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Still RX20-14 Workshop Manual

Still RX20-14 Workshop Manual

Elextric forklift truck

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RX20-15 - 20, RX60-16 - 20

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Summary of Contents for Still RX20-14

Page 1 RX20-15 - 20, RX60-16 - 20...
Page 3 This workshop manual combines the truck series RX20-15 - 20 and RX60-16 - 20. All chapters have been revised. Various corrections and enhancements Facelift integration, Step 1 and 2 Integration of type carrier 6209 (RX20-14). 50638042201 EN - 10/2017...
Page 5 Overview of consumables are communicated via service information docu- ments. STILL Flasher FEM 4.004 test log book The documentation comprises operating instruc- tions, additional workshop manuals, special doc- Service information documents umentation and circuit diagrams.
Page 6 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.
Page 7 We recommend that you obtain approval from the manufacturer and, if necessary, from the relevant regulatory authorities before installing such parts. STILL accepts no liability for any damage caused by the use of non-original parts and accessories without approval. 50638042201 EN - 10/2017...
Page 8 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 STILL's liability and the warranty are no longer applicable once the seal has been damaged.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. 50638042201 EN - 10/2017...
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Page 19 Overhead guard Battery sizes Standard overhead guard Container overhead guard (variant) Load lifting classes Chassis Steering axle Lower chassis 3-wheel, fth-wheel Higher chassis 4-wheel, swing axle RX20 - 14 48 V / 550 Ah 1.4 t 3-wheel 6209 RX20 - 15 48 V / 550 Ah 1.5 t 3-wheel...
Page 20 Joystick 4Plus Push-up roof panel Metal brand emblem Lighting on top of the overhead guard Diagnostic connector (Group connector) in the front structure New truck type RX20-14 (6209) New components: Generation 2 MCU Drive axle AE18-07 Improved properties: Ergonomic driver's workstation...
Page 21 Overhead guard Battery sizes Standard roof Container roof (variant) Load lifting classes Higher chassis 4-wheel, swing axle High RX60 - 16 80 V / 420 Ah 1.6 t 4-wheel 6311 High RX60 - 18 80 V / 420 Ah 1.8 t 4-wheel 6313 High...
Page 22 Improved properties: Ergonomic driver's workstation Drive mode Blue-Q New components: Generation 2 mini-lever Generation 2 display and operating unit Electric parking brake Load measurement Mast vertical position Hydraulics blocking function in accordance with EN ISO 3691-1 50638042201 EN - 10/2017...
Page 23 The truck must not be parked on a slope. If necessary, use wedges to prevent the truck from rolling away. Before servicing, fully lower the unladen fork car- riage. Changes in the centre of gravity caused by attach- ments can lead to additional hazards. If attachments are tted, retract the working cylinders.
Page 24 Do not touch live contact points such as the positive and negative connections of the power control units! Before working on electrical power connections, al- ways check the voltage between all contact points and between the contact points and the truck chassis using a suitable measuring device (capable of measuring up to 1000 V/DC).
Page 25 Park the truck securely on level ground. Turn the key switch OFF. Apply the parking brake. Remove the forks or push them together in the middle. Lift the fork carriage so that the hydraulic jack can be placed on the outer mast. Jack up the truck until the wheels are no longer in contact with the ground.
Page 26 When jacking up the truck, always secure it with ap- propriate means (wedges, wooden blocks) to prevent rolling or tipping. The truck has to be jacked up for various mainte- nance tasks. Always comply with the following: Use only jacks with an adequate load capacity. Jack up the truck only on a level surface Secure the truck against rolling and dropping.
Page 27 Open the battery door and snap into place. Right side of the truck: Place the hydraulic jack on a square timber at the designated position (3) at the chassis. Jack up the truck until the square timber ts under the chassis at the designated position (2).
Page 28 Potential damage to the ceiling! Note the maximum lift height of the particular lift mast. Extend the lift mast. Route the chain along the cross traverse of the outer mast (1) and connect it underneath the cross traverse of the inside mast (2). Lower inside mast until it strikes the chain.
Page 29 Extend the lift mast. Route the chain along the cross traverse of the outer mast (1) and connect it underneath the cross traverse of the middle mast (2). Lower lift mast until it sttrikes the chain. Lower fork carriage down to the stop. Extend the lift mast to slacken the chain.
Page 30 50638042201 EN - 10/2017...
Page 31 Maintenance work must be carried out in accor- dance with the following maintenance intervals. The intervals are designed for standard use. Depending on the application conditions of the truck, shorter maintenance intervals can be set, on agreement with the operating company. These factors may call for shorter maintenance intervals: Contaminated, poor quality roads...
Page 32 50638042201 EN - 10/2017...
Page 33 Check chassis for cracks Check overhead guard/cab and panes of glass for damage Check controls, switches and joints for damage, and apply grease and oil Check driver's seat for correct function and for damage Check driver restraint system for correct function and for damage, and clean. Check the signal horn : Check the dual-pedal variant for damage and correct function, and lubricate Check tyres for wear and check the air pressure if necessary...
Page 34 : Hydraulic battery carrier: Check the oil level and check for leaks Check hydraulic system for condition, correct function and leaks Check the hydraulics blocking function (ISO valve) Check oil level Check mast bearings for damage, and lubricate. Check the tightening torque Check mast pro les for damage and wear, and lubricate Check load chains for damage and wear, adjust and lubricate Check lift cylinders and connections for damage and leaks...
Page 35 Perform all 1000-hour maintenance work Drive wheel unit and multi-disc brake: Change the gearbox oil Replace the bleeder screws on the drive wheel units : Electric parking brake: Replace the actuation push button Renew the hydraulic oil Replace the return line lter and breather lter : Replace the high-pressure lter only: Replace the accumulator 50638042201 EN - 10/2017...
Page 36 50 cm Adaptor cable, service box on truck, diagnostic connector, 7-pin, 6 3903820105 pins assigned, 200 cm Adaptor cable, service box on truck, diagnostic connector, 4-pin 0625028 STILL multimeter including measurement leads 0009418737 Current probe 0156300 Temperature sensor, 20...320 C 0156299...
Page 37 Replacement MetraHit measuring lines, pair of red and black Measuring tips, pair of red and black 0143426 Crocodile clips, pair of red and black 0143427 Measurement wires, pair of red and black 0143425 AMP crimping tool 0144087 Ejector box 0172412 Crimping tool for wire cross-sections of 10...95 mm 0009418107 50638042201 EN - 10/2017...
Page 38 Hydraulic jack, load capacity 5000 kg 0161527 Ratchet hoist, 800 kg Hahn&Kolb 77158080 Round sling 1000 kg, L= 1 m (purple) Hahn&Kolb 77200710 Round sling 1000 kg, L= 2 m (purple) Hahn&Kolb 77200910 Round sling, 2000 kg, L = 2 m (green) Hahn&Kolb 77200920 Safety chains up to 2000 kg 0155297...
Page 39 Thread Grade 4.6 Grade 4.8 Grade 5.8 Grade 6.8 Class 8.8 Grade 10.9 Grade 12.9 1110 1000 1350 1850 2250 1170 1470 1760 2350 3300 3900 Thread Grade 4.6 Grade 4.8 Grade 5.8 Grade 6.8 Class 8.8 Grade 10.9 Grade 12.9 M8x1 M10x1 M10x1.25...
Page 40 The basis for these tables is works standard WN 14031 "Tightening torques for union nuts and threaded ends". M14 x 1.5 10-L M16 x 1.5 12-L M18 x 1.5 15-L M22 x 1.5 18-L M26 x 1.5 22-L M30 x 1.5 28-L M36 x 1.5 M18 x 1.5...
Page 41 Document search by type carrier Document category Document search by truck series Document language Document selection Start the notebook and double-click the icon on the desktop. The STEDS-Navigator opens with the home- page (see above). If necessary, change the document language (2).
Page 42 (CAN 2) and the truck 8 The LED indicates the Bluetooth status 9 Antenna 10 STILL Bluetooth USB stick If all LEDs (3,4,5,6) are ashing, the service box is in programming mode. In this case, the service box must be reset.
Page 43 Diagnostic connector, 7-pin Adaptor cable for diagnostic connector, 7-pin CAN box, BT STILL Bluetooth USB stick The STILL Bluetooth USB stick must be used for Notebook the Bluethooth connection. 50638042201 EN - 10/2017...
Page 44 The notebook is connected directly to the CAN box via the connecting line. The CAN box is connected to the diagnostic connector on the truck via the adaptor cable. Diagnostic connector, 7-pin Adaptor cable for diagnostic connector, 7-pin CAN box, USB Notebook In the medium term the CAN box, USB will be replaced by the CAN box, BT.
Page 45 All trucks are assigned a unique SERVICE access code ex works. This access code is created via a random generator in the truck control unit (MCU, TCU). access code is set to an Fleet manager invalid value ex works. The service engineer can adjust the access code if required.
Page 46 Connect the notebook to the truck and start the truck diagnostics, see the chapter entitled "Introduction to DiaMon": F2: Diagnosis Jobs Select action (4) F2: Diagnosis Execute Jobs Execute Read error list Various types of error lists are available for Clear error list selection: Read error ring buffer...
Page 47 Switch on the truck and wait until the standard screen appears in the display. Press buttons simultaneously. The display will change to the password screen. Enter the password for the service level and con rm by pressing button Determine the unique password; see the chapter entitled "Reading out access codes".
Page 48 It may take some time to read out the error list. When the process is underway, the ashing characters are displayed. When the ? ?? ?? process is complete. the latest error in the list is displayed. indicates that the error list is empty. X 00 00 indicates an error with the process to X -- --...
Page 49 Switch on the truck and wait until the standard screen appears in the display. Press buttons simultaneously. The display will change to the password screen. Enter the password for the service level and con rm by pressing button Determine the unique password; see the chapter entitled "Reading out access codes".
Page 50 Resetting automatically activates the option NO in the framed RESET eld. The error list is not cleared. Press button to jump back to the CONFIG- menu. URATION 50638042201 EN - 10/2017...
Page 51 Manufacturer Designation AF-104-K1 AF-104-I4 Operating voltage 48 V 80 V Motor type 4-pin AC motor with cage rotor Connection Star Star Design voltage (nominal) 3 x 28 V 3 x 48 V Design current (nominal) 128 A 87 A Design speed (nominal) 2000 2645 Maximum speed...
Page 52 U, V, W 1U07 converter, left Rev sensor, left Temperature sensor, left U, V, W 1U06 converter, right Rev sensor, right Temperature sensor, right Travel direction Right drive wheel Right-hand traction motor (FM1) Multi-disc brake Left-hand traction motor (FM2) Motor connections Pump motor Speed sensors Left drive wheel...
Page 53 The temperature sensors are embedded into the stator winding. The plugs are led out of the motors. The traction motors are three-phase AC asyn- chronous motors that are equipped with short-cir- cuit cage rotors. Aluminium conductors are fused into the grooving of the rotor core and connected at the ends with short-circuit rings.
Page 54 Each traction motor has a two-track pin sensor (2) as a rev sensor, which is tted from above into the axle and scans the front-end gearing of the brake disc (1). The rev sensor is sealed with an O-ring and xed in the motor housing by a screw.
Page 55 Supply X10/1 X151/7 Signal A Blue X10/2 X44/24 Black X10/3 X151/8 Signal B White X10/4 X44/23 Supply X12/1 X152/7 Signal A Blue X12/2 X44/36 Black X12/3 X152/8 Signal B X12/4 X44/37 White Insert the mark II test adapter into plug con- nector X10 or X12 Use a digital multimeter with integrated duty cycle (e.g.
Page 56 Type: KTY84-130. Power supply: approx. 1.7 mA Temp- X11/1 X151/3 MCT+ Temp- Blue X11/3 X151/4 MCT- Temp- X13/1 X152/3 MCT+ Temp- Blue X13/3 X154/4 MCT- An improperly conducted insulation test can destroy the temperature sensor. Before the insulation testing, jumper the temperature sensor connections.
Page 57 1063 1129 1197 1268 1340 1415 1493 1572 1654 1739 1825 1914 A defective sensor can be exchanged with the aid of a repair kit containing a temperature sensor and two-component balancing mastic. Knead both components (yellow and blue) of the mastic together until the mass has a uniform green colour Continue kneading the green mass for at least 2 minutes until it is noticeably warm...
Page 58 50638042201 EN - 10/2017...
Page 59 Linde, Juli Manufacturer Designation AE18 - 05AC Weight 170 kg 5 x spherical collar bolts Wheel nuts, per wheel Tightening torque: 210 Nm 6 x hexagon head screws M20 x 40 Drive axle chassis screw joint, per side DIN 933, quality 8.8 Tightening torque: 385 Nm 4 x socket head screw M16 x 50 Traction motor screw joint, right/left...
Page 60 Travel direction Multi-disc brake Right-hand traction motor (FM1) Motor connections Left-hand traction motor (FM2) Speed sensors Pump unit Temperature sensors Left drive wheel Brake actuator Right drive wheel Both traction motors are fully integrated into the drive axle. The traction motors are connected via the motor housing.
Page 61 Removal of the individual units is described in detail in the corresponding chapters. The pump motor can remain in the truck during removal of the drive axle. Discharge the gearbox oil and brake oil at an early stage so that the oil has time to drain off. Park the vehicle safely.
Page 62 Disconnect sensor connectors X10, X11 and X12, X13 from the traction motors; mark beforehand if necessary Unscrew the GND earthing cable from the pump motor Unscrew the power cable from the traction motors; mark beforehand if necessary Remove the retaining split pins from the fastening bolts of the pump motor Use a suitable belt to attach the pump motor to the brake pedal;...
Page 63 Lower the drive axle and pull from beneath the truck Retain and reuse the support bearings' spring elements Installation of the individual units is described in detail in the corresponding chapters. Check screw quality and tightening torques. Note the quality and quantity of gearbox oil, brake oil Place the spring elements on the support bearings...
Page 64 Secure the fastening bolts of the pump motor with retaining split pins Remove the securing belt from the pump motor Protect the mounting screws against corrosion and tighten on both sides Screw the power cables onto the traction motors and assemble the clean splash guard rims Traction motors defective due to water To guarantee the protection type of the traction motors,...
Page 65 Carry out a function check on all traction and hydraulic functions The drive wheel units (1) are structurally identical units. The drive wheel units are screwed directly onto the axle housing (3) with socket head screws (4). The changing of shaft seals (6) at the wheel hubs is the only repair work that is permissible.
Page 66 Snap ring Locking ring Planet gear carrier Slotted nut Planet gear Tapered roller bearing Angular roller bearing Housing Locking ring Screw plug Sun gear O-ring Socket head screw Spacer ring Washer Shaft seal Planet gear carrier Wheel shaft Planet gear Screw plug Cylindrical roller bearing O-ring...
Page 67 The sun gear (6) sits in the gearing of the planet gear carrier (2) and drives the four planet gears (10) of stage 2. The planet gears also move the planet gear carrier (9). The planet gear carrier (9) drives the wheel shaft (20) via the gearing.
Page 68 If necessary, use two M10 screws to push off the drive wheel unit To do so, screw the screws into the threaded holes provided (5 o'clock and 11 o'clock position) Dispose of any remaining oil that escapes in an environmentally friendly manner. Remove the drive wheel unit with planetary transmission Insert a new shaft seal...
Page 69 Fill with gearbox oil via the oil lling opening (1) until the oil ows out of the inspection opening The oil level check is to be carried out when the truck is on level ground. Turn the wheel so that one of the two inspec- tion openings is at 12 o'clock (2).
Page 70 Snap ring Locking ring Planet gear carrier Slotted nut Planet gear Tapered roller bearing Angular roller bearing Housing Locking ring Screw plug Sun gear O-ring Socket head screw Spacer ring Washer Shaft seal Planet gear carrier Wheel shaft Planet gear Screw plug Cylindrical roller bearing O-ring...
Page 71 Using a brass pin and hammer, carefully tap the front end of the wheel shaft to release the bearing halves of tapered roller bearings (14) from one another. Pull the wheel shaft out of the housing. Insert a new shaft seal (19). The lips of the shaft seal point towards the outside of the axle.
Page 72 Right-hand traction motor (FM1) Brake oil ller plugs Left-hand traction motor (FM2) Brake actuator Wheel drive Pump motor bearing pins Drive wheel unit xing screws Pump motor support bearings Multi-disc brake The two traction motors are almost identical to each other in mirror image and, together with the drive wheel units, form the drive axle.
Page 73 Apply the parking brake. Draining the gear lubricant oil Disconnect battery plug. Remove the lift mast Release the wheel bolts, but do not unscrew completely Remove the lift mast, see chapter "Lift mast - installation / removal" Jack up the front of the truck, see chapter "Safety instructions"...
Page 74 Unscrew the drive wheel unit from the traction motor housing Installation of the individual assemblies is described in detail in the corresponding chapters. Check tightening torques and screw quality. Check gear lubricant oil and brake oil quality For values, see "General technical data" in the chapter entitled "Drive axle"...
Page 75 The wet-running multi-disc brake (2) is positioned centrally between the traction motors. The joint brake control (1) of the parking brake (4) and the service brake (3) is located on top of the left traction motor. The disc pack consists of two brake discs that are separated by discs.
Page 76 In the brake control, the brake cables are con- nected to the service brake (2) and the parking brake (1) using ES bolts (3). The pressure plate of the brake is actuated via an eccentric (4) and the discs and brake discs are pressed together.
Page 77 Once the connecting screws have been removed, the drive axle splits into two parts. Prevent the halves of the axles from rolling away To separate the traction motors, release the four M16 connecting screws Screw the lower mast bearing screw on the right-hand side back in again to act as a torque damper when releasing the connecting screws.
Page 78 To establish the depth of the left half of the axle, two measurements are required: Adding both measurements from the left half of the axle gives The depth of the right half of the axle gives To establish the total depth of both halves of the axle, add both measurements together Pile up the complete armature stack and weigh down with approx.
Page 79 Screw the brake control onto the left half of the axle using two cylinder screws Mount the brake discs and laminas, checking the variation and sequence Mount armature stack variation A with springs. Insert the O-ring between both halves of the axle Join the halves of the axle in such a way that the guide pins slot into the guide holes...
Page 80 Designation Linde, Juli Manufacturer Total weight [kg] 170.5 [kg] Permissible axle load 4870 Axle load for track width of [kg] 5430 990 mm Maximum speed [km/h] Tyres (alternative) 18 x 7-8 (200/50 10) Dynamic tyre radius [mm] 211 (229) [mm] 990 (942) Track width Driving torque...
Page 81 Right drive wheel unit Counter bearing Right traction motor Temperature sensor X11 Temperature sensor X13 Left traction motor Brake actuator Left drive wheel unit Speed sensors The images of the drive axle differ somewhat from the installed component in the truck! The devia- tions in the images only relate to the external contours.
Page 82 temperature sensors (3) and (7) monitor the temperature in the coil ends. In the drive direction of the axle, the traction motor connecting boxes are facing upwards. The right traction motor contains the actuating lever of the brake. The identi cation plate for the axle is located on the front of the right traction motor.
Page 83 Dispose of drained oil in accordance with regula- tions. Loosen and unscrew 7 screws from the drive wheel unit. The upper screw acts as a guide; do not unscrew it completely. Remove the two plugs from the threaded holes located opposite. Screw 2 M14 screws (e.
Page 84 Pull the second planetary gear set out of the housing. Secure the drive wheel unit on a suitable xture. Warm the slotted nut to release the Loctite. The hot slotted nut can cause burns. Wear suitable protective gloves. Loosen the slotted nut using a slotted nut spanner and torque multiplier.
Page 85 Drill a hole in the shaft seal, cut the thread and then pull it out using ejector rod WM109. Coat the inside of the new shaft seal between the sealing lip and the dust lip with lithium soap grease. Fill the space to a maximum of 50%. The grease must not be added to the spring chamber.
Page 86 Secure the drive wheel unit on a suitable xture and tighten the slotted nut using the slotted nut spanner and torque multiplier to a tightening torque of 650 Turn the drive wheel unit by 10 revolutions and retighten the slotted nut to a tightening torque of 650 Insert the second planetary gear set.
Page 87 Observe tightening torques and screw quali- ties Observe gearbox oil quality and quantities See "general technical data" for values. Oil and t a new O-ring (1). Attach the drive wheel unit with ller plug (2) facing upwards and screw in the 7 mounting screws (3) on the drive wheel unit.
Page 88 The locking screws of the rotor are positioned opposite one another and are accessible even in the installed position. In order to access the M8x16 locking screws (2) underneath, the threaded pins M8x8 (1) must be removed. The screws are positioned opposite one another (180°).
Page 89 If necessary, unscrew the pinion gear from the rotor shaft (M8x20), so that the rotor can be placed upright for any subsequent work. Pull the rear bearing out of the rotor shaft using a 2-claw extractor. The bearing will be damaged as it is pulled out over the outer ring.
Page 90 Pull the rotor shaft out from the bearing ange or press it out. Knock the front bearing out of the bearing ange. The bearing will be damaged as it is knocked out over the inner ring. Use a new bearing. Press the new bearing into the bearing ange.
Page 91 Wet the surface of the shaft with brake oil. Press the new shaft seal (1) into the bearing ange. Press on the front bearing using assembly sleeve WM451. Press the bearing in over the bearing inner ring, otherwise the bearing will be damaged.
Page 92 Place the bearing ange on the axle casing in such a way that the position of the rotation lock aligns with the notch on the bearing ange. (may differ from the illustration) Push the bearing ange into the housing. Screw in the M8x16 threaded pin (2) (rotation lock) and tighten.
Page 93 The wet-running multi-disc brake is positioned centrally between the traction motors. The brake actuator shared by the service brake and handbrake is located on top of the traction motor housing. The disc pack consists of two brake discs that are separated by discs.
Page 94 The brake cables of the service brake (4) and handbrake (5) are attached in the abutment (6) and secured with locking plates. The brake cables in the brake lever (3) are attached and secured using s-bolts. Brake lever Service brake Handbrake Abutment The entire drive axle must be removed from the...
Page 95 The rev sensor (1) can remain in the axle. Remove the pressure plate (3) and two further brake discs. Place the compression springs (2) to one side. Remove the retaining ring (4) using the installation tool. Carefully remove the cable tie (5). Do not damage the dust protection cover in the process;...
Page 96 Remove the brake lever. Take out the shaft seal. Observe tightening torques and screw quali- ties Observe gearbox oil quality and quantities See "general technical data" for values. Insert the shaft seal. 50638042201 EN - 10/2017...
Page 97 Install the brake lever. Screw in and tighten the screw plug. Check the dust protection cover (6) for damage and replace it if necessary. Secure the dust protection cover using retain- ing ring (5) and cable tie (5). When replacing the brake discs, the brake lift play must be inspected and, if necessary, adjusted.
Page 98 Load the brake package with a weight of 6 kg. Determine the height of the brake package above the housing edge. Determine the depth of the brake chamber in the left traction motor housing. The difference between the depth and height +0.2 measurements can be max.
Page 99 Observe tightening torques and screw quali- ties Observe oil quality and quantities of oil For the values, see the chapter entitled "General technical data" Do not reuse drained gearbox oil and brake oil. Dispose of oil in an environmentally friendly manner Warm up the drive wheel unit Park the truck so that the drive axle is horizon-...
Page 100 Add the gearbox oil via the oil lling opening (1) until the oil ows out of the inspection opening The oil level check must be performed when the truck is on level ground When lling, always undo the upper checking screw (2) so that air can escape Screw in and tighten the oil ller plug (1).
Page 101 Screw in the drain plug with magnetic plug and tighten. Push back the dust protection cover. If the oil lling quantity is too great, it can damage the shaft seal of the rotor shaft. Make sure you use the exact oil lling quantity for the brake.
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Page 103 Apply parking brake Battery door open Separate lock, loosen nut and remove screw The lever by the frame is under spring tension. It shoots towards the frame when released. Fingers can get caught! Firmly grip the lever with the ngers when separating the lock.
Page 104 The counterweight is a massive cast component that differs according to type carrier, dependent on the load-bearing capacity, chassis and steer- ing axle. The counterweight is attached to the chassis with mounting screws. The number, arrangement and tightening torques of the mounting screws are dependent on the type carrier, see the table.
Page 105 The overhead guard is an independent unit that is connected to the chassis and the counterweight via three bearings. At the front, the overhead guard is supported on the chassis on two bearings (1, 2), and at the rear it is supported in the counterweight on one bearing (3) on the bearing ange (4).
Page 106 This bearing was tted until April 2007. Only type carriers 6210 - 6217, 6311, 6313, 6315 The front bearings (1) are pre-assembled units with a built-in spring element. The bearings are connected to the overhead guard via two screws (2-4). Twisting the threaded bush (6) changes the Bearing Undo xing screws...
Page 107 Removal of the overhead guard varies according to truck type and equipment version. Signi cant differences are indicated in the re- moval instructions. For trucks with cabs: Completely remove the cab doors and side parts Remove the roof window Remove the heater Tilt the lift mast fully forward Removing the battery The drive wheels do not need to be disas-...
Page 108 Detach the electrical connection between the overhead guard and the counterweight The number and location of the plug connections vary according to the truck type and equipment version. The control wiring harness (1) to the supply unit is the standard design, and the roof wiring harness (2) is a variant.
Page 109 Tie up the ve loose hoses to the steering column Disassemble the hose guide from the solenoid valve on the overhead guard Remove the cover on the brake actuation Remove the ES bolts from the parking brake (1) and service brake (2) and detach the cables;...
Page 110 Detach plug X23 from the lift lever on the directional control valve block Detach the earthing cable at the directional control valve block Disconnect all the plugs 2Y1 to 2Y11 and 2B5 on the directional control valve block Disconnect the earth wires to the chassis and directional control valve block at the front right of the overhead guard...
Page 111 Detach the directional control valve block holder from the overhead guard From below, loosen the central screw (M8x90) of the left and right front overhead guard bearings Do not change the setting of the threaded bushes (see arrow in picture). The overhead guard height changes according to the screw-in depth.
Page 112 Secure the overhead guard with a lifting sling and a crane or truck The overhead guard may slip sideways Check the fastening and position of the lifting sling Unscrew all four screws on the overhead guard bearings Beware of damage! Work slowly and carefully, with an assistant if possible The solenoid valve must not remain hanging on the overhead guard...
Page 113 Installing the overhead guard varies according to truck type and equipment version. Signi cant differences are indicated in the re- moval instructions. The overhead guard is ready, placed separately on a stack of pallets Only assemble cab parts once the overhead guard has been screwed onto the chassis: Cab doors and side parts Roof window...
Page 114 Position the overhead guard above the chassis and lower it carefully Beware of damage! Work slowly and carefully, with an assistant if possible The solenoid valve must not remain hanging on the overhead guard Check the height of the ceiling Place the overhead guard on the front bearing points and attach it to the chassis using screws and conical spring washers...
Page 115 Screw the directional control valve block holder onto the overhead guard Connect plug X19 of the hydraulic sensor on the directional control valve block Connect plug X23 from the lift lever on the directional control valve block Connect the earthing cable on the directional control valve block Connect all the plugs 2Y1 to 2Y11 and 2B5 on the directional control...
Page 116 Connect the earth wires to the chassis and directional control valve block at the front right of the overhead guard Connect the earth wires to the directional control valve block on the hydraulic tank Connect hoses LS and CF on the priority valve Connect the return line of the steering unit (1) to the return line lter Connect the steering hoses L and R of the...
Page 117 Fit the hose guide from the solenoid valve on the overhead guard Attach the brake cable and assemble the ES bolts of the parking brake (1) and the service brake (2) Check the brake settings; see the chapter entitled "Brake system" Fit the cover on the brake actuation Apply the parking brake.
Page 118 Remove the panelling between the chassis and the overhead guard at the front right and left Install the drive wheels and tighten the ball- seat nuts Lower the truck. Tighten the spherical collar nuts; for tightening torques, see Technical data in the chapter entitled "Drive axle"...
Page 119 Manufacturer Sauer Danfoss Designation OSPF 50 LS EL 1, 50G5128 Delivery rate per rotation ] 50 [bar] 135 140 bar Pressure relief valve [bar] 200 - 220 Shock valve [bar] 250 Connections P and EF [bar] 140 - 145 Connections CF and LS Connections P, T, LS, R and L Tightening torque [Nm]...
Page 120 Steering angle sensors Priority valve Steering unit Hydraulic pump Return line Induction hose LS signal line Directional control valve block Pressure line Steering cylinder connection The steering system is equipped with power steering that works according to the LS principle. It affects the steering cylinder on the steering axle.
Page 121 The oil volume for the steering is directed as a priority to the steering unit by the priority valve in all operating statuses. If the working hydraulics are not actuated, the pump speed for steering is proportional to the rotational speed at the steering wheel (dynamic steering).
Page 122 Optionally, these trucks can be equipped with steering angle detection for the "curve speed control" variant. CSC is a component of the comfort package (assistance system). When the hydraulic pump is in Disconnect the steering unit from operation, the steering actuates the steering column and check for automatically.
Page 123 The steering unit is secured to the steering column ange via four mounting screws. The following valves are tted in the steering unit. Pressure relief valve Shock valve The shock valve has a damping function that prevents major pressure uctuations being transmitted from the hydraulic system to the steering.
Page 124 Remove the steering column adjustment spring and securing bolt (1). Unscrew the earth cable from one of the mounting screws. Unhook the steering column adjustment and tip back. Remove the diaphragm pressure switch, see the chapter entitled "Diaphragm pressure switch" Unscrew all hydraulic connections and protect them from contamination using sealing plugs;...
Page 125 Tightly screw the steering unit onto the steering column using the two front mounting screws. Connect all hydraulic connections. Insert the steering column adjustment into the mount. Swivel the steering column upwards and hook on the steering column adjustment. Fit the steering column adjustment spring and securing bolt.
Page 126 Activation and mode of the dynamic steer support Steering switch not tted Steering stop moment cut-off threshold The diaphragm pressure switch is screwed to the steering unit. Pressure is built up in the steering unit by turning the steering wheel. Once a speci c pressure has been reached, the pressure switch opens and the pump motor starts up.
Page 127 Screw on the parking brake panelling on the left-hand side Carry out a functional test, steering from stop to stop several times 50638042201 EN - 10/2017...
Page 128 The priority valve is screwed directly onto the hydraulic pump. The valve is a hydraulic control unit and ensures that oil is supplied to the steering as a priority in all operating conditions. 50638042201 EN - 10/2017...
Page 129 Steering sticks. The slider in the priority valve Clean the priority valve - or Steering overhaul is prevented from moving in the even better, change it Pivoting problems when starting housing due to dirt particles to steer. Note the screw qualities and tightening torques. Remove the priority valve Release the screw plugs Remove the pre-loading spring...
Page 130 The steering column is screwed to the front structure via the steering column support with four rubber bearings. The inclination of the steering column can be adjusted in four different locking positions within a 10° range. The brake actuation components parking brake lever and brake pedal are mounted on the steering column support.
Page 131 Unhook the steering column adjustment and tip back Remove the diaphragm pressure switch, see the chapter entitled "Diaphragm pressure switch" Remove the steering unit; see the chapter entitled "Steering unit" Remove the ES bolts of the service brake on the front structure Release the locknut for setting the brake cable Push the brake cable forwards Release the nut (SW19) on the bearing axle...
Page 132 Connect the plug contacts at the key switch Install the panelling Clean the bottom plate as necessary; remove any oil Carry out a functional test, steering from stop to stop several times The steering angle sensor is tted below the steering wheel on the steering column and comprises a two-track pulse generator and a magnetic pole wheel.
Page 133 The driver sees the error in the STEERING display. Connect the multimeter between GND-S and track A or track B The displayed voltage must jump between 0.05 and 11 V during slow steering. Fast steering results in an average DC of approx.
Page 134 In order to optimise drive comfort and operational safety, trucks are tted with Curve Speed Control (CSC). This function ensures that the driving speed is reduced when steering. The effect becomes more powerful at higher speeds and is triggered when steering is actuated. Depending on the truck type, CSC is either standard equipment or a variant of the assistance system.
Page 135 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.
Page 136 A trick can be used that enables the controller to still display the steering angle: Maximum speed of the traction motors must not exceed 5 km/h (<1290 rpm).
Page 137 (18.00) (16.20) 4640 4176 18.00 4640 16.20 4176 14.50 3738 13.05 3364 11.40 2939 10.26 2645 10.00 2578 9.00 2320 9.10 2346 8.19 2111 8.50 2191 7.65 1972 8.10 2088 7.29 1879 7.80 2011 7.02 1810 7.67 1977 6.90 1779 7.44 1918 6.70...
Page 138 Manufacturer Linde Designation LA 340 Weight Steering angle 90° Not adjustable Steering angle limit From centre position, 7 teeth to both the right and left Push rods - lift from right to left 103.7 mm 5 x spherical collar nut A14-10 Wheel nuts, per wheel Tightening torque: 195 Nm 1 x hexagon nut M14 x 1.5, DIN 980...
Page 139 The steering axle in the steering turntable version is bolted with the steering box (6) from below to the counterweight using three mounting screws (5). The steering cylinder pipes (11) are screwed to the left and right in the steering box. The steering cylinders' pistons actuate on a rack that performs a turning movement via the gearing in the axle casing (9).
Page 140 Switching range -40° to -20° +20° to +40° Voltage jump From 0 V to 11 V Max. steering angle of steering turntable -70° +70° 3B29 3B28 X29/1 X44/12 12 V X29/4 X44/13 12 V (brown) (brown) 3B29 3B28 Signal Signal X29/2 X44/10 X29/5...
Page 141 Jack up the truck on the right-hand side at the chassis when the battery door is open. Place a supporting block under the counter- weight. Jack up the truck on the left-hand side at the chassis. Place a supporting block under the counterweight.
Page 142 First loosen the front screw. Insert the guide bolt. The screws are secured with pourable plastics. Place the wooden plank at an angle under the steering turntable and prevent it from rolling away with a wheel. Loosen the two front screws. Allow the steering turntable to slide slowly downwards over the wooden plank.
Page 143 Screw in the hydraulic connections on the right-hand side and left-hand side of the steer- ing cylinder. Follow the assembly instructions. Screw in the screw joints up to the blue coating. Then screw the screw joints into position using a minimum of three to a maximum of four revolu- tions.
Page 144 Manufacturer DANA Designation LA 301 Weight approx. 80 kg Steering angle 80 - 82° Steering angle limit DIN 933, M12 x 40-8.8 stop screw Wheel nuts, per wheel [Nm] 5 x spherical collar nuts A14-10 2 x DIN 933, M16 x 50-8.8 hexagon head Screw joint between steering axle and [Nm] screws...
Page 145 Buffer element Axle casing Mounting screws Steering pivot pin Joining plate Wheel hub Steering cylinder mounting Axle stub Tie rod Plug X29 Steering cylinder 3B28 right curve switch Piston rod 3B29 left curve switch Hubcap Stop screw The steering axle in the swing axle version is The steering cylinder's piston rod (10) causes inserted into the counterweight with two buffer a turning movement in the axle stubs via the tie...
Page 146 Curve switches are inductive proximity switches that respond to the proximity of iron. At a de ned steering angle, curve switch 3B29 switches in left-hand curves, and curve switch 3B28 switches in right-hand curves. Curve switches 3B28 (1) and 3B29 (2) are bolted on to the left and right-hand side of the steering axle respectively via angle plates.
Page 147 The battery may need to be removed, depending on the type of truck and equipment. Plug X29 for the cornering switch is located in the counterweight. The cable must be led out downwards. Operating the parking brake Prevent the truck from rolling away using chocks at the front wheels Removing the battery Release the sheet metal cover...
Page 148 The steering axle is retained by the forklift truck Lower the steering axle, carefully tilt it forwards and remove it sideways from the truck Check screw quality and tightening torques Check the quality of pourable plastics For values, see "General technical data" in the chapter entitled "Steering axle"...
Page 149 Tighten the wheel nuts Lead the cable for plug X29 upwards into the counterweight Connect plug X29 Fit the sheet metal cover Install the battery in the truck Carry out a functional test, steering from stop to stop several times Axle casing Slotted spring pin Axle stub...
Page 150 Loosen the wheel nuts (11). Jack up the truck at the counterweight. Remove the wheel. Take off the dust cap (8). Unscrew the nut (9) and remove along with washer (10), making sure that the slotted spring pin (7) is properly seated while doing Take off the wheel hub (5).
Page 151 Check the quality of screws and lubricant, as well as the correct tightening torques. Values vary according to axle type; see "General technical data" in the chapter entitled "Steering axle". Carefully grease the sealing lips of the radial seal ring. Pack the tapered roller bearing between the inner ring and the cage with grease.
Page 152 The steering angle must be 80° 82°. For easier measuring, a supplementary angle can be used. This angle must be 98° 100°. The steering angle is limited by a stop screw (1) on each side. The steering cylinder can be damaged. It is important to ensure that the steering angle is clearly limited by the stop screws.
Page 153 A press is required to install the tie rod. For this reason, the steering axle should be completely removed beforehand; see the chapter entitled "Removing and installing the steering axle". Remove the steering axle; see the chapter entitled "Removing and installing the steering axle"...
Page 154 A press is required to remove the axle stub. For this reason, the steering axle should be completely removed beforehand; see the chapter entitled "Removing and installing the steering axle". Drive out the pin between the tie rod and the axle stub Slacken the hexagon nut (1) Take out the washer (2)
Page 155 Handbrake lever Brake cable pull, handbrake Handbrake switch Brake pedal Brake sensor Brake cable pull, service brake The multi-disc brake on the drive axle is activated via two independent actuation elements: Handbrake lever The hand brake lever effects the brake actua- tion of the multi-disc brake via the brake cable pull (2) Brake pedal...
Page 156 Park the truck safely and secure the truck against rolling away. Disconnect battery plug. Remove oorplate. Remove the panelling on the right-hand side of the front structure The position of the brake cable depends on the equipment on the truck. Remove the ES bolt (1) from the brake cable in the front structure Disconnect the brake pedal return spring (2)
Page 157 Fit the brake cable securing clips Fit the ES bolt Connect the brake cable in the front structure Fit the ES bolt Connect the brake pedal return spring Adjust the brake cable at the adjustment nut Fit the brake lever covering to the drive axle Fit the panelling in the front structure Insert the oorplate Connect the battery plug...
Page 158 Remove the panelling on the right-hand side of the front structure. Remove and detach the s-bolt (1). Detach the brake pedal return spring (2). Loosen the adjustment nut on the brake cable in the front structure and disconnect the brake cable.
Page 159 When the service brake is not actuated, the brake cable must be adjusted so that a distance of X remains between the fork clevis and the brake lever on the axle. 19 mm Brake lever Service brake cable Parking brake cable Abutment Setting dimension Secure the truck against rolling away...
Page 160 Fit the brake lever covering to the drive axle Adjust the brake cable. Fit the panelling in the front structure Insert the oorplate Connect the battery plug Test the handbrake function. RX20-14-20, AE18-05 85 ±8 91 to 110 RX60-16-20 50638042201 EN - 10/2017...
Page 161 RX20-14-20, AE18-07 130 ±5 148 to 159 RX60-16-20 RX20-14-20 AE18-09 130 ±5 148 to 159 Facelift 2014 RX60-25-35 EC35 105 ±8 115 to 133 RX60-40-50 EC50 105 ±8 115 to 133 RX70-16-20 AD20E-02 100 ±8 109 to 128 RX70-22-35 8.20 125 ±8...
Page 162 The cable tie prevents the handbrake from engaging during the test. The parking brake switch 1S3 is located on the left-hand side in the front structure, behind the parking brake lever. The parking brake switch is an NO contact, i.e. when it is not actuated it is open (normally open), whereas when it is actuated it is closed.
Page 163 The brake sensor 1B2 is tightly screwed to the right side part of the operating unit and connected to the truck control unit (MCU) via the plug (1). The brake sensor is a potentiometer that is adjusted by a tappet (2) on the brake pedal. 1B2/1 Yellow X46/41...
Page 164 The accelerator comprises the accelerator pedal and a double-action potentiometer 1B1. The accelerator pedal is tted on a permanently greased, sealed shaft in the housing and is held in place at the lower end in its inactive position by a compression spring. Driving speed is regulated by potentiometer 1B1 when the accelerator pedal is pressed.
Page 165 Operating error Timeout during calibration Value of accelerator's inactive position is outside the valid range Voltage increase does not lie within the valid range X16/1 Free Signal C2 X16/2 1B1 - C2/sw Black Signal C1 X16/3 1B1 - C1/rt 1B1 - C1/C2/ge X16/4 Yellow GND accelerator...
Page 166 The difference in voltage between the transmit- ter's inactive position (N) and maximum actuation (max) is designated as the potentiometer voltage increase. At maximum actuation, the voltage must be at least (up to maximum ) higher than in the neutral position (N). Voltage increase too small The maximum speed is not achieved No problem for the evaluation...
Page 167 Protection class IP64 Temperature range -40° to +65°C The con guration must be parameterised again for all retro tting and conversions related to the accelerator and drive direction. The following components are affected: Single pedal Dual pedal Joystick, ngertip and mini-lever Hand lever Turn indicator module for the drive direction Parameterisation is performed using the truck...
Page 168 X16/4 1B1 - GND Pin 1 GND accelerator Unassigned Unassigned Pin 2 X16/1 Unassigned Unassigned Pin 3 X16/7 1B1 - signal A Pin 4 X16/2 Channel 2 Pin 5 X16/8 12 V accelerator 1B1 - VCC 1B1 - signal B Pin 6 X16/3 Channel 1...
Page 169 Voltage increase too small The maximum speed is not reached No problem for the evaluation The maximum speed is reached but not exceeded. Voltage increase too large The end range of the voltage increase is ignored by the controller (dead travel) Voltage increase signi cantly too large Detection of breakdown with corresponding error message 50638042201 EN - 10/2017...
Page 170 Cover Actuation push button with LED Hand wheel The electric parking brake is available as a variant brake also offers automatic assistance and com- for the following trucks: fort features, which apply the brake automatically and release it again in certain situations. 6209 - 6217 12/2009 6311, 6313, 6315...
Page 171 The function of the electric parking brake is de- pendent on the parameterised operating mode. Parameterising takes place using the truck diag- nostics. The function of the electric parking brake cannot be derived from the operating mode des- ignation. The secure operating status of the electric parking brake is dependent on the parameterised operating mode and drive mode.
Page 172 In emergency operation or during transport without a battery, the electric parking brake can be operated manually via the hand wheel. Risk of injury from the moving parts in the electric parking brake. The electric parking brake must be operated via the hand wheel only when in a voltage-free state.
Page 173 The behaviour of the LED indicates the current operating status of the parking brake. The LED illuminates with a steady light, ashes or does not light up. LED illuminates with a steady Parking brake is applied correctly light Parking brake is released. The truck is ready for operation. Unde ned parking brake status after being restarted LED does not light up The controller cannot detect the parking brake status after the restart...
Page 174 ON after seat Flashing Released Start V engine Apply the parking switch turned Parking brake was brake actuated released to the limit (V engine position switch running, alternator Truck is ready for engaged) operation LED goes out immediately after start-up Unde ned Short are-up: Parking brake was only...
Page 175 Truck is driving Truck rolls to a stop Emergency off switch actuated The parking brake is applied as soon as the setpoint value 0 km/h is reached Release emergency off switch Situation as if restarted Release the parking brake via the push button The electric parking brake consists of a drive unit (3) that is integrated into the console (5) of the operating unit (steering column, brake pedal).
Page 176 The StVZO (German Road Traf c Licensing Regulations) and the torque-regulated handling performance options are not supported in trucks with an electric parking brake. The controller consists of a control processor SR and a monitoring processor UR. The con- trol processor processes the incoming data and activates the power module.
Page 177 The maintenance intervals relate to the operating hours of the truck. The operating hours of the electric parking brake are counted separately and are the speci cations used for the maintenance of the central lubrication device. If necessary, replace compo- All movable components Visible wear nents...
Page 178 Following maintenance work or during the course of the regular security checks in accordance with FEM 4.004, a brake test must be carried out on the electric parking brake. This can be performed in two different ways: Check the holding power of the parking brake at the maximum permissible gradient for this truck.
Page 179 This must then be noted in the test report. To ensure that the electric parking brake is applied whilst the truck is still moving and not once it has already come to a halt, the truck rst needs to be put in "service mode".
Page 180 When applying the electric parking brake, the accelerator must be pressed down and held. Failure to do so would also cause the electric service brake to be applied, which would falsify the test result. Due to the above-mentioned change made to the parameters, the truck is safe for operation.
Page 181 After work has been performed on the electric parking brake (drive unit, central lubrication de- vice, brake cable, limit position switch), calibra- tion must always be carried out. Risk of ngers being crushed upon actuation of the electric parking brake! Do not touch the brake cable during calibration.
Page 182 The calibration may fail and abort with an error message. This is commonly attributed to the following two instances: The increments are not within the valid range for calibration values. Standard range for calibration value "Calibration error" error threshold The repeatability of the travel is so different that calibration is implausible: Limit position switches are incorrectly adjusted or faulty.
Page 183 Disconnect the battery male connector. Jack up the front of the truck. Release the electric parking brake using the hand wheel until the limit position switch is securely actuated. (After the click, the switch has a further 50% of remaining free travel); see the chapter entitled "Limit position switch"...
Page 184 Remove the screw and the wear strips (1), disconnect the brake cable from the tension rod (2), loosen the nut or locking ring (3) and unhook the brake cable. Remove the bottom plate. Release the brake cable from the brake lever on the drive axle.
Page 185 Release the electric parking brake using the hand wheel until the limit position switch is securely actuated. (After the click, the switch has a further 50% of remaining free travel); see the chapter entitled "Limit position switch" Adjust the brake cable using the adjustment nut so that there is no slack in the brake cable.
Page 186 If the service brake is not actuated, the brake lever must rest on the adjustment screw. The gap between the brake lever and the adjustment screw is Carry out calibration and functional test; see the chapter entitled "Calibration" Risk of ngers being crushed upon automatic actuation of the electric parking brake! It is essential that the electric parking brake power supply is disconnected.
Page 187 The limit position switch can only be activated safely in this position. There must subsequently be a distance of 1 1.5 mm between the switch and the actuating lever. Park the truck safely and secure the truck against rolling away. Disconnect the battery male connector.
Page 188 In the event of an error, the drive unit must not be repaired. In the event of an error, the drive unit must be replaced together with the actuation push button and the limit position switch. Park the truck safely and secure the truck against rolling away.
Page 189 Loosen the mounting screws (4) on the central lubrication device. Remove the central lubrication device (5) from the recess in the console. Unscrew the mounting screw (6) from the drive unit (M8 hexagon head screw). Lift up the drive unit together with the central lubrication device approx.
Page 190 Insert the central lubrication device (5) into the recess in the console. Screw the mounting screws (4) tightly into the central lubrication device. Observe the installation position of the tension rod in order to ensure correct function. The wider crosspiece of the tension rod must point forwards (in the drive direction).
Page 191 this cannot be achieved via the diagnostics, the operating hours must be recorded in such a way that they cannot be lost. The central lubrication device functions like a simple grease gun that is triggered by the drive unit mechanism. The position of the rack rail indicates the current grease supply.
Page 192 Check the brake cable setting; see the chapter entitled "Changing the brake cable". Attach the panelling in the area of the electric parking brake. Connect the battery male connector. Reset the operating hours and record in such a way that they cannot be lost. Carry out calibration and functional test;...
Page 193 Pedal, forwards Compression spring Pedal, backwards Guide Hexagon nut Bush Bracket, lower Needle-roller bearing Hexagon head screw, 10 Nm, Loctite Bearing block Protective cap Plate Pinion Bearing block Pinion gear Socket head screw, 18.5 Nm Potentiometer Coach bolt Pan head screw, 2.5 Nm Bracket, upper Wiring harness The accelerator comprises two mechanically...
Page 194 Pre-assemble the pedals (1, 2) using bearing needle rollers (5). Apply lubricant evenly to all bearings of the pedals (1, 2). See "Maintenance". Feed the pedals through the bottom plate from above Fit all individual parts from below Screw socket head screws (9) in tightly using Screw on the pan head screws (21) and secure with locking varnish using a Tighten the compression spring (12) to a...
Page 195 Once calibration is complete, error messages may be displayed. Operating error Timeout during calibration Value of accelerator's inactive position is outside the valid range Voltage increase does not lie within the valid range From software ash package V1.07 onwards, the valid range for calibration can be increased by a parameter change.
Page 196 Correction by turning the C2 accelerator not actuated X16/4 - X16/2 5.5 - 6.5 potentiometer. C1 accelerator fully actuated, Correction by turning the support X16/4 - X16/3 1.0 - 3.8 forwards C2 accelerator fully actuated, Correction by turning the support X16/4 - X16/2 8.2 - 11.0 forwards...
Page 197 The dual-pedal bottom plate is equipped with the accelerator 1B1 and a dual-pedal unit for forwards (2) and backwards (1). The horn button 4S1 is located in the lift lever in this variant. The size of the bottom plate depends on the truck equipment.
Page 198 Pedal, forwards Covering Step plate, forwards Gear segment Pedal, backwards Pinion gear Step plate, backwards Leg spring Cam, backwards Spring holder Cover plate Hexagon head bolt Cam, forwards Coach bolt Wiring harness Bearing block Potentiometer Bearing block The accelerator comprises two mechanically connected accelerator pedals that move in opposite directions.
Page 199 blocks (15, 16) from above using coach bolts (14) Fit the step plates (1a, 2a) Apply lubricant evenly to all bearings of the pedals Screw in the coach bolts (14) to 20 Nm Screw the pan head screws to the potentiome- ter to 2.5 Nm and secure with retaining com- pound Position the pedals in the zero position by...
Page 200 From software ash package V107 onwards, the valid range for calibration can be increased by a parameter change. Parameterising takes place using the display operating unit. Calibration 2 (from ash package V107 series, 06/2010) A 00 050 Calibration 1 (until 06/2010) X16/1 Free Signal C2...
Page 201 GND breakdown detection 11.5 VCC breakdown detection Supply voltage X16/4 - X16/8 11.05 - 12.05 Correction by turning the C1 accelerator not actuated X16/4 - X16/3 4.45 - 7.0 potentiometer. Correction by turning the C2 accelerator not actuated X16/4 - X16/2 4.45 - 7.0 potentiometer.
Page 202 The individual hydraulic functions are operated via the hand levers. Each hydraulic function has a separate operating lever. Like the directional control valve block, the truck is provided with three or four operating levers according to the hydraulic equipment of the truck. "Lift/lower"...
Page 203 Sensors Once calibration is complete, error messages may be displayed. 50638042201 EN - 10/2017...
Page 204 The Joystick 4Plus is an operating device that is built into the armrest of the driver's seat. The Joystick 4Plus controls various functions that the driver can activate using his right hand. As the Joystick 4Plus does not have a turn indicator button, the turn indicator module for the drive direction must always be installed in line with the German road traf c licensing regulations...
Page 205 Emergency off 7S2/2 X71/6 Earth wire at the seat or CPP seat The con guration must be parameterised again for all retro t and conversion work related to the accelerator, drive direction lighting and lighting in line with the German road traf c licensing regulations.
Page 206 Lower Lift Auxiliary hydraulics 1 Auxiliary hydraulics 1 Auxiliary hydraulics 2 Auxiliary hydraulics 2 Tilt backward Tilt forward Tilt forward Tilt backward Lift Lower Auxiliary hydraulics 1 Auxiliary hydraulics 1 Auxiliary hydraulics 2 Auxiliary hydraulics 2 50638042201 EN - 10/2017...
Page 207 The second-generation mini-lever replaces the rst-generation mini-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. Depending on the hydraulic equipment and customer preference, there are different mini- 7312_003-002 lever variants that can be installed in the truck.
Page 208 are available in the spare parts catalogue for the truck may be replaced. For a detailed descrip- tion, see Service Information 512015017. CAN open as standard; CAN bus integrated in the red CAN One dual potentiometer Sensors per axle Software Device detection "I"...
Page 209 Connect the notebook to the truck. Start the "servo hydraulics" diagnostics: Action B - mini-lever, gen. calibration Execute 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.
Page 210 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.
Page 211 The four levers (1-4) can only be moved forwards and backwards in one axis. The emergency stop switch is a variant Lift - lower Tilt Auxiliary hydraulics 1 Auxiliary hydraulics 4 Emergency stop switch The left joystick (1) is a 360° lever which can be used for operating both axes at the same time.
Page 212 case can be read from the "Decal information for actuation". Depending on the operating device, parameter- ising allows for a number of different axle assign- ments and variants. As soon as the axle assignment and conse- quently the operation have been changed, the "Decal information for actuation"...
Page 213 Lift Lower Tilt backward Tilt forward Auxiliary hydraulics 1 Auxiliary hydraulics 1 Auxiliary hydraulics 2 Auxiliary hydraulics 2 50638042201 EN - 10/2017...
Page 214 The ngertip switch is an operating device built into the armrest of the driver's seat. The ngertip switch controls various operations that the driver can activate using his right hand. The F keys can be assigned different functions during parameterising For example: additional electrical equipment, spotlight on/off Ensure that the operation of additional electrical...
Page 215 The con guration must be parameterised again for all retro t and conversion work related to the accelerator, drive direction lighting and lighting in line with the German road traf c licensing regulations. Parameterising is performed using the truck diagnostics in the notebook. This affects the following components: Single pedal Double pedal...
Page 216 Lift Lower Tilt backward Tilt forward Auxiliary hydraulics 1 Auxiliary hydraulics 1 Auxiliary hydraulics 2 Auxiliary hydraulics 2 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)
Page 217 X71/1 24 Volt X71/2 GND truck X71/3 CAN r H X71/4 CAN r L Emergency off 7S2/1 X71/5 Emergency off 7S2/2 X71/6 Earth wire at the seat or CPP seat The con guration must be parameterised again for all retro tting and conversions related to the accelerator and drive direction.
Page 218 The joystick is used to operate all hydraulic func- tions and the auxiliary hydraulics for attachments. The joystick operating functions are only active when the driver is seated, i.e. when the seat contact switch is activated. Various hydraulic functions can be freely as- signed to the individual operating functions of the joystick using parameters.
Page 219 "Left/right" default setting: Operation of swivel device, roller clamp or sideshift, according to choice. "Simultaneously function key F and left/right" default setting: Operation of fork positioner or bale clamp, according to choice. "Simultaneously function key F and for- wards/backwards" default setting: Operation of fork extension or shovel.
Page 220 The assignment of the input channels and axles for hydraulic operation is con gured using the truck diagnostics in the notebook. In the event of repairs, all the switches and push buttons can be changed separately. Individual spare parts are available for the mini-lever; see the truck spare parts list.
Page 221 The individual functions are assigned to the axles and buttons at the factory. The allocation in each case can be read from the "Decal information for actuation". Parameterising allows for a number of different axle assignments and variants. When performing parameterisation, it is important to note that the variants depend on whether the "joystick"...
Page 222 Lift Lower Tilt backward Tilt forward Auxiliary hydraulics 1 Auxiliary hydraulics 1 Auxiliary hydraulics 2 Auxiliary hydraulics 2 50638042201 EN - 10/2017...
Page 223 As a variation, the single-pedal oorplate can be equipped with a dead man switch. The dead man switch is secured to the oorplate from below by four screws. If the dead man switch is not actuated, the traction drive is turned off. The dead man switch is connected to the truck central control (MCU) via the Option Board A22.
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Page 225 The direction of travel asher module (1) com- prises housing and a console. The housing is located below the steering wheel, screwed to the steering column. The console integrates the direction switch (2) and asher lever (3) controls and is screwed to the housing.
Page 226 Remove the console from the housing Unscrew the size 8 TORQUE screw (3) Unscrew the two cross-recessed screws (1) and (2) Disconnect plug X45 Remove the console from the steering column Connect plug X45 Connect the console to the housing Tightly screw in the two cross-recessed screws (1) and (2) Tightly screw in the size 8 TORQUE screw (3)
Page 227 The turn indicator module for the drive direction (FABLI) is installed on all trucks with the "lighting and hand lever" equipment variant and on cus- tomer request. The turn indicators are activated and the drive direction is changed via the turn indicator module.
Page 228 FABLI. Parameterisation is performed using the truck diagnostics in the notebook. Where necessary, load the current software ash package and start the calibration process; refer to the chapter entitled "Software compatibility". A truck restart must always be performed after parameterising. The drive direction turn indicator display is posi- tioned to the right-hand side of the driver's eld of vision in the front structure.
Page 229 Information, malfunction If the fault display lights up, information is dis- played at the same time in the display operating unit. X17 - A1 to all lights 31 (GND) X17 - A2 Forwards 1 X17 - A3 Backwards 1 X17 - B1 Right 1 X17 - B2 Left 1 X17 - B3 Message 1 The direction of travel asher display is destroyed...
Page 230 The display operating unit (ABE) is used to switch electrical accessories on and off via buttons. The integrated display shows information about driving. The display operating unit is held in place inside the panelling by spring pressure to the right of the driver's seat.
Page 231 "Windscreen wiper/washer" button "Front searchlight" button "Rear window wiper/washer" button "Rotating beacon" button "Lighting" button "Hazard warning system" button "Drive program change from 1-5" button Button for "menu change" and changing the soft key columns Card reader for FleetManager data card (variant) Pictogram for soft key (11) Soft key, here with "interior light"...
Page 232 Park the truck safely. Disconnect the battery male connector. The plastic surface is fragile! The ABE must not be levered out of the assembly opening with tools. Remove the plastic plugs from the two assem- bly openings at the top edge of the panelling. Insert a screwdriver through the assembly openings and push down the retaining springs.
Page 233 The manual transfer begins with the question in the display . This means: A–EEPROM VALID? "Are the parameters of the TCU (device A) supposed to be used?" Load software ash package; see chapter entitled "Software compatibility" Start calibration. Delete the error memory. Function check.
Page 234 "Battery indicator / tank display" pictogram "Drive program" pictogram Left turn indicator display Drive direction forwards display Right turn indicator display Drive direction backwards display "Time" pictogram "Operating hours" pictogram Display for active soft key column; in this case, column 2 is active Pictogram for soft key (0), soft key column 2;...
Page 235 Undo the ABE at the lower edge and take it out of the assembly opening on the panelling. Risk of injury! Gloves must be worn to protect hands. The plastic surface is fragile! The ABE must not be levered out of the assembly opening with tools.
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Page 237 Control electronics Digital controller Traction controller Speed-regulated 4-quadrant three-phase AC converter Pump controller Speed-regulated 1-quadrant three-phase AC converter Accelerator Dual-action potentiometer, 4 k each Brake sensor for electric 4 k potentiometer braking Hydraulic transmitter Electric displacement transducer Speed Max. 16 km/h Adjustable via 5 drive programs Nominal voltage 48 Volt...
Page 238 Electrical system Min. 1000 /volt ≈ > 48 k Electrical equipment Min. 1000 /volt ≈ > 48 k Traction battery Min. 1000 Electrical system IP 23, incl. cover IP 54 Electrical equipment IP 54 50638042201 EN - 10/2017...
Page 239 Control electronics Digital controller Traction controller Speed-regulated 4-quadrant three-phase AC converter Pump controller Speed-regulated 1-quadrant three-phase AC converter Accelerator Dual-action potentiometer, 4 k each Brake sensor for electric 4 k potentiometer braking Hydraulic transmitter Electric displacement transducer Speed Forwards 19.9 km/h, backwards 18 km/h Adjustable via 5 drive programs Nominal voltage 80 Volt...
Page 240 Truck control unit A44 Electric forklift trucks Truck control unit A44 IC truck Electric truck: second left-hand pump Pump converter 2U04 motor (HM2, PM2) Electric truck: right-hand traction motor (FM1) Traction inverter 1U06 IC truck: traction motor (1M1, 1M01) Electric truck: second left-hand traction motor (FM2) Traction inverter 1U07 IC truck: second left-hand traction motor...
Page 241 The truck is equipped with a front wheel drive and is powered by two speed-controlled asyn- chronous motors. The hydraulic pump is also operated by a speed- controlled asynchronous motor. Each of the three asynchronous motors is pow- ered by an inverter. The inverters are controlled by the CAN bus (CANopen) via the Supply Unit and Main Control Unit.
Page 242 In the truck as standard: Traction inverters (1, 2) Pump inverter (3) Supply unit (4) Fuse box (6) Variants of the additional electrical equipment: Signal transmitter (9) Distributor card (5) Voltage transformers (7-9) Version with one or two voltage transformers Acceleration sensor (10) 50638042201 EN - 10/2017...
Page 243 50638042201 EN - 10/2017...
Page 244 Display operating unit U-Batt Supply Unit U-Batt Main Control Unit 24V CAN bus FABLI Drive direction turn indicator module 24V CAN bus Main fuse 12V sensor voltage Fuse for SU / MCU U-Batt, intermediate circuit Battery Release 2U03 Key switch Release 1U06 Emergency off switch Release 1U07...
Page 245 Since August 2006, the SU has an internal vol- tage transformer as standard. Until August 2006, the external voltage transformer MTM was requi- red for the 24V supply. For the measurement (3), or (3a, 3b, 3c), these variants are to be conside- red (see below).
Page 246 Supply Unit Converter 2.1 Pump converter 2U03 2.1 Traction inverter 1U06 (FM1) 2.3 Traction inverter 1U07 (FM2) Display and operating unit (ABE) Additional electrical installation (FABLI, CPP) Once the SU is integrated into the network, it communicates with the MCU. The SU charges the converter intermediate circuit to at least 40V in 1.4 seconds.
Page 247 X44/19 X44/1 Approx. 0 V Enable direct to GND-F (Enable 2U03) (GND F) X44/33 X44/1 Level change Enable via internal switching (Enable 1U06) (GND F) to approx. 1.68 V (photocoupler) X44/5 X44/1 Level change Enable via internal switching (Enable 1U07) (GND F) to approx.
Page 248 Replacement control units can contain software versions that do not match the versions in the control units that are still in the truck. This will cause an invalid combination of software that can lead to errors in the truck.
Page 249 Execute A deactivated PAN process can lead to unde ned faults in the truck. The PAN process must always be activated. In the truck, the PAN process ensures that the truck control unit (MCU / TCU) always operates all available controllers in the truck according to the current parameters.
Page 250 The truck parameter set is stored in the truck con- trol unit (MCU). In order to prevent a parameter loss, this parameter set is available as a copy in the supply unit (SU). The parameter sets for SU, ABE, FU and PU are available as copies in the MCU.
Page 251 Con rm your answer to the security question again. In case of any doubt, ARE YOU SURE? the operation can still be interrupted. The error ring buffer displays errors in the same temporal sequence in which they occurred. The precise temporal statement of the error helps with troubleshooting the truck.
Page 252 Disconnect the battery male connector Connect the batt+ and batt- connections on the converter to the discharge circuit. If there is any residual voltage still in the interme- diate circuit, the bulb brie y ashes. Measure the voltage in the intermediate circuit The intermediate circuit is considered discharged when the voltage is less than 11 V.
Page 253 > 24 k 48 V 100 V/DC min. 100 k > 48 k 80 V 100 V/DC min. 200 k > 80 k STILL MetraHit ISO multimeter measuring device with measuring lines Discharge circuit; see chapter "Intermediate circuit". 50638042201 EN - 10/2017...
Page 254 Short-circuit bridge for the battery male connector on the truck side. Short-circuit bridge for the main contactor, consisting of a short laboratory line and two crocodile terminals. Disconnect the battery male connector. Discharge the intermediate circuit; see chapter "Intermediate circuit". Check that all fuses are inserted and main fuses screwed in.
Page 255 elements are installed with direction-dependent breakdown characteristics in the controllers. Insert the red measuring line of the short- circuit bridge into the positive terminal of the measuring device. Insert the red measuring line of the short- circuit bridge into the negative terminal of the measuring device.
Page 256 STILL MetraHit ISO multimeter 50 V/DC 24 V > 1200 Batt+ Battery Battery tray 100 V/DC 48 V > 2400 Batt- 100 V/DC 80 V > 4000 Disconnect the battery male connector. Set the measuring device to the truck-speci c test voltage.
Page 257 48 V > 48 k pump motor 80 V > 80 k MetraHit Isomultimeter STILL Short-circuit bridge for the temperature sen- sors Disconnect the battery male connector - De-energise the converter by disconnecting the power cables and the control cables...
Page 258 The connection cables and, if necessary, the CAN bus plugs, must be connected to the com- ponents, depending on the equipment. 50638042201 EN - 10/2017...
Page 259 20 km/h Maximum driving speed calculated 16 km/h Maximum driving speed in the drive programs Maximum limit on driving speed due to overtemperature 5 km/h Maximum possible acceleration in drive program 5 115% Maximum limit on acceleration due to overtemperature Maximum possible traction motor current 100% Maximum limit on traction motor current via the converter...
Page 260 With regard to current limitation, it must be en- sured that the truck can still be driven in poten- tially dangerous situations (e.g. when driving over a level crossing). The Boost function is in- cluded as a safety feature required by the system for thermal protection of the drives.
Page 261 30 km/h Maximum driving speed calculated 20 km/h Maximum driving speeds in the drive programs 10 km/h Maximum limit on driving speed due to overtemperature Maximum possible acceleration in drive program 5 120 % Maximum limit on acceleration due to overtemperature 40 % Maximum possible traction motor current 100%...
Page 262 With regard to current limitation, it must be en- sured that the truck can still be driven in poten- tially dangerous situations (e.g. when driving over a level crossing). The Boost function is in- cluded as a safety feature required by the system for thermal protection of the drives.
Page 263 Maximum possible traction motor current 100% Maximum limit on traction motor current via the converter error is reset as soon as this CONVERTER OVERTEMPERATURE 75°C temperature is reached and the temperature falls below this value. The error is activated. CONVERTER OVERTEMPERATURE 80°C The error message repeatedly reappears in the display.
Page 264 The converter analyses the signals from the temperature sensor of the pump motor and transmits the temperature values to the truck control unit (MCU). The temperature values are processed in the MCU in accordance with the characteristic curve for thermal protection of the drives.
Page 265 Standard pump motor current 100% Maximum pump motor current limitation via the converter error is reset as soon as this CONVERTER OVERTEMPERATURE 75°C temperature is reached and the temperature falls below this value. Start of the actual limitation of the pump motor current via the converter. The error is activated.
Page 266 Speed-controlled with Series Series Series Series Series optimised performance Torque-regulated Variant Variant Variant Variant Variant Sprint mode Series Series Blue Q Series Series Series Series Series Starting current boost Series Series Series Series Series Stopping on a slope Series Series Series Series Series...
Page 267 By default, the truck will be in ECO mode every time it is started up. SPRINT mode can be activated and deactivated by pushing the function The drive mode "speed-controlled with optimised (ECO mode). performance" is switched on as standard. The If the drive overheats, SPRINT mode is automat- mode applies to that particular drive program ically deactivated.
Page 268 Blue-Q = IQ will stand for a STILL master concept of intelligent economic ef ciency and environ- mental responsibility in the future. Blue-Q stands for a clean environment, IQ stands for intelligence. The intelligent drive mode for economic ef ciency and environmental respon-...
Page 269 A 00 160 Blue-Q not activated Mode FIX A 00 160 Blue-Q is always ON once the truck is started Mode STANDARD A 00 160 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 ON/OFF using the button.
Page 270 A CAN bus (Controller Area Network) is a "linear network" that comprises multiple participants based on microcontrollers. Due to the signal level technology used and the special structure of the data telegram, the CAN bus system is extremely resistant to interference at high transfer speeds. Depending on the truck, there are several discon- nected CAN bus systems that are used to transfer data between the controllers.
Page 271 With a data transfer rate of 250 kBit/s, this 0/1 transmission occurs 250,000 times per second. In terms of measuring technology, this means that averages are adjusted during operation. A value slightly over 2.5 V is measured for the "CAN_H" signal and a value slightly under 2.5 V is measured for the "CAN_L"...
Page 272 ABE Display and operating unit X47/20 - X47/21 MCU Truck control unit Blue X47/10 - X47/24 Joystick, mini-lever Truck diagnostic connector Variant, additional electrical installa- tion Variant, full extension of battery Variant, turn indicator module for the FABLI drive direction FMID Variant, FleetManager Variant, acceleration sensor Variant, electric parking brake...
Page 273 Voltage measurement CAN_H to GND 2.5 V 3.5 V CAN_L to GND 1.5 V 2.5 V CAN H (red) CAN L (red) 24 V Not assigned Not assigned Not assigned Up to the start of 2014, the diagnostic connector was located in the compartment on the right next to the driver's seat.
Page 274 Power cables are electrical wires in accordance with VDE 0295 classes 5 and 6 with a wire cross-section of 10 mm In our trucks, the following components have power cables: Power contactor (1) Conductor rails and bolts in the fuse box (PDU) Converter (2) Electric motor (3) Starter battery (4)
Page 275 Solderless terminals and crimp connectors are used as contact elements for power cables. The following contact elements are used: DIN 46234 crimp-type cable lugs (1) DIN 46235 compression and tubular cable lugs (2) Manufacturer-speci c battery male connector contacts (3) Check all cable connections on the power ca- bles for damage.
Page 276 Measure the push-on length of the press sleeve. Add 10% to the push-on length as a tolerance. Strip the cable along dimension L. Damage to the separate wires causes a reduction in the cross-section. This leads to incorrect crimping, poorer transition resistance and increased heating. Use a suitable tool.
Page 277 The modular fuse box has been tted as standard since August 2005. The A21 fuse box is installed in the counterweight and includes the following components: Main contactor 1K1 Main fuse F01 Current sensor U10 for measuring battery current Horn relay K1 Control fuses 7A21 converter PCB (variant) Battery positive terminal...
Page 278 Supply Unit 10 A Main Control Unit Signal horn 10 A U4 voltage converter 10 A Electric parking brake 20 A 48V searchlight 10 A U4 voltage converter 10 A 10 A Solenoid valve on attachment Voltage converter Up to 2013 30 A Voltage converter F21A...
Page 279 The fuse plate was installed as standard until August 2005 and was then replaced by the fuse box. The fuse plate is still available as a spare part. The fuse plate is installed in the counterweight as a modular unit and includes the following...
Page 280 If necessary, disconnect the plug from the light strip Remove the covering. To do this, release, but do not unscrew completely, screw M6x10 If the intermediate circuit is not discharged, there is a risk of electric shocks. Check the intermediate circuit. Discharge if necessary. Remove the supply unit Release screw XS1 (M8x16) Release the two screws XS4 and XS5 (M8x40)
Page 281 The fuse plate was built in as standard until August 2005 and was then replaced by the fuse box. The fuse plate is still available as a spare part. Fuses are located in two places on the truck. Fuse plate (1)
Page 282 5. Hydraulics 24/48 V Option board 10 A Clamp light Option board 10 A Material Management System (terminal) Option board 10 A As the main contactor, contactor 1K1 switches the power supply for the power electronics. The contactor coil is designed for 24 volt operat- ing voltage and is activated by current control.
Page 283 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.
Page 284 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".
Page 285 Calibration must always be performed after the rst installation or replacement of the tilt angle sensor. Park the truck on even, level ground. Set lift mast to vertical. Check the vertical position using a spirit level. Apply the parking brake. Start calibration via the display and operating unit.
Page 286 Monitoring of both signals A3130 The sum of the signals does not lie VERTICAL MAST between 6 10 V GND1 breakdown A3131 Sensor signal 1 is less than 0.2 V The hydraulics are disabled while VERTICAL MAST VCC1 breakdown A3132 the "vertical lift mast position"...
Page 287 A 10 1A0 A 10 1A1 A 10 1A2 A 10 1A3 A 10 1A4 A 10 1A5 A 10 1A6 A 10 1A7 A 10 1A8 A 10 1A9 A 10 1AA A 10 1AB A 10 1AC A 10 1AD A 10 1AE A 10 1AF A 10 1B0...
Page 288 Diesel and LPG truck Software ash package 0.43 or a more recent version Electric forklift truck Software ash package 1.02 or a more recent version The truck-speci c parameters are provided by your service centre. Lift mast vertical Maximum backwards Chassis stiffener Lever Maximum forwards...
Page 289 With the "load measurement" comfort feature, the weight of a lifted load can be determined. This weight is shown in the display operating unit. As a result, there is increased safety for the driver because the weight of the load to be transported is known.
Page 290 The transient effect after the lowering movement (B) has come to an abrupt stop is used for the load measurement. Only then can the loss of friction that results while breaking away from the static position be disregarded for the evaluation. Three values are determined for the evaluation: Start of the lowering movement Value above the rst maximum values (1) and...
Page 291 The load should now swing freely without touch- ing the ground. After a short time, the weight of the load is shown in the display. An invalid measurement is shown in the display with the value -9999 kg If a lowering procedure is not performed after the button is actuated, the message LOWER FORKS...
Page 292 The fuse box has been built into all trucks as standard since August 2005. Depending on the truck equipment, the 7A21 converter PCB for the 24-V power supply may be installed. The converter PCB rests on the fuse box. Four hexagon head bolts are used as a spacer block and mounting.
Page 293 The Option Board A22 comprises a circuit board in a plastic housing and is always tted to the front structure beneath the truck control unit (MCU, TCU). Depending on the truck equipment, the Option Board supplies the optional additional electrical equipment and sensor system. The Option Board contains the following compo- nents: Electrical connections...
Page 294 Reserve switch 1 (analogue) Right door contact switch Left door contact switch Fork carriage monitoring Lift limitation Load switching Load sensor 5th hydraulic function feed 5th hydraulic function controller X36/2 F2 light Material management system (MMS) 50638042201 EN - 10/2017...
Page 295 CPPs are designed for 12-V and 24-V on-board electrical systems and are used in all trucks. The individual CPPs can only be identi ed by their order number; see the truck-speci c spare parts list. The location and number of CPPs in the truck varies according to the truck type and the equipment;...
Page 296 CAN bus (CAN r) Supply voltage 2 x 2-pin plugs, 1 variable, 1 xed switching output 10 x 2-pin plugs with 7 variable switching outputs Permanent double X53:1A OUTPW 10 assignment 3.5 A X53:1B OUTPW 2 Wiper supply X53:2B 3.5 A OUTPW 1 X54:1B Permanent double...
Page 297 The entire lighting system is connected via the CPP. It is therefore also called CPP lighting. Other electrical consumers cannot be connected. Since January 2010, the CPP 2B (lighting) has replaced CPP 2 and CPP 4. A conversion from CPP 2 and CPP 4 to CPP 2B is not possible. CAN bus (CAN r) Supply voltage 2 x 2-pin plugs, 2 switching outputs...
Page 298 This CPP can be used to connect the various electrical consumers, which will vary according to the truck and equipment. Since January 2010, the CPP 2B (lighting) has gradually replaced CPP 2 and CPP 4 in all trucks. A conversion from CPP 2 and CPP 4 to CPP 2B is not possible.
Page 299 9B17/1 - GND - yellow X61:1A X301/5 - white X301/8 - yellow 9B17/4 - 12 V - green X61:1B X301/7 - green 9B17/3 - signal 2 - black X61:2A 9B17/2 - signal 1 - red X61:2B X301/6 - brown X62:1A X301/12 9B15 - GND - blue X62:1B...
Page 300 Parallel normally open contacts for SK1/3 X541 Normally open contacts for SK2 X549 Relay coil contacts Electric forklift trucks 48 V and Distributor card 7A21: X65, X66, X67 80 V Electric forklift trucks only 48 V Fuse box A21: X27 IC truck Fuse box A21: X162 The RPPs are not CAN bus participants and do...
Page 301 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.
Page 302 Parameter backup for all other units Servo hydraulics (option) The buffer battery (G5) Data storage, as well as storing time, date, km counter and BDE The operating hours are securely stored in the EEPROM and are not lost even if the buffer battery is empty Direct wiring of all standard functions for the drive unit X47, X46...
Page 303 MCU 2 is an enhancement of MCU 1 with a larger processing capacity. New functions in the truck are only supported by MCU 2. The MCU 1 software will no longer be developed with the introduction of the new MCU 2. MCU 2 replaces MCU 1 completely.
Page 304 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.
Page 305 The Supply Unit (SU) is attached to the coun- terweight via the heat sink using a screw, and is protected by panelling. The position of the SU varies according to the truck type. From August 2014, the second-generation SU will be installed for the rst time in the RX20 Facelift 2014 and later in all other truck types.
Page 306 Since August 2006, the SU has contained a built-in voltage transformer. The external MTM voltage transformer that was previously neces- sary is no longer required. Voltage 24 V Current 4.5 A 16-pin SAAB plug Connection to the overhead guard 16-pin SAAB plug Connection to the fuse card Plug X43 has been omitted since August 2006.
Page 307 If the wires remain in the truck, this can lead to malfunc- tions in the electrical system. Correctly remove the wires from the plug and close the slots. Close the slots in plug X42 with blind plugs Remove the MTM Park the truck safely.
Page 308 Unscrew the mounting screw M10. Remove the SU from the counterweight. Clean the contact surfaces of the SU and counterweight of all heat-conducting paste residues. Apply a 0.5 mm thick layer of heat-conducting paste evenly over the contact surfaces of the SU and counterweight.
Page 309 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 message with progress PLEASE WAIT bar. This process can take several minutes and ends with a reset.
Page 310 2U03 1U06 1M1 - FM1 right 1U07 1M2 - FM2 left Each of the asynchronous motors available in the truck is controlled by its own converter. The converters are attached to the counterweight via a heat sink and are protected by panelling. The position and number of the converters, and their performance data, vary according to the truck type.
Page 311 80 V LAC 1 - HAFS 400 80 V 612 A LAC 2 - HAF 600 80 V LAC 2 - HAFS 600 (1) 2 disc springs in the same direction (2) 2 packages each in the opposite direction (3) 2 disc springs in the same direction Heat sink on counterweight 34 Nm Screw M10 x 30, DIN 912...
Page 312 24 V from supply unit Pin 15 GND-F from supply unit Pin 16 SAC 1 - 400 48 V 400 A SAC 1 - 600 48 V 600 A (1) 2 disc springs in the same direction (2) 2 packages each in the opposite direction (3) 2 disc springs in the same direction Heat sink on counterweight Screw M10 x 30, DIN 912...
Page 313 Pin 6 CAN L connected to SU Pin 7 Rev sensor 10 V Pin 8 24 V from SU U monitoring (not used) Pin 9 Enable signal from SU Pin 10 V monitoring (not used) Pin 11 Temperature sensor + Pin 12 W monitoring (not assigned) Pin 13...
Page 314 Park the truck safely. Disconnect the battery male connector. Remove trademark emblem, loosening the left and right side screws but not unscrewing them completely. Optional: Disconnect plug X57 from the light strip. Remove the cover for the electronics. Discharge the intermediate circuit. Remove the supply unit.
Page 315 Work carefully to ensure that no parts fall into the electrical system. The views of the conductor rails may differ from the actual condition in the truck. The conductor rails, mounting elements and tightening torques are dependent on the converter type (LAC / SAC). Converters are destroyed by overheating! Apply a thin layer (approx.
Page 316 Screw the conductor rails to the converters. Connect plug X150, X151, X152. Install the fuse plate. Install the CPP as required. Install the supply unit; see the chapter entitled "Removing and installing the supply unit". Install and tighten the cover for the electronics. Install the trademark emblem.
Page 317 Shut-off threshold If the cut-off threshold is reached, a hydraulic Warning threshold restriction can be activated through parameteris- ing. Before the cut-off threshold is reached, it is possible to determine the residual charge still 50638042201 EN - 10/2017...
Page 318 available via the . A ashing battery indicator in the display activates an alarm indicating the level of residual charge left. The ideal operating temperature for batteries is between 20°C and 40°C. However, the maximum battery capacity is only reached at an optimum temperature of 27 - 30°C.
Page 319 The display-operating unit shows the battery charge (1) as a segmented bar graph in 10% stages (2). At two bars, the display starts to ash. Hydraulic restriction is activated once no bars are visible. Speed reduction can also be activated via parameterisation.
Page 320 The discharge indicator is based mainly on three measuring procedures or calculation procedures: Discharge measurement (voltage measure- ment) Calculation of the charge drawn (current measurement) No load measurement In addition, saved values from these measure- ments are used for the calculation. The battery voltage is measured at the inter- mediate circuit.
Page 321 If the driver switches on a more energy- ef cient drive programme or BLUE Q, the remaining period increases sharply. If the driver switches on a more energy- intensive drive programme or sprint mode, the remaining period decreases sharply. The driver can in uence the remaining oper- ating time via his driving style and the driving cycle.
Page 322 The display and operating unit displays the bat- tery charge either as 10 bars or as a percentage. At 20% residual battery charge or two bars, the display starts to ash. At 0% residual battery charge or no bars, restric- tion of the hydraulics is activated.
Page 323 determined here as ne battery voltage. This in- ternally measured value cannot be measured by the service centre. The ne battery voltage is transmitted to the MCU. The MCU processes this value in accor- dance with the parameters and subsequently calculates the residual battery charge.
Page 324 Each appliance plug must be equipped with an encoder, which ensures that a male connector can only be inserted into a female connector with the same operating voltage. The coding is dependent on the battery voltage and battery technology (wet battery or dry bat- tery).
Page 325 The equipment speci ed can be used in the following combinations: Plug/socket Plug/socket with two pilot contacts Plug/socket with ventilation Plug/socket with ventilation and two auxiliary contacts Plug/socket with two pilot contacts and two auxiliary contacts Appliance plugs are battery plug connectors that are tted in all electric trucks, and to traction batteries, battery chargers and charging stations.
Page 326 Main current contacts with clear fusing and burn-off: Broken main current contacts: Battery male connector with damage due to acid. Battery male connectors covered with acid can da- mage battery charger plugs and appliance plugs. If a plug covered with acid is noticed during mainten- ance, all plug partners must be checked for damage.
Page 327 Strip the cable along ; refer to the table below 16 to 25 35 to 50 70 to 95 Damage to the separate wires causes a reduction in the cross-section. This leads to incorrect crimping, poorer transition resistance and increased heating. Use a suitable tool.
Page 328 Using shrink tube if required, push the contact element onto the stripped cable end and crimp using the appropriate crimping die. Start with the distance (MIN) of the rst crimp. Depending on the plug, then complete a second crimp. Refer to the table for the relevant dimensions.
Page 329 70 to 50 50 to 35 50 to 25 35 to 16 25 to 16 50638042201 EN - 10/2017...
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Page 331 High-pressure gear pump Type Anticlockwise direction of rotation Delivery rate per rotation 2 x socket head screws M10 x 105, 10.9, DIN Hydraulic pump [Nm] 2 x socket head screws M6 x 50, 8.8, DIN 912 Suction ange [Nm] 2 x socket head screws M6 x 20, 8.8, DIN 912 [Nm] 4 x socket head screws M6 x 35, 8.8, DIN 912 [Nm]...
Page 332 3000 h or 2 years Maintenance interval Tightening torque for maintenance [Nm] Tighten by hand cover Degree of ltration [µm] Maintenance interval Maintenance free Degree of ltration [µm] 2 absolute 3000 h or 2 years Maintenance interval Degree of ltration [µm] Tightening torque for hydraulic [Nm]...
Page 333 The pressure in the hydraulics can be relieved on trucks equipped with MCU 2 with software version 2.06 or later. On trucks equipped with FleetManager SIC, access authorisation must be enabled. Switch on the key switch Lower the fork carriage Switch on the hazard warning system.
Page 334 Tolerance ± 12% min. 0.40 0.40 0.40 max. 0.52 0.50 0.50 min. 0.40 0.38 0.38 max. 0.50 0.48 0.48 min. 0.35 0.34 0.34 max. 0.45 0.44 0.44 Maximum permissible single values from lift 1 and lift 2 = 0.6 m/s Tolerance ±...
Page 335 Min. 0.41 Max. 0.60 Min. 0.38 Max. 0.60 Min. 0.41 Max. 0.60 Min. 0.41 Max. 0.60 Min. 0.38 Max. 0.60 The fastest value at nominal load Tele - value from lift 1 Min. NiHo/triple - value from lift 2 Max. Individual value with nominal load from lift 1 and lift 2 Lift 1: Middle cylinder is extended.
Page 336 min. 1.0. max. 3500 1.0. max. min. 3500 5000 max. min. 5000 max. : Hand lever : Servo hydraulics Measurement is performed over the entire tilt range. Speeds are measured at operating tempera- ture. Operating error! With the simultaneous actuation of more than one valve function, higher tilt speeds may occur.
Page 337 Pick up the nominal load and lift free of the ground. Park the truck on level ground and place the lift mast in the vertical position. Apply the parking brake. Attach an angle measurement device, e.g. a spirit level (1) to the mast pro le (2). Check whether the tilt slider of the directional control valve is in the neutral position.
Page 338 All hose lines must be checked at least once a year and must be replaced in the event of the following defects: The outer layer is breached all the way to the middle (wire mesh), e.g. abrasion spots and cracks. There is a connection error on the tting with bubble formation.
Page 339 Steering unit Suction lter Steering return line Working hydraulics pressure line Steering pressure line Working hydraulics return line Pump motor Directional control valve block Priority valve Return lter Hydraulic pump Breather, dipstick Induction hose The hydraulic pump (6) is driven by the pump The returning oil from the steering hydraulics motor (4) via a tappet.
Page 340 Steering angle sensors Priority valve Steering unit Hydraulic pump Return line Suction hose LS signal line Directional control valve block Pressure line Steering cylinder connection The hydraulic pump (7) draws in the hydraulic As soon as the truck is driving at a speed of oil from the hydraulic tank at the intake side and >...
Page 341 Priority valve Connection P Hydraulic pump Connection H Suction hose Connection R (return line) Pressure line Forwards tilt cylinder Connection B Backwards tilt cylinder Connection A Lift cylinders The hydraulic pump (2) supplies the oil to the If a slider is only actuated slightly, the oil ows with priority valve (1) via the suction hose (3).
Page 342 The hydraulic tank is a welded component built into the chassis at an angle in front of the battery compartment. The lter housing is xed to the tank by means of 4 nuts. The return lines of the directional control valve and steering unit are screwed to the lter housing.
Page 343 Unscrew the hydraulic oil drain plug under the hydraulic oil tank; direct the hydraulic oil into a collection vessel. Screw in drain plug with a new seal (Cu A18x22) and tighten Fill with fresh hydraulic oil through the oil dipstick opening The oil level should be between the markings on the dipstick.
Page 344 Degree of ltration 20 µm absolute Filter material Plastic mesh Housing material Polyamide PA66 +0.5 bar Triggering pressure - bypass valve -0.2 bar Tightening torque 11 Nm, 4 x M8 polystop nut with at washer 3000 h or 2 years Maintenance interval The lter element must be disposed of in accor- dance with environmental regulations.
Page 345 The breather lter and the oil dipstick form a unit and are integrated in the return line lter housing. The lter prevents dust and dirt from entering the hydraulic tank. Return line lter cover Breather lter Bypass valve Seal Return line lter Dipstick Steering return pipe Degree of ltration...
Page 346 The hydraulic oil is drawn from the tank by the hydraulic pump via the intake hose and ows through the intake lter from the outside to the inside. The lter insert is a coarse lter and maintenance- free. Degree of ltration 225 µm Stainless steel Filter material...
Page 347 Fill with hydraulic oil. For servo hydraulics, it is a legal requirement (in accordance with VDMA (German Engineering Federation)) that in addition to the return line lter, an additional lter is installed in the pressure line upstream of the directional control valve. The high-pressure lter is located in the pressure line between the connections (EF) of the priority valve and (P) of the directional control valve.
Page 348 The conical nipple tting is equipped with an integrated O-ring. Tighten the tting union nut until you feel a re- sistance and then turn it a maximum of a half revolution (180 degrees). Tightening it even more can lead to deformation and leaking.
Page 349 Screw the functional nut (1) with retaining ring (3) and seal (2)onto the pipe union (5) by hand Push the pipe end into the screw joint and press against the stop in the inner cone An insuf cient insertion depth can lead to an insecure connection and leaks.
Page 350 After assembly, remove the functional nut (1) Check whether there is a gap between the sealing ring (2) and retaining ring (3) Every time you loosen the functional nut (1), please proceed as in the initial assembly Tighten the functional nut (1) until you clearly feel an increase in connection strength, Hold the socket (7) together when doing so In the event of leaks at the screw joint, the...
Page 351 Manufacturer Type AP 104 - L1 AP 108 - K2 Operating voltage 48 V 80 V Engine type 4-pin AC motor with cage rotor Connection Delta Star Rated voltage (nominal) 28 V 45 V Rated current (nominal) 243 A 180 A Rated speed (nominal) 2884 2680...
Page 352 Pump motor Hydraulic pump Temperature sensor Motor suspension Motor power cable Priority valve Motor power cable Motor power cable Aluminium conductors are cast into the slots in the rotor laminations pack, and their ends The pump unit is connected to the drive axle at are connected with short-circuit rings.
Page 353 In the motor, each of the three phases is dis- The motors are controlled using pulse width tributed to four poles in the stator, thereby gen- modulation at a clock frequency of approx. 16 erating the rotating eld required. The motor is kHz.
Page 354 The pump motor windings are wired in a triangu- lar arrangement inside the motor. Location and type of electrical connections: The three main power connections U, V and W are insulated and watertight screw connections and are led out of the motor through a removable terminal board.
Page 355 Transmitter-free control active Rev sensor available The speed of the pump motor 2M1 is registered by a speed sensor. It is situated on the left bearing shield under a covering, and is xed in place using two screws. It consists of an inductive proximity switch.
Page 356 Risk of injury from turning trigger wheel! The motor must be de-energised; detach the motor connections! Detach the motor connections U, V, W at the pump motor Connect the multimeter between X14/3 ( ) and X14/2 (+) Turn the pump motor trigger wheel manually The multimeter shows a clear voltage jump of approx.
Page 357 1000 1063 1129 1197 1268 1340 1415 1493 1572 1654 1739 1825 1914 A defective sensor can be exchanged with the aid of a repair kit containing a temperature sensor and two-component balancing mastic. Knead both components (yellow and blue) of the mastic together until the mass has a uniform green colour Continue kneading the green mass for at least...
Page 358 Make sure that no mastic gets between the sen- sor and winding, as otherwise the temperature measurement will be incorrect. The balancing mastic is fully cured after approx. 2.5 hours Drain hydraulic oil at an early stage so that the oil has time to drain off.
Page 359 Unscrew power cables (1) on the pump motor and label them in advance, if necessary Unscrew power cables (2) on the motor and label them in advance, if necessary Remove cover of brake operation (3) Remove ground line (4) between pump motor and drive axle on pump motor Unscrew the cable guide plate (9) to provide more room for movement in the cabling...
Page 360 Pull safety split pins from the xing bolts Remove bolts. If necessary, push out using a long lock rod (Ø8 x 700). To do this remove the left wheel and use the mounting hole Lift out the pump motor using the chain block Remove the entire pump motor towards the left out of the truck Disconnect battery plug...
Page 361 Use sling band and chain block to hook pump motor on overhead guard The chain must be pulled from the chain block by the steering wheel (see photo). In trucks with a cab, rst remove the roof disk. To keep the pump motor balanced, pay attention to the position of the sling band and the joint The joint of the sling band must lie to the rear and...
Page 362 Insert bolt into the top right motor mount Remove drift punch and insert bolt into the top left motor mount Insert safety split pins into bolt The bolts cannot be inserted by hand in older, dirty trucks. A long rod (Ø8 x 700) may be used to help punch in the bolts.
Page 363 Use jack to lower truck The hydraulic gear pump (5) is screwed to the right-hand bearing shield for the pump motor (1) by means of two diagonally positioned mounting screws (6). The two other screws hold the hy- draulic pump together. The hydraulic pump is driven by the armature shaft pinion (2) and the tappet (3).
Page 364 Place a collection vessel under the hydraulic pump. Dispose of used hydraulic oil in accordance with environmental regulations and do not re-use under any circumstances. The hydraulic pump is located below the oil level in the tank. The hydraulic pump intake pipe is situated beneath the hydraulic tank.
Page 365 Unscrew the two xing screws of the hydraulic pump Carry out any further work with the utmost cau- tion, because any mistakes can easily cause all the oil to escape. Gently release the clip (1) of the suction hose on the pipe union of the hydraulic tank Rotate the suction hose (2) anti-clockwise on the pipe union, until the hydraulic pump (3) is pointing vertically upwards...
Page 366 Sealing rings must always be changed and greased before assembly. Check the quality of screws and hydraulic oil, as well as the correct tightening torques. For values, see "General technical data" in the chapter entitled "Hydraulics (general)". Dispose of used hydraulic oil in accordance with Pump motor environmental regulations and do not re-use Armature shaft pinion...
Page 367 Top up the hydraulic oil to the mark on the dipstick Clean up any spilt hydraulic oil Connect the battery plug Switch on the switch lock Operate the steering and check the hydraulic connections for leaks Bleed the hydraulic system by operating the steering Install the oorplate with the accelerator pedal and connect the plug...
Page 368 1860 3260 1860 3260 1500 6209 - 6217 1600 1860 1960 6311, 6313, 1800 Windscreen 6315 2000 Windscreen and hose line 1860 2710 1500 6209 - 6217 1860 2710 1600 6311, 6313, Windscreen with 1800 6315 windscreen wiper 2000 and hose line 1500 1860 3260...
Page 369 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.
Page 370 Piston rod Lift, dependent on spacer bush Locking ring Eye bolt setting dimension Grooved ring Screw-in depths of the threads Cylinder head O-ring Snap ring Hexagon nut Wiper Variant: Spacer bush (changes the back- Clip wards tilt) Eye bolt Piston guide ring Loctite 270 Piston seal Cylinder bottom...
Page 371 Use a mandril to drive in the snap ring (11) through the bore in the cylinder pipe (17) and use a screwdriver to lever out the snap ring. Pull the piston rod (6) and cylinder head (9) out of the cylinder pipe (17). Clamp the piston rod in the vice Remove the eye bolt (14).
Page 372 During assembly, bear in mind that the location of the threaded elbow pipes depends on the design of the tilt cylinders. Insert the threaded elbow pipe and screw it in by hand up to the TUFLOK coating. Then use a tool to screw it in at least 4 turns and no more than 5.
Page 373 Griptech Shuttle fork arm 1500 Meyer Rotator 5-1502N 1500 Meyer Rotator 5-1504N 1500 Rotator, for attachment to Meyer 5-1502N 1500 sideshift Rotator, for attachment to Meyer 5-1504N 1500 sideshift Sideshift Kaup 1T151P4 Fixed connection Sideshift Kaup 1T151P2 Fixed connection Sideshift Cascade Fixed connection Sideshift...
Page 374 Since 29th December 2009, standard ISO 3691 has been a legal requirement. This standard speci es that attachments which hold the load by exerting pressure on it must be controlled additionally by a second operating function. This prevents an unintentional release of the load.
Page 375 Input for clamping function with servo hydraulics A 00 3EC Time interval, from when the enable is reset. A 00 3ED Default: 3 seconds Clamping function con guration A 00 3EE Default: enable via the F key Crossbar switch index for auxiliary hydraulics 2 axle A 10 023 Crossbar switch index for analogue switch 1, analogue input A 10 030...
Page 376 Crossbar switch index for setpoint value limiter, analogue input Four-way mini-lever A 10 042 In RX60-25-50 (6321 6330) Duplicate mini-lever Fingertip Crossbar switch index for setpoint value limiter, digital input A 10 043 In RX60-25-50 (6321 6330) Four-way mini-lever Crossbar switch index for setpoint value Duplicate mini-lever limiter, analogue input A 10 044...
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Page 378 Accumulators are hydro-pneumatic storage devices that draw on the compressibility of gas to store uids. Accumulators comprise a uid section and a gas section, with a membrane forming a separator. These sections are welded together to form a single unit. The gas section can be re lled.
Page 379 Check the pre-load pressure. Check the connections to ensure they are secure and check for leaks. Check the ttings and safety systems to ensure they are in proper condition. Check the mounting elements. Using the testing device, you can check the pre-load pressure in the accumulator and reduce it as necessary.
Page 380 Slowly open the pressure release valve and relieve the pressure in a controlled manner. The minimum pre-load pressure must not be below 40 bar, as otherwise the membrane will wear quickly. If the gas pressure is too low or the suspension properties are too soft, the lling connection can be used to increase the pressure.
Page 381 Since calendar week 39/2009 Series Manufacturer Buchholz Lift, tilt, auxiliary 1 Monoblock, three-way for all overall heights Lift, tilt, auxiliary 1, auxiliary 2 Monoblock, four-way for all overall heights The hydraulic functions are active when the seat contact Release valve for the hydraulics in accor- switch is actuated, i.e.
Page 382 Plug or ori ce 39 Nominal lift < 3500 mm Nominal lift 3500 - 5000 mm Delivery condition Spare part delivery condition Nominal lift > 5000 mm Ori ce 24 Exchange ori ce M10 x 1 15 Nm 50638042201 EN - 10/2017...
Page 383 The axle is bolted to the valve support and houses the levers for the operating levers. An individual operating lever can be retro tted or removed for any retro tting of three-way hydraulics to four-way hydraulics. The operating lever for lifting is a combination lever that incorporates an electric rocker button.
Page 384 Since calendar week 39/2009, the trucks have been equipped with valve blocks with a check valve as standard. The conversion of older trucks to the current standard is a lot of work and not intended. The following components must be exchanged for a conversion: Valve block Valve block support...
Page 385 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...
Page 386 X19/1 X46/6 X19/2 X46/7 X19/3 X46/4 X19/4 X46/5 GND-S X19/5 X46/24 12 V X19/6 X46/39 The con guration must be parameterised again for all retro tting and conversions. This affects the following components: Lift lever Three-way valve block Four-way valve block A truck restart must always be carried out after parameterising.
Page 387 X19/1 2B1 lift 2B2 tilt X19/2 X19/5 5.5 V 2.0 V 2B3 auxiliary 1 X19/3 2B4 auxiliary 2 X19/4 Park the truck safely. Tilt the lift mast forward against the stop. Lower the fork carriage fully. Release the pressure from the hydraulics. Disconnect the battery male connector.
Page 388 Remove the valve block earth wire. Loosen all hydraulic connections (6-9) at the valve block. Collect any escaping hydraulic oil and dispose of it in an environmentally friendly manner. Loosen the lower rubber-mounted screw on the valve support, do not unscrew completely. Unscrew the two upper rubber-mounted screws on the valve support.
Page 389 Fit the safety plugs and bolts between the levers and valve spools. Lubricate the following bearings: Bolt between lever and link Bolt between link and rod The valve spools must not be turned in the valve block. Insert the valve support with valve block right into the mount from above.
Page 390 Connect plug X23 of the multifunction lever. Screw the earth wire tightly onto the directional control valve block. Install panelling on the right-hand side of driver's compartment and then connect all electric cables and the earth wire. Install the panelling at the valve block. Re t the bottom plate.
Page 391 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 functional components: Directional control valve, three-way Lowering-balance valve (lowering brake) in Lift, tilt, auxiliary hydraulics 1 the lift valve spool...
Page 392 Hydraulic transmitters that send signals to the ori ce used depends on the nominal lift of the lift sensors in the sensor strip are located at the mast. lower end of the valve spools. The discharge pressure governor (lowering The hydraulic transmitters for the individual hy- brake) in the lift valve spool ensures a constant draulic functions generate signals corresponding lowering speed and does this largely irrespective...
Page 393 The input pressure governor in Driver is not seated, "lowering" is the P input of the directional blocked, "lifting" and "tilting" are control valve is contaminated Install a new valve block. possible. and therefore remains open permanently. 50638042201 EN - 10/2017...
Page 394 Directional control valve for tilting Directional control valve addition 2 Connection - pump main Connection - additional hydraulics Connection - return pipe to tank Connection - lift cylinder Valve rod Connection - tilt backwards Hydraulic sensor Connection - tilt forward Flow control valve Test port Idle port...
Page 395 The back-pressure valves (7) are integrated in the directional control valves, preventing oil from owing from the consumer back to the pump port (5). The ow control valve (3) limits the oil amount for the tilting. The restrictor used depends on the mast.
Page 396 If no more directional control valves are provided for the auxiliary hydraulics, an end plate (3) is tted at the tilt valve spool. This end plate seals the directional control valve. Hydraulic transmitters that send signals to the sensors integrated in the sensor strip (16) are located at the lower end of the valve spools.
Page 397 Blocking screw Sensor rail Washer Hydraulic sensor auxiliary 1 Screw of cover plate Middle segment auxiliary 1 O-ring Hydraulic sensor auxiliary 1 or 2 Support ring Screw of hydraulic sensor Terminal block End segment of auxiliary 1 or 2 The directional control valve block for lifting and tilting is a connection block (6) to which one or two directional control valves can be added, depending on the equipment.
Page 398 The directional control valves for the auxiliary hydraulics are identical in function and design. The directional control valves are sealed to one other in the ange surfaces via O-rings (4) and support rings (5). The sensor strip (7) with the sensors for the aux- iliary hydraulics is a component of the directional control valve block for lifting and tilting.
Page 399 A contaminated pressure relief valve can cause pressure loss or reduced lifting and tilting power. Cleaning the PLV might eliminate the pressure loss: Loosen locknut Unscrew adjusting screw until compression spring is relieved Activate consumer brie y and ush PLV Screw in adjusting screw until setting is reached Secure with locknut...
Page 400 The lowering brake is a ow control valve and limits the maximum lowering speed of the load. After loosening the lock nut (10), the lowering speed can be changed via the adjusting threaded pin (11). Screwing in the screw increases the lowering speed Unscrewing the screw reduces the lowering speed...
Page 401 Manufacturer Buchholz Lift, tilt, auxiliary hydraulics 1 Monoblock, three-way for all overall heights Lift, tilt, auxiliary hydraulics 1, auxiliary hydraulics 2 Monoblock, four-way for all overall heights Coil voltage 12 V Coil current 1.8 A maximum Coil resistance - lift, lower 6.0 Ohm Coil resistance - tilt, auxiliary 1, auxiliary 2 8.0 Ohm -25 °C to +90 °C...
Page 402 Solenoid coil Emergency lowering Plug Lift/tilt/auxiliary 1 directional control valve Solenoid coil block Fixing screws Measuring point Valve support The valve support (5) houses the complete valve block and is connected via mounting screws (4) to the cross wall of the overhead guard. 50638042201 EN - 10/2017...
Page 403 The back of the directional control valve is scre- wed to the valve support (5) with three rub- ber-mounted screws (10). Actuation of the hydraulic functions can take place either by joystick, ngertip or mini-lever. The removal and installation of the valve block is performed in the same manner as for the hand lever.
Page 404 Using the 4mm Allen wrench, slowly turn the manual lowering screw out until lowering starts. Do not turn the screw more than 1½ turns. If the load does not lower despite the screw be- ing turned out, there is a mechanical blockage. After the lowering, turn the screw in with Re t the valve block cover.
Page 405 Check valve for hydraulics blocking function Lifting Lifting valve Lowering Emergency lowering Tilting back Lowering valve Tilt forwards Lowering-balance valve (lowering brake) Auxiliary hydraulics 1 Inlet pressure balance Auxiliary hydraulics 1 Pressure relief valve Auxiliary hydraulics 2 Tilting valve Auxiliary hydraulics 2 Auxiliary hydraulics 1 Check valve for hydraulics blocking function Auxiliary hydraulics 2...
Page 406 The check valve (2Y9) is located in the Load The lowering speed is set by adjusting the lower- Sensing chain and releases the control pressure ing cartridge. as soon as the seat contact switch is closed. The pressure relief valve (2) protects the hy- The lowering-balance valve (6) ful ls the func- draulic system from overloading using the input tions of the lowering brake, and limits and regu-...
Page 407 When a spool is moved, the pressure building up ated, the check valve closes the control cable in the consumer acts via the control channels on against the return ow (T) and the lowering-bal- the input pressure governor and closes it along ance valve (3) is enabled.
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Page 409 2 x M16 x 110-10.9 screws, ISO 4762 Mast bearing screws, per side [Nm] 2 x M16 x 45-10.9 screws, ISO 4762 With Tu ok screw locking agent Lubricant The mast bearing is the same in all telescopic and triple masts. Each mast bearing is screwed to the drive axle via two screws.
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Page 411 Line break safety devices [Nm] 23 ± 2 Outer cylinder hydraulic line [Nm] Bleeder screws Support roller diameter [mm] 75.3 Standard size [mm] Minimum play 0.05 Permissible radial play [mm] 0.4 0.6 Maximum play [mm] Minimum play Permissible lateral play [mm] 0.3 1.1 Maximum play Middle roller in case of 6-roller fork...
Page 412 The line break safety valve prevents the load from lowering at an accelerated rate and in an uncontrolled manner in the event of line breakage. The line break safety valve features a valve disc that is lifted from the valve seat by spring force when in a quiescent state, thus keeping a ow cross-section free.
Page 413 The quantity and installation position of the line break safety valve depends on the type of lift mast, the load capacity class and the overall height. A distinction is drawn between three installation positions: Cylinder bottom Hydraulic adapter Cylinder bottom and hydraulic adapter 1600 - 1800 1000 - 1800 From 2660 mm...
Page 414 There is no line break safety valve installed at this point. Number of line break safety valves installed. 50638042201 EN - 10/2017...
Page 415 Support roller Shim ring Pro le sizes After replacing the support rollers, the lateral and radial play between the mast pro le and the support roller must be checked. The radial play is balanced using larger support rollers. The lateral play is balanced using shim rings. [mm] Minimum play 0.05...
Page 416 In order to keep wear and tear to a minimum, note the following: Clean load chains regularly. Spray load chains with STILL chain spray. Measure the chain elongation. Adjust the load chains evenly. Load chains must be evenly tensioned when under load.
Page 417 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.
Page 418 The end stop must lie within the lift cylinder when lift 1 is fully extended. There must always be a minimum distance remaining between the run-out barrier (1) and fork cams (2) when lift 1 is fully extended. The measured value is only a reference dimen- sion.
Page 419 For the work described, it is important to know Hydraulic oil is hazardous to health. Hydraulic oil is pressurised during operation. the overall weight of the lift mast, as well as the Do not spill the hydraulic oil. weight of the fork carriage and any attachments. Spilt hydraulic oil must be cleaned up immediately The following devices are required for the work using oil-binding agents.
Page 420 Park the truck safely. If necessary, depressurise the hydraulics; see the chapter entitled "Depressurising the hydraulics". Remove the fork arms and, if necessary, the attachment. Raise and secure the fork carriage; see the chapter entitled "Securing the fork carriage". Loosen the mast bearing screws; do not completely unscrew them.
Page 421 Seal off hydraulic lines using plugs. Use cable ties to attach the loose hose ends to the lift mast. As soon as the mast bearings and tilt cylinders are unscrewed, the weight of the lift mast is taken entirely by the lifting sling. Ensure that the lifting sling is seated securely on the lift mast.
Page 422 Attach a suitable lifting sling to the top of the outer mast crossmember. Hook the lifting sling onto the forks on the second truck and secure in such a way that it cannot slip off the forks when lifting the lift mast.
Page 423 In the case of NiHo and triple lift masts, also loosen the bleeder screw on the middle cylinder by a maximum of one turn. Screw the bleeder screw back in as soon as oil starts to leak out. Carry out this process for every lift cylinder. Check the hydraulics for leaks.
Page 424 The telescopic lift mast is a high-visibility lift mast. The mast pro le is a double-T pro le. The fork carriage and mast pro les are guided through support rollers (4); these also absorb the lateral forces. When the load is lifted, the inner mast is also raised along with the fork carriage.
Page 425 Lower the lift mast and tilt it back fully. Unscrew the screw (4) on each side of the outer mast and remove the cap (2). The screw (2) features a thread lock. Secure the screw using Loctite 243. Release the nut (3) on both sides. Evenly tension the two load chains at the tensioning nuts (1) until the dimension (X) is reached.
Page 426 Screw the cap (2) securely in place on both sides using a new Tu ok screw (4). Damage due to the fork carriage coming into contact with the run-out barrier! Never compensate for tyre wear by retightening the load chain because the load chain will then be too short.
Page 427 The NiHo lift mast is a high-visibility lift mast. The mast pro le is a double-T pro le. The fork carriage and mast pro les are guided through support rollers (8); these also absorb the lateral forces. When the load is lifted, the fork carriage is raised in free lift in lift 1.
Page 428 The hydraulic oil comes from the directional control valve block. The hydraulic oil is then distributed via a T-piece and directed down to the two outer cylinders. The right-hand outer cylinder is closed at the top. In the left-hand outer cylinder, the hydraulic oil is directed through the piston rod and then down through a hose line to the middle cylinder.
Page 429 Lower the lift mast and tilt it back fully. Unscrew the screw on the middle cylinder and remove the cap (4). The screw (2) features a thread lock. Secure the screw using Loctite 243. Tighten the load chain at the tensioning nut (3) until the dimension (X) is achieved.
Page 430 Damage due to the fork carriage coming into contact with the run-out barrier! Never compensate for tyre wear by retightening the load chain because the load chain will then be too short. 50638042201 EN - 10/2017...
Page 431 The triple mast is a high-visibility lift mast. The mast pro le is a double-T pro le. The fork car- riage and mast pro les are guided through sup- port rollers (8); these also absorb the lateral forces. The function of the triple lift mast is the same as the NiHo lift mast, but it has an increased lift height with the same overall height.
Page 432 The redirection of the outer load chains causes the inner mast to move towards the middle mast at a ratio of 1:2. The end stop is in the cylinder. A run-out barrier prevents the fork carriage from tilting outwards; see the chapter entitled "Run-out barrier".
Page 433 Safely park the truck. Move the lift mast to its vertical position. Apply the parking brake. Raise the fork carriage and secure it to the inner mast crossmember using the safety chain. Remove the fork carriage; see the chapter entitled "Fork carriage" Turn the key switch OFF.
Page 434 Slowly lower the inner mast until the support rollers are freely accessible at the bottom of the inner mast. During the lowering process, the inner mast moves clear of the upper guide and tilts forwards slightly. Hydraulic hoses and other components may become damaged during this process.
Page 435 Release the hydraulic hoses and protect them from contamination. Unscrew the hose guide from the chain roller. Unscrew the hose clips from the outer mast. Unscrew the tensioning pieces on the lift cylinders. Using the hydraulic jack, lift the middle mast until the lift cylinders are no longer guided in the middle mast crossmember.
Page 436 At the same time, the support rollers at the top of the outer mast become free. Remove the 4 support rollers at the top and bottom from the bearing pins. Clean the bearing pins and t new support rollers, adding shim rings as required. Adjust the play of the support rollers;...
Page 437 Fit the locking rings for the piston rods on to the middle mast crossmember. Insert the load chains into the bottom of the inner mast and secure using the locking screw. If necessary, lift the inner mast for this purpose. Remove the supporting block from under the middle mast.
Page 438 Safely park the truck. Move the lift mast to its vertical position. Apply the parking brake. Raise the fork carriage and secure it to the inner mast crossmember using the safety chain. Turn the key switch OFF. Disconnect the battery male connector. Lift the inner mast using a hydraulic jack so that the load chains hang loose.
Page 439 Position the chain roller on the bearing pin. Using a hammer, carefully tap the inner ring. Place the load chain over the chain roller, noting the installation direction of the chain. Screw on the clamping bolt for the load chains to the top of the outer mast crossmember.
Page 440 Safely park the truck. Move the lift mast to its vertical position. Apply the parking brake. Raise the fork carriage and place it on support- ing blocks so that the load chain hangs loose. Turn the key switch OFF. Disconnect the battery male connector.
Page 441 Screw the hose guide onto the fork clevis and screw on the support for the hoses. Connect the battery male connector. Lift the fork carriage, remove the supporting blocks and lower the fork carriage. Adjust the middle load chain; see the chapter entitled "Adjusting the middle load chain".
Page 442 Adjusting the outer load chain only ensures that the masts are ush with each other. The fork carriage position is adjusted via the middle load chain Lower the lift mast and tilt it back fully. Unscrew the screw (2) on each side of the outer mast and remove the cap (1).
Page 443 Lower the lift mast and tilt it back fully. Unscrew the screw on the middle cylinder and remove the cap (4). The screw (2) features a thread lock. Secure the screw using Loctite 243. Tighten the load chain at the tensioning nut (3) until the dimension (X) is achieved.
Page 444 Damage due to the fork carriage coming into contact with the run-out barrier! Never compensate for tyre wear by retightening the load chain because the load chain will then be too short. 50638042201 EN - 10/2017...
Page 445 The lift cylinders are single-action cylinders. The cylinder pipe is welded to the cylinder bottom. The cylinder head is bolted on to the cylinder pipe and secured using pourable plastics. The seal between the cylinder head and cylinder pipe, and between the cylinder head and piston rod (piston barrel), is provided in the form of sealing rings.
Page 446 The hydraulic oil is pressurised during operation and is The following equipment is required to remove hazardous to your health. the lift cylinders: Do not spill the hydraulic oil. Safety chain and lifting sling with an adequate Spilt hydraulic oil must be cleaned up immediately nominal load using oil-binding agents.
Page 447 Unscrew the hydraulic lines from the bottom of the outer cylinders. Unscrew the hydraulic connection from the top of the hydraulic adapter. At the top of the crossmember, disassemble the locking ring from the piston rods. Raise the inner mast using a hydraulic jack far enough for the outer cylinder to be accessed at the top on the crossmember.
Page 448 Raise the middle mast using a hydraulic jack far enough for the outer cylinder to be accessed at the top on the crossmember. Unscrew the tensioning pieces. Risk of injury! Without the tensioning piece, the outer cylinder will tip to the side. Secure the outer cylinder to prevent it from tipping.
Page 449 Screw the hydraulic lines to the outer cylinders. Screw the hydraulic connection to the top of the hydraulic adapter. Extend the lift cylinder until the safety chain is no longer under tension. Open the bleeder screw on the outer cylinder a maximum of one turn.
Page 450 Unscrew the hydraulic adapter. The hydraulic adapter is secured with Loctite, so it may be necessary to gently heat the thread. The next steps of the disassembly process are the same for both of the outer cylinders. Using protective jaws, clamp the cylinder pipe loosely in the vice.
Page 451 Attach the cylinder head and screw it on as far as it will go using a hook spanner. Secure the cylinder head by knocking the hook spanner with two blows of the hammer. Pull the piston rod approx. 20 cm out of the cylinder pipe.
Page 452 Remove the chain roller pin from the fork bearing. Remove the chain roller and set the spacer washers to one side (1). Place a collection vessel for hydraulic oil under the middle cylinder. Release the hydraulic connection on the cylin- der bottom (2) and protect against contamina- tion.
Page 453 Insert the chain roller with spacer washers into the fork bearing (1). When doing so, note the installation position of the bolt. See the chapter entitled "Middle load chain and chain roller". Screw the hose guide and hoses to the fork bearing.
Page 454 Using protective jaws, clamp the cylinder pipe in the vice. Unscrew the cylinder head using a hook spanner. The cylinder head is secured with Loctite, so it may be necessary to gently heat the thread. Remove the cylinder head from the piston rod. Remove the set of seals.
Page 455 Attach the cylinder head and screw it on as far as it will go using a hook spanner. Secure the cylinder head into its nal position by knocking the hook spanner with two blows of the hammer. Clean and degrease the thread in the cylinder pipe and fork clevis.
Page 456 While lowering during lift 2, the end position damping hydraulically brakes the piston rod of the right-hand outer cylinder just before it reaches its end position. This prevents metal striking on metal. The right-hand outer cylinder is equipped with end position damping. In telescopic lift masts, end position damping is not installed.
Page 457 When lifting the fork carriage, the end position damping hydraulically brakes the piston rod just before it reaches its end position. The end dampener is located in the piston cover. The piston rod (5) extends until the cross hole in the piston rod (4) is covered by the cylinder pipe (1).
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Page 459 Safely park the truck. Apply the parking brake. Put the lift mast in its vertical position. Remove the fork arms. If necessary, depressurise the hydraulics; see the chapter entitled "Depressurising the hydraulics". Depending on the equipment tted, remove the attachment and auxiliary hydraulics hoses. Raise the fork carriage to a comfortable working height.
Page 460 Attach the load chains to the fork carriage. Screw in the load chain locking device on the fork carriage. Ensure that the screw overlaps the chain anchor suf ciently. If the fork carriage jams in the inner mast during assembly, gently tilt the lift mast back and forth in order to advance the fork carriage into the inner mast.
Page 462 STILL GmbH 50638042201 EN 10/2017...

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