Workshop literature

STILL
ELECTRONIC
DOCUMENTATION
SYSTEM

Electric forklift truck

RX50-10
RX50-13
RX50-15
RX50-16

5060 5061 5063 5065 5066 first in int ra Iogistics

55048042201 EN - 08/201 1
History of changes r

Edition 08/2011
• Version 1
* First issue

55048042201 [EN]
Header r
Documentation
This workshop manual contains all the informa¬
tion required to assist the trained service engi¬
neers with all work, repairs and maintenance
on this truck. In addition, some of the compo¬
nents have been deliberately excluded from this
workshop manual and are explained elsewhere
in order to ensure a clear overview. Changes at
short notice are possible at any time and are com¬
municated via Service Information documents.
The additional documentation comprises work¬
shop manuals, special documentation and oper¬
ating circuit diagrams.
Workshop manuals
• Display elements -display
• FleetManager™

Special documentation
• Error list
• Overview of truck software
• STILL Flasher
• Overview of consumables
ÿ
FEM 4.004 test log book

Operating circuit diagrams

• see the circuit diagram overview

Symbols Used
The signal terms Danger,Warning, Caution, Note
and Environment note are used in this document
as hazard warnings or for unusual information
that requires special identification:

A DANGER
means that failure to comply involves risk to life and/or
major damage to property can occur.

A WARNING
means that failure to comply involves risk of serious
injury and/or major damage to property can occur.

A CAUTION
means that failure to comply involves risk of material
damage or destruction.

55048042201 [EN] III

 Header

t NOTE

means that particular attention is drawn to com¬

binations of technical factors which may not be
evident even to a specialist.

ENVIRONMENT NOTE
The instructions listedhere must be complied
with as otherwise environmental damage may
result.
Foryoursafety, additional symbols are also used.
Please heed the various symbols.

Changes and retrofitting

Warnings before making changes to the
truck
If the truck is used for work not listed in the
guidelines or truck-specific original operating
instructions and has to be converted or retrofitted
accordingly, you should be aware of the following:
• Any structural modification 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.
• Only for electric forklift trucks: 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.

55048042201 [EN]
Header r
CE conformity >
With the CE declaration of conformity, STILL con¬
firms 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 fulfil 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 office
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.

Working with spare parts

Warning regarding non-original parts
Original parts, attachments and accessories are
specially designed for this truck. We specifi¬
cally draw your attention to the fact that parts,
attachments and accessories supplied by other
companies have not been tested and approved
by STILL.

A CAUTION
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.

55048042201 [EN] V
 1 Header

Working with electronic controls

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 55048042201 [EN]
Table of contents r
00 Product information
Foreword oo- 1
About RX50-10-16 00- 1

Safety information 00- 3

Safety instructions Electrical system 00- 3
Jacking up the front of the truck 00- 3
Jacking up the rear of the truck 00- 4
Securing the fork carriage 00- 5

Maintenance 00- 7
Maintenance as required 00- 7
1000-hour maintenance 00- 9
2000-hour maintenance 00-11
3000-hour maintenance 00-13

Diagnostics 00-15
Measuring and testing equipment 00-15
Special tools 00-16
Standard torques 00-16

11 Electric motor
Traction motor 11- 1
General technical data 11- 1
Electrical connections 11- 1
Drive unit 11- 2

Rev sensor 11- 4

Pinsensor6B17 11- 4

Temperature sensor 11- 6

Temperature sensor KTY84 11- 6

22 Mechanical drive axle

Drive wheel unit 22- 1
Wheel hub removal 22- 1
Installing the wheel hub 22- 2

Power unit 22- 4

General technical data 22- 4
power unit 22- 5

55048042201 [EN] VII

 1
31 Chassis
Chassis 31- 1
Battery removal without the battery carrier 31- 1

Counterweight 31- 3
Counterweight 31- 3

41 Front axle
Running axle 41- 1
General technical data 41- 1
Running axle 41- 2
Replacing the wheel bearings 41- 3

42 Steering system
Hydraulic steering 42- 1
General technical data 42- 1
Steering system 42- 2
Steering — error detection 42- 2
Steering motor 42- 3
Sprocket with trigger wheel 42- 4
Steering unit 42- 5
Priority valve 42- 6
Steering angle-dependent handling performance — CSC 42- 8
CSC — functional test 42- 9
Steering motor sensor 3B29 42-10
Zero position sensor 3B28 42-12

Steering wheel with steering column 42-14

Steering column 42-14
Steering angle sensor 3B01 42-15

49 Brake system
Hydraulic service brake 49- 1
Replacing the brake shoes 49- 1
Checking the service brake 49- 2
Wheel brake cylinder 49- 3
Brake master cylinder 49- 3
Brake sensor 1B2 49- 5
Brake fluid switch 49- 6

VIII 55048042201 [EN]

HWSPflffflPT

Handbrake 49- 7
Adjusting the parking brake 49- 7

50 Operating devices
Single pedal 50- 1
Accelerator — single-pedal 50- 1

Dual pedal 50- 4

Accelerator — dual pedal 50- 4

Operating devices 50- 8

Hand lever 50- 8
Joystick 50-9
Joystick operation 50-11
Generation 2 mini-lever 50- 13
Generation 2 mini-leverActuation 50-15
Tip switch 50-17
Axle assignment 50-19
Depressurising the hydraulics 50-22
Direction indicator module (Fabli) 50-23

56 Display elements
Display 56- 1
Display operating unit (ABE 2) Generation 2 56- 1
ABE 2 Installation and removal 56- 2

60 Electrics/electronics
General 60- 1
General technical data 60- 1
Overview of the controllers 60- 2
Electrical system 60- 3
Electrical components 60- 3
Switching on procedure for the electrical system 60- 4
Software compatibility 60- 6
Parameter management 60- 7
Error ring buffer 60- 8
Traction motor temperature monitoring 60- 9
Pump motor temperature monitoring 60-11
Converter temperature monitoring 60-12
Intermediate circuit 60-13

55048042201 [EN] IX
 1
Insulation testing for electric trucks 60-15
Component insulation testing 60-17
Blue-Q = IQ 60-19

Wiring 60-21
CAN bus connections 60-21

Electrical system 60- 22

Fuse box 60-22
Fuses 60-23
Main contactor 1K1 60-23

Sensor system 60-25

Vertical lift mast position 60-25
Tilt angle sensor 7B46 60-26
Tilt angle sensor parameters 60-28
Installing the lift mast — vertical position 60-30

Additional electrical installations 60-31

Option board 60-31
CAN-Power-Port (CPP) 60-32
CPP 1/CPP 3 60-32
CPP2B 60-33
Relay-Power-Port (RPP) 60-34

64 Electronic controllers
Traction and working hydraulics control 64- 1
Main Control Unit (MCU) 64- 1
MCU with servo hydraulics 64- 2
Main Control Unit (MCU) Removal and installation 64- 3

Converter 64- 5
Converter 64- 5
Removing and installing the converter 64- 7

69 Batteries and accessories

T raction battery 69- 1
battery 69- 1
Battery male connector 69- 3
Discharge indicator 69- 4

x 55048042201 [EN]
 r

70 Hydraulics
General 70- 1
General technical data 70- 1
Lifting operating speeds 70- 2
Tilting operating speeds 70- 3
Operating speeds for lowering 70- 3
Forward tilt safety test 70- 4
Lowering safety test 70- 4
Safety checks of hose assembly 70- 5

Basic hydraulics 70- 6

Basic hydraulics 70- 6
Steering hydraulics 70- 7
Working hydraulics 70- 9
Hydraulic tank 70-10
Hydraulic oil 70-10
Return line filter 70-11
Breather filter 70-12
Suction filter 70-13
High-pressure filter 70-14
Bolted joint 70-15
Conical nipple fittings (CNF) 70-17

71 Working hydraulics
Pump unit 71- 1
General technical data 71- 1
Pumpunit 71- 1
Electrical connections 71- 3
Pump motor with rev sensor 71- 3
Pump motorwithout rev sensor 71- 4
Pump motor temperature sensor 71- 5
Hydraulic pump 71- 8

Tilt cylinder 71- 9

Mast tilt 71-9
Tilt cylinder Removal and installation 71- 9
Changing the set of seals 71-10

Auxiliary hydraulics 71-13

Attachments 71-13

55048042201 [EN] XI
 1
Second operating function for attachments 71-14
Clamp locking mechanism with servo hydraulics 71-14
Clamp locking mechanism for hand levers 71-16

76 Valves
Hand lever 76- 1
General technical data 76- 1
Hand lever valve block 76- 2
Emergency lowering 76- 3
Directional control valve with check valve 2Y46 76- 4
Check valve for hydraulics blocking function 76- 5
Hydraulic transmitter 76- 6

Servo hydraulics 76- 8

General technical data 76- 8
Servo hydraulics valve block 76- 9
Emergency lowering 76- 9
Directional control valve block 76-10
Directional control valve -method of operation 76-12

81 Lift mast
Lift mast 81- 1
General technical data 81- 1
Telescopic lift mast 81- 2
NiHo lift mast 81- 3
Triple mast 81- 4
Lift mast — removal 81- 6
Lift mast — installation 81- 8

Load chains 81-10

Load chains Checking, cleaning 81-10
Adjusting the load chains Telescopic mast 81-11
Adjusting the load chains NiHo lift mast 81-13
Outer load chain Triple mast 81-15
Middle load chain Triple mast 81-17

End position damping 81-20

End position damping of outer cylinder 81-20
Middle cylinder end dampener 81-21

XII 55048042201 [EN]

Table of contents r
Line break safety device 81-22
Hose safety valve of triplex mast 81-22
Shock valve installation positions 81-22

Lift cylinder 81-24

Lift jack 81-24
Outer cylinder 81-24
Centre cylinder 81-26
Cylinder head 81-27

Rollers/support rollers 81-30

Support roller clearance 81-30

84 Load support
Fork carriage 84- 1
Fork carriage 84- 1
Roller 84-2

Annex

X Circuit diagrams
Hydraulics X- 1
Hand lever X- 1
Servo hydraulics X- 3

55048042201 [EN] XIII

Product information r
Foreword
About RX50-10-16

Product program

Type designation Design Type carrier Type carrier

Version
Previous model
Short chassis
RX50-10C 5504 5060 5051
Compact counterweight
RX50-10 5504 Short chassis 5061 —
RX50-13 5504 Long chassis 5063 5053
RX50-15 5504 Long chassis 5065 5054
RX50-16 5504 Long chassis 5066 5055

Special features of this series

The new RX50 is the most compact electrically
driven three-wheel counterbalance truck with
rear wheel drive in its class. It is a fitting addition
to our E truck series and perfectly complements
the product range.

New in this series:

• High-performance three-phase drive for
wear-free driving and lifting
• Improved driving stability through reduction
of the centre of gravity by 36 mm and a sturdy
front axle
• Improved cornering with reduced brake
intervention from the standard CSC
• Low operating and maintenance costs thanks
to low energy consumption, energy recovery
during braking, long maintenance cycles and
wear-free electrical braking

55048042201 [EN] 00-1

 Product information
Foreword

• Reduced noise level

• Blue Q provides savings in energy consump¬
tion of up to 12%
• Vertical lift mast position
• Same lift mast as in the RX20
• All variants feature hydraulic actuation
Hand lever, mini-lever, fingertip and joystick
• IWS bracket doors as a restraint system
• FleetManager™
• Several possibilities for battery replacement
Fixed battery
Battery can be replaced from the side
Onboard battery bridge for changing via crane

00-2 55048042201 [EN]

Product information r

Safety information
Safety instructions
Electrical system
Work on the inverters
A DANGER
Due to the internal energy accumulator in the inverters
and control units, in the event of a fault there can be
dangerously high voltages at the electrical connecti¬
ons, even after the battery plug has been disconnec¬
ted.
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.

Jacking up the front of the truck

General
A DANGER
Risk of accident
When jacking up the forklift truck, always secure it with
the appropriate means (chocks, wooden blocks) to
prevent the truck from slipping or tipping.

The forklift truck has to be jacked up for various

maintenance tasks.
The following must be taken into consideration
when doing this:
• Only use hydraulicjacks with an adequate load
capacity
• Only jack up the forklift truck on a level surface
• Secure the forklift truck against rolling away
and dropping

A WARNING
Risk of injury!
Apply the parking brake and disconnect the battery
plug before jacking up the forklift truck.

55048042201 [EN] 00-3

 Product information
Safety information

Jacking up >
- Park the forklift truck on a level surface

- Turn the key switch OFF

- Apply the parking brake

- Place the hydraulic jack on the lift mast or on

the side of the chassis
- Jack up the forklift truck until the wheels are no
longer in contact with the ground
- Insert square timbers under the chassis on
both sides
- Carefully lower the hydraulic jack, until the
forklift truck rests safely on the square timbers

Jacking up the rear of the truck

General
A DANGER
Risk of accident
When jacking up the forklift truck, always secure it with
the appropriate means (chocks, wooden blocks) to
prevent the truck from slipping or tipping.

The forklift truck has to be jacked up for various

maintenance tasks.

The following must be taken into consideration

when doing this:
• Only use hydraulicjacks with an adequate load
capacity
• Only jack up the forklift truck on a level surface
• Secure the forklift truck against rolling away
and dropping.

A WARNING
Risk of injury!
Apply the parking brake and disconnect the battery
plug before jacking up the forklift truck.

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

A CAUTION
Due to the axis shift, the truck moves once the hydraulic
lever for tilting the lift mast is actuated.
Do not actuate the hydraulic lever for tilting the lift mast!

00-4 55048042201 [EN]

Product information r Safety information

Jacking up
- Park the forklift truck on a level surface

- Disconnect the battery male connector

- Apply the parking brake

- Place the hydraulicjack in the recess provided >

on the left-hand side of the counterweight
- Jack up the forklift truck until the wheel is no
longer in contact with the ground

- Place square timbers under both sides of the >

counterweight.
- Carefully lower the hydraulic jack, until the
forklift truck rests safely on the square timbers.

Securing the fork carriage

General
A DANGER
Risk of accident!
When working at the front of the truck, always secure
the fork carriage to prevent it dropping.

A DANGER
Risk of accident!
Use only chains with adequate lifting capacity to secure
the particular lift mast.

A CAUTION
Potential damage to the ceiling!
Note the maximum lift height of the particular lift mast.

55048042201 [EN] 00-5

 Product information
Safety information

Securing the tele list mast I>

- 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.

NOTE

Extendthe lift mast to slacken the chain.

Securing the Hi-Lo 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 lift mast until it sttrikes the chain.

- Lower fork carriage down to the stop.

NOTE
Extendthe lift mast to slacken the chain.

Securing the triple 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 middle mast (2).
- Lower lift mast until it sttrikes the chain.

- Lower fork carriage down to the stop.

NOTE
Extendthe lift mast to slacken the chain.

00-6 55048042201 [EN]

Product information r
Maintenance
Maintenance as required
Carried out
ÿ X

Before carrying out the procedures

Clean the truck
Chassis, bodywork and fittings
Check and lubricate joints and control devices
Check and lubricate the battery hood lock
Clean the restraining belt and check for correct function
Check the driver's seat
Chassis frame
Check tyres for air pressure and wear
Check wheels for the condition of the wheel fastening and for tightening torques
Check the condition and tension of the steering chain, adjust the tension and oil
Check the oil level of the drive axle and for leaks
Adjust the parking brake
Check brake fluid level
Check the brake fluid level sensor
Electrics/electronics
Check the battery condition, acid level and acid density
Check the fuses.
Hydraulics
Checking the hydraulic oil level
Check the hydraulic system for leaks
Lift mast
Check the tightening torque of the mast bearing screws and lubricate mast bearings
Check the condition and wear of load chains, and lubricate and adjust the load chains
Check chain elongation
Grease the lift mast and roller tracks
Special equipment
Service the restraint system
Lubricate attachments
Service the tow coupling

55048042201 [EN] 00-7

00 Product information
Maintenance

00-8 55048042201 [EN]

Product information r Maintenance

1000-hour maintenance
At operating hours
1000 5000 7000 11000 13000 17000 Carried out
19000 ÿ
*
Depending on the application, environmental conditions and driving style, the following
procedures must be carried out at the intervals specified above.
Before carrying out the procedures
Clean the truck
Read out the error numbers using diagnostics
Reset the maintenance interval using diagnostics
Chassis, bodywork and fittings
Check and lubricate joints and control devices
Check and lubricate the battery hood lock
Clean the restraining belt and check for correct function
Check the driver's seat
Check the accelerator pedal and brake pedal for damage and function, and lubricate
Check the dual pedal variant for damage and function, and lubricate
Check the electric parking brake variant for damage and function
Check the brake system for leaks
Check the brake lining thickness
Chassis frame
Check tyres for air pressure and wear
Check wheels for the condition of the wheel fastening and for tightening torques
Check the condition and tension of the steering chain, adjust the tension and oil
Check the oil level of the drive axle and for leaks
Adjust the parking brake
Check the brake fluid level
Check the brake fluid level sensor
Electrics/electronics
Check the power cable connections
Check the fuses
Check the battery condition, acid level and acid density
Perform insulation testing
Hydraulics
Check the hydraulic oil level
Check the hydraulic system for leaks
Lift mast
Check the tightening torque of the mast bearing screws and lubricate mast bearings
Check the condition and wear of load chains, and lubricate and adjust the load chains
Check chain elongation
Grease the lift mast and roller tracks
Check the lift cylinder and connections for leaks
Check the play between the fork carriage stop and run-out stop
Check the fork arms
Check the reversible fork arm variant

55048042201 [EN] 00-9

00 Product information
Maintenance

At operating hours
1000 5000 7000 11000 13000 17000 Carried out
19000 X

Special equipment
Service the restraint system
Lubricate attachments
Service the tow coupling

00-10 55048042201 [EN]

Product information r Maintenance

2000-hour maintenance
At operating hours
2000 4000 8000 10000 14000 16000 Carried out
20000 ÿ
*
Depending on the application, environmental conditions and driving style, the following
procedures must be carried out at the intervals specified above.
Before carrying out the procedures
Clean the truck
Read out the error memories using the diagnostics
Reset the maintenance interval using diagnostics
Chassis, bodywork and fittings
Check and lubricate joints and control devices
Check and lubricate the battery hood lock
Clean the restraining belt and check for correct function
Check the driver's seat
Check the accelerator pedal and brake pedal for damage and function, and lubricate
Check the dual pedal variant for damage and function, and lubricate
Check the electric parking brake variant for damage and function
Check the brake system for leaks
Check the brake lining thickness
Chassis frame
Check tyres for wear and air pressure
Check wheels for the condition of the wheel fastening and for tightening torques
Check the condition and tension of the steering chain, adjust the tension and oil
Check the oil level of the drive axle and for leaks
Adjust the parking brake
Check the brake fluid level
Check the brake fluid level sensor
Electrics/electronics
Check the power cable connections
Check the fuses.
Check the battery condition, acid level and acid density
Perform insulation testing
Hydraulics
Check the hydraulic oil level
Check the hydraulic system for leaks
Lift mast
Check the tightening torque of the mast bearing screws and lubricate mast bearings
Check the condition and wear of load chains, and lubricate and adjust the load chains
Check chain elongation
Check chain rollers and support bearings
Grease the lift mast and roller tracks
Check the lift cylinder and connections for leaks
Check the play between the fork carriage stop and run-out stop
Check the fork arms

55048042201 [EN] 00-11

 1 Product information
Maintenance

At operating hours
2000 4000 8000 10000 14000 16000 Carried out
20000 X

Check the reversible fork arm variant

Special equipment
Service the restraint system
Lubricate attachments
Service the tow coupling

00-12 55048042201 [EN]

Product information r Maintenance

3000-hour maintenance
At operating hours Carried out
3000 6000 9000 12000 15000 18000 ÿ X

Depending on the application, environmental conditions and driving style, the following
procedures must be carried out at the intervals specified above.
Before carrying out the procedures
Clean the truck
Read out the error memories using the diagnostics
Reset the maintenance interval using diagnostics
Chassis, bodywork and fittings
Check and lubricate joints and control devices
Check and lubricate the battery hood lock
Clean the restraining belt and check for correct function
Check the driver's seat
Check the accelerator pedal and brake pedal for damage and function, and lubricate
Check the dual pedal variant for damage and function, and lubricate
Check the electric parking brake variant for damage and function
Check the brake system for leaks
Check the brake lining thickness
Chassis frame
Check tyres for wear and air pressure
Check wheels for the condition of the wheel fastening and for tightening torques
Check the wheel bearings
Check the condition and tension of the steering chain, adjust the tension and oil
Check the drive axle for leaks
Change the drive axle gearbox oil
Adjust the parking brake
Check the brake fluid level sensor
Change the brake fluid
Electrics/electronics
Check the power cable connections
Check the fuses
Check the battery condition, acid level and acid density
Perform insulation testing
Hydraulics
Change the hydraulic oil
Replace the hydraulic filter
Check the hydraulic system for leaks
Lift mast
Check the tightening torque of the mast bearing screws and lubricate mast bearings
Check the condition and wear of load chains, and lubricate and adjust the load chains
Check chain elongation
Check chain rollers and support bearings
Grease the lift mast and roller tracks
Check the lift cylinder and connections for leaks

55048042201 [EN] 00-13

 1 Product information
Maintenance

At operating hours Carried out

3000 6000 9000 12000 15000 18000 ÿ X

Check the play between the fork carriage stop and run-out stop
Check the fork arms
Check the reversible fork arm variant
Special equipment
Service the restraint system
Lubricate attachments
Service the tow coupling

00-14 55048042201 [EN]

Product information r
Diagnostics
Measuring and testing equipment
Diagnostics
Description Part number
CAN box diagnostics 0636973
Serial line, CAN box — notebook 0625033
Adaptor line, CAN box — truck, diagnostic connector, 7-pin 0171381
Adaptor line, CAN box — truck, diagnostic connector, 4-pin 0625028

Measuring devices
Description Part number
STILL MetraHit ISO multimeter
including measuring lines 0171946
Current probe 0156300
20°C to 320°C temperature sensor 0156299
Hydraulics test box 0147530
Hydraulics digital test box 0009416002

Test adapter
Description Part number
Test adapter, SAAB, 42-pin 8426527
Test adapter, variable — from 2 to 25-pin 0172204
Adaptor line, SAAB, 16-pin 0172201
Adaptor line, SAAB, 2, 4, 6 or 10-pin 0172202
Test adapter, mark II, 2, 4, 6 or 8-pin 0149862
Adaptor line, mark II — JPT, 4-pin, male connector 0157647
Adaptor line, mark II — JPT, 4-pin, female connector 0157648

Measuring equipment
Description Part number
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

Tools
Description Part number
AMP crimping tool 0144087
Ejector box 0172412

55048042201 [EN] 00-15

 1 Product information
Diagnostics

Special tools

Description Part number

Slotted nut spanner 0009050206
C hook for battery removal 1278800005
Restraint strap 0009362012

Standard torques
Standard Threads
TORQUE in Nm
Grade 8.8
SIZE Grade 4.6 Grade 4.8 Grade 5.8 Grade 6.8 STAN¬ Grade 10.9 Grade 12.9
DARD
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

Fine threads
TORQUE in Nm
Grade 8.8
SIZE Grade 4.6 Grade 4.8 Grade 5.8 Grade 6.8 STAN¬ Grade 10.9 Grade 12.9
DARD
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

00-16 55048042201 [EN]

Product information
Diagnostics

M30x2 540 725 905 1085 1450 2050 2500

M36x3 930 1250 1560 1870 2500 3500 4100

55048042201 [EN] 00-17

00 Product information
Diagnostics

00-18 55048042201 [EN]

Electric motor r
Traction motor
General technical data
T raction motor
Power unit component 5060-5066 5051-5055

Manufacturer ABM Greiffenberger

Model TDF 471/4DG 112 Mb-4 TDF 471/4DG 112 MC-4
Engine type AC (delta)
Voltage between the phases 12 V
Rated current (nominal) 314 A 320 A
Rated output (nominal) 4.9 kW 4.9 kW

Mode of operation (nominal) S2 — 60 min

Protection type IP 54
Insulation class for the winding F (155°C)

Cooling Surface/convection

Temperature sensor KTY84-130

Sensor bearing (up to week
Rev sensor Pin sensor
42/2005)
Pin sensor (from week
42/2005)

Cable lengths U = 165 mm U = 350 mm

V = 210 mm V = 350 mm
W = 270 mm W = 350 mm

Electrical connections
Circuit diagram >
The windings are connected to the delta outside U
the machine.

55048042201 [EN] 11-1

 Electric motor
Traction motor

Location of the electrical connections U X13 X12

The six winding connections are fed out at the
upper end of the steering turntable, fixed in
position in a star arrangement and routed to the
right-hand side towards the converter together
with the control cables for the rev sensor and
temperature sensor.

Drive unit
General >
The traction motor is integrated into the power
unit housing. The traction motor cannot be
replaced individually; only the rotor can be re¬
moved. The motor connections U, V, W are fed
upwards out of the power unit.
The temperature sensor is embedded in the
stator winding. The plug is fed upwards out of the
power unit.
The rev sensor is a two-lane pin sensor that scans
a transmitter disk on the rotor.
The power unit housing has convection areas for
cooling in the traction motor area.

T raction motor
The traction motor is a three-phase AC asyn¬
chronous motor, which is equipped with a
short-circuit cage rotor.
Aluminium conductors are fused into the grooving
of the rotor core, which are connected at the ends
with short-circuit rings. The conductors with the
short-circuit rings form the cage and hold the rotor
core together.
The stator consists of the 4-pin core and stator
windings, which are pressed into the power unit
housing as a unit.
The applied voltage is induced in the rotor bars
by the stator winding and causes a current to flow
in the rotor. The resultant current and the rotating
field acting on the stator generate the torque.

Method of operation
The traction motor is controlled by a converter.
The change in speed fundamentally results from

11-2 55048042201 [EN]

Electric motor r Traction motor

a change in the frequency of the applied AC

voltage.
The voltage induced in the rotor generates
current in the rotor bars, depending on the design.
The stator rotating field produces a torque with
the rotor current.

55048042201 [EN] 11-3

 1 Electric motor

Rev sensor
Pin sensor 6B17
Function >
The traction motor has a two-track pin sensor as
a rev sensor, which scans a sensor disk on the
rotor.
The pin sensor is inserted into the bearing shield,
sealed with an O-ring and screwed into the
bearing shield with a screw.
The supply voltage is transferred to the rev
sensor via the converter 1U06. The sensor
signals are analysed in the converter and in the
MCU truck control unit. In addition, the signals
analysed by the converter are sent to the MCU 6B17
truck control unit via the CAN bus. The MCU
compares its own values to the values from the
converter and, in this way, performs additional
monitoring.

Technical data
Type: Pin sensor
64 pulses per revolution
Phase offset: 90° ±45°
Temperature range: -30°C to +150°C
Supply voltage: 12 V

Electrical connections
6B17 1U06 Node MCU
X12/1 Red + 12 V X151/3
X12/2 Blue Signal A X151/5 XK2 X47/27
X12/4 White Signal B X151/6 XK3 X47/12
X12/3 Black GND X151/4

Testing
- Insert the mark II test adapter into the plug
connector X12
- Use a digital multimeter with integrated duty
cycle (e.g. STILL MetraHit)
- Connect the digital multimeter as follows:

Adaptor pin 4 — positive terminal

Adaptor pin 3 — negative terminal
- Then connect the digital multimeter as follows:
Adaptor pin 2 — positive terminal
Adaptor pin 3 — negative terminal
- Switch on key switch S1

11-4 55048042201 [EN]

Electric motor r
Rev sensor

- Measuring range: duty cycle "V~Hz%"

- At full speed, a duty cycle must reach 40-60%

(ideally 50%).

Behaviour in the event of an error

If the sensor is not sending signals to the con¬
verter, the traction motor is operating in slip mode
(creep speed).

A 55048042201 [EN] 11-5

 1 Electric motor

Temperature sensor
Temperature sensor KTY84
General
The temperature sensor 1R17 is located in the
stator winding of the traction motor.
The signal is analysed in the converter.

Technical data
Type: KTY84-130.
Power supply: approx. 2.4 mA

Electrical connections
3-pin mark II plug X13
Generation 5 converter (from November 2004)
Input
Red X13/1 X151/16 signal
Blue X13/3 X151/17 GND

A CAUTION
Improperly conducted insulation testing can destroy
the temperature sensor.
Before performing the insulation testing, the tempera¬
ture sensor must be jumpered at the connections.

Testing
- Insert the test adapter into the plug connector
X13.
- Check the resistance value in accordance with
the table

Reference values for temperature measure¬

ment
Temperature (°C) Resistance (ft)
-40 355
-30 386
-20 419
-10 455
0 493
10 533
20 576
25 598
30 621
40 668
50 718
60 769

11-6 55048042201 [EN]

Electric motor r
Temperature sensor

Temperature (°C) Resistance (O)

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

Replacing the temperature sensor

A defective sensor can be replaced with the aid of
a repair kit containing a temperature sensor and
a two-component balancing mastic.
- Knead both components (yellow and blue) of
the balancing mastic together until the mass
has an even green colour
- Continue kneading the green mass for at least
2 minutes until it is noticeably warm
- Press the sensor with the balancing mastic |>
onto the upper part of the winding

t NOTE
Make sure that no mastic gets between the sen¬
sor and winding, as otherwise the temperature
measurement wit!be incorrect.
- The balancing mastic will be completely
hardened after approx. 2.5 hours

55048042201 [EN] 11-7

11 Electric motor
Temperature sensor

11-8 55048042201 [EN]

Mechanical drive axle r

Drive wheel unit

Wheel hub removal
Removal

fj NOTE

Removalof the individualunits is describedin

detailin the corresponding chapters.
Drain the gearbox oilingood time, so that the
oilhas enough time to drain out.
The workshop hoist can be used to perform
tasks at the wheelhub andthe gearbox while
they are still fitted.
We recommend removing the entire power
unit.

NOTE
- Disconnect the battery male connector.
- Loosen the wheel nuts.

- Jack up the truck onto two square timbers at

the counterweight.
- Remove the drive wheel.
- Drain gearbox oil. The drain plug is located in
the centre of the gearbox cover.
- Remove the power unit; see chapter entitled
"Removing the power unit."

Loosen the gearbox cover screws and remove >

the cover.

55048042201 [EN]
 Mechanical drive axle
Drive wheel unit

- Loosen the thread and unscrew the wheel >

shaft mounting screw as far as it will go using
an open-ended spanner.

NOTE
The threadissecured with Loctite.
• The bonddissolves at temperatures of 180 °C
andabove.
• The gearbox wheels must not be damaged
when hitting them gently with a mandril.

- Secure the wheel hub against turning and >

carefully remove it from the power unit using a
square timber and a hammer.
- Unscrew the mounting screw completely and
remove the wheel hub.

Installing the wheel hub

Sealing and installing

NOTE
• Installation of the individualunits is described
in detailin the corresponding chapters.
• Note the screw quality and tightening torques.
• Note the quality andquantity ofthe gearbox oil.
- Half fill the radial seal ring with grease.

22-2 55048042201 [EN]

Mechanical drive axle
Drive wheel unit

- Install the rotary shaft seal, ensuring that it is i>

correctly positioned.
- Insert the wheel hub into the multiple splining.
- Screw in the new mounting screw until the
wheel hub is in the end position.

A CAUTION
Tighten the mounting screw to the specified tightening
torque!
The mounting screw must not be reused.

- Attach the gearbox cover and tighten the >

screws.
- Replace the oil drain plug sealing ring.
- Install the power unit; see chapter entitled
"Installing the power unit".
- Fill with gearbox oil.

- Attach the drive wheel and tighten the wheel

nuts.
- Lower the truck.
- Tighten the wheel nut.
- Check all tightening torques.
- Carry out a functional test.

55048042201 [EN] 22-3

 1 Mechanical drive axle

Power unit
General technical data

Power unit 5060-5066 5051-5055

Manufacturer ABM Greiffenberger
Description TDF 471/4DG1 12Mb-4 TDF 471/4DG 112MC-4
Weight Approx. 120 kg 115 kg

Speed at the wheel 89 rpm 89 rpm

Iges transmission ratio Iges = 31.3 Iges = 28.27
Output torque 526 Nm 526 Nm

Connecting elements and tightening torques

5 x spherical collar nut
Wheel nut
Tightening torques: 195 Nm
12 x M 16x80 socket head screw
Live ring screw joint — counterweight DIN 912, quality 8.8
Tightening torque: 195 Nm
9 x M 16x60 hexagon head screw
DIN 931, quality 8.8
Tightening torque: 205 Nm
Live ring screw joint — power unit
2 x M 16x60 socket head screw (steering stop)
DIN 6912, quality 8.8
Tightening torque: 205 Nm
Slotted spring pin in the steering stop
Slotted spring pin 18 x 60
DIN 1481
8 x M6x20 socket head screw
DIN 912, quality 8.8
Gearbox cover Tightening torque: 10 Nm
AFM34 sealing ring
Wheel shaft mounting screw Tightening torque: 260 Nm
Special screw
Screw plug — oil drain
Tightening torque: 25 Nm

Consumables 5060-5066 5051-5055

Gearbox oil ARAL Degol GS 220 SAE 80W-90, API GL4+5
Oil volume 2 litres

22-4 55048042201 [EN]

Mechanical drive axle
Power unit

power unit
Description >
The power unit consists of a gearbox housing with
an integrated traction motor and drive wheel. The
drive wheel is screwed into the wheel hub with
spherical collar nuts. The connection between
the power unit and the counterweight consists of
a live ring. Underneath the live ring is a steering
chain, which is connected to the steering motor.

The live ring is screwed into the outer ring (3) at >
the counterweight and into the inner ring (2) at the
power unit.
The steering stop (1) on the inner ring of the live
ring restricts the steering angle.

Cold store
Trucks that are driven in the cold store must
have their lower sealing plug removed. This is so
any condensation water that builds up can drain
through the bore.

55048042201 [EN] 22-5

 Mechanical drive axle
Power unit

22-6 55048042201 [EN]

Chassis r
Chassis
Battery removal without the battery
carrier
General
For trucks with a fixed battery, only the service
technician may remove the battery. For this rea¬
son, the permanent bolt is sealed with a restraint
strap. The restraint strap is destroyed when the
battery is removed and must be replaced once
the battery is installed.
The battery holder is wedge-shaped and clamps
the battery in a lateral direction.

y
/ / \
Preparation
12 3 <
- Park the truck safely
1 Bush
- Open the battery hood 2 Battery holder
3 Restraint strap
- Open the battery door completely 4 Socket head screw with washer
- Disconnect the battery male connector
- Remove the restraint strap and unscrew the
battery permanent bolt using a 12-inch nut.
- Attach the C-hook onto a crane hook using a
suitable lifting sling
- For basic forks: slide the forks onto the fork
carriage as far right as they will go and attach
the C hook onto the right fork arms
- For forks with sideshift: movesideshifttothe
right

55048042201 [EN] 31-1

 Chassis
Chassis

Battery removal

Position Action
Disconnect the battery male connector and place it down flat on the left-hand side
1 of the battery. The C-hook must not touch the battery male connector or the battery
_ cable._
Place the C-hook between the battery hood and battery and carefully retract. To
prevent the battery from being damaged, the stops must stick to the holding magnets
The C hook is positioned correctly if the end is flush with the battery.
Thread the stops into the eyelets of the battery.
Raise the C-hook until the battery is starts to hang freely.
Slowly remove the battery from the truck and set it down in a suitable place.

31-2 55048042201 [EN]

Chassis r
Counterweight
Counterweight
The counterweight is a massive cast part that dif¬
fers according to the type carrier and depending
on the load-bearing capacity.
The counterweight is attached to the chassis with
mounting screws.
Mounting element
Type carrier Number of units Tightening torque
Hexagon head screw Washer
M24x90-10.9-A2C, 24-FST-A2C,
5060-5066 3 930 Nm
ISO 4017 DIN 6796
M24 x 110-8.8-A2C, 24-FST-A2C,
5051-5055 3 660 Nm
ISO 4017 DIN 6796

55048042201 [EN] 31-3

31 Chassis
Counterweight

31-4 55048042201 [EN]

Front axle r
Running axle
General technical data

Running axle 5060-5066

Manufacturer STILL GmbH
Designation
Weight

Connecting elements and tightening torques

12 x hexagon head screws, M20 x 1.5 x 35 - 10.9, DIN 933
Running axle screw joint, on each side 12 x original spare part washers
Tightening torque: 640 Nm
5 x spherical collar nuts A14-10
Wheel nuts, per wheel
Tightening torque: 195 Nm
1 x slotted nut, M30 x 1.5, DIN 981
Tightening torque: 70 Nm, loosen nut, 30 Nm
Wheel hub, on each side
See installation instructions in the chapter entitled "Running
axle"
1 x hexagon head screw M16 x 45 - 10.9, ISO 4017
1 x hexagon head screw M16 x 110 - 10.9, ISO 4017
Mast bearing, on each side
2 x lock washers
Tightening torque: 275 Nm
Union nut M10x1, DIN 74233
Brake pipe
Tightening torque: 16 Nm

Setting dimensions
Gap between brake drum and flange 2-3 mm
Setting dimension for middle of brake
169.4 -0.4 mm
shoes

Operating material
Wheel bearings, gap
Lithium soap grease to
Shaft seal
DIN 51825 KP2K-30
Mast bearings

Brake fluid DOT 4

55048042201 [EN] 41-1

 Front axle
Running axle

Running axle
Removal

NOTE
• Removat of the individualunits is describedin
detailin the corresponding chapters.
• Discharge the brake fluid at an early stage so
that it has time to drain off.
- Park the truck safely.
- Apply the parking brake.
- Disconnect the battery male connector. 1 Mounting screws
2 Flange
- Loosen wheel nuts of the idler wheels, do not
3 Brake drum
unscrew. 4 Pump motor engine mount
- Jack up the front of the truck; see chapter 5 Brake pipe disconnection point
entitled "Safety information". 6 Assembly opening for manual adjustment

- Remove the lift mast, see chapter entitled

"Removal/installation of the lift mast"
- Remove wheel nuts and then the idler wheels.
- Release the parking brake.
- Remove the bottom plate.
- Detach the brake cables from the parking
brake; mark in advance as required.
- Unscrew the brake pipe at the disconnection
point.
- Remove the clamping springs from the fasten¬
ing bolts of the pump motor mount.
- Use a suitable belt to attach the pump motor
to the brake support; use a catch to hold in
position.
- Remove the fastening bolts from the pump
engine mounts.
- Position a lift truck with timbers beneath the
running axle.
- Lift the lift truck until the timbers come into
contact with the running axle.
- Remove the mounting screws from the running
axle on both sides.
- Lower the running axle and pull from beneath
the truck.

41-2 55048042201 [EN]

Front axle
Running axle

Assembling

NOTE
• Installation of the individualunits is described
in detailin the corresponding chapters.
* Note the sere w quality and tightening torques.
• Observe the brake fluid qualities and volume.
- Insert the running axle into the truck and align
with the chassis and pump motor.
- Insert all screws on both sides between the 1 Mounting screws
chassis and running axle, as well as the 2 Flange
fastening bolts for the pump motor. 3 Brake drum
4 Pump motor engine mount
- Secure the pump motor fastening bolts with 5 Brake pipe disconnection point
clamping springs. 6 Assembly opening for manual adjustment
- Remove the securing belt from the pump
motor.
- Protect both sides of the mounting screws
against corrosion and screw in tightly. Check
tightening torques.
- Attach and screw the parking brake cables in
tightly.
- Screw the brake pipe onto the disconnection
point using union nuts.
- Top up the brake fluid; see chapter entitled
"Brake fluid".
- Attach the idler wheels and tighten the wheel
nuts.
- Attach the lift mast; see chapter entitled
"Removal/installation of the lift mast".
- Install the bottom plate.
- Lower the truck.

- Check the tightening torque of the wheel

screws.
- Connect the battery male connector.

- Carry out a functional test on the service brake

and the parking brake.

Replacing the wheel bearings

General
The wheel hub is supported by two tapered roller
bearings. Shim rings are used to set the bearing
clearance.

55048042201 [EN] 41-3

 Front axle
Running axle

Removing the brake drum [>

- Park the truck safely

- Disconnect the battery male connector

- Loosen the wheel nuts from the load wheel, do
not unscrew
- Jack up the truck at the front; see the chapter
entitled "Jacking up the truck at the front"
- Secure the rear wheel with wedges so that the
truck does not roll away
- Remove the load wheel
- Reset the brake shoes by adjusting manually
1 Cap
- Remove cap (1)
2 Slotted nut
- Unbolt the locking plate (3) 3 Locking plate
4 Washer
- Loosen the slotted nuts (2) 5 Outer wheel bearing (32208)
6 Inner wheel bearing (32010)
- Remove the washers (4)
7 Fill gap with grease
- Pull out the brake drum (9) with wheel bearings 8 Brake set
(5, 6) from the axle 9 Brake drum
10 Shaft seal
- Secure the inner ring of outer wheel bearing
(5) so that it does not fall out
- When pulling out, the inner ring of the inner
wheel bearing (6) remains on the axle
- Secure and reuse the shim rings and the ring

Replacing the wheel bearings and fitting the >

brake drum

NOTE
• Installation of the individualunits is described
in detailin the corresponding chapters.
• Note the screw qualities and tightening tor¬
ques.
• Note the qualities and volume ofthe brake fluid
- Pull out the inner ring of the inner wheel
bearing (6) from the axle
- Knock both outer rings out of the brake drum
using a brass mandril Cap
Slotted nut
- Remove the shaft seal Locking plate
- Press the outer rings of the wheel bearings (5,
Washer
Outer wheel bearing
6) into the brake drum. The wheel bearings Inner wheel bearing
must not be interchanged Fill gap with grease
- Press a new shaft seal (10) flush into the brake Brake set
Brake drum
drum
- Coat the rollers of the new wheel bearings with
grease and fill the space between the wheel
bearings (7) with grease

41-4 55048042201 [EN]

Front axle r Running axle

- Slide the ring and shim rings onto the axle

- Slide the inner ring of the inner wheel bearing

(6) onto the axle
- Slide on the brake drum

- Slide the inner ring of the outer wheel bearing

(5) onto the axle
- Fit the slotted nut (2) with washer (4) and
locking plate (3)

fj NOTE
The washer (4) must be installed with the
groundside facing the wheel bearing.
The chamfer of the slotted nut (2) must face
the direction of the truck
Tighten the slotted nut with a tightening torque
of 70 Nm
Rotate the brake drum several times by hand
The bearings should sit securely in place and
the brake drum must not wobble
Loosen the slotted nut completely and tighten
with a tightening torque of 30 Nm
Secure slotted nut with the locking plate (3)
Check whether the gap (X) between the brake
drum and flange is 2-3 mm. If necessary,
disassemble the brake drum and remove or
add a shim ring (11)
Fill the cap (1) one third full with grease and
attach
Manually adjust the brake shoes until they rest ?777Z
on the brake drum. The brake drum can then
no longer be turned manually
Attach the load wheel
Lower the truck
Check the tightening torque of the wheel nuts
Carry out a function test on the service brake
and the parking brake

55048042201 [EN] 41-5

 Front axle
Running axle

41-6 55048042201 [EN]

Steering system f

Hydraulic steering
General technical data

Steering system 5060-5066

Steering unit
Manufacturer Sauer Danfoss
Description Type no.: OSPC 50 LS Dynamic
Delivery rate 50 cm3 per revolution
Pressure relief valve 145-150 bar
Non-return valve in T
Shock valves 200-220 bar
Steering pressure
Connection P 140 bar
Connection T 40 bar
Connections L and R 280 bar
T ransmission ratio

Tightening torques
Connections T, P, L, R and LS G1/2, 100 Nm

Priority valve
Manufacturer Sauer Danfoss
Designation OCSP80
Pre-load pressure
Input volume 80 l/min
Load signal Dynamic
Tightening torques
Hydraulic pump flange 4 x socket head screw M6 x35, 8.8 DIN 912
10 Nm
Load Sensing LS G1/4, 50 Nm
Directional control valve EF G1/2, 100 Nm
Steering CF G3/8, 80 Nm

Steering motor
Manufacturer Sauer Danfoss
Designation Type no. 151-6403 (OMR 125 NA)
Temperature range -30°C to +80°C
Tightening torques
Mounting screws 46 Nm

Steering chain
Hexagon nut
Chain tension at the clamping bolt
5 Nm

55048042201 [EN] 42-1

 1 Steering system
Hydraulic steering

Steering system
General >
The steering system consists of a steering unit
(Orbitrol) at the bottom of the steering column
and a steering motor in the counterweight, which
actuates the power unit via a steering chain.
The steering unit and the steering motor are
connected via two hydraulic lines.
A steering motor sensor 3B29 is installed at
the steering motor and a zero position sensor
3B28 is installed in the counterweight, in order
to record the steering angle. The steering angle
sensor 3B01 is installed at the steering column to
implement dynamic steering.
ÿ Steering unit (Orbitrol)
The hydraulic steering is supplied by the hy- 2 Steering motor
draulic pump on the pump motor via the priority 3 Steering motor sensor
valve. 4 Trigger wheel
5 Steering chain

Basic hydraulics
A steering unit is flange-mounted to the bottom
end of the steering column. The unit 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 steering
wheel rotation. The distributor valve guides this
oil volume to the required side of the steering mo¬
tor.
The oil volume for the steering is directed to the
steering unit by the priority valve as a priority 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.

Steering — error detection

Error Cause Remedy

Self-steering, difficult steering

42-2 55048042201 [EN]

Steering system
Hydraulic steering

*- When the hydraulic pump is in Disconnect the steering unit from

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

Error Cause Remedy

-
Hard spots
Clean the priority valve - even
better, change it.
»- Bleed the LS line at the priority
valve.
ÿ
Air in the LS line. ÿ
Pressure measurement at

- Steering overhaul Dirt in the hydraulic oil causes the priority valve at P and LS. If
ÿ- ÿ-

Pivoting problems when faulty oil flow in the priority valve.

there is no standby pressure or
starting to steer *- No volume flow 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.

Steering motor
General
The steering motor actuates the power unit via a
dual-roller chain. The steering motor is secured
to the counterweight with two socket head screws
(M10x65). The guide is held in place with two
slotted spring pins (013x40).

55048042201 [EN] 42-3

 Steering system
Hydraulic steering

The trigger wheel is a component of the chain >

wheel. The steering motor sensor 3B29 is scre¬
wed to the steering motor via a support (M5x16).

Sprocket with trigger wheel

Dismantle sprocket with trigger wheel

NOTE
To dismantle the sprocket the steering motor
must be remoired.
- Secure sprocket against twisting
- Loosen screw on front side and pull out
sprocket

Mount sprocket with trigger wheel

- Calculate distance between trigger wheel and
steering-motor shaft
- Measure the distance (X) between the top > -

edge of the trigger wheel and the top edge of

the steering motor shaft
- Add shims (l)according to table

- Place adjusting shim (2) on the sprocket

'/A
I \WV

'//
\
\//////~/\ —
%1pF-
X
- Insert pressing disc (3)

- Bolt the chain wheel together with the hexagon

head screw (5) and lock washer (4) and secure
with Loctite 243

42-4 55048042201 [EN]

Steering system
Hydraulic steering

Pi") NOTE
Tightening torque ofhex headsere w 35 Nm

Setting via shims

Shim ring
Dimensions
Measured depth 0.1 mm 0.2 mm 0.5 mm 1.0 mm
in mm
3.05-3.14 0.90 2 1
3.15-3.24 1.00 1
3.25-3.34 1.10 1 1
3.34-3.44 1.20 1 1
3.45-3.54 1.30 1 1 1
3.55-3.64 1.40 2 1
3.65-3.74 1.50 1 1
3.75-3.84 1.60 1 1 1
3.85-3.94 1.70 1 1 1
Dimensions of the shim rings = measured distance (X) + 0.5 mm (shim) + 0.15 mm (play) - 2.85 mm
(pressure disc)

Steering unit
General
The steering unit is screwed to the steering
column flange via four screws.

The following valves are installed in the steering

unit.
• Pressure relief valve
• Shock valve
The shock valve has a damping function that
prevents major pressure fluctuations being
transmitted from the hydraulic system to the
steering.
T Tank connection
P Pump connection
ENVIRONMENT NOTE LS Load-sensing (control connection)
R Right connection
Hydraulic oilmay leak out when unscrewing the
L Left connection
hydraulic connections. Dispose of the hydraulic
oil in an environmentally friendly manner.

NOTE
The values set by the manufacturer mustnot be
changed.

Removal
- Park the truck safely.

- Turn the key switch off.

55048042201 [EN] 42-5

 Steering system
Hydraulic steering

- Disconnect the battery male connector.

- Apply the parking brake.

- Unscrew the steering column panelling.

- Disconnect the key switch plug contacts.

- Undo the four screws (1) and pull the steering

unit downwards out of the steering axle.
- If necessary, unscrew the steering column
from the front structure beforehand — in order
to do this, unscrew the four screws (2) from the
rubber bearings.
- Unscrew the hydraulic connections and mark
them if necessary.
- Protect the open hydraulic hoses from con¬
tamination using sealing plugs.

Installation
- Screw on the hydraulic connections in accor¬
dance with the markings.
- Insert the steering unit into the steering axle
and screw down the four screws (1) with lock
washers.
- Connect the key switch plug contacts.

- Screw on the steering column panelling.

- Carry out a functional test, steering from stop

to stop several times.

Priority valve
General
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 matter of priority in all operating conditions.

Error detection
Error Cause Remedy
ÿ
Steering sticks.
ÿ
Steering overhaul * The slider in the priority valve »- Clean the priority valve — or
is prevented from moving in the
•-Steering problems when starting housing even better, replace it
due to dirt particles
to steer.

42-6 55048042201 [EN]

Steering system
Hydraulic steering

Disassembly for cleaning purposes >

|"j"] NOTE
Maintain tightening torques for the screwplugs.
- Remove screw plugs (1) and (3)
- Take out pretension spring (5)
- Take out slide (2)
- Clean all parts

- Check sealing rings of screw plugs

- Insert slide (2) Screw plug with sealing ring

Slide
- Insert pretension spring (5) Screw plug
sealing ring
- Screw in screw plugs (1) and (3).
Pretension spring

55048042201 [EN] 42-7

 Steering system
Hydraulic steering

Steering angle-dependent han¬

dling performance — CSC
General
In order to optimise driver comfort and opera¬
tional safety, this truck is equipped with Curve
Speed Control (CSC) as standard. 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.

A DANGER
Risk of truck tipping over.
The driving speed must generally be adjusted in such
a way that the CSC is not used.
Deactivation of the CSC is not permitted!

Function
During operation, the speed is limited accord¬
ing to the steering angle. This behaviour follows v = f(a°)
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.
a Steering angle [°]

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 T ruck centre of gravity

a 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 influences 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)

42-8 55048042201 [EN]

Steering system
Hydraulic steering

of the truck is directed at a point outside of the

stability triangle.

CSC — functional test

Components
The steering angle is recorded and calculated via
the following components:
• Zero position sensor 3B28 in the counter¬
weight:
Detects when driving straight ahead and
adjusts the measurement.
• Steering motor sensor 3B29 at the steering
motor:
Detects any changes to the steering angle.
• Steering angle sensor 3B01 at the steering
column:
Implements dynamic steering.
Replacement for the diaphragm pressure
switch.

Behaviour after switching on

Once the electrical system is switched on, the
steering angle is always set to 90° by the con¬
troller and the speed is limited to 5.5 km/h. The
maximum driving speed is only enabled once
the controller has been able to clearly record the
steering angle.
For this to take place, steering must be initiated
so that the steering stop (1) on the inner ring (2)
moves past the zero position sensor 3B28 on
both sides. This causes the increments to be
recorded by the steering motor sensor 3B29 and
the value is stored in the truck control unit.

Functional test
- Park the truck on even ground.

- Jack up the truck at the counterweight so that

the drive wheel is 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

55048042201 [EN] 42-9

 1 Steering system
Hydraulic steering

Engine speed

Once the controller has detected the zero posi¬

tion, the calculated steering angle is shown in the
display.

Forward travel Reverse travel

Steering angle Speed Speed Steering angle Speed Speed
n [km/h] [rpm] n [km/h] [rpm]
0 (13.50) 4518 0 (12.15) 4066
5 13.16 4404 5 11.85 3965
10 10.90 3648 10 9.85 3296
15 9.50 3179 15 8.55 2861
20 8.60 2878 20 7.78 2602
25 8.00 2677 25 7.20 2409
30 7.60 2543 30 6.85 2292
35 7.25 2426 35 6.55 2192
40 7.00 2008 40 6.33 2117
45 6.80 2276 45 6.13 2050
50 6.70 2242 50 6.06 2033
55 6.60 2209 55 5.95 1991
60 6.35 2125 60 5.70 1907
65 6.05 2025 65 5.50 1841
70 5.75 1924 70 5.50 1841
75 5.50 1841 75 5.50 1841
80 5.50 1841 80 5.50 1841
85 5.50 1841 85 5.50 1841
90 5.50 1841 90 5.50 1841

Steering motor sensor 3B29

General >
The steering motor sensor 3B29 detects the
change in the steering angle via a wide locking
washer with 21 teeth and a resolution of 2°.

3B29
Supply voltage 5-15 V
Current draw < 5 mA
Voltage drop < 2.5 V

Electrical connections
3B29 Node MCU
3B29/1 + 12VMCU XK1 X47/15

42-10 55048042201 [EN]

Steering system
Hydraulic steering

3B29/2 Signal 2 X47/1 1

3B29/3 GND_S XK5 X47/28
3B29/4 Signal 1 X47/26

Removal
- Remove the battery and place it on the
left-hand side of the truck, so that it can be
connected when required.
- Loosen the two sensor support screws.
- Remove sensor with support.

Installation
- Turn steering to centre position.

- Screw on the sensor with support.

- Air gap between sensor and locking washer: 1 >

±0.1 mm
- Carefully route the cable to the pump actuator.

Testing
- Insert the mark II test adapter into the plug
connector 3B29
- Use a digital multimeter with integrated duty
cycle (e.g. STILL MetraHit)
- Connect the digital multimeter as follows:
Adaptor pin 4 — positive terminal
Adaptor pin 3 — negative terminal
- Then connect the digital multimeter as follows:
Adaptor pin 2 — positive terminal
Adaptor pin 3 — negative terminal
- Switch on the key switch
- Measuring range: duty cycle "V~Hz%"

- T urn the steering steadily from stop to stop

- A respective duty cycle of 40% to 65% must be

reached

Possible causes of errors

Error Remedy
Error in the display ÿ-
Re-adjust the sensor
ERROR ???? *ÿ
Replace the sensor

55048042201 [EN] 42-11

 1 Steering system
Hydraulic steering

Zero position sensor 3B28

General >
The zero position sensor 3B28 is a proximity
switch that detects when the truck is driving
in a straight line via the steering stop (X) and
adjusts the measurement accordingly. The zero
position sensor is clamped into a bore in the
counterweight using a screw.

3B28
Supply voltage 9.5-35 V
Current draw <10 mA
Voltage drop <2.4 V
Sensing distance 6 mm

Electrical connections
3B29 Node MCU
3B28/1 Brown + 12VMCU XK1 X47/15
3B28/2 Black Signal X47/1 1
3B28/3 Blue GND_S XK5 X47/28

Removal
- Loosen the screw and pull the zero position
sensor out of the bore

Installation
- Insert the zero position sensor into the bore
provided in the counterweight
- Check sensing distance between the steering
stop and zero position sensor
- Clamp the zero position sensor in the counter¬
weight using a clamping bolt

Calibration
The switching angles that trigger the zero position
sensorto switch ON and OFF are stored in such a
way that they are not affected by a loss of voltage.
If no values exist, they must be calibrated. Until
this has occurred, the speed is restricted to 5.5
km/h for safety reasons.
- Switch on the electrical system
- Steer twice from stop to stop
The switching point values are calibrated and
stored during this process.

42-12 55048042201 [EN]

Steering system
Hydraulic steering

Possible causes of errors

Error Cause Remedy
Zero position sensor does not
-
»-
switch ÿ-
The zero position sensor Clean zero sensor with a
ÿ
Calibration required button is dirty cleaning cloth
»- Error message

55048042201 [EN] 42-13

 1 Steering system

Steering wheel with steering column

Steering column
General >
The steering column is positioned above the
bearing block and screwed onto the bottom end
of the front structure with rubber bearings.
The steering column cannot be adjusted.

Removal

1 NOTE
• The mini-console mustberemovedinadvance
ifnecessary.
• The work sequence must be observed.
- Park the truck safely.

- T urn the key switch off.

- Disconnect the battery male connector. 1 Steering wheel
2 Steering angle sensor
- Unscrew the steering column panelling.
3 Steering column with bearing block
- Disconnect the key switch plug contacts. 4 Rubber bearing
5 Steering unit mounting screws
- Undo the four steering unit mounting screws.

- Pull the steering unit downwards out of the

steering column.
- Undo the four steering column mounting
screws and remove the steering column

Installation

m note
The work sequence must be observed.
- Position the steering column bearing block on
the front structure and screw it down with four
mounting screws.
- Insert the steering unit into the steering column
from below and screw it in tightly with four
mounting screws.
- Connect the key switch plug contacts.

- Screw on the steering column panelling

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

42-14 55048042201 [EN]

Steering system
Steering wheel with steering column

Steering angle sensor 3B01

General
The steering angle sensor is fitted 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 firmly connected to the
moving steering column. The pole wheel is fixed
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 Sensor 3B01
2 Mounting screws
3 Cable clip
Technical data 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

Electrical connections
6-pin mark II plug
3B01:1 (br) X46/39 12 Volt
3B01 :2 (sw) X46/36 Signal track 1
3B01:3 (bl) X46/23 GND_S
3B01 (ws)
:4 X46/35 Signal track 2

Error message
In the event of implausible or missing values,
the truck control unit (MCU) generates error
numbers.
The truck then only travels in emergency opera¬
tion at 2 km/h.
The driver sees the STEERING error in the
display.

Function test
- Connect the multimeter between GND-S and
track 1 or track 2.
- The displayed voltage must jump between
0.05 and 11 V during slow steering.

55048042201 [EN] 42-15

 Steering system
Steering wheel with steering column

- Fast steering results in an average DC of

approx. 5.6 V between GND_S and track 1
or GND_S and track 2.
Alternatively, the steering angle display ADJUST
can be activated in the display.

Adjustment
The sensor's sensor surface should rest gently
on the paper at the magnet ring.

42-16 55048042201 [EN]

Brake system r

Hydraulic service brake

Replacing the brake shoes

A CAUTION
Brake testing
The service brake must be tested for function and
uniform braking after all tasks.

Disassembling the brake set

- Park the truck safely
- Disconnect the battery male connector
Brake set
- Loosen the wheel nuts from the load wheel, do 1 Joining plate
not unscrew 2 Retaining spring
3 Compression spring
- Jack up the truck at the front; see the chapter 6 Wheel brake cylinder
entitled "Jacking up the truck at the front" 7 Recuperating spring
8 Adjustment
- Secure the rear wheel with wedges so that the
truck does not roll away
- Remove the load wheel

- Reset the brake shoes manually

- Remove the brake drum; see the chapter

entitled "Replacing the wheel bearings"
- Remove the joining plate (1)

- Detach the retaining springs (2)

- Unhook the compression springs (3) from the

flange
- Detach the brake cable pull
- Remove the brake set; the wheel brake
cylinder remains in the truck

Assembling the brake set

- Install the brake set

- Attach the brake cable pull

- Hook the compression springs (3) into the

flange
- Attach retaining springs (2)

- Fit joining plate (1)

- Install the brake drum; see the chapter entitled

"Replacing the wheel bearing"
- Manually adjust the brake shoes until they rest
on the brake drum. The brake drum can then
no longer be turned manually
- Reset the adjustment until the brake drum can
easily be turned manually.

55048042201 [EN] 49-1

 1 Brake system
Hydraulic service brake

- Attach the load wheel and tighten the wheel

nuts
- Lower the truck

- Check the tightening torque of the wheel

screws
- Perform a function test of the service brake
and the parking brake

Checking the service brake

General
The service brake can only be tested if the brake
shoes are adjusted correctly. To adjust the brake
shoes, see the chapter entitled "Replacing the
brake shoes".

A CAUTION
If the brake shoes have been adjusted incorrectly, it is
possible that the truck may no longer be braked using
the brake.
In order to prevent accidents from occurring, a brake
functional test must be carried out.
For detailed information, see FEM 4.004 test log book.

Function test
A WARNING
Risk of injury! An intact brake brakes the truck hard.
- During the brake test, always fasten the seat belt
and hold on tightly
- Either secure any loose objects in the driver's cab
or remove them completely

- The test is to be carried out, if possible, on

horizontal, even, dry and firm ground
- Accelerate the truck without load to 5 km/h

- Fully actuate the brake pedal during travel

Depending on the condition of the brake, the
truck will brake hard

Extract from the table of permissible braking

distances in accordance with the FEM 4.004 test
log book:_ _
V [km/h] sO [m]
5 0.8
10 1.6
12 1.9

49-2 55048042201 [EN]

Brake system r
Hydraulic service brake

Wheel brake cylinder

Installation >
The wheel brake cylinder (1) is screwed to the
axle plate with two socket head screws (2) from
inside the truck.

1 Wheel brake cylinder

2 Socket head screw
3 Bleeder screw
4 Brake pipe connection

Brake master cylinder

General
The brake fluid reservoir forms a complete unit
with the brake master cylinder. The piston clear¬
ance is adjusted in the brake master cylinder via
the piston rod.

A WARNING
Brake fluid is poisonous and extremely hygroscopic.
Brake fluid has strong dissolving properties.
- Observe the statutory regulations when handling
brake fluid
- Do not allow to come into contact with hot motor
parts.
- Avoid all contact with eyes and skin If contact
occurs, rinse out with plenty of water and consult
a doctor
- Immediately rinse any brake fluid that has splashed
onto paint, clothing, or shoes with plenty of water

Removal
- Park the truck safely
- Tilt the lift mast forward.
- Remove the bottom plate.

- If necessary, undo the mounting screws at the

brake support and unhook the brake support
from the cross wall.

55048042201 [EN] 49-3

 Brake system
Hydraulic service brake

- Unscrew the brake pipe (1) from the brake >

master cylinder and disconnect the electrical
connections (2) from the brake fluid switch
6S4.
- Drain the brake fluid.

- Remove the fork clevis (4).

- Loosen both nuts (3).

- Remove the brake master cylinder from the

brake support.

Installation
- When in the inactive position, the spring force
should cause the brake pedal to lie at the stop.
- Install the brake master cylinder in the brake
support and screw down the nuts.
2 3 5 4
- Check the piston clearance (S) on the brake
master cylinder and adjust as required
- Loosen lock nut (5).
- Adjust the play to 1 mm by turning the piston
rod
- Secure the setting at the fork clevis with the
lock nut.
- Grease the fork clevis and connect to the
actuation device.
- If necessary, hook the brake support to the
cross wall and screw in the mounting screws
tightly, tightening torque 10.5 Nm.
- Screw the brake pipe to the brake master
cylinder and connect the electrical connections
(2) to the brake fluid switch 6S4.
- Add brake fluid.

- Install the bottom plate.

- Test brake pipes for leak-tightness.

49-4 55048042201 [EN]

Brake system
Hydraulic service brake

Brake sensor 1B2

General >
The brake sensor 1B2 is a potentiometer that is
adjusted at the brake pedal by means of a tappet.
The potentiometer is fixed to the inside of the
bearing block with two screws.

Electrical connections
4-pin Timer plug 1B2 if*
1B2/1 X46/41 12VJVICU
1B2/2 X46/13 Signal C1
Not
1B2/3 assigned
1B2/4 X46/16 GND_S

Adjustment
- When in the inactive position, the spring force
should cause the brake pedal to be at the stop.
- During assembly on the bearing block, gently
pre-load the brake sensor so that the output
signal is in the valid value range.
- A calibration must be carried out in order to
finely adjust the potentiometer.

Supply voltage Zero position Max. movement Min. movement

12 V 1.6±0.6 V 7.0 V 5.8 V

Calibration
The zero position must always be calibrated after
the brake sensor has been replaced.
- Connect the notebook to the truck and start the
truck diagnostics:

Actions
ÿ

Calibration

0 . Sensors

Once calibration is complete, error messages

may be displayed.

Possible causes:
• Operating error
• Timeout during calibration process
• Value of the transmitter's inactive position is
outside the valid range

55048042201 [EN] 49-5

 1 Brake system
Hydraulic service brake

Brake fluid switch

General >
The brake fluid reservoir is part of the brake
master cylinder and can be removed only as a
component.
Switch 6S4 is an NO contact that causes an error
message to appear on the display when the filling
level is too low.
SERVICE BRAKE

The speed is reduced to 5 km/h in response to

the error message. The restriction can be lifted
by performing a truck reset.

Electrical connections
6S4/3 X46/9 Signal
6S4/4 X46/22 GND_S

Testing
- Switch on the key switch

- Unscrew the filler cap

- Press the brake fluid switch

- The SERVICE BRAKE error message flashes

in the display
- If the message does not appear in the display,
the switch is faulty
- When testing is complete, screw the filler cap
back on

49-6 55048042201 [EN]

Brake system f

Handbrake
Adjusting the parking brake
General
The parking brake can only be correctly adjusted
if the service brake is adjusted. The brake shoes
of the service brake must always be adjusted first;
see chapter entitled "Replacing the brake shoes".

A CAUTION
If the bowden cables have been adjusted incorrectly,
it is possible that the truck may no longer be braked
using the brake.
In orderto prevent accidents from occurring, afunctio¬
nal test of the brake must be carried out.
For detailed information, see FEM 4.004 test log book.

Adjustment
- Jack up the truck at the front; see chapter
entitled "Jacking up the truck".
- Remove the panelling at the brake lever.

- Put brake lever in the zero position

- The brake cables can be found to the right and > 36 mm

left of the hand brake lever. Adjust each brake
cable so it is always set in the same way as the
other cables.

A CAUTION
The flex on the brake cables must not turn during
adjustment!
The flex can be held in place using long-nose pliers,
which will prevent it from turning.

- For presetting, the brake cables are un¬

screwed via the nuts until the dimension of
36 mm is reached. The distance between the
top edge of the thread and the top edge of the
bush is measured.
- Use the nuts to adjust the brake cable so that
the wheels can be turned freely by hand.
- Apply the brake leverto the first notch: parking
brake switch 1S3 switches.
- Apply the brake lever to the fifth notch + 1: the
full braking effect is achieved
- Secure the setting with the lock nut.

Functional test on the ramp

- Pick up the maximum permissible load (nomi¬
nal load) for the truck.

55048042201 [EN] 49-7

 1 Brake system
Handbrake

fr NOTE

Ifthe maximumpermissible load(nominalload)

is not available, the truck must be tested with the
operating company's maximum operating load.
- Drive up a gradient of at least 15% with the
load facing forwards

A WARNING
The truck may roll away in an uncontrolled fashion!
- Always remain seated on the truck during the brake
test and actuate the service brake in the event of an
emergency

- Stop the truck on the gradient and actuate the

parking brake. The service brake is not used
in this manoeuvre.
- Switch off the truck with the key switch and wait
until the display has turned off.
- If the parking brake is able to hold the truck on
the gradient without it rolling backwards, the
brake holding power is sufficient.

Function test during travel

A WARNING
Risk of injury! An intact parking brake brakes the truck
sharply.
- During the brake test, always fasten the seat belt
and hold on tightly.
- Either secure any loose objects in the driver's cab
or remove them completely

- If possible, the test must be carried out on a

horizontal, even, dry and clean cement floor.
- Accelerate the truck without load .

- The parking brake must be applied during

travel and with the accelerator pedal actuated.
Depending on the condition of the parking
brake, the truck will brake sharply.

1 NOTE
The accelerator signalis switched offas soon as
parking brakeswitch 1S3 actuates. The truck is
then only brakedby the parking brake without the
support of electricalbrake retardation.

Extract from the table of permissible braking

distances in accordance with the FEM 4.004 test
log book:_ _
V [km/h] sO [m]
5 1.33

49-8 55048042201 [EN]

Brake system 49
Handbrake

10 2.66
12 3.17

55048042201 [EN] 49-9

49 Brake system
Handbrake

49-10 55048042201 [EN]

Operating devices r

Single pedal
Accelerator — single-pedal
Bottom plate
The single-pedal bottom plate is equipped as
standard with accelerator 1B1 and horn button
4S1 .
The accelerator is mounted to the bottom plate
from below using two stud bolts. Only the accel¬
erator pedal is fed through the bottom plate.

Accelerator
The accelerator comprises an accelerator pedal
and a dual-action potentiometer 1B1.
The accelerator pedal is fitted on a permanently
greased, sealed shaft in the housing and is held
in place in its inactive position at the lower end
by a compression spring. The driving speed
is specified by potentiometer 1B1 when the
accelerator pedal is pressed.

Removing the accelerator

- Raise the right part of the bottom plate

- Disconnect plug X1 6 from the accelerator

- Lift out the bottom plate

- Loosen the polystop nuts

- Remove the accelerator from the bottom plate

from below.

Configuration
The configuration must be parameterised again
for all retrofitting 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
• Dual pedal
• Joystick, fingertip and mini-lever
• Lift lever
• Drive direction turn indicator module
A truck restart must always be carried out after
parameterising. Calibration can only be carried
out once these processes have been completed.

55048042201 [EN] 50-1

 1 Operating devices
Single pedal

Calibration
Calibration must always take place after the
accelerator has been replaced.
- Connect the notebook to the truck and start the
truck diagnostics:

Action

Calibration

1. Accelerator

Once calibration is complete, error messages

may be displayed.

Possible causes:
• Operating error
• Timeout during calibration
• Value of the transmitter's inactive position is
outside the valid range
• Voltage increase does not lie within the valid
range

Electrical connections

4V
bklc e i
•
H1
\
f rt ge
|
i
I
2

irR - itt ]
Li
t
i A A

Tl-
Accelerator 1B2
X16/1 Free
X16/2 1B1 — C2/bk Black X46/1 1 Signal C2
X16/3 1B 1 — C 1/rt Red X46/12 Signal C1
X16/4 1B1 — C1/C2/ge Yellow X46/38 GND accelerator
X16/5 Free
X16/6 Free
X16/7 Free
X16/8 1B 1 — C1/C2/gn Green X46/40 12-V accelerator

Testing
Measured values
Calibration limit values Measuring points
[Volt]
Supply voltage X16/4 — X16/8 11.05-12.05
C1 accelerator not actuated X16/4 — X16/3 5.32-6.5

50-2 55048042201 [EN]

Operating devices
Single pedal

Measured values
Calibration limit values Measuring points
[Volt]
C2 accelerator not actuated X16/4 — X16/2 5.32-6.5
C1 accelerator fully actuated X16/4 — X16/3 8.2-11.0
C2 accelerator fully actuated X16/4 — X16/2 1.0-3.8
GND breakdown detection 11.5
VCC breakdown detection 0.5

Voltage increase
2,0 -5,4V
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 2 V (up to a maximum of 5.4 V) higherthan
in the neutral position (N).

Errors
Voltage increase too small The maximum speed is not reached
No problem for the evaluation
ÿ
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 significantly too large Detection of breakdown with corresponding error message

55048042201 [EN] 50-3

 1 Operating devices

Dual pedal
Accelerator — dual pedal
Bottom plate
The dual-pedal bottom plate is equipped with ac¬
celerator 1B1 and a dual-pedal unit for forwards
and reverse travel. The horn button 4S1 is lo¬
cated 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.
The dual-pedal unit is screwed to the bottom
plate via the bearing block. Only the accelerator
pedals are fed through the bottom plate.
The stops limit pedal travel.

Accelerator

17 18

Pedal, forwards 5 Needle-roller bearing

Pedal, reverse 6 Bearing block
Rod 7 Sheet metal
Bush 8 Bearing block

50-4 55048042201 [EN]

Operating devices f
Dual pedal

9 Socket head screw 16 Hexagon head screw, 10 Nm, Loctite

10 Coach bolt 17 Protective cap
11 Bracket, upper 18 Gear
12 Compression spring 19 Pinion gear
13 Guide 20 Potentiometer
14 Hexagon nut 21 Pan head screw
15 Bracket, lower 22 Set of cables

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 the pedal (1 , 2) with needle-
roller bearing (5).
- Apply lubricant evenly to all bearings of the
pedals (1, 2)
- Feed the pedals through the bottom plate from
above
- Fit all individual parts from below

- Screw in the socket head screws (9) to 18.5

Nm
- Screw in the pan head screws (21) to 2.5 Nm
and secure with retaining compound
- Tighten compression springs (12) to a pre-load
measurement of 22 mm
- Screw in hexagon head screw (16) to 10 Nm
and secure with Loctite

Parameterising
The configuration must be parameterised again
for all retrofitting 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
• Dual pedal
• Joystick, fingertip, mini-lever
• Lift lever
• Drive direction turn indicator module
A truck restart must always be carried out after
parameterising. Calibration can only be carried
out once these processes have been completed.

55048042201 [EN] 50-5

 1 Operating devices
Dual pedal

Calibration
Calibration must always take place after the
accelerator has been replaced.
- Connect the notebook to the truck and start the
truck diagnostics:

Action

Calibration

1. Accelerator

Once calibration is complete, error messages

may be displayed.

Possible causes:
• Operating error
• Timeout during calibration
• Value of the transmitter's inactive position is
outside the valid range
• Voltage increase does not lie within the valid
range

Electrical connections

4V
bWc e i
•
H1
\
f rt ge
|
i
I
2

irfl - itt ]
Li
t
i A A

Tl-
Accelerator 1B2
X16/1 Free
X16/2 1B1 — C2/bk Black X46/1 1 Signal C2
X16/3 1B 1 — C 1/rt Red X46/12 Signal C1
X16/4 1B1 — C1/C2/ge Yellow X46/38 GND accelerator
X16/5 Free
X16/6 Free
X16/7 Free
X16/8 1B 1 — C1/C2/gn Green X46/40 12 V accelerator

Testing
Measured values
Calibration limit values Measuring points
[Volt]
Supply voltage X16/4 — X16/8 11.5-12.5
C1 accelerator not actuated X16/4 — X16/3 5.32-6.5

50-6 55048042201 [EN]

Operating devices
Dual pedal

Measured values
Calibration limit values Measuring points
[Volt]
C2 accelerator not actuated X16/4 — X16/2 5.32-6.5
C1 accelerator fully actuated, forwards X16/4 — X16/3 8.2-11.0
C2 accelerator fully actuated, forwards X16/4 — X16/2 1.0-3.8
C1 accelerator fully actuated, reverse X16/4 — X16/3 1.0-3.8
C2 accelerator fully actuated, reverse X16/4 — X16/2 8.2-11.0
GND breakdown detection 11.5
VCC breakdown detection 0.5

Voltage increase
2,0 -5,4V
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 2 V (up to maximum 5.4 V) higher than in the
neutral position (N).

Errors
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 significantly too large Detection of breakdown with corresponding error message

55048042201 [EN] 50-7

 1 Operating devices

Operating devices
Hand lever
Operation
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
P
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)
• "Auxiliary hydraulics 1" operating lever(3)
• "Auxiliary hydraulics 2" operating lever(4)
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
Repairs 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.

Parameterising
The configuration must be parameterised again
for all retrofitting 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
Calibration must always take place after the
hydraulic sensor has been changed.
- Connect the notebook to the truck and start the
truck diagnostics:

Action

Transmitter calibration

50-8 55048042201 [EN]

Operating devices
Operating devices

Execute

Once calibration is complete, error messages

may be displayed.

Joystick
General
The joystick is an operating device built into the
armrest of the driver's seat.
The joystick controls various operations that can
be activated by the driver's right hand.
• Rocker (1)
• Horn button (2)
• Drive direction switch (3, 6)
• Precision control (zoom) (4)
• (5)Function button
• Forwards/backwards (7, 8)
• Left/right (9, 10)
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
Repairs 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

Technical data
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

Undo the electrical

6-pin Mark II plugX71
X71/1 24 Volt
X71/2 GND truck
X71/3 CAN rH
X71/4 CAN rL
X71/5 Emergency off 7S2/1

55048042201 [EN] 50-9

 Operating devices
Operating devices

6-pin Mark II plugX71

X71/6 Emergency off 7S2/2
Earth wire at the seat or CPP seat

Configuration
The configuration must be parameterised again
for all retrofitting 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
The joystick can be calibrated if necessary.
- Connect the notebook to the truck and start the
servo hydraulics diagnostics:

Action

Joystick calibration

Execute

50-10 55048042201 [EN]

Operating devices
Operating devices

Joystick operation
Operating functions
The joystick is used to operate all hydraulic func¬
tions and the auxiliary hydraulics for attachments.

NOTE

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 t>

"Decal information for operation" on the valve
cover.

NOTE ;£|)yj@ ÿ
) '(§)
ifchanges are made to the assignment of the
hydraulic functions, the "Decal information for
operation "mustbe modified. The decatinforma-
tion labels can be orderedas spare parts.
©4hO (@Ah>ÿ2d) ÿ

Activating the precision control button (zoom) at

the same time reduces the working speed of all
<2ÿ
( (§) (2)
consumers by half.

Standard functions and default settings

"Forwards/backwards" standard functions: Lo- >
wer/lift lift mast.

"Rocker" standard functions: Tilt lift mast for¬

wards/backwards

55048042201 [EN] 50-11

 Operating devices
Operating devices

"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- D>

wards/backwards" default setting: Operation of
fork extension or shovel.

NOTE
Other settings can be configured using the
diagnostics in the notebook.

50-12 55048042201 [EN]

Operating devices
Operating devices

Generation 2 mini-lever
General

Pf"l NOTE
The generation 2 mini-lever replaces the well
knowngeneration 1mini-lever.
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 hydraulic equipment and customer

preference, there are different mini-lever variants
that can be installed in the truck.
Duplicate mini-lever with emergency stop
8 variants are theoretically possible, for the scope 1 Left joystick
of delivery see the spare parts list: 2 F1 button
3 F2 button
• Each mini-lever variant comes both with and
4 Drive direction / turn indicator cross lever
without the emergency stop switch. 5 Function key for 5th hydraulic function
• Single mini-lever 6 Right joystick
7 Emergency stop switch
Only the left joystick is available to operate the
8 Signal horn button
basic hydraulic functions of lifting, lowering
and tilting.
The single mini-lever variant is no longer
available.
• Duplicate mini-lever
Left joystick for lifting, lowering, tilting.
Rightjoystick for operating the attachment.
• Four-way mini-lever
The left and right joysticks are each replaced
with two levers.
The levers can only be moved forwards and
backwards in one axis.
• Duplicate/four-way mini-lever
A mixture of the duplicate mini-lever and
four-way mini-lever.

Function keys F1, F2

The function keys can be assigned different
functions during parameterising.

Example:
• Second operating function for attachments
• Additional electrical installations
Switching the searchlight on/off
Please remember that additional electrical in¬
stallations must not be activated twice. If the
operation of an additional electrical installation
has been parameterised on one of the function
keys, please deactivate this in the display operat¬
ing unit.

55048042201 [EN] 50-13

 1 Operating devices
Operating devices

Repairs
In the event of repairs, the entire mini-lever
console must be changed. Individual parts are
not available.

Technical data
CANopen as standard
Integrated into the red peripheral CAN bus
Software: truck recognition "I"
Protection class: IP 55
Temperature range: -30°C - +85°C

Electrical connections
6-pin Mark II plugX71
X71/1 12 V or 24 V
X71/2 GND truck
X71/3 CAN r H
X71/4 CAN rL
X71/5 Emergency off 7S2/1
X71/6 Emergency off 7S2/2
Earth wire at the seat or CPP seat

Parameterising
The configuration must be parameterised again
for all retrofitting 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
• Dual pedal
• Joystick, fingertip, mini-lever
• Lift lever
• Drive direction turn indicator module
A truck restart must always be carried out after
parameterising.

Calibration
Calibration is not necessary.

50-14 55048042201 [EN]

Operating devices
Operating devices

Generation 2 mini-lever
Actuation
Single mini-lever
The left joystick (1) is a 360° lever which can
be used for operating both axes at the same
time. The left joystick is used to operate the basic
functions of the lift mast.
Operation of 1st and 2nd hydraulic function:
• To lift fork carriage:
Move the left joystick in the direction of the
arrow (B).
• To lower fork carriage:
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).
• 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

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

7312 003-010

Right joystick

55048042201 [EN] 50-15

 Operating devices
Operating devices

The pictograms show all functions that can be >

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

Operation of 3rd and 4th 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).

Operation of 5th hydraulic function:

• (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).

Four-way mini-lever >

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

50-16 55048042201 [EN]

Operating devices
Operating devices

Duplicate/four-way mini-lever
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

Tip switch
General 1 2 3 4 5 6 7

The fingertip is an operating device built into the

armrest of the driver's seat.
The fingertip controls various operations that can
be activated by the driver's right hand.
• Lift-lower operating lever (11)
• Tilt operating lever (10)
• Operating leverforauxiliary hydraulics 1 or 3rd
hydraulic function (8)
• Operating leverforauxiliary hydraulics 2 or 4th
hydraulic function (9)
• Button for auxiliary hydraulics 3 or 5th hy¬
draulic function (6)
• Signal horn button (4)
• T ravel direction switch (12) 1 F1 function key
• Turn indicator buttons (3, 5) 2 F2 function key
3 Left turn indicator button
• F1 and F2 function keys (1 , 2) 4 Signal horn button
• Emergency stop switch (7) 5 Right turn indicator button
6 Button for 5th function
Like the directional control valve block, the 7 Emergency stop switch
fingertip is provided with three or four operating 8 Auxiliary hydraulics 1 operating lever
levers according to the hydraulic equipment of 9 Auxiliary hydraulics 2 operating lever
the truck. 10 Pull the tilt operating lever
12 Travel direction switch
The assignment of the input channels and axles 11 Lift-lower operating lever
for hydraulic operation is configured using the
truck diagnostics in the notebook.

55048042201 [EN] 50-17

 1 Operating devices
Operating devices

Function keys F1, F2

The function keys can be assigned additional
electrical installation functions during parameter-
ising.
Example: Switch searchlight on/off using func¬
tion key F1.
Please remember that the additional electrical
installation functions must not be activated twice.
If an additional electrical function has been
configured on one of the function keys in the
fingertip, it must be deactivated in the display and
operating unit.

Repairs
In the event of repairs, the entire fingertip console
must be changed. Individual parts are not avail¬
able.
The fingertip console is provided with three or
four operating levers according to the hydraulic
equipment of the truck.

Technical data
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

Undo the electrical

6-pin mark II plugX71
X71/1 24 V
X71/2 Truck GND
X71/3 CAN rH
X71/4 CAN r L
X71/5 Emergency stop 7S2/1
X71/6 Emergency stop 7S2/2
Earth wire at the seat

Parameterising
The configuration must be parameterised again
for all retrofitting and conversions related to the
accelerator and drive direction. Parameterising
takes place using the truck diagnostics in the
notebook.

50-18 55048042201 [EN]

Operating devices f
Operating devices

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
Calibration is not necessary.

Axle assignment
General
The individual operating functions are assigned
to the axles and buttons in the factory. The
allocation in each case can be read from the
"Decal information for actuation".
Parameterising allows a number of different axle
assignments and operating variants. Please
remember that the variants depend on the "joy¬
stick", "fingertip" and "mini-lever" controls.
As soon as the axle assignment and conse¬
quently the operation have been changed, the
"Decal information for actuation" must be mod¬
ified. Current variants of the decal information
can be ordered as spare parts.

f NOTE
As soon as the operation has been changed,
the "Decal information for actuation "must be
modified.

Parameterising
The parameterising of axle assignments and
operating variants takes place using the truck
diagnostics in the notebook.

55048042201 [EN] 50-19

 Operating devices
Operating devices

Joystick [>

Axis Default Variant

X+ Auxiliary 1 Lifting
X- Auxiliary 1 Lowering
Y+ Lowering Tilt forwards W+
Y- Lifting Tilt backwards
W+ Tilt backwards Auxiliary 1
W- Tilt forwards Auxiliary 1

Duplicate mini-lever
Generation 2
Left joystick Default
Y+ Lifting
Y- Lowering
X- Tilt backwards
X+ Tilt forwards
Rightjoystick Default
Z+ Auxiliary hydraulics 1
Z- Auxiliary hydraulics 1
w- Auxiliary hydraulics 2
w+ Auxiliary hydraulics 2

Four-way mini-lever
Generation 2
Lever Default
Y+ Lifting
Y- Lowering
X- Tilt backwards
X+ Tilt forwards
z+ Auxiliary hydraulics 1
z- Auxiliary hydraulics 1
w- Auxiliary hydraulics 2
w+ Auxiliary hydraulics 2

50-20 55048042201 [EN]

Operating devices
Operating devices

Duplicate/ four-way mini-lever

Generation 2
Left joystick Default
Lifting
Lowering
Tilt backwards
Tilt forwards
Lever Default
Auxiliary hydraulics 1
Auxiliary hydraulics 1
Auxiliary hydraulics 2
Auxiliary hydraulics 2

Generation 1 mini-lever
Default
Lifting
Lowering
Tilt backwards
Tilt forwards
Auxiliary hydraulics 1
Auxiliary hydraulics 1
Auxiliary hydraulics 2
Auxiliary hydraulics 2

Fingertip
Default
Lifting
Lowering
Tilt backwards
Tilt forwards
Auxiliary hydraulics 1
Auxiliary hydraulics 1
Auxiliary hydraulics 2
Auxiliary hydraulics 2

55048042201 [EN] 50-21

 Operating devices
Operating devices

Depressurising the hydraulics

Multi-levers >
- Lower the fork carriage

- Tilt back the lift mast to the stop

- Switch off key switch.

- Actuate all operating levers several times up to
their end positions

Joystick >
- Lower the fork carriage
- Tilt back the lift mast to the stop

- Turning on the key switch

- Press the buttons (1 , 2, 3, 4) at the same time

Tip switch
It is not currently possible to "depressurise" the
hydraulics in this way.

Mini-lever
It is not currently possible to "depressurise" the
hydraulics in this way.

1 Direction of travel forwards

2 Direction of travel backwards
3 Function button
4 Precision control (zoom)

50-22 55048042201 [EN]

Operating devices
Operating devices

Direction indicator module

(Fabli)
General
The direction of travel flasher 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 flasher lever (3) controls and is screwed to
the housing.

The direction switch switches three functions; the

direction of actuation is indicated by the adjacent
symbol:
• forwards
• Neutral 1 Direction indicator module
2 Travel direction switch
• Backwards 3 Direction indicator switch
The direction indicator switch switches two
functions; the direction of actuation is indicated
by the adjacent symbol:
• right
• anticlockwise

Retrofitting
For retrofitting, it may be necessary to change
the truck central control MCU/TCU; see Electrical
Connections

Undo the electrical

The direction of travel flasher 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-GNDF

Removal
- Park the vehicle safely.

- Disconnect the battery plug with electric forklift

trucks
- Remove the steering wheel

55048042201 [EN] 50-23

 1 Operating devices
Operating devices

- Remove the console from the housing l>

- 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

Installation
- 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.

Configuration
The configuration must be parameterised again
for all retrofitting 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

50-24 55048042201 [EN]

Operating devices 50
Operating devices

Parameterisation takes place using the truck

diagnostics in the notebook.

55048042201 [EN] 50-25

 Operating devices
Operating devices

50-26 55048042201 [EN]

Display elements f

Display
Display operating unit (ABE 2)
Generation 2
General
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.

_|J NOTE
The displayoperating unitisinstalledin a number
oftrucks. Forthis reason, the detaileddescription
iscontainedina separate workshop manual. See
also the workshop manual "Display elements -
display".

Electrical connections
6-pin MARK II plug X49
X49/1 12 V
X49/2 Truck GND
X49/3 CAN rH
X49/4 CAN rL
X49/5 12 V
X49/6 Hazard warning system

Buttons and display

1 2 3 4 5 6 7 8 9 10 11 12 13 14

2804h

55048042201 [EN] 56-1

 1 Display elements
Display

Number Designation
1 "Hazard warning system" button
2 "Windscreen wiper/washer" button
3 "Blue-Q efficiency mode" button
4 "Searchlight" button
5 "Drive program change from 1-5" button
6 Soft key, here with "searchlight / rear" variant
7 Soft key, here with "heating system / rear window" variant
8 Pictogram for soft key (6), soft key column 1
9 Pictogram for soft key (7), soft key column 1
10 Pictogram status "Blue-Q active"
11 "Battery indicator / tank display" pictogram
12 "Drive program" pictogram
13 Left turn indicator display
14 Drive direction forwards display
15 Right turn indicator display
16 Drive direction backwards display
17 "Time" pictogram
18 "Operating hours" pictogram
19 Display for active soft key column
20 Pictogram for soft key (23), soft key column 2
21 Pictogram for soft key (23), soft key column 1
22 Digits 0-9 in programming mode
23 Soft key, here with "mast vertical position" variant
24 Button for "menu change" and changing the soft key columns
25 "Dipped beam / high beam" button
26 "Rear window wiper/washer" button
27 LED display for button active/inactive

ABE 2
Installation and removal
Removal
- Park the truck safely.

- Only for electric forklift trucks: Disconnect the

battery male connector.

56-2 55048042201 [EN]

Display elements
Display

- Undo the ABE at the lower edge and take it out I>
of the assembly opening on the panelling.

A WARNING
Risk of injury!
Gloves must be worn to protect hands.

A CAUTION
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.

Installation
- 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.

Copying parameters
Only diesel/LPG trucks
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) VAL©?
supposed to be used?"
- Load software flash package; see chapter
entitled "Software compatibility"
- Start calibration.
- Delete the error memory.

- Function check.

55048042201 [EN] 56-3

 Display elements
Display

56-4 55048042201 [EN]

Electrics/electronics r
General
General technical data
Electrical system 5060-5066
Control electronics Digital controller
Traction controller Speed-regulated, 4-quadrant, three-phase AC inverter
Pump controller Speed-regulated 1-quadrant three-phase AC converter
Accelerator Dual-action potentiometer, 4 kft each
Brake sensor for electric braking 4-kf) potentiometer
Transmitter for hydraulics Electric displacement transducer
Speed Forwards 12.5 km/h, Backwards 10 km/h
Can be adjusted via 5 drive programs
Nominal voltage 24 Volt
Traction motor revolution control T ruck control unit (MCU)

Current limitation
T raction motor
FM traction motor T raction against block 450 A
Regulation in accordance with
TSA
Pump motor
HM pump motor Tilt against overpressure 480-500 A
Regulation in accordance with
TSA

1K1 main contactor

24 V (switched)
Relay
24 V (255-fi coil) K1, K2
Fuses
See chapter entitled "Fuses"
G1 traction battery — standard
24 V/460 Ah 5060
24 V/575 Ah 5061
24 V/805 Ah 5063
24 V/920 Ah 5065, 5066

Insulation resistance
Electrical system Min. 1000 fi/Volt = > 24 kfi
Electrical equipment Min. 1000 ft/Volt = > 24 kQ
Traction battery Min. 1000 ft
Electrical protection type
Electrical system IP 23, incl. cover IP 54
Electrical equipment IP 54

55048042201 [EN] 60-1

 1 Electrics/electronics
General

Overview of the controllers

Device Designation Application

A44 truck control unit
MCU E truck (24 V/48 V/80 V)
Main Control Unit
A
A44 truck control unit
TCU IC truck
Truck Control Unit
E truck: traction motor (FM1)
D FU1 1U06 traction converter for 1M 1
IC truck: traction motor (1 M 1)
Two-motordrive: left traction motor (FM2,
E FU2 1U07 traction converter for 1M2
2M1)
F PU Pump converter 2U03 for 2M 1 E truck: pump motor (HM)
Hydraulic control unit Part of the MCU or TCU
H VR
Valve processor Servo hydraulics special equipment
I FIT Joystick, fingertip, mini-lever Servo hydraulics special equipment
J ABE Display and operating unit E truck and IC truck
K FABLI Travel direction indicator module Special equipment
L CPP1 Roof CAN-Power-Port Special equipment
CPP2 Front CAN-Power-Port
M Special equipment
CPP2B Lighting CAN-Power-Port
N CPP3 Seat CAN-Power-Port Special equipment
0 CPP4 Rear CAN-Power-Port Special equipment
Q CIO Battery carrier E truck special equipment (48 V/80 V)
R CS Acceleration sensor FleetManager™ special equipment
S Battery controller E truck special equipment (48 V/80 V)
A43 control unit
T SU E truck (48 V/80 V)
Supply Unit
U DFU Remote data transmission Special equipment
V CPP5 Soot CAN-Power-Port Particle filter special equipment
X ELF Control unit for the electric parking brake Special equipment
Y RFID RFID control unit RFID special equipment

60-2 55048042201 [EN]

Electrics/electronics
General

Electrical system
General 2M1

The truck is equipped with a rear-wheel drive and

is driven by a speed-controlled asynchronous
motor. A 24-volt inverter supplies the traction
motor.
U V w U V w
The hydraulic pump is also driven by a speed- 2U03 1U06
controlled asynchronous motor.

Each asynchronous motor is supplied by its own

converter. The converters are controlled via the
CAN bus (CAN Open) of the truck control unit
(MCU).
The control electronics are supplied by an internal
12-V power supply from the truck control unit.
The electrical additional consumers are supplied
directly via the 24-volt battery voltage. Distribu¬
tion takes place via the fuse box (PDU).

Electrical components
1

Position Description Electrical component

1 3B01 Steering angle sensor Series
2 S1 Key switch Series
3 ABE Display operating unit Series
4 MCU Truck control unit Series
5 Option board Variant
6 CPP and RPP CAN power port and relay power port Variant
7 X2 Battery male connector Series
8 1U06 and 1F01 T raction converter and fuse Series
9 PDU Fuse box Series
10 3B28 Zero position sensor Series

55048042201 [EN] 60-3

 1 Electrics/electronics
General

Position Description Electrical component

11 2U03 and 2F01 Pump converter and fuse Series
12 3B29 Steering motor sensor Series
13 1S1 Drive direction switch in the lift lever Series
14 1S3 Parking brake switch Series
14 1S3, X507, ELF Electric parking brake Variant
15 6S4 Brake fluid switch Series
16 7B46 Vertical lift mast position Variant
17 CS Acceleration sensor Variant
18 4H1 Signal horn Series
19 1B 1 and 1B2 Accelerator and brake sensor Series

Switching on procedure for the

electrical system
Notes
I The GND_L, GND_S, GND_P earth
designations referto the negative battery.
II Battery supply voltage:
Secure switch-on possible from
UBatt > 17 V
Secure operation possible from
UBatt > 13 V
III Monitoring processor and control
processor are components of the MCU
truck control unit.
IV The intermediate circuit is charged via
fuse F20 and the PTC resistor.
Intermediate circuit capacity approx.
38 mF
V Adhesive monitoring:
Only performed with cold start.
If the truck is only turned off briefly
(display remains illuminated), adhesive
monitoring is not performed.

60-4 55048042201 [EN]

Electrics/electronics
General

Switch-on sequence for standard truck

- Apply the parking brake.

- Release the emergency off switch.

- Plug in the battery male connector.

Measurement point Measured value

F20 and PTC resistor ft ft
I I
PDU — 1K1/14 24 V
F11 — X20/6A — XK4
S1/1 24 V i n an
ABE — X49/5 24 V »>rn i
MCU — X47/14 24 V \w TT
F 19 — X20/6B — XK1 6 irt LII

MCU — X47/29 24 V
© HA

r
2Y46/1 24 V @ £
n
- Switch on key switch 1S1.
JM
Z) *
- The MCU control processor and monitoring
T
processor initialise and then switch to operat¬
ing mode.
© lr
- The power supply starts up.

Measurement point Measured value

ABE — X49/1 24 V run-on
2U03 — X150/1 24 V

- The monitoring processor measures the

intermediate circuit voltage cyclically and
transmits the findings to the control processor.
- The control processor links the CAN bus
participant to the CAN bus.
- If the intermediate circuit is charged to > 17
V, the "adhesive monitoring" checks whether
the power contacts of the main contactor 1K1
have adhered.
- The intermediate circuit is loaded for a maxi¬
mum of 1 second by the pump converter.
- If the voltage declines by >2 V, it is ensured
that the power contacts do not adhere.

Measurement point Voltage drop

MCU — X46/20 >2 V
PDU — X20/1A >2 V

- Enable the drive converter

Measurement point Enable signal

1U06 — X151/1 24 V
MCU — X4 7/13 24 V

55048042201 [EN] 60-5

 1 Electrics/electronics
General

- If all status requests are now set for the main

contactor, the main contactor is switched on.
- The drive unit and the hydraulics are now
enabled. The prerequisite for this is the status
of the parking brake and the status of the seat
contact switch

Software compatibility
Software flash packages
Spare part control units can contain software
versions that do not match those in the control
units which have been left in the truck As a
result, the software incompatibility will cause
error statuses in the truck.
An approved software flash package must be
loaded after any control unit on the truck has been
changed. A software flash package contains
compatibility-checked software versions for
all control units. Software incompatibility is
eliminated once the software flash package has
been loaded
Please see the "STILL Flasher" and "Truck
software overview" workshop manuals for more
information on "software flash packages" and
"loading flash packages".

Calibration
Once a software flash package has been loaded,
all transmitters and sensors, as well as the
joystick (variant), must be recalibrated.
- Connect the notebook to the truck and start the
truck diagnostics:

Jobs

Calibration
ÿ

0 . Sensors
1. Accelerator
For hand lever only
2.-5. Hydraulic sensor
Variant
6 . Mast vertical

- Connect the notebook to the truck and start the

servo hydraulics diagnostics:

Jobs

Joystick calibration

60-6 55048042201 [EN]

Electrics/electronics
General

Execute

Parameter management
Concept
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 display operating unit (ABE). When one of the
two components is changed, the parameter set
must be copied from the remaining component.

A CAUTION
Parameter loss
1 Display operating unit
If the display operating unit and the MCU are replaced 2 Truck control unit
at the same time, the truck parameters will be lost. In
3 Pump converter
this case, a truck parameter set must be loaded via the
4 Traction converter
notebook.

The two converters are not affected by parameter

management. These components and all other
CAN bus participants can be changed without
copying parameters.

Copying parameters
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
been installed once 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.
m

55048042201 [EN] 60-7

 Electrics/electronics
General

The manual transfer begins with the question in [>

the display A-EEPROM VALID?. This means:
"Should the parameters of the MCU (device A) be O
used?"
Should the parameters of the MCU (device A) be
used?
• Use the MCU parameters
Confirm by pressing 0button
Copy the parameters from the MCU to the
display operating unit
• Use display operating unit parameters
Say no by pressing 0button
Copy the parameters from the display operat¬
ing unit to the MCU
Confirm your answer to the security question
ARE YOU SURE? again. In case of any doubt,
the operation can still be interrupted.

Error ring buffer

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.

f NOTE
The error ring buffer is notpresent untilcertain
software versions. Fordetails see the document
"Truck software overview"

60-8 55048042201 [EN]

Electrics/electronics r General

Traction motor temperature monitoring

Thermal protection of the drives (TSA)

V[km/h]
a m

Imax

a max
Vmax

amin

Imin
Vmin

V [km/h] Driving speed in km/h

12.5 Maximum driving speed in the drive programs
Vmax km/h
Vmin 5 km/h Maximum limit on driving speed due to overtemperature
a [%] Acceleration in %
3max 90% Standard acceleration in drive program 5
3min 30% Maximum limit on acceleration due to overtemperature
I [%] Traction motor current in %
Imax 100% Standard traction motor current
Imin 30% Maximum limit on traction motor current via the converter
T [°C] Temperature in the traction motor in °C
The A5 022 — TRACTION MOTOR OVERTEMPERATURE error is reset once
Ti 127°C this temperature is reached and when the temperature has fallen below this
value.
The calculated limitation of the speed and acceleration starts as soon as this
T2 128°C
temperature is reached. This has no effect on the truck.
Start of actual limitation of speed and acceleration.
t3 138°C The A5 02 2 — TRACTION MOTOR OVERTEMPERATURE error is activated.
The error message re-appears repeatedly in the display.
End of the linear limitation of speed and acceleration
t4 148°C
Start of the linear regulation of traction motor current via the converter
t5 149°C End of the linear regulation of traction motor current via the converter

The electric drive is protected against overtem-

perature by a two-stage temperature monitoring
system — "thermal protection of the drives".

55048042201 [EN] 60-9

 1 Electrics/electronics
General

The converter analyses the signal from the

traction motor temperature sensor and transmits
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 first stage, a fault is registered at tempera¬
ture (T3) and limitation of the speed and acceler¬
ation begins.
Thanks to linear reduction, the drive is usually
able to re-establish its natural temperature. If
the traction motor temperature drops to value
(T 1), the fault is cleared and all limitations are
removed.
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), the motor current is
reduced to such an extent that the truck may
only be operated in a heavily restricted driving
mode.

Emergency operation
Depending on the truck load, the current limitation
may bring the truck to a standstill. In emergency
operation, it is nevertheless guaranteed that the
truck can be driven out of danger areas. In order
to enable driving for a short period of time, the
maximum motor current can be activated briefly.
- Do not actuate the accelerator pedal for at
least 2 seconds.
- During this time, the driving speed must remain
under 0.5 km/h.
- Actuate the accelerator pedal.

After 2 seconds or a driving speed greater than

2 km/h, the current limitation becomes active
again.

60-10 55048042201 [EN]

Electrics/electronics
r mm
General

Pump motor temperature monitoring

Thermal protection of the drives (TSA)

1 1%]

I max

I [%] Pump motor current in %

Imax 100% Standard pump motor current
Imin 35% Maximum pump motor current limitation via the converter
T[°C] Temperature in the pump motor in °C
The A5 034 — MOTOR OVERTEMPERATURE is reset once this temper¬
T1 135°C
ature is reached and the temperature falls below this value.
Start of the actual limitation of the pump motor current via the converter
T2 145°C The A5 0 3 4 — MOTOR OVERTEMPERATURE error is activated .
The error message re-appears in the display repeatedly.
t3 160°C End of the linear reduction of the pump motor current via the converter

The pump motor and converter are protected

against overtemperature by means of tempera¬
ture monitoring that provides "thermal protection
of the drives".
The converter analyses the signals from the
pump motor temperature sensor and transmits
the temperature values to the truck control unit
(MCU).
The temperature values are processed in the
MCU in accordance with the TSA characteristic
curve.
If the (T2) 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.

55048042201 [EN] 60-11

 Electrics/electronics
General

Thanks to the linear reduction of the motor cur¬

rent, the pump motor is normally able to restore
its temperature balance. If the pump motor tem¬
perature drops to the (T 1) value, the error will
reset and the motor current reduction will be can¬
celled.
From the (T3) temperature, the motor current
is reduced to the extent that only very limited
hydraulic functions are available.

Emergency operation.
Depending on the load of the truck, the current
limitation can greatly impair the hydraulic func¬
tions. The emergency operation current is de¬
signed so that steering is always possible. In
order to raise loads for short periods of time, the
maximum motor current can be briefly activated.
- Do not actuate the lift lever
- The pump motor must not be allowed to run for
at least 2 seconds
- Actuate the lift lever

This activates the maximum motor current for 1

second. The current limitation is then reactivated.

Converter temperature monitoring

Thermal protection of the drives (TSA)

I [%]

I max

Imln

ÿ
3
Ti[°C] T2[°C] T3[°C]

60-12 55048042201 [EN]

Electrics/electronics r General

I [%] T raction motor current in %

Imax 100% Standard traction motor current
Imin 30% Maximum traction motor current limitation via the converter
T [°C] Temperature at the heat sink for the traction converter 1U06
The A5300 — CONVERTER OVERTEMPERATURE error is reset once
T1 85°C this temperature is reached and when the temperature falls below this
value.
Start of the linear regulation of the traction motor current via the converter.
Tz 125°C The A53 0 0 — CONVERTER OVERTEMPERATURE error is activated.
The error message re-appears in the display repeatedly.
t4 126°C End of the linear regulation of the traction motor current via the converter

I [%] Pump motor current in %

Imax 100% Standard pump motor current
Imin 35% Maximum pump motor current limitation via the converter
T [°C] Temperature at the heat sink of the pump converter
The A5 3 6 4 — CONVERTER OVERTEMPERATURE error is reset once
T1 85°C this temperature is reached and the temperature falls below this value.
Start of the actual limitation of the pump motor current via the converter
T2 125°C The A5 3 6 4 — CONVERTER OVERTEMPERATURE error is activated.
The error message re-appears in the display repeatedly.
T3 126°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.

Intermediate circuit
Work on the electrical system
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.

55048042201 [EN] 60-13

 Electrics/electronics
General

A DANGER
Due to the internal energy accumulator in the conver¬
ters and control units, there may be dangerously high
voltages at the electrical connections in the event of a
fault — even after the battery male connector has been
disconnected.
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 measurinq device (capable of measuring up
to 1000 V DC).
Discharge the intermediate circuit.

Discharge circuit >

The discharge circuit is a device for discharging
the intermediate circuit in converters in electric
trucks. The discharge circuit can be designed by
the service engineer himself.

Parts list:
• 24-V/21-W bulb
• 2 x connecting cables
• 2 x banana plugs
• 2 x crocodile clips

Checking the discharge circuit

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 tested before every use.
- Test the bulb

Discharging the intermediate circuit

- Disconnect the battery male connector

- Connect the contacts of the main contactor >

with the discharge circuit.
- Alternatively, it is also possible to 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 briefly flashes.
- Measure the voltage in the intermediate circuit

The intermediate circuit is considered discharged

when the voltage is less than 11 V.
- Test the bulb.
- Replace the faulty bulb and discharge again.

60-14 55048042201 [EN]

Electrics/electronics r General

Insulation testing for electric trucks

General
Insulation testing must generally be carried out
before each diagnostic process. Insufficient in¬
sulation values in the truck can lead to undefined
errors that may not be detected via diagnostic
processes.
The insulation of the entire truck is tested during
this process.

If the event of insufficient 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

A DANGER
Dangerously high voltages can be present in the
electrical drive system (inverter, traction motor, pump
motor)!
Always observe the safety information; see chapter
entitled "Safety information".
Before working on the inverter, first 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.

Minimum value over the

Nominal voltage Test voltage Test values for new trucks
duration of service life
24 V 50 V/DC Min. 50 kfi >24 kil
48 V 100 V/DC min. 100 kft >48 kO
80 V 100 V/DC min. 200 ktl > 80 kn

Measuring aid
• MetraHit Isomultimeter STILL
• Short-circuit bridge for the battery male
connectors on the truck.
Consists of measurement wire and two
crocodile clips
• Discharge circuit; see chapter entitled "Inter¬
mediate circuit".

Preparation
- Disconnect the battery male connector.

55048042201 [EN] 60-15

 Electrics/electronics
General

- Attach the short-circuit bridge to the battery

male connector on the truck.
- Check that all fuses are inserted and main
fuses screwed in.

- Discharge the intermediate circuit; see chapter >

entitled "Intermediate circuit".
- Unlock the emergency off switch.
- Switch lock ON

Measurement
- Set the measuring device to the truck-specific
test voltage.

Connect the positive wire of the measuring

device to the short-circuit bridge on the battery
male connector.
Connect the negative cable to an area of clean
metal on the truck chassis.

Chassis
NOTE
The measurement may take a few seconds, as r--L
capacities are transferred between the truck
chassis andthe electronics.
The measurement must be carried out with
VQ Ijjifjpi C0M mA A
both polarities, as many electronic building Temp
elements are installed with direction-dependent
breakdown characteristics in the controllers.
METRAHIT ISO

60-16 55048042201 [EN]

Electrics/electronics r General

- Connect the negative wire of the measuring l>

device to the short-circuit bridge on the battery
male connector.
- Connect the positive wire to a clean area of
metal on the truck chassis.
Ideally, both measurements should produce
the same value. If the values deviate from one
another, the lower value is valid for the truck.

Follow-up work
The measurements have caused capacities to be
VQ
created in the truck. These must be discharged Temp
in a defined manner. ) <§>
- Leave the measuring device connected until
the voltage value at the truck has decreased to
metrahitI ISO
<10V.
- Remove the discharge circuit from the main
contactor.
- Remove the short-circuit bridge from the truck
battery male connector.

Component insulation testing

General
If, during insulation testing of the entire truck, the
insulation values measured were insufficient,
it is a good idea to test the components of the
drive and pump motor, as well as the battery
individually.

A DANGER
Dangerously high voltages may be present in the
electrical drive system (converter, traction motor,
pump motor)!
Always observe the safety information; see chapter
entitled "Safety information".
Before working on the converter, first 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.

A CAUTION
The test voltage can destroy electronic components.
Disconnect the electrical connections for all control¬
lers.
Connect the temperature sensors to the short-circuit
bridge.

55048042201 [EN] 60-17

 1 Electrics/electronics
General

Test values
Component Test voltage Measurements Nominal voltage Test values
24 Volt > 24 kf2
Traction motor,
500 V/DC U, V, W Housing 48 V >48 kfi
pump motor
80 V >80 kfi
24 Volt > 1000 L2
Battery +,
Battery 500 V/DC Battery tray 48 V > 1000 o
battery -
80 V > 1000 SI

Measuring device
• MetraHit Isomultimeter STILL
• Short-circuit bridge for the temperature sen¬
sors

Preparation
- 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.

Electric motor measurement

- Set the measuring device to the truck-specific
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.

Battery measurement
- Set the measuring device to the truck-specific
test voltage.
- Measure the battery positive terminal in
relation to the battery tray

60-18 55048042201 [EN]

Electrics/electronics r General

- Measure the battery negative terminal in

relation to the battery tray

Follow-up work
- 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.
The connection cables and, if necessary, the
CAN bus plugs, must be connected to the com¬
ponents, depending on the equipment.

Blue-Q = IQ
General >
Blue-Q = IQ will stand for a STILL master concept
of intelligent economic efficiency and environ¬
mental responsibility in the future.
Blue-Q stands for a clean environment, IQ stands
for intelligence. The intelligent drive mode for
economic efficiency 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.

Drive unit with optimised characteristic curve

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 /,, Blue-Q

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
40 m
not affect the lifting capacity, a 10% saving based
on a working cycle (with lifting) is achievable. On
20%
longer routes, you can also reach the maximum
speed with Blue-Q.

Intelligent control of electrical consumers 40 m

Blue-Q mode regulates intelligent switching

on/off of electrical consumers.
Depending on the equipment, the lighting, work¬
ing spotlights, windscreen wipers, seat heaters

55048042201 [EN] 60-19

 1 Electrics/electronics
General

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.

T ruck is stationary, T ruck is stationary, Shut-off depending on

Possible shut-off
driver is not seated driver is seated drive direction
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.

Parameterising
Address Value Description
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

60-20 55048042201 [EN]

Electrics/electronics r

Wiring
CAN bus connections
General

4 1 5 6

St E

9 10 11
CAN bus participant 5 Joystick, fingertip, mini-lever
1 MCU truck control unit 6 Card reader
2 1U06 traction converter 7 Drive direction turn indicator module
3 2U03 pump converter 8 Electric parking brake
9 CPP
"Red" peripheral CAN bus
10 CPP
4 Display operating unit
11 Diagnostic connector

The truck is fitted with two CAN bus circuits Terminating resistor
according to the CAN open principle.
The terminating resistor absorbs the signals in
The "blue" data CAN bus connects the controllers the CAN bus so that no reflections disturb the
and drives. The blue CAN bus is sufficient for signals. To ensure that all CAN bus participants
basic operation, driving and hydraulics. receive the signals without any problems, a
terminating resistor is usually installed in the
The "red" peripheral CAN bus connects the
first and last participant. The resistance can be
additional electrical installation and lighting. The
measured between CAN-high and CAN-low.
diagnostic connector is located in the red CAN
bus. Resis¬
Participants
In the operating circuit diagram, the CAN bus tance
MCU X47/23 —
circuits are clearly identified by their designation: A Blue 120 ft
— SR X47/24
The CAN bus circuits have completely discon¬ D 1U06 Blue 120 SI
nected data lines, but share a 24-V supply from
F 2U03 Blue —
the MCU. A faulty 24-Volt supply (failure, short
MCU X47/20 —
circuit) leads to malfunctions in both CAN bus cir¬ A Red 60 n
cuits. To detect a faulty component, the variable
— UE X47/21
MCU X46/33 —
CAN bus participants must be disconnected from H Red 60 Q
— VR X46/34
the CAN bus one after another.

55048042201 [EN] 60-21

 1 Electrics/electronics

Electrical system
Fuse box
General
The PDU fuse box is installed on the right-hand
side within the counterweight via a support.

The following components can be found in the

fuse box:
• Main contactor 1K1
• Main fuse
• PTC resistor and fuse for charging the inter¬
mediate circuit
• Current sensor for battery current measure¬
ment
• Horn relay
• Control fuses
• Electrical connections, distribution

Electrical connections
Plug Connection
XS1 24-V battery voltage
XS5 GND_P
XS6 Power supply for the electric parking brake
X83 Current sensor
X22 Intermediate circuit charging, main contactor
X27 Additional electrical installation (CPP, RPP)
X21 Signal horn 4H2
X20 Control cables for the truck control unit (MCU)
X26 Voltage transformer U1
Power supply for the valve processor (MCU, servo hydraulics variant)
X65
Power supply for the 5th hydraulic function

60-22 55048042201 [EN]

Electrics/electronics r Electrical system

Fuses

Fuse Connection
Fuse box
F21 30 A Electric parking brake
F20 10 A Charge for intermediate circuit
F19 10 A Hydraulic exhaust valve 2Y46
F18 20 A 24 volts for additional electrical installation (CPP, RPP)
F17 10 A 24 volts for valve processor (MCU, servo hydraulics variant)
F16 10 A Relay for 5th hydraulic function (option board)
F15 10 A Free
F14 10 A Voltage converter U1
F13 30 A 24 volts for additional electrical installation (CPP, RPP)
F12 10 A Signal horn
F 11 10 A Main fuse in front of S1
Converter
1F01 355 A Traction converter
2F01 355 A Pump converter

Main contactor 1K1

General
The main contactor 1K1 switches the power
supply for the power electronics. The coil is
designed for an operating voltage of 24 V and
is current-controlled.
The main contactor is installed flat in the fuse box.

55048042201 [EN] 60-23

 Electrics/electronics
Electrical system

The main contactor cannot be adjusted nor the

contacts replaced. In the event of an error, the
main contactor must be completely replaced.

Technical data
Manufacturer Albright SU 280B
Continuous current 250 A
Operating voltage of the coil 24 V
Coil output (max.) 13.09 W
Coil pull-in voltage (cold, max.) 16 V
Coil relay drop-out voltage (max.) 6V
Coil resistance
On-duration (max.) 100%
Tightening torque 14 ±0.6 Nm
Protection type in accordance with DIN 40050 IP 00

60-24 55048042201 [EN]

Electrics/electronics r
Sensor system
Vertical lift mast position
General
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 fitted in the truck.

Possible equipment variants are as follows:

• Mini-lever
• Joystick
• Fingertip

NOTE

Fornotes on operation, see the operating instruc¬

tions.

Display of the "vertical lift mast position"

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

Automatic approach towards the "Vertical lift

mast position"
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.

Gentle running-in to the end stops

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.

55048042201 [EN] 60-25

 Electrics/electronics
Sensor system

Manual calibration of the "vertical lift mast

position"
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".

Tilt angle sensor 7B46

General
The tilt angle sensor functions without contacts
via a magnetic field 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).

Sensor
Lever

Electrical connections t>

7B46
\\
jn Vjn
s

1 2 3 4 5 6
y' V
yVyy
V y

T+T+T
6210-6217
7311-7316
7B46, 6-pin 5060-5066 6311, 13, 15
7321-7330
6321-6330
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

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Electrics/electronics r Sensor system

Calibration via the display and operating unit

Calibration must always be performed after the
first 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 flashes:
- 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 flashing. The lift mast
must not be moved during this phase.
The reverse drive direction indicator flashes:
- 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 flashing. 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 via the diagnostics

Calibration must always be performed after the
first installation or replacement of the tilt angle
sensor.
- Connect the notebook to the truck and start the
truck diagnostics:

Action
T

Calibration
T

Vertical lift mast position

The notebook shows the steps to be performed

during calibration.

55048042201 [EN] 60-27

 1 Electrics/electronics
Sensor system

Error
Message text/error code Comment Response
Monitoring of both signals
A3130
VERTICAL MAST * The sum of the signals does not
lie between 6-10 V
A3131
VERTICAL MAST
A3 132
-
GND1 breakdown
Sensor signal 1 is less than 0.2 V
VCC1 breakdown
The hydraulics are disabled while
the "vertical lift mast position" is
VERTICAL MAST Sensor signal 2 is greater than 9 V

-
activated via the button.
ÿ

A3133 GND2 breakdown When the "vertical lift mast

VERTICAL MAST Sensor signal 2 is less than 0.2 V position" is deactivated, the
A3 134 VCC2 breakdown hydraulics are enabled again.
VERTICAL MAST »- Sensor signal 2 is greater than 9 V
Angle measurement plausibility
error
A3 135 »• The tilt function is actuated and
VERTICAL MAST ERROR
the angle measurement does not
change

Tilt angle sensor parameters

Notes
When performing retrofits, the truck-specific
parameters must be checked via the display and
operating unit and changed as required.

Basic parameters
Service
Value Description
address
Vertical lift mast position mode
A00 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)
A00 112 02 Offset delay before end stop
A 00 233 11 Configuration of soft key button 3 "Lift mast vertical"
A 00 10F Configuration 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

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Electrics/electronics r Sensor system

Service Description
Value
address
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)

Characteristic curves for the positioning of the lift mast

6210-6217
Service
6311,6313, 6321-6325 6327-6330 7311-7316 7321-7330 5060-5066
address
6315
A101A0 OOh OOh OOh OOh OOh OOh
A 10 1A1 01h 01h 01 h 01h 01h 01 h
A10 1A2 OAh 20h 15h 10h 40h OAh
A 10 1A3 64 h 96h 96h 96h 96h 64h
A 10 1A4 OOh OOh OOh OOh OOh OOh
A10 1A5 08h 2Eh 2Eh 40h 30h 08h
A10 1A6 10h 35h 35h 80h 80h 10h
A 10 1A7 FAh FAh FAh FAh FAh FAh
A10 1A8 OOh OOh OOh OOh OOh OOh
A 10 1A9 01h 01h 01 h 01h 01h 01 h
A 10 1AA OAh 1Eh 1Eh 20h 40h OAh
A 10 1AB 64 h EOh EOh EOh EOh 64h
A 10 1AC OOh OOh OOh OOh OOh OOh
A 10 1AD 10h 28h 28h 20h 20h 10h
A 10 1AE 15h 46h 46h 80h 40h 15h
A101AF FAh FAh FAh FAh FAh FAh
A 10 1B0 OOh OOh OOh OOh OOh OOh
A101B1 01h 01 h 01 h 01 h 01 h 01 h
A 10 1B2 OAh 20h 60h 20h 60h OAh
A101B3 64 h EOh EOh EOh C8h 64h
A101B4 OOh OOh OOh OOh OOh OOh
A 10 1B5 12h 28h 28h 20h 19h 12h
A 10 1B6 15h 37h 37h 80h 20h 15h
A101B7 FAh FAh FAh FAh FAh FAh
A101B8 01 h 11h 11h 01 h 01h 01 h

55048042201 [EN] 60-29

 1 Electrics/electronics
Sensor system

Installing the lift mast — vertical

position
Installation position V1

5060-5066
Side of chassis (2) left V2
Length of lever (3) 100 mm
V1 3° + 1°
R1 5° + 1°
V2 19.6°
R2 23.4°

Retrofitting O

The following must be taken into consideration

when retrofitting the vertical lift mast position: Components
• There must be bores for holding the tilt angle 1 Rod
sensor in the chassis struts 2 Chassis blade
3 Lever
• For spare parts, see the truck-specific spare 4 Tilt angle sensor
part list
Mast tilt
• The truck-specific parameters must be V1 Maximum forward direction
checked via the display and operating unit, N Lift mast vertical position
and changed if necessary R1 Maximum backward direction
Moving the tilt angle sensor
V2 Maximum forward direction
N Neutral
R2 Maximum backward direction

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Electrics/electronics r
Additional electrical installations
Option board
General
The option board is a basic support that houses
different plugs for additional electrical installation
variants. The option board has no further func¬
tions or components, such as relays or fuses.

1 Option board
2 MCU truck control unit

Plug Connection
Fork carriage monitoring
Mast vertical position
X30 Load sensor
Lift limitation
Roller channel
X35
7S15 5th hydraulic function
7Y08
X37 Supply via 12/24-V voltage transformer
X38 FleetManager™

55048042201 [EN] 60-31

 Electrics/electronics
Additional electrical installations

CAN-Power-Port (CPP)
General
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 identified by their
order number; see the truck-specific spare parts
list. The location and number of CPPs in the truck
varies according to truck type and equipment;
see the chapter entitled "Overview of electrical
components".

NOTE

The CPP2B (lighting) was introducedin January

2010 and replaced CPP 2 and CPP 4 (front
structure, rear) in alltrucks in the medium term.
Conversion from CPP2 or CPP 4 to CPP2B is
notpossible

Function
The CPP supplies and controls the various op¬
tional consumers within the additional electrical
installation.
Each CPP has its own identifier and is controlled
by the truck control unit (MCU, TCU) via the "red"
peripheral CAN bus. All CPPs are supplied with
power via the fuse box.

Parameterising
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 additional electrical installation
output display consists of two digits. The first digit
shows the CPP number (1-4), the second digit
shows the channel number (OUTPW 1-9). Both
digits are shown in the truck-specific operating
circuit diagram.

CPP 1/CPP 3
This CPP can be used to connect the various
electrical consumers, which will vary according to
the truck and equipment.

60-32 55048042201 [EN]

Electrics/electronics r
Additional electrical installations

Plug Assignment
X51 CAN bus (CAN r)
X52 Supply voltage
X53 2 x 2-pin plugs, 1 variable, 1 fixed switching output
X54 10 x 2-pin plugs with 7 variable switching outputs

Value
Slot Max. load Channel
CPP 1 CPP 3
X53
X53:1A OUTPW 10 Permanent double
3.5 A assignment 12 32
X53:1 B OUTPW 2 Wiper supply
X53:2B 3.5 A OUTPW 1 11 31
X54
X54:1 B 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 assignment 19 39
X54:10B

CPP2B
The entire lighting is connected via the CPP.
It is therefore also named CPP lighting. Other
electrical consumers cannot be connected.

Plug Assignment
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

Value
Slot Max. load Channel
CPP2B
X53
X53:1A OUTPW 10
3.5 A Front wiper, supply 22
X53:1 B OUTPW 2

55048042201 [EN] 60-33

 1 Electrics/electronics
Additional electrical installations

Value
Slot Max. load Channel
CPP2B
X53:2B 3.5 A OUTPW 1 Front wiper, interval 21
X54
X54:1B Headlight left
OUTPW 3 23
X54:3B Headlight right
X54:2B Side light left
OUTPW 11 2B
X54:6B Rear light left
X54:2A Direction indicator front left
OUTPW 6 26
X54:6A Direction indicator rear left
X54:4A Direction indicatorfront right
OUTPW 5 25
X54:8A Direction indicator rear left
X54:4B Side light right
OUTPW 4 24
X54:8B Rear light right
X54:5B Stop light left
OUTPW 8 28
X54:7B Stop light right
X54:9B OUTPW 7 Back-up light left, right 27
Blower for heating system
X54:10B OUTPW 9 29
Washer

Relay-Power-Port (RPP)
General
The RPP is a simplified 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 has three internal relays. The relays
are directly activated by the SK1 , SK2 and SK3
external relay outputs of the truck control unit.
The position of the RPPs varies according to truck
type; see chapter entitled "Overview of electrical
components"

Electrical connections
RPP plug
X51 Relay — supply voltage of the 24-volt CAN bus
X52 Consumer — supply voltage of X27
X53 Normally open contacts for SK1
X541 Normally open contacts for SK2
X549 Normally open contacts for SK3
X56, 3-pin Relay coil contacts

60-34 55048042201 [EN]

Electrics/electronics r
Additional electrical installations

Configuration
The RPP must not be registered using parame¬
ters.
The outputs are parameterised using the truck
diagnostics in the notebook.

RPP MCU Relay Channel Value

X56:1 X47:33 SK1 out 01
X56:2 X47:5 SK2 out 02
X56:3 X47:19 SK3 out 03

55048042201 [EN] 60-35

60 Electrics/electronics
Additional electrical installations

60-36 55048042201 [EN]

Electronic controllers r

Traction and working hydraulics control

Main Control Unit (MCU)
General b

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: X47 X45 G5 X46 X48
• 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
Configuration using parameters
Evaluation of the coarse and fine 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

55048042201 [EN] 64-1

 1 Electronic controllers
Traction and working hydraulics control

• 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

Undo the electrical

Plug
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

MCU with servo hydraulics

General >
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.

NOTE
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

64-2 55048042201 [EN]

Electronic controllers r
Traction and working hydraulics control

Main Control Unit (MCU)

Removal and installation
Spare part
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)

Removal
- 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.

Installation
- 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.

55048042201 [EN] 64-3

 1 Electronic controllers
Traction and working hydraulics control

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) A-EEPfiCM
VALID?
supposed to be used?"
- Load software flash package and start cal¬
ibration; see the chapter entitled "Software
compatibility"
- Delete the error memory.

- Function check.

64-4 55048042201 [EN]

Electronic controllers r
Converter
Converter
General PU - 2U03
The traction motor and the pump motor are
controlled by their own individual converter. The
converters are attached to the counterweight via
a heat sink and are protected by panelling.
Both converters are completely identical and
therefore common parts.

The converters perform the following tasks in the

truck control unit:
• Controlling and regulating the relevant motor
• Rev counting
• Measuring and monitoring the temperature
Pump motor converter
• Communicating with the MCU truck control 2U03 2M1
unit
Traction motor converter
1U06 1M1

Technical data
Converter Danher Motion ACC2407-500C-23P
Software New software cannot currently be loaded

Power supply Nominal 24 V

Intermediate circuit voltage Maximum 36 V
Supply for controller and driver Nominal 24 Volt
Phase current Standard working cycle 215Aeff
Maximum (2 min) 550 Aeff

LED identification Normal operating mode Continually ON

Warning Flashing with 1 Hz
Error
Flashing with 10 Hz
Power module deactivated

Tightening torques
Tightening torques:
Heat sink on counterweight
Screw M6 x 35 - 4762 - 8.8 8 Nm
VS lock washer 6x10x1
Power cable stud bolt
SK nut -M8- 4032 -8A2C
Disc spring 15x8.2x0.8 15 ±2 Nm
Washer A 8.4
sometimes with square washer

55048042201 [EN] 64-5

 1 Electronic controllers
Converter

Electrical connections
Power connections
B+ U-Batt via fuse
+ U-Batt after main contactor
B- Batt. - (GND-L)
U Motor field connection
V Motor field connection
w Motor field connection
X150
Control wiring harness
X151

Plug assignment X150, X151

Pin 1 24 V from MCU
Pin 2 Not assigned
Pin 3 Rev sensor, +12 V
Pin 4 Rev sensor, GND
Pin 5 Rev sensor, CH 1
Pin 6 Rev sensor, CH 2
Pin 7 CAN GND_S connected to pump converter 2U03
Pin 8 CAN GND_S
Pin 9 120-Ohm terminating resistor (only in traction converter 1U06)
Pin 10 Not assigned
Pin 11 Not assigned
Pin 12 Coding only for pump converter 2U03
Pin 13 Not assigned
Pin 14 CAN L connected to pump converter 2U03
Pin 15 CAN L
Pin 16 Engine temperature sensor, +12 V
Pin 17 Engine temperature sensor, GND
Pin 18 Not assigned
Pin 19 Not assigned
Pin 20 Not assigned
Pin 21 Coding only for pump converter 2U03
Pin 22 CAN H connected to pump converter 2U03
Pin 23 CAN H

64-6 55048042201 [EN]

Electronic controllers
Converter

Removing and installing the

converter
Preparation -
PU 2U03

NOTE FU -1U06
The drive converter andpump converter are
completely identicalin design andean be repla¬
ced with each other interchangeably.

A DANGER
Due to the internal energy accumulator in the conver¬
ters and control units, there may be dangerously high
voltages at the electrical connections in the event of a
fault — even after the battery male connector has been
disconnected.
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.

Removal
- Park the truck safely
- Disconnect the battery male connector

- Remove the cover from the counterweight

- Remove panelling from the converters.

- Discharge the intermediate circuit; see chapter

entitled "Intermediate circuit" X150
X151
- Disconnect plug X1 50 or X1 51.
- Disconnect the three phases U , V and W

- Disconnect the connections B- and B +

- Loosen the four mounting screws.

- Remove the converters
- Clean the contact surfaces of the converters
and counterweight of all heat-conducting paste
residues

Installation

NOTE
Work carefully to ensure that no parts fall into
the electricalsystem
The wiring, mounting elements and tightening
torques are dependent on the converter type

55048042201 [EN] 64-7

 1 Electronic controllers
Converter

A CAUTION
Converters are destroyed by overheating!
Apply a thin layer (approx. 0.5 mm) of heat-conducting
paste evenly over the clean contact surfaces.
Check the tightening torques and mounting elements.

- Before installation, check whether the bottom

plate of the converter lies flush 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
- Align the converter and tightly screw in the 4
socket head screws with lock washers.
- Connect the three phases U, V and W

- Connect the connections B- and B +

- Connect plug X1 50 or X1 51 .

- Install the converter panelling

- Install the counterweight cover

- Connect the battery male connector

X150
- Set key switch S1 to ON X151
- Load software flash package and start calibra¬
tion; see chapter entitled "Software compati¬
bility"
- Delete the error memory

- Carry out a function test

64-8 55048042201 [EN]

Batteries and accessories r
Traction battery
battery
Measuring acid density >
The acid density of a full, charged battery is
1.28-1.30 kg/I.
The acid density decreases as the battery dis¬
charges. When discharged, the acid density
must not fall below 1.14 kg/I.

Battery type Acid density Charging state

PzS (normal) 1.27 kg/I 100%
< 1.14 kg/I 80% (deep-discharged)
PzSH (performance-enhanced) 1.29 kg/I 100%
Increased acid density < 1.14 kg/I 80% (deep-discharged)

The acid density is tested using an acid siphon.

The acid density can be read off directly on the
float (areometer).
After charging, 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, measurements must
only be taken approx. 30 minutes after charging
is complete.

fr NOTE
The acidlevel (filling quantity) of the battery
must be checkedat regular intervals. Once the
minimum mark has been reached, only top up
with distilled water.

Battery capacity depending on temperature

The maximum battery capacity is only reached
with an optimum temperature of 27-30°C.

55048042201 [EN] 69-1

 1 Batteries and accessories
Traction battery

A decrease in temperature reduces the battery

capacity by 1% for every 1°C. At a temperature
of 0°C, the battery undergoes a 27% drop in
capacity, i.e. there is only 73% of the maximum
capacity available.

Sulphated battery
If the battery is incorrectly handled, lead and sul¬
phur bond together to form a hard lead sulphate.
This is known as permanent or hard sulphation.
Permanent sulphation can be detected by the
discolouration of the plates. The positive plates
become 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 sulphated battery:

• Frequent deep discharging
• Full charged incorrectly
• Charging current too low
• Frequent intermediate charging

"Starved" battery
People talk of a starved battery if the recovery
phase until the open-circuit voltage is reached
is too long after charging. The battery becomes
inactive which leads to incorrect values in the
discharge indicator.

battery discharge
When switching on a fully charged battery (i.e.
unloaded), it must have an open-circuit voltage of
at least 2.1 V/cell, which corresponds to a battery
nominal capacity of approx. 100%.
The open-circuit voltage of the battery reduces
as discharging progresses and depends on the
discharge current strength. The stronger the
discharge current, the lower the available battery
capacity.
The discharge limit is determined using the
final discharging voltage. When the battery
is discharged below the discharge limit, this is
called deep discharging.
To avoid deep discharging, the final discharging
voltage is restricted by parameterisation of
the cut-off threshold. If the cut-off threshold
is reached, restriction of the hydraulics can be
activated through parameterisation.
Before the cut-off threshold is reached, it is
possible to determine the residual charge still
available via the warning threshold. A flashing

69-2 55048042201 [EN]

Batteries and accessories
Traction battery

battery indicator activates an alarm indicating the

level of residual charge left.

NOTE
see a/so Chapter "Discharge Indicator"

Battery male connector

General
The battery plug connection consists of two parts:
Appliance plug X1 (female connector)
Appliance plug X2 (male connector)
The appliance plug (X1) is equipped with a
handle and is connected firmly to the battery
via contact bushes. It is simultaneously used as
a charging plug to charge the battery. The driver
can reach the plug at any time with his left hand
\
and disconnect it in the event of danger.
The appliance plug (X2) is screwed to the coun¬
terweight behind the battery on the right-hand
side of the truck.

Coding system
Each plug connection 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.
Both halves of the plug are equipped with an
encoder between the contacts for this very pur¬
pose. The coded operating voltage is visible in
the housing section of the battery male connec¬
tors.
Further encoders are available to correctly as¬
sign battery chargers to the appropriate battery
technology with fluid (wet) or fixed and locked
(gel) electrolytes.

Pilot contact or auxiliary contact

Plug connections can be optionally equipped
with pilot contacts or auxiliary contacts. Pilot
contacts are used to protect against the battery
plug connection being improperly disconnected
between the battery and the battery charger when
the battery is being charged.
The pilot contact ensures that the charging cur¬
rent is switched off at the battery charger before
the plug main contacts are disconnected com¬
pletely. A prerequisite for this is the correspond¬
ing battery charger equipment.

55048042201 [EN] 69-3

 1 Batteries and accessories
Traction battery

Ventilation for battery with electrolyte circu¬

lation (EUW)
Plug connections can be equipped with inte¬
grated ventilation for batteries with EUW. The
ventilation design is manufacturer-specific and
is therefore incompatible with different plug ver¬
sions. The ventilation units are not currently
standardised.

Combination options
The equipment specified can be used in the
following combinations:
• Plug/socket
• Plug/socket with 2 pilot contacts
• Plug/socket with ventilation
• Plug/socket with ventilation and 2 auxiliary
contacts
• Plug/socket with 2 pilot contacts and 2 auxiliary
contacts

Discharge indicator
Display
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 flash.
At 0% residual battery charge or no bars, restric¬
tion of the hydraulics is activated.

Battery capacity
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 flashing 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 configurable 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.

69-4 55048042201 [EN]

 r
Traction battery

(Y) = Warning threshold, a configurable value

which indicates the residual charge by means of
a flashing battery indicator. Valid value range:
0-100%; default 20%.

Measuring procedure
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
(specified adjustment values), the voltage is
determined here as fine battery voltage. This in¬
ternally measured value cannot be measured by
the service centre.
The fine 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.

Initial measurement
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). Ifthis address is
not parameterised or incorrectly parameterised,
an error message will appear.

55048042201 [EN] 69-5

69 Batteries and accessories
Traction battery

69-6 55048042201 [EN]

Hydraulics f

General
General technical data

Hydraulic pump 5060-5066

Type Gear pump
Anticlockwise rotation direction
Delivery rate 9.3 cm3 per revolution
Tightening torques
Hydraulic pump
2 x socket head screw
56 +4 Nm
2 x socket head screw M6 x 20, 8.8, ISO 4762
Intake flange 2 x socket head screw M6 x 50, 8.8, ISO 4762
10 Nm
4 x socket head screw M6 x 35, 8.8, ISO 4762
10 Nm
Priority valve LS: 50 Nm
EF: 100 Nm
CF: 80 Nm
Hydraulic tank
Capacity, total filling quantity with
26 litres
auxiliary hydraulics
Quality as per DIN 51 524/Part 2
Hydraulic oil
HVLP68 or ISO VG 68

Hydraulic speeds
General
Steering, dynamic adaption 400-1 100rpm
Auxiliary hydraulics See the chapter entitled "Auxiliary hydraulics"
Hand lever
Lifting 3900rpm
Tilting
Nominal lift < 3500 mm 1100rpm
Nominal lift 3500-5000 mm 620rpm
Nominal lift > 5000 mm 400rpm
Servo hydraulics
Lifting 3900rpm
Tilting
Nominal lift < 3500 mm 1100rpm
Nominal lift 3500-5000 mm 620rpm
Nominal lift > 5000 mm 400rpm

Hydraulic filter
Return line filter
Degree of filtration 20 pm absolute
T riggering pressure — bypass valve 0.25 ±0.05 bar
Maintenance interval 3000 h or 2 years
Tightening torques

55048042201 [EN] 70-1

 1 Hydraulics
General

Filter cover 30 Nm
Hydraulic connections 30 Nm
Intake filter
Degree of filtration 225 pm absolute
Maintenance interval Maintenance-free
Breather filter
Degree of filtration 7 pm absolute
Maintenance interval 3000 h or 2 years
High-pressure filter
Degree of filtration 12 pm absolute
T riggering pressure — bypass valve 7 ±1 bar
Maintenance interval 3000 h or 2 years
Only used in the servo hydraulics variant!

Lifting operating speeds

Lifting speed with nominal load [m/s]

Truck Telescopic NiHo mast Triple mast
mast Lift 1 Lift 2 Lift 1 Lift 2
min 0.30 0.30 0.30 0.30 0.30
5060, 5061
max 0.45 0.42 0.42 0.42 0.45
min 0.29 0.29 0.29 0.29 0.29
5063
max 0.42 0.39 0.39 0.39 0.42
min 0.28 0.28 0.28 0.28 0.28
5065
max 0.39 0.38 0.38 0.38 0.39
min 0.28 0.28 0.28 0.28 0.28
5066
max 0.38 0.38 0.38 0.38 0.38
Maximum permissible single value from lift 1 and lift 2 = 0.6 m/s

Testing
- Lift 1: Middle cylinder is extended.

- Lift 2: Outer cylinder is extended.

- For NiHo and triple masts, the mean value of

the speeds measured for Lift 1 and Lift 2 is the
authoritative value.
- The maximum permissible individual value
from Lift 1 and Lift 2 must not be exceeded.
- Speeds must be measured at operating
temperature

1 NOTE
Special equipment fitted to trucks may cause the
values recordedto differ from those stated.

70-2 55048042201 [EN]

Hydraulics
General

Tilting operating speeds

5060-5066 Tilt forwards with nominal load [seconds]

Nominal lift [mm] Tilt angle
From To 8°
Min. 1.7
3500
Max. 2.6
Min. 2.6
3500 5000
Max. 4.4
Min. 4.4
5000
Max. 6.9

5060-5066 Tilt forwards with nominal load [seconds]

Nominal lift [mm] Tilt angle
From To 8°
Min. 1.5
3500
Max. 2.5
Min. 2.3
3500 5000
Max. 3.7
Min. 3.8
5000
Max. 6.0

Testing
- Measurement must be performed over the
entire tilt range
- Speeds must be measured at operating
temperature
- For oil temperatures > 50°C, the measure¬
ments are permitted to deviate from the table
values by +20%

A CAUTION
Operating error!
Higher tilt speeds may occur if more than one valve
function is actuated at the same time.

Operating speeds for lowering

5051-5055 Lowering speed with nominal load (m/s)

5060-5066 Telescopic mast NiHo Triple mast
Max. speed
Single value from lift 1 and lift 2
0.60 m/s
Min. speed
Mean value from lift 1 and lift 2
0.41 m/s

Audit
- Lift 1: Middle cylinder is extended.

55048042201 [EN] 70-3

 1 Hydraulics
General

- Lift 2: Outer cylinder is extended.

- Speeds must be measured at operating
temperature.

A CAUTION
The maximum lowering speed of 0.60 m/s should not
be exceeded!
Do not adjust settings on lowering brakes.

Forward tilt safety test

Test
- 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 I>

spirit level (1) to the mast profile (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.

Lowering safety test

Procedure
- 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.

70-4 55048042201 [EN]

Hydraulics f
General

The lift mast must not automatically lower the

load by more than 100 mm in 10 minutes.

Safety checks of hose assembly

Proceed
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 fitting with
bubble formation.
- Leaks.
- There is damage or corrosion at the fitting and
reduced rigidity of the connection between the
fitting 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.

55048042201 [EN] 70-5

 1 Hydraulics

Basic hydraulics
Basic hydraulics
Design

1 Steering unit 8 Intake hose

2 Steering return line 9 Intake filter
3 Steering pressure line 10 Directional control valve block
4 LS signal line 11 Working hydraulics return line
5 Pump motor 12 Working hydraulics pressure line
6 Priority valve 13 Return line filter
7 Hydraulic pump 14 Breather filter and dipstick

The hydraulic pump (7) is driven by the pump

motor (5) via a tappet. Together, they form the
pump unit.
The hydraulic pump and the intake hose (8) are
located below the oil level in the hydraulic tank.
The welded hydraulic tank is built into the chassis
The hydraulic pump draws the oil via a coarse,
maintenance-free intake filter (9) and delivers it
to the priority valve (6).
The priority valve is flange-mounted to the hy¬
draulic pump and distributes the oil between the
steering hydraulics and working hydraulics.

70-6 55048042201 [EN]

TILL
Hydraulics
Basic hydraulics

The returning oil from the steering hydraulics

flows back to the tank unfiltered. The returning or
excess oil from the working hydraulics flows back
to the tank via the return line filter (13).
If the return line filter is clogged, the bypass valve
opens and the oil returns to the tank unfiltered via
the bypass.
The breather filter (14) prevents contamination
from dirty air and is combined with the dipstick to
form a single unit.

Steering hydraulics
Design

1 Steering motor Pressure line

2 Steering unit Return line
3 Cables to the steering motor Priority valve
4 LS signal line Hydraulic pump

55048042201 [EN] 70-7

 1 Hydraulics
Basic hydraulics

The steering system is equipped with power

steering that works in the LS system. It directly
affects the steering motor (1).
LS-System
Load-Sensing-System
Load sensing system
The steering and the working hydraulics are
supplied in LS systems by a shared pump unit.
Oil is distributed between the two systems in the
priority valve (7), with the steering supplied as a
priority.
If the steering is not actuated, the entire oil
volume is sent to the directional control valve
block. If the steering is actuated, the priority valve
sends the oil volume required for steering through
the pressure line (5) to the steering unit (2). The
oil flows back into the tank via the return line (6)
unfiltered.
Pressure is built up in the steering unit by turning
the steering wheel. The pump unit is switched on
in the steering unit via the LS signal line (4).
The oil volume required for steering is signifi¬
cantly lower than the volume required for the
working hydraulics. For this reason, the speed of
the pump unit is kept at a low value for steering
when the working hydraulics is not actuated.
If the hydraulics fail, the steering unit functions
automatically as a hand pump, which means that
the truck can be steered manually (emergency
steering).

70-8 55048042201 [EN]

Hydraulics
Basic hydraulics

Working hydraulics
Design

1 Priority valve 5 Lift cylinder connection

2 Hydraulic pump 6 Pressure line connection
3 Intake hose 7 Tilt cylinder connection
4 Return line connection

The hydraulic pump (2) supplies the oil to the

priority valve (1) via the intake hose (3). The oil
volumes required for steering and the working
hydraulics are distributed in the priority valve.
Steering always has the highest priority.
The oil volume for the working hydraulics is sent
from the priority valve to the directional control
valve (6) via the pressure line.
When a slider is actuated, an oil volume corre¬
sponding to the movement of the slider is sent
from connection (5) to the lift cylinders, from con¬
nection (7) to the tilt cylinders and, if applicable,
to an attachment in the auxiliary hydraulics.
If a slider is only actuated slightly, the oil flows with
a low circulation pressure through the directional
control valve block and back into the tank via the
return line (4).

55048042201 [EN] 70-9

 1 Hydraulics
Basic hydraulics

Hydraulic tank
Design
The hydraulic tank is a welded component built
crosswise into the chassis in front of the battery
compartment.
The filter housing is screwed to the tank by means
of four fastening nuts.
The return lines for the directional control valve
and steering unit are screwed to the filter housing.
Sealing is accomplished by means of sealing
rings.
The intake nozzle is located below the oil level.
1 Intake filter
The breather filter is integrated with the dipstick 2 Return line filter cover
in the filter housing. 3 Breather filter with dipstick
4 Oil drain plug

Hydraulic oil
Technical data
Hydraulic oil filling quantity with the carriage
lowered and the hydraulic system ready for
operation:
• For the total filling 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

Oil change

<ÿ> ENVIRONMENT NOTE

Hydraulic oilmust be disposed ofin accordance
with environmentalregulations.
- Position the truck on a horizontal surface
- Tilt lift mast backwards until it reaches the stop

- Lower fork carriage; if there are attachments,

retract working cylinders
- Disconnect the battery male connector

- Remove the bottom plate

1 Return line filter
- Unscrew the breather filter 2 Dipstick opening
3 Hydraulic tank
- Unscrew the hydraulic oil drain plug under the 4 Hydraulic oil
hydraulic tank and drain the hydraulic oil into a X Oil level
collection vessel
- Screw in drain plug with a new seal (Cu A1 8 x
22) and tighten

70-10 55048042201 [EN]

Hydraulics
Basic hydraulics

- Pour in new hydraulic oil via the breather filter

opening
- The oil level must lie between the markings on
the dipstick

Oil volume [I] incl.

Truck Oil level [mm] Comment
auxiliary hydraulics
5060-5066 26 156 ±15
6210-6217
27 100 ±25
6311, 13, 15
6321-6325 36 122 ±15
6327-6330 54 162 ±15
Triple mast above
6327-6330 58 122 ±15
3300 mm

Return line filter

General
The hydraulic oil that returns from the directional
control valve block is filtered in the return line
filter. The hydraulic oil that returns from the
steering flows back into the tank unfiltered.
If the return line filter is clogged, the hydraulic oil
is rerouted via a bypass and subsequently flows
back into the tank unfiltered.

Technical data
Degree of filtration: 22 pm absolute
f
Filter material: non-woven plastic mesh
Housing material: polyamide PA 66
1 Return line filter cover
Bypass valve opening pressure: 3.4 ±0.3 bar 2 Breather filter
3 Bypass valve
Maintenance interval 4 Seal
• 3000 operating hours or 2 years 5 Return line filter
6 Dipstick
7 Steering return pipe
NOTE

Observe tightening torques; see chapter

entitled "Technical data".

ENVIRONMENT NOTE
The filter element must be disposed ofin accor¬
dance with environmentalregulations.

Changing the filter element

- Unscrew the filter cover
- Unhook the filter cover from the filter element
and replace

55048042201 [EN] 70-11

 Hydraulics
Basic hydraulics

- Hook the filter cover onto filter element

- Screw in the filter cover

Changing the return line filter

- Disconnect the return lines

- Undo the 4 fastening nuts on the tensioned

cover
- Completely remove the filter housing from the
tank
- Place the seal in the tensioned cover for the
filter housing
- Insert the filter housing into the tank

- Screw in four fastening nuts M8 with washers

tightly
- Connect the return lines

Breather filter
General E>
The breather filter and the oil dipstick form a unit
and are integrated in the return line filter housing.
The filter prevents dust and dirt from entering the
hydraulic tank.

Technical data
Degree of filtration: 8 pm nominal
Filter material: non-woven plastic mesh

Maintenance interval
f
• 3000 operating hours or 2 years

ENVIRONMENT NOTE 1 Return line filter cover

2 Breather filter
The filter element must be disposed ofin accor¬
3 Bypass valve
dance with environmentalregulations. 4 Seal
5 Return line filter
Changing the filter element 6 Dipstick
7 Steering return pipe
- Unscrew the breather filter

- Remove the filter cover

- Remove and replace the filter element

- Replace the filter cover
- Screw the breather filter back on.

70-12 55048042201 [EN]

Hydraulics
Basic hydraulics

Suction filter
General
The hydraulic oil is drawn in from the tank by the
hydraulic pump through the suction hose and
flows through the suction filter from the outside to
the inside.
The filter insert is a coarse filter and maintenance-
free.

Technical data
Filter mesh: 225 pm
Filter material: stainless steel mesh
Flousing material: polyamide PA 66 Filter cartridge
Thrust piece
Hose clip
Removal Fixing screws

ENVIRONMENT NOTE
Hydraulic oilshouldbe disposed ofaccording to
the environmentalregulations.
- Draining the hydraulic oil

- Release the hose clip (3) on the suction hose

and disconnect the suction hose from the tank
and hydraulic pump
- Slacken the fixing screw (4) on the clamping
piece on the filter cartridge
- Remove the clamping piece (2)

fj"1 NOTE
itmay be necessary to strike the filter cartridge
using a mandrel to release it from the suction
connection. Use materialthat does not splinter
for this purpose!
- Remove the filter cartridge through the open¬
ing in the return filter

Installation
- Prior to installation, check that the sealing ring
is properly seated on the filter connection and
has not fallen into the tank
- Tighten the fixing screw on the clamping piece
on the filter cartridge
Socket head screw M6 x 1.0, tightening torque 3
Nm
- Install the suction hose between the tank and
hydraulic pump and secure it with the hose
clip.

55048042201 [EN] 70-13

 1 Hydraulics
Basic hydraulics

- Fill with hydraulic oil

High-pressure filter
General
For servo hydraulics, it is a legal requirement
(in accordance with VDMA (German Engineering
Federation)) that in addition to the return line filter,
an additional filter is installed in the pressure line
upstream of the directional control valve.
The high-pressure filter is located in the pressure
line between the connections (EF) of the priority
valve and (P) of the directional control valve.

Technical data
Degree of filtration: 12 pm nominal
Filter material: non-woven plastic mesh
Maintenance interval: 3000 operating hours or 2
years
1 High-pressure filter
Changing the filter element 2 Filter housing
3 Hexagonal

ENVIRONMENT NOTE
The filter element andany oilthat escapes must
be disposed of in an environmentally friendly
manner.
- Place a collection vessel underneath. The oil
volume that drains out is about 0.2I (capacity
of the filter housing).
- Loosen the filter housing (2) at the hexagonal
(3) with a SW30 box-end wrench and unscrew
it.
- Pull the filter element downwards.
- Push the new filter element in until it stops.

- Clean the filter housing and screw on hand

tight.

70-14 55048042201 [EN]

Hydraulics
Basic hydraulics

Bolted joint
General
The screw joints consist of:
• Functional nut (union nut)
• Sealing ring (soft seal)
• Retaining ring (olive)
• Pipe
• Pipe adaptor

Assembly
- Saw pipe at right angles

1 Functional nut
2 sealing ring
3 Retaining ring
4 pipe
5 fitting

- Deburr pipe on inside and outside

A CAUTION
Sharp edges can damage the sealing ring.
Deburr pipe on inside and outside and clean.

- Screw the functional nut (1) with retaining ring >

(3) and seal (2)onto the pipe union (5) by hand

55048042201 [EN] 70-15

 Hydraulics
Basic hydraulics

- Push the pipe end into the screw joint and >
press against the stop in the inner cone

A CAUTION
An insufficient 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,
approx. 1 to 1 Vz turns

NOTE

A marking (6) on the pipe and functional nut

makes counting the turns easier.

Test
- After assembly, remove the functional nut (1)

- Check whether there is a gap between the

sealing ring (2) and retaining ring (3)

Repeat installation
- Every time you loosen the functional nut (1),
please proceed as in the initial assembly

2 3 1

70-16 55048042201 [EN]

Hydraulics
Basic hydraulics

- Tighten the functional nut (1) until you clearly i>

feel an increase in connection strength,
approx. 1 to 1 1/4 turns
- Hold the socket (7) together when doing so

Sealing ring replacement

- In the event of leaks at the screw joint, the >
sealing ring (2) can be removed from the free
pipe end and replaced

Conical nipple fittings (CNF)

General
The conical nipple fitting is equipped with an
integrated O-ring.
Tighten the fitting union nut until you feel a re¬
sistance and then turn it a maximum of a half
revolution (180 degrees).

A CAUTION
Tightening it even more can lead to deformation and
leaking.
Tighten the union nut until it is firmly seated and then
turn it a maximum of a half revolution.

180 o

55048042201 [EN] 70-17

70 Hydraulics
Basic hydraulics

70-18 55048042201 [EN]

Working hydraulics f

Pump unit
General technical data

Pump motor 5060-5066

Manufacturer JULI
Designation AP 4F9-B1-1
Operating voltage 12 V
Engine type Three-phase asynchronous motor with cage rotor
Connection Delta
Direction of rotation Clockwise

Rated current (nominal) 500 A

Rated speed (nominal) 2325rpm
Maximum speed
Rated output (nominal)

Mode of operation (nominal) S3 — 15%

Protection type IP 54
Insulation class F
Cooling Surface/convection

Temperature sensor KTY 84-130

From series start: sensor bearing
Rev sensor As of 15 August 201 1: T ransmitter-free revolution
control

Pump unit
Design
The pump unit is connected to the running axle
via two bolts. The pump unit is supported at the
rear via a spring element on the chassis.
The aluminium motor housing is hermetically
sealed and equipped with cooling fins for heat
dissipation.
The hydraulic gear pump with the flange-
mounted priority valve is located on the right-
hand bearing shield for the pump motor. The
drive is provided via a tappet.
Hydraulic pump
Engine mount
Pump motor Pump motor
Earth wire
The pump motor is an AC motor with a short- Power cable
circuit cage rotor. Aluminium conductors that are Spring element
connected at the ends of the laminations stack
by short-circuit rings are fitted into grooves in
the stack. The conductors and short-circuit rings

55048042201 [EN] 711

 1 Working hydraulics
Pump unit

form the cage and hold the rotor lamination stack

together.
The stator consists of the 4-pin lamination stack
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 flow
in the rotor. The resultant current and the rotating
field acting on the stator generate the torque.
Motor connections U, V and W are fed upwards
and out of the motor as screw connections.
The temperature sensor is embedded into the
stator winding.
The speed is measured by a sensor bearing
on the drive side of the pump motor. With the
introduction of the transmitter-free revolution
control, the rev sensor is no longer needed.
The sensor plugs are fed out of the motor.

Method of operation
The motor is controlled by a converter. A change
in speed occurs as a result of a change in the
frequency and voltage of the applied AC voltage.
A voltage is induced in the rotor, which generates
current in the rotor bars according to the design.
The stator rotating field produces a torque with
the rotor current.

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Working hydraulics f
Pump unit

Electrical connections
Circuit diagram
The pump motor windings are wired in a triangu¬
lar arrangement inside the motor.

Location of the electrical connections

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 fitted when transmitter-free revolution
control is used
• Temperature sensor X1 5
4-pin mark II plug
• GND earth wire for the pump motor

Pump motor with rev sensor

Sensor bearing
The rev sensor consists of a grooved ball bearing
with two offset hall-effect sensors that scan the
inner switching ring.

The direction of rotation is detected via two

phase-shifted signals:
• The inner ring turns clockwise
• The rising edge of signal B occurs before the
rising edge of signal A
• All signals are measured against GND
The protective element 2Z1 prevents electro¬
static interference. The 100-nF condenser is
integrated in the wiring harness, near plug X14.

NOTE
With the introduction of the transmitter-free revo¬
lution control, the sensor bearing andprotective
element are no longer needed.

55048042201 [EN]
 1 Working hydraulics
Pump unit

Technical data > -

Type: Sensor bearing
64 pulses per revolution. 1
Phase offset: 90° ±45°
Temperature range: -30°C to +150°C
Supply voltage: 12 V

Electrical connections
4-pin JPT plug X14 \

Red X14/1 X 150/3 + 12 V

White X14/4 X 150/6 Signal 2 1 Sensor
Blue X14/2 X 150/5 Signal 1 2 Grooved ball bearing
Black X14/3 X 150/4 GND

Protective element 2Z1

2Z1 XK15 X14/1 Red
2Z1 XK14 X14/3 Black

Spare parts supply for repairs

In the event of a faulty sensor bearing, the trans¬
mitter-free revolution control can be activated. A
new sensor bearing does not have to be installed.
- The sensor bearing remains in the pump motor
- The protective element remains in the wiring
harness
- The plug X14 can remain connected

- Set the parameters to "Transmitter-free control

active"
- Mark the pump motor to indicate that transmit¬
ter-free revolution control has been activated

Pump motor without rev sensor

Transmitter-free revolution control
As of 15/08/201 1, the trucks are being built with
a transmitter-less revolution control. The sensor
bearing is no longer a component of the pump
motor and cannot be retrofitted.
The revolution control for the pump motor is cal¬
culated via a model calculation in the converter.
The converter and the necessary truck software
have been installed as standard since the start of
production.

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Working hydraulics
Pump unit

Requirement:
• From flash package V023
• Danher motion converter ACC2407-500C-
23P
• Parameter change

Parameterising
Address Value Comment
A 00 150 Configuration of the hydraulic drive
01 Transmitter-free control active
00 Rev sensor available

Behaviour in the event of an error

A CAUTION
Incorrect parameterising can lead to errors in the pump
motor and burnt power cables.
In pump motors without a rev sensor, the parameter
must be set to "Transmitter-free control active".

If the parameter is set to "Rev sensor available"

in pump motors without rev sensor, the following
error occurs.
- Pump motor only runs at slip speed

- Pump motor draws very high currents while

running at slip speed
- Power cables become hot and can burn

Spare parts supply for repairs

When carrying out a repair, the following conver¬
sions are possible:

Pump motor without sensor, wiring harness with

plug X14:
• Seal plug X14 with dummy plug 7915000310
• Adjust parameters to "Transmitter-free control
active"

Pump motor with sensor, wiring harness without

plug X14:
• Plug X14 remains unused at the pump motor
• Adjust parameters to "Transmitter-free control
active"

Pump motor temperature sensor

General
The pump motor is monitored by a temperature
sensor.

55048042201 [EN] 71-5

 1 Working hydraulics
Pump unit

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.

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

Electrical connections

NOTE
The location of electricalconnections varies
depending on the truck.

2-pin Mark II plug X14

X15/1 Red X 150/3 Temp-MCT +
X15/2 Blue X150/4 Temp-MCT -

A CAUTION
An improperly conducted insulation test can destroy
the temperature sensor.
Before conducting the insulation test, jumper the
temperature sensor connections.

Testing
- Insert the test adapter into plug connector X1 5
- Compare the resistance value to the table

Reference values for temperature measure¬

ment
Temperature (°C) Resistance (T2)
-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

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Working hydraulics
Pump unit

Temperature (°C) Resistance (O)

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

Changing the temperature sensor

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

NOTE
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

55048042201 [EN] 71-7

 1 Working hydraulics
Pump unit

Hydraulic pump
Structure
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 flange-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
Function
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.

Hydraulic pump — error detection

Error Cause Remedy
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

71-8 55048042201 [EN]

Working hydraulics r

Tilt cylinder
Mast tilt
Load Tilt cylinder Tilt Overall height [mm]
Truck capacity Forwards Back¬
L [mm] Lift [mm] From To
[kg] n wards [°]
All lift masts
5060-5066 1000-1600 297 57 3 5 All overall heights

Tilt cylinder
Removal and installation
Removal

A CAUTION
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

A CAUTION
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.

Installation

1 NOTE
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.

55048042201 [EN] 71-9

 1 Working hydraulics
Tilt cylinder

- Screw on the hydraulic connections at the tilt

cylinder.
- Check tilt cylinder for leaks.

Changing the set of seals

Disassembly

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

23 21 20 19 18 17 16

Setting dimensions 12 Wiper

X Lift, dependent on spacer bush (23) 13 Nut
Y Eye bolt setting dimension 14 Clip
1xd Minimum screw depth = 1 x thread diameter 15 Eye bolt
16 Hexagon head screw
Tilt cylinder
17 Cylinder head
1 Cylinder bottom
18 Grooved ring
2 Pipe adaptor for threaded elbow pipe
19 Variant: 6 mm washer (changes the forwards
3 Hexagon nut
tilt)
4 Piston guide ring
20 Variant: 4 mm washer (changes the forwards
5 Piston seal
tilt)
6 Piston
21 Variant: 20 mm washer (changes the for¬
7 Cylinder pipe
wards tilt)
8 Piston rod
22 Loctite 270
9 Pipe adaptor for threaded elbow pipe
23 Variant: Spacer bush (changes the back¬
10 O-ring
wards tilt)
11 Snap ring

A CAUTION
Component damage possible!
Protective jaws must be used to protect the cylinder
and the piston rod in the vice!

- Clamp the tilt cylinder in the vice at the cylinder

bottom (1).
- Remove the threaded elbow pipes from the
cylinder pipe (7) (thread projects into the
cylinder).
- Lightly hammer in cylinder head using a plastic
mandrel
- Use a mandril to drive in the snap ring (11)
through the bore in the cylinder pipe (7) and
use a screwdriver to lever out the snap ring.

71-10 55048042201 [EN]

Working hydraulics
Tilt cylinder

- Pull the piston rod (8) and cylinder head (17)

out of the cylinder pipe.
- Clamp piston rod in a vice.

- Disassemble the eye bolt (15).

- Pull the cylinder head (17) off the piston rod

(8).
- Remove the set of seals from the piston and
cylinder head.

Eye bolt setting dimension

Hexagon nut (3) Setting dimension Minimum screw-in
Type carrier Load capacity
Secured with (Y) depth (1xd)
class
Loctite
5051-5055 1000-1600 130 +1° Nm 46 ±8 mm 20 mm
5060-5066 1000-1600 130 +1° Nm 46 ±8 mm (M20 x 1.5)

Assembly

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

23 21 20 19 18 17 16

- Check all parts for wear.

- Lightly grease the piston seal and piston guide
ring and assemble.
- Fit the cylinder head (17) onto the piston rod
(8) and seal with Loctite 270 (22).
- Screw eye bolt (15) onto the thread of the
piston rod. While doing so, observe the setting
dimension (Y) and minimum screw-in depth
(1xd).
- Prevent the eye bolt from turning by using the
clip (13).
- Insert the piston rod (8) with the cylinder head
(6) into the cylinder pipe (7).

t NOTE
After assembling the piston guide ring, piston
sealandset ofseals, insert the cylinder headinto
the cylinderpipe, taking care that the recess on
the cylinder headfaces the pipeadaptor bore.

55048042201 [EN] 71-11

 1 Working hydraulics
Tilt cylinder

- Assemble the snap ring (11).

ffi
•
NOTE
When assembling a threadedelbow pipe,
always use a newone.
• Note the location of the threadedelbowpipes.
-
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 a minimum of 4
turns and a maximum of 5.

A CAUTION
Leakages caused by incorrectly fitted 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.

55048042201 [EN]
Working hydraulics f

Auxiliary hydraulics
Attachments
Load capacity up to 1600 kg
Pump motor speed
Attachment Make Type
1st attachment 2nd attachment
Shuttle fork arm Griptech RG4 1800
Rotator Meyer 5-1504N 1800
Rotator Meyer 5-1502N 1800
Rotator, for attachment to
Meyer 5-1504N 1800
sideshift
Rotator, for attachment to
Meyer 5-1502N 1800
sideshift

Sideshift
Kaup 1T151P4 700
Fixed connection
Sideshift
Kaup 1T151P2 850
Fixed connection
Sideshift
Cascade 55F 850
Fixed connection
Sideshift
Bolzoni HN4 850
Fixed connection

Fork prong positioner

Kaup 2T466 850 980
Fixed connection
Fork prong positioner
Kaup 2T163 850
Fixed connection
Fork prong positioner Meyer 6-2504F 850
Fixed connection

Multi pallet handler Meyer 6-5204F 850

Multi pallet handler Kaup 2T429 850

Clamp fork Kaup 2T411 850

Operating speeds
Attachment
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

55048042201 [EN] 71-13

 1 Working hydraulics
Auxiliary hydraulics

Second operating function for

attachments
Legal situation
Since 29th December 2009, standard ISO 3691
has been a legal requirement.
This standard specifies 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
retrofitted, the truck must also be retrofitted with
a second operating function.

m note
The damp lockingmechanismis discussedin the
following section.

Actuation
Component Implementing the clamp locking mechanism
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.
Fingertip During 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
Fingertip least 1/3. The enable is indicated by the LED for the F2 key and re¬
Generation 2 mini-lever mains 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.

Clamp locking mechanism with

servo hydraulics
Configuration

fj NOTE

The parameters apply only for the fingertip and

generation 2 mini-lever.
For retrofitting, the current software flash
package may have to be loadedinto the truck.
The addresses and values of trucks RX60-
25-50 (6321-6630) partially deviate from the
standard.

71-14 55048042201 [EN]

Working hydraulics
Auxiliary hydraulics

Enable via the F key

Address Value Description
A00 3EC 27 Input for clamping function with servo hydraulics
Time interval, from when the enable is reset.
A00 3ED 1E
Default: 3 seconds
Clamping function configuration
A00 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

Enable via 1/3 actuation of the operating lever, four-way valve block
Address Value Description
A00 3EC 27 Input for clamping function with servo hydraulics
Time interval, from when the enable is reset.
A00 3ED OA
Default: 1 second
Clamping function configuration
02
A00 3EE Default: enable by moving the lever
01 In RX60-25-50 (6321-6330)
A00 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)
A10 04D 3A Crossbar switch index for universal output 1

Enable via 1/3 actuation of the operating lever, three-way valve block
Address Value Description
A00 3EC 27 Input for clamping function with servo hydraulics
Time interval, from when the enable is reset.
A00 3ED OA
Default: 1 second
Clamping function configuration
02
A00 3EE Default: enable by moving the lever
01 In RX60-25-50 (6321-6330)
A00 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

55048042201 [EN] 71-15

 1 Working hydraulics
Auxiliary hydraulics

Enable via 1/3 actuation of the operating lever, three-way valve block
Address Value Description
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 Duplicate
A10 04D 3A mini-lever
1
2B Fingertip

Clamp locking mechanism for hand

levers
Parameterising

fj NOTE
The parameters apply to the damp locking
mechanism for handlevers
For retrofitting, the current software flash
package may have to beloadedinto the truck.

Service address Value Description

A 00 36 F 05 Reserve 10 input at AND 2 output
A 00 370 37 Reserve 10 output at seat CPP, channel 7
A 00 371 00 Reserve 10 output parameter
A 00 372 05 Reserve 11 input at AND 2 output
A 00 373 38 Reserve 11 output at seat CPP, 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 1 AND 2 input actuated on lever 4

Electrical connections for hand levers

Seat CPP E14 X54: 7

E14 X54: 8

71-16 55048042201 [EN]

Valves r 13

Hand lever
General technical data
Valve block
Valve block 5060-5066
Manufacturer Buchholz
Lifting, tilting, auxiliary 1
Monoblock, three-way
for all overall heights
Lifting, tilting, auxiliary 1, auxiliary 2
Monoblock, four-way
for all overall heights
Check valve for the hydraulics block¬
The hydraulic functions are active when the seat contact
ing function in accordance with
switch is actuated, i.e. when the driver is seated
EN-ISO 3691-1
Hydraulic oil temperature range
-20°C to +95°C
briefly up to 115°C
Tightening torques
A1 , B1 , A2, B2, A3, B3 G3/8, 40 Nm
R G3/4, 140 Nm
P, H G1/2, 70 Nm
SW4, 2.5 Nm
Emergency lowering screw
Loosen by max. 1.5 revolutions
Hydraulic transmitter 3.5 Nm
Valve block on valve block support 20 Nm

Tilt orifice
The tilt orifice is screwed into the back of the valve
block.

Nominal lift 5060-5066

< 3500 mm 0 3.2 mm 110Orpm
3500-5000 mm
0 2.2 mm 620rpm
Spare part delivery condition
> 5000 mm 0 1.7 mm 400rpm
Tightening torque
Orifice M10 x 1 15 Nm

55048042201 [EN] 76-1

 Valves
Hand lever

Hand lever valve block

Design >
The axle houses the levers (2) for the operating
levers. An individual operating lever can be
retrofitted or removed in the event that the device
is to be retrofitted from three-way hydraulics to
four-way hydraulics.
The operating lever for lifting is a multifunction
lever that includes an electric rocker button (1).
The Allen key(9) for the emergency lowering (10)
is secured to the valve support and can therefore
be accessed quickly in an emergency.

1 Drive direction switch 1S1

2 Lever
3 Valve spool
4 Valve block
5 Hydraulic transmitter
6 Plug X19for2B1-2B4
7 Plug X23 for 1S1
8 Valve support
9 Allen key for emergency lowering
10 Emergency lowering
11 Plug 2Y46 for enabling the hydraulics
12 Mounting screw

The back of the valve block (4) is attached to

the valve support (8) by means of three rubber-
mounted mounting screws (13). The valve
support is screwed to the battery wall by means
of three mounting screws (12).
The tilt orifice can be unscrewed at the back and
changed.

76-2 55048042201 [EN]

Valves r 13
Hand lever

Maintenance instructions >

The following bearing points must be greased:
• Bolt between the lever and joining plate
• Bolt between the joining plate and slider

Assembly instructions
• Spare part directional control valve blocks
are supplied without screw joints and with a
standard tilt orifice (nominal lift 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
• Always observe the tightening torques
• The valve spools must not be turned

Emergency lowering
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.

f NOTE
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 max 2.5 Nm
- Fit the panelling at the valve block

55048042201 [EN] 76-3

 Valves
Hand lever

Directional control valve with check valve 2Y46

General 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 orifice, depending on the nominal lift
The function and structure of the monoblocks
are identical in both versions. If a truck is later
ÿ
Check valve for hydraulics blocking function
equipped with third auxiliary hydraulics, the whole (from calendar week 39/2009)

Structure

1 A3 - auxiliary hydraulics 2 11 Hydraulic transmitters 2B1-2B3

2 B3 - auxiliary hydraulics 2 13 Plug X19
3 A2 - auxiliary hydraulics 1 14 Check valve for hydraulics blocking function,
4 B2 - auxiliary hydraulics 1 since 2009
5 A1 - tilt backwards 15 Plug 2Y46
6 B1 - tilt forwards 16 Load holding valve, forwards
7 R - tank return flow 17 Load holding valve, backwards
8 P - pump pressure line 18 Pressure relief valve
9 H - lifting, lowering 19 Emergency lowering
10 Sensor strip

Hydraulic transmitters that send signals to the minimum required number of revolutions for the
sensors in the sensor strip are located at the pump motor.
lower end of the valve spools.
The tilt valve spool incorporates two load holding
The hydraulic transmitters for the individual hy¬ valves that prevent forwards and backwards
draulic functions generate signals corresponding tilting of the load on its own.
to the valve spool displacement. The signals are
A tilt orifice that limits the oil flow fortilting is bolted
transmitted to the truck control unit MCU via plug
to the back of the directional control valve. The tilt
X1 9. From the signals, the MCU calculates the

76-4 55048042201 [EN]

Valves r 13
Hand lever

orifice used depends on the nominal lift of the lift The check valve for the hydraulics blocking
mast. function satisfies the regulations in accordance
with the standard EN ISO 3691-1 and has been
The lowering brake in the lift valve spool ensures
fitted as standard since calendar week 39/2009.
a constant lowering speed that is largely indepen¬
The check valve releases the pressure as soon
dent of the size of the load.
as the seat contact switch is closed, i.e. the driver
The pressure relief valve protects the hydraulic is seated on the driver's seat.
system against overload.

Check valve for hydraulics blocking

function
Function
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 defined in ISO 3691-1 and
has been a legal requirement since 29th Decem¬
ber 2009. The hydraulics blocking function must
not be manipulated.

Electrical connections
2-pin JPT plug
2Y46/1 X46/2 Lowering OFF
2Y46/2 X46/15 GND-S

Error detection
Error Cause Remedy
The input pressure governor
Driver is not seated, "lowering" is in 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.

55048042201 [EN] 76-5

 Valves
Hand lever

Hydraulic transmitter
General
The hydraulic transmitter comprises the valve
spool and a transmitter fitted 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.

Function
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 neutral
position voltage of the individual transmitters is
calibrated automatically when the system starts
up.
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.

Electrical connections
6-pin SAAB plugX19
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
12V X19/6 X46/39

Configuration
The configuration must be parameterised again
for all retrofitting and conversions.

This affects the following components:

• Lift lever
• Three-way valve block
• Four-way valve block

Calibration
Calibration is not necessary.

76-6 55048042201 [EN]

Valves r 13
Hand lever

From truck software version 0.80 onwards,

the hydraulic transmitters can be calibrated
individually using the display operating unit.

Testing
- 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

A CAUTION
The lift mast moves while the transmitter is being tested
and can cause damage
Pay attention to lift mast movements!

Measuring points Voltage

Transmitters
Positive Negative Lever back Lever forward
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

55048042201 [EN] 76-7

 1 Valves

Servo hydraulics
General technical data
Directional control valve block
Servo hydraulics 5060-5066
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

Solenoid coils
Coil voltage 12 V
Coil current 1.8 A maximum
Coil resistance — lifting and lowering 6.0 Ohm
Coil resistance — tilting, auxiliary 1,
8.0 Ohm
auxiliary 2

Hydraulic oil temperature range

-25°C to +90°C
briefly up to 120°C
Tightening torques
A1,A2,A3, B1.B2.B3 40 Nm
P, T, H 140 Nm
SW4, 2.5 Nm
Emergency lowering screw
Loosen by max. 1.5 revolutions
Pressure relief valve 15 Nm
Valve block on valve block support 20 Nm

Tilt orifice
There is no tilt orifice available.

76-8 55048042201 [EN]

Valves to
Servo hydraulics

Servo hydraulics valve block

Design
4 5
The Allen key(5) for the emergency lowering (4)
is secured to the valve support and can therefore
be accessed quickly in an emergency.
The hydraulic functions can be actuated by either
the joystick, fingertip or mini-lever.

J/ O/
_y/

1 Valve support
2 Solenoid coil
3 Valve block
4 Emergency lowering
5 Allen key for emergency lowering
6 Mounting screws
7 Mounting screws
8 Plug 2Y46 for enabling the hydraulics
9 Solenoid coil

The back of the valve block (3) is attached to

the valve support (1) by means of three rubber- _r:
mounted mounting screws (6). The valve support
is screwed to the battery wall by means of three
mounting screws (7).
ÿL, , >\
lA
There is no tilt orifice available. r \ r-<
Assembly instructions
• Spare part valve blocks are supplied without
screw joints
• When making repairs to the valve block, pro¬
ceed 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

Emergency lowering
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.

55048042201 [EN] 76-9

 Valves
Servo hydraulics

fr NOTE
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 max 2.5 Nm
- Fit the panelling at the valve block

Directional control valve block

General The directional control valve block contains the
following functional components:
The directional control valve is a monoblock
design and comes in 2 versions: • Lowering-balance valve (lowering brake)
• Check valve for hydraulics blocking function
• Directional control valve, three-way
Lift, tilt, auxiliary hydraulics 1 • Pressure relief valve
• Directional control valve, four-way • NO tilt orifices
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.

76-10 55048042201 [EN]

Valves r 13
Servo hydraulics

Chassis

Valve block solenoids

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, fingertip 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 fitted
The solenoid coil (2Y 1) 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

55048042201 [EN] 76-11

 Valves
Servo hydraulics

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) fulfils 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.

Directional control valve - method of operation

Schematic diagram

MP

__
—1

I_
T
'

sin

_ j

j
A3 B3

8 8 12 1

Directional control valve Components

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

Method of operation 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 flows 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

76-12 55048042201 [EN]

Valves to
Servo hydraulics

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 flow (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 final 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 flow
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.

55048042201 [EN] 76-13

 Valves
Servo hydraulics

76-14 55048042201 [EN]

Lift mast r
Lift mast
General technical data
5060-5066
Lift mast 6210-6217
6311,6313, 6315
2 x screw M16x45, 10.9
Mast bearing, on each side ISO 4762
Tightening torque: 275 Nm
Line break safety devices Tightening torque: 20 ±2 Nm
Load chains Maximum elongation 3%
Support roller screws Tightening torque: 60 ±6 Nm

Mast weight
The weights of lift masts vary depending on the
model, load-bearing capacity and overall height.
The formulae help to calculate the lift mast
weights.
Weight [kg]
Load capacity [kg] Lift mast without fork carriage and fork arms
<2000 Telescopic mast Mast length [mm]/1000 x 114 + 59
<2000 NiHo mast Mast length [mm]/1000 x 116 + 53
<2000 Triple mast Mast length [mm]/1000 x 165 + 80

55048042201 [EN] 81-1

 Lift mast
Lift mast

Telescopic lift mast

Function >
The telescopic lift mast is a free-view lift mast.
The mast profile is a double-T-profile. The fork
carriage and mast profiles are guided through
support rollers; these also absorb the shear
forces.
When the load is lifted, the inner mast is raised
along with the fork carriage. After a small free
lift of approx. 150 mm, the truck's overall height
changes immediately. This is to 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 fitted
on each side in the outer mast profiles. The lift
pistons are connected to the upper crossmember
(5) of the inner mast.
The load chains are attached to the upper cross-
member (6) of the outer mast via clamping bolts,
are redirected by chain rollers (4) at the inner
mast and are connected to the fork carriage via
an end link.
If the lift cylinders are supplied with pressure oil,
the lift pistons extend and take the inner mast with
them. The redirection of the load chain causes
the inner mast to move towards the fork carriage
at a ratio of 1:2.
The end stop is in the cylinder.
A run-out barrier prevents the fork carriage from
tilting outwards.

Pressure oil route in the lift mast

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 line break safety device installed in the
right-hand outer cylinder prevents the load from
lowering too fast in the event of a line breakage. 1 Outer mast
2 Inner mast
3 Lift cylinder
4 Chain roller
5 Inner mast crossmember
6 Outer mast crossmember

81-2 55048042201 [EN]

Lift mast
Lift mast

NiHo lift mast

Function
The NiHo lift mast is a free-view lift mast. The
mast profile is a double-T-profile. The fork car¬
riage and mast profiles are guided through sup¬
port rollers; these also absorb the shear 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.
The NiHo lift mast consists of an inner mast (2)
and an outer mast (1). A lift cylinder (3) is fitted
on each side in the outer mast profiles. The lift
pistons are connected to the upper crossmember
(6) of the inner mast. The middle cylinder (4) is
fitted in the inner mast.
The load chain (5) is attached to the middle
crossmember (8) of the inner mast via a clamping
bolt and is redirected by a chain roller (7) at the
middle cylinder. The end link of the load chain is
connected to the fork carriage.
If the lift cylinders are supplied with pressure oil,
the lift piston of the middle cylinder extends first,
taking with it the fork carriage via the load chain in
lift 1.
If 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.

Pressure oil route in the lift mast

The hydraulic oil comes from the directional
control valve block, is distributed via a T-piece 1 Outer mast
2 Inner mast
and is directed below into the two outer cylinders
3 Lift cylinder
on the left and right. In the outer cylinders, the 4 Middle cylinder
hydraulic oil is directed through the cylinder 5 Load chain
heads and then down through a pipe connection 6 Inner mast crossmember
to the middle cylinder. 7 Chain roller
8 Inner mast crossmember
Due to the varying piston areas, the middle
cylinder is always raised first and then the two
outer cylinders.
The line break safety device installed in the
outer cylinders and middle cylinder prevents
the load from lowering too fast in the event of a
line breakage.

55048042201 [EN] 81-3

 Lift mast
Lift mast

Triple mast
Function >
The triple lift mast is a free-view lift mast. The
mast profile is a double-T-profile. The fork car¬
riage and mast profiles are guided through sup¬
port rollers; these also absorb the shear forces.
The function of the triple mast is the same as the
NiHo lift mast, but it has an increased lift height at
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. In lift 2, the middle
mast is also raised, taking the inner mast with it
via the outer load chains.
The triple mast consists of an inner mast (3),
a middle mast (2) and an outer mast (1). A lift
cylinder (11) is fitted on each side in the outer
mast profiles. The lift pistons are connected to
the upper crossmember (10) of the middle mast.
The middle cylinder (4) is fitted in the inner mast.
On each side, an outer load chain (7) is attached
to the top crossmember (9) of the outer mast via
a clamping bolt and is redirected by a chain roller
(8) at the middle mast. The end link of the load
chain is connected to the inner mast.
The middle load chain (5) is attached to the cross-
member (12) of the inner mast via a clamping bolt
and is redirected by a chain roller (6) at the mid¬
dle cylinder. The end link of the load chain is
connected to the fork carriage.
If the lift cylinders are supplied with pressure oil,
the lift piston of the middle cylinder extends first,
taking with it the fork carriage via the middle load
chain in lift 1.
If the middle cylinder is in the end position, the lift
pistons of the outer cylinder extend, taking with
3ÿ"Vl
them the middle mast in lift 2 and the inner mast
via the outer load chains. 1 Outer mast
2 Middle mast
The redirection of the outer load chains causes 3 Inner mast
the inner mast to move towards the middle mast 4 Middle cylinder
at a ratio of 1:2. 5 Middle load chain
6 Chain roller
The end stop is in the cylinder. 7 Outer load chains
A run-out barrier prevents the fork carriage from 8 Chain roller
9 Outer mast crossmember
tilting outwards.
10 Middle mast crossmember
11 Lift cylinder
Pressure oil route in the lift mast 12 Inner mast crossmember

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

81-4 55048042201 [EN]

 r
Lift mast

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 first and then the two
outer cylinders.
The line break safety device installed in the
outer cylinders and middle cylinder prevents
the load from lowering too fast in the event of a
line breakage.

55048042201 [EN] 81-5

 1 Lift mast
Lift mast

Lift mast — removal

Preparation
- Ensure that you have a sufficiently large
workplace with wooden blocks and europallets
to place the lift mast down horizontally
- Park the truck safely.

- If there is an attachment present, the hy¬

draulics need to be depressurised.

A WARNING
The hydraulic oil is pressurised during operation and is
hazardous to your health.
- Do not spill the hydraulic oil.
- Comply with legal regulations forthe disposal.
- Do not allow hydraulic oil to come into contact with
hot engine parts.
- Do not allow hydraulic oil to come into contact with
the skin.
- Avoid inhaling spray.
- To avoid injury, use appropriate protective equip¬
ment (protective gloves, industrial goggles, skin
protection and skin care products).

A CAUTION
It must be ensured that no hydraulic oil escapes and
contaminates the environment or penetrates the
ground.
- Spilt hydraulic oil should be removed with oil binding
agents at once and disposed of according to appli¬
cable regulations.

Removal
- Park the truck safely.
- Put the lift mast in its vertical position.
- Apply the parking brake.
- Turn the key switch OFF
- Electric forklift trucks only: Disconnect the
battery male connector.
- Remove the fork arms and, as necessary, the
attachment.

81-6 55048042201 [EN]

Lift mast
Lift mast

- Hook a sufficiently strong chain on to the top of I>

the outer mast crossmember. Then hook the
chain on to the forks of the second truck and
secure in such a way that it cannot slip off the
forks when lifting the lift mast.

- Unscrew the hydraulic hose lines on the outer >

cylinders.

- As necessary, unscrew the connection be¬

tween the auxiliary hydraulic lines and the lift
mast.
- Close off the hydraulic hose lines with hy¬
draulic plugs. Use cable ties to attach the
loose hose ends to the lift mast.

- Disconnect the tilt cylinder from the outer mast. >

To do this, remove the locking ring and knock
out the pins.
- Loosen and unscrew the mast bearing screws.

- Lift out the lift mast using the second truck and
place down carefully at the prepared location.

A CAUTION
Risk of damage to components.
Proceed with care when lifting off the lift mast. Ensure
that the lift mast does not start to swing and collide with
the truck.

55048042201 [EN] 817

 Lift mast
Lift mast

Lift mast — installation

Installation

NOTE
Check screw quality and tightening torques.
For values, see "Genera!technicaldata"in the
chapter entitled "Lift mast".
Hook a sufficiently strong chain on to the top of
the outer mast crossmember. Then hook the
chain on to the forks of the second truck and
secure in such a way that it cannot slip off the
forks when lifting the lift mast.

A CAUTION
Risk of damage to components.
Proceed with care when lifting off the lift mast. Ensure
that the lift mast does not start to swing and collide with
the truck.

- Bring the lift mast into position.

- Screw in the mast bearing screws and check
the tightening torques.
- Connect tilt cylinder to outer mast. To do this, l>
knock in the pins and secure with a locking
ring.

- Screw the hydraulic hose lines onto the outer t>

cylinders.

81-8 55048042201 [EN]

Lift mast
Lift mast

- As necessary, screw in the connection be- D>

tween the auxiliary hydraulic lines and the lift
mast.
- Electric forklift trucks only: Connect the battery
male connector.
- To bleed the lift cylinders, raise the fork
carriage approx. 300 mm.
- Unscrew the bleeder screws in the cylinder
head by 1 turn at the most.
- When oil starts to escape, retighten the
bleeder screw.
- Repeat this process for every lift cylinder.

- Function check.

55048042201 [EN] 81-9

 1 Lift mast

Load chains
Load chains
Checking, cleaning
General
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 fit. A sliding fit 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 as low as possible,

note the following:
• Clean load chains regularly.
• Spray load chains with STILL chain spray.
• Measure the chain elongation.
• Adjust the load chain evenly.
• Load chains must be evenly tensioned when
underload.

Cleaning load chains

A WARNING
Risk of accidents!
Load chains are safety elements
The use of cold/chemical cleaners or fluids 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 paraffin 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.

81-10 55048042201 [EN]

Lift mast r Load chains

Checking the load chains for damage

The load chains must be checked for the following
external damage:
• broken joining plates
• broken bolts
• 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.

1 NOTE
Loadchains must always be changedinpairs to
guarantee an even loaddistribution on the two
chains. Change the loadchains in their entirety,
i.e. includingdamping boltandendlink. Repairs
shouldnot be carriedout on the loadchains!

Measuring the chain elongation

- Hold the marking (1) on the chain wear gauge
against the middle of a chain pin.

Markierung
anau auf
olzanmitt*
Halt an

147419

- Count off 34 chain links. Depending on the

2 3 2 3 2 3
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. 34 Gld 34 Gld
34 Gld.

As soon as the specified maximum elongation

of 3% has been reached, the load chain must be
changed.

Adjusting the load chains

Telescopic mast
Removing the load chain
- Park the truck safely.
- Put the lift mast in its vertical position.

- Apply the parking brake.

55048042201 [EN] 81-11

 Lift mast
Load chains

- Raise the fork carriage.

- Place a square timber under the fork carriage

and lower the fork carriage onto it until the load
chain is loose.
- Turn the key switch OFF.
- Electric forklift trucks only: Disconnect the
battery male connector.
- Lower the inner mast slightly until the load
chains are loose.
- Remove the load chains at the fork carriage
and at the crossmember of the outer mast.

Installing the load chain

- Attach the load chains at the fork carriage and
at the crossmember of the outer mast.
- Electric forklift trucks only: Connect the battery
male connector.
- Lift the inner mast and remove the square
timber.
- Lift the fork carriage, remove the square timber
and lower the fork carriage.

Adjusting the load chains

- Tilt the lift mast right back.

- Lift the fork carriage a little until the load chains

are taut.
- Unscrew mounting screw (4) and remove cap >
(2).
- Unscrew nut (3).

A WARNING
Damage to equipment because the fork carriage
comes 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.

2 4 1 3

81-12 55048042201 [EN]

Lift mast r Load chains

With the lift cylinders extended, tension the l>

load chains at tensioning nuts (1) evenly until a
measurement of (X) has been reached.

Measurement X
Load capacity [kg]
[mm]
1000-1500 25
1600-1800 25
2000-2500 15
3000 15
3500 15

Screw nut (3) loosely onto the rubber washer

but do not tighten.
Screw cap (2) on tightly with mounting screw
(4).

NOTE

The mounting screw (4) is a Tufiok screw with a

threadlock.
• Use the serew once only.
• in an emergency, secure with Loctite.

Run-out barrier
When adjusting the load chains, make sure that
if the lift mast is fully extended, the end stop is in
the lift cylinder.
- The air gap between run-out barrier (1) and
fork cams (2) must not drop below a measure¬
ment of2 mm. An airgap of 10-20 mm is ideal.

NOTE

For lift masts with a considerable overallheight,

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.

Adjusting the load chains

NiHo lift mast
Removing the load chain
- Park the truck safely.

- Put the lift mast in its vertical position.

- Apply the parking brake.

55048042201 [EN] 81-13

 1 Lift mast
Load chains

- Raise the fork carriage.

- Place a square timber under the fork carriage

and lower the fork carriage onto it until the load
chain is loose.
- Turn the key switch OFF.
- Electric forklift trucks only: Disconnect the
battery male connector.
- For auxiliary hydraulics: Remove the hoses >
and finger protection at the bearing fork.
- Remove the load chain at the fork carriage and
at the crossmemberofthe inner mast.

Installing the load chain

- Attach the load chains at the fork carriage and
at the crossmemberofthe inner mast.
-
For auxiliary hydraulics: Fit the hoses and
finger protection at the bearing fork.
- Electric forklift trucks only: Connect the battery
male connector.
- Lift the fork carriage, remove the square timber
and lower the fork carriage.

Adjusting the load chain

- Tilt the lift mast right back.

- Lower fork carriage.

- Unscrew the mounting screw and remove cap >

(4).

A WARNING
Damage to equipment because the fork carriage
comes 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.

81-14 55048042201 [EN]

Lift mast
Load chains

With the lift cylinder extended, retighten

the load chain at tensioning nut (3) until a
measurement of (X) is achieved.

Measurement X
Load capacity [kg]
[mm]
1000—1500 20
1600 20
1800 20
2500 15
3000 10
3500 10

- Screw cap (4) on tightly with the mounting

Wffl- X
screw.

NOTE
The mounting screw is a Tufiok screw with a
threadlock.
• Use the sere w once only.
fy
• In an emergency, secure with Loctite.

Run-out barrier 1 2
When adjusting the load chains, make sure that \ I
if the lift mast is fully extended, the end stop is in
the lift cylinder.
- The air gap between run-out barrier (1) and
fork cams (2) must not drop below a measure¬
ment of 2 mm. An air gap of 10-20 mm is ideal.

Outer load chain

Triple mast
Removing the outer load chains
- Park the truck safely.

- Put the lift mast in its vertical position.

- Apply the parking brake.

- Raise the fork carriage and secure with the
safety chain.
- Turn the key switch OFF.

- Electric forklift trucks only: Disconnect the

battery male connector.
- Lift the inner mast slightly with a jack so that
the load chains hang loose.

55048042201 [EN] 81-15

 Lift mast
Load chains

- Remove the cover on the guide pulley.

- Disassemble the load chains from the inner

mast and outer mast crossmember.

Installing the outer load chains

- Fit the load chains to the inner mast and outer
mast crossmember.
- Fit the cover to the guide pulley.

- Lower the inner mast with a jack.

- Electric forklift trucks only: Disconnect the
battery male connector.
- Lift the fork carriage slightly, remove the safety
chain and lower the fork carriage.

Adjusting the outer load chains

- Tilt the lift mast right back.

- Lift the fork carriage a little until the load chains

are taut.
- Unscrew mounting screw (4) and remove cap t>

- Unscrew nut (3).

A WARNING
Damage to equipment because the fork carriage
comes 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.

2 4 1 3

81-16 55048042201 [EN]

Lift mast
Load chains

- Adjust the load chains at the clamping bolts D>

so that both load chains are equally taut and
so that the middle mast, inner mast and outer
mast are flush at the bottom.
- Screw nut (3) loosely onto the rubber washer
but do not tighten.
- Screw cap (2) on tightly with mounting screw
(4).
-
t NOTE
The mounting screw is a Tufiok screw with a
threadlock.
• Use the screw once only.
• Inan emergency, secure with Loctite.

Run-out barrier >

When adjusting the load chains, make sure that
if the lift mast is fully extended, the end stop is in
the lift cylinder.
- The air gap between run-out barrier (1) and
fork cams (2) must not drop below a measure¬
ment of 2 mm. An air gap of 10-20 mm is ideal.

t NOTE

Forlift masts with a considerable overallheight,

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.

Middle load chain

Triple mast
Removing the middle load chain
- Park the truck safely.

- Put the lift mast in its vertical position.

- Apply the parking brake.

- Raise the fork carriage.

- Place a square timber under the fork carriage

and lower the fork carriage onto it until the load
chain is loose.
- Turn the key switch OFF.

- Electric forklift trucks only: Disconnect the

battery male connector.

55048042201 [EN] 81-17

 1 Lift mast
Load chains

- For auxiliary hydraulics: Remove the hoses D>

and finger protection at the bearing fork.
- Remove the load chain at the fork carriage and
at the crossmemberofthe inner mast.

Installing the middle load chain

- Attach the load chains at the fork carriage and
at the crossmemberofthe inner mast.
- For auxiliary hydraulics: Fit the hoses and
finger protection at the bearing fork.
- Electric forklift trucks only: Connect the battery
male connector.
- Lift the fork carriage, remove the square timber
and lower the fork carriage.

Adjusting the middle load chain

- Tilt the lift mast right back.

- Lower fork carriage.

- Unscrew the mounting screw and remove cap >
(4).

A WARNING
Damage to equipment because the fork carriage
comes 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.

81-18 55048042201 [EN]

Lift mast r Load chains

- With the lift cylinder extended, retighten

the load chain at tensioning nut (3) until a
measurement of (X) is achieved.

Measurement X
Load capacity [kg]
[mm]
1000-1500 20
1600 20
1800 20
2500 15
3000 10
3500 10

- Screw cap (4) on tightly with the mounting

screw.

FT] NOTE
The mounting screw is a Tufiok screw with a
threadlock.
• Use the sere w once only.
• In an emergency, secure with Loctite.

Run-out barrier
When adjusting the load chains, make sure that
if the lift mast is fully extended, the end stop is in
the lift cylinder.
- The air gap between run-out barrier (1) and
fork cams (2) must not drop below a measure¬
ment of2 mm. An airgap of 10-20 mm is ideal.

55048042201 [EN] 81-19

 1 Lift mast

End position damping

End position damping of outer
cylinder
General

_|J NOTE
The endposition damping in the outer cylinder is
a component ofthe Niho and triplex mast.
The end position damping works by hydraulically
slowing down the piston rod of the right outer
cylinder shortly before it reaches its end position
when lowering in lift 2.
This prevents any metal-to-metal collision.
The right lift jack is equipped with end position
damping in the direction of travel.

Function
If pressure oil is applied to the piston rod during
the lifting process, the piston (3) is pushed to¬
wards the base of the cylinder by the elastic force
of the compression spring (4) until the snap ring
(5) on the piston cover (2) reaches the installa¬
tion.
The pressure oil flows through the reducer bore
(1) from compartment "A" to compartment "B".
During the lowering procedure the piston (3) first
appears on the base of the cylinder before the
piston rod reaches its end position. The piston
(3)is pushed towards the piston rod, and the
pressure oil flows from compartment "B" through
the reducer bore (1) into compartment "A".
This pressure differential acts as a hydraulic
brake to the mast.

1 Reducer bore
2 Piston cover
3 Piston
4 Compression spring
5 Snap ring

81-20 55048042201 [EN]

Lift mast r
End position damping

Middle cylinder end dampener

General
The end dampener hydraulically brakes the
piston rod before it reaches its end position when
lifting the fork carriage.
The end dampener is located in the piston cover.

Function
The piston rod (5) extends until the cross hole 5
in the piston rod (4) enters the cylinder head (1).
The raise speed is reduced as soon as the cross
4
hole is covered by the cylinder head.
Once the cross hole of the piston rod(4) is entirely 3
covered by the cylinder head, the returning
hydraulic oil has no direct return path. 2
As a result of the increasing pressure in the cross
hole inside the cylinder cover (2), the valve piston
(6) is forced into contact with the threaded pin (9). 1
The hydraulic oil flows back throttled by the cross
hole (2), the orifice in the valve piston (6) and the
threaded pin (9). *
This causes the piston rod to undergo hydraulic
braking before reaching its end position.

\9

1 Cylinder head
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

55048042201 [EN] 81-21

 1 Lift mast

Line break safety device

Hose safety valve of triplex mast
General
The line break safety device prevents the load
from being abruptly lowered in an uncontrollable
manner in the event of a line breakage.
The line break safety device has a valve disc,
which is lifted from the valve seat by spring force
when in the quiescent state, thus keeping a flow
area free.
Under normal operation, the spring keeps the
valve open. In the event of a line breakage, the
flow rate increases, the flow forces exceed the
spring force and the valve closes immediately.
A small bore in the valve disc allows the load to
be lowered slowly with the valve closed.

NOTE
Do not change the setting ofthe hose safety valve

Variants
There are two different versions of the line break
safety device:
• Manufacturer: Hawe (4)
Tightening torque 20 Nm
• Manufacturer: Buchholz (5)
Tightening torque 20 Nm

Shock valve installation positions

Telescopic outer cylinder >
- In each of the two outer cylinders, a line break
safety device (1) is screwed into the cylinder
bottom.

A.
ill II II Mil

81-22 55048042201 [EN]

Lift mast
Line break safety device

Middle cylinder NiHo — triplex

- In the middle cylinder, the line break safety
device (1) is screwed into the cylinder bottom

ii;i II II 11'11

Outer cylinder NiHo - triplex

- In each of the two outer cylinders, a line break
safety device (1) is screwed into the cylinder
bottom.

i; II II Mill

A further line break safety device (1) is screwed >

into the adaptor (2) of the left outer cylinder
The line break safety device is screwed into
the adaptor by hand, without using a tool
The line break safety device in the adaptor is
peened three times at the circumference to
prevent it from working loose
The O-ring (3) is inserted into the adaptor with
grease upon assembly
The adapter is caulked three times along the
perimeter in the piston tube using Loctite 243

55048042201 [EN] 81-23

 1 Lift mast

Lift cylinder
Lift jack
General
The lift cylinders are single-action cylinders. The
cylinder pipe and cylinder bottom are welded
together.
The cylinder head is screwed onto the cylinder
pipe and secured using pourable plastics.
An O-ring provides sealing between cylinder
head and cylinder barrel.
The seal between the cylinder head and piston
rod (piston barrel) is provided by a grooved ring.
The lift is restricted by a piston cover screwed into
the piston rod (piston barrel) and secured using
pourable plastics.

ffl NOTE
• The piston cover is securedandsealed using
Loctite 275 across its fullsurface
• The tightening torque is 350 +5° Nm

Outer cylinder
Removal
A WARNING
Beware of risk of personal injury and property damage.
Follow the safety instructions in Chapter 001.

ENVIRONMENT NOTE
Hydraulic oil can leak out.
- Apply parking brake
- Keep the mast in the vertical position

- Raise fork carriage and use safety chain to

secure
- Electric forklift trucks only: Disconnect the
battery male connector
- Lower fork carrier until the safety chain is taut

81-24 55048042201 [EN]

Lift mast
Lift cylinder

- Disassemble the locking ring of the lift cylinder l>

mounting at the top of the cross beam

- Dismantle spanner

- Lift the inner mast (or the middle mast in the >
case of a triple mast) a little using a hydraulic
jack until the outer cylinder at the top of the
cross beam is exposed

f NOTE
Place catch tray for hydraulic oilunderneath.
- Loosen top and bottom hydraulic connections
- Remove cylinder

Installation
- Place cylinder in outer mast

- Lower the inner mast (or the middle mast in

the case of a triple mast) using a hydraulic jack
until the outer cylinder is flush at the top of the
cross beam

NOTE
Note position of vent screw!

55048042201 [EN] 81-25

 Lift mast
Lift cylinder

- Mount spanner >

- Mount top and bottom hydraulic connections

- Assemble the locking ring of the lift cylinder D>

mounting at the top of the cross beam
- Slight raise fork carrier, remove safety chain

- Lower fork carrier

- Bleed lift cylinder

Centre cylinder
Removal
A WARNING
Beware of risk of personal injury and property damage.
Follow the safety instructions in Chapter 001 .

<ÿ> ENVIRONMENT NOTE

Hydraulic oil can leak out.

- Apply parking brake
- Keep the mast in the vertical position

- Raise fork carriage and lower on pad >

- Electric forklift trucks only: Disconnect the
battery male connector

81-26 55048042201 [EN]

Lift mast
Lift cylinder

- Remove the auxiliary hydraulics hoses and fin- D>

ger protection at the bearing fork as necessary

- Dismantle chain on fork carriage and take from >

idler pulley
- Loosen hydraulic connection to cylinder base
- Remove clamp on cylinder
- Take out centre cylinder

Installation
-
Place centre cylinder in inner mast

NOTE
Note position of vent screw!
- Mount clamp on cylinder

- Mount hydraulic port

- Place chain on idler pulley and mount on fork

carriage
- Fit the auxiliary hydraulics hoses and finger
protection at the bearing fork as necessary
- Raise fork carriage and remove pad

- Lower fork carrier

- Bleed lift cylinder

Cylinder head
Removal of outer cylinder

NOTE
Use braces to protect the cylinder or the piston
rodin the vise!
- Clamp cylinder in vice using protective jaws

- Use sickle spanner to unscrew cylinder head

55048042201 [EN] 81-27

 Lift mast
Lift cylinder

fr NOTE

Ifthe cylinder headcan not be moved, carefully

apply flame to warm up the thread area
Applies only to left outer cylinder:
- Take out piston rod from cylinder barrel
- Clamp piston rod in vice using protective jaws

- Remove adapter

- Pull cylinder head from piston rod

- Remove seal kit

Centre cylinder removal

ffl note
Use braces to protect the cylinder or the piston
rodin the vise!
- Clamp cylinder in vice using protective jaws
- Use sickle spanner to unscrew cylinder head

fj~) note
Ifthe cylinder headcan not be moved, carefully
apply flame to warm up the thread area
- Take out piston rod from cylinder barrel

- Clamp piston rod in vice using protective jaws

- Remove bearing fork

- Pull cylinder head from piston rod

- Remove seal kit

Outer cylinder installation

fj~l NOTE
Lightly lubricatesealkit before assembly.
- Place seal kit

- Fit cylinder head on piston rod

Applies only to left outer cylinder:
- Mount adapter

1 NOTE

Adapter is caulked on three points along the

perimeter using Loctite 275
- Insert piston rod into cylinder barrel
- Tighten cylinder head on cylinder barrel

81-28 55048042201 [EN]

Lift mast
Lift cylinder

Centre cylinder installation

NOTE
Lightly lubricate sealkit before assembly.
- Place seal kit
- Mount bearing fork

NOTE
Bearing fork is caulkedon three points along the
perimeter using Loctite 275
- Insert piston rod into cylinder barrel

- Tighten cylinder head on cylinder barrel

55048042201 [EN] 81-29

 Lift mast

Rollers/support rollers
Support roller clearance
Test
After every replacement of the support roller,
monitor the lateral and radial clearance between
mast profile and support roller. Adjust, if neces¬
sary.
Lateral clearance:
min. 0.3 mm
max. 1.8 mm
Radial clearance:
min. 0,1 mm
max. 1,1 mm

81-30 55048042201 [EN]

Load support f

Fork carriage
Fork carriage
Removal
A WARNING
There is a danger of injury or damage to equipment.
Observe safety regulations.

- Apply the parking brake.

- Set lift mast to vertical.

- Lift the fork carriage and set down on a square
timber.
- Slightly lower the inner mast and until the load
chains become loose.
- Release the safety bolts on the load chains.

- Detach the load chains from the fork carriage.

- Lift the inner mast until the fork carriage is free.

- Disconnect the battery plug (electric fork lift

trucks only).
- Place the fork carriage on a pallet.

Installation
- Place the fork carriage below the inner mast
and secure with a jack.
- Carefully lower the inner mast and insert into
the fork carriage.
- Using the jack, insert the fork carriage into the
inner mast and set it down on a square timber.

NOTE

Ifthe fork carriagejams inside the inner mast,

attempt to insert it with a slight tilting motion of
the lift mast. Otherwise, pulldown the inner mast
using a pulley attached to the innerand outer
mast cross traverses.
- Insert the load chains into the fork carriage and
secure with the safety bolt.
- Check lateral and radial clearance.

Adjustment
Lateral clearance between inner mast and roller
guide:
Min. clearance = 0.3 mm
Max. clearance = 1.8 mm.

55048042201 [EN] 84-1

 1 Load support

Radial clearance between inner mast and sup¬

port roller:
Min. clearance = 0.1 mm
Max. clearance =1.1 mm.

Roller
Removal
- Remove rollers by unscrewing countersunk
screws

1 NOTE
The countersunk screw is secured with Loctite
242. ifthe countersunk sere w cannot be unscre¬
wed, heatthe Loctite gently.

Installation

fj NOTE
Always use new countersunk screws
Tightening torque 60 Nm
Secure with Loctite 242
Install rollers with new countersunk screws

84-2 55048042201 [EN]

STILL GmbH
Berzeliusstrasse 10
D-22113 Hamburg

Identno. 55048042201 EN
Workshop literature

STILL
ELECTRONIC
DOCUMENTATION
SYSTEM

Electric forklift truck

RX50-10
RX50-13
RX50-15
RX50-16

5060 5061 5063 5065 5066 first in intralogistics

55048042201 EN -08/2011
Annex
Circuit diagrams r

Hydraulics
Hand lever

Ausf uhrung A Ausfuhrung B Ausfiihrung C

__
rfSSjii
EF
_ jj"
CF |LS

Jks
17— i"

A 55048042201 [EN]
a
Hydraulics
i Circuit diagrams

1a Steering motor 7 Directional control valve block (auxiliary hydraulics 2) 14 Breather filter
2 Steering unit 8 Tilt cylinder 15 Priority valve
3 Hydraulic tank 9 Discharge pressure governor 16 Mini measurement port
4 Return line filter 10 Line break safety device 17 Metering orifice
5 Pump unit 11 Lift cylinder 18 Emergency lowering
6 Directional control valve block (lifting/tilting/auxiliary 12 Load holding valve 19 Exhaust valve
hydraulics 1) 13 Pressure relief valve 20 Flow pressure governor

Hydraulic version according to lift mast

Overall Tele¬
Load
height scopic NiHo Triple
capacity [kg] mast mast
[mm] mast
1000-1600 <2760 A
1000-1600 >2810 B
1000-1600 <2510 C
1000 <2510 C
1300-1500 <2710 C
1600 <2610 C

X-2 55048042201 [EN]

Circuit diagrams
Hydraulics

Servo hydraulics

Bypass veririL
l.t- bar
Ausfiihrung A Ausfiihrung B Ausfuhrung l

v10

55048042201 [EN] X-3

a
Hydraulics
i Circuit diagrams

1 Steering motor 6 —
Directional control valve block lift-tilt-auxiliary 1 11 Lift cylinder 16 Mini measurement port
2 Steering unit 7 Directional control valve block — auxiliary 2 12 Load holding valve 17 Emergency lowering
3 Hydraulic tank 8 Tilt cylinder 13 Pressure relief valve 18 Exhaust valve
4 Return line filter 9 Discharge pressure governor 14 Breather filter 19 Flow pressure governor
5 Pump unit 10 Line break safety device 15 Priority valve

Hydraulic version according to lift mast

Overall Tele¬
Load NiHo Triple
height scopic
capacity [kg] mast mast
[mm] mast
1000-1600 <2760 A
1000-1600 >2810 B
1000-1600 <2510 C
1000 <2510 C
1300-1500 <2710 C
1600 <2610 C

X-4 55048042201 |EN]

Circuit diagrams X
Hydraulics

55048042201 [EN] X-5

STILL GmbH
Berzeliusstrasse 10
D-22113 Hamburg

Ident no. 55048042201 EN