RX50 16

Workshop manual 5051 - 55 01
Chassis, counterweight
Chassis-counterweight
General technical data

Chassis-counterweight bolted connection
3 hexagon bolts M24x110 8.8 DIN 933
Tightening torque = 660 Nm
Weight
5051 = 567 kg
5052 = 720 kg
5053 = 720 kg
5054 = 926 kg
5055 = 974 kg 1
Jacking up the truck

The truck should be jacked up only at the specified
points:
At the mast:
- Bring the mast into a vertical position.
- Raise the mast and secure with securing chain
(Fig. 1).
- Jack up the truck at the mast (Fig. 2).
- Lower the truck with the front part of the chassis
supported on blocks of wood.
2
At the counterweight:
- Apply the parking brake.
- Position the jack on the left side of the counterweight
in the recess provided (Fig. 4) and jack up the truck
(Fig. 3).
- Place blocks of wood on the left and right side under
the counterweight and lower the truck (Fig. 3).
4
 STILL GmbH Position as per: 08/2002 (Replaces version: ) 01
Axle
Table of contents Page
General technical data 2
General part 3
Removing the wheel hub 3
Fitting the wheel hub 3
ã STILL GmbH Position as per: 08/2002 (Replaces version: ) 1

Axle
Axle
Tightening torques
Wheel hub MA=195 Nm
wheel nut MA=195 Nm
Lubricant
Grease F according to DIN51825-KP2K -20,

Wheel hub bearings
litthium saponified
Grease F according to DIN51825-KP2K -30,
litthium saponified

Axle
Functional description
The wheel hub runs in two taper roller bearings.

The wheel hub and axle journal are designed so
that adjustment of the bearing clearance with
washers is unnecessary.
Note:
Maximum axial clearance of bearings 0.35 mm.
Removing the wheel hub/brake drum
- Disconnect the battery plug

- Slightly loosen the wheel bolts
- Jack up the truck using blocks of wood for
support and chocks to prevent the truck rolling
.
- Remove wheel
- Remove hub cap (1)
- Loosen hexagon bolt (2)
- Remove plain washer and disc washer (3)
- Remove brake drum (6) with taper roller bearings

(4) from axle journal (5)
Note:
Secure the wheel bearing to stop it falling out.
Replacing the wheel bearing
- Remove wheel bearing from axle journal

- Renew seal
- Knock outer race out of wheel hub with a
steel mandrel and hammer
- Fit new bearing
Fitting the wheel bearing/brake drum
- Fitting takes place in reverse order to removal
Note:
The disc spring (3) must be fitted with the ground
side facing the taper roller bearing (4).
- When refilling the wheel hub with grease,

no more than 1/3rd of the bearing shell volume
should be filled, as grease could enter the brake.
Tightening torques:
Hexagon bolt (2) 195 Nm
Wheel bolts 195 Nm

Wheel drive
Contents Page

Description of wheel drive 3
Fitting four-point bearing/stop 3
Removing and fitting the wheel drive 4
Removing and fitting the wheel shaft/radial seal 5

Wheel drive
Technical data
Transmission designation/ Manufacturer TFD471 / DG112MC-4 ABM Greiffenberger
Screw ring mount on transmission 11 cheese-head screws DIN 912 M16x55 8.8
Tightening torque: 205 Nm
Pin in steering stop Pin 18x60 according to DIN 1481
Screw ring mount on counterweight 12 cheese-head screws DIN 912 M16x 80
Screws aluminium cover/ transmission 8 cheese-head screws DIN 912 M6x20 8.8
M 16x45 tightening torque: 260 Nm secured with
Bolt/wheel shaft Loctite 243
Transmission oil /specification DIN 51517- 3 BG 100 bzw. SAE 80W API GL 4
Oil capacity 2 Litres
Drive/weight 115 kg

Wheel drive
The drive consists of a transmission case with a
permanently integrated motor (see Group 11).
In the upper area, the ring mount with steering chain

(see Group 06) is permanently bolted to the drive body.
The compete drive is bolted to the counterweight.
Seated on the wheel hub is the tyre fixed with nuts

(see Group 04).
5
In order to make the wheel drive steerable, a
permanetly bolted ring mount (four-point bearing) 4 6
(item 8) with screw fitted stop (Item 7) is arranged
between the transmission and counterweight. 3
Note: 7
Stop fitted offset 90° to direction of travel (see Fig.). 2
1
Direction of travel
front
9

Wheel drive
Removing the wheel drive
Secure truck, jack up and support with two blocks of

wood.
Remove battery (see Group 09).
Remove rear wheel.
Drain transmission oil (drain plug located below
transmission case).
Disconnect electric motor cable.
Unscrew cable support (seated on top of wheel drive)
and screw in eye bolt (M10).
Loosen steer chain.
Mark position of ring mount/transmission.
Bring wheel into removal position as illustrated.
Attach block and tackle to overhead guard with the

aid of a rope. Subsequently attach hook/chain of block
and tackle to eye bolt. Tension block and tackle/chain.
Loosen wheel drive/counterweight bolted connection.

Lower wheel drive with block and tackle and
subsequently remove hook of block and tackle.
Withdraw wheel drive towards the rear.
Fitting the wheel drive
Fitting takes place in reverse order to removal.
Tightening torque of hexagon socket screws counter

weight/wheel drive: 195 Nm.

Wheel drive
Removing and fitting wheel shaft/radial seal
Work on the transmission can be carried out in a

fitted condition.
- Loosen wheel nuts
- Jack up rear of truck and secure
- Remove wheel
- Drain transmission oil (oil sump)
- Loosen screws of bottom cover and remove
- Remove cover
- Loosen wheel shaft bolt

- Force bolt head against a socket or similar, as
illustrated.
- Unscrew bolt until wheel shaft is forced out of

splines.
- Fully unscrew bolt and remove wheel shaft.
- Radial seal can be replaced in this position

- Fill half of radial seal with grease
- Note correct position when fitting the radial seal
- Fitting of the radial shaft takes place in reverse
order to removal.
- Use new bolt
- Bolt tightening torque: 260 Nm.

Tyres
Contents Page
ã STILL GmbH Position as per: 10/2002 ( Replaces version: ) 1

Wheels/Tyres
Group 04
Wheels and tyres
Tighten bolts crosswise

Fix front wheels with five M14 x 29 bolts
Retighten first bolt
respectively
Tightening torque 195 Nm
Tighten nuts crosswise
Fix drive wheel with five nuts Retighten first bolt
Tightening torque 195 Nm
Tyres types
Only the tyre types shown in the spare parts
list may be used.
See STILL spare parts list (STEDS)
The inflation pressures for pneumatic tyres
specified on the tyre pressure labels (on
truck chassis) must be observed.
Note on fitting and removing SE tyres Regrooving SE tyres

Preparation When the original tread is worn, the tyre has
- Clean rim and remove any burr. reached about half its useful life. It can still be
- Coat tyre and rim on sliding surfaces with the used and regrooved if necessary to ensure good
recommended fitting grease. adhesion on wet and dirty roads.
- Fit rim on base plate of the press using the To make the tyre suitable for retreading, the wear
correct retaining ring. and regrooving limit should not be exceeded. The
tread patterns can be regrooved up to the top edge
Fitting grease: of the 60 Joule strip.
- Use a volatisable fitting grease: Regrooving should only be carried out in steps.
Recommended are SIPIOL-G of Messrs Henkel Only when the tread pattern has worn again,
KGaA or solid rubber tyre grease Article No. should the available remainder be regrooved in a
5930388 of Messrs Tip Top Stahlgruber (Munich). second step.
Do not use the fitting grease customary for Attention!

pneumatic tyres, as tight seating of the tyre Industrial pneumatic tyres must not be
will not be ensured. regrooved.
ã STILL GmbH Position as per: 11/2002 (Replaces version: 01/1998 02

)
Steering
Table of contents Page
Functional description 3
Priority valve
Component description 4
Removal/Fitting 5
Steering column
Steering column adjustment 6
Steering unit
Removing the steering unit 8
Fitting the steering unit 9
Repairing the steering unit 9
Pressure switch
Arrangement of pressure switch 10
Hydraulic motor
Steer chain
Removing and fitting the steer chain 12

Steering
Steering unit
Make Danfoss
Type OSPC 50 LS 150 - 1214
Delivery capacity 4 0 cm 3 / U
+ 5
Relief valve 125 / 0 bar
+ 20
Shock valve 180 / 0 bar
Prioriy valve
Make Hydraulik Nord Fluidtechnik
Type P V P S 80 - 04 / 32 - 64M
Pressurising pressure 4 bar spring
Inlet volume 80 L / min
max. pressures
Connections P and EF 250 bar
Connections CF and LS 175 bar
Hydraulic motor
Make Danfoss
Type OMR 125 151 X 2333 (OMR125LL)

NOTE:
Figures 1 and 2 are diagrams. In the case of the
R50, the steering cylinder is replaced by a steer
motor and steer chain.
The control principle of both systems is identical.
The steering unit functions are shown in the blue $ $
area in the diagrams. $
The priority valve is shown in the red area.
LS (Load Sensing ) components of the $

dynamic system:
$
LS system of the second generation $G
A constant oil flow of 0.6-0.9 l/min is required

also when the steering is not operated.
The dynamic oil flow is the reason for rapid 33EOHHG /6EOHHG
reaction times at the start of steering.
The steering system always has the oil

temperature of the complete system and is
therefore is not subject to fluctuations.
:RUNLQJ
Pumpenmotor
(QJLQH 3XPS Wegeventil
The LS cross-section reducer must be larger than +\GUDXOLF
the dynamic cross-section reducer
Figure 1
Static steering system in neutral position
(Fig. 1)
$ $
$
$
$
$G
33EOHHG /6EOHHG
:RUNLQJ
Pumpenmotor
(QJLQH 3XPS Wegeventil
+\GUDXOLF
Static steering system with steering movement
(Fig. 2) Figure 2
ã STILL GmbH Stand: 08/2002 ( Ersatz für Stand: ) 3

Priority valve
Component description
The priority valve is directly screwed to the hydraulic

pump. The valve is a hydraulic control unit and
ensures that an oil supply to the steering is
available in all operating conditions.
The hydraulic lines must be connected to the
priority valves with the correct tightening torque.
CF: MA =100 Nm
EF: MA =100 Nm
P : MA =100 Nm
LS: MA = 45 Nm
Figure 1
Figure 2

Priority valve
Removing the priority valve
The priority valve can malfunction due to contaminants

in the hydraulic oil. Free movement of the valve rod
(3) in the housing is prevented due to dirt particles.
This is noticeable by sluggish/jerky steering.
1 Screw plug
2 O-ring
3 Valve rod
4 Spring
5 LS plug 12
3
6 Housing
6
- Unscrew screw plug (1) and LS plug (5)
- Remove valve rod (3)
- Clean and blow-out all parts
4
2
Fitting the priority valve 5
Tightening torque for parts (1) and (5): 50 Nm
Figure1
LS
CF
EF
Bild 2

Steering column
Steering column adjustment
The steering column is attached to the cowl.

The steering column can be tilted within a range of
about 10° after loosening the grip screw (turning
anticlockwise).
After adjustment to the required position, the steering
column must be locked in place again by tightening
the grip screw. (Fig. 1)
Figure1

Steering unit
The steering unit is screwed to the flange of the

steering column with four cheese-head screws.
The following valves are installed in the steering

unit, which are set by the manufacturer to a fixed
value.
+5
Relief valve 125 /0 bar
Shock valve 180 + 20/0 bar
Note:
The valve settings must not be altered.
Figure 1

Steering unit
Steering unit
The steering unit (1) is fixed to the steering column

bearing with four cheese-head screws.
The following valves are installed in the steering unit,
which are set by the manufacturer to a fixed value:
Relief valve: 125 + 5/0 bar
Shock valve: 180 +20/0 bar
Check valve: 2 bar in connection T
NOTE:
The valve settings must not be changed.
Removing the steering unit
Remove covering in cowl.

Unscrew left interior covering.
Unscrew steering column rear cover.
Disconnect plug contacts of pressure switch (EL).
Unscrew hydraulic connections T (tank), P (priority
valve), L (left connection), R (right connection),LS Fig. 1
(control connection) and mark.
ATTENTION:
When unscrewing the hydraulic connections,
hydraulic oil will discharge. Collect the hydraulic oil
and dispose of in a proper manner.
T P LS R L
Loosen the four cheese-head screws and remove
the hand pump downwards.
While loosening the steering wheel with steering

column must be tilted back or forward.

Steering unit
Fitting the steering unit
No Designation Remarks
1 Cheese-head screw MA = 46Nm
2 Washer 7
7 Steering column Tilt forward and back
Remove steering 1
column rear cover. 9
2
8 Union MA = 50Nm 8 9
4
9 Reducing union MA = 100 Nm 5
4
10 HP hose 3
11 Relief valve Installed in steering
unit.
10 6
MA = 50 ±1Nm
Figure 1
ATTENTION:
The marked hydraulic lines must be screwed back
into their original positions to prevent a risk of
accident.
Repairing the steering unit
In case of damage, the steering unit must be 11

replaced
Exception: Oil leakage 12
Available for this repair, is a seal kit
Ident. No:XXXXXX consisting of:
1 x Lip seal (14)
1 x Dust seal (15)
7 x Washers (16)
3 x O-rings (17) 12
1 x Fitting instructions. Figure 2
NOTE:
For changing the lip seal and dust seal, special tools
of Messrs Danfoss are required.
14
To remedy union leaks at the steering unit 15
connections, seals are available from STILL spare
parts service. The tightening torque of the pipe
connection should be previously checked.
17
Figure 3
16 13

Pressure switch
Arrangement of pressure switch
The pressure switch (1) is screwed to the steering

unit. When the steering wheel is turned, pressure
builds up in the steering unit. The pressure switch
opens at a pressure of 0.25 bar, which activates the
pump control.
The pressure switch has an operating range of 0.1

to 1.0 bar. Adjustment takes place with the screw
on the front of the pressure switch.
The screw is coated with sealing lacquer.
Note:
The factory setting of the pressure switch must not
be altered.
1 Figure 1
Pressure switches with removed or damaged

sealing lacquer must immediately be replaced.

Hydraulic motor
The gear drive is turned by a hydraulic steer motor.

Power transmission between the gear drive and
hydraulic motor takes place via a double-link roller
chain.
Left
Right Figure 1

Steer chain
Removal:
- Hammer roll pin (2) flush with the holder
- Loosen bail nut (1) of steer chain

Practical tip: The 19 mm socket should be
milled on the front
- Loosen screw (3) of chain holder

Note: Note direction of holder (4)
Fitting:
- Screw holder with screw (3) Detail drawing, see

Fig. 2 Fig. 1
- Bring steer chain into position
- Tighten bail nut (1), tightening torque 20 Nm
- Turn steering from stop to stop

1
- Check torque
4
2
3
Fig. 2

Brake
Brake
Brake type Oil pressure Duo-Servo- brake with manual adjustment
Brake fluid DOT3/DOT4 MIL-VV-B 680b DIN 4925 (ISO)
Brake lining Beral 1109
Brake diameter 180 x 40
Brake fluid change 1x yearly (see regulations for prevention of accidents)
Note: Only brake linings approved by the

manufacturer should be used.

Brake
Brake
Service brake
The hydraulic service brake is a duo-servo brake which
acts on the running axle. The brake is identical in all
load capacity classes.
1
Repair
Note: Only brake linings approved by the manufacturer
should be used.
Removal
- Bring mast into a vertical position. 1
- Raise fork carriage and secure with check chain (1)
(Fig. 1).
- Jack up truck at the mast (see Group 01, page 01).
- Release hand brake.
- Remove plastic covering on left side wall.
- Loosen nuts (2) on brake cables until brake cables
2
are loose (Fig. 2).
- Remove wheels.
2
- Remove plastic cap (3) on back of axle plate
(Fig. 3).
- Move back brake shoes via gear of manual adjuster
(hole in back of axle plate).
- Remove dust cap.
- Remove bolt M16x35 including washer and thrust
washer.
- Remove brake drum. 2
- Brake parts can be removed.
3
3

Brake
Repair 1
Disassembly (brake shoes, brake cable)

- Remove plate (1).
- Hang out brake cable. 3
- Remove brake shoe retaining springs (2).
- Remove brake shoes including adjuster (4), brake
shoe return spring (5) and pressure member (6). 2
Assembly (brake shoes, cable)

- Fit brake shoes including adjuster(4), brake shoe
return spring (5) and pressure memeber (6) (Fig. 2).
- Position fitted brake shoes on axle plate and fit brake 1
shoe retaining springs (2).
- Fit tension springs (3) in plate (1) and fit plate.
- Hang in brake cable.
Note : The brake shoes of the complete axle must be
replaced.
Fitting
- Fit brake drum.
- Fit bolt M16x35 incl. washer and thrust washer.
- Fit dust cap.
- See adjustments.
- Fit plastic cap on back of axle plate.
- Fit wheels.
- See parking brake adjustment.
2
Adjustments
- Adjust service brake. Adjust brake shoes via gear of
manual adjuster (hole in back of axle plate), so that
brake shoes rest against the brake drum (brake drum
can no longer be turned by hand). Move back 3 1 3 6
readjuster, so that the brake drum can be turned easily
by hand.
Function test after repair

The service brake must be tested after the repair for
proper functioning and an even braking action.
2 4 5 2

Brake
Parking brake
Repair
Prior to adjustment of the parking brake, basic
adjustment of the service brake must be carried out
first.
Note: An even braking action of the service brake is a
basic requirement for perfect adjustment of the parking
brake.
Never adjust the parking brake evenly if the service
brake brakes unevenly.
Adjustments
- Bring handbrake lever into 0 position. 1
- Adjust brake cables at the nuts until a noticeable
clearance of about 0.5 mm is present. The balance
must be located at right angles to the brake cables.
- Set the parking brake lever to the first notch, the 1 3
handbrake switch operates.
- Set the parking brake lever to the second notch, the
brakes start to make contact.
- Set the parking brake lever to the third notch, the
wheels can no longer be turned by hand.
- Set the parking brake lever to the fourth notch, full
braking action.
1 - Balance
3 - Brake cable to handbrake lever
2 - Brake cables to wheel brakes
2 2

Brake
Wheel cylinder 5 4
Replacement
The wheel cylinder(4) is bolted to the axle plate with
2 hexagon bolts M6x25 (5).
Note: When fitting the wheel cylinder, it is important

that the area around the bleeder is sealed with silicone
rubber number 518227.
Brake cylinder
Removal
- Remove plate.
- Remove brake support.
The brake support is fixed with 2 screws and is hooked
into the partition (see Fig.).
- Remove ES bolt.
- Remove brake cylinder.
Fitting
- Fit brake cylinder.
- Fit ES bolt. Grease ES bolt before fitting.
- Fit brake support.
Adjustments
Check or adjust piston clearance (S) on brake
cylinder.
- Loosen lock nut.
- Adjust 1 mm clearance by turning piston rod.
- Fix clevis with lock nut.

Electrical installation
Contents Page

Electrical installation 3
Block diagram 5
Insulation test 6
Control computer control panel 7

Operation in programming mode 8
Menu items password level 1 10
Menu items password level 2 13
Keypad 14
Control computer 15
Controller, compl. 17
Contactor 17
Fuses 17
Pump controller 18
Converter 20
Lock switch 25
Travel sender, 1-pedal 26
Travel sender switch 26
Travel sender, 2-pedal 27
Brake sender 29
Brake fluid switch 30
Parking brake switch 31
Emergency switch 32
Direction switch 33
Hydraulic sensors 34
Horn, horn button 35
Seat contact switch 36
Belt lock switch not yet realised
Steering not yet realised
Steer angle neutral switch not yet realised
Angle of lock transmitter not yet realised
Motor speed sensor see BG 11
Hydraulic motor speed sensor see BG 11
Motor temperature sensor see BG 11
Hydraulic motor temperature sensor see BG 11
Battery not yet described

Battery plug not yet described
Discharge indicator not yet described
Joystick not yet realised

Control electronics Digital control
Drive control Speed-controlled 4-quadrant three-phase converter
Pump control Speed-controlled 1-quadrant direct d.c. converter (DC)
Travel sender Potentiometer 4 kOhm
Brake sender for electrical braking Potentiometer 4 kOhm
Transmitter, hydraulics Electrical displacement sensor
Rated voltage 24 Volt

Current limitation
Motor FM 520 A phase current
Operation against block - gradually after 30 sec to 80A
Regulation on overtemperature:
Motor - linear from 140°C to 0 A
Converter - linear from 85°C to 0 A
Pump motor HM 600 A
Regulation on overtemperature
Pump motor - emergency operation (180 A) from 160°C
Pump controller - linear from 85°C to about 180 A
Speed Settable via drive programs, max. 12.5km/h
Speed reduction Settable via 5 drive programs
STILL contactor 1K 1 2-pole with blowout magnet

— C oi l 12 Volt (connected)
— Contacts/Contact material Interchangeable, silver alloy
Relays K 1, K 2 24 Volt (coil 25 Ohm )
Fuses
— Main fuse 400 A - 2F 2
355 A - 1F 2
— Control fuses 20 A - F4
10 A - F 1, F 2, F 6, F 7
Traction battery G1 24 Volt / 500 Ah (5051)
24 Volt / 700 Ah (5053)
24 Volt / 800 Ah (5044)
24 Volt / 800 Ah (5055)
Insulation resistance
— Electrical installation min 1000 Ohm / Volt — about 24 kOhm
— Electrical machines min 1000 Ohm / Volt — about 24 kOhm
— Traction battery G1 min 1000 Ohm
Electrical degree of protection

— Electrical installation IP 23
— Electrical machines FM IP 54, HM IP 20
— Pump controller IP 23, including cover IP 54
— Converter IP 23, including cover IP 54

The electrical installation includes the components
listed below. All non-standard components are
marked as optional.
Main components
- Control computer
- Pump controller
- Converter
- Main contactor
- Main fuses
- Transmitters/senders, switches, sensors
- Motor FM1
- Pump motor HM
Cowl/footwell:
- Control computer
incl. control panel with display and membrane keys
incl. CAN bus circular connector for diagnostics
- Keypad
- Lock switch (steering column) S1
- Direction switch (mast transmitter) 1S1
- Horn button (floor plate) 4S1
- Travel sender 1B1 Converter Controller, compl.
- Travel sender switch 1S16
- Brake sender 1B2
- Pressure transducer, hydraulics 2B1-2B5
- Relay box, front (optional)
- Distributor board, front (optional)
incl. control fuses F6, F7
incl. relay K1, K2
- Horn 4H1
Motor 1M2
- Temperature sensor 1R17
- Speed sensor 6B17
Pump motor 2M1

- Temperature sensor 2R17
- Speed sensor 6B22
- Brush monitoring unit 2M1S
- Fan (optional)
In counterweight
- Controller,compl. encapsulated in plastic case
Hood
incl. pump controller 2A13
- Parking brake switch 1S3
incl. control fuses F1, F2
- Emergency switch 7S2
incl. ADD-On p.c. board (optional)
- Seat contact switch 7S1
incl. main contactor 1K1
- Belt lock switch (not available) 7S17
incl. main fuse pump controller 2F1
- Seat heating (optional) 9E12
incl. fuse (optional) F4
- Converter 1U06
incl. main fuse converter 1F2
- Steering zero sensor 2B28
- Steering switch 3B29
- Acceleration sensor (optional)

General
The truck has a rear-wheel drive and is driven by a
variable speed asynchronous motor. A 24V converter
supplies the motor.
The hydraulic pump is driven by a 4-pole series-wound
motor. The pump motor is supplied via the pump
controller.
All control systems are interconnected via one CAN
bus circuit with a high transfer rate (250kBaud). The
CAN bus is isolated to the battery ground for all control
systems.
The control computer supplies all front transmitters/
senders and switches with external 10V and evaluates
the signals. Diagnostics
The pump controller supplies the rear transmitters/
senders and switches (optional for steer angle Control computer
detection) with external 12V and evaluates the
signals.
Additional electrical consumers are supplied directly
via the 24V battery voltage. All components of the
additional electrical installation are isolated to the
truck chassis, as the battery is also isolated.
Pump Converter
controller

Control computer Pump controller Converter
Communication Communication
CAN bus 250KB Communication CAN bus 250KB
CAN bus 250KB
Power supply 10V
ext Power supply
12V ext/24V CAN Power supply
2B1
2B2 Hydraulic
2B3 transmitter
2B4
Measuring Measuring
2B5
circuit circuit
10V ext. Pump motor Motor
GND
Workshop manual 5051 - 55
1B1 Travel sender
ã STILL GmbH Position as per: 01/2003 (Replaces version:

Open-phase
10V ext.
protection
GND
U, V, W
1B2 Brake sender
) 5
Power section
10V ext.
GND
Evaluation Steer angle

switch Neutral switch
Steer angle
Distributor board, +10V supply transmitter
GND
not yet realised!
front
d.c. link
SK1_OUT
Precharge d.c.
link
SK2_OUT
Contactor control
ADD-On p.c.
board
Relay box
Block diagram
08
Insulation test
General
An insulation test must generally be carried out prior
to each diagnostic procedure.
Insufficient insulation values can cause undefined
faults in the truck, which cannot be detected through
diagnosis with certainty.
Test arrangement
- Discharge d.c. link, check discharge of d.c. link
- Disconnect battery plug
- Isolate converter from the supply by disconnecting
the power cabling and connector X151.
- Disconnect power cabling, connecting able and
CAN bus connector on the pump controller
- Disconnect SAAB connector X45 and CAN bus
connector on the control computer
- Short-circuit/bridge all temperature sensors
Depending on the truck status, the connecting cables
and/or CAN bus connectors of the following
components must be disconnected
- ADD-On p.c. board
- Mini console
- Relay box
- Distributor board, front
- (Hydraulic controller)
Measurement
Measuring instrument: Metra Hit 16L
- Cable to electrical machines: Measurement to earth
- Traction battery: Voltage measurement from tray
to positive and negative pole
ATTENTION
The temperature sensors must be short-circuited/
bridged.
For the insulation test of the electrical machines, the
instructions in Group 11 must be observed.
Test values
The truck must have an insulation resistance of
minimum 24,000 Ohm (24kOhm). If this value is not
reached, the insulation is inadequate.

Control computer - control panel
General
The control computer is a combination unit consisting
of a control panel and a controller, the actual control
computer.
The control panel consists of a display, two direction 8
lamps and eight unmarked, concealed menbrane 7
keys.
1 2 3
The control computer functions are described
separately. 4 5 6
Display
Indication takes place on the control panel of the Membrane keys
control computer via an LCD display. After switching
on, the message PLEASE WAIT appears on the The membrane keys can only be actuated when the
display until the control is ready for operation. The truck is stationary and the hand brake is applied.
display subsequently changes automatically to For setting handling characteristics and additional
display level 1. functions, reading out error lists and for
parameterisation purposes, the control panel of the
After switching off via the lock switch, the display
control computer has eight unmarked, concealed
and control remain active until the control shuts down
mebrane keyss.
completely after about 50 seconds.
1 Field 1 key
Information and error messages
activates display field 1
In various situations, information and error messages 2 Field 2 key
are shown in plain text on the display. activates display field 2
Information is shown on the display (e.g. HAND 3 Up key (arrow key)
BRAKE, SEAT SWITCH, PLEASE WAIT) and does page up/count, edit
not have to be acknowledged. 4 Field 3 key
activates display field 3
Error messages are displayed cyclic and do not have 5 Field 4 key
to be acknowledged. The display constantly reverts activates display field 4
back to display level 1. Detailed information on error 6 Down key (arrow key)
messages can be found in the error list. page down/count, edit
Display level 1 7 ENTER key
Selection between display levels 1 and 2.
Display level 1 is the standard display for the driver. In programming mode: Confirmation, YES
Changing to display level 2 can only take place when 8 ESCAPE key
the truck is stationary and the hand brake is applied. In programming mode: Cancel, NO
When the hand brake is released, the display
automatically changes to display level 1.
Direction lamps
This means that all displays required by the driver for
truck operation must be displayed on display level 1. The selected direction is indicated via direction lamps
(arrows) in the control computer.
Example display with pressure relief unit variant:
PROG 1 12:47
BATT: 100% 50bar FleetManager
If the truck is provided with FleetManager, the card
holder is arranged at the bottom right of the control
panel of the control computer. The card device is
integrated in the control computer in this variant.

Control computer - operation in programming mode
DISPLAY 1 (5) DISPLAY 2 (6)

PGR
DISPLAY 3 (7) DISPLAY 4 (8)
PGR
General Program keys

The membrane keys can only be actuated when the For confirming or cancelling edited values.
truck is stationary and the hand brake is applied.
PGR ESC (Escape) key for cancelling, NO
When the hand brake is released, the display
automatically changes from the programming mode
to display level 1. PGR ENTER key for confirmation, YES
Membrane keys
For direct selection of display fields Programming mode
Field 1 key The programming mode can be started and ended
by pressing the ESC key and ENTER key
Field 2 key simultaneously.
Field 3 key The display immediately changes to the programming
level 0, the driver level (no password).
Field 4 key
Accessible menu items can be selected by paging
with the Up/Down key.
Arrow keys Active lines or fields are indicated by flashing or
For the selection of menu items and editing highlighted in grey.
parameters, numbers and texts.
Up key for paging up/editing
Down key for paging down/editing

Control computer operation in programming mode
Programming
- The programming mode can be selected by
pressing the ESC key and ENTER key
simultaneously.
DISPLAY 1 DISPLAY 2
- The following appears in the display: DISPLAY 2 DISPLAY 4
PGR
PGR
LANGUAGE GERMAN
- The required menu item can be selected by paging
with the Up/Down key.
- Field 2 can be activated with the Field 2 key.
Activated fields are indicated by flashing.
- Field 2 flashes and can be edited with the Up/Down
key.
Menu items of password level 0 (Driver)
- The edited value can be confirmed with the ENTER
key. LANGUAGE GERMAN TIME 11:17
- When multi-digit values are confirmed, the cursor DATE 23.01.00 DAY-KM 0.0km/T
automatically jumps to the next digit. Each digit DAY-HOUR 0.0h/D PASSWORD LEVEL 1
must be confirmed individually. CODE 0000
- When the procedure is completed, the complete
line flashes after confirmation.
+ Menu items of password level 1 (Fleet Mana-
- Further programming operations can follow. ger)
NOTE BATTERY DISPLAY FIELD 1
Changes are initially effective in the truck control TYPE LEAD PROG 1
system when the truck is switched off by the lock
switch and the electrical installation has shutdown MAX. PROGRAM 5 PROG 1
completely (the display goes blank after about 50 VMAX,V 12.5km/h
seconds). DRIVE HYDRAULIC
Further options are disconnecting the battery plug or MODE 00 LIFT 2400/min
initiating a truck reset in the programming mode.
VERSION A LOAD 0kg
SW1 V0.09
Selecting password levels RESET - PASSWORD LEVEL 1
Higher password levels that allow access to additio- RESET NO NEW CODE XXXX
nal menu items can be selected from the password
level 0.
+ Menu items of password level 2 (Service)
- With Up/Down key to menu item:
PASSWORD LEVEL 1 SERVICE IN 990h
CODE 0000 F-ID 5051001234
- To select the password level, activate Field 2 with ERROR LIST - ERROR LIST -1-
the Field 2 key. ERROR LIST - COUNTER MODE 2
- Edit values with the Up/Down key and confirm with RESET NO
the ENTER key. SERVICE ADDR. A000 PASSWORD LEVEL 2
- To enter the code, activte Field 4 with the Field 4 VALUE ?? NEW CODE XXXX
key.
- Edit values with the Up/Down key and confirm with
the ENTER key.
The display changes to the first menu item of the
selected password level. A truck reset is
unnecessary.

Menu items password level 1
Described in the following are the menu items of pass
word levels 1 and 2 (with Up key).
Battery
BATTERY DISPLAY 2
DISPLAY 1 PGR
TYPE LEAD DISPLAY 2 DISPLAY 4 PGR
The type can be set to the respective battery.
Selection:
LEAD - CSM - GEL - GEL-SO - SPECIAL1 -
SPECIAL2
Display
DISPLAY FIELD 1
PROG 1
The display fields are displayed on two levels. Dis- Drive program setting
play fields 1 to 4 are displayed on level 1 and display PROG 1
fields 5 to 8 on level 2. The fields can be used to VMAX,V 12.5km/h
display various information. Drive programs 1 to 5 can be set for special handling
Selection: characterstics.
PROG1 Drive program Selection:
BATT: Battery bar display VMAX,F 12.5km/h
BATT. 80% Battery per cent display VMAX,R 12.5km/h
00124.6h Hour meter ACCEL,F 50%
12:43 Time ACCEL,R 50%
09.10.02 Date DECEL,F 50%
0.0km/h Speed DECEL,R 50%
012430 Total km indicator REVERS,F 50%
0.0km/D Trip odometer REVERS,R 50%
0.0h/D Hour trip odometer MODE 1
SERVICE IN 990h Hours to service BRAKING DECEL.60%
219 bar Pressure regulator in bar Values for speed, acceleration, deceleration and
II < Steer angle detection reversing, respecitvely forward and reverse, as well
219 psi Pressure regulator in psi as the braking deceleration (electric servobraking)
BLANK No indication, blank field can be set. The mode (drive mode) can also be set
for each drive program.
Number of drive programs
MAXPROGRAM 5 Standard drive program settings
The number of drive programs available to the driver
can be defined by changing the value (from 1 - 5). Drive program 1 2 3 4 5 Range
For example, Value 3: Programs 1, 2 and 3 are Speed
available to the driver. 12,5 12,5 12,5 12,5 12,5 2 - 12,5
km/h
Acceleration
50 60 70 80 90 23-100
in %
Deceleration (5) 15-
50 60 70 70 70
in % 100
Reversing
50 60 70 80 90 15-100
in %
Mode
0 0 0 0 0 0-2
(drive mode)
Braking
deceleration 60 70 80 90 100 25-100
in %

Drive mode
PROG 1
MODE 0
Distinction is made between speed-controlled and
torque-controlled drive mode. Only the speed- DISPLAY 1 DISPLAY 2 PGR
controlled drive mode is currently supported: DISPLAY 2 DISPLAY 4
PGR
MODE 0 Speed-controlled
Max. deceleration range: 15% - 100%
Drive mode selection

DRIVE Hydraulics
MODE 01 HYDRAULICS
This mode serves for configuaration of the travel sender LIFT 2400/min
and travel direction signal. Selectable are the speeds for the individual hydraulic
MODE 0 1-pedal, travel direction in lift lever functions and steering in 1/min.
The hydraulic function to be activated can be selected
MODE 1 1-pedal, travel direction in joystick via the hydraulics mode.
MODE 2 1-pedal, travel direction in mini console LIFT Default without fan: 2400 1/min
MODE 3 1-pedal, direction in mini console and lift power increased with fan: 3200 1/min
lever TILT Default value: 500 1/min
MODE 4 1-pedal, travel direction in mini console Range of values: 300 ... 2550 1/min
and joystick ADD 1 Default value: 500 1/min
MODE 5 2-pedal Range of values: 300 ... 2550 1/min
ADD 2 Default value: 2550 1/min
Range of values: 300 ... 2550 1/min
STEERING Default value: 500 1/min
Range of values: 500 ... 800 1/min
MODE Configuration of hydraulic function.
Functions can be enabled via the hex
value. Several functions can be enabled
by adding the hex values.
01 Lift active
02 Tilt active
04 Additional active 1
08 Additional 2 active
10 Pressure sensor
20 Solenoid valve for lift deactivation
40 Hydraulic controller (joystick)
80 Oil pressure switch for steering
Example: Lift, tilt and pressure sensor

01 + 02 + 10 = 13

Software versions
VERSION A
SW1 V0.03
The hardware (HW) and software (SW) versions of
the various control system (devices) can be read out DISPLAY 1 DISPLAY 2 PGR
via the display of the control computer. DISPLAY 2 DISPLAY 4 PGR
- The device code is shown in Field 2.
- Activate Field 2 and edit the device code from A to
Z with the mit Up key.
- Confirm changes with the ENTER key or cancel
with the ESC key.
- Field 4 shows the version after a short while.
- Activate Field 3 and page through the version types
with the Up key.
- The version selection mode can be left by pressing Load measurement
the ESC key or ENTER key. This function is currently not supported!
LOAD 0kg
NOTE
The load measurement is only suitable in the variant
If a device or version is unknown, V??? is displayed
with FleetManager for statistical evaluations. A load
as the HW or SW version.
weighing device is not realised!
Device codes and read-out options

Truck reset
All devices (collective RESET -
- co d e ) Read-out error lists A and X
RESET NO
SW versions A truck reset is the complete restarting of the
A Control computer
Truck reset electrical installation. The contactor is briefly released
Read-out error list A, reset and all CAN bus users are automatically shutdown
error codes
and restarted.
E Converter
SW versions A truck reset is necessary in order to activate
Error codes via error list A
parameter changes in the control computer.
H Hydraulic controller Option currently unavailable - Activate Field 2 and set the device code to A with
the Up key.
I Joystick Option currently unavailable - Confirm changes with the ENTER key.
Supervisory computer - Activate Field 4 and select YES with the Up key.
J (integral part of control No data currently available - The electrical installation is reset when the ENTER
computer) key is pressed.
SW versions NOTE
K Mini console
Error codes via error list A
A reset of the electrical installation is only possible
L ADD-On p.c. board No data currently available when the device code was set to A.
M Relay box No data currently available

Password change on level 1
P Acceleration sensor SW versions PASSWORD LEVEL 1
SW versions
NEW CODE XXXX
X Pump controller Read-out error list X, reset ATTENTION
error codes
The password can be changed as required on
password level 1.

Service interval
SERVICE IN 990h
F-ID 5051001234
The service interval can be entered on the top line as
required. Max. value 990 hours. DISPLAY 2
DISPLAY 1 PGR
The entered hours count down appropriate to the hour DISPLAY 2 DISPLAY 4 PGR
meter setting. After lapse of the service interval, the
following message is displayed:
SERVICE NECESSARY!
The truck serial number is displayed on the bottom
line:
F-ID 5051001234
Error lists
ERROR LIST - Setting operating hours
In the diagnostic mode, various error lists can be read- VALUE 00013.9h
out. Details are given in the separate error list. SET 00010.0h
The control computer has two independent hour
Hour meter meters. The starting condition for both hour meters
COUNTER MODE 2 is defined via the counter mode.
The starting condition of the hour meter can be defined The operating hours of the control computer are
via the counter mode. displayed on the top line, which are counted up
appropriate to the setting in the counter mode. This
0 Counter counts when lock switch or blinker is value cannot be changed and can only be read-out in
switched on this menu item.
1 Counter counts when lock switch is switched on The operating hours can be changed as required in
2 Counter counts when drive motor or pump motor steps of ten on the bottom line. Only this variable
operational value can be indicated to the driver via the display.
4 Counter counts when driver is seated - Activate Field 4, the first tens digit flashes.
- Edit with the Up key and confirm with the ENTER
Parameterisation via service addresses key.
SERVICE ADDR. A000 - The curser moves to the next digit, repeat
VALUE ?? procedure until all digits have been confirmed.
Truck, lighting and additional electrical installation - When the procedure is completed, the complete
parameters can be chamged via the service bottom line flashes.
addresses. Details are given in Group 09.
Password change on level 2

PASSWORD LEVEL 2
NEW CODE XXXX
ATTENTION
The password can be changed as required on
password level 2.

Keypad
General
The keypad is clipped into the plastic cover on the
left of the steering column and contains three
membrane keys, which depending on the truck status,
are assigned various functions.
Key assignments
Series:
1 Rabbit
Key assignment is defined.
The drive programs can be paged up with overflow
(1-2-3-4-5-1-2-3-4-5) by clicking the key.
2 Searchlight, rear
Key assignment can be changed.
Searchlight, rear on/off. Series
3 Searchlight, front
Key assignment can be changed.
1
Searchlight, front on/off.
Variants:
The keys 2 and 3 can be used for the various truck
status variants. For this purpose, key fields with
appropriate front foil (searchlight, rotating warning
2 3
light, wiper, blinker) must be fitted.
The assignments for keys 2 and 3 must be
parameterised according to the truck status.
Fitting
The keypad is connected to the control computer via RoadTraffic Licensing Regulations Variant
a 5-pole connector.
– X389/1 – XK5 – X45/38
5S6 – X389/2 – X45/14
1S14 – X389/3 – X45/42
Blinker
The blinker system in the variant complying with Road
Traffic Licensing Regulations can be activated via the
“Blinker“ membrane keys on the keypad.
Blinker key – Pump controller – Battery
5S2 – X389/4 – X355/4 – F1 – X352/1.2 – G1(X)

Control computer
Functions
As the Master (main computer) in the truck control
system, the control computer carries out tasks that
are divided into functions.
Display and control functions
- Key evaluation, display
- Menu guidance, display, parameterisation
Error management
- Management of error numbers A (control computer)
- Management of error numbers E (converter)
- If necessary management of error numbers K (mini
console)
Communication Master
- Pump controller
- Converter
- If necessary Add-On p.c. board, mini console, relay
box and distributor card
Main fuse circuit Master
- Contactor control
- Release and lockout of drive and hydraulic drive
Drive
- Control, regulation, monitoring
Hydraulic drive
- Control, regulation, monitoring
Processing of input signals from:
- Travel sender, brake sender and hydraulic
transmitters
- Direction switch
- All switches in the frontal truck area
Monitoring and safety concept
Discharge indicator
Evaluation of additional electrical installation
Processing of FleetManager data (ODA)
Can bus Back-up battery Can bus
Diagnostics, download
Saving of truck parameters
Supply
The control computer is supplied from the pump
controller via the 24V CAN bus voltage.
All external transmitters/senders and switches are
supplied with 10V via the internal power supply (to
chassis).
The back-up battery serves for data storage as well
as for time, date, mileage meter and ODA storage.
The operating hours are permanently written into the
EEProm and are retained even if the back-up battery
is drained.
SAAB connector Chassis grounding
terminal

Control computer
Renewing the controller
If the control computer has to be replaced due to an
irreparable fault on the control computer, the following
should be noted prior to its removal.
The replacement control computer normally does not
contain any data or parameters. The data and
parameters are normally saved through continuous
automatic back-up both in the control computer as
well as in the pump controller. The truck parameters
should be saved on disk as a text file for safety however.
Removing/fitting the control computer

- Park the truck.
- Disconnect battery plug.
- Remove covering on right side
- Loosen both screwed connectors and electrical
connections and renew control computer.
- Refit the covering.
- Connect battery plug.
- Set lock switch S1 to ON.
- The following appears on the display:
PLEASE WAIT
- All parameter information of the pump controller is
transferred to the control computer.
- This is followed by an automatic reset.
- The control computer is now ready for operation.
When fitting control computers already containing a
valid parameter set, the procedure is as follows:
- Set lock switch S1 to ON.
The following message appears on the display:
K EEPROM VALID?
>>are the parameters in the control computer
valid?<<
- As the control computer was renewed and the
parameter set from the pump controller is required,
this question must be answered with NO (ESCAPE
key).
The following message appears on the display:
ARE YOU SURE?
- This question must be answered with YES (ENTER
key).
The data of the pump controller is now transferred
to the control computer without display
- By displaying the truck serial number, a check can
be made so see if the correct parameters were
loaded.
- Set lock switch S1 to OFF.

Controller, compl. – fuses – contactor
Controller, compl.
The controller, compl. is a complete module that
accommodates the following components in a plastic
housing:
- Pump controller 2A13
If necessary with ADD-On p.c. board (see BG09)
- Control fuses F1 and F2
- Main contactor 1K1
- Main fuse 2F1
- Optional fuses F4, F5
A label is provided on the inside of the plastic cover
showing the locations and designations of all
connectors and fuses as well as the tightening torques
of the power terminals.
Contactor 1K1
As the main contactor, contactor 1K1 switches the
power supply for the power electronics. It is located
in the plastic housing on its side and fixed in place
with a stud.
The contactor coil is designed for an operating voltage 1K1
of 12 V and is energised current-controlled.
Technical data
Contactor coil operating voltage 12 V
Coil resistance about 5 Ohm

Connection (parallel) resistor and about 10 Ohm
diode (in series) 1N4001
Tightening torque 10 + 1 Nm
F4
Contact pressure (energised > 9.0 N F5
Seal-in path 1.3 - 2.7 mm
Adjustment: F u ses
- Energise contactor.
- Attach centre of contact to a spring balance and D es. Value Connection
load with 9.0 N. F1 10 A Main fuse upstream of S1
- The contact pressure can be adjusted with the
hexagon bolt running through the contact spring. F2 10 A Horn 4H1
- The pressure can be increased by turning the
hexagon bolt clockwise.
NOTE 24V - additional electrical
The contact spring has a certain friction. The contact F4 20 A installation, distributor board,
pressure is therefore corrrectly adjusted when loaded front, relay box
with a withdrawal force of 10 - 10.5N, when the contact 24V - additional electrical
does not yet close when advanced slowly, but makes F5 20 A installation, ADD-On p.c.
contact and closes when advanced quickly. board, rear
2F 1 400 A Main fuse pump controller

Pump controller
Function
The pump controller has the following truck control
functions:
Precharging of pump controller and converter d.c. link,
before main contactor 1K1 closes in order to supply
power to both control systems.
Main fuse circuit downstream of control computer
- Control of main contactor 1K1
- Control of power supply for complete electrical
installation
- Monitoring of phases U, V, W.
Control of power section of hydraulic drive
Ratings: 24 V – 600 A
Pump controller with ADD-On p.c. board
Power supply
The pump controller is connected to 24V battery
voltage.
The internal power supply delivers two voltages
- 24V (to chassis) for supplying CAN bus
- 12V (to battery ground) for supplying all switches
and transmitters/senders at rear of truck.
Terminal diagram

Pump controller
Behaviour with overtemperature
Overtemperature in the pump controller and pump
motor is signalled directly to the driver in the form of
a plain text message.
Pump controller
OVERHEATING
ERROR X2004
With an integrated temperature sensor, the pump
controller monitors its internal temperature.
From an internal temperature of 85°C, the pump
controller starts to limit its output power, whereby the
current is reduced linearly to 30% (about 180A).
Pump motor
OVERHEATING
ERROR A5034 For fitting pump controllers already containing a valid
The pump controller monitors the signals of the parameter, the procedure is as follows:
temperature sensor integrated in the pump motor. - Set lock switch S1 to ON
From a motor temperature of 160°C, the pump The following message appears on the display:
controller switches to emergency operation, whereby K EEPROM VALID?
the current is limited to about 180A. >>are the parameters in the control computer
After cooling down to 120°C, an enabling signal is valid?<<
generated and emergency operation is reset. - As the pump controller was renewed and the
parameter set from the control computer is required,
this question must be answered with YES (ENTER
Removing/fitting the pump controller key).
- Park truck safely. The following message appears on the display:
- Disconnect battery plug. ARE YOU SURE?
- Discharge d.c. link. - This question must be answered with YES (ENTER
- Remove cover and disconnect all connections and key).
mark if necessary. The data of the control computer is now transferred
- Remove ADD-On p.c. board if necessary to the pump controller without display
- The pump controller may adhere to the - This is followed by an automatic reset.
counterweight due to the heat transfer compound.
- Carefully lever out the pump controller with a NOTE
screwdriver, taking care not to damage the heat The bolt tightening torques must be observed to
sink. ensure optimal heat dissipation.
- Heat transfer compound residues must be removed
completely.
- Prior to fitting, a check must be made to see that
the base plate of the pump controller rests flush
against the heat sink.
- Evenly apply a thin coat of heat transfer compound
to the heat sink.
- Tighten the two M10 bolts with 34Nm.
- Connect all connections, observing the specified
tightening torques (M8 - 9.8Nm)
- Set lock switch S1 to ON
- The following message appears on the control
computer display:
PLEASE WAIT
- All parameter information of the control computer
is transferred to the pump controller.
- The pump controller is now ready for operation.

Converter
Function
The converter has the following truck control functions:
B W V U +
- Motor control and regulation
- Motor speed measurement
1F2
- Motor temperature measurement
Communication with control computer
Ratings: 24 V 550 A
B+
Fuse: 1F2 355 A
Power terminals X151

B : negative battery pole
+ : + positive battery pole LED
B+ : Terminal for fuse 1F2
U : Motor field terminal
V : Motor field terminal
W : Motor field terminal
Pin assignments of connector X151
Pin1 : Lock switch input
Pin2 : Free X151
Pin3 : Speed sensor supply (12V/50mA)
Pin4 : GND for speed sensor/temperature sensor
Pin5 : Speed sensor phase input
Pin6 : Speed sensor phase input
Pin7 : Motor temperature sensor input
Pin8 : Free
Pin 9 : Free
Pin10 : CAN High terminal
Pin11 : CAN Low terminal
Pin12 : CAN terminator
Pin13 : CAN GND

Converter
Converter status
The converter signals its internal status via LED:
B W V U +
LED constantly on:
- Converter operating perfectly
LED off: 1F2
- No supply from battery computer (faulty)
- Converter does not function/faulty
LED flashes:
- Error status
B+
- Converter in inactive status
- An error code is displayed via the console
Behaviour with overtemperature X151

Motor overtemperature is signalled directly to the driver
in the form of a plain text message. LED
Converter
With an integrated temperature sensor, the converter
monitors its internal temperature.
From an internal temperature of 85°C, the converter
starts to continuously reduce its output power,
whereby the current is linearly reduced (from 85°C)
to 0A.
Motor
OVERHEATING
ERROR A5044
The converter monitors the signals of the temperature
sensor integrated in the motor winding.
From a motor temperature of 140°C, the converter
starts to continuously reduce its output power,
whereby the current is linearly reduced (from 140°C)
to 0A.

Converter
Testing internal backup capacitors
Before removing the converter, a test must be carried
B W V U +
out to ensure that the internal backup capacitors are
discharged.
1F2
- Connect a multimeter between + (Batt+) and B
(Batt-).
- With the truck switched off, only a low voltage (<1V)
should be measured.
B+
Activating discharge circuit
- If a voltage is measured that is equal to the battery
voltage (24V), the internal discharge circuit of the X151
converter must be activated.
- Switch on lock switch S1, the multimeter indicates LED
the battery voltage.
- Switch off the lock switch, the internal discharge
circuit automatically discharges the backup NOTE
capacitors. This procedure takes about 1 minute. The bolt tightening torques must be observed to
- When the control computer display is switched off, ensure optimal heat dissipation.
the voltage should reduce to < 5V.
- If this is not the case, switch on the lock switch S1
again until the contactor closes and then disconnect
the battery plug. The voltage will reduce and the
backup capacitors are discharged.
NOTE:
If the discharge circuit cannot be activated, the
capacitor circuit can be discharged with a suitable
discharge resistor (50Ohm/50W) or a 24V lamp. For
this purpose, the discharge resistor, like the
multimeter, must be connected between +(Batt+)
and B (Batt-).
Removing/fitting the converter

- Discharge d.c. link circuit or backup capacitor.
- Disconnect connector X151.
- Loosen power terminals and 4 base plate bolts and
remove the converter.
- Heat transfer compound residues must be removed
completely.
- Prior to fitting, a check must be made to see that
the base plate of the converter rests flush against
the heat sink.
- Evenly apply a thin coat of heat transfer compound
to the heat sink.
- Tighten the 4 base plate bolts and terminals with
34Nm.
- Connect connector X151.

Lock switch
Lock switch S1
The lock switch S1 is arranged on the right-hand
side of the steering column and is operated with a
removable key.
The lock switch S1 serves for locking the truck to
prevent unauthorised use.
The lock switch S1 is used for switching on the control
computer as well as the supply voltage for the horn
and lighting.
The lock switch S1 has two positions:
0 = OFF
1 = ON
These positions are arranged 90° clockwise.
Electrical connections
Battery G1 pump controller lock switch S1:
G1 (+) X352 F1 X355/1 X47/1 S1
Lock switch S1 Pump controller Converter:
S1 X47/2 X350/4 X151/1

Travel sender, 1-pedal
Single-pedal control
The driving speed can be regulated by actuating the
travel sender 1B1 via the pedal.
When the pedal is depressed, the safety switch 1S16
is initially closed and the potentiometer 1B1
subsequently actuated.
The travel sender is mounted on two studs below the
pedal on the right-hand side of the plate. Only the
pedal passes through the plate. The pedal made of
glass fibre reinforced plastic is supported in the
housing on a permanently greased, sealed shaft and
1B1
is held in a neutral position at the lower end with a
tension spring.
Test:
Travel sender voltage unactuated 1S16
yellow X16/4 (–) against red X16/3 (+)
= 4.7 V – 5.3 V
Correction is possible by loosening the screws (1)
and turning the potentiometer.
1B1
Travel sender voltage actuated
yellow X16/4 (–) against red X16/3 (+)
= 8.5 V – 9.5 V
Correction is possible by loosening the screws (2)
and turning the bracket.
X16
Power supply
yellow X16/4 (–) against green X16/8 (+)
= about 10 V 1
Safety switch unactuated
black X16/2 – blue X16/1 – continuity
Safety switch actuated

black X16/2 – green X16/5 – continuity
Removal
- Lift plate on the left side
- Disconnect connector X16 from travel sender 2
- Lift out floor plate
- Loosen Polystopp nuts
- Remove travel sender from floor plate downwards.

Two-pedal control
The direction of travel is determined by two direction-
dependent pedals. The pedals are mechanically
interconnected and move in opposite directions.
Arranged below the bearing bracket is a double-action
potentiometer, integrated into which are two individual,
contra-rotating potentiometers.
Mechnical adjustment of the potentiometer is
unnecessary. The voltage values in a neutral position
and forward and reverse actuation are measured during
necessary calibration. If the values are within the
limits, they are stored as parameters in the EEProm.
If the values exceed the limits, the following error
message is displayed:
TRAVEL SENDER Causes
ERROR A3505 - Parameterisation error, no reset
When the truck control is switched on, the parameters - Calibration operating error
stored in the EEProm are also checked for their - Check parameterisation of travel sender
validity. Operation of the truck is only possible when - Travel sender voltage was not reached
all values are correct. If a parameter should be outside - Potentiometer adjustment error
a limit, the following message is displayed: - Plate mechanically incorrectly adjusted
ADJUST
ERROR A3504 Parameterisation
Calibration When retrofitting a two-pedal control, parameter

address must be adjusted:
It must be ensured that the travel sender is configured
for two-pedal operation, otherwise calibration will not Address A06A Configuration of travel sender
be possible. Calibration is initiated via the control and direction of travel
computer. Value 00 Mode 0 1-pedal, direction of travel only
in lift lever (standard)
Addr. A0F2 to value 03 Value 02 Mode 2 1-pedal, direction of travel only
Press ENTER key of control computer with mini console
The value only initiates calibration once and then Value 03 Mode 3 1-pedal, direction of travel with
automatically resets itself to 00. mini console and lift lever
Actions are indicated by the direction lamps on the Value 05 Mode 5 2-pedal
control computer.
Address A06F Adjustment with mech. wear
There are three states: Value 96 = 300mV (100mV...500mV)
1. Both direction lamps flash –> travel sender pedals Resolution 2mV (Decimal 50...250)
in neutral position.
Address A06E Adjustment with mech. wear
2. Forward direction lamp flashes –> fully depress Value 96 = 300mV (100mV...500mV)
forward pedal and hold until both lamps flash. Resolution 2mV (Decimal 50...250)
3. Reverse direction lamp flashes –> fully depress
reverse pedal and hold until both lamps flash.
When calibration is complete, an error message may
appear on the display
TRAVEL SENDER
ERROR A3505
This may be due to either incorrect operation, the
calibration time being exceeded or the plate being
mechanically incorrectly adjusted.

+ 10V - X16/1
Set value 2 - X16/2
Set value 1 - X16/3
GND - X16/4
Basic adjustment
- Adjust pedals to the same height (about 85mm
above base plate)
- Plug Mark II plus measuring adapter into connector
X16.
- Set lock switch to ON
- Measure voltage at measuring adapter:
Pot 1: X16/3 (+) – X16/4 (–)
Pot 2: X16/2 (+) – X16/4 (–)
- Supply voltage: 9.8 - 10.4V from control
computer power supply
- Pedals in neutral position, potentiometer in
neutral position: Voltage: 4.5 - 5.5 V per
potentiometer.
- Forward pedal, fully depressed:
X16/3 (+) – X16/4 (–), voltage 7.0 - 9.0 V
X16/2 (+) – X16/4 (–), voltage 1,0 - 3,0V
- Reverse pedal, fully depressed:
X16/3 (+) – X16/4 (–), voltage 1.0 - 3.0 V
X16/2 (+) – X16/4 (–), voltage 7.0 - 9.0 V
The difference in voltage at Pot 1 between the neutral
position and with the forward or reverse pedal fully
depressed must be minimum 2.5V.
That means that when the forward pedal is fully
depressed, the voltage must be minimum 2.5V high-
er than in the neutral position (e.g. neutral 5.2V +
2.5V = 7.7V or higher).
When the reverse pedal is fully depressed, the voltage
must be minimum 2.5V lower than in the neutral
position (e.g. neutral 5.2V - 2.5V = 2.7V or lower).
Adjustment of neutral position

The pedals can be positioned by moving the plates
Item 1. Adjust the plates so that they are congruent
to ensure that the forward pedal is backlash-free in
the neutral position. The reverse pedal always has
backlash in upward direction.
Forward/reverse adjustment
Forward adjustment can take place after adjusting
the screw V.
Reverse adjustment can take place after adjusting
the screw R.

Brake sender
Brake sender 1B2
The brake sender 1B2 is screwed to the inside of the
bearing bracket with two screws via a plate. The
sender is a pedal-actuated potentiometer.
+10 Volt – X45/39 – 1B2/3 green
Sollwert – X45/41 – 1B2/2 red
GND – X45/40 – 1B2/1 yellow
Testing the brake sender
- Plug Mark II plus measuring adapter into connector
1B2.
- Connect a digital multimeter to the measuring
adapter: 1B2/2 (+) – 1B2/1 (–)
- Brake pedal unactuated:
In a neutral position, the value is between 1 – 4 V.
- Brake pedal actuated:
When the brake pedal is actuated, the sender
voltage continuously increases.
- At a sender voltage below 0.3 V and above 9 V, an
error is set; the control computer detects a
deviation.
Adjusting the brake sender

Lightly pretighten potentiometer 1B2 when fitting to
the bearing bracket, so that the given neutral position
voltage (1-4 V) is reached.
For fine potentiometer adjustment (sender
adjustment), calibration must be carried out.
Calibration
When the sender has been replaced, it must be
calibrated. The value only initiates this action and is
not stored in the EEProm.
Addr. A0F2 Value 02 Calibrate sender
When calibration is complete, an error message may
appear on the console display.
This may be due either to incorrect operation, the
calibration time being exceeded or the value of the
brake sender neutural position being outside the valid
range.

Brake fluid switch
Brake fluid switch 6S4
The brake fluid switch is attached to the left side of
the front cover plate.
The switch 6S4 is a normally-open contact that causes
an error message to be displayed if the level is too
low.
SERVICE BRAKE
ERROR A3035
As a reaction to the error message, the speed is
reduced to 5km/h. This restriction can be only be
lifted via a truck reset.
– X45/30 – 6S4/3
– X45/31 – 6S4/4

Parking brake
Parking brake switch 1S3
The parking brake switch 1S3 is arranged below the
parking brake lever in the hood.
When the parking brake is not applied. the switch is
closed. When the parking brake is applied, te switch
is opened and the drive is switched off.
The parking brake can be adjusted by loosening the
bolts and moving holder.
The parking brake switch S3 is directly directly
connected to the control computer.
1S3/1 – X45/28
1S3/2 – X45/29
NOTE
When the parking brake is applied, the drive is
switched off.
If the truck is parked on a ramp, the parking brake
must be firmly applied.
If the parking brake is not firmly applied, the truck
can roll, as the electrical braking system is non-
functional.
ã STILL GmbH Position as per 01/2003 (Replaces version: ) 31

Emergency switch
Emergency switch 7S2
- The emergency switch is a red mushroom button
that is located on the right between the seat and
parking brake.
- All truck functions are deactivated when this switch
is actuated.
- Reactivation takes place by lifting the button.
- When the emergency switch is actuated, a
message is displayed when the pedal is depressed
after selecting a direction of travel.
G1 (+) – X352 – F1 – X354/1 – 7S2
7S2 – X28 – X352 – 1K1

Direction switch
Direction switch 1S1
In the standard truck version, the direction switch 1S1
is integrated into the Lift hydraulic lever and is
thumb-actuated via a rocker switch.
The direction selection options are parameterisable.
Only the direction variant via mini console is currently
available.
Parameterisation
Address A06A Configuration of travel sender and
direction of travel
Value 00 Mode 0 1-pedal, direction only in lift lever
(standard)
Value 02 Mode 2 1-pedal, direction only on mini
console
Value 03 Mode 3 1-pedal, direction only on mini
console and lift lever
Value 05 Mode 5 2-pedal
Rocker switch operation

Forward: Press top half of rocker switch
Reverse: Press bottom half of rocker
switch
Neutral position: Press top or bottom half of rocker
switch
After the drivers seat being left, the direction
automatically changes to the neutral position after
10 seconds. Time preselection is parameterisable.
Address A06D Value 05 (Default 10 seconds)
Range 0 - 300 seconds
X45/23 X23/4
X45/24 X23/2
X45/25 X23/3
X45/26 X23/1

Hydraulic sensors
Hydraulic sensors 2B1 – 4
The hydraulic sensors select the hydraulic motor
speeds for the operation of hydraulic components. 2B1
The following sensors are available: 2B2
- 2B1 Lift sensor 2B3
- 2B2 Tilt sensor
- 2B3 Sensor additional hydraulics 1 (optional)
2B4
- 2B4 Sensor additional hydraulics 2 (optional)
These sensors are displacement sensors, whose
output voltage varies proportional to the control rod
stroke. Electrical connection of the sensor currently
takes place via a 3-pole bayonet connector of Messrs
Schlemmer.
Pin 1: +10 V
Pin 2: Speed
Pin 3: GND
The sensors are connected to the control computer
via the connector X45.
Testing the sensors

- Plug SAAB adapter into connector X45 on control 2
3
computer
- Set lock switch to ON 1
- Connect digital multimeter to measuring adapter
as shown in table and check voltage.
Attention: Observe mast movements!
Calibration
S en so r Measuring Voltage in Volt
points Following the replacement of one or several sensors,
these should be calibrated.
Lever Lever
P os Neg Addr. A0F2 Valuet 03 Calibrate sensors
b a ck forward
Lift 2B 1 1 3 The value only initiates the action and is not stored
in the EEProm.
Tilt 2B 2 1 3
7.5 2.5
A dd 1 2B 3 1 3
A dd 2 2B 4 1 3
Function/Adjustment/Replacement
A detailed description is given under Group 10.

Worshop manual 5051 - 55 08
Horn, horn button
Horn button 4S1
The horn button is fitted in the floor plate in the front
on the left-hand side.
4S1 – X16/7 – 4H1 – X356/1 – F2
4S1 – X16/6 – X356/2 – G1 (–)
The horn button can be levered out of the floor plate

with the aid of a screwdriver. The connecting cable to
the horn button can subsequently be disconnected
or connected.
Horn 4H1
The horn is an acoustic warning device that enables
the driver to warn other persons of a dangerous
situation.
The horn is therefore part of the safety equipment
and must be fully operational at all times.
The horn is mounted in the centre of the running axle
in the direction of travel.

Seat contact switch
Seat contact switch 7S1
The seat contact switch is a mechanical switch that
is located under the seat cushion. It already switches
when light load is exerted.
When the driver sits on the seat, the seat contact
switch 7S1 is closed and the drive is enabled by the
control computer.
The seat contact switch 7S1 is directly connected to
the control computer.
7S1/3 – XXK5 – X45/38
7S1/4 – X45/37
ATTENTION
The seat contact switch is a safety device and must
not be overridden. The drive is switched off when the
seat is not used.
Removing the seat contact switch

muss noch geprüft werden!
- Disconnect the connector under the battery hood
and remove the seat.
- Cut off the holder for the previous cabling.
- Screw the mechanical switch to the seat scissor
mechanism. The switch must be adjusted with the
seat unloaded, so that the control lever still has a
travel of about 2-3mm.
- Place the seat on the four mounting bolts and set
the weight adjuster to the lowest weight.
- Load the seat with about 40 kg and then relieve.
When the seat is loaded, the switch must be closed
(continuity).

Additional electrical installation
Contents Page
Arrangement of additional electrical installation 2

CAN bus connections 3
Mini console 4
Keypad 5
ADD-On p.c. board 6
Distributor board, front 7
Relay board 8
FleetManager not yet realised

FleetManager keys
Emergency Stop with FleetManager
Acceleration sensor
Parameterisation 12

Arrangement of additional electrical installation
Arrangement of additional electrical installation Variants

Electrical consumers such as searchlights, wipers, There are three different status variants for the lighting
seat heating, lighting, etc., are supplied via the and additional electrical installation. The standard
following components: keypad must be replaced by a variant keypad,
dependig on the truck status.
- Distributor board, front with relays K1 and K2
- ADD-On p.c. board on pump controller Status A
- Mini console No optional components:
- Relay board - Signal transmitter
Consumers with 24V operating voltage can be directly Distributor board, front with relays K1 and K2:
used. - Signal transmitter, front searchlight, wiper
- Signal transmitter, front searchlight, 5th hydraulic
Activation of the electrical consumers takes place
function
via membrane keys in the keypad and mini console
and/or via switches/sensors in the electrical Status B
installation. ADD-On p.c. board:
- Rear searchlight, flashing warning light, brake light
The relay board is controlled by the control computer
via the CAN bus. The cabling for the distributor board ADD-On p.c. board, distributor board, front:
and relay board is pre-installed in the truck. Only the - Rear searchlight, flashing warning light, brake light
cabling needs to be installed for retrofitting. and
- Wiper, washer, front searchlight
Mini console, ADD-On p.c. board, distributor board,
front:
- Rear searchlight, flashing warning light, brake light
and
- Wiper, washer, front searchlight and
- Seat heating, rear lighting
Status C
Mini console, ADD-On p.c. board, relay board:
- Standard lighting
- Lighting for road use

CAN bus connections
Diagnostics Diagnostics
Control Control
computer computer
Hydraulic
controller
Joystick
Pump Converter Pump Converter

controller controller
Distributor board, Distributor board,

Mini Relay box front Min Relay box front
console console
Diagnostics Diagnostics
Control Control
computer computer
Hydraulic
Acceleration sensor Acceleration sensor
controller
Joystick
Pump Converter Pump Converter

converter converter
ADD-On p.c. board ADD-On p.c. board
CAN bus circular connector

CAN bus single cable terminal
free CAN bus connector (for diagnostics)
possibly CAN bus tee unit or extension (not yet clarified)

Mini console
Mini console
Retrofitting and conversion as well as removal and
fitting to be clarified.
Key assignments
For switching on the additional electrical consumers,
the mini console has six membrane keys on the right.
1 Parking light, headlamp
1st actuation: Parking light ON
2nd actuation: Headlamp ON
3rd actuation: OFF
2 Wiper, washer
1st actuation: Intermittent ON
2nd actuation: Continuous ON
3rd actuation: OFF 1
Prolonged actuation: Washer ON with return to
previous status. 2
3 Front searchlight
Searchlight ON/OFFs 3
4 Rear searchlight
Searchlight ON/OFF
5 Warning flashing light 4
Warning flashing light ON/OFF 5
6 Seat heating
Seat heating ON/OFF 6

Keypad
General
The keypad is clipped into the plastic cover on the
left of the steering column and contains three
membrane keys that are assigned various functions,
depending on the truck status.
Key assignments
1 Rabbit
Key assignment is defined and identical on all
variants.
For paging up through drive programs (1-2-3-4-5-1-
2-3-..).
2 Rear searchlight
Rear searchlight ON/OFF.
3 Front searchlight
Front searchlight ON/OFF.
1
4 Front or rear searchlight
Front or rear searchlight ON/OFF
5 Warning flashing light
Warning flashing light ON/OFF Status A, B
6 Wiper, washer
1st actuation: Intermittent ON
2nd actuation: Continuous ON 2 3
3rd actuation: OFF
7 Function key
For special function (only in status C)
8 Blinker
Blinker system ON/OFF Status B
4 5
Parameterisation
Parameterisation of key assignments 2 to 8 takes
place via reserve switch 5 (X45/14) and reserve switch
6 (X45/42) of the control computer. Status A
6 5
Status B
6 4
Status C
7 8

Hydraulic system
Contents Page
Hydraulic system - block diagram/function 3
Control valve block - layout 4
Control valve block - diagram/function 5
Control valve block - pressure regulator/function 6
Control valve block - removal 7
Control valve block - tilt cross-section reducer 8
Hydraulic pump - function 9
Hydraulic pump - removal and fitting 10
Hydraulic tank - oil change/breather filter 11
Air filter 12
Hydraulic unions - installation 13 - 15
Safety checks 16
Speeds 17
Hydraulic diagram - schematic 18
Hydraulic diagram - legend 19

Hydraulic pump
Delivery capacity 11 cm3
per revolution
Direction of rotation Anticlockwise
Bolt tightening torque Intake flange and priority valve = 12Nm

Hydraulic pump = 56 +4 Nm
Pump speeds
Lift 2400 1/min
Tilt 500 1/min

Steering 500 1/min
Additional hydraulics (see also BG 1st add. hydr. = 500 1/min 2nd add. hydr. = 2550 1/min
13)
Control valve block
Relief valve Setting = 230 ± 5 bar

Setting range = 60 to 280 bar
Bolt tightening torque 20 Nm
up to rated lift 3500 mm = 1.0 mm ø (in connection A)

Tilt cross-section reducers
up to rated lift 5000 mm = 0.9 mm ø (in connections A + B)
Load holding valve Forward tilt = 125 bar
Backward tilt = 25 bar (from rated lift 5000 mm)
Air filter
Filterfeinheit 20 µ absolute
Ansprechdruck - Bypassventil 0.25 ± 0.05 bar
Hydrauliktank
Capacity about 20 litres
Hydraulic oil ( OZ ) Quality according to DIN 51524/Part 2 HLP and ISO VG 46

HM
Breather filter - filter fineness 7µ
S p eed s
Lifting with rated load 5051 5053 5054 5055
Tele 0.26 m/sec. 0.26 m/sec. 0.26 m/sec. 0.26 m/sec.
Niho 0.24 m/sec. 0.24 m/sec. 0.24 m/sec. 0.24 m/sec.
Triple 0.24 m/sec. 0.24 m/sec. 0.24 m/sec. 0.24 m/sec.

up to rated lift 3500 mm = min. 0.21 / max. 0.33 sec. / per degree
Tilting with rated load (forward tilt) up to rated lift 5000 mm = min. 0.33 / max. 0.55 sec. / per degree
above rated lift 5000 mm = min. 0.55 / max. 0.87 sec. / per degree
Lowering with rated load = 0.48 m / sec - without load = 0.52 m /sec

Hydraulic system - block diagram/function
1 2
10
3
9
7
6 5
Control valve block (1) contains the following
The hydraulic oil drawn out of the tank (3) by the
functional components:
gear pump (8) via the filter (4) flows into a priority
valve (7) flanged on to the pump.
- A lowering brake limits the lowering speed when
Here, the oil required for the steering flows via
lowering the load.
connection -CF- to the steering unit (6), connection
-P-.
- A relief valve protects the hydraulic system against
An oil volume proportionate to steering operation flows
overloads.
to the steer motor (5) via connections -L- and -R-.
The oil not required for the steering flows back into
- Load holding valves in the tilt control valve prevent
the tank (3) via connection -T-.
independent tilting of the load.
The residual oil flows via connection - EF - of the
priority valve to the control valve block (1), connection
- A controllable relief valve in the control valve of
- P -.
the additional hydraulics protects attachements
With only slight actuation (displacement) of a valve
and loads.
rod, the oil flows with low circulation pressure through
the control valve block from connection -R- back into
the tank.
On further actuation, an oil volume proportionate to
Attention
the displacement of the valve rod flows from In the interest of safety, before carrying out
connection - H - to the lift cylinders (2) and from any work on the hydraulic system, the fork
connections - A- and - B - to the tilt cylinder (9) and carriage must be fully lowered, the mast
to an attachment (10) in the additional hydraulics. tilted fully forward and the battery plug
disconnected.

Control valve block - layout
III II I
1
2
3
13 B B B H 4
14 P 5
6
13 A A
12 M1
A M
R 7
11
8
9
10
Layout The way valve (III) for the additional hydraulics is
simultaneously designed as a plate.
I. Control valve block - lift/tilt Where only one additional hydraulics is used with
II. Way valve - 1st additional hydraulics the control valve block, the way valve (II) is replaced
III. Way valve - 2nd additional hydraulics by the way valve (III).
1. Valve rod
2. Connection B - (forward tilt) As a variant, the way valve (III) can be used with a
3. Connection A - (backward tilt) variable pressure regulator in the first or second addi-
4. Connection H - (lift/lower) tional hydraulics.
5. Connection P - (pump line)
6. Measuring connection The pressures of all consumers can be measured
7. Connection R - (tank return) with a pressure gauge at measuring connection (6).
8. Main relief valve In the case of the variant way valve (III) with one
9. Lowering brake variable pressure regulator, the adjusted pressure
10.Displacement sensor can be measured at connection B via measuring
11. Load holding valve - (forward tilt) connection (12).
12.Measuring connection - (additional hydr. valve) NOTE
13.Bolts - Repairs to the control valve block must be carried
14.Connections - (1st + 2nd additional hydraulics) out with particular care, as fouling and damage to
sealing surfaces can give rise to malfunctions and
The control valve block (I) contains the valve rod (1) leaks.
for the lift and tilt hydraulics. - The valve rods (1) must not be turned or twisted.
Relief valve (8)
If no further way valves are provided for additional Setting : 230 bar
hydraulics, a plate is fitted to this block downstream Setting range : 60 to 280 bar
of the tilt valve rod. ATTENTION
The setting of 230 bar must not be exceeded.
The way valves (II) and (III) of the additional hydraulics Tightening torque Item 13 = 20 Nm
are basically identical in terms of function and design.

Control valve block - diagram/function
III II I
2 3
A M1 B A B A B H M
9 8 7 6 5 10
Way valve I : back into the tank via the return port R.
P = Connection - pump line
R = Connection - return line/tank The idle port is closed with increasing valve
H = Connection - lift cylinder displacement and the oil flows via the pump port P
A = Connection - backward tilt to the consumers. When a consumer reaches its
B = Connection - forward tilt maximum limit, the relief valve (4) opens when its
M = Connection - pressure gauge set final pressure is exceeded in the pump port. The
Way valve II : oil flows via the return R into the tank.
A+B = Connection - additional hydraulics
Way valve III : Relief valve (1)
A+B = Connection - additional hydraulics Relief valve for connection B.
M1 = Connection - pressure gauge Setting range: 20 to 200 bar.
1. Relief valve Load holding valve (2)

2. Load holding valve - forward tilt Prevents the load tilting forward independently.
3. Check valve Setting range: 125 bar.
4. Main relief valve
5. Displacement sensor Check valves (3)
6. Valve rod Prevents oil from consumers flowing back into the
7. Lowering brake pump port.
8. Idle port
9. Flow restrictor Displacement sensors (5)
10. Pump port Select the pump motor speeds proportional to the
Function valve rod displacement.
When a valve rod (6) is actuated, the pump motor
speed and in turn the delivery capacity of the hydraulic Lowering brake (7)
pump are controlled proportional to the valve rod Limits the load lowering speed.
displacement via the displacement sensor (5).
Flow restrictor (9)
With only minimal valve rod displacement, the oil Restricts the oil flow for tilting to 15 litres per minute.
entering P flows via the idle port (8) through the way
valve to the plate or end valve and from there

Control valve block - pressure regulator/function
1. Way valve with relief valve
2. Relief valve
3. Wing lock nut
4. Adjusting screw
5. Bolts 4
6. Displacement sensor 3
Function 2
For protection of the attachment and goods being
transported, a way valve (1) with manually controllable 5 1
relief valve (2) can be used in the control valve block,
e.g. when using a clamp function.
The pressure in connection B of the additional

hydraulics can be increased or reduced by tightening
or loosening the adjusting screw (4).
Setting range: 20 to 200 bar
6
ATTENTION
For this setting, the specifications of the manufacturer
relating to the maximum pressure load of the
attachment must be observed (see identification plate
of attachment).
The final pressure set at the relief valve is indicated

on the console display when a consumer reaches its
maximum limit.
NOTE
A falling pressure indication, e.g. after clamping a
load and the valve rod assuming a neutral position, is
caused by leakage oil at the valve rod and is not a
pressure drop at the attachment, as the attachment
must be fitted with a stop valve for the load holding
function.

Control valve block - removal
Arrangement
1. Valve support 2. Control valve block 9

3. Rubber pad 4. Lever
5. Pin 6. Balancer
7. Axle 8. Bolt
9. Direction switch connector
7 4
10.Way valve fixing bolts
11. Displacement sensor connector
12.Valve lever
- The valve support (1) is flexibly attached to the

chassis partition with three rubber pads (3).
1 2
- The balancer (6) is arranged rotatable on the valve
support.
- The axle (7) for receiving the lever (4) is pressed
11
into the balancer.
The balancer, axle and lever can therefore only
be replaced as a complete unit. The trucks are
generally provided with four levers for retrofitting ad-
ditional hydraulics if required.
- Appropriate to the functions, there are various control
symbols on the upper side of the valve lever (12). 6
- A direction switch is also arranged on the side of
the -Lift- valve lever. 5 12
Removal 4 7
- Tilt mast fully forward, lower fork carriage completely
and disconnect battery plug. 3 8
2
- Remove plate.
1
- Unscrew covering.
- Disconnect connector (9).

3 3
- Disconnect all (11) displacement sensor connectors
- Disconnect all hydraulic connections.
- Unscrew three valve support fixing bolts at Item 3

and remove complete valve support
- Remove all bolts (8) between the valve rods and levers
(4)
- Separate control valve block from valve support by

loosening the three bolts (10)
10
NOTE
The valve rods of the control valve block must not be
turned or twisted.
3

Control valve block - tilt cross-section reducer
Tilt cross-section reducer
2
1. Union with cross-section reducer bore
2. Cross-section reducer mark (notch)

1
For dosing the oil flow and in the event of malfunction
of the pump motor control (excessive pump motor
speed) and to counteract an excessively rapid tilting
motion of the mast, the following cross-section reducer
unions (1) are used in the tilt way valve connections,
independent of the rated mast lift.
Up to rated lift 3500 mm in connection A = 1.0 mm Æ
Up to rated lift 5000 mm in connection A = 0.9 mm Æ

in connection B = 0.9 mm Æ
Union tightenting torque: 66 Nm B P H

NOTE
The installation of a cross-section reducer union (1) A R
is recognisable by the outer notch (2) on the hexagon.
ATTENTION
When replacing the mast, a check must be made to
ascertain which cross-section reducer unions are to
be used depending on the rated mast lift.

Hydraulic pump - function
LS
CF
EF
1 2 3 4 5 6 7
Technical data
Type : Gear pump (6)
Delivery capacity : 11 cm3/per revolution
Direction of rotation : Anticlockwise
Drive : Pump motor (1) via armature 9
shaft journal (2) and catch (3)
Sealing : Via radial seal in pump motor
and O-ring (4)
Function
Via the pump (6), the hydraulic oil is drawn out of the
tank via the air filter (8) and pipe (7) under pressure
and pumped directly into a priority valve (5) flanged
on to the pump.
Via the connection -EF- of the priority valve, the way

6
valve (9) and in turn the lift/tilt and additional hydraulics 8
are supplied with oil. 7
5 LS
Via the connection -CF- of the priority valve, the hand
pump (10) of the steering is supplied with oil. EF CF
10

Hydraulic pump - removal and fitting
Removal
- Disconnect battery plug and remove plate
- Unscrew all hydraulic connections from priority valve
(5).
- Disconnect air intake (7) from air filter cover.
- Unscrew two pump fixing bolts (12).
- Remove pump (6) flanged on priority valve
(5) and remove air intake (7).
- Separate priority valve and air intake hose from pump.
LS
CF
EF
NOTE
Access to the pump is improved if the mast is exten-
ded and secured against unintentional lowering with
a chain placed across the cross members of the inner
and outer mast (see Group 01).
After fitting the chain, lower the inner mast until the 1 2 3 4 5 6 7
chain makes contact.
Fitting
- Complete new pump with new, greased seals
(8 + 10), priority valve and air intake (7).
- Position catch (3) on pump shaft journal.
- Grease O-ring (4) on pump neck.
- Place pump in pump motor (1) so that shaft journal
(2) of motor armature engages in catch (3).
- Fix pump to motor with two bolts (12).
- Connect all hydraulic connections at priority valve.
- Fill air intake (7) with oil and clamp in place on air
filter cover.
- Bleed air intake (7) by operating the steering.
- Compensate oil loss.
Tightening torques: Item 9 + 11 = 10 Nm

12
Item 12 = 56 + 4 Nm
11
NOTE
In the event of pump noise, foaming of the oil in the
tank or delayed consumer movement, the following
parts must be checked for leaks, i.e. air supply:
- Radial seal in pump motor.
5
- O-ring Item 8. 10
- Connection points of air intake hose (7) on pump
flange or filter cover.
8
7
9
12
Hydraulic tank - oil change/breather filter
The hydraulic tank (1) is a welded construction and
is integrated transversely into the chassis in front of 1
the battery compartment.
2
The return tubes (4) and (5) are fixed to the tank with
cover (3) and bolt (2).
Sealing takes place with O-rings (6).
1. Breather filter with dipstick 3

2. Cover fixing bolt (3)
3. Cover
4. Return tube - control valve block 4
5. Return tube - steering unit
6. O-rings 5
7. Hydraulic tank
8. Air intake hose - pump
9. Air filter
6
10. Oil drain plug
7
Tightening torque for Item 2 = 10 Nm
8
Hydraulic oil change 9
Every 3000 operating hours (however, minimum every
2 years)
- Park truck on a level surface
- Tilt mast fully back
- Fully lower fork carriage
- Disconnect battery plug
- Remove plate
- Unscrew breather filter (1) 10
- Unscrew drain plug (10) and collect oil in a collecting
container.
- Fit drain plug and tighten.
- Fill new hydraulic oil via breather filter opening.
- Check level
With the breather filter fully tightened, the oil level
must reach the mark (arrow) on the dipstick.
Capacity: 20 litres
2
(Total capacity of hydraulic system)
Hydraulic oil ( OZ )
Quality according to DIN 51524, part 2/HLP
ISO VG 46 H
Breather filter 1
The breather filter (1) with a filter fineness of 7µ
prevents dust and dirt entering the hydraulic tank.
The breather filter must be replaced every 3000

operating hours.

Air filter
Type: Air filter with glass fibre filter cartridge,
bypass valve and protective screen.
Filter cartridge (3) : Filter fineness = 20 µ (absolu-
te)
Bypass valve (1) : Operating pressure: 0.25 ± 0.05 bar
Protective screen (2) : Filter fineness = 200 µ
Function
1. Bypass valve
2. Protective screen
3. Filter cartridge
4. Seal
5. Air intake to pump
6. O-ring
7. Filter cover
8. 4 nuts
9. Tank plate
10. Pipe
11. Notch
The oil drawn out of the tank by the hydraulic pump

flows through the filter cartridge (3) from the outside
to the inside. .
For the protection of the hydraulic pump, the bypass
valve (1) opens at a low pressure of 0.25 ± 0.05 bar
(filter cartridge clogged) and allows the oil to flow via
a protective screen (2).
The insertion depth of the filter cartridge (3) is limited
by notches (11) in the pipe.
Replacing filter cartridge (3)

- Loosen four nuts (8).
- Lift cover (7) with filter cartridge (3).
- Remove filter cartridge from cover.
- Renew seal (4) on pipe (10).
- Fit new filter cartridge in pipe.
- Fit cover (7) and fix in place with nuts (8).
Tightening torque Item 8: 9.8 Nm 8 7
NOTE: Do not clean filter cartridges. Replace if
clogged.
Maintenance intervals
3
Replace filter cartridge (3) every 3000 operating hours 4
(however, minimum every 2 years).
NOTE
If there are no or jerky consumer movements, loud 10
pump noise or foaming oil, the seal Item 4 and the
connection between the filter cover (7) and air intake
hose must be checked for an air supply.

Hydraulic unions - fitting
Tilt cylinder unions
For sealing in the cylinder barrel at the thread (arrow),

the threaded pipes are plastic covered.
Fitting:
After positioning the union in the cylinder barrel (max
1 full turn), the following screwing depths should be
observed:
minimum = 4 full turns
maximum = 5 full turns
NOTE
The union must be correctly positioned while being
screwed in place. Any unscrewing of the union during
or after screwing will result in leaks.
In case of leaks, the union should not be screwed in
further, but renewed.
Cone unions with O-ring (DKO)
After tightening (noticeable resistance), the union nuts

of these unions must be finally tightened maximum
half a turn (180 °).
Excessive tightening can result in deformations and
leaks.
180 o

Pipe union with soft seal (EO2)
1 2
The previous antifriction collar pipe unions have been
replaced by a new, improved sealing union system
with soft seal.
3
The new unions consist of:
1. Function nut (union nut)

4
2. Seal
3. Retaining ring (antifriction collar)
5
Pipes (4) and threaded pipes (5) correspond to the
old antifriction collar pipe union.
Fitting
Saw pipe at right angles
Deburr pipe on inside and outside
ATTENTION
Burr on the outer diameter of the pipe can damage
the seal (2).
Tighten function nut (1) with retaining ring (3) and seal
(2) hand-tight on the threaded pipe. 1
Insert pipe end into the union and press against the
stop in the inner cone.
ATTENTION
The pipe must be fully inserted into the union.
Tighten function nut (1) until a distinct increase in

force is noticeable (about 1 to 1 1/2 full turns).
For this purpose, a mark (6) should be made on the 1

pipe and function nut.

Check
After fitting, loosen the function nut (1) and check

whether the gap between the seal (2) and retaining
ring (3) is closed.
2 3 1
Repeat fitting
Each time the function nut (1) is loosened, repeat

fitting must take place with the same torque as initial
fitting. 1
The threaded pipes (7) must be countered.
1
Replacing the seal 3
2
In the event of union leaks, the seal (2) can be
removed from the free pipe end and replaced.
ã STILL GmbH Psoition as per: 08/2002 (Replaces version: ) 15

Safety checks
Check for independent load forward tilt:
- Take up the rated load and lift.
- Park truck on a level surface and place the mast

vertical.
- Attach an angle measuring device (spirit level) (1)

to the mast (2).
- Set switch key to the O position and check whether

1
tilt valve rod of way valve is in the neutral position.
NOTE
According to the regulations for prevention of
accidents, the mast must now not move forward more
than 0.5 degress per minute.
Check for independent load lowering:
- Lift rated load about 0.5 m
- After about 2 minutes, mark the fork carriage and

outer mast
2
- After about 10 minutes, measure the lowering
distance
NOTE 1
According to the regulations for prevention of
accidents, the permissible, independent load lowering
rate can be maximum 100 mm in 10 minutes.
Checking hose lines:
All hose lines must be checked minimum once

annually and replaced if they have the following faults:
- Damage to the outer layer up to the insert (wire 2

fabric), see Figures 1 and 2.
- Leaky points.
- Incorrect connection at the fitting with bubble

formation, see Figure 3.
- Damage or corrosion to the fitting with noticeable

reduction in the strength of the fitting/hose line.
3
- Stiffeness or brittleness of the outer layer with
cracking.
- Deformations such as kinked and crushed points

or torsion.

Speeds
The trucks are delivered with the following working
speeds, measured with rated load:
Lifting:
5051 - 55
Tele 0.26 m/sec.
Niho / Triple 0.24 m/sec.
( Tolerance ± 12 % )
NOTE
For the Niho and triple masts, the mean from the
measured speeds in Lift I and Lift II is decisive.
Lowering: with load = 0.48 m/sec

without load = 0.52 m/sec
ATTENTION
0.60 m / sec. must not be exceeded!
Tilting:
Tilting speed w ith load

(forw ard tilt)
Tilting angle
Nennhub - h3
seconds per
above up to
degree
min. about 0.21
3500
max. about 0.33
min. about 0.33
3500 - 5000
max. about 0.55
min. about 0.55
5000
max. about 0.87
Tilting time = tilting speed x tilting angle
Measurement must be made over the entire tilting

range.
NOTE
Trucks with special status can produce deviating
values.

Hydraulic diagram

Hydraulic diagram
1. Hydraulic pump
2. Priority valve
3. Steering unit
4. Steer motor
5. Control valve block
6. Load holding valve, forward tilt
7. Load holding valve, backward tilt (from rated

lift 5000)
(Installation planned for a later date)
8. Tilt cylinder
9. Lift cylinder
10a. Way valve (single additional hydraulics)
10b. Way valve (double additional hydraulics)
10c. Way valve with relief valve

(variant)
11. Intake filter
12. Tank
13. Hose failure safety device
14. Breather filter
Mast type
Overall
height Tele Niho Triple
mm
up to 2760 A - -
above 2810 B - -
up to 2510 - C -
up to 2760 - - D

Table of contents
Contents Page
Technical Service Data 2
Motor
Asynchronous motor 3
Mode of operation 3
Diagram 4
Location of electrical connections 4
Removing and fitting wheel drive 5
Removing and fitting rotor 5
Removing and fitting speed sensor bearing 6
Temperature sensor 7
Speed sensor bearing 8
Pump motor
Design 9
Diagram 9
Neutral zone 9
Main power terminals 9
Removing pump motor 10
Checking brushes 11
Brush monitoring unit 11
Speed sensor 12
Temperature sensor 13
General information
Insulation measurement 14
Commutator machining 14

Service data
Group 11 Motor Pump motor
Manufacturer ABM JULI
Type TDF471/DG112MC-4 GP116-B3
Motor type AC (delta) 4-pole series-wound motor
Voltage (V) 12 24
Current (A) 320 400
Power factor 0.9 -
Nominal speed ( rpm) 2500 2200
Maximum speed (rpm) - 2400 / 3200 P. gest.
Overspeed test speed (rpm) 4800 5000
Power input (kW) 4.9 7.6
Mode S2-60 min S3-15%
Degree of protection IP54 00/20
Insulation class F F
Temperature sensor yes yes
Speed sensor yes, sensor bearing yes
Brush dimensions - 12.5x40x40
Number - 4
Brush monitoring unit - yes
Residual length indication - 16mm

Motor
Asynchronous motor Mode of operation
This truck uses an asynchronous squirrel-cage motor. In the rotor a voltage is induced, which due to its
Aluminium conductors are incorporated in the core design, induces currents in the cage bars. The stator
slots, which are connected to the short-circuiting rings rotating field together with the rotor current produces
at the end of the core. The conductors with the short- a torque. Machines with this mode of operation are
circuiting rings form the rotor cage and also hold the also called induction machines.
core together. For this installed machine, a slanted arrangement of
The stator consists of a laminated stator core and the conductors in the rotor was selected. This
stator windings which are arranged in the wheel drive arrangement counteracts a reduction of torque in the
housing. lower speed range.
The wheel drive has a convection surface in the area The machine in this truck is controlled by a converter.
of the motor for cooling purposes. This control functions on the pulse width modulation
principle with a cycle frequency of about 16 kHz (see
Group 08).
Speed variation of the asynchronous machine
generally takes place via a change in the frequency
of the applied alternating voltage.

Motor
Diagram
The stator diagram is shown in the Figure.

U
The windings are appropriately connected outside the
machine (at the converter).
The stator has 36 slots with a two-layer winding.
W V
Location of electrical connections
The three main terminals U, V and W are led out at

the upper end of the turntable, fixed in position via a
star and connected to the converter. This is located
on the right-hand side in the counterweight.
The six winding terminations of the three stator coils X12
are initially connected in delta at the converter.
The connectors x12 (speed sensor) and x13

(temperature sensor) are located on the right and left X13
of the main power cable (see Figure).
W V U

Motor
Fitting and removing complete wheel drive
Removal of the wheel drive is described in Group 03.
Removal and fitting rotor with motor speed

sensor
Attention, for work to be carried out under

the warranty, the rotor must be sent in
complete with the speed sensor bearing and
bearing retainer plate. The warranty will be
invalidated if the speed sensor bearing is
removed from the rotor shaft. This applies
similarly to the bearing retainer plate!
Requirements:
- Wheel drive removed or
- Turn wheel drive with wheel hub in the direction of

the battery compartment and remove the battery
- Disconnect connector x12 from speed sensor and

route downwards through the ring mount.
- Loosen 4 hexagon socket screws from bearing

retainer plate, remove bearing retainer plate with
rotor.
- When fitting the rotor, the shaft seal should be fitted

with a special tool (Figure/Drawing) - sealing between
motor and transmission.
Order Number: 163647

Speed sensor/Motor
Removing and fitting speed sensor bearing
- Remove motor rotor with bearing retaining plate

- Remove lock washer on sensor bearing
- Remove rotor with sensor bearing from bearing
retainer plate (if necessary hammer down bearing
retainer plate with a rubber hammer/this damages
the sensor bearing)
- Remove lock washer from rotor shaft
- Remove sensor bearing with a puller
- An O-ring (means of locking the outer bearing)
remains in the bearing retainer plate and a plastic
washer as a stop.
Attention:
When fitting the sensor bearing, the sensor
bearing must be handled with the utmost care,
as it can otherwise be damaged when fitting on
the rotor shaft.
To fit the bearing without causing any damage, the

bearing must not be struck with a hammer under any
circumstances.
When the rotor is fitted, a new shaft seal should be Order Number: 163647
fitted with a special tool (Figure/Drawing) - sealing
between motor and transmission.
The washer must be fitted before fitting the rotor

with sensor bearing!
Place the rotor with fitted sensor bearing in the

machine. Attention should be paid to the routing of
the sensor bearing cable. The bearing retainer plate
must subsequently be securely bolted again to the
wheel drive housing.
Establish electrical connections.

Speed sensor bearing
Speed sensor bearing 6B17
The speed sensor consists of a ball bearing with two
Hall effect sensors that scan the internal connector
ring.
The phase displacement is 90° +/- 45° and is defined
as follows:
– The inner ring rotates in clockwise direction
– The rising edge of signal B is located in front of the
rising edge of signal A
– All signals are measured to GND
Connections
Motor (1M2):
Sensor (red) – X12/1 – X151/3 – +12Volt
Sensor (white)– X12/4 – X151/6 – Signal A
Sensor (blue)– X12/2 – X151/5 – Signal B
Sensor (black)– X12/3 – X151/4 – GND
The motor sensor emits 64 pulses per revolution.

Testing the sensor bearing
– Plug Mark II measuring adapter with digital
multimeter connected (with integrated pulse duty
factor measurement, e.g. Metra Hit 16L) into the
connector X12 (X14, X51).
– Connect digital multimeter to:
Positive – Adapter, Pin 4
Negative – Adapter, Pin 3
Positive – Adapter, Pin 2
Negative – Adapter, Pin 3
– Switch on lock switch S1
– Measuring range: Pulse duty factor - AC %
– At full throttle, the digital multimeter should show a
pulse duty factor reading of
40% - 60% (ideal 50%)

Temperature sensor/Motor
Temperature sensor 1R17
The temperature sensor 1R17 is located on the stator

winding of the motor.
The temperature sensor is supplied with a current of
about 2.6 mA from the converter.
Test:
Disconnect connector x13
Test resistance value according to table.
During the insulation test, the temperature sensor

must always be electrically short-circuited! If this
measure is not taken, the sensor can be
damaged.
The replacement sensor must be bonded here
If the sensor if faulty, a replacement sensor must be
fitted.
In the spare parts list, a sensor with adhesive is °C Ohm °C Ohm
offered. This adhesive is required to bond the sensor
to the stator winding. The replacement sensor is - 40 355 90 939
bonded to the upper part of the winding (see Fig.)
with this adhesive.
- 30 386 10 0 1000
- 20 419 110 1063
- 10 455 12 0 1129
0 493 130 1197
10 533 140 1268
20 576 150 1340
25 598 160 1415
30 621 170 1493
40 668 180 1572
50 718 190 1654
60 769 200 1739
70 824 2 10 1825
80 880 220 1914

Pump motor
Pump motor design
This machine is a 4-pole series-wound motor. A

bearing retainer plate is provided on the drive side for
mounting a hydraulic pump.
Machine diagram
The diagram shows a series-wound motor. In this dia-

gram a positive voltage is applied to terminal A1 with
clockwise rotation.
A1 and A2 = rotor
D1 and D2 = series winding
Neutral zone
The brush yoke ring is non-adjustable. This is

unnecessary as the neutral zone is already defined
by the design.
Main power terminals
The terminals A1 and D2 are led out (see diagram). A1

The two other points of the rotor and field are internally
D2
connected.

Pump motor
Removing the pump motor
- Disconnect the battery plug

- Secure the mast
After removing the floor plate with pedal, etc., the
covering on the right can be removed, the brake
linkage loosened and unhooked and set to one side.
The electrical connections to the system can be

disconnected (x14, x15 and main terminal A1 and
D2).
Loosen pipe clamp on pump motor (connection from

priority valve to slider). The next step is to remove
the hydraulic pump from the pump motor (see BG
10).
The horn should be removed.
An eyebolt (M8) must now be screwed into the pump

motor housing and the pump motor secured with a
chain winch.
Loosen the pump motor support (with 4 bolts on pump

motor and 4 bolts on chassis, see photo on right)
and remove. Remove the support and lift out the motor
with a chain winch.

Pump motor
Checking brushes
The brushes can be checked by opening the pump

motor strap and moving the same slightly to the left
or right. The brushes are now accessible.
The new brush has a length of 40 mm.
If the brush has a length between 15 and 18 mm, it
should be renewed.
Brush monitoring unit 2M1S

Functional principle
The brush yoke ring in the pump motor is provided

with monitoring switches (normally closed contacts).
When the remaining brush length limit is reached,
these switches are actuated by the brush spring and
opened.
In the event of an interruption due to a switch opening

or a wire becoming disconnected, this is indicated
on the instrument panel. When the cause responsible
for error indication is located, the error must be
acknowledged.
Testing the brush monitoring unit:
- Disconnect the battery plug.

- Remove the brush and hook in the brush spring.
- Disconnect the plug connection and connect the
digital multimeter to x15/2 and x15/3 on the motor
side.
- Set the digital multimeter to resistance measurement
and actuate the switch (see circle) with the brush
spring.
Switch unactuated: Low ohm value (about

0 Ohm or continuity)
Switch actuated: High ohm value (in megaohm

range or no continuity)

Speed sensor/Pump motor
Speed sensor 6B17
1
The speed sensor of the hydraulic motor 2M1 is
scanned by a pulse generator, which is located at
the top of the bearing retainer plate and fixed in place
with two bolts.
This is an inductive proximity switch. 2,8 +- 0,2
This switch reacts to metal - in this case to the 12
segments of the sensor wheel.
When the sensor wheel rotates, the pulse generator
delivers a positive voltage. From this, the controller
calculates the motor speed. To ensure that the pulse
generator functions correctly, it must be readjusted
when replacement is made.
Adjustment
Loosen the two fixing screws (1) and adjusted the

pulse generator with a feeler gauge to a distance of
2.8 ±2.0 mm to the sensor wheel.
Perfect functioning is only ensured with correct
adjustment.
The pulse generator is supplied with +10V by the

controller.
Sensor – X14/1 – X11/11 – about 10V

Sensor – X14/2 – X11/40 – Signal
Sensor – X14/3 – X11/7/8 – GND
Function test
Attention
The motor must be currentless, disconnect
armature lead!
The proximity switch can be tested for proper

functioning with the motor fitted:
• Disconnect armature lead A1 at the controller.
• Connect multimeter between X14/3 (–) – X14/2 (+)
• Turn sensor wheel of hydraulic motor manually.
• Multimeter shows a clear voltage increase of

about 8V.

Temperature sensor/Pump motor
Temperature sensor 2R17/functional principle
As a temperature sensor, a silicon temperature sensor

is integrated into the brush yoke ring of the pump
motor.
The temperature sensor is supplied with a permanetly

adjusted current of 1.3mA from a power source in the
pump controller. The voltages across the temperature
sensors vary depending on the temperature.
The voltage is scaled in the pump controller and the
power of the machine is reduced.
Testing the temperature sensor
The power source that supplies the temperature

sensor can be tested. A current of about 1.3mA must °C Ohm °C Ohm
flow.
- 40 355 90 939
Resistance to temperature sensor: - 30 386 10 0 1000
• Disconnect the battery plug. - 20 419 110 1063
• Disconnect connector x361 or x15. - 10 455 12 0 1129

0 493 130 1197
• Compare resistance value with the table opposite
(x361 Pin 3 and 4 or x15 Pin 1 and 4) 10 533 140 1268
20 576 150 1340
25 598 160 1415
30 621 170 1493
40 668 180 1572
50 718 190 1654
60 769 200 1739
70 824 2 10 1825
80 880 220 1914

General information
Checking insulation value
The insulation resistance of all windings to frame and

the windings with respect to each other must have a
minimum value of 1000 Ohm per volt measured with
500V d.c.
For 24V trucks, the insulation value must be minimum
24000 ohms.
Attention
During the insulation test of the electrical
machines, the machines must be isolated and
the temperature sensor short-circuited!
Motor
Attention: The motor terminals must be U V W

disconnected from the inverter, otherwise the
inverter will be damaged by excessive voltage !
Measurement U or V or W to frame.
(Measurement to be carried out only in this way if the
windings are connected in delta. Otherwise, each
winding must be individually measured to frame).
Pump motor
Attention: The machine must be disconnected

from the direct d.c. converter and the
temperature sensor short-circuited!
Winding D2 or A1 to frame.
Commutator skimming
Permissible commutator eccentricity

up to rated speed 2000-2900 rpm 0.02 mm
above rated speed 2000-2900 rpm 0.01 mm
D2 A1
Commutator eccentricity can be removed by turning
the removed rotor on a lathe. A good surface condition
is achieved at high speed and at a low feed rate. Mica is not correctly
Mica is correctly removed -mica is still
Minimum permissible commutator diameter removed present on the
segment flanks
The commutator may only be skimmed to a minimum
value.
Pump motor 78 mm
Removal of commutator mica insulation
The mica insulation between the individual segments

must be carefully sawn or milled out. It must be
ensured that the entire mica width, also on the
segment flanks, is removed completely.
Sawing depth: about segment width

Additional hydraulics
Contents Page
Hose lines, fitting/pressurising 3

Pressure regulator
Relief valve Setting range = 20 to 200 bar

(in control valve block) Setting = according to specifications of attachment manufacturer
Way valves - additional

hydraulics
Cross-section reducer
installation Cross-section reducer diameter to be determined
Cross-section
reducer...............mm Ø
Pump motor speeds
With full displacement Sideshift functions = 500 rpm
Other functions = 2550 rpm

Hose line - fitting/pretensioning
Hose line on mast
- PA/PUR plastic hose with textile braid
- Nominal size: DN 6
- Operating pressure: 250 bar
- Bursting pressure: > 840 bar at 20°C
- Temperature resistant from -40°C to +100°C
Chemical resistance:
Outer hose = resistant to oil, grease, detergent and
solvent.
Inner hose = resistant to mineral based hydraulic
oil 3mm 26,5 mm
Fitting screw fittings

When fitting the sleeve (1) to the hose (2), it must be
ensured that the hose is not fully inserted.
To enable the hose material in the sleeve to yield
when screwing in the screw nipple, an annular gap of
3 mm must be maintained.
Before screwing on the sleeve, the hose should 1
therefore be either marked at 26.5 mm (arrow) and
2
the sleeve only inserted up to the mark or the sleeve
fully screwed on and then turned back 1.5 full turns.
NOTE
- Sleeve has a left-hand thread
- Lubricate hose and fittings prior to fitting
Hose line pretensioning

To avoid excessive compression of the hose lines on
the guide pulleys in the mast, the following hose
pretensions must be provided when fitting the hose
lines.
Telescopic and Triple mast (Lift 2):

15 mm (see Fig. 1)
Niho and Triple mast (Lift 1):
Fitting
10 mm (see Fig. 2) 1
- Attach hose lines to fork carriage
- Place hose lines over guide pulleys and pretension
by hand only to the extent that the hose lines run
in a straight line from the fork carriage to the guide
pulleys and rest on all pulleys.
The fork carriage must be fully lowered when doing
this.
- Clamp hose line in place.
- Mark the hose 10 to 15 mm above the clamp
(see arrow).
- Loosen clamp and pull the hose to the extent that
the mark is flush with the top edge of the clamp.
2
Mast
Telescopic Niho Triple mast
Support roller bolts Tightening torque = 60 Nm ± 6
Mast bearing bolts Tightening torque = 73 Nm
Hose failure safety device Tightening torque = 20 Nm ± 2
Maximum elongation 3% according to accident

Chains
prevention regulations
Lowering speed Maximum permissible 0.6 m/sec
Mast weight
Telescopic: e.g. overall height 2490 mm weight = 387 kg (without fork carriage, without fork)
Niho : e.g. overall height 2190 mm weight = 353 kg (without fork carriage, without fork)
Triple: e.g. overall height 2190mm weight = 475 kg (without fork carriage, without fork)

Worksop manual 5051 - 55 20
Mast
Telescopic mast
When the mast is raised, the inner mast is also raised
with the fork carriage, i.e. after extending 150 mm,
the overall height changes. This should be taken into
account when operating in areas with limited
headroom.
The Telescopic mast has 2 lift cylinders, which are
attached to the outer mast. The lift cylinder pistons
are connected to the upper cross member of the inner
mast. When the lift cylinders are pressurised with
hydraulic oil, the mast pistons extend and raise the
inner mast (limit stop in lift cylinder). The chains are
attached to the outer mast, are guided via chain rollers
along the inner mast and connected to the fork
carriage. The inner mast therefore extends in a ratio
of 1:2 with respect to the fork carriage. A carriage
stop prevents the fork carriage tilting out.
Niho mast
When the first mast section is raised, the fork carriage
is also raised. When the second mast section is
raised, the inner mast is extended, i.e. the overall
height does not change within the free-lift range of
the first mast section.
The Niho mast has 3 lift cylinders and a centre chain
on the centre cylinder. The centre cylinder (first mast
section) is located in the inner mast and raises the
fork carriage via the centre chain within the free-lift
range. The outer cylinders (second mast section) are
are connected to the upper cross member of the inner
hydraulic oil, first the lift piston of the centre cylinder
extends (first mast section, limit stop in lift cylinder),
then the lift pistons of the outer cylinder extend the
inner mast (second mast section, limit stop in list
cylinder). A carriage stop prevents the fork carriage
tilting out.

Mast
Triple mast
Triple mast
The function is similar to the Niho mast, however with
an extended lift height for the same overall closed
height.
The triple mast has 3 lift cylinders, a centre chain
and 2 outer chains. The centre cylinder (first mast
section) is located in the inner mast and via the centre
chain raises the fork carriage within the free-lift range.
The outer cylinders (second mast section) are
are connected to the upper cross member of the centre
hydraulic oil, first the lift piston of the centre cylinder
is extended (first mast section, limit stop in lift
cylinder), the the lift pistons of the outer cylinder extend
the centre mast (second mast section, limit stop in
lift cylinder). The inner mast is simultaneously raised
via the outer chains. One end of the outer chains is
attached to one side of the outer mast (bail screw)
and are guided by a pulley on the centre mast. The
other end is attached to the inner mast (final link).
The inner mast is therefore raised in a ratio of 1:2.
The carriage stop prevents the fork carriage tilting out.

Mast
Repair
Removal
- Place mast in a vertical position.
- Remove fork, attachment.
- Raise fork carriage and secure with check chain.
- Jack up truck at the mast and support on wooden
blocks placed under the chassis at the front.
Subsequently jack up truck on counterweight and
support on wooden blocks at the rear (BG 25 , Page
01, Fig. 1).
- Remove plastic covering on left side wall.
- Loosen brake cable nuts (Fig.1).
- Remove high pressure hose on brake cylinder.
- Support mast on upper outer mast cross member
with the aid of a crane.
- Only loosen hydraulic hose line to mast on valve 1
bank, do not remove.
- Remove tilt cylinder control mechanism on running
axle.
- Lower inner mast.
- Disconnect hydraulic hose line to mast on valve
block.
- Remove mast bearing pin (Fig. 2).
- Remove mast bearing.
Fitting
- Support mast at upper mast cross member by
crane..
- Fit spacers on mast bearing journal and grease mast
bearing journal and bores for tilt cylinder pins.
- Insert mast in mast bearing bores.
- Fit mast bearing; per side with 2 hexagon bolts
M10x30, bolt head outside (Fig. 2), hexagon nut 2
inside, detent ring between hexagon nut and chassis.
- Tightening torque = 73 Nm.
- Connect hydraulic hose line.
- Attach tilt cylinder control mechanism hook to
running axle.
- Connect high pressure hose to master cylinder.
- Fit brake cables (Fig. 1).
- Remove check chain on fork carriage and lower fork
carriage.
- Remove chain, rope from crane on outer mast cross
member.
- Loosen bleeders on lift cylinders about1/2 to 1 full
turn and raise fork carriage about 300mm for bleeding.
- Adjust parking brake (BG 07, Page 04).
 STILL GmbH Position as per: 08/2002 (Replaces versions: )04

Mast
Mast support roller replacement
Repair
Disassembly
- Tilt mast back.
- Raise fork carriage and support with check chain
(Fig. 1).
- Disconnect battery plug.
- Lower piston rod of centre cylinder (Niho and Triple).
- Remove pipe from left outer cylinder to centre cylinder.
- For additional hydraulics, remove hose guide rails
(left and right next to centre cylinder), lower union
and draw out guide rails (Fig. 2).
- For outer cylinders, remove tensioners (clamp on
top of lift cylinder, Fig. 1). 1
- Remove lock ring of lift cylinder mount on top side
of cross member.
- Slightly raise inner mast with a jack until outer
cylinders lie free at the top on the cross member .
- Move outer cylinder to the side (Fig. 3).
- Lower complete inner mast with a jack.
- Support rollers at the top of the outer mast (Fig. 3)
and at the bottom of the inner mast (Fig. 4) are free
and can be removed.
Removal
- Remove support roller. Countersunk screw is locked 2
with Loctite 242. If the countersunk screw cannot be
removed, heat lightly with a flame.
Fitting
- Fit support roller. Use new countersunk screw.
Tightening torque of countersunk screw 60Nm.
Assembly
- Raise inner mast with a jack so that the outer cylinder
can be fitted.
- Move outer cylinder towards outer mast.
- Lower inner mast with a jack.
- Attach outer cylinder to cross member with lock
ring.
- Fit tensioners on outer cylinders.
- For additional hydraulics, fit hose guide rails to centre
3
cylinder.
- Fit pipe from left outer cylinder to centre cylinder.
Adjustments
- Check lateral and radial clearance between mast
section and support roller.
Lateral clearance min.= 0.3mm/radial clearance min=
0.1 mm
Lateral clearance max.=1.8mm/radial clearance
max= 1.1mm
4
Mast
Carriage stop
Function
The carriage stop prevents the fork carriage tilting out
of the inner mast.
When adjusting the chain, it must be ensured that 2
the limit stop takes place in the lift cylinder and not
at the carriage stop when the mast is fully extended.
It must be ensured that a gap of minimum 2mm is

present between the stop (1) on the fork carriage and
cheese-head screw (2) located on the upper inner
mast cross member.
Note: For masts with a large overall height, it can be
easily be determined how large the gap is by applying
a small amount of modelling clay to the stop (1),
1
raising the fork carriage up to the stop and then
measuring the thickness of the modelling clay with a
caliper rule.

Mast
Stop damping system

Outer cylinder
Function
On the Niho and Triple masts, the stop damping
system serves to brake the piston rod of the outer
cylinder shortly before reaching its final position when
the mast is lowered in the transition from extension A
of the first to the second mast section.
1
Metallic impact is thus prevented.
Viewed in the direction of travel, the right cylinder
respectively is provided with the stop damping system 2
on the Niho and Triple masts. 3
B
Function 4
When the piston rod is pressurised with hydraulic oil
as the mast is raised, the piston (3) is moved under
the force of the spring (4) in the direction of the cylinder
liner until the circlip (5) comes to rest against the
piston cover (2). The hydraulic oil flows via the cross-
section reducer (1) from chamber A to chamber B. 5
B
When the mast is lowered, the piston (3) initially
makes contact with the cylinder liner before the piston
rod reaches its final position. The piston (3) is moved
in the direction of the piston rod, whereby the hydraulic
oil flows from chamber B via the cross-section reducer
into chamber A. The mast is thus hydraulically braked
by this pressure compensation. 2
Centre cylinder
When the fork carriage is extended (extension of first

mast section), the stop damping system serves to
hydraulically brake the piston rod shortly before it
reaches its final position.
This makes the transition from extension of the first
mast section to the second mast section softer.
1 - Cross-section reducer bore

2 - Piston cover
6
3 - Piston
4 - Spring
5 - Circlip
6 - Plunger 7
7 - Seal
8 - Guide
9 - Stud 8
9

Mast
Centre cylinder
The centre cylinder is a single-action cylinder. The 1
cylinder barrel and cylinder liner are welded together.
The cylinder head is bolted to the cylinder barrel and 2
sealed with liquid plastic. The cylinder head and
cylinder barrel are sealed with an O-ring. The cylinder 3
head and piston rod are sealed with a grooved ring. A 4
piston cover screwed into the piston rod and sealed
with liquid plastic serves as a carriage stop. 5
Repair
Removal
- Place mast vertical.
- Raise fork carriage, place wooden block below, lower
fork carriage.
- Remove chain on fork carriage.
- Disconnect hydraulic connection on cylinder liner.
- Remove clamp on cylinder.
- Remove lift cylinder.
Disassembly
- Clamp cylinder in a vice (protective jaws).
- Dismantle cylinder head with a hook-type wrench.
Note: If the cylinder head cannot be moved, heat with 6
a flame.
- Withdraw piston rod from cylinder barrel.
- Clamp piston rod in a vice (protective jaws) and
remove bearing yoke.
- Seal kits can now be replaced.
Assembly
- Fit cylinder head on piston rod.
- Fit bearing yoke.
Note: Bearing yoke is locked with Loctite 243.
3 points on the circumference.
- Insert piston rod into cylinder barrel. 7
- Screw cylinder head to cylinder barrel.
Note: Cylinder head is locked with Loctite 243. 5
3 points on the circumference.
Fitting 8
- Place cylinder in inner mast.
- Fit clamp.
Note: Note position of bleeder.
- Connect hydraulic connection. 1 - Wiper
- Fit chain. 2 - Grooved ring
- Raise fork carriage, remove wooden block, lower 3 - Bleeder
fork carriage. 4 - Cylinder head
- Bleed lift cylinder. 5 - O-ring
6 - Piston cover, locked full surface with
Loctite 275.
Tightening torque 350 Nm +50
7 - Hose failure safety device
8 - Hydraulic connection

Mast
Telescopic outer cylinder (top diagram)
Repair
Removal
- Slightly raise inner mast to remove lock ring.
- Remove lock ring from piston fastener.
- Place wooden block between top outer mast and
inner mast cross member. 1
- Fully lower piston rods.
- Remove tensioners.
- Disconnect hydraulic connection.
2
Disassembly
- Disassembly of cylinder head, see Page 08
3
Assembly
- Assembly of cylinder head, see Page 08
4
Fitting
5
- Place cylinder in outer mast.
- Fit tensioners.
Note: Note position of bleeder.
- Connect hydraulic connection.
- Extend piston rods to fit lock rings.
- Fit lock ring of piston fastener.
Niho-Triple outer cylinder (bottom diagram)

Removal
- Removal takes place as described on Page 05
Disassembly
- Disassembly of cylinder head, see Page 08
Assembly 6
- Assembly of cylinder head, see Page 08
Fitting
- Fitting takes place as described on Page 05.
1 - Wiper
2 - Grooved ring 7
3 - Bleeder
1
4 - Cylinder head
5 - O-ring
8
6 - Adapter
Note: Locked with 275, 2
3 points on circumference.
7 - O-ring 3
Note: Fitted with grease.
8 - Hose failure safety device 4
Note: Screwed in manually without tools. Locked
against loosening 3x on circumference. 5
Hose failure safety device setting must not be altered.

Mast
Hose failure safety device

Function
The hose failure safety device prevents uncontrolled,
rapid lowering of the load in the event of hose fracture.
The hose failure safety device(1) has a valve disc (3)
which is raised from the valve seat by spring force in
a normal position and thus maintains a free flow cross-
section. In normal operation, the spring keeps the
valve open. In the event of hose failure, the flow
increases, the flow forces exceed the spring force
and the valve instantaneously closes.
A small bore in the valve disc allows the load to be
lowered slowly with the valve closed. 1
Repair
Hose failure safety devices (1) are fitted at the
following points in the mast:
Telescopic
Left and right cylinders in cylinder liner (4).
Niho
Centre cylinder in cylinder liner (see Page 08).
Left cylinder in cylinder liner(4) and adapter (Diagram 3

1).
Note: The adapter is secured in the piston barrel and 1
sealed with Loctite 243.
Right cylinder in cylinder liner (4).
Triple 4
Centre cylinder in cylinder liner (see Page 08).
Left cylinder in cylinder liner (4) and adapter.

Note: The adapter is secured in the piston barrel and
sealed with Loctite 275.
Right cylinder in cylinder liner (4).
Note: The hose failure safety device setting must not

be altered.
1 - Hose failure safety device (Hawe)

Tightening torque 20Nm
Use a socket wrench
2 - Hose failure safety device (Buchholz)
Tightening torque 20Nm
Use a 10mm hexagon socket screw key
1 2
3 - Valve disc (Hawe)
4 - Cylinder liner
 STILL GmbH Stand: 08/2002 ( Ersatz für Stand: ) 10

Mast
Chains
Telescopic mast
Repair
Removal
- Lower mast slightly to slacken chains.
- Remove chains on fork carriage.
- Remove chains on outer mast cross member.
Fitting
- Fit chains on outer mast cross member.
- Fit chains on fork carriage.
- Raise innser mast until chains are taut and check
chain is slack.
- Remove check chain and lower fork carriage.
Adjustments
- The chains must be adjusted at the bail screws (1), 1
so that the chains are evenly tensioned when lifting.
- The centre of the top support rollers of the fork
carriage must remain minimum 25mm in the inner
mast section with the mast fully extended.
- For chain adjustment, the minimum distance of 2mm
at the carriage stop must be maintained (Page 06).
Niho mast
Removal
- Raise fork carriage slightly, place wooden block
below and lower fork carriage on to wooden block.
- Remove chain on fork carriage and inner mast cross
member.
Fitting
- Fit chain.
- Lift fork carriage slightly, remove wooden block, lower
fork carriage.
Adjustments
- The chain must be adjusted at the bail screw (2), so
that the centre of the top support rollers of the fork
carriage remain minimum 20mm in the inner mast
section with the centre cylinder fully extended.
Note: Never compensate tyre wear by retensioning 2

the chains.

Mast
Chains
Triple mast
Outer chains
Repair
Removal
- Raise inner mast slightly with a jack to slacken
chains.
- Remove chains on inner mast and outer mast cross
member.
Fitting
- Fit chains on inner mast and outer mast cross
member.
- Lower inner mast with jack.
- Remove check chain and lower fork carriage.
Adjustments
- The chains must be evenly adjusted at the bail 1
screws (1) until the mast sections are flush.
Centre chain
Removal
- Raise fork carriage slightly, place wooden block
below and lower fork carriage on to wooden block.
- Remove chain on fork carriage and inner mast cross
member.
Fitting
- Fit chain.
- Lift fork carriage slightly, remove wooden block, lowr
fork carriage.
Adjustments
- The load chain must be adjusted at the bail screw
(2) , so that the centre of the top support rollers of the
fork carriage remains minimum 20mm in the inner
mast section with the centre cylinder fully extended.
Note: Never compensate tyre wear by retightening

the chains.
Note: If no complete lift chains are used for chain

replacement, the chain connecting parts (final link,
2
bail screw) must be renewed. This applies to all chains.

Fork carriage
Fork carriage
Repair
Removal
- Apply parking brake.
- Raise fork carriage and support with jack (Fig. 1).
- Lower inner mast slightly to slacken chain(s).
- Hang out chain(s) on fork carriage.
- Raise inner mast hydraulically until fork carriage
comes free from inner mast.
- Fork carriage is now free (Fig. 2), support rollers
can be removed.
Disassembly
- Remove support roller. Countersunk screw is locked
with Loctite 242. If the countersunk screw cannot be 1
moved, heat lightly with a flame.
Assembly
- Fit support roller.
Use new countersunk screw!
Fitting
- Apply parking brake.
- Raise inner mast so that fork carriage support rollers
can be fitted in inner mast.
- Place fork carriage below inner mast and support
with a jack.
- Lower inner mast and guide fork carriage into inner
mast by raising fork carriage with a jack.
Note: If during assembly the fork carriage should stick
in the inner mast, attempt to release the fork carriage 2
by tilting slightly, or lower inner mast via inner and
outer mast cross member with block and tackle.
- Fit chain(s) on fork carriage and secure with a lock
bolt. LC
Adjustments
- Check lateral clearance (LC) between inner mast
and support roller.
Minimum clearance = 0.3 mm
Maximum clearance = 1.8 mm
- Check radial clearance (RC) between inner mast RC 1

and support roller.
Minimum clearance = 0.1 mm
Maximum clearance = 1.1 mm
1 - Countersunk screw
Tightening torque = 60 Nm ±6

Fork carriage
Telescopic fork carriage
Repair
- Before welding the bearing (1), the position of the
2
notch should be noted.
- The bearings must be welded to the roller retainer
with a 5mm outer fillet weld.
- Welding takes place with a basic-coated electrode
(BC electrode).
- Material of bearing and roller retainer St52-3. 1
The diagram shows the left roller retainer. The right 2

roller retainer is mirror-inverted.
1 - Bearing number 327175

2 - Notch in bearing
3 - Support roller
4 - Roller retainer
4
3
1 2

Fork carriage
Niho Triple fork carriage
Repair
- Before welding the bearing (1), the position of the
notch should be noted. 2
- The bearings must be welded to the roller retainer
with a 5mm outer fillet weld.
- Welding takes place with a basic-coated electrode
(BC electrode).
- Material of bearing and roller retainer St52-3.
1
The diagram shows the left roller retainer. The right

roller retainer is mirror-inverted.
2
1 - Bearing number 327175

2 - Notch in bearing
3 - Support roller
4 - Roller retainer
2
1

Tilt cylinder
Tilt cylinder
Repair
Removal
- Jack up truck at mast and lower front of chassis on
to wooden blocks. Subsequently jack up truck at
counterweight and lower rear of chassis on to wooden
blocks (Fig. 1).
- Fix mast with rope across overhead guard and outer
mast cross member (Fig. 2). With lightly tensioned
block and tackle, fix mast with rope or strap from
running axle (Fig. 3) under truck to top mounting (Fig.
2). Secure mast to prevent it tilting forward or back!
- Disconnect hydraulic lines on tilt cylinder. Carefully 1
loosen hyraulic connection as system is still under
pressure.
- Remove tilt cylinder bolt on running axle.
- Lower hook so that tilt cylinder bolt lies free on
mounting on chassis (Fig. 4).
- Remove tilt cylinder bolt on chassis.
Disassembly
- Clamp tilt cylinder at cylinder liner in a vice.
- Remove threaded pipe on cylinder head (thread
protrudes into cylinder).
- Drive in cylinder head slightly with a plastic mandrel.
- Push circlip through bore in cylinder barrel with
mandrel and lever out circlip with a screwdriver. 2
- Withdraw piston rod and cylinder head from cylinder
barrel.
- Clamp piston rod in a vice (use protective jaws!).
- Remove seal kit.
Assembly
- Fit seal kit of cylinder head and piston.
- Lightly grease piston guide ring seal.
- Insert piston rod and piston into cylinder barrel.
- Lightly grease cylinder head and fit in cylinder barrel.
Note: Recess in cylinder head must point
towardsthreaded pipe bore.
- Fit circlip.
- Screw on eyebolt and tighten. 3
Note: When fitting the eyebolt, dimension 78.5± 8
must be maintained (see Page 02).

Tilt cylinder
Tilt cylinder
Repair
Fitting
- Mount tilt cylinder on chassis.
- Fit tilt cylinder and hook on running axle.
- Connect hydraulic lines to tilt cylinder.
Note: When fitting, use new unions! Follow procedure
below for fitting the union:
- Position union and tighten by hand up to the TUFLOK
coating.
- Subsequently tighten minimum 3 full turns,
maximum 4 full turns with a suitable tool.
Note: Do not not turn back union! 78,5 ± 8
1 2 4
Note: When replacing ball socket at eyebolt. Ball Note: The hexagon nut (2) or spacer (4) is locked
socket (1) is caulked on both sides at the marked with Loctite 270.
points to prevent lateral movement. Tightening torque 130 Nm +10.
Piston (3) is is sealed on piston rod with Loctite
270.

Tilt cylinder
Mast tilt
Overall
Mast Overall height Tilt Tilt Length L Lift
height
vor rück
von bi s mm mm
(Grad) (Grad)
Telescopic 1860 3260 3 6 332 112
Niho 1860 2510 3 6 332 112
Triple Solid
1860 2760 3 5 332 100
rubber tyres
^Triple
Pneumatic and SE 1860 2760 3 4 332 88
tyres
Note: When carrying our repairs to the tilt cylinder,

it must be ensured that the mast tilt is not altered.
Altering the tilt angle will affect the stability.

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Workshop manual 5051 - 55 01

General technical data

Jacking up the truck

General technical data 2

Removing the wheel hub 3

Fitting the wheel hub 3

ã STILL GmbH Position as per: 08/2002 (Replaces version: ) 1

Wheel hub MA=195 Nm

wheel nut MA=195 Nm

Grease F according to DIN51825-KP2K -20,

ã STILL GmbH Position as per: 11/2002 (Replaces version: ) 2

The wheel hub runs in two taper roller bearings.

Removing the wheel hub/brake drum

- Disconnect the battery plug

- Remove brake drum (6) with taper roller bearings

Replacing the wheel bearing

- Remove wheel bearing from axle journal

Fitting the wheel bearing/brake drum

- Fitting takes place in reverse order to removal

- When refilling the wheel hub with grease,

Hexagon bolt (2) 195 Nm

Wheel bolts 195 Nm

ã STILL GmbH Position as per: 08/2002 (Replaces version: ) 3

General technical data 2

ã STILL GmbH Position as per: 11/2002 (Replaces version: ) 1

Transmission designation/ Manufacturer TFD471 / DG112MC-4 ABM Greiffenberger

Tightening torque: 205 Nm

Pin in steering stop Pin 18x60 according to DIN 1481

Screw ring mount on counterweight 12 cheese-head screws DIN 912 M16x 80

Tightening torque: 195 Nm

Oil capacity 2 Litres

ã STILL GmbH Position as per: 11/2002 (Replaces version: ) 2

In the upper area, the ring mount with steering chain

Seated on the wheel hub is the tyre fixed with nuts

ã STILL GmbH Position as per: 11/2002 (Replaces version: ) 3

Secure truck, jack up and support with two blocks of

Attach block and tackle to overhead guard with the

Loosen wheel drive/counterweight bolted connection.

Fitting the wheel drive

Fitting takes place in reverse order to removal.

Tightening torque of hexagon socket screws counter

ã STILL GmbH Position as per: 11/2002 (Replaces version: ) 4

Work on the transmission can be carried out in a

- Loosen wheel shaft bolt

- Unscrew bolt until wheel shaft is forced out of

- Radial seal can be replaced in this position

ã STILL GmbH Position as per: 11/2002 (Replaces version: ) 5

General technical data 1

ã STILL GmbH Position as per: 10/2002 ( Replaces version: ) 1

Wheels and tyres

Tighten bolts crosswise

Note on fitting and removing SE tyres Regrooving SE tyres

Do not use the fitting grease customary for Attention!

ã STILL GmbH Position as per: 11/2002 (Replaces version: 01/1998 02

General technical data 2

Steering column adjustment 6

Removing the steering unit 8

Fitting the steering unit 9

Repairing the steering unit 9

LS (Load Sensing ) components of the $

A constant oil flow of 0.6-0.9 l/min is required

The steering system always has the oil

Remove covering in cowl.

In case of damage, the steering unit must be 11