FEM 4.004 test log book.

Pick up the maximum permissible load for the

truck.

If the maximum permissible load for the truck

cannot be picked up because such a load is not
available where you are, the greatest load usually
carried at the respective place of use should be
used. This must then be noted in the test report.
Drive up the gradient with the load facing
forwards.
Stop the truck on the gradient without using the
service brake.
Shut down the truck with the key switch.
Wait until the display has turned off. If the
parking brake was able to hold the truck during
this period and it did not roll back, the holding
power is suf cient.

The brake retardation attainable is the maximum

drivable gradient in %.

Carry out the brake test in both drive directions.

When testing in the opposite direction to the

-24 50638042201 EN - 10/2017

https://truckmanualshub.com/

load (drive direction backwards), pick up the

maximum permissible load, if possible.

Risk of the load slipping during the brake test.

Carry out the brake test in the opposite direction to
the load only.
Always carry out the brake test in the load-side
direction a load.

Risk of the load slipping during the brake test.

Before carrying out the brake test, secure the load with
suitable devices so that it cannot slip or fall down.

If the maximum permissible load for the truck

cannot be picked up because such a load is not
available where you are, the greatest load usually
carried at the respective place of use should be
used. This must then be noted in the test report.
To ensure that the electric parking brake is
applied whilst the truck is still moving and not
once it has already come to a halt, the truck rst
needs to be put in "service mode".
Switch to service mode via the display on the
operating unit. To do this, change the following
parameters:

Hydraulics block when no weight is detected on the seat

A 00 103 02
(standard value)
Hydraulics block when no weight is detected on the seat
00 cancelled (service mode)
A 00 1E8 01 Display error list (standard value)
00 Do not display error list (service mode)

Reset the truck.

Risk of injury! An intact electric parking brake brakes

the truck very hard.
During the brake test, fasten the seat belt
and hold on tightly.
Secure any loose objects in the driver's cab or
remove them completely.

Accelerate the truck.

While travelling, actuate the switch for the
electric parking brake. Depending on the
condition of the parking brake, the truck will
brake hard.

50638042201 EN - 10/2017 -25

https://truckmanualshub.com/

When applying the electric parking brake, the

accelerator must be pressed down and held.
Failure to do so would also cause the electric
service brake to be applied, which would falsify
the test result.

Due to the above-mentioned change made to the

parameters, the truck is safe for operation. The
truck may be given to the customer in this condition!
Once the brake test on the electric parking brake
has been completed, both parameters must be
changed back to their original status (standard
value). Failure to do so would cause the hydraulics
blocking function in accordance with ISO to be
cancelled.
Only after this has been done may the truck be given
back to the customer.

Maximum value:
780 Until the zero position is detected
after switching on
650 "Calibration error" error threshold
500 to 600 Standard range for calibration value
Zero position
0 Switching point of limit position
switch 1S3
Approx.
"Brake released" inactive position
-45
Central lubrication device provides
-90 to -130
a portion of grease
Minimum value:
-130
Lower stop

CAL + 130 "Cable break" error threshold

CAL + 110 "Cable break" warning threshold
+ 110 until "Brake fully actuated "tolerance
CAL range
"Brake fully actuated" calibration
CAL
value
CAL until "Brake fully actuated "tolerance
-35 range
CAL -35 "Brake not applied" error threshold
.

-26 50638042201 EN - 10/2017

https://truckmanualshub.com/

After work has been performed on the electric

parking brake (drive unit, central lubrication de-
vice, brake cable, limit position switch), calibra-
tion must always be carried out.

Risk of ngers being crushed upon actuation of the

electric parking brake!
Do not touch the brake cable during calibration.
Before carrying out adjustment work on the brake
cable, the battery male connector must always be
disconnected.

Connect the battery male connector.

Connect the notebook to the truck and start the
truck diagnostics:
Start calibration.

Actions

Calibration

9. Electric parking brake

Calibration is carried out automatically, during

which the electric parking brake is applied and
released several times.
Reset the truck after every calibration.
Read out increments.

F4: Monitor

Electric parking brake

Increments

Calibration value to be aimed for

550
(middle of the standard range)
>> 550 Shorten brake cable
<< 550 Extend brake cable
Corresponds to 2 revolutions of the
50 adjustment nut
(2 revolutions =ˆ 46.3 increments)

Function test
The calibration must be carried out anew after
each time the brake cable is adjusted.

50638042201 EN - 10/2017 -27

https://truckmanualshub.com/

The calibration may fail and abort with an error

message. This is commonly attributed to the
following two instances:
The increments are not within the valid range
for calibration values.
Standard range for calibration value
"Calibration error" error threshold
The repeatability of the travel is so different
that calibration is implausible:
Limit position switches are incorrectly adjusted
or faulty.
Too much play in the brake cable suspension
(screw, nut, wear strips)

At low temperatures, the calibration requires

several cycles until a static value is set.

Risk of ngers being crushed upon actuation of the

electric parking brake!
During the function check, the brake cable must not
be touched.
Before carrying out adjustment work on the brake
cable, the battery male connector must always be
disconnected.

Connect the battery male connector.

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

F4: Monitor

Electric parking brake

Increments
Apply and release the electric parking brake.
While doing so, read out the values in the
"applied" and "released" positions in the
"increments" eld.
Repeat this process 3 times.
If the values in the three processes deviate from
each other considerably, the limit position switch
has been incorrectly adjusted or is faulty; see the
chapter entitled "Limit position switch"
If the values are the same in each of the pro-
cesses, please check the following:

-28 50638042201 EN - 10/2017

https://truckmanualshub.com/

Disconnect the battery male connector.

Jack up the front of the truck.
Release the electric parking brake using the
hand wheel until the limit position switch is
securely actuated. (After the click, the switch
has a further 50% of remaining free travel); see
the chapter entitled "Limit position switch"
After releasing the electric parking brake, the
front wheels must be able to be easily turned
by hand. The brake lever on the axle must lie
against the stop screw; see the chapter entitled
"Changing the brake cable".

Risk of ngers being crushed by automatic actuation of

the electric parking brake!
It is essential that the electric parking brake power
supply is disconnected.

Park the truck safely and secure the truck

against rolling away.
Disconnect the battery male connector.
Release the parking brake fully using the hand
wheel.
Remove the panelling in the area of the electric
parking brake.
Loosen the brake cable mounting in the front
structure.

50638042201 EN - 10/2017 -29

https://truckmanualshub.com/

Remove the screw and the wear strips (1),

disconnect the brake cable from the tension
rod (2), loosen the nut or locking ring (3) and
unhook the brake cable.
Remove the bottom plate.
Release the brake cable from the brake lever
on the drive axle.
Detach the brake cable from the counter
bearing and pull it downwards and out.

Attach the brake cable to the counter bearing

on the drive axle.
Connect the brake cable to the brake lever and
guide upwards to the parking brake.
Connect the brake cable to the tension rod (2)
and install the screw with the wear strips (1).
Secure with a nut or locking ring (3).

Only brake cables with washers (X) may be used.

The console must not be deformed.

Tighten self-locking nuts to the extent that 0.1 0.5 mm
of play remains between the nut and the wear strip.

Fit the brake cable mounting to the front

structure.
Adjust the brake cable at the adjustment nut;
see the chapter entitled "Adjusting the brake
cable".
Insert the bottom plate.
Connect the battery male connector.
Carry out calibration and functional test; see
the chapter entitled "Calibration"
Attach the panelling in the area of the electric
parking brake.

Remove the panelling in the area of the electric

parking brake.
Remove the bottom plate.

-30 50638042201 EN - 10/2017

https://truckmanualshub.com/

Release the electric parking brake using the

hand wheel until the limit position switch is
securely actuated. (After the click, the switch
has a further 50% of remaining free travel); see
the chapter entitled "Limit position switch"
Adjust the brake cable using the adjustment
nut so that there is no slack in the brake cable.

The values indicated are binding. As necessary,

the rope must be adjusted so that it is not as tight.
Carry out calibration and functional test; see
the chapter entitled "Calibration"

If the service brake is not actuated, the brake

lever must rest on the adjustment screw. The
gap between the brake lever and the adjustment
screw is .
Carry out calibration and functional test; see
the chapter entitled "Calibration"

50638042201 EN - 10/2017 -31

https://truckmanualshub.com/

If the service brake is not actuated, the brake

lever must rest on the adjustment screw. The
gap between the brake lever and the adjustment
screw is .
Carry out calibration and functional test; see
the chapter entitled "Calibration"

Risk of ngers being crushed upon automatic actuation

of the electric parking brake!
It is essential that the electric parking brake power
supply is disconnected.

The limit position is activated by the wear strip.

In this position, the electric parking brake is
released.
The limit position switch has just activated. A click
is audible.
After the click, the wear strip continues to move
another 2 mm. A 2-mm movement corresponds
to one revolution of the hand wheel.

-32 50638042201 EN - 10/2017

https://truckmanualshub.com/

The limit position switch can only be activated

safely in this position. There must subsequently
be a distance of 1 1.5 mm between the switch
and the actuating lever.

Park the truck safely and secure the truck

against rolling away.
Disconnect the battery male connector.
The limit position switch is screwed to the
console with two M2 screws and nuts.

Defective or faulty limit position switches due to defor-

med housing!
When screwing in, please use a very low tightening
torque.

Move the limit position switch to the right within

the play and gently tighten the nuts.
0.13±0.02 Nm.
Secure nuts/thread with pourable plastics.

Since 12/2011, a threaded plate has replaced the

nuts.
Carry out calibration and functional test; see
the chapter entitled "Calibration"

50638042201 EN - 10/2017 -33

https://truckmanualshub.com/

In the event of an error, the drive unit must not

be repaired. In the event of an error, the drive
unit must be replaced together with the actuation
push button and the limit position switch.

Park the truck safely and secure the truck

against rolling away.
Disconnect the battery male connector.
Release the parking brake fully using the hand
wheel.
1 Hand wheel
Remove the panelling in the area of the electric 2 Tappet for hand wheel
parking brake. 3 Drive unit
4 Controller
Remove the steering column panelling and 5 Console
move the steering column to its forwardmost 6 Tension rod
position. 7 Limit position switch
8 Central lubrication device
Disconnect the SAAB plug X506 from the
9 Brake cable
control unit of the electric parking brake.
Remove the screw and the wear strips (1),
disconnect the brake cable from the tension
rod (2), loosen the nuts or locking ring (3) and
unhook the brake cable.

-34 50638042201 EN - 10/2017

https://truckmanualshub.com/

Loosen the mounting screws (4) on the central

lubrication device.
Remove the central lubrication device (5) from
the recess in the console.

Unscrew the mounting screw (6) from the drive

unit (M8 hexagon head screw).
Lift up the drive unit together with the central
lubrication device approx. 2.5 cm and then
remove towards the rear of the console.

The drive unit is installed in the console slot on

the right-hand side together with the central
lubrication device and is held in place by the
M8 screw with a conical spring washer.

It is important that the drive unit housing is tted

accurately because only in this way can the
power be transmitted.
The drive unit housing must rest securely on
the console crosspiece.

Screw in the drive unit mounting screw (6) (M8

hexagon head screw, 20 Nm).

50638042201 EN - 10/2017 -35

https://truckmanualshub.com/

Insert the central lubrication device (5) into the

recess in the console.
Screw the mounting screws (4) tightly into the
central lubrication device.

Observe the installation position of the tension rod in

order to ensure correct function.
The wider crosspiece of the tension rod must point
forwards (in the drive direction).

Connect the brake cable to the tension rod (2)

and install the screw with the wear strips (1).
Secure with a nut or locking ring (3).

Only brake cables with washers (X) may be used.

The console must not be deformed.

Tighten self-locking nuts to the extent that 0.1 0.5 mm
of play remains between the nut and the wear strip.

Connect the X506 SAAB plug to the control

unit for the electric parking brake.
Attach the steering column panelling.
Check the brake cable setting; see the chapter
entitled "Changing the brake cable".
Connect the battery male connector.
Carry out calibration and functional test; see
the chapter entitled "Calibration"
Attach the panelling in the area of the electric
parking brake.

The operating hours of the electric parking brake

are counted separately and are the speci cations
used for the maintenance of the central lubrica-
tion device.
After carrying out repairs, the operating hours
of the electric parking brake must be reset. If

-36 50638042201 EN - 10/2017

https://truckmanualshub.com/

this cannot be achieved via the diagnostics, the

operating hours must be recorded in such a way
that they cannot be lost.
The central lubrication device functions like
a simple grease gun that is triggered by the
drive unit mechanism. The position of the rack
rail indicates the current grease supply. The
grease supply is designed for approx. 20,000
parking brake operating hours and approx.
30 relubrications with normal use and correct
function. With each relubrication, the rack rail
retracts 1.2 mm.

Check position of the rack rail 100% Status when new

The distance from the "new
condition" to the 20% mark is
20% mark
approx. 32 mm, i.e. approx. 27
portions of grease.
Change the central lubrication
10% mark
device
Low parking brake operating
hours and it is clear that the
Change the central lubrication
rack rail has been retracted
device and reset the operating
Check the plausibility of the signi cantly.
hours; record the operating hours
position High parking brake operating
in such a way that they cannot be
hours and it is clear that the rack
lost
rail has not been retracted very
far.
.

The central lubrication system can be removed

only if the drive unit has been removed.
Park the truck safely and secure the truck
against rolling away.
Disconnect the battery male connector.
Remove the drive unit, see the chapter entitled
"Drive unit".
Disconnect the screw joint (2) between the
grease gun and the lubrication hose.

1 Central lubrication device

2 Grease gun screw joint lubrication hose
Screw the grease gun tightly into the lubrica- 3 Lubrication hose
tion hose.
Install the drive unit, see the chapter entitled
"Drive unit".

50638042201 EN - 10/2017 -37

https://truckmanualshub.com/

Check the brake cable setting; see the chapter

entitled "Changing the brake cable".
Attach the panelling in the area of the electric
parking brake.
Connect the battery male connector.
Reset the operating hours and record in such
a way that they cannot be lost.
Carry out calibration and functional test; see
the chapter entitled "Calibration"

-38 50638042201 EN - 10/2017

https://truckmanualshub.com/

1 Pedal, forwards 12 Compression spring

2 Pedal, backwards 13 Guide
3 Rod 14 Hexagon nut
4 Bush 15 Bracket, lower
5 Needle-roller bearing 16 Hexagon head screw, 10 Nm, Loctite
6 Bearing block 17 Protective cap
7 Plate 18 Pinion
8 Bearing block 19 Pinion gear
9 Socket head screw, 18.5 Nm 20 Potentiometer
10 Coach bolt 21 Pan head screw, 2.5 Nm
11 Bracket, upper 22 Wiring harness

The accelerator comprises two mechanically

connected accelerator pedals that move in
opposite directions. When the accelerator pedal
is pressed, the double-action potentiometer 1B1
regulates the driving speed.
Follow the instructions speci ed below when
assembling the complete unit:

50638042201 EN - 10/2017 -39

https://truckmanualshub.com/

Pre-assemble the pedals (1, 2) using bearing

needle rollers (5).
Apply lubricant evenly to all bearings of the
pedals (1, 2). See "Maintenance".
Feed the pedals through the bottom plate from
above
Fit all individual parts from below
Screw socket head screws (9) in tightly using
a
Screw on the pan head screws (21) and secure
with locking varnish using a

Tighten the compression spring (12) to a

pre-load measurement of 22 mm
Screw on the hexagon head screw (16) and
secure with Loctite using a

Lubricate the pedals evenly at the points

indicated.

The con guration must be parameterised again

for all retro tting and conversions related to the
accelerator and drive direction.

The following components are affected:

Single pedal
Double pedal
Joystick, tip switch, mini-lever
Hand lever
Direction indicator module
Parameterisation takes place using the truck
diagnostics in the notebook.

Calibration must always take place after the

accelerator has been changed.
Connect the notebook to the truck. Start the
truck diagnostics:

Job

Calibration

1. Accelerator

-40 50638042201 EN - 10/2017

https://truckmanualshub.com/

Once calibration is complete, error messages

may be displayed.

Operating error
Timeout during calibration
Value of accelerator's inactive position is
outside the valid range
Voltage increase does not lie within the valid
range
From software ash package V1.07 onwards, the
valid range for calibration can be increased by a
parameter change. Parameterising takes place
using the display operating unit.

Calibration 2 (from ash package V107 series,

26
A 00 050 06/2010)
25 Calibration 1 (until 06/2010)
.

X16/1 Free
X16/2 X16/2 1B1 - C1 Signal C1
X16/3 X16/3 1B1 - C2 Signal C2
X16/4 X16/4 1B1 - C1/C2 GND accelerator
X16/5 Free (Horn button)
X16/6 Free (Horn button)
X16/8 X16/1 1B1 - C1/C2 12 V accelerator
.

Supply voltage X16/4 - X16/8 11.05 - 12.05

Correction by turning the
C1 accelerator not actuated X16/4 - X16/3 5.5 - 6.5
potentiometer.

50638042201 EN - 10/2017 -41

https://truckmanualshub.com/

Correction by turning the

C2 accelerator not actuated X16/4 - X16/2 5.5 - 6.5
potentiometer.
C1 accelerator fully actuated,
X16/4 - X16/3 1.0 - 3.8 Correction by turning the support
forwards
C2 accelerator fully actuated,
X16/4 - X16/2 8.2 - 11.0 Correction by turning the support
forwards
C1 accelerator fully actuated,
X16/4 - X16/3 8.2 - 11.0 Correction by turning the support
reverse
C2 accelerator fully actuated,
X16/4 - X16/2 1.0 - 3.8 Correction by turning the support
reverse
GND breakdown detection 11.5
VCC breakdown detection 0.5

Supply voltage X16/4 - X16/8 11.05 - 12.05

Correction by turning the
C1 accelerator not actuated X16/4 - X16/3 4.45 - 7.0
potentiometer.
Correction by turning the
C2 accelerator not actuated X16/4 - X16/2 4.45 - 7.0
potentiometer.
C1 accelerator fully actuated,
X16/4 - X16/3 1.0 - 3.8 Correction by turning the support
forwards
C2 accelerator fully actuated,
X16/4 - X16/2 8.2 - 11.0 Correction by turning the support
forwards
C1 accelerator fully actuated,
X16/4 - X16/3 7.2 - 11.0 Correction by turning the support
reverse
C2 accelerator fully actuated,
X16/4 - X16/2 1.0 - 4.5 Correction by turning the support
reverse
GND breakdown detection 11.5
VCC breakdown detection 0.5
.

The difference in voltage between the transmit-

ter's inactive position (N) and maximum actuation
(max) is designated as the potentiometer voltage
increase.
At maximum actuation, the voltage must be at
least and up to a maximum of higher
than in the neutral position (N).

Voltage increase too small The maximum speed is not achieved

No problem for the evaluation
The maximum speed is reached but not exceeded.
Voltage increase too large
The controller ignores the end range of the voltage increase
(dead travel)
Voltage increase signi cantly too large Detection of breakdown with corresponding error message
.

-42 50638042201 EN - 10/2017

https://truckmanualshub.com/

The dual-pedal bottom plate is equipped with

the accelerator 1B1 and a dual-pedal unit for
forwards (2) and backwards (1). The horn button
4S1 is located in the lift lever in this variant.
The size of the bottom plate depends on the truck
equipment. For trucks equipped with a heating
system, the bottom plate is shortened on the
right-hand side in the area around the hydraulics.

1 Backward
2 Forward
1B1 Accelerator

The dual-pedal unit is screwed to the bottom plate

via four coach bolts (3). Only the accelerator
pedals are fed through the bottom plate.
Pedal travel is restricted by stop plates that are
screwed to the pedals.

50638042201 EN - 10/2017 -43

https://truckmanualshub.com/

1 Pedal, forwards 8 Covering

1a Step plate, forwards 9 Gear segment
2 Pedal, backwards 10 Pinion gear
2a Step plate, backwards 11 Leg spring
3 Cam, backwards 12 Spring holder
4 Cover plate 13 Hexagon head bolt
5 Cam, forwards 14 Coach bolt
6 Wiring harness 15 Bearing block
7 Potentiometer 16 Bearing block

The accelerator comprises two mechanically

connected accelerator pedals that move in
opposite directions. Actuating the accelerator
pedals regulates the driving speed via the double
action potentiometer 1B1.
The following instructions should be followed
when assembling the complete unit:
Pre-assemble all individual parts without the
step plates (1a, 2a)
Bolt the complete unit to the bottom plate from
below, guiding the pedals through the bottom
plate and tightly screwing on the bearing

-44 50638042201 EN - 10/2017

https://truckmanualshub.com/

blocks (15, 16) from above using coach bolts

(14)
Fit the step plates (1a, 2a)
Apply lubricant evenly to all bearings of the
pedals
Screw in the coach bolts (14) to 20 Nm
Screw the pan head screws to the potentiome-
ter to 2.5 Nm and secure with retaining com-
pound
Position the pedals in the zero position by
moving the spring holder (12)
Screw the hexagon head screws (13) to 8.3
Nm and secure with retaining compound

The con guration must be parameterised again

for all retro tting and conversions related to the
accelerator and drive direction.

This affects the following components:

Single pedal
Double pedal
Joystick, tip switch, mini-lever
Lift lever
Direction indicator module
Parameterisation takes place using the truck
diagnostics in the notebook.

Calibration must always take place after the

accelerator has been changed.
Connect the notebook to the truck and start the
truck diagnostics:

Job

Calibration

1. Accelerator
Once calibration is complete, error messages
may be displayed.

Operating error
Timeout during calibration
Value of accelerator's inactive position is
outside the valid range
Voltage increase does not lie within the valid
range

50638042201 EN - 10/2017 -45

https://truckmanualshub.com/

From software ash package V107 onwards, the

valid range for calibration can be increased by a
parameter change. Parameterising takes place
using the display operating unit.

Calibration 2 (from ash package V107 series,

26
A 00 050 06/2010)
25 Calibration 1 (until 06/2010)
.

X16/1 Free
X16/2 X16/3 1B1 - C2 Signal C2
X16/3 X16/2 1B1 - C1 Signal C1
X16/4 X16/4 1B1 - C1/C2 GND accelerator
X16/5 Free (Horn button)
X16/6 Free (Horn button)
X16/8 X16/1 1B1 - C1/C2 12 Volt accelerator
.

Supply voltage X16/4 - X16/8 11.05 - 12.05

Correction by turning the
C1 accelerator not actuated X16/4 - X16/3 5.5 - 6.5
potentiometer.
Correction by turning the
C2 accelerator not actuated X16/4 - X16/2 5.5 - 6.5
potentiometer.
C1 accelerator fully actuated,
X16/4 - X16/3 1.0 - 3.8 Correction by turning the support
forwards
C2 accelerator fully actuated,
X16/4 - X16/2 8.2 - 11.0 Correction by turning the support
forwards
C1 accelerator fully actuated,
X16/4 - X16/3 8.2 - 11.0 Correction by turning the support
reverse
C2 accelerator fully actuated,
X16/4 - X16/2 1.0 - 3.8 Correction by turning the support
reverse

-46 50638042201 EN - 10/2017

https://truckmanualshub.com/

GND breakdown detection 11.5

VCC breakdown detection 0.5

Supply voltage X16/4 - X16/8 11.05 - 12.05

Correction by turning the
C1 accelerator not actuated X16/4 - X16/3 4.45 - 7.0
potentiometer.
Correction by turning the
C2 accelerator not actuated X16/4 - X16/2 4.45 - 7.0
potentiometer.
C1 accelerator fully actuated,
X16/4 - X16/3 1.0 - 3.8 Correction by turning the support
forwards
C2 accelerator fully actuated,
X16/4 - X16/2 8.2 - 11.0 Correction by turning the support
forwards
C1 accelerator fully actuated,
X16/4 - X16/3 7.2 - 11.0 Correction by turning the support
reverse
C2 accelerator fully actuated, Correction by turning the support
X16/4 - X16/2 1.0 - 4.5
reverse
GND breakdown detection 11.5
VCC breakdown detection 0.5
.

The difference in voltage between the transmit-

ter's inactive position (N) and maximum actuation
(max) is designated as the potentiometer voltage
increase.
At maximum actuation, the voltage must be at
least (up to maximum ) higher than
in the neutral position (N).

Voltage increase too small The maximum speed is not achieved

No problem for the evaluation
The maximum speed is reached but not exceeded.
Voltage increase too large
The end range of the voltage increase is ignored by the
controller (dead travel)
Voltage increase signi cantly too large Detection of breakdown with corresponding error message
.

50638042201 EN - 10/2017 -47

https://truckmanualshub.com/

1 2 3 4

The individual hydraulic functions are operated

via the hand levers. Each hydraulic function has
a separate operating lever.
Like the directional control valve block, the truck
is provided with three or four operating levers
according to the hydraulic equipment of the truck.
"Lift/lower" operating lever (1)
"Tilt" operating lever(2) 5

"Auxiliary hydraulics 1" operating lever(3) 6

"Auxiliary hydraulics 2" operating lever(4)

5060_003-107

Depending on the truck equipment, the drive

direction switch (6) or horn button is integrated 1 "Lift/lower" operating lever
into the lift lever. 2 "Tilt" operating lever
3 "Auxiliary hydraulics 1" operating lever
4 "Auxiliary hydraulics 2" operating lever
5 "5th function" function switch
6 Drive direction switch or horn button
In the event of repairs, individual operating levers
can be changed. For spare parts see the truck
spare parts list.

The con guration must be parameterised again

for all retro tting and conversions related to the
accelerator and drive direction. Parameterising
takes place using the truck diagnostics in the
notebook.

This affects the following components:

Single pedal
Double pedal
Joystick, tip switch, mini-lever
Lift lever
Direction indicator module
A truck restart must always be carried out after
parameterising. Calibration can only be carried
out once these processes have been completed.

Calibration must always take place after the

hydraulic sensor has been changed.
Connect the notebook to the truck and start the
truck diagnostics:

Action

Calibration

-48 50638042201 EN - 10/2017

https://truckmanualshub.com/

0. Sensors
Once calibration is complete, error messages
may be displayed.

50638042201 EN - 10/2017 -49

https://truckmanualshub.com/

The Joystick 4Plus is an operating device that

is built into the armrest of the driver's seat. The
Joystick 4Plus controls various functions that the
driver can activate using his right hand.
As the Joystick 4Plus does not have a turn
indicator button, the turn indicator module for
the drive direction must always be installed in line
with the German road traf c licensing regulations
on lighting.
The Joystick 4Plus is available in two variants
with and without an emergency off switch.
1 Emergency off switch
2 Housing
3 Joystick
4 Turn indicator module for the drive direction

9
1

8
The shift key can be assigned different func-
tions during the parameterising process
7
For example: the 3rd auxiliary hydraulics or
5th hydraulic function 2
6

3
In the event of repairs, the entire Joystick 4Plus
must be replaced. For spare parts, refer to the 5
truck spare parts catalogue. 6210_003-087

1 Horizontal rocker button for the 3rd hydraulic

function
CAN open as standard; 2 Symbols for the basic hydraulic functions
CAN bus integrated into the red 3 Symbols for the 5th hydraulic function and the
CAN bus clamp locking mechanism
Sensors 1 Hall sensor per axle 4 Symbols for the 3rd and 4th hydraulic func-
Software Device detection "I" tions
5 LED for the clamp locking mechanism
Protection class IP 65 6 Slider for the 4th hydraulic function
Temperature range -30°C - +85°C 7 Drive direction
.
8 Shift key "F"
9 Signal horn button

X71/1 12 V or 24 V
X71/2 Truck GND
X71/3 CAN r H
X71/4 CAN r L
X71/5 Emergency off 7S2/1

-50 50638042201 EN - 10/2017

https://truckmanualshub.com/

X71/6 Emergency off 7S2/2

Earth wire at the seat or CPP seat
.

The con guration must be parameterised again

for all retro t and conversion work related to the
accelerator, drive direction lighting and lighting
in line with the German road traf c licensing
regulations. Parameterising is performed using
the truck diagnostics in the notebook.

This affects the following components:

Single pedal
Dual pedal
Joystick, ngertip switch and mini-lever
Lift lever
Turn indicator module for the drive direction
A truck restart must always be performed after
parameterising.

Calibration is not necessary.

The individual functions are assigned to the axles

and buttons at the factory. The allocation in each
case can be read from the "Decal information for
actuation".
Depending on the operating device, parameter-
ising allows for a number of different axle assign-
ments and variants.
As soon as the axle assignment and conse-
quently the operation have been changed, the
"Decal information for actuation" must be mod-
i ed. Current variants of the decal information
can be ordered as spare parts.

As soon as the operation has been changed,

the "Decal information for actuation" must be
modi ed.

50638042201 EN - 10/2017 -51

https://truckmanualshub.com/

Lower
Lift
Auxiliary hydraulics 1
Auxiliary hydraulics 1
Auxiliary hydraulics 2
Auxiliary hydraulics 2
Tilt backward
Tilt forward

Tilt forward
Tilt backward
Lift
Lower
Auxiliary hydraulics 1
Auxiliary hydraulics 1
Auxiliary hydraulics 2
Auxiliary hydraulics 2
.

-52 50638042201 EN - 10/2017

https://truckmanualshub.com/

3 4
2

1
5
The second-generation mini-lever replaces the
rst-generation mini-lever.
F1 F2
6

The generation 2 mini-lever is an operating

device built into the armrest of the driver's seat.
The generation 2 mini-lever controls various
operations that can be activated by the driver's
right hand. 8

Depending on the hydraulic equipment and 7

customer preference, there are different mini-
7312_003-002

lever variants that can be installed in the truck.

The customer can choose from three mini-lever 1 Central lever for lifting and tilting
variants: 2 F1 button
3 F2 button
Each variant is available both with and without 4 Drive direction preselection and turn indicator
an emergency off switch 5 Function key for 5th hydraulic function
Mini-lever, 2 lever 6 Cross lever, auxiliary hydraulics
7 Emergency off switch
Left: central lever for lifting, lowering, tilting 8 Horn button
Right: cross lever for the auxiliary hydraulic
functions
Mini-lever, 3 lever
Left: central lever for lifting, lowering, tilting
Right: two single levers for the auxiliary
hydraulic functions replace the cross lever
Mini-lever, 4 lever
Four single levers replace the central lever on
the left and the cross lever on the right.

The F keys can be assigned different functions

during parameterising
Example: additional electrical installation,
switching the spotlight
Ensure that the operation of additional electrical
installations is not activated twice. If the operation
of an additional electrical installation has been
parameterised to one of the function keys, it must
be deactivated in the display-operating unit.

The function key actuates the 5th hydraulic

function or the 3rd auxiliary hydraulics

Mini-levers can be repaired by replacing defec-

tive components. Only those components that

50638042201 EN - 10/2017 -53

https://truckmanualshub.com/

are available in the spare parts catalogue for the

truck may be replaced. For a detailed descrip-
tion, see Service Information 512015017.

CAN open as standard;

CAN bus integrated in the red CAN
bus
One dual potentiometer
Sensors
per axle
Software Device detection "I"
Protection class IP 65
Temperature range -30°C to +85°C
.

X71/1 12 V or 24 V
X71/2 GND
X71/3 CAN r H
X71/4 CAN r L
X71/5 Emergency off 7S2/1
X71/6 Emergency off 7S2/2
Earth wire on the driver's seat or CPP driver's
seat
.

The con guration must be parameterised again

for all retro t and conversion work related to the
accelerator, drive direction and lighting in line with
the German road traf c licensing regulations.
Parameterisation is performed using the truck
diagnostics in the notebook.

The following components are affected:

Single pedal
Dual pedal
Joystick, ngertip, mini-lever
Hand lever
Drive direction turn indicator module
A truck restart must always be carried out after
parameterising.

Calibration is not required after replacing a

complete component.
The mini-lever must be re-calibrated following
any repairs.

-54 50638042201 EN - 10/2017

https://truckmanualshub.com/

Connect the notebook to the truck. Start the

"servo hydraulics" diagnostics:

Action

B - mini-lever, gen. 2
calibration

Execute
.

The left joystick (1) is a 360° lever which can

C
be used for operating both axes at the same
time. The left joystick is used to operate the basic
functions of the lift mast.
A
F1
F2

To lift fork carriage:

B
Move the left joystick in the direction of the
arrow (B). 1
To lower fork carriage: D
Move the left joystick in the direction of the
arrow (A).
To tilt the lift mast forwards:
Move the left joystick in the direction of the
arrow (C). 7312_003-142

To tilt the lift mast backwards:

1 Left joystick
Move the left joystick in the direction of the A Lowering
arrow (D). B Lifting
C Tilt forwards
D Tilt backwards

50638042201 EN - 10/2017 -55

https://truckmanualshub.com/

1
In addition to the left joystick, a second joystick 2
is available on the right. The right joystick (2) is A
a cross lever which can be used for operating in D
two axes, one axis at a time. The right joystick
is used to operate attachments, depending on C
the equipment. The 5th hydraulic function can be
B
activated using function key (1).

7312_003-010

1 Right joystick

The pictograms show all functions that can be

operated with the right joystick and the function
key for the 5th hydraulic function.

(A): Move the right joystick in the direction of

arrow (A).
(B): Move the right joystick in the direction of
arrow (B).
(C): Move the right joystick in the direction of
arrow (C).
(D): Move the right joystick in the direction of
arrow (D).

(E): Actuate the function key and move the

right joystick in the direction of arrow (A).
(F): Actuate the function key and move the
right joystick in the direction of arrow (B).

-56 50638042201 EN - 10/2017

https://truckmanualshub.com/

The four levers (1-4) can only be moved forwards

and backwards in one axis.
The emergency stop switch is a variant

1 Lift - lower
2 Tilt
3 Auxiliary hydraulics 1
4 Auxiliary hydraulics 4
5 Emergency stop switch

The left joystick (1) is a 360° lever which can be

used for operating both axes at the same time. As
standard, the left joystick operates the lift mast.
The two right levers (2, 3) can only be moved
forwards and backwards in one axis.
The emergency stop switch is a variant

1 Left joystick
2 Auxiliary hydraulics 1
3 Auxiliary hydraulics 2
4 Emergency stop switch

The individual functions are assigned to the axles

and buttons at the factory. The allocation in each

50638042201 EN - 10/2017 -57

https://truckmanualshub.com/

case can be read from the "Decal information for

actuation".
Depending on the operating device, parameter-
ising allows for a number of different axle assign-
ments and variants.
As soon as the axle assignment and conse-
quently the operation have been changed, the
"Decal information for actuation" must be mod-
i ed. Current variants of the decal information
can be ordered as spare parts.

As soon as the operation has been changed,

the "Decal information for actuation" must be
modi ed.

Lift
Lower
Tilt backward
Tilt forward

Auxiliary hydraulics 1
Auxiliary hydraulics 1
Auxiliary hydraulics 2
Auxiliary hydraulics 2
.

Lift
Lower
Tilt backward
Tilt forward

Auxiliary hydraulics 1
Auxiliary hydraulics 1

Auxiliary hydraulics 2
Auxiliary hydraulics 2
.

-58 50638042201 EN - 10/2017

https://truckmanualshub.com/

Lift
Lower

Tilt backward
Tilt forward

Auxiliary hydraulics 1
Auxiliary hydraulics 1

Auxiliary hydraulics 2
Auxiliary hydraulics 2
.

50638042201 EN - 10/2017 -59

https://truckmanualshub.com/

1 2 3 4 5 6 7

The ngertip switch is an operating device built

into the armrest of the driver's seat. The ngertip F1 F2

switch controls various operations that the driver

can activate using his right hand.

The F keys can be assigned different functions

during parameterising
12 11 10 9 8
For example: additional electrical equipment,
spotlight on/off
Ensure that the operation of additional electrical
installations is not activated twice. If the operation 6321_003-004

of an additional electrical installation has been

1 F1 button
parameterised on one of the function keys,
2 F2 button
this key must be deactivated in the display and
3 Left turn indicator button
operating unit. 4 Signal horn button
5 Right turn indicator button
6 Function key for 5th hydraulic function
The function key operates the 5th hydraulic 7 Emergency off switch
function and the 3rd auxiliary hydraulics 8 Auxiliary hydraulics 1 operating lever
9 Auxiliary hydraulics 2 operating lever
10 Pull the tilt operating lever
12 Travel direction switch
In the event of repairs, the entire ngertip console 11 Lift-lower operating lever
must be changed. Individual parts are not avail-
able.

CAN open as standard;

CAN bus integrated in the red CAN
bus
Sensors
Software Device detection "I"
Protection class IP 55
Temperature range -30°C - +85°C
.

X71/1 24 V
X71/2 Truck GND
X71/3 CAN r H
X71/4 CAN r L
X71/5 Emergency stop 7S2/1
X71/6 Emergency stop 7S2/2
Earth wire at the seat
.

-60 50638042201 EN - 10/2017

https://truckmanualshub.com/

The con guration must be parameterised again

for all retro t and conversion work related to the
accelerator, drive direction lighting and lighting
in line with the German road traf c licensing
regulations. Parameterising is performed using
the truck diagnostics in the notebook.

This affects the following components:

Single pedal
Double pedal
Joystick, tip switch, mini-lever
Lift lever
Direction indicator module
A truck restart must always be carried out after
parameterising.

Calibration is not necessary.

The individual functions are assigned to the axles

and buttons at the factory. The allocation in each
case can be read from the "Decal information for
actuation".
Depending on the operating device, parameter-
ising allows for a number of different axle assign-
ments and variants.
As soon as the axle assignment and conse-
quently the operation have been changed, the
"Decal information for actuation" must be mod-
i ed. Current variants of the decal information
can be ordered as spare parts.

As soon as the operation has been changed,

the "Decal information for actuation" must be
modi ed.

50638042201 EN - 10/2017 -61

https://truckmanualshub.com/

Lift
Lower
Tilt backward
Tilt forward
Auxiliary hydraulics 1
Auxiliary hydraulics 1
Auxiliary hydraulics 2
Auxiliary hydraulics 2
.

1 2 3 4 5

The joystick is an operating device built into the

armrest of the driver's seat.
F 6
The joystick controls various operations that can
be activated by the driver's right hand.
Rocker (1) 7
Horn button (2)
Drive direction switch (3, 6)
Precision control (zoom) (4)
8
(5)Function button
Forwards/backwards (7, 8)
Left/right (9, 10) 7321_003-016_V2

The joystick also contains the following electrical

components: 1 Rocker
2 Horn button
Built-in evaluation electronics 3 Forwards travel direction switch
4 Precision control (zoom)
CAN bus controller
5 Function button
Emergency stop switch 7S2 6 Backwards travel direction switch
7 Lift: pull joystick back
8 Lower: push joystick forward
9 Auxiliary hydraulics: push joystick to the left
In the event of repairs, the entire joystick must be 10 Auxiliary hydraulics: push joystick to the right
changed. Individual parts are not available. 11 Emergency stop switch 7S2

CAN open as standard

Integrated into the red peripheral CAN bus
Software: truck recognition "I"
Protection class: IP 55
Temperature range: -30°C - +85°C

-62 50638042201 EN - 10/2017

https://truckmanualshub.com/

X71/1 24 Volt
X71/2 GND truck
X71/3 CAN r H
X71/4 CAN r L
X71/5 Emergency off 7S2/1
X71/6 Emergency off 7S2/2
Earth wire at the seat or CPP seat
.

The con guration must be parameterised again

for all retro tting and conversions related to the
accelerator and drive direction. Parameterising
takes place using the truck diagnostics in the
notebook.

This affects the following components:

Single pedal
Double pedal
Joystick, tip switch, mini-lever
Lift lever
Direction indicator module
A truck restart must always be carried out after
parameterising. Calibration can only be carried
out once these processes have been completed.

The joystick can be calibrated if necessary.

Connect the notebook to the truck and start the
servo hydraulics diagnostics:

Action

Joystick calibration

Execute
.

50638042201 EN - 10/2017 -63

https://truckmanualshub.com/

The joystick is used to operate all hydraulic func-

tions and the auxiliary hydraulics for attachments.

The joystick operating functions are only active

when the driver is seated, i.e. when the seat
contact switch is activated.
Various hydraulic functions can be freely as-
signed to the individual operating functions of the
joystick using parameters.
1 Rocker
2 Horn button
3 Forwards travel direction switch
4 Precision control (zoom)
5 Function button
6 Backwards travel direction switch
7 Joystick directions of movement
8 Emergency stop switch 7S2

The allocation in each case can be read from the

"Decal information for operation" on the valve
cover.

If changes are made to the assignment of the

hydraulic functions, the "Decal information for
operation" must be modi ed. The decal informa-
tion labels can be ordered as spare parts.
Activating the precision control button (zoom) at
the same time reduces the working speed of all
consumers by half.

"Forwards/backwards" standard functions: Lo-

wer/lift lift mast.

"Rocker" standard functions: Tilt lift mast for-

wards/backwards

-64 50638042201 EN - 10/2017

https://truckmanualshub.com/

"Left/right" default setting: Operation of swivel

device, roller clamp or sideshift, according to
choice.

"Simultaneously function key F and left/right"

default setting: Operation of fork positioner or
bale clamp, according to choice.

"Simultaneously function key F and for-

wards/backwards" default setting: Operation of
fork extension or shovel.

Other settings can be con gured using the

diagnostics in the notebook.

The mini-lever is an operating device built into the

armrest of the driver's seat.
The mini-lever controls various operations that
can be activated by the driver's right hand.
Lift-lower operating lever (1)
Tilt operating lever (2)
Operating lever for auxiliary hydraulics 1 or 3rd
hydraulic function (3)
Operating lever for auxiliary hydraulics 2 or 4th
hydraulic function (4)
Button for auxiliary hydraulics 3 or 5th hy-
draulic function (5) 1 Lift-lower operating lever
2 Pull the tilt operating lever
Signal horn button (7) 3 Auxiliary hydraulics 1 operating lever
Travel direction switch (8, 9) 4 Auxiliary hydraulics 2 operating lever
5 Auxiliary hydraulics 3 button
Emergency stop switch (6)
6 Emergency stop switch
The mini-lever is always provided with four 7 Signal horn button
operating levers, regardless of the hydraulic 8 Direction switch, forwards
equipment of the truck. 9 Direction switch, backwards

50638042201 EN - 10/2017 -65

https://truckmanualshub.com/

The assignment of the input channels and axles

for hydraulic operation is con gured using the
truck diagnostics in the notebook.

In the event of repairs, all the switches and push

buttons can be changed separately. Individual
spare parts are available for the mini-lever; see
the truck spare parts list.

CAN open as standard

Integrated into the red peripheral CAN bus
Software: truck recognition "I"
Protection class: IP 55
Temperature range: -30°C - +85°C

X71/1 24 Volt X70/3

X71/2 Truck GND X70/4
X71/3 CAN r H X70/1
X71/4 CAN r L X70/2
Emergency
X71/5 X71/3
stop 7S2/1
Emergency
X71/6 X71/4
stop 7S2/2 X18 Driver's seat connection
Earth wire to seat CPP mounting X71 Joystick
.

The con guration must be parameterised again

for all retro tting and conversions related to
the accelerator, drive direction and hydraulic
controls.

This affects the following components:

Single pedal
Double pedal
Joystick, tip switch, mini-lever
Lift lever
Direction indicator module
Parameterisation takes place using the truck
diagnostics in the notebook.

Calibration is not necessary.

-66 50638042201 EN - 10/2017

https://truckmanualshub.com/

The individual functions are assigned to the axles

and buttons at the factory. The allocation in each
case can be read from the "Decal information for
actuation".
Parameterising allows for a number of different
axle assignments and variants. When performing
parameterisation, it is important to note that the
variants depend on whether the "joystick" or
"mini-lever" operating devices are tted.
As soon as the axle assignment and conse-
quently the means of operation have been
changed, the "Decal information for actuation"
must be modi ed. Current variants of the decal
information can be ordered as spare parts.

As soon as the means of operation has been

changed, the "Decal information for actuation"
must be modi ed.

Auxiliary 1 Lift
Auxiliary 1 Lower
Lower Tilt forward
Lift Tilt backward
Tilt backward Auxiliary 1
Tilt forward Auxiliary 1
.

50638042201 EN - 10/2017 -67

https://truckmanualshub.com/

Lift
Lower
Tilt backward
Tilt forward
Auxiliary hydraulics 1
Auxiliary hydraulics 1
Auxiliary hydraulics 2
Auxiliary hydraulics 2
.

-68 50638042201 EN - 10/2017

https://truckmanualshub.com/

As a variation, the single-pedal oorplate can be

equipped with a dead man switch. The dead man
switch is secured to the oorplate from below by
four screws.
If the dead man switch is not actuated, the traction
drive is turned off.

The dead man switch is connected to the truck

central control (MCU) via the Option Board A22.
X318 - X31/2 - X47/35 (7S13)
X318 - X31/3 - X47/1 (GND)
X318 - X31/1 - X47/15 (12V-S)

The dead man function must be activated through

parameterisation.
Parameterisation takes place using the truck
diagnostics in the notebook, category "Traction
program".

50638042201 EN - 10/2017 -69

https://truckmanualshub.com/

-70 50638042201 EN - 10/2017

https://truckmanualshub.com/

The direction of travel asher module (1) com-

prises housing and a console. The housing is
located below the steering wheel, screwed to the
steering column.
The console integrates the direction switch (2)
and asher lever (3) controls and is screwed to
the housing.

The switches three functions; the

direction of actuation is indicated by the adjacent
symbol:
forwards 1 Direction indicator module
Neutral 2 Travel direction switch
3 Direction indicator switch
Backwards

The switches two

functions; the direction of actuation is indicated
by the adjacent symbol:
right
anticlockwise

For retro tting, it may be necessary to change

the truck central control MCU/TCU; see Electrical
Connections

The direction of travel asher module is con-

nected to the truck central control MCU/TCU via
the 4-pin CAN bus plug X45.
Since June 2007, the plug X45 has no longer
formed part of standard equipment for the truck
central control MCU/TCU.
X45/1 CAN r H
X45/2 CAN r L
X45/3 - CAN supply
X45/4 GND F

Park the vehicle safely.

Disconnect the battery plug with electric forklift
trucks
Remove the steering wheel

50638042201 EN - 10/2017 -1
https://truckmanualshub.com/

Remove the console from the housing

Unscrew the size 8 TORQUE screw (3)
Unscrew the two cross-recessed screws (1)
and (2)

Disconnect plug X45

Remove the console from the steering column

Connect plug X45

Connect the console to the housing
Tightly screw in the two cross-recessed
screws (1) and (2)
Tightly screw in the size 8 TORQUE screw (3)
Attach the steering wheel
Connect the battery plug in electric fork lift
trucks.
Perform an operational test.

The con guration must be parameterised again

for all retro tting and conversions related to the
accelerator, direction of travel and hydraulic
controls.

This affects the following components:

Single pedal
Double pedal
Joystick, tip switch, mini-lever
Lift lever
Direction indicator module
Parameterisation takes place using the truck
diagnostics in the notebook.

-2 50638042201 EN - 10/2017
https://truckmanualshub.com/

The turn indicator module for the drive direction

(FABLI) is installed on all trucks with the "lighting
and hand lever" equipment variant and on cus-
tomer request. The turn indicators are activated
and the drive direction is changed via the turn
indicator module.
The FABLI consists of two parts. On the left is the
operating unit (1) with the turn indicator switch (2)
and drive direction switch (3), on the right is the
ange housing (4).
The FABLI is screwed onto the steering column
below the steering wheel.

CAN open as standard;

CAN bus integrated into the red
CAN bus
Software Device ID "K"
Protection class 1 Operating unit
Temperature range 2 Turn indicator switch
3 Drive direction switch
4 Flange housing
.

5 Openings to unlock the upper shell

X45/1 CAN r H
X45/2 CAN r L
X45/3 12 V or 24 V
X45/4 Truck GND
.

Remove the upper shell from the ange

housing. To do this, unlock the three latches
(5) from below using a screwdriver.
Screw the operating element and ange
housing onto the steering column below the
steering wheel using four socket head screws.
Place the upper shell on the ange housing
and snap it into place.
Connect plug X45.

The con guration must be re-parameterised

for all retro tting and conversions related to the

50638042201 EN - 10/2017 -3
https://truckmanualshub.com/

FABLI. Parameterisation is performed using the

truck diagnostics in the notebook.
Where necessary, load the current software ash
package and start the calibration process; refer
to the chapter entitled "Software compatibility".
A truck restart must always be performed after
parameterising.

The drive direction turn indicator display is posi-

tioned to the right-hand side of the driver's eld of
vision in the front structure.
The ve lights of the drive direction turn indicator
display represent the drive direction, the turn
indicators and malfunctions.

Since October 2009, the drive direction turn

indicator display is no longer being tted to the
trucks as a separate component. The drive
direction turn indicator display is integrated in
the generation 2 display operating unit.

Direction of travel forwards (1)

Direction of travel backwards (2)

Left asher (1)

Right asher (2)
Hazard warning lights (3)

-4 50638042201 EN - 10/2017
https://truckmanualshub.com/

Information, malfunction
If the fault display lights up, information is dis-
played at the same time in the display operating
unit.

X17 - A1 to all lights 31 (GND)

X17 - A2 Forwards 1
X17 - A3 Backwards 1
X17 - B1 Right 1
X17 - B2 Left 1
X17 - B3 Message 1
.

The direction of travel asher display is destroyed

during removal.
Only remove the direction of travel asher display if
damaged.

The instrument is provided with spread clamps

that clip under the edge when installed.
Press out the drive direction turn indicator
display; the spread clamps break off
Disconnect plug X17 and remove the direction
of travel asher display

Connect plug X17

Check the direction of travel asher display for
correct operation
This function inevitably determines the instal-
lation position
Press the drive direction turn indicator display
onto the holding xture by lightly pressing on
the edge

50638042201 EN - 10/2017 -5
https://truckmanualshub.com/

The display operating unit (ABE) is used to switch

electrical accessories on and off via buttons.
The integrated display shows information about
driving.
The display operating unit is held in place inside
the panelling by spring pressure to the right of the
driver's seat.

The display operating unit was installed in various

different trucks until October 2009. For this
reason, the detailed description is contained
in a separate workshop manual. See also the
workshop manual "Display elements - display".

X49/1 12 V
X49/2 Truck GND
X49/3 CAN r H
X49/4 CAN r L
X49/5 12 V
X49/6 Hazard warning system
.

-6 50638042201 EN - 10/2017
https://truckmanualshub.com/

1 "Windscreen wiper/washer" button

2 "Front searchlight" button
3 "Rear window wiper/washer" button
4 "Rotating beacon" button
5 "Lighting" button
6 "Hazard warning system" button
7 "Drive program change from 1-5" button
8 Button for "menu change" and changing the soft key columns
9 Card reader for FleetManager data card (variant)
10 Pictogram for soft key (11)
11 Soft key, here with "interior light" variant
12 Pictogram for soft key (13)
13 Soft key, here with "rear window heating" variant
14 Pictogram for soft key (15)
15 Soft key, here with "rear searchlight" variant
16 "Time" pictogram
17 Time display
18 "Operating hours" pictogram
19 Operating hours display
20 "Drive program" pictogram
21 Drive program display
22 "Battery indicator / tank display" pictogram
23 Battery charge or fuel level display
.

50638042201 EN - 10/2017 -7
https://truckmanualshub.com/

Park the truck safely.

Disconnect the
battery male connector.

The plastic surface is fragile!

The ABE must not be levered out of the assembly
opening with tools.

Remove the plastic plugs from the two assem-

bly openings at the top edge of the panelling.
Insert a screwdriver through the assembly
openings and push down the retaining springs.
This pushes the ABE forward out of the
panelling.
Disconnect plug X49 and remove the ABE.

Connect the plug X49.

Attach the guide plates of the ABE to the lower
edge of the assembly opening.
Insert the ABE at the lower edge into the
assembly opening until the springs engage.

In order to prevent a parameter loss, this param-

eter set is available as a copy in the ABE. When
the ABE is changed, the parameter set must be
copied from the remaining component.

There are two ways of copying:

Automatic transfer
Manual transfer
Also see the chapter entitled "Parameter man-
agement".
The automatic transfer is indicated in the display
by the PLEASE WAIT message with progress
bar. This process can take several minutes and
ends with a reset.

-8 50638042201 EN - 10/2017
https://truckmanualshub.com/

The manual transfer begins with the question in

the display A–EEPROM VALID?. This means:
"Are the parameters of the TCU (device A)
supposed to be used?"
Load software ash package; see chapter
entitled "Software compatibility"
Start calibration.
Delete the error memory.
Function check.

1 "Windscreen wiper/washer" button Number 1 in programming mode

2 "Rear window wiper/washer" button Number 2 in programming mode
3 "Searchlight" button Number 3 in programming mode
4 "Blue-Q ef ciency mode" button Number 4 in programming mode
5 "Dipped beam / high beam" button Number 5 in programming mode
6 "Drive program change from 1-5" button Number 6 in programming mode
Button for "menu change" and changing the
7 Number 7 in programming mode
soft key columns
8 Soft key, here with "searchlight / rear" variant Number 8 in programming mode
Soft key, here with "heating system / rear
9 Number 9 in programming mode
window" variant
Soft key, here with "mast vertical position" Number 0 in programming mode
0
variant
11 "Hazard warning system" button
12 LED display for button active/inactive
13 Pictogram for soft key (8), soft key column 1
14 Pictogram for soft key (9), soft key column 1
15 Pictogram status "Blue-Q active"

50638042201 EN - 10/2017 -9
https://truckmanualshub.com/

16 "Battery indicator / tank display" pictogram

17 "Drive program" pictogram
18 Left turn indicator display
19 Drive direction forwards display
20 Right turn indicator display
21 Drive direction backwards display
22 "Time" pictogram
23 "Operating hours" pictogram
24 Display for active soft key column; in this case, column 2 is active
25 Pictogram for soft key (0), soft key column 2; in this case, for the "rotating beacon" variant
Pictogram for soft key (0), soft key column 1; in this case, for the "vertical mast position"
26
variant
.

The display operating unit (ABE) is used to switch

electrical accessories on and off via buttons.
The integrated display shows information about
driving.
The display operating unit is located in the front
structure, to the right of the steering wheel.

The display operating unit is installed in a number

of trucks. For this reason, the detailed description
is contained in a separate workshop manual. See
also the workshop manual "Display elements -
display".

X49/1 12 V
X49/2 Truck GND
X49/3 CAN r H
X49/4 CAN r L
X49/5 12 V
X49/6 Hazard warning system
.

Park the truck safely.

Disconnect the
battery male connector.

-10 50638042201 EN - 10/2017

https://truckmanualshub.com/

Undo the ABE at the lower edge and take it out

of the assembly opening on the panelling.

Risk of injury!
Gloves must be worn to protect hands.

The plastic surface is fragile!

The ABE must not be levered out of the assembly
opening with tools.

Disconnect plug X49 and remove the ABE.

Connect the plug X49.

Attach the guide plates (1) of the ABE to the
lower edge of the assembly opening.
Insert the ABE at the lower edge into the
assembly opening until the springs (2) engage.

In order to prevent a parameter loss, this param-

eter set is available as a copy in the ABE. When
the ABE is changed, the parameter set must be
copied from the remaining component.

There are two ways of copying:

Automatic transfer
Manual transfer
Also see the chapter entitled "Parameter man-
agement".
The automatic transfer is indicated in the display
by the PLEASE WAIT message with progress
bar. This process can take several minutes and
ends with a reset.

The manual transfer begins with the question in

the display A–EEPROM VALID?. This means:
"Are the parameters of the TCU (device A)
supposed to be used?"
Load software ash package; see chapter
entitled "Software compatibility"
Start calibration.
Delete the error memory.
Function check.

50638042201 EN - 10/2017 -11

https://truckmanualshub.com/

-12 50638042201 EN - 10/2017

https://truckmanualshub.com/

Control electronics Digital controller

Traction controller Speed-regulated 4-quadrant three-phase AC converter
Pump controller Speed-regulated 1-quadrant three-phase AC converter
Accelerator Dual-action potentiometer, 4 k each
Brake sensor for electric 4 k potentiometer
braking
Hydraulic transmitter Electric displacement transducer
Speed Max. 16 km/h
Adjustable via 5 drive programs
Nominal voltage 48 Volt
Traction motor revolution Truck control unit (MCU)
control

Traction motors FM1 and Traction against block 231 A effective phase current (50 Nm)
FM2 Traction against block with 335 A effective phase current (75 Nm)
starting current boost
only with SAC converter

Pump motor HM Tilt against over pressure 360 A effective phase current (52 Nm)

LAC 1 Regulation in the event of from 540 A effective to 0 A

overtemperature
LAC 1A Regulation in the event of from 404 A effective to 0 A
overtemperature
SAC - 400 Regulation in the event of from 404 A effective to 0 A
overtemperature

LAC 1 Regulation in the event of from 540 A effective to 0 A

overtemperature
SAC - 600 Regulation in the event of
overtemperature

24 V (switched) 2-pin coil

Contacts: changeable
Contact material: silver alloy

24 V (coil 255 ) K1, K2

see chapter "Fuses"

48 V / 550 Ah 6211, 6212, 6213, 6215, 6216

48 V / 700 Ah 6214, 6217

50638042201 EN - 10/2017 -1
https://truckmanualshub.com/

Electrical system Min. 1000 /volt ≈ > 48 k

Electrical equipment Min. 1000 /volt ≈ > 48 k
Traction battery Min. 1000

Electrical system IP 23, incl. cover IP 54

Electrical equipment IP 54
.

-2 50638042201 EN - 10/2017
https://truckmanualshub.com/

Control electronics Digital controller

Traction controller Speed-regulated 4-quadrant three-phase AC converter
Pump controller Speed-regulated 1-quadrant three-phase AC converter
Accelerator Dual-action potentiometer, 4 k each
Brake sensor for electric 4 k potentiometer
braking
Hydraulic transmitter Electric displacement transducer
Speed Forwards 19.9 km/h, backwards 18 km/h
Adjustable via 5 drive programs
Nominal voltage 80 Volt
Traction motor revolution Truck control unit (MCU)
control

Traction motors FM1 and Traction against block 150 A effective phase current (55 Nm)
FM2 Traction against block with 193 A effective phase current (75 Nm)
starting current boost

Pump motor HM Tilt against over pressure 237 A effective phase current (65 Nm)

Regulation in the event of from 316 A effective to 0 A

LAC 1
overtemperature

LAC 2 Regulation in the event of from 612 A effective to 0 A

overtemperature

24 V (switched) 2-pin coil

Contacts: changeable
Contact material: silver alloy

24 V (coil 255 ) K1, K2

see chapter "Fuses"

80 V / 420 Ah 6311, 6313, 6315

Electrical system Min. 1000 /volt ≈ > 80 k

Electrical equipment Min. 1000 /volt ≈ > 80 k
Traction battery Min. 1000

Electrical system IP 23, incl. cover IP 54

Electrical equipment IP 54
.

50638042201 EN - 10/2017 -3
https://truckmanualshub.com/

MCU Truck control unit A44 Electric forklift trucks

A
TCU Truck control unit A44 IC truck
Electric truck: second left-hand pump
B PU2 Pump converter 2U04
motor (HM2, PM2)
Electric truck: right-hand traction motor
D FU1 Traction inverter 1U06 (FM1)
IC truck: traction motor (1M1, 1M01)
Electric truck: second left-hand traction
motor (FM2)
E FU2 Traction inverter 1U07
IC truck: second left-hand traction motor
(1M1, 1M02)
Electric truck: right-hand pump motor
PU1 Pump converter 2U03
(HM1, PM1)
F
Generator processor integrated in the
PU1-GR IC truck: equipment variant hybrid II
converter to support the hydraulic pump
G FMID Card reader FleetManager special equipment
H VR Valve processor integrated in TCU/MCU Equipment variant for servo hydraulics
I FIT Joystick, ngertip and mini-lever Equipment variant for servo hydraulics
J ABE Display operating unit E truck and IC truck
K FABLI Travel direction indicator module Equipment variant
L CPP1 Roof CAN-Power-Port Equipment variant
CPP2 Front CAN-Power-Port
M Equipment variant
CPP2B Lighting CAN-Power-Port
N CPP3 Seat CAN-Power-Port Equipment variant
O CPP4 Rear CAN-Power-Port Equipment variant
Equipment variant for electric forklift
P CIO Battery carrier
trucks up to 3.5 t
R CS Acceleration sensor Equipment variant for FleetManager
Battery controller Equipment variant for electric forklift
S
LIB Lithium-ion battery trucks
SU Control unit A43 (Supply Unit) E truck (48 V/80 V)
T
SDC1 DC/DC converter Equipment variant for hybrid trucks
U DFÜ Remote data transfer Equipment variant for FleetManager
V CPP5 Soot CAN-Power-Port Equipment variant for particle lter
X ELF Control unit for the electric parking brake Equipment variant
Y RFID RFID control unit Equipment variant for RFID equipment

c SHS1 Energy accumulator 1 Equipment variant for Hybrid trucks

d SHS2 Energy accumulator 2 Equipment variant for Hybrid trucks
.

-4 50638042201 EN - 10/2017
https://truckmanualshub.com/

The truck is equipped with a front wheel drive

and is powered by two speed-controlled asyn-
chronous motors.
The hydraulic pump is also operated by a speed-
controlled asynchronous motor.
Each of the three asynchronous motors is pow-
ered by an inverter. The inverters are controlled
by the CAN bus (CANopen) via the Supply Unit
and Main Control Unit.
The control electronics are powered by an inter-
nal 12-Volt voltage supply from the Main Control
Unit.
The additional electrical consumers have a
24-Volt supply from external voltage transform-
ers. The number and power rating of the voltage
transformers must be selected according to the
overall rating of all of the equipment.

1 Traction inverter 1U06 6 Fuse box A21

2 Traction inverter 1U07 7 U1 voltage transformer
3 Pump inverter 2U03 8 U2 voltage transformer
4 Supply unit A43 9 Signal transmitter 4H2
5 Distributor card 7A21 10 Acceleration sensor

The number of electrical components in the

counterweight depends on the equipment.

50638042201 EN - 10/2017 -5
https://truckmanualshub.com/

In the truck as standard:

Traction inverters (1, 2)
Pump inverter (3)
Supply unit (4)
Fuse box (6)

Variants of the additional electrical equipment:

Signal transmitter (9)
Distributor card (5)
Voltage transformers (7-9)
Version with one or two voltage transformers
Acceleration sensor (10)

-6 50638042201 EN - 10/2017
https://truckmanualshub.com/

50638042201 EN - 10/2017 -7
https://truckmanualshub.com/

ABE Display operating unit 1 U-Batt

A43 Supply Unit 2 U-Batt
A44 Main Control Unit 3 24V CAN bus
FABLI Drive direction turn indicator module 4 24V CAN bus
F01 Main fuse 5 12V sensor voltage
F11 Fuse for SU / MCU 6 U-Batt, intermediate circuit
G1 Battery 7 Release 2U03
S1 Key switch 8 Release 1U06
7S2 Emergency off switch 9 Release 1U07
1K1 Main contactor 10 Main contactor release
1M2 Left traction motor 11 Main contactor release
1M1 Right traction motor
2M1 Pump motor
1U06 Right traction motor converter
3a U-Batt
1U07 Left traction motor converter
3b 24V from MTM
2U03 Pump motor converter
3c 24V CAN bus
4a 12V sensor voltage

Emergency off switch unlocked.

Handbrake applied.
Key switch at ON.

From batt.+ to fuse F11 in the fuse box

From fuse F11 via plug X20/4B to the SU
X42/2.

U-Batt GND-L
X42/2 X42/12

U-Batt from the SU X41/10 to switch lock S1/1

and warning light X49/5 in the ABE
From switch lock S1/2 back to the SU X41/6.
From switch lock S1/2 to emergency off switch
7S2.

U-Batt GND-L
X41/6 X42/12
.

The battery male connector is connected and the

key switch is in the ON position. Measurements
(1) and (2) have given correct values. Regardless
of the status of the emergency off switch, the 5-V
processor supply and the internal 24-V supply
are active.

-8 50638042201 EN - 10/2017
https://truckmanualshub.com/

Since August 2006, the SU has an internal vol-

tage transformer as standard. Until August 2006,
the external voltage transformer MTM was requi-
red for the 24V supply. For the measurement (3),
or (3a, 3b, 3c), these variants are to be conside-
red (see below).
The SU starts up and carries out a self-check.
A safety relay in the SU issues the enable for
U-Batt.
The internal voltage transformer of the SU
generates the 24V supply voltage from U-Batt
for the MCU. All converters and the CAN bus
participants, example: FABLI.

24 V CAN bus GND-F

X41/2 X41/1

The supply voltage of the MCU is wired directly

to the supply voltage of the converter. If the
measurement (3) gives correct values, 24 Volt
is also present at the converters (X44/2-1U07,
X44/16-1U03, X44/30-1U06).

24 V CAN bus GND-F

X47/14 X47/1

A short circuit in one of the CAN bus participants,

example FABLI leads to the failure of the 24V
supply.
The MCU carries out a self-check. At the same
time, the 5V processor supply and the 12V
transmitter supply are switched on in the MCU.

12 V GND-S
X46/28
X46/38
X46/39
X46/15 to X46/27
X46/40
X46/41
X47/15

The MCU starts up the networks of the indi-

vidual CAN bus participants in a de ned se-
quence.

50638042201 EN - 10/2017 -9
https://truckmanualshub.com/

1. Supply Unit
2. Converter
2.1 Pump converter 2U03
2.1 Traction inverter 1U06 (FM1)
2.3 Traction inverter 1U07 (FM2)
3. Display and operating unit (ABE)
Additional electrical installation (FABLI,
4.
CPP)

Once the SU is integrated into the network, it

communicates with the MCU.
The SU charges the converter intermediate
circuit to at least 40V in 1.4 seconds.

The intermediate circuit is charged for all conver-

ters at the same time. A defective converter will
result in charging faults for all converters.
To nd the defective converter, disconnect
the converters individually and repeat the
switching on process.

U-Batt Batt
XS4 XS5

The converter node allocation takes place

whilst the intermediate circuit is being charged.
During the node allocation, the enable is set
for a short time via the enable line. After this,
the individual converters are allocated to the
electric motors. The node allocation takes
place in a de ned sequence:

1. Pump converter 2U03

2. Traction inverter 1U06 (FM1)
3 Traction inverter 1U07 (FM2)

Together with the MCU for node allocation, the

SU enables the converters. The converters
are enabled via the enable line X150/11-2U03,
X151/11-1U06, X152/11-1U07. The enable
signals can be measured via a level change.

Level change
(9a,b) X41/14 X47/25
to approx. 1.68 V

If the enable lines of the converters are reversed,

the converters will thus be controlled incorrectly.

-10 50638042201 EN - 10/2017

https://truckmanualshub.com/

X44/19 X44/1
(7) Approx. 0 V Enable direct to GND-F
(Enable 2U03) (GND F)
X44/33 X44/1 Level change Enable via internal switching
(8)
(Enable 1U06) (GND F) to approx. 1.68 V (photocoupler)
X44/5 X44/1 Level change Enable via internal switching
(9)
(Enable 1U07) (GND F) to approx. 1.68 V (photocoupler)

Approx. 1.7 seconds after the 24 V have been

stabilised for the CAN bus, the enable for the
safety relay KSI is set (reset). The KSI in the
SU switches on (relay click is audible).

X47/1 Level change from 24 V

(10) X47/11 Enable direct to GND-F
(GND F) to approx. 0.8 V
X47/1 Level change from 24 V
(11) X41/9 Enable direct to GND-F
(GND F) to approx. 0.8 V

The supply voltage for K1 is present at the

main contactor 1K1.
If all security questions have been con rmed
positively (all status bits are set), the contactor
current regulation in the SU X42/5 is switched
on
Only now does the main contactor 1K1 close.
The drives are ready.
The drive unit and the hydraulics are now
enabled. Prerequisite for this is the status of
the handbrake and the seat contact switch.

This measurement (3) is only for trucks that are

equipped with the external voltage transformer
MTM.
The SU starts up and carries out a self-check.
A safety relay in the MTM issues the enable for
U-Batt, (relay click is audible)
The external voltage transformer MTM gener-
ates the 24V supply voltage from U-Batt for the
MCU. All converters and the CAN bus partici-
pants, example: FABLI.

U-Batt GND-F
X42/15 X42/14

24 V from MTM GND-F

X42/13 X42/14

50638042201 EN - 10/2017 -11

https://truckmanualshub.com/

24 V CAN bus GND-F

X41/2 X42/14

The further measurements take place as for

trucks with an internal voltage transformer.

Replacement control units can contain software

versions that do not match the versions in the
control units that are still in the truck. This will
cause an invalid combination of software that can
lead to errors in the truck.
An approved software ash package must be
loaded whenever any of the control units in the
truck are replaced. A software ash package
contains compatibility-checked software ver-
sions for all control units. Loading a software
ash package eliminates any invalid software
combinations.
Please see the "STILL Flasher" and "Truck
software overview" workshop manuals for more
information on "software ash packages" and
"loading ash packages".

Once a software ash package has been loaded,

all transmitters and sensors, as well as the
joystick (variant), must be recalibrated.
Connect the notebook to the truck. Start the
truck diagnostics:

Jobs

Calibration

0. Sensors
1. Accelerator
For hand lever only
2.-5. Hydraulic sensor
Variant
6. Mast vertical
Connect the notebook to the truck. Start the
servo hydraulics diagnostics:

Jobs

Joystick calibration

-12 50638042201 EN - 10/2017

https://truckmanualshub.com/

Execute
.

A deactivated PAN process can lead to unde ned

faults in the truck.
The PAN process must always be activated.

In the truck, the PAN process ensures that the

truck control unit (MCU / TCU) always operates
all available controllers in the truck according to
the current parameters.
Each time the truck is started, the PAN process
ensures that the checksums of the individual
controllers are compared with the checksums
saved in the truck control unit (MCU / TCU).
In the event of parameter changes, software
changes or changes of individual controllers,
the PAN process ensures that the relevant
controllers and the truck control unit (MCU / TCU)
process the changes correctly.
It is essential that the PAN process always
remains activated, otherwise the necessary
checksum comparisons and adjustments cannot
be carried out.

Error pro le generated when a PAN process is

not being performed correctly:
After switching on, the display of the display
operating unit remains frozen on the welcome
screen.
Please wait appears in the display during
operation
The current status of the PAN process can be
checked via the truck diagnostics.

F4: Monitoring

Status

Status PAN
.

50638042201 EN - 10/2017 -13

https://truckmanualshub.com/

The truck parameter set is stored in the truck con-

trol unit (MCU). In order to prevent a parameter
loss, this parameter set is available as a copy in
the supply unit (SU).
The parameter sets for SU, ABE, FU and PU are
available as copies in the MCU.
As soon as one of these components is replaced,
the parameter set copy must be copied from the
remaining components. MCU Truck control unit
ABE Display operating unit
SU Supply unit
Parameter loss FU Traction converter
PU Pump converter
If the MCU and SU are replaced at the same time, the
parameters will be lost.
If the MCU and FU/PU are replaced at the same time,
the parameters will be lost.
If the ABE and MCU are replaced at the same time, the
parameters will be lost.
A truck parameter set must be loaded via the notebook
in all cases.

There are two ways of carrying out the copying

procedure:
Automatic transfer
Automatic transfer starts for components that
do not have a functioning parameter set. This
generally applies to brand-new components
and spare parts.
Manual transfer
Manual transfer starts for components that
have a functioning parameter set. This is an
indication that the component has already
previously been installed in a truck.
The automatic transfer is indicated in the display
by the PLEASE WAIT message with progress
bar. This process can take several minutes and
ends with a reset.

An automatic transfer generally takes place when

a converter is installed.

-14 50638042201 EN - 10/2017

https://truckmanualshub.com/

The manual transfer begins with the question in

the display A–EEPROM VALID?. This means:
"Should the parameters of the MCU (device A) be
used?"

Should the parameters of the MCU (device A) be

used?
Use the MCU parameters
Con rm with button
Copy of parameters from the MCU to the SU
Use the SU parameters
Say no by pressing the button
Copy of parameters from the SU to the MCU
Con rm your answer to the security question
ARE YOU SURE? again. In case of any doubt,
the operation can still be interrupted.

The error ring buffer displays errors in the same

temporal sequence in which they occurred. The
precise temporal statement of the error helps
with troubleshooting the truck. This is under the
condition, however, that the time and date in the
display operating unit is correctly set.

The following data is stored per error:

A-errors of the truck control unit (A44,
MCU/TCU)
Date
Time
Designation of the error
Operating hours of the truck control unit (A44,
MCU/TCU)
Operating hours of the truck
The error ring buffer is read out via the truck
diagnostics in the notebook. To do this, start
the diagnostics and carry out the action "Read
out error ring buffer". A maximum of 256 errors
are stored in the ring. These are automatically
overwritten after 256 entries.

The error ring buffer is not present until certain

software versions. For details see the document
"Truck software overview"

50638042201 EN - 10/2017 -15

https://truckmanualshub.com/

Before carrying out any work on the electrical

system, the charging state of the intermediate
circuit must be checked and a discharge process
initiated as is necessary.
If you carry out work on the electrical system with
a charged intermediate circuit, there is a risk of
electric shocks caused by short circuits with tools
and parts of the body.

Do not touch live contact points such as the positive

and negative connections of the power control units!
Before working on electrical power connections,
always check the voltage between all contacts and
between the contacts and the truck chassis using a
suitable measuring device (capable of measuring up
to 1000 V DC).
Discharge the intermediate circuit.

The discharge circuit is a device for discharging

the intermediate circuit in converters in electric
trucks.

The bulb acts as a fuse against too high residual

voltages in the intermediate circuit and can blow
in the event of a fault.
For this reason, the bulb must be checked for
correct function before and after every use and
replaced if necessary.

Disconnect the battery male connector

Connect the batt+ and batt- connections on
the converter to the discharge circuit.
If there is any residual voltage still in the interme-
diate circuit, the bulb brie y ashes.
Measure the voltage in the intermediate circuit
The intermediate circuit is considered discharged
when the voltage is less than 11 V.

-16 50638042201 EN - 10/2017

https://truckmanualshub.com/

Insulation testing must be carried out on the entire

truck at least once a year as part of the FEM test.
Insulation testing must also be carried out after
any work on the electrical system or repairs to the
electrical system.
Insuf cient insulation values in the truck can lead
to unde ned errors that are not reliably detected
via diagnostic processes.
The insulation of the entire truck is tested during
this process.

If the event of insuf cient measured values,

insulation measurement is to be carried out on
the following components in order to ensure that
no errors have gone undetected:
Traction motor
Pump motor
Battery

Always observe the safety information; see chapter

entitled "Safety information".
Before working on the inverter, rst check the charge
state of the intermediate circuit voltage.
If the intermediate circuit voltage is not discharged
to 0 V, take particular care when working on the
inverter.
Follow the correct sequence for removing the
inverter.

24 V 50 V/DC Min. 50 k > 24 k

48 V 100 V/DC min. 100 k > 48 k
80 V 100 V/DC min. 200 k > 80 k
.

STILL MetraHit ISO multimeter measuring

device with measuring lines
Discharge circuit; see chapter "Intermediate
circuit".

50638042201 EN - 10/2017 -17

https://truckmanualshub.com/

Short-circuit bridge for the battery male

connector on the truck side.
Short-circuit bridge for the main contactor,
consisting of a short laboratory line and two
crocodile terminals.

Disconnect the battery male connector.

Discharge the intermediate circuit; see chapter
"Intermediate circuit".
Check that all fuses are inserted and main
fuses screwed in.
Attach short-circuit bridge on the truck side to
the battery male connector.

Connect short-circuit bridge to the main

contactor.
Unlock the emergency off switch.
Switch lock ON

Set the measuring device to the truck-speci c

test voltage.
Connect the black measuring line to a clean
area on the truck chassis e.g. the screw joint
at the chassis and counterweight.
Insert both measuring lines into the measuring
device; see the following schematic view
Hold down the ENTER button and read the
value.

The measurement may take a few seconds, as

capacities are transferred between the truck
chassis and the electronics.
The measurement must be carried out with
both polarities, as many electronic building

-18 50638042201 EN - 10/2017

https://truckmanualshub.com/

elements are installed with direction-dependent

breakdown characteristics in the controllers.

Insert the red measuring line of the short-

circuit bridge into the positive terminal of the
measuring device.

Insert the red measuring line of the short-

circuit bridge into the negative terminal of the
measuring device.
Ideally, both measurements should produce
the same value. If the values deviate from one
another, the lower value is valid for the truck.

The measurements have caused capacities to be

created in the truck. These must be discharged
in a de ned manner.
Leave the measuring device connected until
the voltage value at the truck has decreased to
< 10 V.
Remove the discharge circuit from the main
contactor.
Remove the short-circuit bridge from the truck
battery male connector.

The insulation resistance of the truck and the

battery must be tested individually.
The test voltage must be greater than the
nominal battery voltage but not higher than
100 V or three times the nominal battery
voltage.

The insulation resistance of the battery is

tested when the battery is disconnected, lled
and charged, and installed in the truck.
The insulation resistance is tested between
the electrically active parts of the battery and
the battery tray.
Test value [ ] > (50 /V x UBatt)

50638042201 EN - 10/2017 -19

https://truckmanualshub.com/

STILL MetraHit ISO multimeter

50 V/DC 24 V > 1200

Batt+
Battery 100 V/DC Battery tray 48 V > 2400
Batt-
100 V/DC 80 V > 4000
.

Disconnect the battery male connector.

Set the measuring device to the truck-speci c
test voltage.
Measure from the battery positive terminal
against an electrically conductive point on the
battery tray.
Measure from the battery negative terminal
against an electrically conductive point on the
battery tray.

During insulation testing of the entire truck, if the

insulation values measured were insuf cient, it is
a good idea to test the components of the traction
motor and pump motor individually.

Always observe the safety information; see chapter

entitled "Safety information".
Before working on the converter, rst check the char-
ging state of the intermediate circuit voltage.
If the intermediate circuit voltage is not discharged
to 0 V, take particular care when working on the
converter.
The correct sequence must be followed when
removing the converter.

The test voltage can destroy electronic components.

Disconnect the electrical connections for all control-
lers.
Connect the temperature sensors to the short-circuit
bridge.

-20 50638042201 EN - 10/2017

https://truckmanualshub.com/

24 Volt > 24 k
Traction motor,
500 V/DC U, V, W Housing 48 V > 48 k
pump motor
80 V > 80 k
.

MetraHit Isomultimeter STILL

Short-circuit bridge for the temperature sen-
sors

Disconnect the battery male connector

- De-energise the converter by disconnecting
the power cables and the control cables
- De-energise the truck control unit by dis-
connecting the SAAB plugs and the CAN bus
plugs
- Connect all electric motor temperature
sensors to the short circuit plug
The connection cables and, if necessary, the
CAN bus plug, must be disconnected from the
components, depending on the equipment.

Set the measuring device to the truck-speci c

test voltage.
Measure the windings U, V, W of the traction
motor in relation to the housing.
Measure the pump motor windings U, V, W in
relation to the housing.
The measurements must be carried out one after
another for each winding.
In order to verify a frame fault on electric motors,
it may be necessary to increase the test voltage
to 1000 V.

Connect the power cables and the control

cables to the converters.
Connect the SAAB plugs and CAN bus plugs
to the truck control unit.
Remove the short-circuit bridge from the
temperature sensors.

50638042201 EN - 10/2017 -21

https://truckmanualshub.com/

The connection cables and, if necessary, the

CAN bus plugs, must be connected to the com-
ponents, depending on the equipment.

-22 50638042201 EN - 10/2017

https://truckmanualshub.com/

20 km/h Maximum driving speed calculated

Vmax
16 km/h Maximum driving speed in the drive programs
Vmin 5 km/h Maximum limit on driving speed due to overtemperature

amax 115% Maximum possible acceleration in drive program 5

amin 30% Maximum limit on acceleration due to overtemperature

Imax 100% Maximum possible traction motor current

Imin 30% Maximum limit on traction motor current via the converter

The TRACTION MOTOR OVERTEMPERATURE error is reset as soon as this

T1 122°C
temperature is reached and the temperature falls below this value.
Start of actual limitation of speed and acceleration.
T2 132°C The TRACTION MOTOR OVERTEMPERATURE error is activated.
The error message repeatedly reappears in the display.
End of linear limitation of speed and acceleration
T4 152°C
Start of the linear regulation of the traction motor current via the converter
T5 153°C End of the linear regulation of the traction motor current via the converter

The electric drive is protected against overtem-

perature by a two-stage temperature monitoring
system, a process known as "thermal protection
of the drives".
The converters evaluate the signals from the
temperature sensors for the traction motor and
transmit the temperature values to the truck
control unit (MCU). The temperature values are
processed in the MCU in accordance with the
TSA characteristic curve.
In the rst stage, an error is generated at tem-
perature (T2) and limitation of the speed and
acceleration begins. Thanks to linear reduction,
the drive is usually able to re-establish its natural

50638042201 EN - 10/2017 -23

https://truckmanualshub.com/

temperature. If the traction motor temperature

drops to the (T2) value, all limitations are can-
celled. If the traction motor temperature drops to
the (T1) value, the error is reset.
If it is not possible to re-establish the natural
temperature, stage 2 is triggered.
In the second stage, the motor current is reduced
at temperature (T4). This is accomplished by
limiting the setpoint values that the MCU sends to
the converter. From temperature (T5) onwards,
the motor current is reduced to such an extent
that only heavily limited driving is possible.

Depending on the load on the truck, the reduction

in motor current may bring the truck to a standstill.

With regard to current limitation, it must be en-

sured that the truck can still be driven in poten-
tially dangerous situations (e.g. when driving
over a level crossing). The Boost function is in-
cluded as a safety feature required by the system
for thermal protection of the drives.
If the accelerator is not actuated for a period of 2
seconds and the truck speed is below 0.5 km/h,
temperature-dependent current limitation is
deactivated. The truck will travel in normal
operation mode again for a short period.
Temperature-dependent current limitation is
re-activated as soon as a truck speed of 2 km/h
is exceeded or the accelerator is actuated for 2
seconds.

-24 50638042201 EN - 10/2017

https://truckmanualshub.com/

30 km/h Maximum driving speed calculated

Vmax
20 km/h Maximum driving speeds in the drive programs
Vmin 10 km/h Maximum limit on driving speed due to overtemperature

amax 120 % Maximum possible acceleration in drive program 5

amin 40 % Maximum limit on acceleration due to overtemperature

Imax 100% Maximum possible traction motor current

Imin 30 % Maximum limit on traction motor current via the converter

The error TRACTION MOTOR OVERHEATING is reset as soon as this temper-

T1 137°C
ature is reached and when it falls below.
The calculated limitation of the speed and acceleration starts as soon as this
T2 142 °C
temperature is reached. This has no effect on the truck.
Start of actual limitation of speed and acceleration.
T3 147°C The error TRACTION MOTOR OVERHEATING is activated.
The error message re-appears in the display repeatedly.
End of the linear limitation of speed and acceleration
T4 152 °C Start of the linear regulation of traction motor current via the converter
T5 153 °C End of the linear regulation of traction motor current via the converter

The electric drive is protected against overtem-

perature by two-stage temperature monitoring -
"thermal protection of the drives".
The converters evaluate the signals from the
temperature sensors for the traction motor and
transmit the temperature values to the truck
control unit (MCU). The temperature values are
processed in the MCU in accordance with the
TSA characteristic curve.
In the rst stage, an error is generated at tem-
perature (T3) and limitation of the speed and
acceleration begins. Thanks to linear reduction,

50638042201 EN - 10/2017 -25

https://truckmanualshub.com/

the drive is usually able to re-establish its natural

temperature. If the traction motor temperature
drops to the (T1) value, the error is reset.
If it is not possible to re-establish the temperature
management, stage 2 is triggered.
In the second stage, the motor current is reduced
at temperature (T4). This is accomplished by
limiting the setpoint values that the MCU sends to
the converter. From temperature (T5) onwards,
the motor current is reduced to such an extent
that only heavily limited driving is possible.

Depending on the load on the truck, the reduction

in motor current can bring the truck to a standstill.

With regard to current limitation, it must be en-

sured that the truck can still be driven in poten-
tially dangerous situations (e.g. when driving
over a level crossing). The Boost function is in-
cluded as a safety feature required by the system
for thermal protection of the drives.
If the accelerator is not actuated for a period of 2
seconds and the truck speed is below 0.5 km/h,
temperature-dependent current limitation is
deactivated. The truck will travel in normal
operation mode again for a short period.
Temperature-dependent current limitation is
re-activated as soon as a truck speed of 2 km/h
is exceeded or the accelerator is actuated for 2
seconds.

-26 50638042201 EN - 10/2017

https://truckmanualshub.com/

Imax 100% Maximum possible traction motor current

Imin 30% Maximum limit on traction motor current via the converter

The CONVERTER OVERTEMPERATURE error is reset as soon as this

T1 75°C
temperature is reached and the temperature falls below this value.
The error CONVERTER OVERTEMPERATURE is activated.
T2 80°C
The error message repeatedly reappears in the display.
T4 90°C Start of the linear regulation of the traction motor current via the converter
T5 115°C End of the linear regulation of the traction motor current via the converter

The converter monitors its own temperature bal-

ance by means of an internal temperature sen-
sor. If the temperature exceeds a critical value,
the traction motor current is reduced linearly and
an error is generated. If the temperature balance
is re-established, the error is cleared and the re-
duction cancelled.

Imax 100% Standard pump motor current

Imin 35% Maximum limit on pump motor current via the converter

The error OVERHEATING MOTOR is reset as soon as this temperature is

T1 133°C
reached and when it falls below.
Start of the actual limitation of pump motor current via the converter
T4 143°C The error OVERHEATING MOTOR is activated.
The error message re-appears in the display repeatedly.
T5 168°C End of the linear reduction of pump motor current via the converter

The pump motor and pump converter are pro-

tected against overtemperature by temperature
monitoring that provides "thermal protection of
the drives".

50638042201 EN - 10/2017 -27

https://truckmanualshub.com/

The converter analyses the signals from the

temperature sensor of the pump motor and
transmits the temperature values to the truck
control unit (MCU). The temperature values are
processed in the MCU in accordance with the
characteristic curve for thermal protection of the
drives.
If the (T4) temperature is reached, an error is gen-
erated and the motor current is reduced linearly.
This is accomplished by limiting the setpoint val-
ues that the MCU sends to the converter.
By the linear reduction of the motor current, it is
normally possible for the pump motor to restore
its temperature balance. If the pump motor
temperature drops to the value (T1), the error
will reset and the motor current reduction will be
cancelled.
From the (T4) temperature upwards, the motor
current is reduced to the extent that only very
limited hydraulic functions are available.

Depending on the load on the truck, the motor

current reduction can lead to signi cant impair-
ment of hydraulic functions, especially lifting
operations.

With regard to current limitation, it must be en-

sured that the truck hydraulics can be operated.
The Boost function is included as a safety feature
required by the system for thermal protection of
the drives.
If the pump motor is not operated for a period
of 2 seconds, temperature-dependent current
limitation is deactivated. The maximum current is
available for 1 second.

-28 50638042201 EN - 10/2017

https://truckmanualshub.com/

Imax 100% Standard pump motor current

Imin 35% Maximum pump motor current limitation via the converter

The CONVERTER OVERTEMPERATURE error is reset as soon as this

T1 75°C
temperature is reached and the temperature falls below this value.
Start of the actual limitation of the pump motor current via the converter.
T4 80°C The error CONVERTER OVERTEMPERATURE is activated.
The error message repeatedly re-appears in the display.
T5 90°C End of the linear reduction of the pump motor current via the converter.

The converter monitors its temperature balance

by means of an internal temperature sensor.
If the temperature exceeds a critical value,
the traction motor current is reduced linearly
and an error is generated. If the temperature
balance is re-established, the error is reset and
the reduction cancelled.

50638042201 EN - 10/2017 -29

https://truckmanualshub.com/

Speed-controlled with
Series Series Series Series Series
optimised performance
Torque-regulated Variant Variant Variant Variant Variant
Sprint mode Series No No No Series
Blue Q Series Series Series Series Series
Starting current boost Series Series (1) Series Series Series
Stopping on a slope Series Series Series Series Series
(1)
only with SAC converters

All driving behaviour listed here is activated or

deactivated via parameterising.
The availability is dependent on truck type, model
and truck software.

Torque-regulated mode
The driving modes are distinguished by differ- When the accelerator pedal is released,
ences in the starting and braking characteristics. deceleration is activated as per the traction
program.
Acceleration, deceleration and reversing are
At deceleration of 15% the truck will coast.
limited by the speci cations of the drive program,
regardless of the mode. Dual pedal: The reversing delay when the
pedal for the opposite drive direction is pressed
By default, the trucks are driven in speed-regu- takes precedence over the delay when the
lated mode. accelerator pedal is released.
Torque-regulated mode is activated by means of Reverse deceleration should be greater than
parameterisation in the relevant drive program. just deceleration
The mode applies to that particular drive program DECELER 40%
and cannot be changed by the driver. REVERSE 120%
If the truck is stationary on a slope with the
Speed-regulated mode
downhill drive direction selected, it will roll
When the accelerator pedal is released, downhill with no braking.
deceleration is activated as per the traction
If the truck is stationary on a slope with no drive
program.
direction selected or the uphill drive direction
If the truck is on a slope, it will slowly roll selected, it will roll downhill with braking.
downhill at the regulated speed of 1 cm/sec.
When under load on level ground, it is not
If the truck is under load on level ground, it is subject to drag.
subject to drag.
It is possible to start up the truck with the
It is possible to start up the truck with the handbrake and footbrake actuated. This
handbrake and footbrake actuated. This ensures that the truck can be started on a
ensures that the truck can be started on a slope without rolling backwards.
slope without rolling backwards.

-30 50638042201 EN - 10/2017

https://truckmanualshub.com/

By default, the truck will be in ECO mode every

time it is started up. SPRINT mode can be
activated and deactivated by pushing the function
The drive mode "speed-controlled with optimised key S (ECO mode).
performance" is switched on as standard. The
mode applies to that particular drive program If the drive overheats, SPRINT mode is automat-
and cannot be changed by the driver. It is only ically deactivated. The truck will drive in ECO
possible to switch to other driving modes through mode. If the temperature balance has been re-
parameter changes. stored, SPRINT mode can be activated again
using the function key.
Effects:
The further the accelerator pedal is actuated,
the greater the acceleration, until the respec-
tive drive program setting is reached. Boosting the starting current increases the start-
When the accelerator pedal is depressed, the ing torque from stationary.
truck brakes immediately depending on the The starting current boost is activated by means
respective drive program setting. of parameterisation.
For single-pedal control, the braking effect
The parameterised mode always applies for all
becomes greater the further the accelerator drive programs and cannot be changed by the
pedal is actuated during reversing (change of
driver.
driving direction).
For dual-pedal control, the braking effect The current boost is active at every start-up for a
becomes greater the further the contrary maximum of 3 seconds, as long as the truck does
accelerator pedal is actuated. not move.
If the truck is positioned on a slope without
a driver, it will roll at a regulated speed of 1
cm/sec slowly downhill. Safe parking can only The "Stopping on a slope" driving behaviour is
be ensured with the parking brake engaged. switched on as standard. The driving behaviour
If the truck is positioned on a slope with a is set once and applies to all drive programs.
driver, the truck behaves in accordance with
the "Stopping on a slope" driving behaviour. Effects that occur only when the driver is sitting
and the seat contact switch is actuated.
If the truck is under load on level ground, it is
subject to drag. Function switched on
Driver is sitting, the truck is stationary on the
slope and does not roll downhill.
Function turned off
In SPRINT mode, the performance of the traction
drive increases, thereby improving the dynamic Driver is sitting, the truck is stationary on
the slope and rolls at a regulated speed of 1
acceleration of the truck.
cm/sec slowly downhill.
SPRINT/ECO mode is activated by means of The truck remains stationary on the slope if
parameterisation. the drive direction is neutral and the driver
actuates the accelerator gently.

50638042201 EN - 10/2017 -31

https://truckmanualshub.com/

Blue-Q = IQ will stand for a STILL master concept

of intelligent economic ef ciency and environ-
mental responsibility in the future.
Blue-Q stands for a clean environment, IQ stands
for intelligence. The intelligent drive mode for
economic ef ciency and environmental respon-
sibility
Blue-Q can be activated at the touch of a button
and controls the drive unit and the activation of
additional consumers.

By using intelligent characteristic curve optimi-

sation of the drive, energy is saved whenever a
reduction does not noticeably impair the dynam-
ics of the work process.
Blue-Q maintains the truck dynamics when
accelerating up to a speed of 7 km/h. Above
this speed there is low acceleration, which results
in energy savings. In this way, Blue-Q reduces
energy consumption for stretches between 3 m
and 40 m by up to 20%. Because Blue-Q does
not affect the lifting capacity, a 10% saving based
on a working cycle (with lifting) is achievable. On
longer routes, you can also reach the maximum
speed with Blue-Q.

Blue-Q mode regulates intelligent switching

on/off of electrical consumers.
Depending on the equipment, the lighting, work-
ing spotlights, windscreen wipers, seat heaters
and cab heating will automatically switch off after
the driver's seat has been vacated.
When travelling in reverse for more than 3 km/h,
the front working spotlight and windscreen wipers
are switched off automatically.

Working spotlights X X X
Lighting X X
Windscreen wipers X X X
Seat heater and cab
X
heating

Individual parameterising settings can be made

using the truck diagnostics in the notebook to
determine which of the electrical consumers are
to be switched off.

-32 50638042201 EN - 10/2017

https://truckmanualshub.com/

A 00 160 00 Blue-Q not activated

Mode FIX
A 00 160 3A
Blue-Q is always ON once the truck is started
Mode STANDARD
A 00 160 35
Blue-Q can be switched ON/OFF using the button
Mode FIX-FLEX
Blue-Q is active once the truck is started and can then be switched
A 00 160 3F
ON/OFF using the button. This mode is a combination of FIX and
STANDARD
.

50638042201 EN - 10/2017 -33

https://truckmanualshub.com/

A CAN bus (Controller Area Network) is a "linear

network" that comprises multiple participants
based on microcontrollers. Due to the signal level
technology used and the special structure of the
data telegram, the CAN bus system is extremely
resistant to interference at high transfer speeds.
Depending on the truck, there are several discon-
nected CAN bus systems that are used to transfer
data between the controllers.

In CAN bus systems, re ections at the ends of the

wires can cause errors in the signal transmission.
Resistors are placed in the wires to dampen these
re ections. This is called "termination".

Depending on the truck and the installed CAN bus

participants, these resistors are used in different
ways.
Terminating resistors of approx. 120 de ne
the start point and end point of the CAN
bus. In between the start and end points are
additional, high-ohmic CAN bus participants,
usually decoupled with a resistor of approx.
40 k .
Terminating resistors can be tested when the
truck is switched off.
In newer truck generations, resistors of vary-
ing size are placed in one of the CAN bus
participants (such as the truck control unit) via
software. These resistors terminate the CAN
bus as required.
It is not possible to test these resistors, as they
are deactivated via the software when the truck
is switched off.

The signals used are "difference signals". The

difference is measured between the "CAN_L"
and "CAN_H" signals.
If both signals are at an idle level of 2.5 V, there
is no "difference signal". A '"0 information"' is
transmitted.
If the "CAN_H" signal is increased to 3.5 V and
the "CAN_L" signal is simultaneously dropped to
1.5 V, a "difference signal " of 2 V is produced. A
'"1 information"' is transmitted.

-34 50638042201 EN - 10/2017

https://truckmanualshub.com/

With a data transfer rate of 250 kBit/s, this 0/1

transmission occurs 250,000 times per second.
In terms of measuring technology, this means
that averages are adjusted during operation.
A value slightly over 2.5 V is measured for the
"CAN_H" signal and a value slightly under 2.5 V
is measured for the "CAN_L" signal.

50638042201 EN - 10/2017 -35

https://truckmanualshub.com/

ABE Display and operating unit Red

Red 120 X47/20 - X47/21
MCU Truck control unit
Blue 120 X47/10 - X47/24
FIT Joystick, mini-lever Red
X50 Truck diagnostic connector Red
Variant, additional electrical installa-
CPP Red
tion
CIO Variant, full extension of battery Red
Variant, turn indicator module for the
FABLI Red
drive direction
FMID Variant, FleetManager Red
CS Variant, acceleration sensor Red
ELF Variant, electric parking brake Red
Red 120 X41/8 - X41/16
SU Supply unit
Blue 120 X41/7 - X41/15
2U03 Pump motor converter Blue
1U06 Right-hand traction motor converter Blue
1U07 Left-hand traction motor converter Blue

There are independent CAN bus systems in this

truck. These are used to transfer data between
the controllers:
Truck CAN bus (red)
Converter CAN bus (blue)
The MCU is the "master" and is connected to all
CAN bus systems.

-36 50638042201 EN - 10/2017

https://truckmanualshub.com/

Voltage measurement
CAN_H to GND 2.5 V 3.5 V
CAN_L to GND 1.5 V 2.5 V
.

1 CAN H (red)
2 CAN L (red)
3 24 V
4 GND
5 Not assigned
6 Not assigned
7 Not assigned
.

Up to the start of 2014, the diagnostic connector

was located in the compartment on the right next
to the driver's seat.

1 CAN H (red)
2 CAN L (red)
3 24 V
4 GND
.

50638042201 EN - 10/2017 -37

https://truckmanualshub.com/

Power cables are electrical wires in accordance

with VDE 0295 classes 5 and 6 with a wire
cross-section of 10 mm2.

In our trucks, the following components have

power cables:
Power contactor (1)
Conductor rails and bolts in the fuse box (PDU)
Converter (2)
Electric motor (3)
Starter battery (4)
Traction battery (5)
Battery male connector (6)

The images are to be understood as examples;

they may not apply to all trucks.

-38 50638042201 EN - 10/2017

https://truckmanualshub.com/

Solderless terminals and crimp connectors are

used as contact elements for power cables.

The following contact elements are used:

DIN 46234 crimp-type cable lugs (1)
DIN 46235 compression and tubular cable
lugs (2)
Manufacturer-speci c battery male connector
contacts (3)

Check all cable connections on the power ca-

bles for damage. Check that the connections
are securely attached, check the condition and
check for corrosion
Check the condition of conductor rails and
bolts and check for corrosion
Remove oxidation residue
Replace brittle and defective cables
Check the tightening torques

Due to the wide range of cable shoes available

from different manufacturers, we distinguish
between the following types:
DIN 46234 cable shoe
DIN 46235 cable shoe
Cable lug optimized for ne-stranded cables,
similar to DIN 46235

The main difference between the cable shoes is

in the interior diameter of the press sleeve.

50638042201 EN - 10/2017 -39

https://truckmanualshub.com/

Measure the push-on length of the press

sleeve.
Add 10% to the push-on length as a tolerance.

Strip the cable along dimension L.

Damage to the separate wires causes a reduction in

the cross-section. This leads to incorrect crimping,
poorer transition resistance and increased heating.
Use a suitable tool.

Push the contact element onto the stripped

end of the cable and crimp centrally using the
appropriate crimping die.
Perform the crimping process until it is clearly
noticeable that the pressure relief valve has
been triggered.
Open the crimping pliers using the release
lever.

Only crimp each contact once!

-40 50638042201 EN - 10/2017

https://truckmanualshub.com/

The modular fuse box has been tted as standard

since August 2005.
The A21 fuse box is installed in the counterweight
and includes the following components:
Main contactor 1K1
Main fuse F01
Current sensor U10 for measuring battery
current
Horn relay K1
Control fuses
7A21 converter PCB (variant)

XS1 Battery positive terminal 13 Nm

XS2 Distributor card supply 13 Nm
XS4 Batt+ after main contactor 13 Nm
XS5 Battery negative terminal 13 Nm

X20 Control cables to the SU

X21 Signal horn
X22 Contactor coil
X26 Signal transmitter
X27 Voltage converters U1, U2
Voltage converter U4, 5th hydraulics
X271
feed
.

Fuses are located in various positions on the

truck. As standard, each truck is equipped with
the fuse box located at the rear in the counter-
weight.
Depending on the truck equipment, the 7A21
converter PCB for the 24-V power supply may be
installed.

50638042201 EN - 10/2017 -41

https://truckmanualshub.com/

Supply Unit
F11 10 A
Main Control Unit
F12 10 A Signal horn
10 A U4 voltage converter
F14 20 A Electric parking brake
10 A 48V searchlight
10 A U4 voltage converter
F15
10 A Solenoid valve on attachment

F21 30 A Voltage converter Up to 2013

F21A 15 A Voltage converter As of 2014
F21B 15 A Voltage converter As of 2014
F21C 15 A Voltage converter As of 2014
40 A U-Batt 48 V
F22 Heating system
30 A U-Batt 80 V
Option Board,
F23 10A
Solenoid valve on attachment
F24 10 A CPP rear
F25 10 A Proportional technology
25 A Roof CPP
F26
10 A RPP
25 A Seat CPP
F27
10 A RPP
15 A Front CPP
F28
10 A RPP
Option board,
F29 15 A
Material management system (MMS)
.

-42 50638042201 EN - 10/2017

https://truckmanualshub.com/

The fuse plate was installed as standard until

August 2005 and was then replaced by the fuse
box. The fuse plate is still available as a spare
part.
The fuse plate is installed in the counterweight
as a modular unit and includes the following
components:
Main contactor 1K1
Main fuse F01
Current sensor U10 for measuring battery
current
Horn relay K1
Control fuses
Optional fuses
In addition, it is also used as a distributor plate for
supplying the additional electrical equipment.

XS1 Battery positive terminal 13 Nm

XS2 Distributor card supply 13 Nm
XS4 Batt+ after main contactor 13 Nm
XS5 Battery negative terminal 13 Nm
Heating system positive
XS6
supply
Heating system negative
XS7 supply

X20 Control cables to the SU

X21 Signal horn
X22 Contactor coil
X23 CPP 4, rear
X24 CPP 2, front structure
X25 Option board
X26 Signal transmitter
X27 5th hydraulics feed
.

Disconnect battery plug.

Remove the trademark emblem

50638042201 EN - 10/2017 -43

https://truckmanualshub.com/

If necessary, disconnect the plug from the light

strip
Remove the covering. To do this, release, but
do not unscrew completely, screw M6x10

If the intermediate circuit is not discharged, there is a

risk of electric shocks.
Check the intermediate circuit. Discharge if necessary.

Remove the supply unit

Release screw XS1 (M8x16)
Release the two screws XS4 and XS5 (M8x40)
Release the two ring eyelets XS6 and XS7
Disconnect all plug connectors
Disconnect the cable ties on the right-hand
side of the fuse plate until the wiring harness is
completely detached
Move the cable under the fuse plate
Remove the fuse plate by pulling it upwards

Move the fuse plate to the left under the sheet

metal cover

Be careful of the cable guide!

Cables must not become trapped!

Insert screw XS4 (M8x40) and screw in a few

turns
Insert screw XS5 (M8x40) and screw in a few
turns
Insert screw XS1 (M8x16)
Now screw in all three screws
Attach the wiring harness on the right-hand
side of the fuse plate using cable ties
Screw in the two ring eyelets XS6 and XS7
Connect all plug connectors
Attach the covering and tighten the screw
Attach the trademark emblem. If necessary,
connect the light strip plug
Functional test

-44 50638042201 EN - 10/2017

https://truckmanualshub.com/

The fuse plate was built in as standard until

August 2005 and was then replaced by the fuse
box. The fuse plate is still available as a spare
part.
Fuses are located in two places on the truck.
Fuse plate (1)
Main fuse
Control fuses
Fuses for add. electrical installation

Option board (2)

Control fuses
Fuses for add. electrical installation

F01 400 A Main fuse Fuse plate

Supply Unit
F11 10 A Fuse plate
Main Control Unit
F12 5A Alarm horn Fuse plate
F13 50 A 2 kW heater supply Fuse plate
F14 20 A 1 kW voltage transformer Fuse plate
F15 10 A Proportional technology Fuse plate
F16 10 A Heater supply Fuse plate
F17 15 A Solenoid valve supply Fuse plate

50638042201 EN - 10/2017 -45

https://truckmanualshub.com/

F1 10 A 5. Hydraulics 24/48 V Option board

F2 10 A Clamp light Option board
F3 10 A Material Management System (terminal) Option board
.

As the main contactor, contactor 1K1 switches

the power supply for the power electronics.
The contactor coil is designed for 24 volt operat-
ing voltage and is activated by current control.
The contactor is clamped on its side on the fuse
plate by a stud bolt (S).

Operating voltage of
24 V
contactor coil
Coil resistance Approx. 20
Protective circuit (in
parallel) Approx. 47
resistor & diode (in 1N4001
series)
Tightening torque 10+1Nm
Contact pressure (fully
≥ 9.0 Nm
activated)
Passage path 1.3 to 2.7 mm
.

Fully actuate the contactor.

Connect the centre of the contacts to the spring
balance. Load with 9.0 N.
Use the hexagon head screw that passes
through the contact spring to adjust the contact
pressure.
Turn the hexagon head screw clockwise to
increase the pressure.

The contact spring has a certain amount of fric-

tion. The contact pressure is correctly adjusted
when with a pull-down force load of 10 to 10.5 N,
the contact does not close when being introdu-
ced slowly, but moves and remains closed when
being introduced quickly.

-46 50638042201 EN - 10/2017

https://truckmanualshub.com/

With the "vertical lift mast position" comfort

feature, goods such as rolls of paper can be
positioned so that they are precisely vertical and
thus avoid damage during unloading. In addition,
the gentle running-in of the tilt cylinders into the
end stops saves energy and reduces wear.
The function is only possible with servo hy-
draulics. The way in which the "vertical lift mast
position" is operated depends on which operating
devices are tted in the truck.

Possible equipment variants are as follows:

Mini-lever
Joystick
Fingertip

For notes on operation, see the operating instruc-

tions.

The driver can see the lift mast tilt in the display
of the display operating unit. The bar shows the
current lift mast position, the arrow indicates the
"vertical lift mast" position.
End of the bar at the far left - max. backwards
tilt
End of the bar at the far right - max. forwards
tilt
End of the bar under the arrow - lift mast
vertical

When the driver actuates the tilt forwards func-

tion, the lift mast stops automatically as soon as
the "Vertical lift mast position" is reached. The
automatic approach of the "Vertical lift mast po-
sition" must be activated by the driver via the
corresponding button on the display operating
unit. When deactivated, the lift mast moves be-
yond the vertical position without stopping.

The lift mast is braked gently at the end of its tilt

range. This prevents a sudden impact caused by
the lift mast and the truck does not jerk.

50638042201 EN - 10/2017 -47

https://truckmanualshub.com/

Under certain circumstances, the lift mast cannot

move exactly into the preset vertical position.

Possible causes:
Uneven ground
Bent forks or attachments
Worn tyres
A severely bent lift mast
In this case, the customer can correct and store
the changed vertical position by pressing and
holding the corresponding button for "vertical lift
mast position".

The tilt angle sensor functions without contacts

via a magnetic eld and a Hall sensor. The angle
range is +60° to 60° without mechanical stops.
The sensor is protected against short circuit with
an unlimited short-circuit duration.
There are two variants of the tilt angle sensor and
the only difference between the two is the length
of the lever (80/100 mm).

1 Sensor
2 Lever

7B46/1 GND X20:S3/A2 X32C/3 X32C/3

7B46/2 12 V X20:S3/A1 X32C/1 X32C/1
7B46/3 Signal OUT 1 X20:S3/B1 X32C/2 X32C/2
7B46/4 GND X20:S4/A2 E54 - X31C/3 E54 - X31A/3
7B46/5 12 V X20:S4/A1 E54 - X31C/1 E54 - X31A/1
7B46/6 Signal OUT 2 X20:S4/B1 E54 - X31C/2 E54 - X31A/2
.

-48 50638042201 EN - 10/2017

https://truckmanualshub.com/

Calibration must always be performed after the

rst installation or replacement of the tilt angle
sensor.
Park the truck on even, level ground.
Set lift mast to vertical. Check the vertical
position using a spirit level.
Apply the parking brake.
Start calibration via the display and operating
unit.
Switch to service mode and select the MAST
sub-item in the CALIBRATION menu item.
Start calibration.
The forwards drive direction indicator ashes:
Tilt the lift mast forwards to the end stop and
leave it in this position.
The measured value is saved once both drive
direction indicators start ashing. The lift mast
must not be moved during this phase.
The reverse drive direction indicator ashes:
Tilt the lift mast backwards to the end stop and
leave it in this position.
The measured value is saved once both drive
direction indicators start ashing. The lift mast
must not be moved during this phase.
Carry out a truck reset.
Check the function of the vertical lift mast
position.

Calibration must always be performed after the

rst installation or replacement of the tilt angle
sensor.
Connect the notebook to the truck and start the
truck diagnostics:

Action

Calibration

Vertical lift mast position

The notebook shows the steps to be performed

during calibration.

50638042201 EN - 10/2017 -49

https://truckmanualshub.com/

Monitoring of both signals

A3130
The sum of the signals does not lie
VERTICAL MAST
between 6 10 V
A3131 GND1 breakdown
VERTICAL MAST Sensor signal 1 is less than 0.2 V The hydraulics are disabled while
A3132 VCC1 breakdown the "vertical lift mast position" is
VERTICAL MAST Sensor signal 2 is greater than 9 V activated via the button.
A3133 GND2 breakdown When the "vertical lift mast posi-
VERTICAL MAST Sensor signal 2 is less than 0.2 V tion" is deactivated, the hydraulics
A3134 VCC2 breakdown are enabled again.
VERTICAL MAST Sensor signal 2 is greater than 9 V
Angle measurement plausibility
error
A3135
The tilt function is actuated and
VERTICAL MAST ERROR the angle measurement does not
change
.

When performing retro ts, the truck-speci c

parameters must be checked via the display and
operating unit and changed as required.

Vertical lift mast position mode

A 00 110 0B
Function active, current position display, manual calibration
Input for vertical lift mast position
A 00 111 31
Status button 10 (soft key 3)
A 00 112 02 Offset delay before end stop
A 00 233 11 Con guration of soft key button 3 "Lift mast vertical"
A 00 10F Con guration of the lift mast vertical position characteristic curve
5060 5066
01 6210 6217
7311 7316
6311, 6313, 6315
02
7321 7330
03 6321 6325
04 6327 6330
A 10 1B8 Positioning logic for vertical lift mast position
00 No stop when the lift mast is vertical
01 Only stop if the lift mast is vertical during forward tilt (standard)
02 Only stops if the lift mast is vertical during backwards tilt
03 Always stops when the lift mast is vertical
6321 6330
10 Swap forward tilt/backward tilt in trucks with reversed tilting hoses.
This value is added to the upper values (10 + 01 = 11)
.

-50 50638042201 EN - 10/2017

https://truckmanualshub.com/

A 10 1A0 00h 00h 00h 00h 00h 00h

A 10 1A1 01h 01h 01h 01h 01h 01h
A 10 1A2 0Ah 20h 15h 10h 40h 0Ah
A 10 1A3 64h 96h 96h 96h 96h 64h
A 10 1A4 00h 00h 00h 00h 00h 00h
A 10 1A5 08h 2Eh 2Eh 40h 30h 08h
A 10 1A6 10h 35h 35h 80h 80h 10h
A 10 1A7 FAh FAh FAh FAh FAh FAh
A 10 1A8 00h 00h 00h 00h 00h 00h
A 10 1A9 01h 01h 01h 01h 01h 01h
A 10 1AA 0Ah 1Eh 1Eh 20h 40h 0Ah
A 10 1AB 64h E0h E0h E0h E0h 64h
A 10 1AC 00h 00h 00h 00h 00h 00h
A 10 1AD 10h 28h 28h 20h 20h 10h
A 10 1AE 15h 46h 46h 80h 40h 15h
A 10 1AF FAh FAh FAh FAh FAh FAh
A 10 1B0 00h 00h 00h 00h 00h 00h
A 10 1B1 01h 01h 01h 01h 01h 01h
A 10 1B2 0Ah 20h 60h 20h 60h 0Ah
A 10 1B3 64h E0h E0h E0h C8h 64h
A 10 1B4 00h 00h 00h 00h 00h 00h
A 10 1B5 12h 28h 28h 20h 19h 12h
A 10 1B6 15h 37h 37h 80h 20h 15h
A 10 1B7 FAh FAh FAh FAh FAh FAh
A 10 1B8 01h 11h 11h 01h 01h 01h
.

When retro tting the vertical lift mast position,

note the following:

There must be bores for holding the tilt angle

sensor in the chassis stiffener.
Start of series production from calendar week
02/2010.

In accordance with the truck-speci c spare

parts list
The software and parameters must be modi ed
depending on the truck type.

50638042201 EN - 10/2017 -51

https://truckmanualshub.com/

Diesel and LPG truck

Software ash package 0.43 or a more recent
version
Electric forklift truck
Software ash package 1.02 or a more recent
version

The truck-speci c parameters are provided by

your service centre.

N Lift mast vertical

1 Rod R1 Maximum backwards
2 Chassis stiffener
3 Lever
V2 Maximum forwards
4 Tilt angle sensor
N Neutral
R2 Maximum backwards
V1 Maximum forwards

7310 - 7316 right 80 mm 8° + 1° 50.8° 9° + 1° 45°

6210 - 6217 right 80 mm 8° + 1° 54.1° 9° + 1° 45.4°
6311, 6313, 6315 right 80 mm 8° + 1° 54.1° 9° + 1° 45.4°

-52 50638042201 EN - 10/2017

https://truckmanualshub.com/

With the "load measurement" comfort feature,

the weight of a lifted load can be determined.
This weight is shown in the display operating unit.
As a result, there is increased safety for the driver
because the weight of the load to be transported
is known.
Load measurement can be activated via a button
on the ABE, and for mini-lever 2 and ngertip
also via the F1 button. Load measurement is only
possible when the truck is at a standstill.
The way in which the load measurement is
operated depends on which hydraulic operating
devices are tted in the truck.

Possible equipment variants are as follows:

Mini-lever
Joystick
Fingertip
Hand lever

For notes on operation, see the operating instruc-

tions.

The load measurement has an accuracy level of

±3% over the entire measurement range, based
on the rated capacity of the truck.
The accuracy of the measurement is in uenced
by the transient effect of the load when the
lowering movement is stopped abruptly. A
noticeable vibration of the load has a positive
effect on the accuracy of the measurement.

Prerequisite for an accurate and awless load

measurement:
Hydraulic oil at normal operating temperature
of 10 - 80 °C.
Minimum loads:
10% of the nominal load for trucks up to 2.5t.
5% of the nominal load for trucks of 3.0t and
more.
Measurement within the rst lifting stage.
The load must rest before the measurement
and noticeably swing freely after the abrupt
stop.

50638042201 EN - 10/2017 -53

https://truckmanualshub.com/

The transient effect after the lowering movement

(B) has come to an abrupt stop is used for the
load measurement.
Only then can the loss of friction that results
while breaking away from the static position be
disregarded for the evaluation.

Three values are determined for the evaluation:

A Start of the lowering movement
Value above the rst maximum values (1) and
B Abrupt stop of the lowering movement and
minimum values (1) in the transient effect. start of the transient effect
Average value (2) during the whole transient
effect. 1 Minimum/maximum values for transient
Value after the transient effect (3) oscillation
2 Average value during the transient effect
The most accurate load measurement is deter- 3 Value after the transient effect
mined by aligning all three values.

For aligning the different lift mast heights, fork

arms and attachments and for calibrating the
pressure sensor, a zero adjustment must be
carried out before the load measurement. The
zero adjustment should be carried out once a day
without a load.
Lift the forks (fork carriage with attachment
as necessary) within the rst lifting stage to a
height of 300-800 mm above the ground.
Set lift mast to vertical.
On the ABE, press the button for load mea-
surement for longer than 3 seconds.
In the display, the symbol switches to zero adjust-
ment.
Lower the forks quickly by approx. 100-200
mm. Quickly actuate and release the operating
device for lowering so that it jumps back to
neutral position.
For a valid zero adjustment, a weight of 0 kg is
shown in the display.

Lift the load within the rst lifting stage to a

height of 300-800 mm above the ground.
Set lift mast to vertical.
On the ABE, press the button for load mea-
surement.
Lower the load quickly by approx. 100-200
mm. Quickly actuate and release the operating
device for lowering so that it jumps back to
neutral position.

-54 50638042201 EN - 10/2017

https://truckmanualshub.com/

The load should now swing freely without touch-

ing the ground. After a short time, the weight of
the load is shown in the display.
An invalid measurement is shown in the display
with the value -9999 kg.
If a lowering procedure is not performed after the
button is actuated, the LOWER FORKS message
is shown in the display after approx. 3 - 5 sec-
onds.

The pressure sensor is used in the lifting hy-

draulic line or directly at connection H on the
directional control valve block. The installation
position is dependent on the truck type and is the
same as that of the well known "load detection"
FleetManager function.

Danfoss, model
Pressure sensor
MBS3250
Connection G1/4 A 1 Pressure sensor
0 - 250 bar 2 on the lift mast
Measuring range 3 Lifting separation point (example)
0.5 - 5 Volt
. 4 on the directional control valve block

7B45/1 br Brown 12 V 3 X34A/1

7B45/2 bl Blue GND 2 X34A/3
7B45/3 sw Black Signal OUT 1 1 X34A/2
.

50638042201 EN - 10/2017 -55

https://truckmanualshub.com/

The fuse box has been built into all trucks as

standard since August 2005.
Depending on the truck equipment, the 7A21
converter PCB for the 24-V power supply may be
installed.
The converter PCB rests on the fuse box. Four
hexagon head bolts are used as a spacer block
and mounting.

A M5 x 10 - 2.5 Nm Hexagon head bolt made from polyamide

B M5 x 10 - 2.5 Nm Hexagon head bolt made from polyamide
XS2 Batt+ M6 x 16 - 4.1 Nm Hexagon head bolt
XS5 Batt- M6 x 16 - 4.1 Nm Hexagon head bolt
XS6 Heating system battery +
XS7 Heating system battery -
X63 Option board
X64 CPP, rear
Option board
CPP, front
X65
Servo hydraulics
U4 voltage converter
X66 CPP, roof
X67 CPP, seat
X81 Voltage converters U1, U2, U3
X82 Voltage converters U1, U2, U3
X83 Voltage converters U1, U2, U3
.

-56 50638042201 EN - 10/2017

https://truckmanualshub.com/

The Option Board A22 comprises a circuit board

in a plastic housing and is always tted to the front
structure beneath the truck control unit (MCU,
TCU). Depending on the truck equipment, the
Option Board supplies the optional additional
electrical equipment and sensor system.

The Option Board contains the following compo-

nents:
Electrical connections
Fuses F1, F2 and F3
Relay K1
The assignment of electrical connections varies
according to the truck and individual equipment.
For detailed information, see the truck operating
circuit diagram.

F1 5A
F2 10 A
F3 10 A

K1 5th hydraulic function

.

X30 Control cables for truck control unit TCU/MCU

X37 12 volt supply
Reserve switch 4 (analogue)
X31 Dead man switch
Reserve switch 2 (digital)

50638042201 EN - 10/2017 -57

https://truckmanualshub.com/

Reserve switch 1 (analogue)

X32 Right door contact switch
Left door contact switch
X33 Fork carriage monitoring
Lift limitation
X34 Load switching
Load sensor
X35 5th hydraulic function feed
X36/2 5th hydraulic function controller
F2 light
X38
Material management system (MMS)
.

-58 50638042201 EN - 10/2017

https://truckmanualshub.com/

CPPs are designed for 12-V and 24-V on-board

electrical systems and are used in all trucks. The
individual CPPs can only be identi ed by their
order number; see the truck-speci c spare parts
list. The location and number of CPPs in the
truck varies according to the truck type and the
equipment; see the chapter entitled "Overview of
electrical components".

The CPP 2B (lighting) was introduced in January

2010 and replaced the CPP 2 and CPP 4 (front
structure, rear) in all trucks in the medium term. It
is not possible to convert from CPP 2 and CPP 4
to CPP 2B.

The CPP supplies and controls the various op-

tional consumers within the additional electrical
installation.
Each CPP has its own identi er and is controlled
by the truck control unit (MCU, TCU) via the "red"
peripheral CAN bus. The CPPs are all supplied
via the fuse box.

The CPPs are CAN bus participants and need to

be registered using parameters. The outputs are
parameterised using the truck diagnostics in the
notebook.
The value for the output display of the additional
electrical installation consists of two hexadecimal
characters. The rst character shows the CPP
number (1-4), the second character shows the
channel number (1-B). Both digits are shown in
the truck-speci c operating circuit diagram.

This CPP can be used to connect the various

electrical consumers, which will vary according to
the truck and equipment.

50638042201 EN - 10/2017 -59

https://truckmanualshub.com/

X51 CAN bus (CAN r)

X52 Supply voltage
X53 2 x 2-pin plugs, 1 variable, 1 xed switching output
X54 10 x 2-pin plugs with 7 variable switching outputs

X53:1A OUTPW 10 Permanent double

3.5 A assignment 12 32
X53:1B OUTPW 2 Wiper supply
X53:2B 3.5 A OUTPW 1 11 31

X54:1B Permanent double

10 A OUTPW 3 13 33
X54:2B assignment
X54:3B Permanent double
10 A OUTPW 4 14 34
X54:4B assignment
X54:5B 3.5 A OUTPW 6 16 36
X54:6B 3.5 A OUTPW 5 15 35
X54:7B 3.5 A OUTPW 8 18 38
X54:8B 3.5 A OUTPW 7 17 37
X54:9B Permanent double
10 A OUTPW 9 19 39
X54:10B assignment
.

-60 50638042201 EN - 10/2017

https://truckmanualshub.com/

The entire lighting system is connected via the

CPP. It is therefore also called CPP lighting.
Other electrical consumers cannot be connected.

Since January 2010, the CPP 2B (lighting) has

replaced CPP 2 and CPP 4. A conversion from
CPP 2 and CPP 4 to CPP 2B is not possible.

X51 CAN bus (CAN r)

X52 Supply voltage
X53 2 x 2-pin plugs, 2 switching outputs
X54 10 x 2-pin plugs, 14 slots, 8 switching outputs

Please note the following information in relation

to the Imax values:
The maximum currents must not be exceeded
for each slot or dual slot.
The total of all currents must not exceed 30 A.

X53:1A 10
3.5 Front wiper, supply A00 317 22
X53:1B 2
X53:2B 3.5 1 Front wiper, interval A00 318 21

X54:1B Left headlight

9.2 3 A00 2D2 23
X54:3B Right headlight
X54:2B Left side light
2.1 11 A00 2D7 2B
X54:6B Left rear light
X54:2A 1.75 Front left direction indicator
6 A00 2C9 26
X54:6A 1.75 Rear left direction indicator
X54:4A 1.75 Front right direction indicator
5 A00 2C7 25
X54:8A 1.75 Rear left direction indicator
X54:4B Right side light
2.1 4 A00 2D9 24
X54:8B Right rear light
X54:5B Left stop light
3.5 8 A00 2DC 28
X54:7B Right stop light
X54:9B 1.75 7 Left/right back-up light A00 3E1 27
Blower heating system via output at
X54:10B 9.2 9 A00 300 29
reserve 4
.

50638042201 EN - 10/2017 -61

https://truckmanualshub.com/

This CPP can be used to connect the various

electrical consumers, which will vary according to
the truck and equipment.

Since January 2010, the CPP 2B (lighting) has

gradually replaced CPP 2 and CPP 4 in all trucks.
A conversion from CPP 2 and CPP 4 to CPP 2B
is not possible.

X51 CAN bus (CAN r)

X52 Supply voltage
X53 2 x 2-pin plugs with 2 permanently assigned switching outputs
X54 6 x 2-pin plugs with 6 permanently assigned switching outputs

X53:1A OUTPW 10
3.5 A 22 42
X53:1B 4-pin OUTPW 2
X53:2B 3.5 A OUTPW 1 21 41

X54:1B 2-pin 10 A OUTPW 4 24 44

X54:2B 2-pin 3.5 A OUTPW 6 26 46
X54:3B 2-pin 3.5 A OUTPW 5 25 45
X54:4B 2-pin 3.5 A OUTPW 8 28 48
X54:5B 2-pin 3.5 A OUTPW 7 27 47
X54:6B 2-pin 10 A OUTPW 9 29 49
.

The hydraulic battery carrier is activated via the

CPP battery carrier.
The CPP battery carrier is a CIO (CAN Input
Output). The CIO provides the inputs and outputs
and evaluates the signals.

The CPP battery carrier can be used exclusively

for the hydraulic battery carrier. No other use is
possible.

X51 CPP3, X51 CAN bus (CAN r)

X52 CPP3, X52 Supply voltage

-62 50638042201 EN - 10/2017

https://truckmanualshub.com/

X61:1A X301/5 - white 9B17/1 - GND - yellow

X61:1B X301/8 - yellow 9B17/4 - 12 V - green
X61:2A X301/7 - green 9B17/3 - signal 2 - black
X61:2B X301/6 - brown 9B17/2 - signal 1 - red

X62:1A X301/12 9B15 - GND - blue

X62:1B X301/14 9B15 - 12 V - brown
X62:1B X301/9 - green 9B16 - 12 V - brown
X62:2B 9S24/1 - button 1, retract
X62:3A 9S24/2 - GND button 1+2
X62:3B 9S24/3 - button 2, extend
X62:4B X301/13 9B15 - signal - black
X62:5A X301/11 - blue 9B16 - GND - blue
X62:5B X301/10 - pink 9B16 - signal - black
X62:6A A2 9K37
X62:6B A1 9K37
X62:7A X301/4 - yellow 9Y11
X62:7B X301/3 - green 9Y11
X62:8A X301/2 - brown 8Y12
X62:8B X301/1 - white 9Y12
.

The Relay-Power-Port (RPP) is a simpli ed

variant of the CPP and is a further development
of the relay plate.
The RPP is not a CAN bus participant, but uses
the CAN bus plug as a power supply only.
The RPP contains two internal relays, which are
directly controlled by the outputs of the truck
control unit (MCU, TCU). The truck control unit
has three outputs for the external relays SK1,
SK2, SK3. This enables three switching functions
that can be carried out by two or three RPPs.
The location of the RPPs in the truck corresponds
to the location of the CPPs and varies according
to truck type; see the chapter "Overview of
electrical components".

X51 Relay supply voltage

X52 Consumer supply voltage
X53 Normally open contacts for SK1/3

50638042201 EN - 10/2017 -63

https://truckmanualshub.com/

X541 Parallel normally open contacts for SK1/3

X549 Normally open contacts for SK2
X56 Relay coil contacts

Electric forklift trucks 48 V and

Distributor card 7A21: X65, X66, X67
80 V
Electric forklift trucks only 48 V Fuse box A21: X27
IC truck Fuse box A21: X162
.

The RPPs are not CAN bus participants and do

not need to be registered using parameters.
Parameterising of the outputs takes place using
the truck diagnostics in the notebook.

X56:2 X47:5 SK2 out Option board channel 2 / RPP1 K2 02

X56:1 X47:33 SK1 out Option board channel 1 / RPP1 K1 01
X56:1 X47:19 SK3 out Option board channel 3 / RPP2 K1 03
.

-64 50638042201 EN - 10/2017

https://truckmanualshub.com/

The Main Control Unit (MCU) is attached to the

front right of the front structure and is protected
by panelling.
The MCU consists of a control processor (SR)
and a monitoring processor (UE). As the truck
control unit, the MCU is responsible for control-
ling, regulating, monitoring and enabling.
In the extended version with servo hydraulics, the
valve processor (VR) is built into the housing as
an additional printed circuit board.

The individual MCU tasks are listed by function:

Error management
Fault number management A (MCU)
Main fuse circuit
Parent contactor controller
Enabling and blocking of hydraulic and traction
drive
Traction drive
Controller, control system, monitoring
Hydraulic drive
Controller, control system, monitoring
Processing input signals from:
Accelerator, brake sensor, hydraulic sensor
Direction controls
All switches in the front of the vehicle
Discharge indicator
Con guration using parameters
Evaluation of the coarse and ne battery
voltage and current provided by the Supply
Unit.
Calculation and representation of the battery
residual capacity
Monitoring and safety concept
Add. electrical installation evaluation
FleetManager data (BDE) processing
Diagnostic, download
Storing vehicle parameters

50638042201 EN - 10/2017 -1
https://truckmanualshub.com/

Parameter backup for all other units

Servo hydraulics (option)
The buffer battery (G5)
Data storage, as well as storing time, date, km
counter and BDE
The operating hours are securely stored in the
EEPROM and are not lost even if the buffer
battery is empty

Direct wiring of all standard functions for the drive unit

X47, X46 42-pin SAAB plug 12 volt output voltage for external transmitter and switch
CANopen as standard
X48 42-pin SAAB plug Servo hydraulics (variant)

Supply of the drive direction turn indicator module (variant

X45 CAN bus connector
since June 2007)

G5 Cover Buffer battery

.

The hydraulic control unit is a variant of the truck

control unit MCU. The valve processor (VR) for
the servo hydraulics is built into the truck control
unit MCU as an additional printed circuit board.
From the outside, the variant can only be recog-
nised by the additional SAAB plug X48.
Construction, position and function are identical
to the truck control unit in the standard design.

X45 Drive direction turn indicator module (variant)

For further information, refer to the chapter X46 MCU series
entitled "Main Control Unit" X47 MCU series
X48 Proportional technology (variant)
The hydraulic control unit also takes over the G5 Buffer battery
following tasks in the truck control unit:
Evaluation of the control, joystick, mini-lever,
tip switch
Activation of the release valve
Activation of the individual solenoid coils in the
proportional valves
Distribution and forwarding of all signals
relevant to the proportional technology to the
truck control unit

-2 50638042201 EN - 10/2017
https://truckmanualshub.com/

MCU 2 is an enhancement of MCU 1 with a

larger processing capacity. New functions in the
truck are only supported by MCU 2. The MCU 1
software will no longer be developed with the
introduction of the new MCU 2.

MCU 2 replaces MCU 1 completely. In the event

of an error, MCU 1 is replaced by MCU 2. Retro t-
ting MCU 2 back to MCU 1 is not recommended.
MCU 2 can be identi ed clearly by referring to
the identi cation plate and the software version.
All software and hardware versions begin with
V2.xx.

Install MCU 2 as described in the chapter

entitled "MCU - removal and installation".
In trucks that are equipped with ABE 1, the
corresponding software ash package must
be loaded. Refer to the "Software overview"
documentation.

If the MCU needs to be changed, there is some

information that should be taken into considera-
tion before removal:
As a rule, the spare part MCU does not contain
any data or parameters.
The data and parameters are saved both in
the MCU and in the Supply Unit (SU) through
constant automatic backups.
Before carrying out service tasks, save a copy
of the truck parameters on the notebook.
It is important to take into consideration the
X45 Drive direction turn indicator module (variant)
truck equipment when ordering the MCU: X46 MCU series
Servo hydraulics (plug X48) X47 MCU series
Drive direction turn indicator module (plug X48 Proportional technology version
G5 Buffer battery
X45)

50638042201 EN - 10/2017 -3
https://truckmanualshub.com/

Park the truck safely.

Disconnect the battery male connector.
If necessary, remove the heating system.
Remove panelling at the front structure.
Disconnect the SAAB plugs and, as required,
the CAN bus connector.
Loosen the two M6 nuts and remove the MCU
from the threaded bolts.

Place the MCU onto the two threaded bolts

and tighten the M6 nuts.

Connect the SAAB plugs and, as required, the

CAN bus connector.
Fit the panelling to the front structure.
If necessary, install the heating system.
Connect the battery male connector.
Set key switch S1 to ON.
The truck parameter set is stored in the MCU. In
order to prevent a parameter loss, this parameter
set is available as a copy in the Supply-Unit (SU).
When one of the two components is changed, the
parameter set must be copied from the remaining
component.

There are two ways of copying:

Automatic transfer
Manual transfer
Also see the chapter entitled "Parameter man-
agement".

The automatic transfer is indicated in the display

by the PLEASE WAIT message with progress
bar. This process can take several minutes and
ends with a reset.

The manual transfer begins with the question in

the display A–EEPROM VALID?. This means:
"Are the parameters of the MCU (device A)
supposed to be used?"
Load software ash package and start cal-
ibration; see the chapter entitled "Software
compatibility"
Delete the error memory.
Function check.

-4 50638042201 EN - 10/2017
https://truckmanualshub.com/

The Supply Unit (SU) is attached to the coun-

terweight via the heat sink using a screw, and is
protected by panelling.
The position of the SU varies according to the
truck type.

From August 2014, the second-generation SU

will be installed for the rst time in the RX20
Facelift 2014 and later in all other truck types.
The SU 2 can be identi ed clearly by referring to
the identi cation plate and the software version.
All software and hardware versions begin with
V2.xx.

The SU performs the following tasks in the truck

control unit:
Pre-charging the inverter intermediate circuit
24-V power supply for the CAN bus
Distributing and forwarding the speed sensor
signals to the MCU
Monitoring the phasing of the motors
Emergency off
Processing input signals:
Inverter release
Additional electrical equipment variants
Discharge indicator:
Battery current measurement
Battery voltage measurement
Using correction parameters (adjustment
values), the coarse and ne battery voltage
is determined and forwarded to the MCU.
Activation of key switch S1
Activation of horn relay K1
Activation of signal horn 4H1

50638042201 EN - 10/2017 -5
https://truckmanualshub.com/

Since August 2006, the SU has contained a

built-in voltage transformer. The external MTM
voltage transformer that was previously neces-
sary is no longer required.
Voltage 24 V
Current 4.5 A
.

X41 16-pin SAAB plug Connection to the overhead guard

X42 16-pin SAAB plug Connection to the fuse card
Plug X43 has been omitted since August 2006. In the event
X43
of a conversion, please observe the changes in wiring.
X44 42-pin SAAB plug Truck chassis switch and sensors
X40 CAN bus plug CAN bus for variant (CPP)
.

To integrate an SU with a built-in voltage trans-

former into a truck electrical system with an MTM
external voltage transformer, the following adap-
tions must be made to the wiring harness:
Disconnect all the wires to the MTM at plug
X42
Discard the affected contacts at plug X42

X42:13 +24 Volt MTM

X42:14 GND-F
X42:15 U-Batt
X42:16 GND-L

-6 50638042201 EN - 10/2017
https://truckmanualshub.com/

If the wires remain in the truck, this can lead to malfunc-

tions in the electrical system.
Correctly remove the wires from the plug and close the
slots.

Close the slots in plug X42 with blind plugs

Remove the MTM

Park the truck safely.

Disconnect the battery male connector.
Remove trademark emblem, loosening the left
and right side screws but not unscrewing them
completely.
Optional: Disconnect plug X57 from the light
strip.
Remove the cover for the electronics.
Discharge the intermediate circuit, see chapter
"Intermediate circuit".

Do not touch energised contact points such as the

positive and negative connections of the power control
unit!
Before working on electrical power connections,
always check the voltage between all contacts and
between the contact and the truck chassis using a
suitable measuring device (capable of measuring up
to 1000V DC).
Discharge the intermediate circuit.

Disconnect all SAAB plugs and, if necessary,

the CAN bus connector at the SU.

50638042201 EN - 10/2017 -7
https://truckmanualshub.com/

Unscrew the mounting screw M10.

Remove the SU from the counterweight.
Clean the contact surfaces of the SU and
counterweight of all heat-conducting paste
residues.

Apply a 0.5 mm thick layer of heat-conducting

paste evenly over the contact surfaces of the
SU and counterweight.

The internal power electronics in the converters and

control units generate high temperatures that can lead
to the destruction of these components.
Apply a 0.5 mm thick layer of heat-conducting paste
evenly over the clean contact surfaces.
Check tightening torques and mounting elements.

Position the SU on the contact

surface in the counterweight and move under
the joining plate of the sheet metal cover.
Position the SU on the contact
surface in the counterweight.

Combine two disc springs in parallel to form

a packet, and combine each two packets in
alternate directions. Tightly screw the socket
head screw M10x30 to the spring column;

Connect all SAAB plugs and, if necessary, the

CAN bus connector at the SU.
Install and tighten the cover for the electronics.
Install the trademark emblem.
Optional: Connect plug X57 of the light strip.
Connect the battery male connector.
Set key switch S1 to ON.
The truck parameter set is stored in the MCU. In
order to prevent a parameter loss, this parameter
set is available as a copy in the Supply-Unit (SU).
When one of the two components is changed, the
parameter set must be copied from the remaining
component.

-8 50638042201 EN - 10/2017
https://truckmanualshub.com/

There are two ways of copying:

Automatic transfer
Manual transfer
Also see the chapter entitled "Parameter man-
agement".

The automatic transfer is indicated in the display

by the PLEASE WAIT message with progress
bar. This process can take several minutes and
ends with a reset.

The manual transfer begins with the question in

the display A–EEPROM VALID?. This means:
"Are the parameters of the MCU (device A)
supposed to be used?"
Load software ash package and start cal-
ibration; see the chapter entitled "Software
compatibility".
Delete the error memory.
Function check.

50638042201 EN - 10/2017 -9
https://truckmanualshub.com/

2U03 2M1 1U06 1M1 - FM1 right

1U07 1M2 - FM2 left

Each of the asynchronous motors available in

the truck is controlled by its own converter. The
converters are attached to the counterweight via
a heat sink and are protected by panelling.
The position and number of the converters, and
their performance data, vary according to the
truck type. The converters perform identical
functions in the truck control unit.

The converters perform the following tasks in the

truck control unit:
Control and regulation of the relevant motor
Speed measurement
Temperature measurement and monitoring
Communication with truck control unit MCU
Communication with the Supply Unit

LAC 1 - HAF 400 48 V 540 A A 2

LAC 1A - HAFS 400 48 V 404 A A 3

LAC 1 - HAF 600 48 V B 2

LAC 1 - HAFS 600 48 V 540 A B 3

LAC 1 - HAF 400 80 V 316 A C 2

-10 50638042201 EN - 10/2017

https://truckmanualshub.com/

LAC 1 - HAFS 400 80 V C 3

LAC 2 - HAF 600 80 V 612 A E 2

LAC 2 - HAFS 600 80 V D 3
.

(1) 2 disc springs in the same direction

(2) 2 packages each in the opposite direction
(3) 2 disc springs in the same direction

Heat sink on counterweight

34 Nm
Screw M10 x 30, DIN 912
Power cable stud bolt
Nut M8 10 Nm
Conical spring washer
.

Batt. (GND-L)
+ U-Batt after main contactor
U Motor eld connection
F Motor eld connection
W Motor eld connection
X150
X151 Control wiring harness
X152

Pin 1 V monitoring (not used)

Pin 2 Not assigned
Pin 3 Temperature sensor +
Pin 4 Temperature sensor
Pin 5 Rev sensor track A from supply unit
Pin 6 Rev sensor track B from supply unit
Pin 7 Rev sensor 10 V
Pin 8 Rev sensor GND-L
Pin 9 U monitoring (not used)
Pin 10 Not assigned
Pin 11 Enable signal from supply unit
Pin 12 Not assigned
Pin 13 CAN H connected to supply unit
Pin 14 CAN L connected to supply unit

50638042201 EN - 10/2017 -11

https://truckmanualshub.com/

Pin 15 24 V from supply unit

Pin 16 GND-F from supply unit
.

SAC 1 - 400 48 V 400 A A

SAC 1 - 600 48 V 600 A B

.

(1) 2 disc springs in the same direction

(2) 2 packages each in the opposite direction
(3) 2 disc springs in the same direction

Heat sink on counterweight

Screw M10 x 30, DIN 912 34 Nm
Disc springs 4 x A20, DIN 2093
Power cable stud bolt
Hexagon nut MS 8, ISO 4032 8 Nm
Spring washer MS 8.4, ISO 7089
.

Batt. (GND-L)
+ U-Batt after main contactor
U Motor eld connection
F Motor eld connection
W Motor eld connection
X150
X151 Control wiring harness
X152

Pin 1 Rev sensor GND-L

Pin 2 GND-F from SU
Pin 3 Rev sensor track A from SU
Pin 4 CAN H connected to SU
Pin 5 Rev sensor track B from SU

-12 50638042201 EN - 10/2017

https://truckmanualshub.com/

Pin 6 CAN L connected to SU

Pin 7 Rev sensor 10 V
Pin 8 24 V from SU
Pin 9 U monitoring (not used)
Pin 10 Enable signal from SU
Pin 11 V monitoring (not used)
Pin 12 Temperature sensor +
Pin 13 W monitoring (not assigned)
Pin 14 Temperature sensor
.

It is not recommended to change the converter

types from LAC to SAC because various compo-
nents are not compatible:
Threaded holes in the counterweight
Wiring harness
Conductor rails

Do not touch energised contact points such as the

positive and negative connections of the power control
unit!
Before working on electrical power connections,
always check the voltage between all contacts and
between the contact and the truck chassis using a
suitable measuring device (capable of measuring up
to 1000V DC).
Discharge the intermediate circuit.

Work carefully to ensure that no parts fall into

the electrical system.
The views of the conductor rails may differ
from the actual condition in the truck.
The conductor rails are dependent on the
converter type (LAC / SAC).

50638042201 EN - 10/2017 -13

https://truckmanualshub.com/

Park the truck safely.

Disconnect the battery male connector.
Remove trademark emblem, loosening the left
and right side screws but not unscrewing them
completely.
Optional: Disconnect plug X57 from the light
strip.
Remove the cover for the electronics.
Discharge the intermediate circuit.
Remove the supply unit.
Remove the CPP as required.
Remove the fuse plate.
Unscrew the conductor rails to the converters.

Remove the conductor rail package with the

lower insulation foil from the counterweight.
Disconnect plug X150 or X151, X152.
Loosen the three phases U, V, W.
Loosen the four mounting screws with short
extender and 8-mm hexagon socket.
Remove the converters.
Clean the contact surfaces of the converters
and counterweight of all heat-conducting paste
residues.

-14 50638042201 EN - 10/2017

https://truckmanualshub.com/

Work carefully to ensure that no parts fall into

the electrical system.
The views of the conductor rails may differ
from the actual condition in the truck.
The conductor rails, mounting elements and
tightening torques are dependent on the
converter type (LAC / SAC).

Converters are destroyed by overheating!

Apply a thin layer (approx. 0.5 mm) of heat-conducting
paste evenly over the clean contact surfaces.
Check tightening torques and mounting elements.

Before installation, check whether the bottom

plate of the converter lies ush on the contact
surfaces in the counterweight.
Apply a thin layer (approx. 0.5 mm) of heat-
conducting paste evenly over the contact
surfaces of the converter and counterweight.

Risk of short circuit in the motor wiring!

The cable shoes of the motor cables must not come
into contact with the conductor rails.

Position the converters on the contact surface

in the counterweight.
Combine two disc springs (1, 3) in parallel to
form a packet, and combine each two packets
(2) in alternate directions, then tighten with a
socket head screw.

Screw in the three phases U, V, W evenly.

50638042201 EN - 10/2017 -15

https://truckmanualshub.com/

Screw the conductor rails to the converters.

Connect plug X150, X151, X152.
Install the fuse plate.
Install the CPP as required.
Install the supply unit; see the chapter entitled
"Removing and installing the supply unit".
Install and tighten the cover for the electronics.
Install the trademark emblem.
Optional: Connect plug X57 of the light strip.
Connect the battery male connector.
Functional test

-16 50638042201 EN - 10/2017

https://truckmanualshub.com/

The acid density can be used to calculate the

no-load voltage U o per battery cell.
Uo [volts] = acid density [kg/l] + 0.84
The acid density is tested using an acid siphon
(hydrometer). The acid density can be read off
directly on the oat of the acid siphon.
The acid density decreases as the battery dis-
charges.
Once the charging process is complete, it takes
a certain amount of time for the acid above the
plates to mix with the acid between the plates
and then settle. In order to obtain accurate
values, the measurement must only be taken
approx. 30 minutes after the charging process is
complete.

PzS (standard lead 1.27 2.11 100%

battery) < 1.13 < 1.97 20% (deep discharge)
PzS/L (performance- 1.29 2.13 100%
enhanced lead battery) < 1.13 < 1.97 20% (deep discharge)
1.29 2.13 100%
CSM (gel battery)
< 1.15 < 1.99 20% (deep discharge)
.

When switching on a fully charged, unloaded

battery, it must have a of at least
2.1 V per cell. This corresponds to a
of 100%.
The no-load voltage of the battery reduces as
discharging progresses and depends on the
. The stronger
the discharge current, the lower the available
.
The discharge limit is determined using the
. Discharging the battery
below the discharge limit is known as
A Nominal battery capacity
. B Available battery charge
To avoid deep discharge, the nal discharge volt- C Residual battery capacity
age is limited by means of the . D Available residual battery charge
X Shut-off threshold
If the cut-off threshold is reached, a hydraulic
Y Warning threshold
restriction can be activated through parameteris-
ing.
Before the cut-off threshold is reached, it is
possible to determine the residual charge still

50638042201 EN - 10/2017 -1
https://truckmanualshub.com/

available via the . A ashing

battery indicator in the display activates an alarm
indicating the level of residual charge left.

The ideal operating temperature for batteries is

between 20°C and 40°C. However, the maximum
battery capacity is only reached at an optimum
temperature of 27 - 30°C.
A decrease in temperature reduces the battery
capacity by 1% for every 1°C. At a temperature of
0°C, the battery has a capacity loss of 27%. Only
73% of the maximum capacity remains available.
Electrolyte temperatures of over 55°C cause
permanent damage to the battery and shorten
the service life considerably.

If the battery is incorrectly handled, lead and sul-

phur bond together to form a hard lead sulphate.
This process is known as permanent or hard sul-
phation.
Permanent sulphation can be detected by the
discolouration of the plates. The positive plates
turn light brown and the negative plates turn
a matt, off-white colour. Sulphation reduces
the capacity of the battery and its ability to be
recharged.

Reasons for a sulphated battery:

Frequent deep discharging
Incorrect full charge
Charging current too low
Frequent intermediate charging
Battery temperatures of over 55°C when
charging and discharging

Always follow the battery manufacturer's notes

and rules regarding the correct handling proce-
dure for batteries.

-2 50638042201 EN - 10/2017
https://truckmanualshub.com/

The display-operating unit shows the battery

charge (1) as a segmented bar graph in 10%
stages (2). At two bars, the display starts to ash.
Hydraulic restriction is activated once no bars are
visible. Speed reduction can also be activated
via parameterisation.
Every 10 seconds, the display switches from
showing the battery charge to the remaining
operating time (3).
The power rating indicator (4) shows the current
average energy consumption (6). Trends relating
to the energy consumption (5) are displayed as a 1
vertical bar graph. 2 Available battery charge [%]
3 Remaining operating time [h]
4
5 Typical energy consumption (trend)
6 Average energy consumption [kWh/h]
The display shown corresponds to the standard
setting. The displays can be changed and adju-
sted via parameterisation.

The measuring procedure of the battery dis-

charge indicator uses the voltage behaviour of
the battery to determine the maximum charging
state, or SOC (State-Of-Charge).
The recovery phase of the battery plays a role
in this process. The measuring procedure is
optimised for short battery recovery phases. An
older battery can become increasingly inactive,
which increases the recovery phase. As a result
of this battery characteristic, the measured value
can be up to 20% too high at a high charge level.
The improved initial measurement checks
whether the battery has been recharged or not
when the truck is switched on. If the battery has
not been charged, the value used is the last value
measured before the truck was switched off. As
a result, the actual charging state of the battery is
displayed when the truck switched on.
The lower cell voltage value can be adjusted dur-
ing the initial measurement via parameterisation.
If the value is not parameterised or is incorrectly
parameterised, an error message will appear.

Speci cation 1.97

Value range 1.95 2.05
.

50638042201 EN - 10/2017 -3
https://truckmanualshub.com/

The discharge indicator is based mainly on three

measuring procedures or calculation procedures:
Discharge measurement (voltage measure-
ment)
Calculation of the charge drawn (current
measurement)
No load measurement
In addition, saved values from these measure-
ments are used for the calculation.
The battery voltage is measured at the inter-
mediate circuit. Using correction parameters
(speci ed adjustment values), the voltage is
determined here as ne battery voltage. This
internally measured value cannot be measured
by the service centre. The ne battery voltage is
transmitted to the MCU.
The MCU processes this value in accordance
with the parameters and subsequently calculates
the available battery charge.

The remaining period shows how long the truck

can continue to be used until the indicated avail-
able battery charge is 0% (no bars).
The remaining operating time is dependent
on the actual battery charge status (SOC) and
average energy consumption.
The average energy consumption is calculated
from the consumption by the drive functions
and hydraulic functions.
The energy consumption is averaged out over
the preceding 30 minutes.
The drive program and the drive mode have
an effect on the remaining operating time.
The impact on the remaining operating time is
determined by certain factors:
Switching to a more energy-ef cient drive
programme increases the remaining period by
approximately 5%.
Switching to BLUE Q increases the remaining
period by approximately 10%.

-4 50638042201 EN - 10/2017
https://truckmanualshub.com/

If the driver switches on a more energy-

ef cient drive programme or BLUE Q, the
remaining period increases sharply.
If the driver switches on a more energy-
intensive drive programme or sprint mode,
the remaining period decreases sharply.
The driver can in uence the remaining oper-
ating time via his driving style and the driving
cycle.
The remaining period decreases faster than
expected in the BLUE Q drive mode if, for
example, the hydraulic functions are used a
lot.
When the truck is switched off, the last
recorded values for the average energy con-
sumption and the remaining period are re-
tained. Both values change when the truck is
driven.

The power rating indicator shows the average

energy consumption [kWh/h] and trends.

Average energy consumption

The average energy consumption is calculated
from the consumption by the drive functions
and hydraulic functions.
The energy consumption is averaged out over
the preceding 30 minutes.

Trend display
The trend display supplements the average
energy consumption display.
The trend display compares the current
energy consumption with the average energy
consumption.
The current energy consumption is averaged
out over the preceding ve minutes.
When the truck is switched on, the trend
symbol for the average energy consumption
is displayed. The trend display only changes
once the truck is in operation.

Signi cant increase (> 50%)

Increase (up to 50%)
Slight increase (up to 30%)
Average; no change
Slight decrease (up to 30%)
Decrease (up to 50%)
Signi cant decrease (> 50%)
.

50638042201 EN - 10/2017 -5
https://truckmanualshub.com/

The display and operating unit displays the bat-

tery charge either as 10 bars or as a percentage.
At 20% residual battery charge or two bars, the
display starts to ash.
At 0% residual battery charge or no bars, restric-
tion of the hydraulics is activated.

The diagram shows the proportion of battery ca-

pacity that is available for use, and the proportion
that is processed by the discharge indicator.
(A) = 100% nominal battery capacity
(B) = 100% of the available battery charge,
equivalent to approx. 80% of nominal battery
capacity. The display shows battery charge
either as 10 bars or as a percentage.
(C) = approx. 20% of the battery's residual
capacity, which is not available. This protects
the battery from deep discharging.
A Nominal battery capacity
(D) = The available residual charge in the battery, B Available charge in battery
indicated by a ashing battery indicator in the C Remaining capacity of battery
display. D Remaining available capacity of battery
X Switch-off threshold
(X) = Cut-off threshold, a con gurable value that
Y Warning threshold
determines the discharge limit and activates
hydraulic limitation. Valid value range: 1.83 2.00
Volt per cell; default 1.94 Volt per cell.
(Y) = Warning threshold, a con gurable value
which indicates the residual charge by means of
a ashing battery indicator. Valid value range:
0 100%; default 20%.

The discharge indicator depends mainly on three

measuring or calculating procedures:
Discharge measurement (voltage measure-
ment)
Calculating the charge drawn
Idling measurement
These measuring procedures are not affected by
parameterisation.
The battery voltage is measured at the inter-
mediate circuit. Using correction parameters
(speci ed adjustment values), the voltage is

-6 50638042201 EN - 10/2017
https://truckmanualshub.com/

determined here as ne battery voltage. This in-

ternally measured value cannot be measured by
the service centre.
The ne battery voltage is transmitted to the
MCU. The MCU processes this value in accor-
dance with the parameters and subsequently
calculates the residual battery charge. This is
then shown in the display.

The battery's recovery phase plays a key role in

the initial measurement. The measurement is
optimised for short battery recovery phases. An
older battery can become more inactive, which
increases the recovery phases. In the interests
of safety, the lower value of the cell voltage can
be adjusted during the initial measurement by
means of parameterisation.
The mandatory default value is 1.97 Volt per cell.
(Valid value range: 1.95 2.05 V). If this address is
not parameterised or incorrectly parameterised,
an error message will appear.

The battery male connector consists of two parts:

X1: The battery male connector is the utility
socket on the traction battery
X2: The appliance plug is a component of the
truck
The battery male connector (X1) is equipped
with a handle and is connected rmly to the
battery via contact bushings. The coding (C)
prevents unsuitable operating voltages from
being connected and prevents batteries from
being connected to unsuitable battery chargers.
The appliance plug (X2) is mounted on the right
side of the counterweight on a support mounting.

X2 (+) XS1 (Batt +) F01 1K1

X2 (-) XS5 (GND L)
.

50638042201 EN - 10/2017 -7
https://truckmanualshub.com/

Each appliance plug must be equipped with an

encoder, which ensures that a male connector
can only be inserted into a female connector with
the same operating voltage.
The coding is dependent on the battery voltage
and battery technology (wet battery or dry bat-
tery).

A Pin
B Bushing
C Coding
D Voltage coding
E Application coding

N.2 Pin housing for charging station - wet battery

"N"
N.1 Bushing housing for battery connector - wet
battery "N"
T.2 Pin housing for charging station - dry battery
"T"
T.1 Bushing housing for battery connector - dry
battery "T"
U.1 Pin housing for truck, universal "U"

Both halves of the plug are equipped with a

coding pin between the contacts for this purpose.
The coded operating voltage is visible in one
section of the housing for the appliance plug.

As an option, appliance plugs can be equipped

with pilot contacts or auxiliary contacts.
Pilot contacts are used to protect against the
battery male connector being improperly discon- 1 Coding for battery bushing housing
nected from the battery charger when the battery T.1 Bushing housing - dry battery
is being charged. The pilot contact ensures that N.1 Bushing housing - wet battery
the charging current is switched off at the battery
charger before the plug main contacts are dis- 2 Coding for charging station pin housing
connected completely. T.2 Pin housing for charging station - dry battery
N.2 Pin housing for charging station - wet battery
The charger has to be adequately equipped.

3 Coding for truck pin housing

U.3 Pin housing, universal

Appliance plugs can be equipped with integrated

ventilation for batteries with electrolyte circula-
tion. The ventilation design is manufacturer-spe-
ci c and is therefore incompatible with different
appliance plugs. The ventilation design is not
currently standardised.

-8 50638042201 EN - 10/2017
https://truckmanualshub.com/

The equipment speci ed can be used in the

following combinations:
Plug/socket
Plug/socket with two pilot contacts
Plug/socket with ventilation
Plug/socket with ventilation and two auxiliary
contacts
Plug/socket with two pilot contacts and two
auxiliary contacts

Appliance plugs are battery plug connectors

that are tted in all electric trucks, and to traction
batteries, battery chargers and charging stations.

Linguistic de nition:
The is a component of the truck
The is the utility socket
on the traction battery
The is the appliance plug
of the battery charger or the charging station

Damaged appliance plugs and utility sockets can

cause damage to other appliance plugs and utility
sockets as a result of alternating operation.
All appliance plugs and utility sockets belonging to a
truck, battery and battery charger must be checked
and replaced as required.

Check the housing and handle for damage

Check the strain relief for correct operation
Check the contact lock for correct operation
Check the coding pin for damage
Check the main current contacts for damage
Optional: Check the air duct for leaks and
correct operation
Optional: Check the pilot contacts

Damage to the main current contacts is dif cult to

detect. Therefore, special care is important in this
case. The images provide examples of damage
to the main current contacts.

50638042201 EN - 10/2017 -9
https://truckmanualshub.com/

Main current contacts with clear fusing and

burn-off:

Broken main current contacts:

Battery male connector with damage due to acid.

Battery male connectors covered with acid can da-

mage battery charger plugs and appliance plugs.
If a plug covered with acid is noticed during mainten-
ance, all plug partners must be checked for damage.

Contact bolt is damaged or is missing completely:

-10 50638042201 EN - 10/2017

https://truckmanualshub.com/

Strip the cable along ; refer to the

table below

16 to 25 18
35 to 50 20
70 to 95 25

Damage to the separate wires causes a reduction in

the cross-section. This leads to incorrect crimping,
poorer transition resistance and increased heating.
Use a suitable tool.

Using shrink tube if required, push the contact

element onto the stripped cable end and crimp
behind the contact retaining ridge using
the appropriate crimping die.
Perform the crimping process until it is clearly
noticeable that the pressure relief valve has
been triggered.
After the crimping process, the gap between
the insulation and the contact element must be
no more than .
Open the crimping pliers using the release
lever.

Only crimp each contact once!

Strip the cable along ; refer to the

table below

SB 50 14
SB 120 24
SB 175 29
SB 250 35

Damage to the separate wires causes a reduction in

the cross-section. This leads to incorrect crimping,
poorer transition resistance and increased heating.
Use a suitable tool.

50638042201 EN - 10/2017 -11

https://truckmanualshub.com/

Using shrink tube if required, push the contact

element onto the stripped cable end and crimp
using the appropriate crimping die.
Start with the distance (MIN) of the rst crimp.
Depending on the plug, then complete a
second crimp. Refer to the table for the
relevant dimensions.

SB 50 6.5
SB 120 10
SB 175 20 6.5
SB 250 22 13

Perform the crimping process until it is clearly

noticeable that the pressure relief valve has
been triggered.

Open the crimping pliers using the release

lever.

When working with reducer sleeves on battery

main contacts, the following is to be noted:
Only one reducer sleeve may be used per
contact
The use of reducer sleeves affects the maxi-
mum current load of a battery male connector.
The smaller wire cross-section reduces the
maximum current load
Only appliance plugs from a single manufac-
turer and of a particular type may be connected
The use of the reducer sleeve is dependent on
the manufacturer; refer to the tables below

[mm2]
[mm2] [mm2]
50 70 70 to 50 No No Yes No No Yes
35 50 50 to 35 No Yes Yes No Yes No
25 50 50 to 25 No Yes Yes No Yes No
16 35 35 to 16 No No No No No No
16 25 25 to 16 Yes No No Yes No No
.

-12 50638042201 EN - 10/2017

https://truckmanualshub.com/

[mm2]
[mm2] [mm2]
50 70 70 to 50 No No No No No
35 50 50 to 35 No Yes Yes Yes Yes
25 50 50 to 25 No Yes Yes Yes Yes
16 35 35 to 16 Yes Yes No Yes No
16 25 25 to 16 Yes Yes No Yes No
.

50638042201 EN - 10/2017 -13

https://truckmanualshub.com/

-14 50638042201 EN - 10/2017

https://truckmanualshub.com/

High-pressure gear pump

Type
Anticlockwise direction of rotation
Delivery rate per rotation [cm3] 11 14

2 x socket head screws M10 x 105, 10.9, DIN

Hydraulic pump [Nm] 56
912
2 x socket head screws M6 x 50, 8.8, DIN 912
Suction ange [Nm] 9 +1
2 x socket head screws M6 x 20, 8.8, DIN 912
[Nm] 9 +1 4 x socket head screws M6 x 35, 8.8, DIN 912
[Nm] 35 LS
Priority valve
[Nm] 90 EF
[Nm] 70 CF

Steering rpm 400 800 Dynamic alignment

Auxiliary hydraulics See the chapter entitled "Auxiliary hydraulics"

Lifting rpm 3500 2800

Tilting Nominal lift < 3500 rpm 1150 1300
Tilting Nominal lift 3500 5000 rpm 800 630
Tilting Nominal lift > 5000 rpm 550 450

Lifting rpm 3500 2600

Tilting Nominal lift < 3500 rpm 1150 1300
Tilting Nominal lift 3500 5000 rpm 800 640
Tilting Nominal lift > 5000 rpm 550 500
.

Quality as per DIN 51524/part 3

Hydraulic oil, total lling quantity [l] 27
HVLP or ISO VG 68
.

Degree of ltration [µm] 20

Operating pressure (maximum) [bar] 10
Triggering pressure - bypass valve [bar] 3.4 ± 0.3

50638042201 EN - 10/2017 -1
https://truckmanualshub.com/

Maintenance interval 3000 h or 2 years

Tightening torque for maintenance
[Nm] 20 Tighten by hand
cover

Degree of ltration [µm] 135

Maintenance interval Maintenance free

Degree of ltration [µm] 2 absolute

Maintenance interval 3000 h or 2 years

Degree of ltration [µm] 12

Tightening torque for hydraulic
[Nm] 200+20 Pipe union M33 x 2
connections
Maintenance interval 3000 h or 2 years
.

Switch on the key switch

Lower the fork carriage
Switch off the key switch
Actuate all operating levers several times up to
their end positions

-2 50638042201 EN - 10/2017
https://truckmanualshub.com/

The pressure in the hydraulics can be relieved

on trucks equipped with MCU 2 with software
version 2.06 or later.
On trucks equipped with FleetManager or
SIC, access authorisation must be enabled.
Switch on the key switch
Lower the fork carriage
Switch on the hazard warning system. Ac-
tuate the push button, even if the truck is not
F1 F2

equipped with a hazard warning system.

F1
F2

Switch off the key switch

By actuating the hazard warning system, the
electrical system will be prevented from switching
off. The switch lock deactivates the converters
and opens the main contactor.
Now actuate the operating lever (1) for lifting, 1 1
tilting and the auxiliary hydraulics.
Open the valves without the pump motor running.
The pressure in the hydraulic system is relieved.

1
6311_003-034_V2

Switch on the key switch

Lower the fork carriage
Press the (1, 2, 3, 4) buttons at the same time

50638042201 EN - 10/2017 -3
https://truckmanualshub.com/

Tolerance ± 12%

min. 0.40 0.40 0.40

max. 0.52 0.50 0.50
min. 0.40 0.38 0.38
max. 0.50 0.48 0.48
min. 0.35 0.34 0.34
max. 0.45 0.44 0.44
Maximum permissible single values from lift 1 and lift 2 = 0.6 m/s

Tolerance ± 12%

min. 0.47 0.46 0.45

max. 0.59 0.58 0.57
min. 0.46 0.44 0.43
max. 0.58 0.56 0.55
min. 0.40 0.38 0.37
max. 0.50 0.48 0.47
Maximum permissible single values from lift 1 and lift 2 = 0.6 m/s

Lift 1: Middle cylinder is extended.

Lift 2: Outer cylinder is extended.
For NiHo and triple lift masts, the mean value
of the speeds measured for Lift 1 and Lift 2 is
the one that counts.
The maximum permissible single value from
lift 1 and lift 2 must not be exceeded.
Speeds are measured at operating tempera-
ture.

Special equipment tted to trucks may result in

values varying from those stated.

, ,
Min. 0.41
Max. 0.60

-4 50638042201 EN - 10/2017
https://truckmanualshub.com/

Min. 0.41
Max. 0.60
Min. 0.38
Max. 0.60
Min. 0.41
Max. 0.60
Min. 0.41
Max. 0.60
Min. 0.38
Max. 0.60
The fastest value at nominal load
Min. Tele - value from lift 1
NiHo/triple - value from lift 2
Max. Individual value with nominal load from lift 1 and lift 2

Lift 1: Middle cylinder is extended.

Lift 2: Outer cylinder is extended.
Speeds must be measured at operating
temperature.

The maximum lowering speed of 0.60 m/s must not be

exceeded!
Do not adjust settings on lowering brakes.

min. 0.6 0.7 0.8 1.0. 1.1 1.2 1.3

3500 max. (1) 1.0. 1.2 1.4 1.6 1.8 2.0 2.2
max. (2) 1.2 1.4 1.6 1.9 2.1 2.4 2.6
min. 1.0. 1.2 1.4 1.6 1.8 2.0 2.2
3500 5000
max. 1.8 2.2 2.5 2.9 3.3 3.7 4.0
min. 1.4 1.7 2.0 2.3 2.6 2.9 3.1
5000
max. 2.8 3.4 3.9 4.5 5.1 5.6 6.2
(1): Hand lever
(2): Servo hydraulics

50638042201 EN - 10/2017 -5
https://truckmanualshub.com/

min. 0.4 0.5 0.6 0.7 0.8 0.9 1.0.

3500 max. (1) 0.8 1.0. 1.2 1.4 1.5 1.7 1.9
(2)
max. 0.9 1.2 1.4 1.6 1.7 2.0 2.2
min. 0.9 1.1 1.2 1.4 1.5 1.7 1.9
3500 5000
max. 1.6 1.9 2.2 2.5 2.8 3.1 3.4
min. 1.4 1.7 2.0 2.3 2.6 2.9 3.1
5000
max. 2.4 2.8 3.3 3.8 4.3 4.8 5.2
(1): Hand lever
(2)
: Servo hydraulics

Measurement is performed over the entire tilt

range.
Speeds are measured at operating tempera-
ture.

Operating error!
With the simultaneous actuation of more than one
valve function, higher tilt speeds may occur.

-6 50638042201 EN - 10/2017
https://truckmanualshub.com/

Pick up the nominal load and lift free of the

ground.
Park the truck on level ground and place the lift
mast in the vertical position.
Apply the parking brake.
Attach an angle measurement device, e.g. a
spirit level (1) to the mast pro le (2).
Check whether the tilt slider of the directional
control valve is in the neutral position.
Turn the key switch to OFF.
Measure the change in angle after one minute.
The lift mast must not tilt forwards automatically
by more than 5° in 10 minutes.

Pick up the nominal load and lift to approx. 0.5

m.
Park the truck on level ground and place the lift
mast in the vertical position.
Apply the parking brake.
Check whether the lift transmitter of the
directional control valve is in the neutral
position.
Turn the key switch to OFF.
After approx. 2 minutes, apply markings to the
fork carriage and outer mast.
After waiting another 10 minutes, measure the
distance lowered.
The lift mast must not automatically lower the
load by more than .

50638042201 EN - 10/2017 -7
https://truckmanualshub.com/

All hose lines must be checked at least once a

year and must be replaced in the event of the
following defects:
The outer layer is breached all the way to the
middle (wire mesh), e.g. abrasion spots and
cracks.
There is a connection error on the tting with
bubble formation.
Leaks.
There is damage or corrosion at the tting and
reduced rigidity of the connection between the
tting and the hose has been detected.
The outer layer has been become stiff or brittle
with cracks.
There are deformation such as kinks, pinch
points and torsion.

-8 50638042201 EN - 10/2017
https://truckmanualshub.com/

1 Steering unit 8 Suction lter

2 Steering return line 9 Working hydraulics pressure line
3 Steering pressure line 10 Working hydraulics return line
4 Pump motor 11 Directional control valve block
5 Priority valve 12 Return lter
6 Hydraulic pump 13 Breather, dipstick
7 Induction hose

The hydraulic pump (6) is driven by the pump The returning oil from the steering hydraulics
motor (4) via a tappet. Together they constitute ows back to the tank un ltered.
the pump unit.
The returning or excess oil from the working
The hydraulic pump and the suction hose (7) are hydraulics ows back to the tank via the return
located the oil level in the hydraulic tank. lter (12).
The welded hydraulic tank is built into the chassis.
If the return lter is clogged, the by-pass valve
The hydraulic pump draws the oil via a coarse, opens and the oil returns to the tank un ltered via
maintenance-free suction lter (8) and delivers it the by-pass valve.
to the priority valve (5).
The breather (13) prevents soiling as the result of
The priority valve is ange-mounted to the hy- dirty air and is combined with the dipstick to form
draulic pump and handles the oil distribution a single unit.
between the steering hydraulics and working hy-
draulics.

50638042201 EN - 10/2017 -9
https://truckmanualshub.com/

1 Steering angle sensors 6 Priority valve

2 Steering unit 7 Hydraulic pump
3 Return line 8 Suction hose
4 LS signal line 9 Directional control valve block
5 Pressure line 10 Steering cylinder connection

The hydraulic pump (7) draws in the hydraulic As soon as the truck is driving at a speed of
oil from the hydraulic tank at the intake side and > 0.1 km/h, the pump motor starts running.
delivers it to the priority valve at the pressure
The oil volume required for steering is signi -
side. The oil quantities required for steering and
cantly lower than the oil volume required for the
the working hydraulics are allocated in the priority
working hydraulics. For this reason, the speed is
valve. The steering always takes priority.
adjusted to a low value (steering speed) when the
The volume of oil required for steering is delivered working hydraulics are not actuated. The steer-
via the pressure line (5) to the steering unit (2). ing speed is adjusted according to the steering
movement and the speed at which the steering
The return line (3) directs the hydraulic oil back
wheel is turned. See the chapter entitled "Steer-
into the hydraulic tank un ltered.
ing system - Dynamic steering".

-10 50638042201 EN - 10/2017

https://truckmanualshub.com/

1 Priority valve 7 Connection P

2 Hydraulic pump 8 Connection H
3 Suction hose 9 Connection R (return line)
4 Pressure line 10 Forwards tilt cylinder
5 Connection B 11 Backwards tilt cylinder
6 Connection A 12 Lift cylinders

The hydraulic pump (2) supplies the oil to the If a slider is only actuated slightly, the oil ows with
priority valve (1) via the suction hose (3). The oil a low circulation pressure through the directional
quantities required for steering and the working control valve block from connection R to the tank
hydraulics are allocated in the priority valve. via the return line (9).
Steering always has the highest priority.
The directional control valve block contains the
The oil volume for the working hydraulics is fed following functional components:
from the priority valve via the pressure line (4) to
The pressure relief valve protects the hydraulic
the directional control valve connection P.
system against overloading.
When a slider is actuated, an oil volume cor- The lowering brake limits the lowering speed
responding to the displacement of the slider is when lowering the load.
supplied from connection H to the lift cylinders,
Two load holding valves prevent the load from
from connection A or B to the tilt cylinders and, if
tilting on its own.
necessary, to an attachment in the auxiliary hy-
draulics. The ow control valve limits the oil ow for
tilting.

50638042201 EN - 10/2017 -11

https://truckmanualshub.com/

The hydraulic tank is a welded component built

into the chassis at an angle in front of the battery
compartment.
The lter housing is xed to the tank by means of
4 nuts.
The return lines of the directional control valve
and steering unit are screwed to the lter housing.
Sealing is accomplished by means of sealing
rings.
The suction connection is located below the oil
level.
1 Hydraulic tank
The breather is combined with the dipstick in the 2 Directional control valve block return line
lter housing. 3 Return lter cover
4 Breather lter with dipstick
5 Steering hydraulics return line
6 Fixing screws
7 Filter housing
8 Fixing screws
9 Oil drain plug
10 Suction connection

Fill quantity of hydraulic oil with carriage lowered

and hydraulic system ready for operation:
For the total lling quantity, see the chapter
entitled "General Technical Data"
For quality, see the chapter entitled "General
Technical Data"

Maintenance interval
3000 operating hours or 2 years

Hydraulic oil should be disposed of according to

the environmental regulations.
Position truck horizontally.
Tilt lift mast backwards against stop.
Lower fork carriage; if there are attachments,
retract working cylinder.
Disconnect battery plug.
Remove oorplate.
Unscrew the dipstick and remove it

-12 50638042201 EN - 10/2017

https://truckmanualshub.com/

Unscrew the hydraulic oil drain plug under the

hydraulic oil tank; direct the hydraulic oil into a
collection vessel.
Screw in drain plug with a new seal (Cu
A18x22) and tighten

Fill with fresh hydraulic oil through the oil

dipstick opening
The oil level should be between the markings
on the dipstick.
Reinsert the dipstick and tighten it

The hydraulic oil that returns from the directional

control valve block is ltered in the return line
lter. The hydraulic oil that returns from the
steering ows back into the tank un ltered.
If the return line lter is clogged, the hydraulic oil
is rerouted via a bypass and subsequently ows
back into the tank un ltered.

1 Return line lter cover

2 Breather lter
3 Bypass valve
4 Seal
5 Return line lter
6 Dipstick
7 Steering return pipe

50638042201 EN - 10/2017 -13

https://truckmanualshub.com/

Degree of ltration 20 µm absolute

Filter material Plastic mesh
Housing material Polyamide PA66
Triggering pressure - bypass valve 3.4 +0.5 bar -0.2 bar
Tightening torque 11 Nm, 4 x M8 polystop nut with at washer
Maintenance interval 3000 h or 2 years

The lter element must be disposed of in accor-

dance with environmental regulations.

Unscrew the lter cover

Unhook the lter cover from the lter element
and replace
Hook the lter cover onto lter element
Screw in the lter cover

Disconnect the return lines

Undo the 4 fastening nuts on the tensioned
cover
Completely remove the lter housing from the
tank
Place the seal in the tensioned cover for the
lter housing
Insert the lter housing into the tank
Screw in four fastening nuts M8 with washers
tightly
Connect the return lines

-14 50638042201 EN - 10/2017

https://truckmanualshub.com/

The breather lter and the oil dipstick form a unit

and are integrated in the return line lter housing.
The lter prevents dust and dirt from entering the
hydraulic tank.

1 Return line lter cover

2 Breather lter
3 Bypass valve
4 Seal
5 Return line lter
6 Dipstick
7 Steering return pipe

Degree of ltration 8 µ absolute

Filter material Plastic mesh
Maintenance interval 3000 h or 2 years

The lter element must be disposed of in accor-

dance with environmental regulations.

Unscrew the breather lter

Remove the lter cover
Remove and replace the lter element
Replace the lter cover
Screw the breather lter back on.

50638042201 EN - 10/2017 -15

https://truckmanualshub.com/

The hydraulic oil is drawn from the tank by the

hydraulic pump via the intake hose and ows
through the intake lter from the outside to the
inside.
The lter insert is a coarse lter and maintenance-
free.

Degree of ltration 225 µm

Stainless steel
Filter material
mesh
Housing material Polyamide PA 66 1 Filter cartridge
2 Thrust piece
Mounting screw M6 x 1, 8+2 Nm 3 Hose clip
.

4 Fixing screws

Hydraulic oil should be disposed of according to

the environmental regulations.
Drain the hydraulic oil.
Release the hose clip (3) on the intake hose
and remove the intake hose from between the
tank and hydraulic pump.
Release the mounting screw (4) on the lter
cartridge tensioning piece.
Pull out the tensioning piece (2).

It may be necessary to strike the lter cartridge

using a mandril to release it from the intake
nozzle. Use material that does not splinter for
this purpose!
Remove the lter cartridge through the open-
ing in the return line lter.

Prior to installation, check that the sealing ring

is properly seated on the lter connection and
has not fallen into the tank.
Tighten the mounting screw on the lter
cartridge tensioning piece.
Install the intake hose between the tank and
hydraulic pump and secure it with the hose
clip.

-16 50638042201 EN - 10/2017

https://truckmanualshub.com/

Fill with hydraulic oil.

For servo hydraulics, it is a legal requirement

(in accordance with VDMA (German Engineering
Federation)) that in addition to the return line lter,
an additional lter is installed in the pressure line
upstream of the directional control valve.
The high-pressure lter is located in the pressure
line between the connections (EF) of the priority
valve and (P) of the directional control valve.

Degree of ltration: 12 µm nominal

Filter material: non-woven plastic mesh
Maintenance interval: 3000 operating hours or 2
years
1 High-pressure lter
2 Filter housing
3 Hexagonal

The lter element and any oil that escapes must

be disposed of in an environmentally friendly
manner.
Place a collection vessel underneath. The oil
volume that drains out is about 0.2l (capacity
of the lter housing).
Loosen the lter housing (2) at the hexagonal
(3) with a SW30 box-end wrench and unscrew
it.
Pull the lter element downwards.
Push the new lter element in until it stops.
Clean the lter housing and screw on hand
tight.

50638042201 EN - 10/2017 -17

https://truckmanualshub.com/

The conical nipple tting is equipped with an

integrated O-ring.
Tighten the tting union nut until you feel a re-
sistance and then turn it a maximum of a half
revolution (180 degrees).

Tightening it even more can lead to deformation and

leaking.
Tighten the union nut until it is rmly seated and then
turn it a maximum of a half revolution.

The screw joints consist of:

Functional nut (union nut)
Sealing ring (soft seal)
Retaining ring (olive)
Pipe
Pipe adaptor

Saw pipe at right angles

1 Functional nut
2 sealing ring
3 Retaining ring
4 pipe
5 tting

Deburr pipe on inside and outside

Sharp edges can damage the sealing ring.

Deburr pipe on inside and outside and clean.

-18 50638042201 EN - 10/2017

https://truckmanualshub.com/

Screw the functional nut (1) with retaining ring

(3) and seal (2)onto the pipe union (5) by hand

Push the pipe end into the screw joint and

press against the stop in the inner cone

An insuf cient insertion depth can lead to an insecure

connection and leaks.
Insert pipe up to the screw stop.

Tighten the functional nut (1) until you clearly

feel an increase in connection strength,

A marking (6) on the pipe and functional nut

makes counting the turns easier.

50638042201 EN - 10/2017 -19

https://truckmanualshub.com/

After assembly, remove the functional nut (1)

Check whether there is a gap between the
sealing ring (2) and retaining ring (3)

Every time you loosen the functional nut (1),

please proceed as in the initial assembly

Tighten the functional nut (1) until you clearly

feel an increase in connection strength,

Hold the socket (7) together when doing so

In the event of leaks at the screw joint, the

sealing ring (2) can be removed from the free
pipe end and replaced

-20 50638042201 EN - 10/2017

https://truckmanualshub.com/

Manufacturer
Type AP 104 - L1 AP 108 - K2
Operating voltage 48 V 80 V
Engine type 4-pin AC motor with cage rotor
Connection Delta Star

Rated voltage (nominal) 28 V 45 V

Rated current (nominal) 243 A 180 A
Rated speed (nominal) 2884 rpm 2680 rpm
Rated output (nominal) 9 kW 11 kW
Maximum speed 3500 rpm 3200 rpm

Mode of operation (nominal) S3 - 15%

Protection type IP 54
Insulation class F
Weight Approx. 36 kg
Cooling Surface/convection
Temperature sensor KTY84-130
IFM sensor with trigger wheel
Rev sensor
Transmitter-free control
.

50638042201 EN - 10/2017 -1
https://truckmanualshub.com/

1 Pump motor
2 Hydraulic pump X14 Temperature sensor
3 Motor suspension U Motor power cable
4 Priority valve V Motor power cable
W Motor power cable

Aluminium conductors are cast into the slots

in the rotor laminations pack, and their ends
The pump unit is connected to the drive axle at
are connected with short-circuit rings. The
the top by two bolts and by two rubber-mounted
conductors with the short-circuit rings form the
motor supports at the bottom.
cage rotors and hold the rotor laminations pack
The hydraulic gear pump with the ange- together.
mounted priority valve is located on the right-
The stator consists of the 4-pole laminated stator
hand bearing shield for the pump motor. The
core and the stator windings, which are pressed
pump is driven via a tappet.
into the motor housing as a unit.
Motor connections U, V and W are fed upwards
The applied voltage is induced in the rotor bars
and out of the motor as screw connections.
by the stator winding and causes a current to ow
The temperature sensor is embedded into the in the rotor. The resultant rotor current and the
stator winding. The plug for the sensor is routed rotating eld acting on the stator generate the
out of the motor. torque.

The pump motor is a three-phase AC asyn- The motor is controlled by a converter. The
chronous motor, which is equipped with short-cir- speed is changed by changing the frequency
cuit cage rotors. and voltage of the applied AC voltage.

-2 50638042201 EN - 10/2017
https://truckmanualshub.com/

In the motor, each of the three phases is dis- The motors are controlled using pulse width
tributed to four poles in the stator, thereby gen- modulation at a clock frequency of approx. 16
erating the rotating eld required. The motor is kHz.
operated in a three-phase delta connection and
is supplied with pulsing voltage by the converter.

50638042201 EN - 10/2017 -3
https://truckmanualshub.com/

The pump motor windings are wired in a triangu-

lar arrangement inside the motor.

Location and type of electrical connections:

The three main power connections U, V
and W are insulated and watertight screw
connections and are led out of the motor
through a removable terminal board.
Rev sensor X14
4-pin Junior Power Timer plug
Plug not tted when transmitter-free revolution
control is used
Temperature sensor X15
4-pin mark II plug
GND earth wire for the pump motor

The pump motor is installed in the truck without a

rev sensor and sensor disk. A rev sensor cannot
be retro tted in this pump motor.
The revolution control for the pump motor is cal-
culated via a model calculation in the converter.

Pump motor number 0009760940

From Flash package V085
Converter SAC V2017

The pump motor is installed with a rev sensor.

However, the rev sensor is no longer evaluated
by the software.
The revolution control for the pump motor is cal-
culated via a model calculation in the converter.

From Flash package V085

Converter LAC V076

A 00 0F6 Con guration of the hydraulic drive

-4 50638042201 EN - 10/2017
https://truckmanualshub.com/

01 Transmitter-free control active

00 Rev sensor available
.

The speed of the pump motor 2M1 is registered

by a speed sensor. It is situated on the left bearing
shield under a covering, and is xed in place
using two screws. It consists of an inductive
proximity switch.
This switch responds in the proximity of iron in
this case the 12 cams of the trigger wheel.
As the trigger wheel turns, the speed sensor
delivers a voltage pulse at every cam.
The one-way speed sensor is supplied by the
inverter with 10 V. The speed signal is connected
directly to the inverter.
The evaluation takes place in the inverter whilst
monitoring occurs in the Main Control Unit
(MCU).

The location of electrical connections varies

depending on the truck.
4-pin JPT plug X14
X14/1 Red X150/7 +10 V
X14/2 Blue X150/5 Signal
X14/3 Black X150/8 GND-L
X14/4
.

Release the two xing screws

The distance between the speed sensor and
the trigger wheel is
Tighten the two xing screws

When the speed sensor is tted, there is a simple

way to check that it is functioning correctly:

50638042201 EN - 10/2017 -5
https://truckmanualshub.com/

Risk of injury from turning trigger wheel!

The motor must be de-energised; detach the motor
connections!

Detach the motor connections U, V, W at the

pump motor
Connect the multimeter between X14/3 ( ) and
X14/2 (+)
Turn the pump motor trigger wheel manually
The multimeter shows a clear voltage jump of
approx. 8 V

The pump motor is monitored by a temperature

sensor.
The watertight temperature sensor is embedded
in the stator winding and is led out of the motor.
The evaluation of the signals is carried out in the
inverter.

Type: KTY84-130.
Power supply: approx. 1.7 mA

The location of electrical connections varies

depending on the truck.
2-pin Mark II plug X14
X15/1 Red X150/3 Temp-MCT +
X15/2 Blue X150/4 Temp-MCT -

An improperly conducted insulation test can destroy

the temperature sensor.
Before conducting the insulation test, jumper the
temperature sensor connections.

Insert the test adapter into plug connector X15

Compare the resistance value to the table

-6 50638042201 EN - 10/2017
https://truckmanualshub.com/

-40 355
-30 386
-20 419
-10 455
0 493
10 533
20 576
25 598
30 621
40 668
50 718
60 769
70 824
80 880
90 939
100 1000
110 1063
120 1129
130 1197
140 1268
150 1340
160 1415
170 1493
180 1572
190 1654
200 1739
210 1825
220 1914
.

A defective sensor can be exchanged with the

aid of a repair kit containing a temperature sensor
and two-component balancing mastic.
Knead both components (yellow and blue)
of the mastic together until the mass has a
uniform green colour
Continue kneading the green mass for at least
2 minutes until it is noticeably warm
Unscrew the terminal board with the main
power connections
Press the sensor against the side of the
winding using the balancing mastic

50638042201 EN - 10/2017 -7
https://truckmanualshub.com/

Make sure that no mastic gets between the sen-

sor and winding, as otherwise the temperature
measurement will be incorrect.
The balancing mastic is fully cured after
approx. 2.5 hours

Drain hydraulic oil at an early stage so that the oil

has time to drain off.

Follow environmental regulations when discar-

ding hydraulic oil.
Disconnect battery plug
Jacking up the truck
Activate parking brake
Remove base plate with accelerator pedal
Fully depress brake pedal and secure with
cable ties
Screw on cover to the right on the valve block

-8 50638042201 EN - 10/2017
https://truckmanualshub.com/

Unscrew power cables (1) on the pump motor

and label them in advance, if necessary
Unscrew power cables (2) on the motor and
label them in advance, if necessary
Remove cover of brake operation (3)
Remove ground line (4) between pump motor
and drive axle on pump motor
Unscrew the cable guide plate (9) to provide
more room for movement in the cabling
Loosen the holder of the hydraulic lines to the
steering cylinder to provide more room for
movement in the hydraulic line
Screw off return lines (6) of steering unit
Remove hydraulic pump (7) (see Chapter
"Hydraulic Pump").
Disconnect connectors X14 and X15 (8)
Use sling band and chain block to hook pump
motor on overhead guard

The chain must be pulled from the chain block by

the steering wheel (see photo).

In trucks with a cab, rst remove the roof disk.

To keep the pump motor balanced, pay

attention to the position of the sling band and
the joint

The joint of the sling band must lie to the rear and
left on the terminal board of the power cable.

50638042201 EN - 10/2017 -9
https://truckmanualshub.com/

Pull safety split pins from the xing bolts

Remove bolts. If necessary, push out using a

long lock rod (Ø8 x 700). To do this remove the
left wheel and use the mounting hole
Lift out the pump motor using the chain block
Remove the entire pump motor towards the
left out of the truck

Disconnect battery plug

Jacking up the truck
Activate parking brake
Remove base plate with accelerator pedal
Fully depress brake pedal and secure with
cable ties
Screw on cover to the right on the valve block

-10 50638042201 EN - 10/2017

https://truckmanualshub.com/

Use sling band and chain block to hook pump

motor on overhead guard

The chain must be pulled from the chain block by

the steering wheel (see photo).

In trucks with a cab, rst remove the roof disk.

To keep the pump motor balanced, pay

attention to the position of the sling band and
the joint

The joint of the sling band must lie to the rear and
left on the terminal board of the power cable

Drain pump motor and lower on the rubber-

cushioned motor holder.

If necessary, swing the pump motor forward using

a mounting lever, positioning the lever between
tank and pump motor.
As a mounting aid against twisting, insert a drift
punch through the top left motor mount

50638042201 EN - 10/2017 -11

https://truckmanualshub.com/

Insert bolt into the top right motor mount

Remove drift punch and insert bolt into the top
left motor mount
Insert safety split pins into bolt
The bolts cannot be inserted by hand in older,
dirty trucks. A long rod (Ø8 x 700) may be used to
help punch in the bolts. In this case, proceed as
follows:

Remove the right wheel and use mounting

hole
Insert rod through mounting hole and through
the top right motor mount
Remove drift punch at left
Align motor mount
Place bolt and strike with rod
Withdraw rod
Align right motor mount
Place bolt and strike with rod
Insert safety split pins into bolt
Mount right wheel
Then continue in the same way in both cases:
Install hydraulic pump (see Chapter "Hydraulic
Pump").
Screw power cable (1) on the pump motor
Screw power cable (2) on the motor to the left
Mount cover of brake operation (3)
Connect ground line (4) between pump motor
and drive axle to pump motor
Screw on cable guide plate (9)
Screw on holder for hydraulic lines to the
steering cylinder
Screw on return lines (6) of steering unit
Install hydraulic pump (7) (see Chapter "Hy-
draulic Pump")
Connect connectors X14 and X15 (8)
Insert base plate with accelerator pedal
Screw on cover to the right on the valve block
Remove cable ties on brake pedal
Connect battery plug
Carry out functional test

-12 50638042201 EN - 10/2017

https://truckmanualshub.com/

Use jack to lower truck

The hydraulic gear pump (5) is screwed to the

right-hand bearing shield for the pump motor (1)
by means of two diagonally positioned mounting
screws (6). The two other screws hold the hy-
draulic pump together.
The hydraulic pump is driven by the armature
shaft pinion (2) and the tappet (3). The priority
valve (4) is ange-mounted directly onto the
hydraulic pump.
The hydraulic pump draws the hydraulic oil from
the hydraulic tank via the intake hose (8) and
supplies the pressurised oil to the priority valve.
1 Pump motor
The directional control valve, and therefore the 2 Armature shaft pinion
lifting, tilting and auxiliary hydraulics are supplied 3 Tappet
with oil via connection (EF) at the priority valve. 4 Priority valve
5 Hydraulic pump
The steering unit is controlled and supplied with
6 Fixing screws
oil via connections (LS) and (CF) at the priority 7 Pump clip
valve. 8 Induction hose
9 Tank clip

The hydraulic pump is connected to the pump

motor via a tappet. The pump motor starts
up once a hydraulic function is activated. The
pump motor speed corresponds to the hydraulic
function activated. The speeds of the hydraulic
functions are set using parameters.
If multiple hydraulic functions are activated at the
same time, the pump motor always runs at the
highest speed required.
The hydraulic pump delivery volume is depen-
dent on the speed of the pump motor. Oil is dis-
tributed to the steering hydraulics and working
hydraulics by the priority valve.

Noise in the hydraulic pump - Check the radial seal ring in the
Hydraulic oil is frothy pump motor
The hydraulic system is leaking - Check the O-ring between the
Hydraulic functions are slow to and is taking in air intake hose and hydraulic pump
respond - Mechanical damage in the
hydraulic pump
.

50638042201 EN - 10/2017 -13

https://truckmanualshub.com/

Place a collection vessel under the hydraulic

pump.
Dispose of used hydraulic oil in accordance
with environmental regulations and do not
re-use under any circumstances.
The hydraulic pump is located below the oil
level in the tank. The hydraulic pump intake
pipe is situated beneath the hydraulic tank.
Draining all of the hydraulic oil is to be avoided if
possible. For this reason, it is important to follow
the instructions for removal.
Park the truck safely
Tilt the lift mast forwards
In order to reduce the volume of oil in the tank,
extend the lift mast as far as the ceiling allows
and secure it
Disconnect battery plug.
Remove the oorplate with the accelerator
pedal and disconnect the plug
Detach the hydraulic connections on the
priority valve
Unscrew the priority valve from the hydraulic
pump

-14 50638042201 EN - 10/2017

https://truckmanualshub.com/

Unscrew the two xing screws of the hydraulic

pump

Carry out any further work with the utmost cau-

tion, because any mistakes can easily cause all
the oil to escape.

Gently release the clip (1) of the suction hose

on the pipe union of the hydraulic tank
Rotate the suction hose (2) anti-clockwise on
the pipe union, until the hydraulic pump (3) is
pointing vertically upwards

During this procedure, the upper end of the

suction hose is positioned just above the oil level
in the tank.
Attach the clip (1) on the pipe union of the
hydraulic tank
Release the suction hose clip (4) on the
hydraulic pump intake pipe and remove the
hydraulic pump
For any further work, the open suction hose
must be protected against soiling
Unscrew the intake pipe from the hydraulic
pump

50638042201 EN - 10/2017 -15

https://truckmanualshub.com/

Sealing rings must always be changed and

greased before assembly.
Check the quality of screws and hydraulic oil,
as well as the correct tightening torques.
For values, see "General technical data" in the
chapter entitled "Hydraulics (general)".

Dispose of used hydraulic oil in accordance with 1 Pump motor

environmental regulations and do not re-use 2 Armature shaft pinion
under any circumstances. 3 Tappet
4 Priority valve
Screw the intake pipe with O-ring onto the
5 Hydraulic pump
hydraulic pump
6 Fixing screws
Connect the suction hose with the hydraulic 7 Pump clip
pump intake pipe 8 Induction hose
9 Tank clip
Attach the clip on the hydraulic pump intake
pipe
Gently release the clip on the pipe union of the
hydraulic tank
Rotate the suction hose in a clockwise direc-
tion on the pipe union until the hydraulic pump
is in the correct position in relation to the pump
motor
Attach the clip on the pipe union of the hy-
draulic tank
Position the O-ring and tappet between the
hydraulic pump and the pump motor
Screw on the two xing screws of the hydraulic
pump
Screw the priority valve with O-ring onto the
hydraulic pump
Attach the hydraulic connections to the priority
valve

-16 50638042201 EN - 10/2017

https://truckmanualshub.com/

Top up the hydraulic oil to the mark on the

dipstick
Clean up any spilt hydraulic oil
Connect the battery plug
Switch on the switch lock
Operate the steering and check the hydraulic
connections for leaks
Bleed the hydraulic system by operating the
steering
Install the oorplate with the accelerator pedal
and connect the plug
Operational test

50638042201 EN - 10/2017 -17

https://truckmanualshub.com/

332 78 7 4 1860 3260

1500 302 78 3 8 1860 3260
6209 - 6217
1600 1860 1960
6311, 6313,
1800 Windscreen
6315 314 66 7 6
2000
Windscreen and
hose line

314 66 3 6 1860 2710

1500
6209 - 6217 332 78 7 4 1860 2710
1600
6311, 6313, Windscreen with
1800
6315 328 50 3 4 windscreen wiper
2000
and hose line

1500 314 66 3 6 1860 3260

6209 - 6213
1600
6215 - 6217
1800 332 78 7 4 1860 3260
6315
2000
1860 2360
328 50 3 4 Windscreen with
6214 1600 windscreen wiper
6311, 6313 1800 and hose line
314 66 3 6 1860 3260
332 78 7 4 1860 3260
.

There is a risk of injury or damage to property!

Observe the safety instructions in chapter 001.

Park the truck safely

Tilt the lift mast forward
Apply the parking brake
Disconnect the battery male connector

-18 50638042201 EN - 10/2017

https://truckmanualshub.com/

The lift mast can tilt over forwards and backwards.

The lift mast must be secured in both directions.

Disconnect the tilt cylinder from the outer mast.

To do this, remove the locking ring and knock
out the pins.
Release the hydraulic connections at the tilt
cylinder
Disconnect the tilt cylinder from the chassis.
To do this, remove the locking ring and rubber
washers and knock out the pins.

Grease tilt cylinder bolts before installation!

Connect tilt cylinder to chassis. To do this,
knock in the pins and rubber washers and
secure with a locking ring.
Connect the tilt cylinder to outer mast. To do
this, knock in the pins and secure with a locking
ring.
Screw on the hydraulic connections at the tilt
cylinder.
Check tilt cylinder for leaks.

50638042201 EN - 10/2017 -19

https://truckmanualshub.com/

6 Piston rod
X Lift, dependent on spacer bush 7 Locking ring
Y Eye bolt setting dimension 8 Grooved ring
Z Screw-in depths of the threads 9 Cylinder head
10 O-ring
11 Snap ring
1 Hexagon nut
12 Wiper
2 Variant: Spacer bush (changes the back-
13 Clip
wards tilt)
14 Eye bolt
3 Piston guide ring
15 Loctite 270
4 Piston seal
16 Cylinder bottom
5 Piston
17 Cylinder pipe

6209 - 6217 1500 - 2000 130 +10 Nm

Max. 19 mm
6311, 6313, 6315 1600 - 2000 130 +10 Nm 22 mm
(M20 x 1.5)
7311 - 7316 1600 - 2000 130 +10 Nm Max. 19 mm

4041 - 4043 1600 - 2000 130 +10 Nm Max. 19 mm -6 mm

22 mm +2/-6
4044 - 4046 1600 - 2000 130 +10 Nm Max. 19 mm -6 mm
.

Component damage possible!

To protect the cylinder and the piston rod in the vice,
protective soft jaws must be used!

Clamp the tilt cylinder (16) in the vice at the

cylinder bottom.
Remove the threaded elbow pipes from the
cylinder head (9) (thread projects into the
cylinder).
Using a plastic mandril, drive in the cylinder
head a little

-20 50638042201 EN - 10/2017

https://truckmanualshub.com/

Use a mandril to drive in the snap ring (11)

through the bore in the cylinder pipe (17) and
use a screwdriver to lever out the snap ring.
Pull the piston rod (6) and cylinder head (9) out
of the cylinder pipe (17).
Clamp the piston rod in the vice
Remove the eye bolt (14).
Pull the cylinder head (9) off the piston rod (6).
Remove the set of seals from the piston and
cylinder head.

Check all parts for wear.

Lightly grease the piston seal and piston guide
ring and install.
Fit the cylinder head (9) onto the piston rod (6)
and seal with Loctite 270 (15).
Screw the eye bolt (14) on to the thread of the
piston rod (6); observe the setting dimension
(Y) and minimum screw-in depth (Z).
Prevent the eye bolt from turning by using the
clip (13).
Insert the piston rod (6) with the cylinder head
(9) into the cylinder pipe (17).

After assembly of the piston guide ring, piston

seal and set of seals, insert the cylinder head into
the cylinder pipe, taking care that the recess on
the cylinder head faces the pipe adaptor bore.
Fit the snap ring (11).

When assembling a threaded elbow pipe,

always use a new one.
Note the location of the threaded elbow pipes.

50638042201 EN - 10/2017 -21

https://truckmanualshub.com/

During assembly, bear in mind that the location

of the threaded elbow pipes depends on the
design of the tilt cylinders.
Insert the threaded elbow pipe and screw it in
by hand up to the TUFLOK coating.
Then use a tool to screw it in at least 4 turns
and no more than 5.

Leakages caused by incorrectly tted threaded elbow

pipes.
If a threaded elbow pipe has been screwed in too far, it
must not be unscrewed again. A new threaded elbow
pipe must always be used.

-22 50638042201 EN - 10/2017

https://truckmanualshub.com/

Shuttle fork arm Griptech RG4 1500

Rotator Meyer 5-1502N 1500
Rotator Meyer 5-1504N 1500
Rotator, for attachment to
Meyer 5-1502N 1500
sideshift
Rotator, for attachment to
Meyer 5-1504N 1500
sideshift

Sideshift
Kaup 1T151P4 550
Fixed connection
Sideshift
Kaup 1T151P2 700
Fixed connection
Sideshift
Cascade 55F 700
Fixed connection
Sideshift
Bolzoni HN4 700
Fixed connection

Fork prong positioner

Kaup 2T466 700 1900
Fixed connection
Fork prong positioner
Kaup 2T163 700 800
Fixed connection
Fork prong positioner
Meyer 6 2504F 700 1900
Fixed connection

Multi pallet handler Meyer 6 5204F 700 1900

Multi pallet handler Kaup 2T429 700 1900
Clamp fork Kaup 2T411 700 1900
.

Rotator
Rotational speed [rpm] 2 4
Rotary clamp
Sideshift with end position damping
Shift speed [m/s] 0.05 0.15
Push/pull attachments
Clamps
Clamp speed [m/s] No limitation
Fork prong positioners
Shovels
Tipping speed [°/s] 10 60
Tippers
.

50638042201 EN - 10/2017 -23

https://truckmanualshub.com/

Since 29th December 2009, standard ISO 3691

has been a legal requirement.
This standard speci es that attachments which
hold the load by exerting pressure on it must be
controlled additionally by a second operating
function. This prevents an unintentional release
of the load.
If such attachments (clamping devices) are
retro tted, the truck must also be retro tted with
a second operating function.

The clamp locking mechanism is discussed in the

following section.

Hand lever Actuate operating lever together with an additional switch

Actuate the joystick function together with the F key.
Joystick The auxiliary hydraulics function with F key is parameterised via the
diagnostics in the notebook.
Press the F key to enable the attachment function for 3 seconds. Dur-
Fingertip ing this time, the attachment can be actuated via the corresponding
Generation 2 mini-lever operating lever. The function remains enabled until 3 seconds has
passed without the operating lever being actuated.
To enable, the operating lever must be moved forwards once by at least
Fingertip 1/3. The enable is indicated by the LED for the F2 key and remains
Generation 2 mini-lever active for approx. 1 second. During this time, the attachment can be
actuated via the corresponding operating lever.
Generation 1 mini-lever The function is not implemented for the generation 1 mini-lever.
.

The parameters apply only for the ngertip and

generation 2 mini-lever.
For retro tting, the current software ash
package may have to be loaded into the truck.
The addresses and values of trucks RX60-
25-50 (6321 6630) partially deviate from the
standard.

-24 50638042201 EN - 10/2017

https://truckmanualshub.com/

A 00 3EC 27 Input for clamping function with servo hydraulics

Time interval, from when the enable is reset.
A 00 3ED 1E
Default: 3 seconds
Clamping function con guration
A 00 3EE 00
Default: enable via the F key
A 10 023 2C Crossbar switch index for auxiliary hydraulics 2 axle
A 10 030 3A Crossbar switch index for analogue switch 1, analogue input
A 10 031 1B Crossbar switch index for analogue switch 1, Enable input

A 00 3EC 27 Input for clamping function with servo hydraulics

Time interval, from when the enable is reset.
A 00 3ED 0A
Default: 1 second
Clamping function con guration
02
A 00 3EE Default: enable by moving the lever
01 In RX60-25-50 (6321 6330)
A 00 3EF C4 Setpoint value input from the operating device for the clamping version
39 Crossbar switch index for auxiliary hydraulics 2 axle
A 10 023
38 In RX60-25-50 (6321 6330)
A 10 036 3A Crossbar switch index for AND element 1, input A
A 10 037 1B Crossbar switch index for AND element 1, input B
00 Crossbar switch index for setpoint value limiter, analogue input
A 10 042
3A In RX60-25-50 (6321 6330)
00 Crossbar switch index for setpoint value limiter, digital input
A 10 043
31 In RX60-25-50 (6321 6330)
3A Crossbar switch index for setpoint value limiter, analogue input
A 10 044
00 In RX60-25-50 (6321 6330)
31 Crossbar switch index for setpoint value limiter, digital input
A 10 045
00 In RX60-25-50 (6321 6330)
A 10 04D 3A Crossbar switch index for universal output 1

A 00 3EC 27 Input for clamping function with servo hydraulics

Time interval, from when the enable is reset.
A 00 3ED 0A
Default: 1 second
Clamping function con guration
02
A 00 3EE Default: enable by moving the lever
01 In RX60-25-50 (6321 6330)
A 00 3EF C4 Setpoint value input from the operating device for the clamping version
39 Crossbar switch index for auxiliary hydraulics 1 axle
A 10 022
38 In RX60-25-50 (6321 6330)
2B Four-way mini-lever
Crossbar switch index for AND element 1,
A 10 036 3A Duplicate mini-lever
input A
2B Fingertip
A 10 037 1B Crossbar switch index for AND element 1, input B

50638042201 EN - 10/2017 -25

https://truckmanualshub.com/

00 Crossbar switch index for setpoint value limiter, analogue input

2B Four-way mini-lever
A 10 042
3A In RX60-25-50 (6321 6330) Duplicate mini-lever
3A Fingertip
00 Crossbar switch index for setpoint value limiter, digital input
A 10 043
31 In RX60-25-50 (6321 6330)
2B Four-way mini-lever
Crossbar switch index for setpoint value
3A Duplicate mini-lever
A 10 044 limiter, analogue input
3A Fingertip
00 In RX60-25-50 (6321 6330)
31 Crossbar switch index for setpoint value limiter, digital input
A 10 045
00 In RX60-25-50 (6321 6330)
2B Four-way mini-lever
Crossbar switch index for universal output
A 10 04D 3A Duplicate mini-lever
1
2B Fingertip
.

The parameters apply to clamp locking me-

chanisms for hand levers, even those with
Sauermann restraint systems.
For retro tting, the current software ash
package may have to be loaded into the truck.

A 00 36F 05
A 00 370 37 These service addresses are no longer used
A 00 371 00

A 00 372 05 Reserve 11 input at AND 2 output

A 00 373 37 Reserve 11 output at CPP 3, channel 8
A 00 374 00 Reserve 11 output parameter
A 00 326 8E 1 AND 2 input at reserve 2 low (knob on the 4th lever)
A 00 327 BC Input 2 AND 2 "actuated on lever 4"
.

Seat CPP E14 X54: 7

-26 50638042201 EN - 10/2017

https://truckmanualshub.com/

E14 X54: 8

50638042201 EN - 10/2017 -27

https://truckmanualshub.com/

Accumulators are hydro-pneumatic storage

devices that draw on the compressibility of gas
to store uids. Accumulators comprise a uid
section and a gas section, with a membrane
forming a separator. These sections are welded
together to form a single unit. The gas section
can be re lled. The uid section is connected to
the hydraulic circuit. The membrane features a
valve plate in its base. When the gas section is
completely empty, this valve plate closes off the
hydraulic outlet. This prevents damage being
sustained to the membrane.
If the pressure in the hydraulics system rises, the
accumulator is lled with hydraulic oil and the vol-
ume of gas is compressed. If the pressure in the
hydraulics system falls again, the compressed
gas expands and pushes the hydraulic oil back
into the hydraulic circuit. These damping charac-
teristics can be altered as required by adjusting
the pre-load pressure

At nominal load, the accumulator absorbs the

vibrations prevailing in the lift mast. This reduces
the impact factor and/or load factor for the frame
and tilt cylinders when driving on uneven ground.
On all trucks with a nominal load of 5000 kg and
a load centre of gravity of 600, the accumulator is
a component relevant to safety that is subject to
regular maintenance.

Gas, re llable Nitrogen

Gas connection M28 x 1.5
Max. operating
250 bar
pressure
Pre-load pressure 130 bar
Min. operating
40 bar
pressure
Hydraulic connection G 1/2
.

-28 50638042201 EN - 10/2017

https://truckmanualshub.com/

Check the pre-load pressure.

Check the connections to ensure they are
secure and check for leaks.
Check the ttings and safety systems to ensure
they are in proper condition.
Check the mounting elements.

Using the testing device, you can check the

pre-load pressure in the accumulator and reduce
it as necessary. To do this, screw the testing
device on to the gas valve on the accumulator.
If the accumulator also needs to be lled, the
testing device must be connected to a standard
nitrogen container via a lling hose.
The testing device is a screw joint tting with a
pressure gauge, non-return valve and a spindle
attached. The spindle is used to open the gas
valve for testing purposes.
1 Test port (accumulator)
2 Pressure release valve
3 Hand wheel
4 Pressure gauge
Remove the accumulator before checking it. 5 Filling connection (gas cylinder)
This is the only way to reliably detect a faulty
membrane.
Unscrew the protective cap from the gas
connection on the accumulator.
Loosen the socket-head screw slightly, as this
is very dif cult to turn via the hand wheel on the
testing device.
Securely bolt the testing device on to the gas
connection on the accumulator.
Close the pressure release valve on the testing
device.
Open the accumulator via the hand wheel.
Read the accumulator gas pressure on the
pressure gauge.

If the gas pressure is too high or the suspension

properties are too hard, the pressure release
valve can be used to reduce the pressure in a
controlled manner.
Open the accumulator via the hand wheel.
Read the accumulator gas pressure on the
pressure gauge.

50638042201 EN - 10/2017 -29

https://truckmanualshub.com/

Slowly open the pressure release valve and

relieve the pressure in a controlled manner.
The minimum pre-load pressure must not be
below 40 bar, as otherwise the membrane will
wear quickly.

If the gas pressure is too low or the suspension

properties are too soft, the lling connection can
be used to increase the pressure.
Set the pressure reduction valve to the re-
quired pressure.
Open the accumulator via the hand wheel.
Close the pressure release valve on the testing
device.
Read the accumulator gas pressure on the
pressure gauge.
Select a nitrogen cylinder that is as full as
possible and connect to the lling connection.
Increase the pressure in a controlled manner.

-30 50638042201 EN - 10/2017

https://truckmanualshub.com/

,
Series Since calendar week 39/2009
Manufacturer Buchholz
Lift, tilt, auxiliary 1
Monoblock, three-way
for all overall heights
Lift, tilt, auxiliary 1, auxiliary 2
Monoblock, four-way
for all overall heights
Release valve for the hydraulics in accor- The hydraulic functions are active when the seat contact
dance with EN-ISO 3691-1 switch is actuated, i.e. the driver is seated

-20 °C to +95 °C
brie y up to 115 °C

A1, B1, A2, B2, A3, B3 G3/8, 40 Nm

R G3/4, 140 Nm
P, H G1/2, 70 Nm
Emergency lowering screw SW4, 2.5 Nm
Hydraulic transmitter 3.5 Nm
Valve block on valve block support 20 Nm
.

,
Series Until calendar week 38/2009
Manufacturer Have
Lift, tilt with end plate
Monoblock
for all overall heights
Lift, tilt, middle segment for auxiliary 1 with end plate
Monoblock and auxiliary hydraulics 1
for all overall heights
Lift, tilt, middle segment for auxiliary 1 and end segment for
Monoblock and auxiliary hydraulics 1 and 2 auxiliary 2
for all overall heights

-20 °C to +95 °C
brie y up to 115 °C

A1, B1, A2, B2, A3, B3 G3/8, 70 Nm

P, H, R G3/4, 180 Nm
M G1/2, 20 Nm
Hydraulic transmitter 3.5 Nm
Valve block on valve block support 20 Nm
.

50638042201 EN - 10/2017 -1
https://truckmanualshub.com/

,
Nominal lift < 3500 mm Plug or ori ce 39
Nominal lift 3500 - 5000 mm
Delivery condition
Spare part delivery condition
Nominal lift > 5000 mm Ori ce 24

Exchange ori ce M10 x 1 15 Nm

.

-2 50638042201 EN - 10/2017
https://truckmanualshub.com/

The axle is bolted to the valve support and houses

the levers for the operating levers. An individual
operating lever can be retro tted or removed
for any retro tting of three-way hydraulics to
four-way hydraulics.
The operating lever for lifting is a combination
lever that incorporates an electric rocker button.

1 Axle
2 Lever
3 Valve rod
4 Valve support
5 Lift/tilt valve block
6 Auxiliary hydraulics 1 middle segment
7 Auxiliary hydraulics 2 end segment
8 Connector X19
9 Sensor rail
10 Hydraulic sensor

The back of the valve block is xed via three

screws (12) to the valve support. The valve
support houses the complete valve block and is
connected via rubber-mounted mounting screws
(7) to the cross wall of the overhead guard.
The tilt ori ce (13) can be unscrewed at the back
and changed.

50638042201 EN - 10/2017 -3
https://truckmanualshub.com/

Since calendar week 39/2009, the trucks have

been equipped with valve blocks with a check
valve as standard. The conversion of older trucks
to the current standard is a lot of work and not
intended.

The following components must be exchanged

for a conversion:
Valve block
Valve block support
Hydraulic hoses, pressure line, tilt forwards, tilt
backwards
Allen key (SW4) for emergency lowering to be
kept in the truck
Wiring harness, pre-assembled for 2Y46 at
X46 1 Lift/tilt/auxiliary hydraulics valve block
Software ash package V0.98 (or a more 2 Check valve for hydraulics blocking function
recent version) 3 Plug 2Y46
4 Emergency lowering
Parameterising 5 Sensor rail
Calibration 6 Hydraulic sensor
7 Connector X19

Lubricate the following bearings:

Bolt between lever and link
Bolt between link and rod

Spare part directional control valve blocks

are delivered without screw joints and with a
standard tilt ori ce (nominal lift < 3500 mm).
When making repairs on the directional control
valve block, proceed with extreme care, as dirt
and damage to the sealing surfaces can result
in malfunctions and leakages.
Always observe the tightening torques.
The valve spools must not be turned.

If a load that is in a raised position can no longer

be lowered due to an error in the valve control,
manual emergency lowering is possible. The
4-mm Allen key required for this is part of the
truck equipment.

-4 50638042201 EN - 10/2017
https://truckmanualshub.com/

See chapter entitled "Valve block design".

The place where the Allen key is stored
depends on the truck
The position of the emergency lowering
feature depends on the valve block type
Remove the panelling at the valve block
Use the Allen key to slowly undo the screw
for the emergency lowering feature in an
anti-clockwise direction until lowering begins
Do not undo the screw more than 1.5 turns
If lowering still does not begin, there is a me-
chanical block. Do not under any circum-
stances continue to unscrew the emergency
lowering feature
After lowering is complete, the screw must
be screwed back in again; do not exceed a
tightening torque of
Fit the panelling at the valve block

The hydraulic transmitter comprises the valve

spool and a transmitter tted to the lower end of
the spool. The return springs bring the unactu-
ated valve spools back to their neutral position.
The transmitter is located in a housing. The
housings of individual transmitters are screwed
to the sensor strip.
The Hall sensors for the valves in the valve block,
as well as the central plug, are integrated in the
sensor strip.

Actuation of the valve spool moves the trans-

mitter in the housing and generates an output
voltage in the sensor that is proportional to the
spool stroke.
The return springs bring the unactuated valve
spool back to its neutral position.
The sensors forward the voltage as signals to
the truck control unit MCU. These values are
converted in the MCU into speed setpoints for the
pump motor.

50638042201 EN - 10/2017 -5
https://truckmanualshub.com/

2B1 X19/1 X46/6

2B2 X19/2 X46/7
2B3 X19/3 X46/4
2B4 X19/4 X46/5
GND-S X19/5 X46/24
12 V X19/6 X46/39
.

The con guration must be parameterised again

for all retro tting and conversions.

This affects the following components:

Lift lever
Three-way valve block
Four-way valve block
A truck restart must always be carried out after
parameterising. Calibration can only be carried
out once these processes have been completed.

Calibration must always take place after the

hydraulic sensor has been replaced.
Connect the notebook to the truck and start the
truck diagnostics:

Actions

Calibration

0. Sensors
Once calibration is complete, error messages
may be displayed.

Insert SAAB adapter into the MCU plug

connector X46
Key switch ON
Connect the digital multimeter to the test
adapter according to the table and test the
voltage

The lift mast moves while the transmitter is being tested

and can cause damage
Pay attention to lift mast movements!

-6 50638042201 EN - 10/2017
https://truckmanualshub.com/

2B1 lift X19/1

2B2 tilt X19/2
X19/5 5.5 V 2.0 V
2B3 auxiliary 1 X19/3
2B4 auxiliary 2 X19/4
.

Park the truck safely.

Tilt the lift mast forward against the stop.
Lower the fork carriage fully.
Release the pressure from the hydraulics.
Disconnect the battery male connector.
Remove the bottom plate.
Remove panelling on the valve block.
Remove panelling on the right-hand side of
driver's compartment and then disconnect all
electric cables and the earth wire.
Disconnect plug X19 and, if necessary, 2Y46.

Disconnect plug X23 from the multifunction

lever.

50638042201 EN - 10/2017 -7
https://truckmanualshub.com/

Remove the valve block earth wire.

Loosen all hydraulic connections (6-9) at the

valve block.

Collect any escaping hydraulic oil and dispose of

it in an environmentally friendly manner.
Loosen the lower rubber-mounted screw on
the valve support, do not unscrew completely.
Unscrew the two upper rubber-mounted
screws on the valve support.
Lift the valve support with valve block right up
and out of the mount.
Remove the fused plug and bolt between lever
and valve rod
Unscrew the three mounting screws on the
back of the valve support.
Disconnect the valve block from the valve
support.

The valve block is supplied without screw joints

and with a standard ow control valve (for nomi-
nal lifts of 3500 - 5000 mm).
The tilt ori ce must be changed according
to the lift mast nominal lift, see the chapter
entitled "General technical data".
Install all screw joints from the package group
in the new valve block; check the tightening
torques. See the chapter entitled "General
technical data"

Attach the valve block to the valve support

using three mounting screws.

-8 50638042201 EN - 10/2017
https://truckmanualshub.com/

Fit the safety plugs and bolts between the

levers and valve spools.
Lubricate the following bearings:
Bolt between lever and link
Bolt between link and rod

The valve spools must not be turned in the valve

block.
Insert the valve support with valve block right
into the mount from above.
Screw the lower rubber-mounted screw tightly
onto the valve support.
Screw the two upper rubber-mounted screws
tightly onto the valve support.

Connect all hydraulic connections (6-9) to

the directional control valve block, check the
tightening torques.

Connect plug X19 and, if necessary, 2Y46.

50638042201 EN - 10/2017 -9
https://truckmanualshub.com/

Connect plug X23 of the multifunction lever.

Screw the earth wire tightly onto the directional

control valve block.
Install panelling on the right-hand side of
driver's compartment and then connect all
electric cables and the earth wire.
Install the panelling at the valve block.
Re t the bottom plate.
Top up the hydraulic oil if necessary.
Connect the battery male connector.
Carry out calibration
Delete error list.
Perform a functional test.

-10 50638042201 EN - 10/2017

https://truckmanualshub.com/

monoblock must be exchanged. In addition, an

extra lever must be added to the controls.
The directional control valve is a monoblock
design and comes in 2 versions: The directional control valve contains additional
Directional control valve, three-way functional components:
Lift, tilt, auxiliary hydraulics 1 Lowering-balance valve (lowering brake) in
the lift valve spool
Directional control valve, four-way
Pressure relief valve
Lift, tilt, auxiliary hydraulics 1, auxiliary hy-
draulics 2 Two load holding valves in the tilt valve spool
Tilt ori ce, depending on the nominal lift
The function and structure of the monoblocks
are identical in both versions. If a truck is later Check valve for hydraulics blocking function
equipped with third auxiliary hydraulics, the whole (from calendar week 39/2009)

1 A3 - auxiliary hydraulics 2 13 Plug X19

2 B3 - auxiliary hydraulics 2 14 Check valve for hydraulics blocking function,
3 A2 - auxiliary hydraulics 1 since 2009
4 B2 - auxiliary hydraulics 1 15 Plug 2Y46
5 A1 - tilt backwards 16 Load holding valve, forwards
6 B1 - tilt forwards 17 Load holding valve, backwards
7 R - tank return ow 18 Discharge pressure governor (lowering
8 P - pump pressure line brake)
9 H - lifting, lowering 19 Emergency lowering
10 Sensor strip 20 Pressure relief valve
11 Hydraulic transmitters 2B1 2B3

50638042201 EN - 10/2017 -11

https://truckmanualshub.com/

Hydraulic transmitters that send signals to the ori ce used depends on the nominal lift of the lift
sensors in the sensor strip are located at the mast.
lower end of the valve spools.
The discharge pressure governor (lowering
The hydraulic transmitters for the individual hy- brake) in the lift valve spool ensures a constant
draulic functions generate signals corresponding lowering speed and does this largely irrespective
to the valve spool displacement. The signals are of the size of the load.
transmitted to the truck control unit MCU via plug
The pressure relief valve protects the hydraulic
X19. From the signals, the MCU calculates the
system against overload.
minimum required number of revolutions for the
pump motor. The check valve for the hydraulics blocking
function satis es the regulations in accordance
The tilt valve spool incorporates two load holding
with the standard EN ISO 3691-1 and has been
valves that prevent forwards and backwards
tted as standard since calendar week 39/2009.
tilting of the load on its own.
The check valve releases the pressure as soon
A tilt ori ce that limits the oil ow for tilting is bolted as the seat contact switch is closed, i.e. the driver
to the back of the directional control valve. The tilt is seated on the driver's seat.

The discharge pressure governor (lowering

brake) in the lift valve spool ensures a constant
lowering speed that is largely independent of the
size of the load.
After loosening the lock nut, the lowering speed
can be changed via the adjusting threaded pin.
Screwing in the screw increases the lowering
speed
Unscrewing the screw reduces the lowering
speed

The check valve 2Y46 only enables the working

hydraulics once the seat contact switch is closed.
None of the hydraulic functions can be activated
unless the driver is seated on the driver's seat.
This safety function is de ned in ISO 3691-1 and
has been a legal requirement since 29th Decem-
ber 2009. The hydraulics blocking function must
not be manipulated.

2Y46/1 X46/2 Lowering OFF

2Y46/2 X46/15 GND-S
.

-12 50638042201 EN - 10/2017

https://truckmanualshub.com/

The input pressure governor in

Driver is not seated, "lowering" is the P input of the directional
blocked, "lifting" and "tilting" are control valve is contaminated Install a new valve block.
possible. and therefore remains open
permanently.

50638042201 EN - 10/2017 -13

https://truckmanualshub.com/

I Directional control valve for tilting III Directional control valve addition 2
P Connection - pump main A+B Connection - additional hydraulics
R Connection - return pipe to tank
H Connection - lift cylinder
1 Valve rod
A Connection - tilt backwards
2 Hydraulic sensor
B Connection - tilt forward
3 Flow control valve
M Test port
4 Idle port
5 Pump port
II Directional control valve addition 1 6 Pressure relief valve
A+B Connection - additional hydraulics 7 Back-pressure valve
8 Lowering brake
9 Load holding valve

Activating the valve rod (1) will regulate the speed

of the pump motor and thus the discharge of the
hydraulic pump in proportion to the control rod
stroke via the hydraulic sensor (2).
Only when the displacement of the rod is small will
the oil entering through the pump main (P) ow
back via the idle port (4) through the directional
control valves up to the backup plate and from
there through the return pipe (R) into the tank.
As the displacement of the rod increases, the idle
port closes and the oil is conveyed through the
pump port (5) to the consumers.
The pressure limiting valve (6) opens as soon as
the set maximum pressure in the pump port is
exceeded. The oil ows back through the return
pipe (R) into the tank.

-14 50638042201 EN - 10/2017

https://truckmanualshub.com/

The back-pressure valves (7) are integrated in

the directional control valves, preventing oil from
owing from the consumer back to the pump port
(5).
The ow control valve (3) limits the oil amount
for the tilting. The restrictor used depends on the
mast.

1 Blocking screw 13 Port H - lifting/lowering

2 Washer 14 Port R - return tank
3 Backup plate 15 Pressure relief valve
4 Sealing 16 Sensor rail
5 Port A - tilt backward 17 Connector X19
6 Port B - tilt forward 18 Lowering brake
7 Tilting valve rod 19 Lift hydraulic sensor
8 Load holding valve - forward 20 Screw of hydraulic sensor
9 Port P - pump pressure line 21 Tilt hydraulic sensor
10 Valve rod for lifting/lowering 22 Load holding valve, forward
11 Screw of cover plate 23 Sensor port, auxiliary 1
12 Test port G1/8? 24 Sensor port, auxiliary 2

The directional control valve contains the valve

spools for lifting (10) and for tilting (7).

50638042201 EN - 10/2017 -15

https://truckmanualshub.com/

If no more directional control valves are provided

for the auxiliary hydraulics, an end plate (3) is
tted at the tilt valve spool. This end plate seals
the directional control valve.
Hydraulic transmitters that send signals to the
sensors integrated in the sensor strip (16) are
located at the lower end of the valve spools.
The hydraulic transmitters for lifting (19) and
tilting (21) generate signals that correspond to
the displacement of the valve spools in the sensor
strip.
The signals are sent to the truck control unit
(MCU) via plug X19 (9). They are then converted
into speed setpoints for the pump motor.
The tilt valve spool contains two load holding
valves that prevent the load from tilting forwards
(8) or backwards (22) of its own accord.
A ow control valve is screwed into the back of the
directional control valve. This ow control valve
limits the oil ow used for tilting. The ow control
valve is dependent on the overall height of the lift
mast.
The lowering brake (18) in the lift valve spool
ensures a constant lowering speed and does this
largely irrespective of the size of the load.
The pressure relief valve (15) limits the maximum
pressure of the entire hydraulic system.
At measurement connection M (12), the pressure
of the entire hydraulic system can be measured
using a pressure gauge.

Replacement directional control valve blocks

are supplied without screw joins and with a
standard ow control valve (for nominal lifts of
3500 5000 mm).
When making repairs to the directional control
valve block, proceed with extreme care, as dirt
and damage to the sealing surfaces can result
in malfunctions and leakages
Note tightening torques.
The valve spools must not be turned

-16 50638042201 EN - 10/2017

https://truckmanualshub.com/

1 Blocking screw 7 Sensor rail

2 Washer 8 Hydraulic sensor auxiliary 1
3 Screw of cover plate 9 Middle segment auxiliary 1
4 O-ring 10 Hydraulic sensor auxiliary 1 or 2
5 Support ring 11 Screw of hydraulic sensor
6 Terminal block 12 End segment of auxiliary 1 or 2

The directional control valve block for lifting and

tilting is a connection block (6) to which one or
two directional control valves can be added,
depending on the equipment.
When adding an auxiliary hydraulics, the end
segment (12) is attached to the connection
block (6). In this version, the end segment with
integrated end plate is the directional control
valve for auxiliary hydraulics 1.
When adding two auxiliary hydraulics, the middle
segment (9) and end segment (12) are attached
to the connection block (6). In this version, the
middle segment is the directional control valve
for auxiliary hydraulics 1 and the end segment
with integrated end plate is the directional control
valve for auxiliary hydraulics 2.

50638042201 EN - 10/2017 -17

https://truckmanualshub.com/

The directional control valves for the auxiliary

hydraulics are identical in function and design.
The directional control valves are sealed to one
other in the ange surfaces via O-rings (4) and
support rings (5).
The sensor strip (7) with the sensors for the aux-
iliary hydraulics is a component of the directional
control valve block for lifting and tilting.

Replacement directional control valve blocks

are supplied without screw joins and with a
standard ow control valve (for nominal lifts of
3500 5000 mm).
When making repairs to the directional control
valve block, proceed with extreme care, as dirt
and damage to the sealing surfaces can result
in malfunctions and leakages
Note the tightening torques.
The valve spools must not be turned

The pressure relief valve (DBV) is integrated in

the directional control valve block for lifting and
tilting, limits the maximum pressure and protects
the hydraulic system from overloading.
If a consumer is moved against the stop and the
set nal pressure value is exceeded, the DBV
opens. This causes the conus (6) to be pushed
out of the valve seat against the compression
spring (5). The pressurised oil can ow out into
the hydraulic tank via the return line.
After releasing the lock nut (2), the pressure
setting can be changed via the adjustment screw
(1).
Screwing in the screw increases the pressure
Unscrewing the screw reduces the pressure
1 Adjusting screw
2 Locknut
3 Housing
Set value: 230±2.5 bar 4 Thrust piece
5 Compression spring
Adjustment range: 60 to 280 bar
6 Taper
7 Damping
8 Sealing
Do not exceed the maximum setting.
Only adjust the pressure relief valve with a pressure
measurement.

-18 50638042201 EN - 10/2017

https://truckmanualshub.com/

A contaminated pressure relief valve can cause

pressure loss or reduced lifting and tilting power.
Cleaning the PLV might eliminate the pressure
loss:
Loosen locknut
Unscrew adjusting screw until compression
spring is relieved
Activate consumer brie y and ush PLV
Screw in adjusting screw until setting is
reached
Secure with locknut

Load holding valves prevent the load from tilting

forwards or backwards of its own accord. The di-
rectional control valve block for tilting is equipped
with two load holding valves, one for forwards
tilting and one for backwards tilting.
The lift mast must not tilt forwards automatically
by more than 5° in 10 minutes.

Observe the safety test for forwards tilting.

Set value: 125 +10 bar 1 Load holding valve, forward

2 Sealing
3 Load holding valve, back

50638042201 EN - 10/2017 -19

https://truckmanualshub.com/

The lowering brake is a ow control valve and

limits the maximum lowering speed of the load.
After loosening the lock nut (10), the lowering
speed can be changed via the adjusting threaded
pin (11).
Screwing in the screw increases the lowering
speed
Unscrewing the screw reduces the lowering
speed

Setting range: 35 l/min at 150 bar

1 Nut
2 Socket
3 Ring
4 Piston
5 Screw
6 Compression spring
7 Disk
8 Sealing
9 Flange
10 Locknut
11 Adjusting grub screw
12 Screw

-20 50638042201 EN - 10/2017

https://truckmanualshub.com/

Manufacturer Buchholz
Lift, tilt, auxiliary hydraulics 1
Monoblock, three-way
for all overall heights
Lift, tilt, auxiliary hydraulics 1, auxiliary hydraulics 2
Monoblock, four-way
for all overall heights

Coil voltage 12 V
Coil current 1.8 A maximum
Coil resistance - lift, lower 6.0 Ohm
Coil resistance - tilt, auxiliary 1, auxiliary 2 8.0 Ohm

-25 °C to +90 °C
brie y up to 120 °C

A1, A2, A3, B1, B2, B3 70 Nm

P, T, H 180 Nm
Emergency lowering screw 2.5 Nm
Pressure relief valve 15 Nm
Valve block on valve block support 20 Nm
.

There is no tilt ori ce available.

50638042201 EN - 10/2017 -21

https://truckmanualshub.com/

1 Solenoid coil 6 Emergency lowering

2 Plug 7 Lift/tilt/auxiliary 1 directional control valve
3 Solenoid coil block
4 Fixing screws 8 Measuring point
5 Valve support

The valve support (5) houses the complete valve

block and is connected via mounting screws (4)
to the cross wall of the overhead guard.

-22 50638042201 EN - 10/2017

https://truckmanualshub.com/

The back of the directional control valve is scre-

wed to the valve support (5) with three rub-
ber-mounted screws (10).
Actuation of the hydraulic functions can take
place either by joystick, ngertip or mini-lever.

The removal and installation of the valve block is

performed in the same manner as for the hand
lever.

Spare part directional control valve blocks are

delivered without screw joints.
When making repairs on the directional control
valve block, proceed with extreme care, as dirt
and damage to the sealing surfaces can result
in malfunctions and leakages.
Always observe the tightening torques.
The valve spools must not be turned.

If the raised load can no longer be lowered due

to a valve control failure, the load can be lowered
manually.
To do so, proceed as follows:

The 4mm Allen wrench is located in the tray to the

right of the seat.
Remove the valve block cover.

50638042201 EN - 10/2017 -23

https://truckmanualshub.com/

Using the 4mm Allen wrench, slowly turn

the manual lowering screw out until lowering
starts.
Do not turn the screw more than 1½ turns.
If the load does not lower despite the screw be-
ing turned out, there is a mechanical blockage.
After the lowering, turn the screw in with
.
Re t the valve block cover.

The directional control valve block contains the

following functional components:
The directional control valve is a monoblock
Lowering-balance valve (lowering brake)
design and comes in 2 versions:
Directional control valve, three-way Check valve for hydraulics blocking function
Pressure relief valve
Lift, tilt, auxiliary hydraulics 1
NO tilt ori ces
Directional control valve, four-way
The tilt speed is restricted by the pump speed,
Lift, tilt, auxiliary hydraulics 1, auxiliary hy-
dependent on the overall height of the lift mast.
draulics 2
If lifting and tilting are actuated at the same
The function and structure of the monoblocks time, the tilt speed is prioritised.
are identical in both versions. If a truck is later
equipped with auxiliary hydraulics, the whole
monoblock must be exchanged.

-24 50638042201 EN - 10/2017

https://truckmanualshub.com/

1 Check valve for hydraulics blocking function 2Y1 Lifting

2 Lifting valve 2Y2 Lowering
3 Emergency lowering 2Y3 Tilting back
4 Lowering valve 2Y4 Tilt forwards
5 Lowering-balance valve (lowering brake) 2Y5 Auxiliary hydraulics 1
6 Inlet pressure balance 2Y6 Auxiliary hydraulics 1
7 Pressure relief valve 2Y7 Auxiliary hydraulics 2
8 Tilting valve 2Y8 Auxiliary hydraulics 2
9 Auxiliary hydraulics 1 2Y9 Check valve for hydraulics blocking function
10 Auxiliary hydraulics 2

The valve spools of the directional control valves (P), as well as the connections (B) to the return
are controlled by solenoid coils in proportion to line (T).
the degree of actuation of the joystick, ngertip or
Lifting and lowering are activated by separate
mini-lever.
valve spools that are each controlled by solenoid
The directional control valves for tilting, auxiliary coils.
hydraulics 1 and auxiliary hydraulics 2 are tted
The solenoid coil (2Y1) moves the lift valve spool
on both sides with solenoid coils.
and opens the connection (H) to the pressure line
The upper solenoid coils push the valve spools (P).
down and open the connections (B) to the pres-
The solenoid coil (2Y2) pushes on the lowering
sure line (P), as well as the connections (A) to the
valve (1) and opens the connection (H) to the
return line (T).
return line (T).
The lower solenoid coils push the valve spools up
and open the connections (A) to the pressure line

50638042201 EN - 10/2017 -25

https://truckmanualshub.com/

The check valve (2Y9) is located in the Load The lowering speed is set by adjusting the lower-
Sensing chain and releases the control pressure ing cartridge.
as soon as the seat contact switch is closed.
The pressure relief valve (2) protects the hy-
The lowering-balance valve (6) ful ls the func- draulic system from overloading using the input
tions of the lowering brake, and limits and regu- pressure governor (5).
lates the lowering speed, regardless of the load.

T Tank return line port 1 Lift control valve

P Pressure line port 2 Lowering directional control valve
H Lift cylinder port 3 Lowering-balance valve
A1 Forward tilt port 4 Check valve
B2 Backward tilt port 5 Inlet pressure balance
A2 Auxiliary hydraulics 1 port 6 Pressure relief valve
B2 Auxiliary hydraulics 1 port 7 Tilt directional control valve
A3 Auxiliary hydraulics 2 port 8 Load holding valve
B3 Auxiliary hydraulics 2 port 9 Aux 1 directional control valve
X Test port 10 Aux 2 directional control valve
MP Test port 11 LS chain
12 Changeover valve

the spool in neutral position, there is no pressure

from the consumer side that affects the control
The movement of the joystick is forwarded as a
channels. The control channels are depres-
signal via the peripheral CAN bus (CAN r) to the
surised.
hydraulics control unit in the MCU. The hydraulics
control unit evaluates the signals and controls the The oil entering through the pressure line (P)
solenoid coils in the respective directional control can open the input pressure governor (5) against
valve. the spring force. The oil delivered by the pump
is almost pressure-less as it ows through the
The directional control valve block works accord-
return line (T) into the tank.
ing to the principle of 3-way current control. With

-26 50638042201 EN - 10/2017

https://truckmanualshub.com/

When a spool is moved, the pressure building up ated, the check valve closes the control cable
in the consumer acts via the control channels on against the return ow (T) and the lowering-bal-
the input pressure governor and closes it along ance valve (3) is enabled.
with the spring force.
If the check valve is not actuated, no control
With a consumer stop (e.g. tilting against over pressure can build up in the control channels.
pressure), the pressure in the control channels The input pressure governor is not actuated and
increases. The pressure relief valve (6) opens as the pressure oil runs directly back into the tank.
soon as the set nal pressure value is reached. In addition, the lowering-balance valve is blocked
The higher pressure in the pressure line (P) and lowering is then not possible.
pushes the input pressure governor against the
With the shuttle valves (12), it is guaranteed that
spring force and the entire amount of oil can ow
the simultaneous actuation of several consumers
via the opened return line (T) into the tank.
causes the highest respective working pressure
The check valve (4) is controlled via a solenoid to reach the pressure governor via the control
coil by the hydraulics control unit. When actu- channels.

50638042201 EN - 10/2017 -27

https://truckmanualshub.com/

-28 50638042201 EN - 10/2017

https://truckmanualshub.com/

2 x M16 x 110-10.9 screws, ISO 4762

Mast bearing screws, per side
[Nm] 310 2 x M16 x 45-10.9 screws, ISO 4762
With Tu ok screw locking agent
Lubricant
.

The mast bearing is the same in all telescopic and

triple masts.
Each mast bearing is screwed to the drive axle
via two screws. Once the mast bearings are
unscrewed from the drive axle, they can be
removed from the bearing pins of the lift mast.

The mast bearing must be lubricated via the

lubricating nipple every 1000 operating hours.
Depending on the application in which the truck 1 Right-hand mast bearing
is used, it may be necessary to lubricate the mast 2 Left-hand mast bearing
3 Spherical bearing
bearings even earlier.
4 Conical lubricating nipple
Defective mast bearings must always be 5 Screw
replaced in full and in pairs 6 Screw
The mast bearing screws must always be 7 Lock washer
replaced
Old screws must not be reused
It is not permitted to use uncoated screws with
pourable plastics

To ensure that the grease also penetrates to

the load-bearing points, the bearing must be
unloaded.
Slightly raise the lift mast on the outer mast
using a hydraulic jack.
Grease the mast bearings.

50638042201 EN - 10/2017 -1
https://truckmanualshub.com/

-2 50638042201 EN - 10/2017
https://truckmanualshub.com/

;
Line break safety devices [Nm] 23 ± 2
Outer cylinder hydraulic line [Nm]
Bleeder screws
;
Support roller diameter [mm] 75.3 Standard size
[mm] 0.05 Minimum play
Permissible radial play
[mm] 0.4 0.6 Maximum play
[mm] 0.1 Minimum play
Permissible lateral play
[mm] 0.3 1.1 Maximum play
Middle roller in case of 6-roller fork The play of the middle roller is 0.2 mm larger than the play
carriage of the upper rollers
;
Support roller diameter [mm] 80.9 Standard size
[mm] 0.05 Minimum play
Permissible radial play
[mm] 0.4 0.6 Maximum play
[mm] 0.1 Minimum play
Permissible lateral play
[mm] 0.3 1.1 Maximum play
Middle roller in case of 6-roller fork The play of the middle roller is 0.2 mm larger than the play
carriage of the upper rollers

Upper support rollers in case of Countersunk screw, M12 x 25, ISO 10642
[Nm] 60 ± 6
6-roller fork carriage Loctite 242

The weights of lift masts vary depending on the

model, load-bearing capacity and overall height.

Without fork carriage, fork arms, attachments

Telescopic mast Mast length (mm)/1000 x 114 + 59
NiHo mast 108 1600 - 1800 Mast length (mm)/1000 x 116 + 53
Triple mast Mast length (mm)/1000 x 116 + 53
Telescopic mast Mast length (mm)/1000 x 139 + 52
NiHo mast 117 2000 Mast length (mm)/1000 x 139 + 61
Triple mast Mast length (mm)/1000 x 206 + 70
.

50638042201 EN - 10/2017 -1
https://truckmanualshub.com/

The line break safety valve prevents the load

from lowering at an accelerated rate and in
an uncontrolled manner in the event of line
breakage.
The line break safety valve features a valve disc
that is lifted from the valve seat by spring force
when in a quiescent state, thus keeping a ow
cross-section free. Under normal operation, the
spring keeps the valve open. In the event of a
line breakage, the volume ow rate increases,
the ow forces become greater than the spring
force and the valve closes immediately. A small
hole in the valve disc (ori ce) allows the load to
be lowered slowly when the valve is closed.
If there is more than one line break safety valve
tted in a lift mast, the sequence in which the
line break safety valves close is critical. The
sequence is critical to ensure safe conditions in
the event of line breakage. For this reason, line
break safety valves with differing trigger ows
are tted. The trigger ow [l/min] speci es the
volume ow rate at which the individual line break
safety valve closes.

If line break safety valves are missing or not of the cor-

rect size, this poses the risk of safety being jeopardised
in the event of line breakage.
Use the correct line break safety valves as shown on
the spare parts list.

The line break safety valves differ in terms of their

basic type, overall size and trigger ow. Refer
to the relevant spare parts list for details of the
correct line break safety valve.

Hawe (4) 23 Nm
Buchholz (5) 23 Nm

The settings of the line break safety valve must

not be changed!
Lift cylinders tted as spare parts must be
checked to ensure that the line break safety
valves are pre-assembled correctly!

-2 50638042201 EN - 10/2017
https://truckmanualshub.com/

The quantity and installation position of the line

break safety valve depends on the type of lift
mast, the load capacity class and the overall
height. A distinction is drawn between three
installation positions:
Cylinder bottom
Hydraulic adapter
Cylinder bottom and hydraulic adapter

1600 - 1800 0 1
1000 - 1800
1 1
From 2660 mm
2000 0 1
2500 0 1
3000 - 3500 0 1
4000 0 1
4500 - 5000 0 1

1600 1800 1 1 1 1
2000 1 1 1 1
2500 1 1 0 0
2500
1 1 1 1
From 2200 mm
3000 1 1 0 0
3500 1 1 0 0

1600 - 1800 1 1 1 1
2000 1 1 1 1
2500 0 0 1 1
3000 1 0 1 1
3500 1 0 1 1
4000 1 1 each 0
4500 0 1 each 1
5000 0 1 each 1

There is no hydraulic adapter present.

50638042201 EN - 10/2017 -3
https://truckmanualshub.com/

There is no line break safety valve installed at this point.

Number of line break safety valves installed.
.

-4 50638042201 EN - 10/2017
https://truckmanualshub.com/

1 Support roller
2 Shim ring
P Pro le sizes

After replacing the support rollers, the lateral

and radial play between the mast pro le and the
support roller must be checked.
The radial play is balanced using larger
support rollers.
The lateral play is balanced using shim rings.

[mm] 0.05 Minimum play

Permissible radial play
[mm] 0.4 - 0.6 Maximum play
[mm] 0.1 Minimum play
Permissible lateral play
[mm] 0.3 - 1.1 Maximum play
The play of the centre roller is 0.2 mm larger than the play of
6-roller fork carriage, centre roller
the upper rollers

108 75.3 75.6 75.9 76.2

117 80.9 81.2 81.5 81.8
130 89.9 90.2 90.5 90.8

108 35 x 45 x 0.1 35 x 45 x 0.3 35 x 45 x 1.0

117 36 x 52 x 0.2 36 x 52 x 0.5
130 40 x 50 x 0.2 40 x 50 x 0.5
.

50638042201 EN - 10/2017 -5
https://truckmanualshub.com/

Multi-plate chains, also called leaf chains, are

used as load chains. Leaf chains consist of chain
pins and joining plates. The outer joining plates
are given a press t. A sliding t is provided for the
inner joining plates to ensure that the leaf chains
can move freely.
Depending on the working cycle and place of
use, the load chains may be subjected to high
loads and will therefore wear more quickly. Load
chains will stretch due to wear at the chain pins.

In order to keep wear and tear to a minimum, note

the following:
Clean load chains regularly.
Spray load chains with STILL chain spray.
Measure the chain elongation.
Adjust the load chains evenly.
Load chains must be evenly tensioned when
under load.

Risk of accidents!
Load chains are safety elements
The use of cold/chemical cleaners or uids that are
corrosive or contain acid or chlorine can damage the
chains and is therefore forbidden!

Place a collection container under the lift mast.

Clean with paraf n derivatives such as ben-
zine (and follow the manufacturer's safety
information)
When cleaning with a steam jet, do not use
additives.
Remove any water in the chain links with
compressed air immediately after cleaning.
Move the chain around during this procedure.
Spray the chain immediately with STILL chain
spray. Move the chain around during this
procedure.

The load chains must be checked for the following

external damage:
broken joining plates
broken bolts

-6 50638042201 EN - 10/2017
https://truckmanualshub.com/

loose and crooked bolts

surface rust
stiff joints
wear and tear, damage to the clamping bolt
and end link
If any of the above-mentioned damage has
occurred, the load chain must be changed without
delay. If the load chain is damaged, it may break
before reaching the permissible elongation.

Improper repairs can lead to serious damage!

Always replace the load chains. It is not permitted
to carry out repairs to load chains.
Load chains must always be replaced in pairs to
ensure equal load distribution between the two load
chains.
Load chains must always be replaced in full, inclu-
ding the clamping bolt and end link.

Hold the marking (1) on the chain wear gauge

against the middle of a chain pin.

Count off 34 chain links. Depending on the

size of the chain, the marking (2) indicates the
normal length of 34 chain links.
The marking (3) indicates the chain length at
3% elongation.
As soon as the speci ed maximum elongation
of 3% has been reached, the load chain must be
changed.

50638042201 EN - 10/2017 -7
https://truckmanualshub.com/

The end stop must lie within the lift cylinder when
lift 1 is fully extended.
There must always be a minimum distance
remaining between the run-out barrier (1) and
fork cams (2) when lift 1 is fully extended.
The measured value is only a reference dimen-
sion.

Ideal air gap 10 - 20 mm

Minimum dimension 5 mm

For lift masts with a considerable overall height,

the distance to the run-out barrier can be easily
determined:
Stick plasticine to the fork cams on the fork
carriage.
Raise the fork carriage to the stop.
Use the slide gauge to measure the thickness
of the plasticine.

-8 50638042201 EN - 10/2017
https://truckmanualshub.com/

For the work described, it is important to know Hydraulic oil is hazardous to health. Hydraulic oil is
the overall weight of the lift mast, as well as the pressurised during operation.
weight of the fork carriage and any attachments. Do not spill the hydraulic oil.
Spilt hydraulic oil must be cleaned up immediately
The following devices are required for the work using oil-binding agents.
described: Comply with statutory regulations for disposal.
Second truck or crane with a suf cient nominal Do not allow hydraulic oil to come into contact with
load hot engine parts.
Safety chains and lifting slings with a suf cient Do not allow hydraulic oil to come into contact with
nominal load the skin.
Supporting blocks and europallet Avoid inhaling spray.

Hydraulic jack with suf cient nominal load, To avoid injury, use the appropriate protective
equipment (protective gloves, protection goggles,
lifting bag if necessary skin protection and skin care products).
Release the pressure from the system before
carrying out any work on the hydraulics.

50638042201 EN - 10/2017 -9
https://truckmanualshub.com/

Park the truck safely.

If necessary, depressurise the hydraulics;
see the chapter entitled "Depressurising the
hydraulics".
Remove the fork arms and, if necessary, the
attachment.
Raise and secure the fork carriage; see the
chapter entitled "Securing the fork carriage".
Loosen the mast bearing screws; do not
completely unscrew them.
Lower the fork carriage and put the lift mast
into a vertical position.
Apply the parking brake.
Turn the key switch OFF.
Disconnect the
battery male connector.
Attach a suitable lifting sling to the top of the
outer mast crossmember.
Hook the lifting sling onto the forks on the
second truck and secure in such a way that
it cannot slip off the forks when lifting the lift
mast. Tilt back the lift mast on the second
truck, for example.
Use the second forklift truck to raise the lift
mast slightly until it is suspended taut on the
lifting sling.
Place collection vessels for hydraulic oil under
the outer cylinders.
Unscrew the hydraulic lines on both outer
cylinders.
Depending on the equipment, unscrew the
auxiliary hydraulic lines from the lift mast.

-10 50638042201 EN - 10/2017

https://truckmanualshub.com/

Seal off hydraulic lines using plugs. Use cable

ties to attach the loose hose ends to the lift
mast.

As soon as the mast bearings and tilt cylinders are

unscrewed, the weight of the lift mast is taken entirely
by the lifting sling.
Ensure that the lifting sling is seated securely on the
lift mast.
Ensure that the lift mast is raised slightly and is taut
on the lifting sling.

Unscrew the mast bearing screws and, if

necessary, remove the mast bearings from
the bearing pins.
Depending on the equipment on the tilt cylin-
der, unscrew the mast vertical position lever.
Disconnect both tilt cylinders from the outer
mast. To do this, remove the locking ring and
knock out the bolts.
Lift out the lift mast using the second truck
and set it down carefully on the prepared
EUR-pallet.

Risk of damage to components.

Proceed with care when lifting out the lift mast. Ensure
that the lift mast does not start to swing and collide with
the truck.

Only use new mast bearing screws for the

installation; see the chapter entitled "Mast
bearings".
Note the screw quality and tightening torques.
See "General technical data" for values.
Safely park the truck.

50638042201 EN - 10/2017 -11

https://truckmanualshub.com/

Attach a suitable lifting sling to the top of the

outer mast crossmember.
Hook the lifting sling onto the forks on the
second truck and secure in such a way that
it cannot slip off the forks when lifting the lift
mast. Tilt back the lift mast on the second
truck, for example.

Risk of damage to components.

Proceed with care when lifting the lift mast. Ensure that
the lift mast does not start to swing and collide with the
truck.

Move the lift mast into position and screw on

the mast bearing screws; see the chapter
entitled "Mast bearings".
Connect both tilt cylinders to the outer mast.
To do this, knock in the bolts and secure them
using the locking ring.
Depending on the equipment on the tilt cylin-
der, bolt on the mast vertical position lever.

Screw the hydraulic lines to the outer cylinders.

Depending on the equipment, screw the
auxiliary hydraulic lines on the lift mast.
Connect the battery
male connector.
To bleed the lift cylinders, raise the fork
carriage by approx. 300 mm.

On the outer cylinders, loosen the bleeder

screw in the cylinder head by a maximum of
one turn.

-12 50638042201 EN - 10/2017

https://truckmanualshub.com/

In the case of NiHo and triple lift masts, also

loosen the bleeder screw on the middle
cylinder by a maximum of one turn.
Screw the bleeder screw back in as soon as oil
starts to leak out.
Carry out this process for every lift cylinder.
Check the hydraulics for leaks.
Check the seating and position of the load
chains and hose guides.
Function check.

50638042201 EN - 10/2017 -13

https://truckmanualshub.com/

The telescopic lift mast is a high-visibility lift mast.

The mast pro le is a double-T pro le. The fork
carriage and mast pro les are guided through
support rollers (4); these also absorb the lateral
forces.
When the load is lifted, the inner mast is also
raised along with the fork carriage. After a small
free lift of approx. 150 - 160 mm, the overall
height of the truck changes immediately. This
must be taken into consideration if there are low
ceilings and gates.
The telescopic lift mast consists of an inner mast
(2) and an outer mast (1). A lift cylinder (3) is
tted on each side in the outer mast pro les.
The lift pistons are connected to the inner mast
crossmember (5).
The load chains (8) are connected to the outer
mast crossmember (6) via clamping bolts. The
load chains are redirected by chain rollers (7) on
the inner mast. The end links of the load chains
are connected to the fork carriage.
If the lift cylinders are supplied with hydraulic oil,
the lift pistons extend and take the inner mast with
them. The redirection of the load chains causes
the inner mast to extend towards the fork carriage
at a ratio of 1:2.
The end stop is located in the lift cylinder. 1 Outer mast
2 Inner mast
A run-out barrier prevents the fork carriage from 3 Lift cylinder
tilting outwards; see the chapter entitled "Run-out 4 Support roller
barrier". 5 Inner mast crossmember
6 Outer mast crossmember
7 Chain roller
8 Load chains

The hydraulic oil comes from the directional

control valve block. It is distributed via a T-piece
and is directed down to the two outer cylinders on
the left and right.
The line break safety valve (LBS) is installed
in the outer cylinder. This valve prevents the
load from lowering too quickly in the event of line
breakage; see the chapter entitled "Line break
safety valve".

-14 50638042201 EN - 10/2017

https://truckmanualshub.com/

Lower the lift mast and tilt it back fully.

Unscrew the screw (4) on each side of the
outer mast and remove the cap (2).

The screw (2) features a thread lock.

Secure the screw using Loctite 243.
Release the nut (3) on both sides.
Evenly tension the two load chains at the
tensioning nuts (1) until the dimension (X)
is reached.

A Bottom edge of the inner mast

Bottom edge of the support
B
roller
X Setting dimension

1000 1800 27.5 -2.5

2000 30.5-2.5

2500 3500 35.0 -2.5

Screw the nut (3) in place against the rubber

washer on both sides so that it is loose. Do not
tighten.

50638042201 EN - 10/2017 -15

https://truckmanualshub.com/

Screw the cap (2) securely in place on both

sides using a new Tu ok screw (4).

Damage due to the fork carriage coming into contact

with the run-out barrier!
Never compensate for tyre wear by retightening the
load chain because the load chain will then be too
short.

-16 50638042201 EN - 10/2017

https://truckmanualshub.com/

The NiHo lift mast is a high-visibility lift mast.

The mast pro le is a double-T pro le. The fork
carriage and mast pro les are guided through
support rollers (8); these also absorb the lateral
forces.
When the load is lifted, the fork carriage is raised
in free lift in lift 1. In free lift, the overall height of
the truck does not change. In lift 2, the inner mast
is also raised and the overall height of the truck is
changed.

Using a 6-roller fork carriage presents an excep-

tion in this regard. Even in lift 1, this fork carriage
rises a few centimetres above the top of the inner
mast, so that the overall height of the truck chan-
ges.
The NiHo lift mast consists of an inner mast
(2) and an outer mast (1). A lift cylinder (3) is
tted on each side in the outer mast pro les.
The lift pistons are connected to the inner mast
crossmember (6) at the top.
The middle cylinder (4) is installed within the
inner mast. The load chain (5) is connected to
the middle bridge piece for the inner mast (9)
via a clamping bolt. The load chain is redirected
1 Outer mast
by a chain roller (7) on the middle cylinder. The
2 Inner mast
end link of the load chain is connected to the fork
3 Outer cylinder
carriage. 4 Middle cylinder
When the lift cylinders are supplied with hydraulic 5 Load chain
6 Inner mast crossmember
oil, the lift piston of the middle cylinder extends
7 Chain roller
rst, taking with it the fork carriage via the load
8 Support rollers
chain in lift 1. 9 Middle bridge piece for the inner mast
When the middle cylinder is in the end position,
the lift pistons of the outer cylinder extend, taking
with them the inner mast in lift 2.
The end stop is in the cylinders.
A run-out barrier prevents the fork carriage from
tilting outwards; see the chapter entitled "Run-out
barrier".

50638042201 EN - 10/2017 -17

https://truckmanualshub.com/

The hydraulic oil comes from the directional

control valve block. The hydraulic oil is then
distributed via a T-piece and directed down to the
two outer cylinders. The right-hand outer cylinder
is closed at the top. In the left-hand outer cylinder,
the hydraulic oil is directed through the piston rod
and then down through a hose line to the middle
cylinder.
Due to the varying piston areas, the middle
cylinder is always raised rst (lift 1) and then
the two outer cylinders (lift 2); see the chapter
entitled "Lifting sequence problem".
Line break safety valves (LBS) are installed in
the outer cylinders and middle cylinder. These
valves prevent the load from lowering too quickly
in the event of line breakage; see the chapter
entitled "Line break safety valve". I Lift 1
II Lift 2
LBS Line break safety valve

-18 50638042201 EN - 10/2017

https://truckmanualshub.com/

Lower the lift mast and tilt it back fully.

Unscrew the screw on the middle cylinder and
remove the cap (4).

The screw (2) features a thread lock.

Secure the screw using Loctite 243.
Tighten the load chain at the tensioning nut (3)
until the dimension (X) is achieved.

3
4
7094_813-001

A Bottom edge of the inner mast

Bottom edge of the support
B
roller
X Setting dimension

1000 1800 27.5 +0/-2.5

2000 25.5 +0/-2.5

2500 3000 35.0 +0/-2.5

3500 35.0+0/-2.5

Screw the cap (1) on tightly using a screw (4).

Secure the screw with Loctite.

50638042201 EN - 10/2017 -19

https://truckmanualshub.com/

Damage due to the fork carriage coming into contact

with the run-out barrier!
Never compensate for tyre wear by retightening the
load chain because the load chain will then be too
short.

-20 50638042201 EN - 10/2017

https://truckmanualshub.com/

The triple mast is a high-visibility lift mast. The

mast pro le is a double-T pro le. The fork car-
riage and mast pro les are guided through sup-
port rollers (8); these also absorb the lateral
forces.
The function of the triple lift mast is the same
as the NiHo lift mast, but it has an increased lift
height with the same overall height.
When the load is lifted, the fork carriage is raised
in free lift in lift 1. In free lift, the overall height
of the truck does not change. Only in lift 2 is the
middle mast also raised, taking the inner mast
with it via the outer load chains.

Using a 6-roller fork carriage presents an excep-

tion in this regard. Even in lift 1, this fork carriage
rises a few centimetres above the top of the inner
mast, so that the overall height of the truck chan-
ges.
The triple mast consists of an inner mast (3),
a middle mast (2) and an outer mast (1). A lift
cylinder (13) is tted on each side in the outer
mast pro les. The lift pistons are connected to
the middle mast crossmember (10). The middle
cylinder (4) is installed within the inner mast. 1 Outer mast
An outer load chain (7) is connected via a clamp- 2 Middle mast
3 Inner mast
ing bolt on the upper outer mast crossmember (9)
4 Middle cylinder
on each side. The load chains are redirected by
5 Middle load chain
chain rollers on the middle mast. The end links of 6 Chain roller
the load chains are connected to the inner mast. 7 Outer load chains
8 Support rollers
The middle load chain (5) is connected to the
9 Outer mast crossmember
middle bridge piece for the inner mast (12) via
10 Middle mast crossmember
a clamping bolt. The load chain is redirected 11 Inner mast crossmember
by a chain roller (6) on the middle cylinder. The 12 Middle bridge piece for the inner mast
end link of the load chain is connected to the fork 13 Lift cylinder
carriage.
When the lift cylinders are supplied with hydraulic
oil, the lift piston of the middle cylinder extends
rst, taking with it the fork carriage via the middle
load chain in lift 1.
When the middle cylinder is in the end position,
the lift pistons of the outer cylinder extend, taking
with them the middle mast in lift 2 and the inner
mast via the outer load chains.

50638042201 EN - 10/2017 -21

https://truckmanualshub.com/

The redirection of the outer load chains causes

the inner mast to move towards the middle mast
at a ratio of 1:2.
The end stop is in the cylinder.
A run-out barrier prevents the fork carriage from
tilting outwards; see the chapter entitled "Run-out
barrier".

The hydraulic oil comes from the directional

control valve block, is distributed via a T-piece
and is directed below into the two outer cylinders
on the left and right. The right-hand outer cylinder
is closed at the top. As for the left-hand outer
cylinder, the hydraulic oil is directed through the
cylinder head and then down through a hose line
to the middle cylinder.
Due to the varying piston areas, the middle
cylinder is always raised rst (lift 1) and then
the two outer cylinders (lift 2); see the chapter
entitled "Lifting sequence problem".
Line break safety valves (LBS) are installed in
the outer cylinders and middle cylinder. These
valves prevent the load from lowering too quickly
in the event of line breakage; see the chapter
entitled "Line break safety valve".
I Lift 1
II Lift 2
LBS Line break safety valve

-22 50638042201 EN - 10/2017

https://truckmanualshub.com/

Safely park the truck.

Move the lift mast to its vertical position.
Apply the parking brake.
Raise the fork carriage and secure it to the
inner mast crossmember using the safety
chain.
OR:
Remove the fork carriage; see the chapter
entitled "Fork carriage"
Turn the key switch OFF.
: Disconnect the
battery male connector.

If necessary, release the pressure from the

hydraulics; see the chapter entitled "Releasing
the pressure from the hydraulics".
If necessary, loosen the auxiliary hydraulics
hoses on the inner mast.
Unscrew the load chain locking device on both
sides at the bottom of the inner mast.

Using the hydraulic jack, lift the inner mast

until the load chains fall out of the lower guide.
Set the load chains aside so that they do not
become trapped when lowering the inner mast.

50638042201 EN - 10/2017 -23

https://truckmanualshub.com/

Slowly lower the inner mast until the support

rollers are freely accessible at the bottom of
the inner mast.

During the lowering process, the inner mast moves

clear of the upper guide and tilts forwards slightly.
Hydraulic hoses and other components may become
damaged during this process. However the inner mast
cannot fall out forwards!
To avoid any possible damage, lower the hydraulic
jack slowly.

At the same time, the support rollers at the top

of the middle mast become free. The inner
mast is tilted forwards slightly.
Remove the 4 support rollers at the top and
bottom from the bearing pins.
Clean the bearing pins and t new support
rollers, adding shim rings as required.
Adjust the play of the support rollers; see the
chapter entitled "Support roller play"

Use the hydraulic jack to lift the inner mast until

it is once again guided by the upper support
roller on the middle mast.

Place the inner mast on a at supporting block.

The inner mast must be placed in as low a
position as possible to ensure there is suf cient
room to remove the upper support roller from
the bearing pin.

At the top of the middle mast crossmember,

disassemble the locking rings from the piston
rods.
Left hand side: Unscrew the pipe line from the
hydraulic adapter.
Unscrew the auxiliary hydraulics hoses from
the middle mast.

-24 50638042201 EN - 10/2017

https://truckmanualshub.com/

Release the hydraulic hoses and protect them

from contamination.
Unscrew the hose guide from the chain roller.
Unscrew the hose clips from the outer mast.

Unscrew the tensioning pieces on the lift

cylinders.
Using the hydraulic jack, lift the middle mast
until the lift cylinders are no longer guided in
the middle mast crossmember.
Move the lift cylinders aside.

Remove the load chains from the chain roller

and the outer mast crossmember.
Remove the hose guide from the outer mast
crossmember.

Lower the middle mast as far as the outer mast

crossmember and support it on a supporting
block.
If necessary, lower the inner mast until the
bottom support rollers on the middle mast are
freely accessible. Support the middle mast
and inner mast on a supporting block.

Do not lower the masts to the ground. It must be

possible to bring the hydraulic jack into position
to raise the masts!

50638042201 EN - 10/2017 -25

https://truckmanualshub.com/

At the same time, the support rollers at the top

of the outer mast become free.
Remove the 4 support rollers at the top and
bottom from the bearing pins.
Clean the bearing pins and t new support
rollers, adding shim rings as required.
Adjust the play of the support rollers; see the
chapter entitled "Support roller play"

Initial position after replacing the support

rollers.

Using a hydraulic jack, raise the middle mast

until the chain rollers are above the outer mast
crossmember.
Loosely position the two lift cylinders using
the tensioning pieces but do not tighten the
tensioning piece at this point.
Place the outer load chain over the chain roller,
making sure that the chain anchor is in the
correct position.
Bring the hydraulic hoses with hose guide
into position, but do not screw them tightly
into place at this point. Connect the hydraulic
hoses.
Slowly lower the middle mast until the lift
cylinders are routed through the middle mast
crossmember.

-26 50638042201 EN - 10/2017

https://truckmanualshub.com/

Fit the locking rings for the piston rods on to the

middle mast crossmember.

Insert the load chains into the bottom of the

inner mast and secure using the locking screw.
If necessary, lift the inner mast for this purpose.
Remove the supporting block from under
the middle mast. The middle mast is now
suspended on its load chains.

Tighten the tensioning pieces so that the lift

cylinders are securely positioned.
Left hand side: Screw the pipe line on to the
hydraulic adapter.
Screw the hose clips on to the outer mast.
Screw the auxiliary hydraulics hoses on to the
middle mast.
Use the second truck to lift the fork carriage
into the lift mast from above. See the chapter
entitled "Installing the fork carriage"
Adjust the load chains and tension them
equally; see the chapter entitled "Adjusting
the load chains"
Screw the hose guide on tightly and tension
the hydraulic hoses. The hydraulic hoses must
not suffer impacts during operation.
Perform a functional test and leak test.

50638042201 EN - 10/2017 -27

https://truckmanualshub.com/

Safely park the truck.

Move the lift mast to its vertical position.
Apply the parking brake.
Raise the fork carriage and secure it to the
inner mast crossmember using the safety
chain.
Turn the key switch OFF.
Disconnect the
battery male connector.
Lift the inner mast using a hydraulic jack so that
the load chains hang loose. Using supporting
blocks, secure the inner mast.

Unscrew the chain guide from the chain rollers

on both sides.
Remove the load chains from the chain rollers.

Remove the chain roller from the bearing pin,

using a puller if necessary.
Remove the load chains from the inner mast
crossmember at the bottom and unscrew the
load chains from the outer mast at the top.

Clean the bearing pins and coat them with

multi-purpose oil.

-28 50638042201 EN - 10/2017

https://truckmanualshub.com/

Position the chain roller on the bearing pin.

Using a hammer, carefully tap the inner ring.
Place the load chain over the chain roller,
noting the installation direction of the chain.
Screw on the clamping bolt for the load chains
to the top of the outer mast crossmember.

Attach the chain anchor for the load chains in

the inner mast at the bottom and secure using
the locking screw.

Screw on the chain guide, together with the

hose guide if necessary.
Remove the supporting blocks from under the
inner mast.
Connect the battery
male connector.
Lift the fork carriage slightly, remove the safety
chain and lower the fork carriage.
Adjust the outer load chains; see the chapter
entitled "Adjusting the outer load chains".

50638042201 EN - 10/2017 -29

https://truckmanualshub.com/

Safely park the truck.

Move the lift mast to its vertical position.
Apply the parking brake.
Raise the fork carriage and place it on support-
ing blocks so that the load chain hangs loose.
Turn the key switch OFF.
Disconnect the
battery male connector.
Remove the hoses
from the support and unscrew the hose guide
from the fork clevis. Put everything to one side.
Remove the load chain from the chain roller.

Press the chain roller pin out of the fork clevis.

Remove the chain roller and set the spacer
washers to one side.
Detach the load chain on the fork carriage and
unscrew it from the inner mast crossmember.

Clean the fork clevis and coat it with multi-

purpose oil.

Insert the chain roller with spacer washers

into the fork clevis. When doing so, note the
installation position of the bolt.
Place the load chain over the chain roller,
noting the direction of the chain.
Attach the load chains to the fork carriage and
screw onto the inner mast crossmember.

-30 50638042201 EN - 10/2017

https://truckmanualshub.com/

Screw the hose guide

onto the fork clevis and screw on the support
for the hoses.
Connect the battery
male connector.
Lift the fork carriage, remove the supporting
blocks and lower the fork carriage.
Adjust the middle load chain; see the chapter
entitled "Adjusting the middle load chain".

50638042201 EN - 10/2017 -31

https://truckmanualshub.com/

Adjusting the outer load chain only ensures that

the masts are ush with each other. The fork
carriage position is adjusted via the middle load
chain
Lower the lift mast and tilt it back fully.
Unscrew the screw (2) on each side of the
outer mast and remove the cap (1).

The screw (2) features a thread lock.

Secure the screw using Loctite 243.

Tension both load chains equally at the

clamping bolts (3) until the bottom edges of
the middle mast, inner mast and outer mast
are ush with each other.
Screw the cap (1) tightly into place on both
sides using the screw (2).

Damage due to the fork carriage coming into contact

with the run-out barrier!
Never compensate for tyre wear by retightening the
load chain because the load chain will then be too
short.

-32 50638042201 EN - 10/2017

https://truckmanualshub.com/

Lower the lift mast and tilt it back fully.

Unscrew the screw on the middle cylinder and
remove the cap (4).

The screw (2) features a thread lock.

Secure the screw using Loctite 243.
Tighten the load chain at the tensioning nut (3)
until the dimension (X) is achieved.

3
4
7094_813-001

A Bottom edge of the inner mast

Bottom edge of the support
B
roller
X Setting dimension

1000 1800 27.5 +0/-2.5

2000 25.5 +0/-2.5

2500 3000 35.0 +0/-2.5

3500 35.0+0/-2.5

Screw the cap (1) on tightly using a screw (4).

Secure the screw with Loctite.

50638042201 EN - 10/2017 -33

https://truckmanualshub.com/

Damage due to the fork carriage coming into contact

with the run-out barrier!
Never compensate for tyre wear by retightening the
load chain because the load chain will then be too
short.

-34 50638042201 EN - 10/2017

https://truckmanualshub.com/

The lift cylinders are single-action cylinders.

The cylinder pipe is welded to the cylinder bottom.
The cylinder head is bolted on to the cylinder pipe
and secured using pourable plastics.
The seal between the cylinder head and cylinder
pipe, and between the cylinder head and piston
rod (piston barrel), is provided in the form of
sealing rings. O-rings and grooved rings are
used depending on the type of lift cylinder.
The lift is restricted by a piston cover screwed into
the piston rod (piston barrel) and secured using
pourable plastics.

1 Snap ring
2 Double wiper
3 Grooved ring
4 Bleeder screw with copper seal
5 O-ring
6 Cylinder head
7 Guide bush
8 Piston barrel/piston rod
9 Cylinder pipe
10 Piston cover
11 Cylinder bottom

50638042201 EN - 10/2017 -35

https://truckmanualshub.com/

The following equipment is required to remove The hydraulic oil is pressurised during operation and is
hazardous to your health.
the lift cylinders:
Do not spill the hydraulic oil.
Safety chain and lifting sling with an adequate
nominal load Spilt hydraulic oil must be cleaned up immediately
using oil-binding agents.
Supporting blocks Comply with statutory regulations for disposal.
Hydraulic jack Do not allow hydraulic oil to come into contact with
hot motor parts.
The following equipment is required to disassem-
Do not allow hydraulic oil to come into contact with
ble the lift cylinders:
the skin.
Vice Avoid inhaling spray.
Protective jaws To avoid injury, use the appropriate protective
Hot-air gun equipment (protective gloves, industrial goggles,
skin protection and skin care products).

Applying too much heat can lead to thermal damage.

Only heat threads secured with Loctite using a hot-air
gun on a selective basis. Do not heat large areas of the
thread using a naked ame.

Safely park the truck.

Set the lift mast to vertical.
Apply the parking brake.
Raise the fork carriage and secure it to the
inner mast crossmember using the safety
chain.
Lower the fork carriage until the safety chain is
taut. The lift cylinders must be fully retracted.
Turn the key switch OFF.
Disconnect the
battery male connector.
The process for removing the outer cylinders is
virtually identical for both sides. Deviations are
described in the next section.
Place collection vessels for hydraulic oil under
the outer cylinders.

-36 50638042201 EN - 10/2017

https://truckmanualshub.com/

Unscrew the hydraulic lines from the bottom of

the outer cylinders.

Unscrew the hydraulic connection from the top

of the hydraulic adapter.

At the top of the crossmember, disassemble

the locking ring from the piston rods.

Raise the
inner mast using a hydraulic jack far enough
for the outer cylinder to be accessed at the top
on the crossmember.

50638042201 EN - 10/2017 -37

https://truckmanualshub.com/

Raise the middle mast

using a hydraulic jack far enough for the
outer cylinder to be accessed at the top on
the crossmember.

Unscrew the tensioning pieces.

Risk of injury! Without the tensioning piece, the outer

cylinder will tip to the side.
Secure the outer cylinder to prevent it from tipping.

The outer cylinder swivels to the side. Lift the

outer cylinder out of the bottom holding xture.

Place the outer cylinder in the bottom holding

xture on the outer mast.
Loosely position the outer cylinder using
the tensioning piece but do not tighten the
tensioning piece at this point.

Note the location of the bleeder screw.

The bleeder screw faces outwards.
Lower the
inner mast using a hydraulic jack far enough
for the outer cylinder to be guided through the
crossmember of the inner mast.
Lower the middle mast
using a hydraulic jack far enough for the outer
cylinder to be guided through the crossmem-
ber of the middle mast.
Assemble the locking ring for securing the lift
cylinder on the top of the crossmember.

-38 50638042201 EN - 10/2017

https://truckmanualshub.com/

Screw the hydraulic lines to the outer cylinders.

Screw the hydraulic connection to the top of

the hydraulic adapter.
Extend the lift cylinder until the safety chain is
no longer under tension.

Open the bleeder screw on the outer cylinder

a maximum of one turn.
Tighten the bleeder screw again as soon as oil
starts to leak out.
Remove the safety chain and slowly lower the
fork carriage.
Check the hydraulics for leaks.
Check the seating and position of the load
chains and hose guides.
Perform a function check.

Pull the piston rod approx. 20 cm out of the

cylinder pipe.
Using protective jaws, clamp the piston rod in
the vice.

50638042201 EN - 10/2017 -39

https://truckmanualshub.com/

Unscrew the hydraulic adapter. The hydraulic

adapter is secured with Loctite, so it may be
necessary to gently heat the thread.
The next steps of the disassembly process are
the same for both of the outer cylinders.

Using protective jaws, clamp the cylinder pipe

loosely in the vice.
Unscrew the cylinder head using a hook
spanner. The cylinder head is secured with
Loctite, so it may be necessary to gently heat
the thread.
Remove the cylinder head from the piston rod.
Remove the set of seals.

Clean the cylinder head and check for signs of

wear and damage.
Insert a new set of seals into the cylinder head.
Lightly coat the seals with hydraulic oil.

Check the piston rod and the chamfer for

damage.
Clean and degrease the thread on the cylinder
pipe and cylinder head.
Secure the thread by spreading three drops of
over the entire thread.

-40 50638042201 EN - 10/2017

https://truckmanualshub.com/

Attach the cylinder head and screw it on as far

as it will go using a hook spanner. Secure the
cylinder head by knocking the hook spanner
with two blows of the hammer.

Pull the piston rod approx. 20 cm out of the

cylinder pipe.
Using protective jaws, clamp the piston rod in
the vice.
Clean and degrease the thread in the cylinder
pipe and hydraulic adapter.
Secure the thread by spreading three drops of
over the entire thread.
Attach the hydraulic adapter and screw it on as
far as it will go.

Safely park the truck.

Put the lift mast in its vertical position.
Apply the parking brake.
Remove the hoses
from the support and unscrew the hose guide
from the fork bearing. Put everything to one
side.
Raise the fork carriage and secure it to the
inner mast crossmember using the safety
chain.
Fully lower the middle cylinder, ensuring that
the load chain remains at the top.
Turn the key switch OFF.
Disconnect the
battery male connector.

50638042201 EN - 10/2017 -41

https://truckmanualshub.com/

Remove the chain roller pin from the fork

bearing. Remove the chain roller and set the
spacer washers to one side (1).
Place a collection vessel for hydraulic oil under
the middle cylinder.
Release the hydraulic connection on the cylin-
der bottom (2) and protect against contamina-
tion.
Unscrew the clip or tensioning piece from the
middle bridge piece for the inner mast (3).

Without the tensioning piece, the middle cylinder is not

secured and may tip forward.
Secure the middle cylinder from tilting outwards by
accident.

Lift out the middle cylinder.

Position the middle cylinder within the inner

mast (2) and secure the middle cylinder in
place using the clip or tensioning piece (3). Do
not tighten the tensioning piece.

Note the location of the bleeder screw (4).

The bleeder screw points to the left or to the
right by ± 30°
Screw the hydraulic connection with the
sealing ring to the cylinder bottom (2).
Tighten the clip or tensioning piece to the
middle bridge piece for the inner mast (3).

-42 50638042201 EN - 10/2017

https://truckmanualshub.com/

Insert the chain roller with spacer washers into

the fork bearing (1). When doing so, note the
installation position of the bolt. See the chapter
entitled "Middle load chain and chain roller".

Screw the hose guide and hoses to the fork

bearing.
Extend the lift cylinder until the safety chain is
no longer under tension.

Loosen the bleeder screw on the middle

cylinder by a maximum of one rotation.
Screw the bleeder screw back in as soon as oil
starts to leak out.
Remove the safety chain and slowly lower the
fork carriage.
Check the hydraulics for leaks.
Check the seating and position of the load
chains and hose guides.
Perform a function check.

Pull the piston rod approx. 20 cm out of the

cylinder pipe.
Using protective jaws, clamp the piston rod
loosely in the vice.
Unscrew the fork clevis. The fork clevis is
secured with Loctite, so it may be necessary to
gently heat the thread.

50638042201 EN - 10/2017 -43

https://truckmanualshub.com/

Using protective jaws, clamp the cylinder pipe

in the vice.
Unscrew the cylinder head using a hook
spanner. The cylinder head is secured with
Loctite, so it may be necessary to gently heat
the thread.

Remove the cylinder head from the piston rod.

Remove the set of seals.

Clean the cylinder head and check for signs of

wear and damage.
Insert a new set of seals into the cylinder head.
Lightly coat the seals with hydraulic oil.

Check the piston rod and the chamfer for

damage.
Clean and degrease the thread in the cylinder
pipe and cylinder head.
Secure the thread by spreading three drops of
over the entire thread.

-44 50638042201 EN - 10/2017

https://truckmanualshub.com/

Attach the cylinder head and screw it on as far

as it will go using a hook spanner. Secure
the cylinder head into its nal position by
knocking the hook spanner with two blows
of the hammer.
Clean and degrease the thread in the cylinder
pipe and fork clevis.
Secure the thread by spreading three drops of
over the entire thread.
Attach the fork clevis and screw it on as far as
it will go. Secure the fork clevis into its nal
position by knocking it with three blows of the
hammer.

50638042201 EN - 10/2017 -45

https://truckmanualshub.com/

While lowering during lift 2, the end position

damping hydraulically brakes the piston rod of the
right-hand outer cylinder just before it reaches its
end position.
This prevents metal striking on metal.
The right-hand outer cylinder is equipped with
end position damping. In telescopic lift masts,
end position damping is not installed.

During lifting, the piston (4) is moved towards

the cylinder bottom (1) by the spring force of the
compression spring (5) until the snap ring (6) lies
against the piston cover (3). The hydraulic oil is
unrestricted as it ows out of the cylinder.
During lowering, the oil ows out of the cylinder
unrestricted until the piston (4) reaches the
cylinder bottom (1). The piston (4) is moved into
the piston cover (3). As a result, the hydraulic oil
ows from area (B) into area (A) via the ori ce
bore (2).
This pressure balancing brakes the lift mast
hydraulically.

1 Reducer bore
2 Piston cover
3 Piston
4 Compression spring
5 Snap ring

-46 50638042201 EN - 10/2017

https://truckmanualshub.com/

When lifting the fork carriage, the end position

damping hydraulically brakes the piston rod just
before it reaches its end position.
The end dampener is located in the piston cover.

The piston rod (5) extends until the cross hole in

the piston rod (4) is covered by the cylinder pipe
(1). The lifting speed is reduced as soon as the
cross hole is covered by the cylinder pipe.
Once the cross hole of the piston rod (4) is entirely
covered by the cylinder head, the returning
hydraulic oil has no direct return path.
As a result of the increasing pressure in the cross
hole inside the piston cover (2), the valve piston
(6) is forced into contact with the threaded pin (9).
The hydraulic oil ows back at a restricted rate
via the cross hole (2), the ori ce bore in the valve
piston (6) and the threaded pin (9).
As a result, the piston rod is hydraulically braked
before reaching its end position.

1 Cylinder pipe
2 Cross hole in piston cover
3 Piston cover
4 Cross hole in piston rod
5 Piston rod
6 Valve piston
7 Piston packing
8 Guide ring
9 Threaded pin

50638042201 EN - 10/2017 -47

https://truckmanualshub.com/

-48 50638042201 EN - 10/2017

https://truckmanualshub.com/

Safely park the truck.

Apply the parking brake.
Put the lift mast in its vertical position.
Remove the fork arms.
If necessary, depressurise the hydraulics;
see the chapter entitled "Depressurising the
hydraulics".
Depending on the equipment tted, remove
the attachment and auxiliary hydraulics hoses.
Raise the fork carriage to a comfortable
working height.
Unscrew the hose guide from the fork carriage.
Turn the key switch OFF.
Disconnect the
battery male connector.
Unscrew the run-out barrier at the top of the
inner mast.
Attach a suitable lifting sling to the fork car-
riage.
Hook the lifting sling onto the forks on the
second truck and secure in such a way that
it cannot slip off the forks during the lifting
process.

For NiHo and triple lift masts, a middle load

chain is used
For telescopic lift masts, two outer load chains
are used
Unscrew the load chain locking device on the
fork carriage.
Detach the load chains from the fork carriage.
Use the second truck to lift the fork carriage up
and out of the lift mast.
Place the fork carriage on a EUR-pallet.

Use the second truck to lift the fork carriage

into the lift mast from above.
Lower the fork carriage to a comfortable
working height.

50638042201 EN - 10/2017 -1
https://truckmanualshub.com/

Attach the load chains to the fork carriage.

Screw in the load chain locking device on the
fork carriage. Ensure that the screw overlaps
the chain anchor suf ciently.

If the fork carriage jams in the inner mast during

assembly, gently tilt the lift mast back and forth in
order to advance the fork carriage into the inner
mast.
Continue to lower the fork carriage until the
load chain is taut.
Remove the lifting sling from the fork carriage.
Adjust the play of the support rollers; see the
chapter entitled "Support roller play".
Attach the fork arms. Depending on the
equipment installed, t the attachment and the
a
auxiliary hydraulics hoses to the fork carriage.
Function checking

-2 50638042201 EN - 10/2017
https://truckmanualshub.com/
https://truckmanualshub.com/

STILL GmbH

50638042201 EN 10/2017
https://truckmanualshub.com/

RX20-15 - 20, RX60-16 - 20

https://truckmanualshub.com/
https://truckmanualshub.com/

-1
50638042201 EN - 10/2017
a
1a Steering cylinder fth wheel axle 6a Directional control valve block (version as of 2006) 13 Lift cylinders 20 Mini measurement port
1b Steering cylinder swing axle 7 Directional control valve block - auxiliary hydraulics 1 14 Load holding valve 21 Suction lter
2 Steering unit 8 Directional control valve block - auxiliary hydraulics 2 15 Pressure relief valve 22 By-pass valve
3 Hydraulic tank 9 Tilt ori ce 16 Breather 23 Release valve
4 Return lter 10 Tilt cylinder 17 Priority valve 24 Direction of travel (steering cylinder)
5 Pump unit 11 Lowering brake 18 Pressure switch
6 Directional control valve block (lift/tilt) 12 Line breakage protection 19 Hydraulic accumulator (variant)

1500 - 1800 ≤ 2760 A

1500 - 1800 ≥ 2810 B
1500 - 2000 ≤ 2710 C
1500 - 2000 ≤ 3260 C
2000 ≤ 3260 A
.
https://truckmanualshub.com/

-2 50638042201 EN - 10/2017
https://truckmanualshub.com/

-3
50638042201 EN - 10/2017
1a Steering cylinder, turntable steering axle 7 Directional control valve block - auxiliary hydraulics 1 14 Load holding valve (125 bar) 21 Check valve for hydraulics blocking function
1b Steering cylinder, swing axle 8 Directional control valve block - auxiliary hydraulics 2 15 Pressure relief valve (250 bar) 22 Pressure-balance valve
2 Steering unit 9 Tilt ori ce 16 Breather lter 23 Emergency lowering
3 Hydraulic tank 10 Tilt cylinder 17 Priority valve 24 Drive direction (steering cylinder)
4 Return line lter 11 Lowering-balance valve 18 Pressure switch (electrical NC contact)
5 Pump unit 12 Line break safety device 19 Hydraulic accumulator (variant)
6 Directional control valve block - lifting/tilting 13 Lift cylinder 20 Mini measurement port

1500 - 1800 ≤ 2760 A

1500 - 1800 ≥ 2810 B
1500 - 2000 ≤ 2710 C
1500 - 2000 ≤ 3260 C
2000 ≤ 3260 A
.
https://truckmanualshub.com/

-4 50638042201 EN - 10/2017
https://truckmanualshub.com/

-5
50638042201 EN - 10/2017
1a Steering cylinder fth wheel axle 9 Mini measurement port 17 Priority valve
1b Steering cylinder swing axle 10 Tilt cylinder 18 Pressure switch
2 Steering unit 11 Valve for lowering 19 Check valve for hydraulics blocking function
3 Hydraulic tank 11a Lowering brake 20 High-pressure lter
4 Return lter 12 Line breakage protection 21 Suction lter
5 Pump unit 13 Lift cylinders 22 By-pass valve
6 Directional control valve block - Lift-Tilt-Auxiliary 1 14 Load holding valve 23 Pressure governor
7 Directional control valve block - Lift-Tilt-Auxiliary 1, 2 15 Pressure relief valve 24 Flow control valve
8 Hydraulic accumulator (variant) 16 Breather 25 Direction of travel (steering cylinder)

1500 - 1800 ≤ 2760 A

1500 - 1800 ≥ 2810 B
1500 - 2000 ≤ 2710 C
1500 - 2000 ≤ 3260 C
2000 ≤ 3260 A
.
https://truckmanualshub.com/

-6 50638042201 EN - 10/2017
https://truckmanualshub.com/
https://truckmanualshub.com/

STILL GmbH

50638042201 EN 10/2017