Still FM14, 17 y 20 Tipo429 (Ingles 09-1997) PDF

Workshop Manual FM Type 429
Copyright protected. No part of this manual

may be reproduced in any form. Copyright
reserved.
7/0457
First issued: 9/97 Workshop

Last revision: Manual FM Type 429 Id. no. 8 054 140
Foreword
Foreword
This workshop manual provides specifications

and describes functional characteristics of the 5/0002
standard truck.
This provides you with a comprehensive

documentation to ensure better understanding
of the vehicle technology and so permit correct
maintenance and repair work to be carried out.
The workshop manual is always updated by

supplementary sheets.
5/0003
Updating of workshop manuals
The industrial truck range is subject to

continuous further development. This means
reserved.
that certain components or assemblies are

exchanged or modified.
To ensure that the holder of this manual always

5/0004
has the most up to date version of the
documentation, it is important to abide by the
following updating system.
7/0457
Issue: 9/97 Workshop Sheet no.

Replaces issue: manual
FM Typ 429 I
Foreword
Updating workshop manuals

(Contd.)
1. Exchanging faulty sheets

Page baseline of the existing sheet
If a particular page contains mistakes, for
example due to altered setting values, the Issue: 9/97 Workshop sheet.no.
Replaces issue: Manual FM Typ 429 A1
respective sheet must be exchanged.
A newly inserted sheet can be recognized by the
altered left-hand baseline (1). Here, the date of 1 4
compilation is updated in the line entitled Issue 2
(2). In the line Replaces issue (3) is the Page baseline of the corrected sheet
compilation date of the sheet to be replaced. The
sheet no. remains the same (4). Issue: 1/98 Workshop sheet-no.
Replaces issue: 9/97 Manual FM Typ 429 A 1
With every revision the first sheet will be repla-
ced. In (9) you see the first issue and the date of
the last revision. This tells you the revision state 3
of the whole book.
Page baseline of the first sheet

2. Insertion of supplementary First issue: 9/97
Last revision:
Workshop SERVICE
Manual FM Typ 429 TRAINING
sheets
9
If new, modified or additional components are
included in the series truck, it may be necessary
to add one or more supplementary sheets.
The additional sheet is recognized by the left- Page baseline of the existing sheet
reserved.
hand and right-hand page baseline (5+6).

Issue: 9/97 Workshop sheet-no.
In the Issue line on the left-hand side is the Replaces issue: Manual FM Typ 429 A 1
compilation date (7). On the right, the
supplementary sheet is marked by the sheet no.
with continuous index (8).
5 6
In addition, the table of contents of the respective
assembly must also be exchanged. Page baseline of the supplementary sheet
Issue: 1/98 Workshop sheet-no.
Newly compiled sheets, whether replacements or Replaces issue: Manual FM Typ 429 A 1.1
supplementary sheets, and the new tables of
contents are sent by post to all known holders of 7
8
workshop manuals.

FM Typ 429 II
Foreword
Remarks, imprint
No guarantee claims arise as a result of

working in accordance with the instructions
contained in this manual.
This does not affect the guarantee stipula-

tions.
We are continuously involved in the further

development of our industrial trucks. Please
appreciate that this documentation is subject
to alteration and error, and that no claims

may be derived from information, illustrations
and descriptions contained in the workshop
manual .
reserved.
Publisher
STILL WAGNER
GMBH & CO KG
Trainingszentrum
Ernst-Wagner-Weg 1-5
72766 Reutlingen-Mittelstadt

FM Typ 429 III
Foreword
Production number and consecutive identification numbers
From now on, a production number will be used for the identification of industrial
trucks. This production number is shown on the vehicle nameplate.
In the production number, the vehicle type is shown in the form of a code, and a
consecutive identification number is included. In future, alterations will be introduced
starting from a certain number.
When making enquiries, however, please always quote the complete production
number.
As previously, the type number printed above will be used for identification of this
workshop manual, in which all vehicle types in the FM group are described, and will
continue to be quoted in the footer of every page, e.g.

Replaces issue: Manual
FM Typ 429 M16
This workshop manual describes 429 vehicle types with the new travel and pump
control system introduced in 1997.
This new travel and pump control system is integrated in vehicles with the consecutive
identification numbers quoted below and those built later.
Production number
reserved.
61 1855 0 52800
Consecutive ID number
FM14
Production number
61 1856 0 58300
FM17
Production number
61 1857 0 64300
FM20

FM Type 429 IV
Foreword
Definition of movement directions
Tilt
Forwards Backwards
Reach Reach
Lift backwards forwards
Lower
reserved.
Backwards Forwards
travel travel
5/0005
Left and right are as seen when looking in the direction of forwards travel.

FM Typ 429 V
Assemblies
Assemblies:
A Travel drive
B Steering
C Brake
M Electrical system
N
Hydraulic system
R Lubrication plan
reserved.

FM Typ 429 0
Assembly A Travel drive
Contents
Sheet
Motor, general ................................................................................................A 2

Terminal markings at the motor .....................................................................A 3
Exchanging the carbon brushes.....................................................................A 4
Changing the drive wheel...............................................................................A 5
Removing the travel drive system ..................................................................A 6
Commissioning...............................................................................................A 7
Oil change, gearbox .......................................................................................A 8
reserved.

Travel motor
Id. no. W8 406 776
General information
The travel motor used is a 48 V shunt motor.

The armature and field windings are
controlled separately by the travel and pump
control system.
The travel movement is initiated when the
armature is supplied with voltage and the field
excitation is 17A.
As soon as the armature voltage is equal to
the battery voltage, the field current is

reduced, in order to increase the speed.
The actual speed of the travel motor is
determined by a current measurement
(measuring shunt) in the travel and pump
control system.
The travel motor has temperature (140°C)
and carbon brush monitors.
reserved.
For adjustment of the travel motor, see sheet

no. M16.
7/0431

Replaces issue: Manual FM Type 429 A2
Terminal markings at the motor
Marking at the motor Meaning
Main current terminals
A1 Start of the rotor winding

A2 End of the rotor winding
F1 Start of the shunt field winding
F2 End of the shunt field winding
Sensor terminals
X15.1 0 V signal, temperature sensor

X15.4 0 V supply, temperature sensor

X15.2 48 V signal, carbon brush monitor
X15.5 Signal for carbon brush monitor
reserved.
F1 X15
F2
7/0430
A2 A1
7/0431

Replaces issue: Manual FM Type 429 A3
Exchanging the carbon

brushes
Min. 15 mm
The carbon brushes must be replaced when

they wear of about 50 %.
Always replace the complete set of four

carbon brushes.
Removing the brushes

5/0034
1. Pull out the battery plug.
2. Remove the vehicle covers.
3. Remove the travel motor tensioning belt
(1).
4. Lift off the brush spring (2) with a hexa- 1
gon socket screw key and pull out the
carbon at the connecting cable (3).

5. Disconnect the connecting cable (4).
6. Clean out the commutator compartment
with compressed air.
Caution: Never breathe in carbon
dust.
7. Mount the new carbon brushes.
Remark: After exchanging the
reserved.
brushes, do not run the

motor straight away under
full load. The carbon
brushes run in relatively
quickly under minimal
loads. 7/0431
Checking the brush springs

Id. no. W8 405 853
2
Brush springs with insufficient pre-tension
lead to burning of the commutator.
Ensure that the carbon brushes run easily in

the shaft. 4
3
5-03 34

Changing the drive wheel

(complete)
Id. no. W8 365 234
New dimensions: Ø 343 mm/136 mm 230 mm
It is necessary to change the drive wheel Bild 1

when: 5-01 19
- the running surface is pitted or

out of round,
- the tyre diameter has reduced
by 10%,
e.g. 343 mm - 10% = 309 mm.
Removing the drive wheel

Bild 2
2. Jack up the truck by approx. 230 mm 5-01 17
(Fig. 1) and secure against rolling away.
3. Remove the covers.
reserved.
4. Apply the handbrake.

5. Turn the drive wheel into the position for
forwards travel and release the 7 drive-
wheel nuts (Fig. 2).
6. Position the drive wheel at a 90° angle
and remove the nuts (Fig. 3).
7. Pull off the drive wheel, taking care not to Bild 3
5-01 18
damage the threaded bolts.
8. Tip the drive wheel off under the gearbox
and pull it out (Fig. 4).
When mounting the new drive wheel, tighten
the nuts in diagonal sequence.
Tightening torque: 140 Nm
5-01 20 Bild 4

Removing the travel drive

system

230 mm
2. Jack up the truck by approx. 230 mm
(Fig. 1) and secure it against rolling Bild 1
away. 5-01 19

4. Remove the drive wheel.
5. Remove the travel motor.
6. Drain off the gear oil (see sheet no. A8).
7. Replace the oil drainage screw.
8. Remove the steering chain (see sheet

no. B19).
9. Suspend the gearbox on a pulley (Fig. 2)
or use a second fork lift truck to support it
from below.
Bild 2
10. Remove the 6 cheese-head screws 5-01 31
M12x50 (Fig. 3, no. 1).

1
reserved.
11. Carefully lower the gearbox on the cable

or the second fork lift truck. The wheel
bolts should point upwards.
12. Remove the gearbox, pulling it forwards
and tilting it upwards (Fig. 4).
Mounting 5/0023
Bild 3
To mount the travel drive system, follow the

instructions above in reverse order. Ensure
that the emergency steering feature of the
steering assembly (mechanical components)
moves freely and does not produce any
noise.
Bild 4
1 5-03 02
2

Commissioning the gearbox
(after exchanging) 1
Id. no. W8 421 614
Oils must be used with the following viscosi-

ties:
Standard oil: SAE 80

Ambient temperature: 0°C to 40°C
Id. no. W8 036 925
Low-temperature oil: SAE 75 W-90 5-01 23

partly synthetic
Ambient temperature: to -40°C
Id. no. W8 036 929
2
For special requirements, we recommend
contacting the manufacturer.
Ölstand
Oil quantity: approx. 3.6 l

Multiplication: i = 15.93
Remark:
The specified oil quantity is a guideline value.
The correct oil quantity is ascertained by filling
the tank up to the lower edge of the filling hole
(1). At this level, about 1/3 of the the spur
reserved.
wheel is submerged in oil (2). 5/0037

Overfilling must be avoided. Otherwise oil le-
aks out of the gearbox breather nipple, the se-
als can be destroyed or the operating tempe-
rature raises extensively. 3
It is important to avoid overfilling, as otherwise

the seals will be damaged and it is possible
that the operating temperature will not be
maintained. The gearbox breather nipple is to
be checked for cleanliners.
Lubrication of the bogie bearing:

The bogie bearing should be relubricated once
a year using the two lubricating nipples (3), in
particular after cleaning the gearbox (using a
5/0038
steam jet).
Grease type: all-purpose grease

Oil change gearbox
The first oil change should take place after

around 50-100 operating hours.
All subsequent oil changes should be carried
out at intervals of 2000 operating hours or
once a year.
Between oil changes, the oil level should be
checked once a quarter and topped up if
necessary.
Remark: The gear oil must be drained

when at service temperature.
The maximum permissible
service temperature is 80°C.
Changing the oil

5-01 12
Bild 1
1. Jack up the vehicle and secure it against
1
rolling away.
2. Set the gearbox to the oil drainage
position (see Fig. 1).
3. Place an oil catchment vessel under the
oil drainage screw (Fig. 1, no. 1) (capacity
reserved.
at least 4 l).
4. Unscrew the oil filler cap (Fig. 2, no. 2). 2
5. Remove the oil drainage screw and drain
off the oil.
Caution: The oil temperature can be

as high as 80°C.
6. Replace the oil drainage screw, at the

same time replacing the sealing ring
(Id. no. W8 001 795).
7. Fill up with new gear oil to the lower edge
of the threaded hole for the oil filler cap.
8. Replace the oil filler cap with a sealing 5/0038
ring.

Assembly B Steering
Contents
Sheet no.
General ..........................................................................................................B 2
Structure of the steering system ....................................................................B 3
Functional characteristics of the steering sensor ...........................................B 4
Removing the steering column.......................................................................B 6
Setting the steering sensor ............................................................................B 8
Servo unit, general .........................................................................................B 11
Exchanging the carbon brushes.....................................................................B 12
Removing the servo unit ................................................................................B 13
Steering transmission, general.......................................................................B 14

Removing the steering transmission ..............................................................B 15
Removing the chain wheels and their bearings .............................................B 16
Chain tensioning ............................................................................................B 18
Exchanging the steering chain .......................................................................B 19
reserved.
Steering controlle, general .............................................................................B 20

Steering controlle, block diagram...................................................................B 21
Functional characteristics...............................................................................B 22
Safety monitoring ...........................................................................................B 23
Setting ............................................................................................................B 25
Commissioning...............................................................................................B 26
Pin assignment...............................................................................................B 27

Replaces issue: Manual FM Typ 429 B1
Assembly B Steering
General 1
48 V
The electrical steering boost is a device for

supporting the steering process in trucks with
steering columns.
There is also a mechanical emergency 2 7/0432

steering system available for the event that
the electrical steering boost fails.
The control unit is designed to operate at a

voltage of 48 V. The current is limited at max.
30 A (for setting, see sheet no. B25).
The electronic control circuitry and main

current circuit are housed in a closed

structural unit (1).
The setpoint generator (2) is located on the

steering column and is designed as a
proximity-type magnetoresistive transducer.
5/0045
The steering lock is 95° to either side.
reserved.
7/0432
6/0329

Assembly B Steering
Structure of the steering system

The lower end of the inclinable steering column
with steering wheel is connected to the steering
transmission (2) by a cardan joint (1).
The steering transmission has a chain wheel (3)

at the top and is flange-mounted (4) to the frame
above the chain wheel.
The chain (5) is tightened at the steering

transmission by means of an adjusting screw 9
(6). Transmission of the steering force to the fifth
wheel is effected by means of a steering chain
(7). Two adjusting screws (8) are used for
tensioning here.
The bearing pedestal of the steering transmis-
sion must be displaced to tension the chain. Af-
ter tensioning, tighten the fastening screws. 1
Caution: Do not tighten chains too taut!

(see sheet no. B18) 3
Remark: If the FM is fitted with reversing
steering, there is no chain (5). The 5 4
chain wheels are then replaced by
toothed wheels which intermesh 6
directly with one another. 2
reserved.
10 8
The following elements are also required for the 7
electrical steering system:
- A steering column with electrical sensor (9),
- A servo unit consisting of the steering servo
motor with reducing gear (10), 5/0060
- Electronic control circuitry (see sheet no. B2,

no.1).
The steering servo motor is flange mounted on

the steering transmission by a retainer and is
connected by a chain to the shaft of the steering
transmission.
The control system, which works fully
electronically, is demand-responsive, and
accommodated in an open housing below the
valve cover.

Assembly B Steering
Functional characteristics of the
steering sensor
Id. no. W8 420 134
The steering column is divided into two parts. The upper

part with the steering wheel can be twisted using the car-
dan joint by ± 7° out of centre in opposition to the lower
part against two torsion elements made of foam rubber
(Id. no. W8 410 477).
To measure the turning angle, which is proportional to the
steering force, a differential magnetoresistive sensor (1)
and a permanent magnet (2) are used (Id. no. W8 410
938).
The differential magnetoresistive sensor is mounted on 2

the lower part of the steering column, the magnet on the
upper part. When the two parts are turned relative to
each other, the magnetic flow changes depending on the
angle, so changing the output signal of the differential
magnetoresistive sensor. 1 mm
The voltage alteration at the magnetoresistor amounts to

approx. ± 1.5 Volt relative to the reference potential for
the centre point, depending on the sense of rotation. This 1
voltage alteration is also dependent on the distance of the
magnetoresistor from the magnet. For this reason, the di-
stance between the magnetoresistor and magnet should
be a maximum of 1 mm.
Remark: For reasons of EMC (EMC = electromagnetic

reserved.
compatibility), the supply line to the steering

sensor is shielded and is integrated in the
vehicle cable harness.The shielding is laid on
the housing of the steering controller.
The steering sensor itself has not changed.
5/0055
Functional characteristics of the magne-

toresistor
Id. no. W8 410 475
The magnetoresistor is a magnetic field-dependent resis-

tor. The resistors used in the sensor are differential resis-
tors consisting of two series-connected resistors (in one
housing) with centre tap. Depending on the position and
influence of the magnetic field, the resistance ratio bet-
ween the two changes, so, with applied voltage (approx.
5 V) at the external terminals (1 and 3), changing the po-
tential at the centre tap (2). This change in potential is fed +5V ±1,5V 0V
to the electronic control system as a control signal. von
Mpsp
5/0056

Assembly B Steering
Functional characteristics of
the steering sensor (contd.)
Slipring system:
Id. no. W8 410 468 (sliprings)

Id. no. W8 410 471 (brush holder)
As the differential magnetoresistive sensor

turns with the steering column, a rotating
voltage supply is required.
The current supply and tap-off are carried out

using sliding-action contacts (2 x 3 switched

in parallel operation) by means of a slipring

system.
These sliding contacts are maintenance-free.
5/0057
Remark: The sliding-action contacts should
reserved.
rest against the slipring system

under slight pressure.

Assembly B Steering
Removing the steering column
Caution: As the vehicle can no longer be 5 8

steered once the steering column 6
has been removed, the vehicle
must first be jacked up and secured
against rolling away.
1. Remove the cover (1) in front of the

accelerator pedal; to do so, set the pe- 7
dal adjuster to its lowest position.
2
3. Release the steering column adjuster
with the knob (2) and fold out the stee-
ring column completely.
4. Pull off the knob, washer and sleeve.
5. Push screw (3) into the housing.

6. Remove the steering system cover (4)
by removing the 3 screws, applying the
handbrake and lifting off the cover.
Note: Before removing the cover
entirely, disconnect the
connector for the key-opera- 4 3 1
ted switch. 5/0047
reserved.
7. Remove the steering wheel cover cap

(5) with a screwdriver.
8. Undo the nut (spanner size 27) and
remove the circlip.
9. Pull off the steering wheel. If it is very
tight, use a plastic mallet or a puller de-
vice.
10. Remove the curved housing from the
steering sensor (6).
11. Remove the metal housing (7).
Continued on sheet no. B7

Assembly B Steering
Contd.
Removing the steering column
Continued from sheet no. B6
12. Disconnect the electrical connector for

the steering sensor.
13. Remove the clamping screw of the
cardan joint (1).
14. Hold the steering column steady in one
hand and with the other pull the screw
(2) right out of the steering wheel clamp.
15. Pull the steering column out of the
cardan joint, forcing open the cardan
joint with a screwdriver if necessary. 3
16. Tap the steering column out of the

bearing (3) with a rubber mallet.
1
2
Mounting 5/0047
reserved.
To mount the steering column, follow the

instructions above in reverse order. Check
the bearing and sliding surfaces for easy
running.
Note: Observe the setting instructions

for the steering sensor (see
sheet no. B8).

Replaces issue: Manual h FM Typ 429 B7
Assembly B Steering
Setting the steering sensor

General:
Caution:
No steering boost may be connected to the

battery without a correctly set steering sen-
sor, as otherwise danger is incurred from the
steering wheel movement. For this reason,
exercise particular caution when setting the
steering wheel. Never reach through the
steering wheel when carrying out setting
work.
The steering sensor is pre-tested, i.e. in nor-

mal cases no setting is required. Should set- 1 mm
ting be necessary for any particular reason,

for example after exchanging the steering 1

sensor, repairing the steering column etc.,
proceed as follows:
A voltmeter is required (10 V), e.g. Beck-

mann HD 110 T.
In mounted condition:
reserved.
2. Remove both central connections "2" at

the slipring. 5/0055
3. Connect the voltmeter, with plus at "1" and

minus at "3".
4. Insert the battery plug.
5. Note the measured value (approx. 5 V).
7. Connect the voltmeter plus pole to "2" and

the minus pole to "3". Insert the battery
plug.
5/0058

Assembly B Steering

In mounted condition (contd.):
8. Release the clamping screw (1) at the

magnetoresistor holder, and position it
approx. 1 mm below the magnet. The
magnetoresistor should be located cen-
trally under the magnet, so that 2,47 V (±
0.03 volt) is measured between "2" - "3".
9. Then turn the steering wheel until the

clamping sleeve is stopped by the sensor 2
(mechanical end stop, 2).
The voltage between "1" - "2" and "2" -
"3" must change by approx. 1.5 volts (full
modulation). 1 mm
If the voltage alteration is too small, the
distance between the magnetoresistor

1
and the magnet must be reduced.
10. Checking voltage reset:

When the steering wheel is released, the
voltage must return to the previously set
central position. If this does not happen,
check all the bearing points in the stee-
reserved.
ring column and test for easy running. If

necessary exchange the foam rubber tor-
sion segments (Id. no. W8 410 477).
11. Performance check: 5/0055
Pull out the battery plug, reconnect the

two central terminals "2", re-insert the
battery plug. It should be possible to turn
the steering wheel to the left and right
with the same level of force.
In the zero position of the steering wheel,

the steering motor must be switched off.
No motor current should flow.
If this is not the case, carry out the setting
again or calibrate the steering controller
(see sheet no. B25).
5/0058

Assembly B Steering
In an unmounted condition:
For this setting work, the sensor must be

tensioned with a shaft end in a vice in order
to simulate the torsion occurring during stee-
ring.
Lay a supply voltage of 5 volts using a power

supply unit to terminals "1" and "3".
2
1. Release the clamping screw (1) at the
magnetoresistor holder, and position it
approx. 1 mm below the magnet. The
magnetoresistor should be located cen- 1 mm
trally under the magnet, so that 2,47 V (±

0.03 volt) is measured between "2" - "3".

1
2. Now displace the sensor (e.g. with gripper
pliers) until the clamping sleeve stops
against the sensor (mechanical end stop,
2). The voltage between "1" - "2" and "2" -
"3" must change by approx. 1.5 volts (full
modulation).
reserved.
If the voltage alteration is too small, the

distance between the magnetoresistor and
the magnet must be reduced.
3. Checking the voltage reset: 5/0055
When the steering is released, the voltage

must return to the previously set central
position. If this does not happen, check all
the bearing points in the steering sensor
and test for easy running. If necessary ex-
change the foam rubber torsion segments.
4. The sensor is now pre-set. It is, however,

still essential to carry out a performance
check once the steering sensor is moun-
ted.
5/0058

Replaces issue: Manual FM Typ 429 B 10
Assembly B Steering
Servoeinheit
Temperature monitor
Id. Nr. W8 421 248 (new part) Signal carbon
Id. Nr. W8 421 458 (exchange part)
General
The servo unit consists of an electric motor

(48 V) (1) and a flange-mounted gear (2).
The servo unit is executed with two separate 5/0048
series field windings (split field motor). Left

and right-hand rotation is therefore possible
without repoling. 2 1
The ball-bearings are maintenance-free. If

the bearings are removed during repair work,

they must be replaced. The bearings must be
renewed after approx. 25,000 operating Temperature monitor
hours.
Signal carbon
The gear is maintenance-free; it has
sufficient lubrication for the duration of its
operating life.
reserved.
To improve its operation, the motor is fitted

5/0049
with a temperature monitor and a signal
carbon for monitoring carbon brush wear.
Terminal coding on terminal board
A1 = Armature
Dr/D1 = Field 1 for right-hand rotation
Dl/D2 = Field 2 for left-hand rotation Side Side
A B
5/0050

Assembly B Steering
Exchanging the carbon brushes

Id. Nr. W8 407 174
Id. Nr. W8 407 175 (signal carbon brush)
More detailed information on this subject can be

found in the travel motor section (see sheet no.
A4).
New length: 22 mm
Change at residual length: 11 mm
Set of carbon brushes: 2 brushes
Remark: The signal carbon ican be identi-

fied by the black wire.
reserved.

Assembly B Steering
Removing the servo unit
1. Jack up the vehicle and secure it against

rolling away.
3. Move the electrial seat adjuster to the top
end position. 3
4. Turn the steering so that the chain joint of
the steering transmission chain (small
chain) is in a suitable position for moun-
ting.
1
5. Isolate the vehicle from the power supply.
6. Mark and disconnect the steering motor
connections.
7. Relax the tension on the steering
transmission chain.
8. Open the chain joint and remove the
chain.
9. Remove the retaining screw M12x50 from 2
the carrier plate of the steering motor (1).
10. Lift the steering motor with the carrier pla-
te (clear of the tensioning pin) and remove
reserved.
the servo unit. If necessary, use a screw-

driver for leverage.
11. Remove the four cheese-head screws
M6x12 (2) from the carrier plate and pull
the carrier plate off over the chain wheel.
12. Remove the cheese-head screw M8x16
(3) from the chain wheel and then pull off
the chain wheel (Id. no. W8 415 972, z =
15).
To mount, follow instructions in reverse order.
5/0051
Ensure the screw tightening torques are correct

(see illustration) and tension the chain when
the servo unit is fully mounted (see sheet no.
B18). Check that the steering moves freely and
does not produce any noise.

Assembly B Steering
Steering transmission, general
The steering transmission consists of four

chain wheels:
1. The chain wheel of the servo unit (see

sheet no. B13, point 12).
2. The chain wheel of the steering column
(1)
Id. no. W8 415 972, z = 15
3. Large chain wheel (2)
Id. no. W8 415 971, z = 38
4. Chain wheel of the steering chain (3)

5/0052
Id. no. W8 256 984, z = 15
Added to these components are 4 deep-groo- 1

ve ball bearings (no. 4: Id. no. W8 416 154;
no. 5: Id. no. W8 012 951) and their respective
assembly fittings.
reserved.
Defective or worn bearings and/or chain

wheels will detract from optimum steering per-
formance. 5
This can lead to premature wear of the 4

interacting components of the steering
transmission.
Pay particular attention to deep-groove ball

bearings and chain wheels ("scraping noi- 3
ses").
5/0053

Assembly B Steering
Removing the steering

transmission
3
1. Remove the steering column (see sheet
no. B6).
2. Remove the servo unit (see sheet no.

B13).
3. Screw the two chain tensioners of the

steering chain right in (1). To do so,
release the lock nuts.
4. Remove the two retaining screws (2) of

5-01 27
the bearing pedestal and then remove the
1
steering chain (3).
5. Remove the bearing pedestal.
Mounting
To mount, follow the instructions above in

reserved.
reverse order.
Ensure that the steering chain is correctly

tensioned (see sheet no. B18).
5-01 25
Also ensure that the steering transmission is
mounted parallel to the side of the chassis. 2
This is usually the case if the chain is
tensioned evenly.
Once the steering transmission is mounted,

turn the drive wheel by hand to check that no
noise is produced.

Assembly B Steering
Removing the chain wheels and
their bearings
A. Chain wheel of the steering column

with its bearings
1. Remove the steering transmission (see

sheet no. B15).
2. Remove the self-locking nut (no. 1, span-
ner size 24) and pull the shaft (2) out of
the bearing pedestal or knock it out with a
rubber mallet and drift if necessary.
3. Pull the chain wheel (3) off the shaft (ta- 2
king care of the adjusting spring).
4. Knock the deep-groove ball bearing (4) out 6
of the bearing pedestal using a drift. Take

care of the distance sleeve.

5/0052

reverse order. Check that the bearings move
freely.
3
Take care not to install the shaft the wrong
way round (see illustration to the right). Ensure
reserved.
the tightening torque of the self-locking nut (1)

is correct.
B. Chain wheel of the steering chain and 4

large chain wheel with their bearings
1. Remove the steering transmission (see
sheet no. B15).
2. Remove the self-locking nut (no. 5, span-
ner size 24).
3. Pull off the chain wheel of the steering 1
chain with a puller device.
4. Remove the adjusting spring and the di- 5
5/0053
stance sleeve.
5. Knock out the shaft (6) with a rubber mal-
let and a drift.

Assembly B Steering
Removing the chain wheels and

their bearings
Continued from sheet no. B16
6. Knock out the deep-groove ball bearing (7)

using a drift and rubber mallet (taking care
of the distance sleeve).
7. Remove the distance sleeve from the shaft

(6) and knock the large chain wheel (8) off
the shaft with a rubber mallet. 2
6
Mounting
5/0052

reverse order. 8
Check that the bearings move freely. Ensure

the tightening torque of the self-locking nut (5) 3
is correct.
reserved.
4
7
5
5/0053

Assembly B Steering
Chain tensioning
The reliability and easy running of the steering
are largely dependent on the correct chain
tension. Excessive tension necessitates
greater manual force and in the long term will
serve to damage the steering transmission
and chains, while insufficient tension increa-
ses response times and also wear of the
chains and pinions.
Tensioning the steering transmis-

sion chain:
(small chain), Id. no. W8 006 314
1
2. Release the retaining screw (1).
3. Using the tensioning screw (2) set the

tension of the chain so that the chain gives 5-01 25
by one thumb's width when a slight 2 3

pressure is exerted on the longest part of
the chain.
4. Tighten the retaining screw and lock the
tensioning nut.
Tensioning the steering chain:

reserved.
(large chain), Id. no. W8 006 348

2. Release the retaining screw (3).
3. Using the two retaining screws (4), tension
the chain as described above.
Adjust the tensioning screws evenly,
otherwise the tension will be different at
the front and back of the chain.
4. Tighten the retaining screws and lock the 5-01 27
tensioning nut.
4
Remark: The steering chain must always be
tensioned first. After tensioning the
steering chain, the steering
transmission chain must be
checked for correct tension.

Assembly B Steering
Exchanging the steering chain

Id. no. W8 006 348 (available by the metre)
The steering chain must be replaced if the

chain can no longer be tensioned with the 1
tensioning device or if the chain is damaged.
2. Turn the drive so that the chain join is

easily accessible (see photo to the right).
3. Relax the tension on the steering chain

completely (see sheet no. B18).
4. Open the chain at the chain joint (1) and

remove the chain. 5-01 29
Mounting
To fit a new chain, follow the instructions
reserved.
above in reverse order.
Ensure that the steering chain is correctly

tensioned (see sheet no. B18).

Assembly B Steering
Steering controller
Id. no. W8 407 058 or W8 407 010
1
General
Note: Two different steering controllers are
used. The steering controllers are
practically interchangeable 1:1. If the
steering controller W8 407 010 is used,
the
configuration (LR-NEW) must be altered
in the electronic evaluation system (see
sheet no. M93).
Steering controller W8 407 010 is easy to 7/0432
identify by the number of trimmers (3).

The trimmer labelled (2) is not fitted.
The following description refers to steering

controller W8 407 010
The torque requirement from the steering wheel is
registered and evaluated by the magnetoresistor,

which in turn activates the integrated MOSFET power
output stage.
In combination with the non-linear current/torque

characteristic curve, this gives steering performance
that guarantees both high stability during fast travel
and light steering when stationary.
6/0329
The numerous monitoring functions ensure the
reserved.
steering system functions safely:
- Overvoltage/undervoltage protection
- Short-circuit proof power output stage with
pulse-by-pulse current limitation
- Temperature monitoring of power output stage
- Reverse voltage protection 3
- External enable input
- Signal output for "steering error"
- Steering motor carbon brush monitoring with
signal output
- Setpoint generator wire breakage monitoring X2
The steering controller can be adjusted to the vehicle
with a potentiometer. The maximum motor current is
limited to 30 A by fixed resistors. X1
The steering controller is protected by a 30A/125V 2
input fuse (1), Id. no. W8 405 541 (see also block
diagram, sheet no. B21).
The electrical connections are made with a 6-pin
"6.3 mm Fast-on" combination connector for the
operating voltage and the motor and with a 6-pin
AMP low-voltage connector for the sensor system.

Replaces issue: Manual FM Type 429 B 20
Assembly B Steering
Setpoint generator Block diagram for steering controller
(magnetoresistor)
+48V
Rmin:
200 Ω
. Emergency-off impact button
3F1
1
20A
0 volts
X1 o 6 o4 o 1 X2 o 6 o2
W8 407 010
2.5V 5V
±1.5V Imax: 25mA 30A
Voltage
monitor
. . Safety relay
. X2
o
5
Undervoltage: 12V
Overvoltage: 75V ±5%
48V Reverse
voltage protection
5V
Error monitor
P1 balance Amplification P2
**
Signal
o
Actual P.W. modulator carbon

4
Set
P3
o Uon
Dead zone
Function generator Current Current regulator
limiter (30A)
Short-circuit (pulse-by-pulse) M
Internal
approx. 60A enable
Overvoltage Error
monitor .
.
Undervoltage
reserved.
Safety relay Left Right

Temperature
100°C
Setpoint
generator
monitor
.
1
Current
measurement .
Imax: 200mA
.. . .. . o
3
Signal
carbon
. .. . o
1
Output stage ** see note on sheet B20

X1 o 2 o5 o3 enable
"Not ready" "Carbon

brush
o Key-operated
to switch
electronic wear"
to F2
*TPS = evaluation electronic 10A
Travel and
pump control
system
system
(TPS)*
evaluation
system
(TPS)*
. 1
5/0059

Replaces issue: Manual FM Type 429 B 21
Assembly B Steering
Steering controller
Functional characteristics
The steering sensor is supplied with stabilized

5 V power by the steering controller. This
voltage is short-circuit proof, but must not be
greater that 25 mA in continuous operation.
A1
Depending on how far the steering setpoint M
changes from the non-operation region of B
2.47 V, the maximum change being ± 1.5 V,
L12/1 L12/2 L12
the corresponding power MOSFET of the out- 48V Dl Dr
put stage is activated and activates the minus
pole via the outputs "Field L" and "Field R".

The result is that if the setpoint is altered X2:4 X2:3 X2:1 X2:5 X1:1 X1:4 X1:5
slightly, the transistor timing is slow, and if a Carbon Field L Field R Armature Vref + Sensor Vref -
Steering motor Lenksollwert
greater setpoint alteration is made, the Steering controller 5V 2,47 ± 1,5V 0V
transistor timing is faster. The steering system 30A Freigabe not
ready carbon
is demand-responsive. X1.2 X1.5
X1.3
X2.6 X2.2
reserved.
The output stage is not activated until there 0V

+48 V
via
emergency- to
are 48 V at the external enable input (X1.3) off button to key-
operated
electronic evalua-
tion system (AWE)
and the supply voltage is also 48 V switch
5/0064
(X2.2/X2.6).
In addition, the output stage is not activated if

the safety monitor has responded (see sheet
no. B23).
If the "signal carbon" signal is activated (48 V

at X2.4), the "open collector" output "Carbon"
(X1.5) switches to 0 V.

Assembly B Steering
Steering controller
Safety monitoring
1. Operating voltage
The supply voltage is additionally buffered

by internal buffer capacitors in the
appliance.
If the voltage exceeds 75 V or drops below
12 V, the steering controller cuts out.
2. Short-circuit proof output stages
In the event that the motor short-circuits,

the maximum current is maintained at ap-
prox. 30 A by the pulse-by-pulse current li-

miter, which prevents the transistors being
damaged.
If the system is placed at risk by transient
high current peaks (higher than 60 A) or
the current limiter is defective, a short-cir-
cuit monitor switches the steering control- 7/0432
ler off.
reserved.
3. Excess temperature 1
The power output stage is protected

against overheating.
The steering controller is switched off
when approx. 100 °C is reached at the he-
at sink of the output stage.
4. Reverse voltage protection
If the 48 V supply voltage is connected at

the wrong poles (X2.6 = 0V, X2.2 = 48 V),
the internal safety relay (1) does not
function.
Continued on sheet no. B 24

Assembly B Steering
Steering controller
Safety monitoring
Continued
5. External enable input
The internal pulse width modulator which

generates the timing of the transistors is
not enabled until there are 48 V at input
X1.5.
6. "Steering error" signal output
If the safety monitor is actiated under

conditions 1, 2, 3 or 8 (see also sheet no.

B23), the safety relay (1) becomes
inoperative, the motor is cut off from +48 V
and the "open collector" output X1.2
switches off the 0 V signal (Imax. 200 mA).
The pulse width modulator is locked 7/0432
internally.
reserved.
7. Carbon brush monitor 1
If there is a 48 V signal at input X2.4, the

"open collector" output X1.5 switches to
0 volts (Imax. 200 mA).
The steering controller is not switched off.
8. Setpoint generator wire breakage

monitor Remark:
If the supply voltage lines to the setpoint If the fuse 3F1 (power supply to the
generator are broken, the steering steering controller at X2.2) or the
controller cuts out and the "Steering error" internal 30A fuse in the steering
output switches off the 0 V signal. If the controller is faulty, the two outputs
setpoint lead is broken, the "Steering "Steering error" (X1.2) and "Carbon
error" output is also switched off. brush monitor" (X1.5) also switch to a
0 volt signal, which causes error
messages FE 40 and FE 41 to be
displayed on the console display.

Assembly B Steering
Steering controller
Setting
The steering controller is preset in the factory and
does not need to be reset with the 3
potentiometers (1).
If, however, the steering performance is not ideal

or the steering motor tends to overheat, a check
should be carried out to ensure that the steering
sensor is set correctly (see sheet no. B8).
*Potentiometer P1, "balance"
Note: Potentiometer P1, "balance" is 1

calibrated in the factory and must not
be adjusted!
P2 "amplification"
X2
Potentiometer P2, "amplification" P3 "dead zone"

P1 "balance"
This potentiometer can be used to vary the ratio
between the steering setpoint and the steering X1
motor modulation.
It cannot, however, be used to alter the maximum
current limitation of 30 A, since this is defined by
fixed resistors.
This potentiometer can only be used to decrease
the maximum current, which in turn also decreases
reserved.
the maximum torque. 2
Potentiometer P3, "dead zone"
The dead zone can be set so that the steering

system is more sensitive to slight steering
movements (during fast travel). The larger the
dead zone, the greater the manual force required
for slight steering movements.
If a dead zone is selected which is too small, the
current may flow even when the steering is not
operative. This must be avoided at all costs!
The power steering should be activated at a 6/0165
setpoint change of ± 0.25 V and is preset to this
value in the factory!
The potentiometer can be accessed via a hole (2)
in the cover.
* See also remark on sheet no. B20

Assembly B Steering
Steering controller
Comissioning
For comissioning purposes, the motor field

circuit (terminals field R, field L) is not
connected.
After switching on the operating voltage, first

check the wiring to the magnetoresistor. There
should be a voltage of 2.47 V at the centre tap
of the magnetoresistor when the steering is in
the idle position. If the steering wheel is turned
to the mechanical stop, the voltage should
change by approx. 1 V or 4 V, depending on
the sense of rotation.
Now reconnect the motor field circuit.
You will now notice that the control sense is

reversed, since the steering controller now
operates against the desired steering
movement and a greater manual force is
reserved.
required. The steering may also be unstable.

In this case, the two motor field terminals must
be exchanged.
If necessary, the steering controller can then

also be calibrated as described on sheet no.
B25.

Assembly B Steering
Pin assignment
Connector X2
X2 pin no. Designation Function
1 Field R Field terminal of motor for X2
right-hand rotation
5 3 1
6 4 2
2 +BAT (48V) Positive supply voltage
terminal
3 Field L Field terminal of motor for
left-hand rotation
4 Carbon_E (48V) Inlet for signal carbon
5 Armature Positive motor terminal X1
2
1
6 -BAT (0V) Negative supply voltage
4
3
terminal
6
5
5/0066
reserved.
Connector X1
X1 pin no. Designation Function
1 Vref+ (5V) Positive reference voltage 1 Field R +Bat 2
for magnetoresistor
3 Field L Carbon 4
2 N_ready Error output
(when error at high)
5 Armature -Bat 6
3 FG Enable input (48 V =
steering motor active)
4 Sensor (2.47V) Bridge output voltage
of the magnetoresistor
2 N_ready Vref+ 1
5 Carbon_A Carbon output
(when signal carbon at low)
4 Sensor FG 3
6 Vref- (0V) Negative reference voltage
6 Vref- Carbon_A 5
for magnetoresistor

Assembly C Brake
Contents
Sheet no.
Functional characteristics...............................................................................C 2
Plan of hydraulic brakes.................................................................................C 3
Setting the brake clearance ...........................................................................C 6
Setting the handbrake ....................................................................................C 7
Setting the brake pedal ..................................................................................C 8
Braking distances...........................................................................................C 10
Measuring the brake deceleration..................................................................C 11
Main brake cylinder
- General ..............................................................................................C 13
- Special bottom valve ..........................................................................C 14
- Removing ...........................................................................................C 15
Bleeding/filling the brake system....................................................................C 16
reserved.

Replaces issue: Manual FM Typ 429 C1
Assembly C Brake
Hydraulic/mechanical
brake system 1
Functional characteristics 6
This brake system is a positive acting system

consisting of a mechanical component, the 5
parking brake (handbrake) and the hydraulic
component, the service brake (brake pedal),
which applies the travel motor and lead
wheel brake. 2
3
When the brake pedal is actuated, pressure
is applied to the wheel brake cylinder (Fig. 1, 5
no. 1) via the main brake cylinder. This then

presses the brake shoes (Fig. 1, nos. 2 + 3)

against the brake drums (Fig. 1, no. 4) 4
= braking action. Bild 1 5/0067
When the brake pedal is released, the brake

shoes are returned to their home position by
tension springs (Fig. 1, no. 5).
reserved.
When the handbrake is used, the brake

shoes are actuated by cable (Fig. 1, no. 6)
This only acts on the travel motor brake.
At the same time, the 0V signal to the

combined travel and lift pulse control is
interrupted by a handbrake switch and the
travel function is blocked electrically.
6/0283
Bild 2

Assembly C Brake
Plan of hydraulic brakes
Without load wheel brake

reserved.
6/0284

Assembly C Brake
Plan of hydraulic brakes
With load wheel brake

reserved.
6/0285

Assembly C Brake
Travel motor brake,

mounting/removal
Id. no. W8 412 026 (complete brake,
1
without housing and drum)
Note: Since the brake (1) is flange-

mounted on the travel motor, the
vehicle is in an unbraked
condition after the brake has
been
removed. 5/0009
For this reason, secure the

vehicle to prevent it rolling away.
Removal
2
1. Release the handbrake.
2. Remove the covers. 3

5/0071
4. Remove the 4 cheese-head screws
reserved.
M8x35 (2) and lay the brake to one

side, complete with the speed sensor.
5. Remove the brake hose (4), ensuring

that no oil escapes over the brake.
6. Unhook the handbrake cable, relieving

the cable tension at the setting device of
the handbrake lever if necessary (see 4
sheet no. C7).
7. Remove the brake plate from the

housing by releasing the M8 cheese-
head screws (3).
5-01 02
To mount the travel motor brake, follow the

instructions above in reverse order. On
completion, carry out a brake performance
check and if necessary bleed the brake and
check the brake clearance.

Assembly C Brake
Setting the brake clearance

Performance check of brake pedal /
Performance check of handbrake.
Note: Check brake deceleration values

once a year and after all
adjustments or repairs to the bra-
ke system (for setting values,
see sheet no. C10).
Checking brake lining thickness:
There are holes (1) built into the brake plate

for visual inspection of the brake linings. If a
lining thickness of only approx. 2 mm re-
mains, the brake shoes must be exchanged.

5/0074
Id. no. Brake shoe: W8 412 077

Id. no. Brake shoe with
parking function: W8 412 076
2
Setting the brake:
The internally acting shoe brake has a central

reserved.
setting for adjusting play and the envelope

circle. The setting process draws a key (2)
between the support points of the brake
shoes, which alters the envelope circle. This
results in optimum utilization of the brake li-
nings and at the same time better leverage
for initiation of the braking force on the brake
drum. After each readjustment of this brake
key, re-centre the brake shoes by braking se-
veral times.
Setting:
Turning the setting hexagon (2) to the right

5/0075
draws the key upwards, i.e. increases the
envelope cirvcle and so readjusts the brake
lining. Turning to the left reduces the envelo- 1
pe circle, brake clearance 0.3 - 0.5 mm.

Assembly C Brake
Setting the handbrake

Id. no. W8 331 449 (complete handbrake)
Id. no. W8 004 723 (handbrake switch)
Like the brake pedal, the handbrake acts on

the drive wheel. The brake cable needed for
this purpose is suspended at one end on the
hook of the brake shoe and at the other end
on the brake lever in the driver's cab. It is at
this end that the brake cable must be adju-
sted.
Before the handbrake can be adjusted, the

brake clearance must be set correctly (see
sheet no. C6).
Setting
1. Remove the covers behind the steering

column (see sheet no. B6, points 1-6).
2. Set the bowden cable setting device (1)

in such a way that it is only possible to
latch the toothing of the handbrake lever
reserved.
onto the 4th tooth by exerting considera-

ble force.
1
3. Subsequent inspection: 5/0076
Jack up the vehicle securely and accele-

rate the motor at full speed by bypassing
the handbrake switch.
The motor must now block at the latest

when the 3rd tooth latches in.
To determine the exact braking force, a

test must be carried out with the vehicle
in motion. When you reach maximum
speed, brake the vehicle using the hand-
brake. A brake deceleration value of 15
% must be achieved (see also sheet no.
C10).

Assembly C Brake
Setting the brake pedal
The brake pedal must be adjusted when:
- the main brake cylinder (Fig. 1, no. 1) has

been exchanged,
- the piston rod clearance (snifter clearance) 3
(Fig. 1, no. 2) is not correct,
4
- brake pedal components have been
exchanged.
Note: Since the vehicle is not properly

braked during the setting
1
procedure on the brake pedal,
the vehicle must be secured 5
2
against rolling away.

2. Slightly loosen the nut (figs. 1+2, no. 3) in Bild 1 5/0077
the mechanical stop for the brake pedal.

3. Push the stop (Fig. 1, no. 4) along the
longitudinal slot until the distance bet-
ween the top edge of the brake pedal and
the carrier plate for the accelerator pedal
measures approx. 96 mm (see fig. 2). The
measurement must be made with the
reserved.
rubber pedal cover removed.

4. Tighten the nut (figs. 1+2, no. 3).
5. After releasing its nut (Fig. 2, no. 7), turn
the threaded rod (Fig. 2, no. 6) until there
96 mm
is a clearance of 1 mm between the pis-

ton and piston rod of the main brake cylin-
der. Lock the nut again.
This "snifter clearance" is not visible, as
the protective cap covers the end of the
piston rod. However, it is easy to "feel" it
by slowly pressing the brake pedal down
manually out of the idle position. Once the
piston rod has moved by 1 mm, a slight Bild 2 5-03 26
resistance should be felt. This is caused

3 6 7
by the piston rod making contact with the
piston.

Assembly C Brake
Continued
Setting the brake pedal
6. Bend the actuator plate (1) of the brake

pedal switch by hand so that when the
brake pedal is not activated, the switch is
activated and when the pedal is tapped
lightly the switch is released.
This can be heard as a quiet "click" of the
switch.
The return force of the pedal is fixed by the

tension spring (2).
This setting cannot be altered.

5-03 26
The spring should be replaced as required 2 1

(Id. no. W8 010 089) and the mechanical
components tested regularly for easy
running.
reserved.

Assembly C Brake
Braking distances
The table of braking distances below is intended purely as an approximate guide. The
exact braking force can only be determined by measuring the brake deceleration value
with measuring equipment (see sheet no. C11).
Speed of travel v Time in s for distance of Permissible braking

10 m (flying start) distance in metres
in km/h m/s with rated load without rated load
6 1.67 6.0 1.2 0.7

7 1.94 5.2 1.4 0.9
8 2.22 4.5 1.6 1.0
9 2.50 4.0 1.9 1.1

10 2.78 3.6 2.1 1.3
11 3.06 3.3 2.3 1.4
12 3.33 3.0 2.5 1.5
13 3.61 2.8 2.7 1.7
reserved.
Remark: These values apply only for industrial trucks belonging to Group A as per
DIN 15161, with a type-related speed of between 5.0 and 13.4 km/h.
This measurement must always be made in the travel direction of the forks.
The braking distance must be measured on a surfaced area which is level

and dry.
The lifting device must be drawn in during the braking tests!
Example: The measurement distance of 10 m is travelled in 6.0 seconds at a travelling

speed of 6 km/h. At this speed, a braking distance of 1.2 m with rated load
and 0.6 m without a load must be achieved.

Replaces issue: Manual FM Typ 429 C 10
Assembly C Brake
Measuring the brake

deceleration
General
The brake deceleration value is measured with
the dynometer (Fig. 1), Id. no. W8 050 605. 2
This works on the principle of the pendulum,

which registers irregular movements with great
precision.
During travel at a steady speed over an even

surface, the pendulum always hangs vertically
and shows zero on the dial (Fig. 2). On
acceleration, the pointer deflects to the right 1
(clockwise) and on braking (deceleration), it 5/0115
moves to the left. Bild 1

Preparations for measurement
Moisten the rubber sucker on the underside of

the measuring instrument (ideally with glycerin),
then use the lever (Fig. 1, no. 1) to fasten the
dynometer onto a horizontal surface.
The dial must face towards the driver's seat and

be mounted in the direction of travel.
reserved.
Before every deceleration measurement, the

3
measuring case (Fig. 1, no. 2) must be tipped to 5/0116
move the measuring pointer to zero. The Bild 2

dynometer has been set to the correct zero
position by tipping the case when the measuring 4
pointer can move almost a full turn to the left
(anti-clockwise) from zero and almost half a turn
to the right.
The maximum pointer (Fig. 2, no. 3) must be

reset manually, by turning the knob at the centre
of the dial (Fig. 2, no. 4) clockwise, until the
pointer is set as closely as possible to zero.
During the braking process, the maximum pointer

moves to the maximum deflection point together
with the measuring pointer and remains there Bild 3 5/0117
when the other moves back (Fig. 3).

Verzögerung in %

Assembly C Brake
Continued
Measuring the brake deceleration
Evaluating the measurement
1. Calculate the maximum vehicle speed

(V = distance/time).
2. Accelerate the vehicle to Vmax. in the

direction of the forks (backwards)
3. Stop the vehicle by applying the brakes with

full force, and read the braking deceleration
value "F" off the dynometer (i.e. the
maximum pointer reading).
4. The following values are required:
Example for v = 10 km/h
With rated load Without rated load
F = 1.86 x V F = 1.86 x 1.6 x V

reserved.
F = 1.86 x 10 km/h F = 1.86 x 1.6 x 10 km/h
F = 18 % F = 29.76 %

Assembly C Brake
Main brake cylinder

Id. no. W8 415 954
The main brake cylinder is located under the bra-

ke pedal on the floor of the cab and is connected
to the brake pedal by a guide mechanism.
2
The entire braking process is started and
controlled by the main brake cylinder, since when
the brake pedal is depressed, the main brake cy-
linder piston (1) pushes the brake fluid in the bra-
ke system into the wheel cylinder. 3 4 1
The equalizing tank (2) is mounted directly on the
main brake cylinder. It must always be filled with
sufficient brake fluid, to approx. 15 - 20 mm be- F
low the edge of the lid.
5/0078
Equalizing tank: Id. no. W8 415 955

"copper" sealing ring: Id. no. W8 006 209
Remark: Only use original brake fluid! Do not
fill with mineral oil! The brake fluid
must be changed once a year.
The main brake cylinder is fitted with a protective

cap (3) to prevent dust and water entering the
cylinder. This cap has a vent hole, which lets the
reserved.
air contained in the protective cap escape when

the main brake cylinder is actuated.
The protective cap must be mounted in such a

way that the vent hole is at the bottom. If the pro-
tective cap is mounted so that the vent hole is at
the top, water can collect in the cap, from where it
can enter the main cylinder when the brake is ac-
tuated.
The results of this are:
- Rust formation at the main brake cylinder bo-

re, which causes damage to the secondary
sleeve (4) and loss of brake fluid.
- The main brake cylinder piston can freeze so-

lid at minus temperatures.
Continued on sheet no. C14

Assembly C Brake
Continued
Main brake cylinder
If leaks are found at or in the main brake

cylinder, or the cylinder is found to be
otherwise damaged, the entire main brake
cylinder must always be replaced, since
special tools and expertise are needed to
carry out repairs.
Special bottom valve
So that excess pressure in the brakes can be

relieved entirely when the brakes are Bild 1 5/0078
released, bringing the pressure to 0, the main

brake cylinder is fitted with a special bottom
valve (1).
This feature, in combination with the "snifter
clearance" of 1 mm, makes it possible to 1
release the brake linings without difficulty
(see sheet no. C8, point 5).
Unlike the normal bottom valve, the special

reserved.
bottom valve has a throttling port "D" (Fig. 2).
The throttling port has two functions. Firstly, it

makes it possible for excess pressure to be
relieved entirely, and secondly, it guarantees
that on fast operation of the pedal in certain
situations, brake fluid can be "pumped" into
the pipe system by the main brake cylinder Bild 2 5/0079
piston; for example, when filling and bleeding

the brake system, if there is no filling or
bleeding equipment available.
In order to avoid main brake cylinders with a

special bottom valve being confused with
other main brake cylinders, they must be
marked with a metal or adhesive tape
labelled "cylinder fitted with a special bottom
valve".

Assembly C Brake
Continued
Main brake cylinder
Removing
Caution: Secure the vehicle against

3
rolling away, since the brake
system is not fully operational.

2. Release the lock nut on the fork head (1)
and push out the fastening screw.
3. Release the two fastening screws (2)
and tilt the main brake cylinder.

4. Remove the fork head and the actuator

5-03 27
plate (3) of the brake pedal switch.
2 1
5. Remove both the fastening screws (2)
and the mechanical stop.
6. Pull out the main brake cylinder and lay
it to one side.
reserved.
Remark: The main brake cylinder

must be set down with the
storage tank at the top,
otherwise the brake fluid will
run out through the vent
hole.
7. Remove the brake hose.
To mount the cylinder, follow the instructions

After installation, bleed the brake system, set

the brake pedal to the correct position and
check the brake clearance and the brake
deceleration value.

Assembly C Brake
Bleeding/filling
the brake system
Caution: When handling brake fluid, ensure
that the aggressive fluid does not co-
me into contact with the eyes, the
skin, clothing or parts of the truck. If
brake fluid comes into contact with
the eyes or skin, rinse immediately
with plenty of water and wash with
soap.
Never mix brake fluid with mineral

oil or dispose of the two together.
Filling
Brake fluid is hygroscopic, i.e. it takes moisture
from the air. We therefore recommend renewing
the brake fluid every year.
When filling and bleeding new or repaired brake

systems, do not use brake fluid which has

overflowed to refill the brake system. 5/0075
1
1. Fill the storage tank with brake fluid.
2. Remove the dust protection cap from the
bleeding valve (1), pull on a hose which fits
on the valve and hang the end of the hose in-
to an open glass vessel positioned at a hig-
reserved.
her level.
Remark: Only use the bleeding valve at
the brake hose, never at the bra-
ke plate. Wind a cloth or some-
thing similar around the bleeding
valve to prevent brake fluid ente-
ring the brake.
3. Open the bleeding valve by a quarter to half
turn.
4. "Pump" the brake pedal until brake fluid runs
out of the hose. If necessary, add more brake
fluid to the storage tank.
5. Close the bleeding valve.
6. Bleed the brake system (see sheet no. C17).

Assembly C Brake
Continued
Bleeding/filling
the brake system
Bleeding
If perfect braking performance is only

achieved after treading on the brake pedal
several times, or if the brake system has
been refilled, the brake unit needs bleeding.
If an "Ate filling and bleeding device" is

available, proceed according to the operating
instructions provided by Teves.
If an appliance of this kind is not available,

the brake system must be bled by the

following method. This process requires two
people if the FM is fitted with a load wheel
brake:
5/0075
1. Drain the storage tank and fill it with new 1

brake fluid.
reserved.
2. Remove the dust protection cap from the

bleeding valve (1), pull on a hose which
fits on the valve and hang the end of the
hose into an open glass vessel
positioned at a higher level.
3. One person presses the brake pedal

down as far as it will go and holds it in
this position.
Caution: Ensure that the bleeding

hose is fitted firmly. Cover
the glass with a cleaning
cloth to catch any splashes.

Assembly C Brake
Continued
Bleeding/filling
the brake system
4. A second person opens the bleeding

valve (1) by a 1/4 to 1/2 turn.
5. Brake fluid should run out under the

pressure of the brake pedal.
6. Close the bleeding valve again

immediately.
7. Move the brake pedal to its home

position.
Repeat this process 4 to 7 times until only

bubble-free, clear brake fluid emerges in the 5/0075
glass. 1
If the oil level in the equalizing tank drops
rapidly, top up with new "Ate brake fluid".
Do not reuse brake fluid which has

reserved.
overflowed.
Remark: The individual cylinders are

bled one after the other. Start
with the brake cylinder which is
furthest away from the main
cylinder. If you notice that there
is air in the brake system
particularly often, or if the brake
cylinders lose brake fluid, the
brake cylinder must be
exchanged.

Assembly M Electrical system
Contents Sheet no.
Guide to components .................................................................................................M 3
Traction and pump controller (FPS)

- General.............................................................................................................M 5
- Guide to components .......................................................................................M 7
- Main current terminals ......................................................................................M 8
- Control current terminals ..................................................................................M 9
- Block diagram...................................................................................................M 10
- Logic circuit board, general ..............................................................................M 12
- Electronic evaluation system, general ..............................................................M 13
- Travel/hydraulics output stages, general..........................................................M 14
- DC/DC converter, general ................................................................................M 15
- Control of the travel motor ................................................................................M 16
- Operating principle of the main current circuit for travel ...................................M 17
- Operating principle of the main current circuit for generator braking................M 19
- Operating principle of the main current circuit for hydraulics............................M 20
- Safety circuit
- General ....................................................................................................M 21
- Anti-roll monitor........................................................................................M 22
- Description of errors ................................................................................M 23
- Removing the logic board.................................................................................M 38

- Removing the electronic evaluation system .....................................................M 40
- Removing the hydraulics output stage .............................................................M 41
reserved.
- Removing the travel output stage.....................................................................M 42

- Removing the DC/DC converter .......................................................................M 43
- Removing the logic circuit board software........................................................M 44
- Control signals for travel (Vmax) ......................................................................M 45
- Control signals for travel (2.5 km/h)..................................................................M 46
- Control signals for hydraulics ...........................................................................M 47
- Installation of the super-console notebook software ........................................M 48
- Working with the software ................................................................................M 51
- Menu - Konsole verbinden........................................................................M 53
- Menu - Parameter.....................................................................................M 54
- Menu - Speichern .....................................................................................M 56
- Menu - Zurückspeichern ...........................................................................M 57
- Menu - Inhaltsverzeichnis .........................................................................M 58
- Menu - Konfiguration ................................................................................M 60
- Menu - Fehlermeldung..............................................................................M 64
- Menu - Tester ...........................................................................................M 65
- Menu - Pedaljustierung.............................................................................M 67
- Menu - Programm beenden......................................................................M 68

Replaces issue: Manual FM Typ 429 M1
Contents Sheet no.
Travel and pump control system

- Electronic evaluation system, general ..............................................................M 69
• Steuerung der Hydraulik ...........................................................................M 70
- Block diagram........................................................................................M 71
- Truth table .............................................................................................M 72
- Block diagram, pump setpoint ...............................................................M 73
- Simultaneous movements .....................................................................M 74
- Compulsory reset ..................................................................................M 75
- Shift damper function.............................................................................M 75
• Hydraulic options ......................................................................................M 76
• Control of the console display...................................................................M 78
• Error list ....................................................................................................M 82
• Maintenance intervals...............................................................................M 84
• TEWAK interface software........................................................................M 85
- Installing the TEWAK program ..............................................................M 86

- Opening the TEWAK program...............................................................M 86

- Closing the TEWAK program ................................................................M 87
- Diagnosis and commissioning - Software, general ...............................M 88
• Menu structure and use.................................................................M 89
- Main menu ................................................................................M 90
- Configuration.............................................................................M 91
- Commissioning .........................................................................M 95
- Parameters ...............................................................................M 99
reserved.
- Error list.....................................................................................M 101

- Maintenance interval .................................................................M 102
• Replacing the electronic evaluation system software....................M103
- Serial communication, logic circuit board and electronic evaluation system ....M 105
- Setting the battery discharge characeristic curve.............................................M 107
- Guide to pin assignment...................................................................................M 108
Interface adapter ........................................................................................................M 112

Guide to components
Id. no.
S1 Key-operated switch W8 014 175

1S1 Travel direction switch W8 405 278
2S2 Tilting key W8 405 279
2S3 Mast side shift key W8 405 279
2R2 Potentiometer for main lift W8 405 280
2R3 Potentiometer
for ancillary movements W8 405 280 1S3 X55
3M1
3A1 Steering controller W8 407 058
or W8 407 010 1S25X59
1S28 Creep speed rocker switch W8 405 328
4S1 Horn rocker key W8 405 329 7M20
Q1 Emergency-off switch W8 405 281

F1-5F7 See below
9M5
K1 Main contactor W8 400 132 1S27

1A10 Travel/pump control,
complete W8 406 821 4H1
9M6 Fan (1) 24V/48V W8 407 443 7/0433
6A10 Operating status 7/0434
display circuit board W8 405 489

F1
1B1 Travel transducer with switch W8 415 984
1B2 Brake pedal switch W8 004 723
1M1 Travel motor W8 406 776
reserved.
1S27 Battery lock switch W8 004 723

3F1
4F1
5F1
F2
F3
4H1 Horn W8 020 542

2M1 Hydraulics motor W8 405 521
Fuses
F1 Main current fuse 250 A W8 401 067

F2 Switch latch 5 A W8 402 856
F3 DC/DC converter input 10 A W8 402 857
3F1 Servomotor 10 A W8 403 857
4F1 Horn 10 A W8 402 857
5F7 Reserve 20 A W8 403 428
7/0435

Continued
Components
Id. no.
1S3 Handbrake switch W8 004 723
3M1 Servomotor, steering exch. W8 417 438
2Y25 "Shifting" on/off valve W8 412 269
(electr. components only)
7M20 Seat adjustment motor W8 415 949
7S21/22 Seat end switch W8 004 723
3S24 Central wheel position
switch W8 004 723
2Y29 "Tilting" on/off valve W8 412 269

7/0436
2Y44 Mast side shift on/off valve W8 412 269
2S39/38 Proximity switch for
shift damper function W8 405 321
reserved.
7/0437
Legende:
oder = or

Traction and pump controller

(FPS)
Id. no. W8 406 821

Id. no. W8 407 463 (AT)
General
The FPS is a combined travel and pump

control system. It is used to control a shunt
motor (for travel) and a series-wound motor
(for hydraulics).
The motors are timed via output stages using
a microprocessor-controlled logic circuit
board.
An electronic evaluation system evaluates
the setpoint (hydraulics) and transmits it
further in the system. It also evaluates

various different input signals.
The main current circuits are constructed
using MOSFET technology and are timed
with a frequency of 16 kHz. The voltage is
controlled on the principle of pulse width
modulation (PWM).
When generator braking of the motor takes

reserved.
place, power flows back to the battery. 7/0435

Travel against the applied handbrake (for 2
secs.) and anti-roll monitoring are integrated
as standard features.
Various components are directly connected

to the FPS (see block diagram on sheet no.
M11).
The logic board of the FPS is connected to
the electronic evaluation system with a ribbon
cable. This means that it is possible to
exchange (see sheet no. M105) or
delete data.

General, continued
The control system uses numerous control
3F1
4F1
5F1
current circuits to conduct continuous self-
F2
F3
diagnosis, and switches itself off in the event of
a fault being identified.
Once the control system has been tested

sucessfully, the main contact becomes
operative.
After 200 ms the main contactor is supplied 1
with 28 volts, in order to prevent the main
contactor coil overheating.
2
The software can be used together with a
notebook and an interface adapter to 3

change the parameters in the control system, in
order to adjust the travel and braking 7/0439
performance. System diagnosis can also be

carried out.
There is an interface (1) at the FPS which can

be switched over from the electronic evaluation
reserved.
system to the FPS (logic circuit board) by

means of an interface switch (2).
Information about the current software version

for the electronic evaluation system and the 7/0435
logic circuit board is provided on the cover of

the FPS.


(FPS)
The FPS is made up of the following

components:
(1) Electronic evaluation system
(2) Logic circuit board
(3) Travel motor output stage
(4) Pump motor output stage
(5) DC/DC converter
(6) Main contactor
(7) Fan
(8) Heat sink
(9) Control current fuses
7
reserved.
3 4
7 9
6
7/0435
1 5
10
Main current terminals
(1) + Batt (A1 travel motor)

(2) - Batt (travel output stage)
8 9
(3) A2 (clocked minus VMN - travel motor)
(4) + Batt (hydraulics output stage)
(5) P + (pump motor A1)
(6) - Batt (hydraulics output stage)
(7) P - (VMN - clocked minus) pump motor D2
(8) F1 Travel motor field terminal
(9) F2 Travel motor field terminal

(10) G + (48V from battery)
7/0435
reserved.
1 2 3 4 5 6 7
+ -
Emergency-off
G+
•
Main contactor
Travel motor
+ Batt (travel output stage)
A2 A1
M
- Batt (travel output stage)
A2 (VMN travel motor)

F1
F2 F1 F2
+ Batt (pump motor output stage)
- Batt (pump motor output stage)

Pump motor
A2 A1
M P+
D2 P- (VMN)


Control current terminals
Connector Components
(1) X10 (10-pin) Electronic

13
evaluation system
(AWE)
(2) X11 (6-pin) Electronic
evaluation system
(AWE)
(3) X5 (Interface) Logic circuit board 14
/ AWE
(4) X20 (Ribbon cable) Logic circuit board
/ AWE
(5) X100 (Ribbon cable AWE
to display) 7
8
(6) X 4 (18-pin) Logic circuit board 1
2
(7) E (4-pin internal Logic circuit board
main contactor (see sheet M12) 3
control) 9
reserved.
(8) X2 (14-pin) Logic circuit board 4 11

(9) X12 (4-pin) AWE 5 10
6
(10) X13 (18-pin) AWE 12
(11) X3 (10-pin) Logic circuit board
(12) X14 (10-pin) AWE
7/0435
(13) X8 (10-pin) Switchboard
(14) CN I (4-pin) internal DC/DC converter
(see sheet M15)

Block diagram
Steering On/off valves Display

column
Steering
controller
Hydraulics
setpoints
Hydraulics
sensor system
FPS Electronic evaluation system Notebook
+24 volts
Logic board
• Travel
Power unit
setpoint
+48 volts DC/DC
• Accelerator
Heat sink pedal switch
• Brake pedal
reserved.
switch
• Handbrake
• Foot-switch
• Battery lock
• Direction of
travel
See also M11
Travel Monitoring system: Pump Monitoring system:

motor -Carbon brushes motor -Carbon brushes
-Temperature -Temperature

Replaces issue: Manual FM Typ 429 M 10
reserved.
Issue: 9/97
Notebook
Replaces issue:
Schlüsselschalter
Schlüsselschalter
Assembly M
Block diagram
Fahren 1 Fahren 2 Sensorik Sicherungen Mikroschalter
Logic circuit board Interface to AWE
Flachband-
kabel
Manual
Workshop
Electronic evaluation system
FM Typ 429
Steering
Sheet no.
Valves
7/0449
M 11
Electrical system
Logic circuit board
Id. no. W8 407 374

Id. no. W8 407 457 (exchange)
Connector E
General 1
The logic circuit board is inegrated in the travel
and pump control system.
Using the microprocessor mounted on the board,
the logic circuit board monitors the switching

inputs and the safety circuit and makes logical 5

connections. x2
4
The microprocessor (1) is monitored by a higher-
level processor (2).
x3
Various parameter sets are stored in an EPROM
(3) and can be adjusted using a notebook.
x4
reserved.
This makes it possible to optimise the travel and

braking performance of the vehicle. 6/0326
The logic circuit board passes information on to

the output stages which is based on the digital 2 3
input signals and the information provided by the
electronic evaluation system (pump setpoint,
enable pump).
An interface switch (4) is fitted on the logic circuit
board, which can be used to switch over the
interface (5) (see also sheet no. M112).
For instructions on removing the logic circuit

board,
please refer to sheet no. M 38

General
See sheet no. M69

7/0453
reserved.

General
Travel/hydraulics output stages
Id. no.:Travel W8 407 446

output stage W8 407 459 (exch.)
Id. no.:Hydraulics W8 407 447
output stage W8 407 461 (exch.)
The two output stages for travel (1) and

hydraulics (2) are supplied with the necessary
information about the control situation via ribbon
cables (3 and 4). 3
The power transistors (MOS-FETs) which are

fitted on the output stages are responsible for
control of the motors.
4
For instructions on removing the output stages,
please refer to sheet nos. M41 - M42
reserved.
1
2
7/0440

DC/DC converter
Id. no. W8 407 445
3 2
6
General
The DC/DC converter (1) is one of the components

integrated in the FPS.
The +48 volt battery voltage is reduced here to a
+24 volt power supply.
A green LED (6) lights up to indicate that the output
voltage is in order. 4
Terminals: 5
(2) : 0 volts - Terminal stud H

(3) +24 volts - Terminal stud T
(4): CN I connector - See illustration below

(5): S connector - See illustration below
(7) Fuse: input end

7/0440
Id. no. W8 407 456
7 1
For instructions on removing the DC/DC converter,
please refer to sheet no. M43
reserved.
Technical data
2+48V 10AT
Input end: +48V/10A Key-operated
Output end: +24V/10A, F3 switch
Options
short-circuit proof Options
3+48V
Supply for
logic circuit
board
CNI 2 3 4 S
•
T (24 volts)
H (0 volts)
DC/DC converter

Control of the travel motor
At low speeds (potentiometer setpoint < 60%) the

field current is equal to the rated current (IF nom =
17A) and the armature voltage changes with the
setpoint from 0 volts to 48 volts.
If the setpoint is above 60 %, the armature

voltage remains constant (48 volts) and the field
UArmature
IArmature
current is reduced so that the speed is increased, UA
IField
until the set minimum field current is reached UA = UBatt
IA
(Max.Speed. parameter).
If, however, the armature current (under load) is

Bild 3 t
Field weakening area
slightly increased, the minimum field current is not Armature adjustment range
6/0270
reached, but the field current remains high in

relation to the level of the armature voltage. The
torque or efficiency are given priority over the
speed.
Similarly, on a slope, an increasingly higher torque

reserved.
is required and the armature current increases. At

the same time, the field current increases until
double the nominal value is reached. The
armature current then almost reaches the
maximum current.


Operating principle of the main current
circuit
Travel
The 48 V voltage is supplied to the main current Main Key-operated

circuit via the main contactor K1 and is active as con-
tactor
switch
long as the voltage at the capacitor package (1) is Charging circuit

for capacitor bank
higher than 10V. The capacitor package is +
charged constantly. In the event that a serious 48V A1

Q3
fault occurs, the main contactor becomes + 16kHz
A
inoperative. A2
The main current circuit for travel control consists
1
of an armature control via terminals A2 and A1 for Measuring
shunt
the armature of the travel motor (Fig. 1) and a full

Q2
bridge (four-quadrant) via terminals F1 and F2 for
control of the travel motor field winding (Fig. 2).
7/0451
The armature and the field are controlled

separately, depending on the travel situation.
The control variables for the armature and the field
are:
- Travel setpoint
reserved.
- the actual speed and the actual current, which is

limited by the measuring shunt (Hall sensor).
When the vehicle moves off, the motor is operated 48V from F1
as a series-wound motor, i.e., with normal field Q7 Q9
excitation (I nom = 17 A) in the breakaway phase, • •
4x
in order to achieve the normal breakaway torque. 4x 800Hz
• •
F1 F2
Q8 Q10
• •
4x 4x
• • •
Measuring
shunt
0V


circuit for travel, continued
The speed is increased by increasing the armature

voltage or the armature current (I max = 290 A)
until the armature voltage is equal to the the
battery voltage (48 V).
Main Key-operated
In order to reach the final speed, the field con- switch
tactor
excitation is then weakened. Charging circuit
for capacitor bank
+
In normal operation, the field and armature 48V A1

Q3
controls alternate, depending on the operating + 16kHz
A
situation. A2
The MOSFET Q3 operates with delayed timing 1

Measuring
antiparallel to the MOSFET Q2, which generates a
shunt
clear square signal and reduces the induced Q2
voltage.
7/0451
The operating principle is similar for control of the
field current (full bridge).
When current flows from F1 to F2, Q10 connects
through and Q7 and Q8 switch antiparallel with
reserved.
delayed timing. For a current to flow from F2 to F1,

Q8, Q9 and Q10 switch antiparallel with delayed
timing.
48V from F1
Q7 Q9
• •
4x
4x 800Hz
• •
F1 F2
Q8 Q10
• •
4x 4x
• • •
Fig. 2
Measuring
shunt
0V


circuit for generator braking
In generator brake operation, the field is first fully

excited. This leads to a voltage increase at the Main
con-
Key-operated
switch
armature of the travel motor during the braking tactor
K1 Charging circuit
process. for capacitor bank
+
48V
U Motor is greater than U Batt and a current flows +
Q3 A1
16kHz
A
from A1 back to the battery via MOSFETs Q2 and A2
the main contactor K1.
1
Measuring
shunt
The maximum current is limited by the timing of
the MOSFETs. Q2
If U Motor is smaller than U Batt, the current flows 7/0451
regulated through MOSFETs Q3.
This process continues until the motor comes to a

standstill.
48V from F1
Q7 Q9
• •
Generator brake operation is initiated: 4x
reserved.
4x 800Hz
• •
- when the travel direction switch is set to neutral F1 F2
- when the accelerator pedal is released Q8 Q10

• •
- when the brake pedal is pressed gently 4x 4x
- when the travel direction is changed while the • • •
accelerator pedal is pressed
- when the foot-switch is released Measuring
shunt
- when the vehicle is at a standstill and rolls away
during the monitoring phase.
0V


circuit for hydraulics
For the capacitor bank charging circuit, please

refer to sheet no. M17.
The main current circuit for hydraulics control is Main
con-
Key-operated
switch
connected via the MOSFETs Q1 (14 MOSFETs in tactor
parallel). Charging circuit

for capacitor bank
+ 2
The main current circuit controls the current which
48V
flows to the hydraulics motor (pulse width
+
modulation), which is connected at the main P+
current terminals P+ and P-. A
The maximum current is 400 A, and can be

adjusted with parameter settings.

P-
Freewheel diodes D1 (6 diodes parallel) are used Q1

to keep the induced voltage low.
7/0452
Control of the motor is proportional to the "pump

setpoint" input signal (1).
The only possible error message is PUMP I = 0 Setpoint potentiometer

reserved.
Immer or PUMP STBY I hoch, i.e., there is a

problem with the armature current registration.
Error: Pump I = 0 Immer = main contactor does AWE

not become inoperative
Pump setpoint
Error: Pump STBY I hoch = main contactor
1
becomes inoperative
Logic circuit board
The actual current flowing is determined by a
measuring shunt (2).
Output stage

Safety circuit
General
There are two possible error situations:
1. The main contactor becomes inoperative in the

event of failure or does not become operative
when the vehicle is switched on. This affects
operation of the vehicle.
2. The main contactor does not become

inoperative, but operation of the vehicle is still
affected.
The following tables (sheet nos. M23-M28) show

whether and as a result of which errors the main
contactor becomes inoperative.
reserved.

Safety circuit
Anti-roll monitor
The monitor is activated when:
- the handbrake is released,

- the pump motor is running,
- a lowering movement is initiated,
- the generator braking procedure is complete,
- the vehicle is started up,
- the "travel enable" signal has been sent.
Monitoring is interrupted as soon as the handbrake

is applied.
Once the monitor is activated, the speed of the

travel motor is monitored for 20 seconds by field
excitation.
Current pulses with a duration of 300 ms are sent to
the field every 1.48 seconds.
The first pulse at the field is 15% of the nominal

value, and all further pulses 30%.
reserved.
If a movement of the travel motor is determined

within the test time (20 secs.), the vehicle is braked
by means of generator braking.
The vehicle cannot, however, be brought to an

absolute standstill in this way.

Safety circuit
Description of errors
A detailed description of each error is given on the specified pages.
Remark: The text error message is displayed on the notebook (see sheet no. M64) and
the error number (FE01) appears on the vehicle display (see sheet no. M82).
Message Main contactor Description Possible cause Possible remedy
Batterylock (FE01) Battery lock •Microswitch faulty Test/replace

see M29 does not become inoperative is not locked •Wiring Test/replace
•Logic board Test/replace
Forw. + Backw. (FE05) The travel direction •Travel direction Test/replace

does not become inoperative signals are both sent switch faulty
see M29 simultaneously •Wiring Test/replace
•Logic board Replace
Incorrectstart (FE06) Start-up sequence •Microswitch enable

does not become inoperative not in order faulty Test/replace
see M29 •Foot-switch faulty Test/replace
•Wiring error Test
•Logic board Replace
reserved.
VACC not o.k. (FE07) The setpoint from the travel •Potentiometer Test/replace
potentiometer is >1 volt incorrectly adjusted
becomes inoperative than the min. programmed •Enable switch does Test/replace
see M30 value, as long as the not close
enable switch is open •Logic board is faulty Replace
ACC out of range (FE08) Travel setpoint is •Travel potentiometer Test/replace

becomes inoperative outside the set range is faulty
see M30 • Logic board is faulty Replace logic
board

Safety circuit
EEPROM KO (FE10) Fault in non-volatile •Fault in EEPROM

see M30 does not become inoperative memory •Fault in microprocessor Replace
•Logic board is faulty logic board
Driver shorted (FE11) Main contactor control •Fault in main Test/replace

contactor coil
•Short circuit in main Logic/replace

see M30 becomes inoperative contactor driver
•Wiring error Test
•Logic board is faulty Replace logic
Logic failure #1 (FE11) becomes inoperative Main contactor control •Logic board is faulty Replace
see M30
Contactor driver (FE11) becomes inoperative Main contactor control •Driver open Replace
see M31 •Logic board is faulty logic board
Microprocessor is faulty •Logic board is faulty Replace logic

Micro ST 6215 KO (FE11 board
reserved.
see M31 becomes inoperative
No field current (FE12) Field current smaller •Field not connected Check motor
than required and wiring
becomes inoperative •Logic board is faulty Replace
•Ribbon cable from Replace
see M31 logic board to travel output stage
output stage is
faulty
•Travel output stage Replace output
is faulty stage
High field current (FE13) Current flow is identified •Logic board is faulty Replace logic
becomes inoperative over the field, although board
see M31 no control signal has •Measuring shunt is Travel output
been sent. faulty stage
•Ribbon cable from Replace travel
logic board to travel output stage
output stage is
faulty

Safety circuit
Pumpe I = 0 Ever (FE14) No current flows, although •Hydraulics output Replace output
does not become inoperative a control signal has been stage is faulty stage
see M31 sent to the pump motor •Logic board is faulty Replace logic
board
•Pump motor is faulty Test/replace
Pump stby I high (FE14) Current flow is identified •Hydraulics output Replace
becomes inoperative in pump motor armature, stage is faulty
see M 31 although no control signal •Logic board is faulty Replace
sent to the output stage
Capacitor charge becomes inoperative

(FE15) The capacitors do not
see M 32 charge up
reserved.
VMN not o.k. (FE16) The voltage at the travel •MOSFET short-circuit Replace output
becomes inoperative motor is different from the stage
see M 33 applied voltage •Travel motor short- Test/replace
circuit
board
V Field not o.k. The field voltage is not •Travel motor faulty Test/replace
(FE17) becomes inoperative half the battery voltage •Field is not closed Test
see M 34
board
•MOSFETs faulty Replace travel
output stage

Safety circuit
Stby I high (FE18) Current flow is identified •Travel output stage Replace
becomes inoperative in travel motor armature is faulty
see M34 although no control signal •Logic board is faulty Replace

sent to the output stage
I = 0 Ever (FE18) Signal is sent to travel •Travel output stage Replace

becomes inoperative motor armature but the is faulty
see M34 microprocessor does not •Logic board is faulty Replace
receive return signal •Travel motor is faulty Test/replace
Contactor closed Discharge circuit of the •Main contactor con- Test/replace

(FE19) becomes inoperative capacitors is faulty tacts wrongly welded
see M35 •Logic board is faulty Replace
reserved.
Coil shorted (FE19) Main contactor short- •Main contactor short Replace main
becomes inoperative circuit circuit contactor
see M35 •Main contactor driver Replace
logic board
•Logic board is faulty Replace
logic board
Traction Motor Temp. Travel motor •Temperature > 140° C

(FE20) excess temperature
does not become inoperative •Temperature switch Rest/replace
see M 35 faulty
•Wire breakage Test/replace
logic board
Traction Brushes Travel motor carbon •Carbon brushes Replace

(FE21) does not become inoperative brushes worn worn down
see M 35 down •Wiring Test

Safety circuit
Th. Protection (FE22) Travel output stage •Temperature > 77° C

does not become inoperative temperature too high/
see M36 too low •Temperature < - 10° C

logic board
•Temperature sensor Replace output
is faulty stage
Pump Motor Temp. Pump motor •Temperature > 160° C

(FE30) does not become inoperative excess temperature •Temperature switch
see M36 faulty Test/replace
•Wire breakage Test/replace
board
reserved.
Pump Brushes Pump motor carbon •Carbon brushes Replace

(FE31) does not become inoperative brushes worn down worn down
see M36 •Wiring Test
Pump Temperature Hydraulics output stage •Temperature > 77° C

(FE32) does not become inoperative temperature too high/
see M36 too low •Temperature < - 10° C
board
•Temperature sensor Replace output
is faulty stage

Safety circuit
State output k.o. (FE 42) Short-circuit at •Electronic evaluation Replace

becomes inoperative status output system faulty
Battery out of range (FE43) Battery voltage •Battery voltage too Charge battery
does not become inoperative < 30V low
reserved.


Battery lock (FE01) see M23
The battery is not locked.

The travel speed is reduced.
The travel setpoint is reduced internally to 20%.
Forw. + Backw. (FE05) see M23
Both travel direction signals are sent

simultaneously.
Incorrect.start (FE06) see M23
This error message is produced if the signal from

the accelerator pedal microswitch is applied for at
least 0.5 seconds, but there is no signal from the
foot-switch.
Travel is not enabled or is interrupted.
reserved.
In order to restart, the foot-switch must be pressed

first, and then the accelerator pedal.


VACC not o.k. (FE07) see M23
As long as the accelerator pedal microswitch is

open, the travel setpoint must not deviate from the
stored minimum value by more than + 1V.
ACC out of range (FE08) see M23
The setpoint must lie between 4V and 9.6V.

Remark: If this error is already registered when
the vehicle is switched on, the main
contactor does not become operative.
EEPROM KO (FE10) see M24
EEPROM check sum error.
Driver shorted (FE11) see M24
When the capacitors charge up (see M32), a

check is made to determine whether the driver for
reserved.
the main contactor is open, i.e., whether + 48V is

supplied to the negative terminal of the main
contactor coil.
Logic Failure (FE11) see M 24
Main contactor control not in order.
Contactor driver (FE11) see M24
In order to close the main contactor, a pulse is

sent to the driver. A check is made to confirm that
the driver has closed, and after 200 ms, control of
the main contactor is pulsed with a pulse width
modulation (PWM) of 60%.


Micro St 6215 KO (FE11) see M24
Microprocessor faulty.
No Field current (FE12) see M24
A check is carried out to ascertain whether the

microprocessor receives an acknowledgement via
the actual field current when a signal is sent to the
field.
High Field current (FE 13) see M24
Field current too high, is not monitored during

anti-roll monitoring.
The field current is recognised, although no signal
has been sent.
reserved.
Pump I = 0 Ever (FE14) see M25
Monitoring of the pump current.

No current flows, although a signal has been sent
to the pump motor.
Pump Stby I High (FE14) see M25
Monitoring to ascertain whether current flows

through the pump motor although the output stage
is not driving.


Capacitor charge (FE15) see M25
+
• Main
• contactor
1
+ • • Pump
Key-operated R Travel motor
switch Q2A M motor M
C
•
VMN Q1
Q2B
-
The capacitor bank (1) is loaded when the key-

operated switch is switched on.
If the voltage at V M N (Voltage Motor Negative) does
not rise above 5.5 V, the error message is sent.
A check must be carried out with the control system

reserved.
turned off, to ascertain whether there is a short-circuit

between positive and negative (via the MOSFETs) or
whether the short-circuit is due to the motor
connection.
1. Turn off the vehicle

2. Disconnect the travel motor armature and switch
on.
If the short-circuit has disappeared, it was
caused by the travel motor.
If the short-circuit is still present, it is due to the
hydraulics or travel output stage.
3. Repeat the procedure with the pump motor to
ascertain whether the travel or hydraulics output
stage is faulty.


VMN not o.k. (FE16) see M25
+ •
Key-operated
switch M
C
•
VMN (Voltage-Motor-Negative)
-
This error message is issued if the voltage at the

travel motor armature deviates from the applied
voltage by > 1V (anti-roll monitor not active).
During anti-roll monitoring, the VMN can deviate
from UBatt by max. 3.5V.
If the deviation is too great, the error message is

issued.
reserved.
This can indicate either a short-circuit at the VMN

or that the vehicle is moving at too high a speed
for it to be stopped.


V Field not o.k. (FE 17) see M25
The voltage at the travel motor field (1) must be

about half the voltage at the armature (VMN).
For the error message to be issued, the voltage
deviation must be more than 4.4 volts and continue
for more than 2 seconds.
The voltage at the field must, however, be more than
4.4 volts.
(Only when anti-roll monitor not active)
+ •
Key-operated R
M
1
switch C
• •
VMN Measuring
point
micro-
processor
-
reserved.
Stby I High (FE18) see M26
- The armature current of the travel motor is too high

when the motor is idling.
- Current flow is detected in the travel motor

armature, although no control signal has been
sent.
I = 0 Ever (FE18) see M26
- Control signal is sent to the travel motor armature,

but the microprocessor does not receive
acknowledgement.


Contactor closed (FE19) see M26
The capacitors are discharged again briefly after

switching on in order to test the condition of the
contactor contacts.
Remark: This error message is issued if there is a

fault in the field current circuit.
Coil shorted (FE19) see M26
The condition of the flip-flop control of the main

contactor is checked for short-circuits.
The flip-flop determines hardware cut-out of the main
contactor.
Traction Motor Temp. (FE20) see M26
Travel motor excess temperature from 140° C.

The maximum armature current is temporarily reduced
by half and after 5 minutes it is set to zero.
The field is maintained at the nominal value.
reserved.
As soon as the temperature switch closes again, the

monitoring process is stopped.
The braking current is maintained.
The cut-out can be reset with the key-operated switch.
Travel is then possible again for 5 minutes.
Traction Brushes (FE 21) see M26
This message is issued when the carbon brushes for

the travel motor are worn down.
This has no effect on the system.


Th. Protection (FE22) see M27
The temperature is too high or too low at the travel

output stage.
If the temperature is lower than -10° C, the speed is
reduced, i.e., the setpoint is decreased by 60% and
the maximum current reduced to 80%.
If the temperature is higher than 77° C, the speed is
reduced, i.e., the setpoint is decreased by 60% and
the current reduced linear to a further temperature
increase from the set value to zero.
I max = 0 at 92° C
Pump. Motor Temp (FE30) see M27

Pump motor excess temperature 160° C.

When the temperature switch opens, the full power
of the pump motor is maintained for 15 seconds.
After this, there is a cut-out.
This can be reset by switching off the key-operated
switch. If the temperature is then still above 160° C,
the pump motor can be run again for 15 seconds
reserved.
longer.
Pump Brushes (FE31) see M27
This message is issued as soon as the carbon

brushes in the pump motor are worn down.
This has no effect on the system.
Pump Temperature (FE32) see M27
See (FE22)
Hydraulics output stage is too high or too low.


State output KO (sok) (FE42) see M28
The control system (logic board) makes available an

output which is active when the main contactor is
closed. It is deactivated when the main contactor is
open.
This output is checked for short circuits every 8 ms.
This output is also referred to as "control started
successfully".
The output is sent to the electronic evaluation
system via a ribbon cable.
If this information is not available at the electronic
evaluation system, the electronic evaluation system
blocks the following signals:
- Pump setpoint
- Pump enable
- Power outputs to the valves.
Batt out of range (FE43) see M28

reserved.
Battery voltage outside the window.
This message is issued if the battery voltage is less

than 30V.


(FPS)
Removing the logic circuit board
1. Remove the protective panel

(see U2 (1))
8
2. Remove the cover (see U2 (2))
6 7
3. Pull out the battery plug (1)
1
4. Pull out all the connectors (2-5)
4
5. Mark the travel motor field terminals (6) 2
X12 X2
and disconnect them.
12
6. Mark and disconnect the voltage

transformer terminals (7). 5
7/0439
X14 X13 X3
7. Unscrew the 3 screws (8-10).
X11 X100
8. Remove the cover (11) carefully, taking

care to ensure that the interface switch 3
(12) is not damaged.
reserved.
9 10
11
7/0435


(FPS)
1 2 1
Removing the logic circuit board
Continued
9. Unscrew the 4 nuts (1) at the electronic

evaluation system (2).
3
10. Remove the electronic evaluation system
11. Disconnect the connector (3).
12 Remove the ribbon cable (4-6).
13. Unscrew the 6 nuts (7).
14. Remove the logic board (8).

7/0453
To replace the logic circuit board, follow the 1 1

instructions above in reverse order.
If the logic circuit board is replaced, the 8
parameter and configuration settings must be 7
checked (see sheet nos. M54 and M60-62). 7
reserved.
7
7 5
7
6/0326


(FPS)
Removing the electronic
evaluation system
1. Carry out steps 1-10 on sheet nos.

M38 and 39.
To replace the electronic evaluation

system, follow the instructions above in
reverse order.
If the electronic evaluation system is

replaced, the parameter and configuration
settings must be checked (see sheet nos.
M91-94 and M99-100).
reserved.

Replaces issue: Manual
FM Typ 429 M 40

(FPS) 3
Removing the hydraulics output
stage 4
1. Carry out steps 1-14 from sheet nos.

M38 and 39.
2. Mark the main current terminals (2) and 5

5
disconnect them.
6
3. Disconnect the cable (3).
4. Pull out the connector (4). 5

5
5. Unscrew the 6 screws (5).
6. Remove the entire switchboard (6) 8

from the vehicle.
5
5
7. Lay the switchboard to one side on a
clean work surface with the heat sink
facing upwards.
reserved.

2 2 2 2 2 2 2
9. Turn over the switchboard (6) and
remove the output stage (8). 7/0440
To replace the output stage, follow the

that the insulating foil between the output
stage heat sink and the switching board
heat sink is in good condition.


(FPS)
Removing the travel output stage
1. Carry out steps 1-14 on sheet nos.

M38 and 39.
2. Carry out steps 2-7 on sheet no. M41.

2
4. Turn over the switchboard (2).
5. Remove the output stage (3).
3
To replace the output stage, follow the

that the insulating foil between the output
stage heat sink and the switching board
heat sink is in good condition. 7/0440
reserved.


(FPS)
Removing the DC/DC converter
3. Unscrew the 4 screws (1) and remove

the DC/DC converter (3).
To replace the DC/DC converter, follow the

instructions above in reverse order.
7/0440
reserved.


(FPS)
Replacing the logic circuit board
software
1. Carry out steps 1-8 on sheet no. M38

and steps 9-10 on sheet no. M39.
2. Pull off the EPROM (1) using suitable

tools.
To replace the logic board software, follow

the instructions above in reverse order. 6/0326
Fig. 1 1
Remark: Note the installation position of

the EPROM (see Fig. 2). The
markings (2) must be on the
same side.
reserved.
Remark: For instructions on replacing the OOOOOOOO

electronic evaluation system, O O
OOOOOOOO
see sheet no. M103 6/0005
Fig. 2


Control signals for travel (Vmax)
Remark: For input wiring, see sheet no. M108 - M111
Preconditions
Signal name Connector/PIN Explanation
1. Emergency-off not pressed
2. Main current fuse F1 O.K.
3. Fuse F2 X8.1 (see M9) +48V in front of key-operated switch
4. Fuse F3 CN I/3 (see M15) +48V from G+ for DC/DC converter
5. Power supply for BATT + (see M8) + 48V after main contactor
travel output stage
6. Power supply for E1 (see M12) 3+48V after key-operated switch via
logic board DC/DC converter CNI/2 (see M15)
7. Power supply for E2 (see M12) +24V after DC/DC converter from T-bolt
logic board
8. No travel motor excess temp. X4.2 (see M9) 0V=no excess temperature (see M35)
9. No travel output stage excess Error 22 must not appear

temperature (see M36)
Truth table
Remark: The signals listed below can all be read off from the tester menu
(see sheet no. M65).
reserved.
HB= Handbrake none 0volts, when applied (ON) Connector X2.10 (see M9)
FB= Footbrake none 0volts, when pressed (ON) Connector X2.12 (see M9)
FS= Footbrake 0volts, when pressed (ON) Connector X3.2 (see M9)
FV= Forw. travel direction 0volts, when selected (ON) Connector X2.8 (see M9)
FR= Reverse travel direction 0volts, when selected (ON) Connector X2.6 (see M9)
FF= Travel enable (micro- 0volts, when pressed (ON) Connector X2.4 (see M9)
switch for acc. pedal)
Set= Setpoint dependent on voltage which is read in Connector X2.2 (see M9)
HB FB FS FV FR FF Set Parameter
Forw. travel Off Off On On Off On >min
Rever. travel Off Off On Off On On >min
Generator Off Off Off On Off On x Release brake
brake Off Off On Off (or) Off On x Release brake
Off Off On x x Off min Release brake
Off On x x x x x Pedal brake
Off Off On On Off On max/min Inversbrake
Off Off On Off On On max/min Inversbrake


Control signals for travel (2.5 km/h)
For preconditions see sheet no. M45
FR1 (X3.4) Deceleration on = selected - no 0-volt signal
BV (X3.6) Battery lock on = Battery lock open - no 0-volt signal
The signals can be read off from the tester menu (see M65-66)
FR1 BV
2.5 km/h On Off

Off On
On On
reserved.


Control signals for hydraulics
Remark: For input wiring, see sheet no. M108 - M111
Preconditions
Signal name Connector/PIN Explanation
Emergency-off not pressed
Main current fuse F1 O.K.
Fuse F2 X8.1 (see M9) +48V in front of key-operated switch
Fuse F3 CN I/3 (see M15) +48V from G+ for DC/DC converter
Power supply for E1 (see M12) 3+48V after key-operated switch via
logic board DC/DC converter CNI/2 (see M15)
Power supply for E2 (see M12) +24V after DC/DC converter T-bolt
logic board
Power supply for BATT + (see M8) + 48V after main contactor
hydraulics output stage

No pump motor excess temp. X4.6 (see M9) 0V=no excess temperature (see M36)
No hydraulics output stage Error 32 must not appear
excess temperature (see M36)
Input signals in the logic board from the electronic evaluation system
reserved.
Pump setpoint
see M72 see M72
Enable pump
Electronic evaluation system Logic board
The pump setpoint and enable pump signals can be read off from the tester menu.

Installation of the Superconsole notebook

software
Id. no. W8 407 481 (english)
General
The software is for configuration, parameterising
and error diagnosis at the FPS (logic board) (1).
The control data can also be stored on the hard
disk of the notebook and reprocessed. A maximum
of 500 different control models can be managed.
Storage of the data is based on a DBASE format,
so that it would be possible to process it further if
necessary.
It is possible to depict various electrical and
physical variables in the form of graphics.
This description is intended as a guide to the

software. It can help: 1
6/0326
- the user understand and try out certain parts of

the software. The parameters, functions and
graphics in each case are dependent on the
controls.
- give an overall impression of how the software
reserved.
can be useful in work situations.

- the user learn how to use the many software
functions.
Hard and software requirements

The following system requirements are necessary for
trouble-free operation of the software:
Remark: This software version is not WINDOWS

compatible.
- 286 processor or higher
- At least 640 kB working memory (RAM)
- At least 20 MB hard disk memory
- Serial interface RS232 (COM1) and interface
adapter (see sheet no. M112)
- Operating system MS-DOS 3.2 or higher
- 3.5 " disk drive, 1.44 MB

Installation of Superconsole Notebook-

software
Note: Step 1-9 have to be implemented once

only. 4 6 1
7/0380
Symbol Keyboard combination ESC F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12
Enter Enter (1) !

1
"
2
§
3
$
4
%
5
&
6
/
7
(
8
)
9
=
0
?
ß
`
´
Space _ Space (2) Q W E R T Z U I O P Ü *
+
Backslash \ AltGr (3) and \ (4) A S D F G H J K L Ö Ä '
#
Star * Shift (5) and * (6) > Y X C V B N M ; : _ Bild
< µ , . -
Colon : Shift (5) and : (7) Strg Alt Fn ° Alt Gr Einf Entf
^
Full-Stop . Full-stop (7) Bild
1. Switch on notebook, display shows "system prompt"

2 3 7
(8). 5
2. Put disc in drive A (9).

3. Erect directory "SCONE"
(SCONE = Superconsole English). 8
Therefore enter: md_ C:\SCONE (1)
4. Copy disc to directory.
C:\
Enter: xcopy_ a:\*.*_ c:\_/s (1)
reserved.
5. Modify the data CONFIGSYS.

Enter:
EDIT_CONFIG.SYS (1)
ESC F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12
! " § $ % & / ( ) = ? `
1 2 3 4 5 6 7 8 9 0 ß ´
Line "BUFFERS" must show BUFFERS = 20, Q W E R T Z U I O P Ü *
+
eventually you just have to change the value. A S D F G H J K L Ö Ä '
#
Check and modify line FILES = 30, respectively. >

<
Y X C V B N M
µ
;
,
:
.
_
-
Bild
Strg Alt Fn ° Alt Gr Einf Entf

^ Bild
7/0380
9

Installation of Superconsole Notebook-

software (Continuation)
6. Leave CONFIG.SYS and save modifications,

respectively 2 5
• Press key "Alt" (1)
• Press key D
! " § $ % & / ( ) = ? `
1 2 3 4 5 6 7 8 9 0 ß ´
• Press key B Q W E R T Z U I O P Ü *
+
A S D F G H J K L Ö Ä '
#
> Y X C V B N M ; : _ Bild
< µ , . -
If one line was changed the notebook asks to save the Strg Alt Fn °
^
Alt Gr Einf Entf
Bild
line.
Cursor indicates Yes, (5)
3 1 4
To move the Cursor to No press TAB-button (2).

7/0380
7. Change file AUTOEXEC.BAT.

Enter therefore:
EDIT_AUTOEXEC.BAT (5)
reserved.
Add the line SET_CLIPPER = F40.

8. Leave AUTOEXEC.BAT and save changes,
respectively.
• Press key "Alt" (1)
• Press key D
• Press key B
look step no. 6
9. Carry out soft reset. Therefore enter:
Strg Alt Entf.

(3) (1) (4)
Note: You have to press the key combination
simultaneously.
Strg = ctrl
entf = del

Working with the Superconsole software
1. Make the connections and adjustments between the

control system and the notebook (COM1) using the
interface adapter (see M112).
2. Switch on the notebook, "System prompt" C:\ (1)
appears.
3. Enter: ZHPULSE (2) (5) 1 2
4. The main menu of the superconsole software
appears (see M52).
C:\ ZHPULSE
! " § $ % & / ( ) = ? `
1 2 3 4 5 6 7 8 9 0 ß ´
Q W E R T Z U I O P Ü *
+
A S D F G H J K L Ö Ä '
#
> Y X C V B N M ; : Bild
reserved.
_
< µ , . -
^ Bild
5
Space bar/
space

Switching on
When the notebook is switced on and the Superconsole software started up, the following
display appears:
INIT CONNECTION
PROGRAM
SAVE PC SUPER CONSOLE
RESTORE FOR chopper B1-H6 - H2 - SEM1- SEM2
BROWSE MODEL VXX COPYRIGHT (C) 1996
CONFIG. MENU ALL RIGHTS RESERVED
ALARMS INC VIA PARMA 59, PORIGLIO (RE) ITALY
TESTER TEL (0522) 96 00 50
PROGRAM VACC TELEFAX (0522) 96 02 59
MOTOR DATA
SPECIAL FUNCTION
SPECIAL MENU
TRACE FUNCTION
EXIT
reserved.
7/0381
All further steps are dependent on the selected menu point, so that further information
can be found under the relevant menu point:
The available menu points are as follows:
- INIT CONNECTION (Initialisation process, see M53)
- PROGRAM (Parameter settings, see M54)
- SAVE (Storing parameters on hard disk, see M56)
- RESTORE (Loading parameters from the hard disk back into the control
system, see M57)
- BROWSE MODEL (List of contents for the stored parameter sets, see M58-59)
- CONFIG. MENU (Adjustable options for the operating hours counter, see M60-62)
- ALARMS (see M64)
- TESTER (see M65-66)
- PROGRAM VACC (Adjustment of the travel potentiometer, see M67)
- MOTOR DATA (not available)
- SPECIAL FUNCTION (not available)
- SPECIAL MENU (not available)
- TRACE FUNCTION (no function)
- EXIT

INIT CONNECTION
The first and absolutely essential point. This starts the initialisation process and initial
data exchange.
Once data exchange is successfully completed, all the information about the control
system which is currently connected appears in the information window on the right.
INIT CONNECTION
PROGRAM CHOPPER NAME: COMBI WAG. VXX
SAVE NOM.BATTERY: 48V
RESTORE MAX CURRENT.: 300 AMPERE
BROWSE MODEL HOURS: xh
CONFIG. MENU
ALARMS ALARMS:
TESTER
PROGRAM VACC
MOTOR DATA
NO ALARMS
SPECIAL FUNCTION
SPECIA LMENU
TRACE FUNCTION
EXIT
7/0381
2
reserved.
4
1. Use the cursor keys (1) to select the menu point P Ü *
INIT CONNECTION (2). 3 +
L Ö Ä '
2. Press the Enter key (3). #
1 : _ Bild
3. The information window (4) is displayed. . -

Alt Gr Einf Entf
4. The ESC key (5) can be used to close the Bild
information window and return to the menu.
Remark 1: The operating hours displayed are the 7/0380

operating hours for the travel and pump
control system and not for the vehicle. 5 ESC F1 F2 F3 F4
Remark 2: If no connection can be made between ! " § $ %

1 2 3 4 5
the notebook and the control system, a
message to this effect is displayed in the Q W E R
information window.
A S D F
> Y X C
PROGRAM
For setting the acceleration, braking and speed parameters.
When this program point is selected, the values currently set in the control system are
read in and displayed. If necessary, these can be altered and written back into the
control system.
INIT CONNECTION PARAMETERNAME VAL

PROGRAM
ACCELER. DELAY 3
SAVE DECELER. DELAY 3
2
RESTORE 5 5
BROWSE MODEL Parameter 3
CONFIG. MENU 7
see on sheet 4
ALARMS
M55 8
TESTER
PROGRAM VACC 8
5
MOTOR DATA 5
SPECIAL FUNCTION
5
SPECIA LMENU 2
TRACE FUNCTION
EXIT
< F2> SAVE
7/0381
1. Use the cursor keys (1) to select the menu point
reserved.
PROGRAM (2). 4
P Ü *
2. Press the Enter key (3). The values which are 3 +
currently set are read in. '
L Ö Ä
#
3. The Parameter window (4) is displayed.
1 : _ Bild
4. Use the cursor keys (1) to select the required . -
parameter. Alt Gr Einf Entf
Bild
5. Press the Enter key (3) to access Editing mode
(wide cursor, 5)
6. Enter the required value.
6 7/0380
7. Press the Enter key (3) to quit Editing mode
(narrow cursor). 7 ESC F1 F2 F3 F4
9. To write the altered values back into the control ! " § $ %

system, press the F2 key (6). 1 2 3 4 5
10.To close the information window, press the ESC Q W E R

key (7).
A S D F
> Y X C
PROGRAM
Table of adjustable values
Parameter Unit Value Factory

0 1 2 3 4 5 6 7 8 9 setting
Acceleration sec. 0.3 0.6 0.9 1.3 1.6 1.9 2.2 2.5 2.8 3.1 4
Deceleration sec. 6.1 6.3 6.5 7.0 7.4 8.1 8.8 9.7 10.6 11.5 2
Release Braking sec. soft hard 5
Pedal Braking sec. soft hard 5
Invers Braking sec. soft hard 5

Cut Back Speed %Acc 17 21 25 29 33 39 45 51 57 63 4
Max. Speed Fw %Fld.Nom. 100 82 67 56 49 44 40 37 34 32 8
Max. Speed Bk %Fld.Nom. 100 82 67 56 49 44 40 37 34 32 8
*Imax Trac. A 247 252 257 262 267 273 280 287 293 300 5
Creep Speed %PWM 2.3 3.5 4.7 5.9 7.0 8.2 9.4 10.6 11.8 12.9 0
Pump Imax. A 329 335 342 349 355 364 373 382 391 400 8
reserved.
* Remark: If the travel motor armature current is to be measured, see M55.1.
Explanation of parameters
Acceleration: The time required for the vehicle to reach the desired speed.
Deceleration: Braking when the accelerator pedal position is altered
Release Braking: Generator brake when the accelerator pedal is released
Pedal Braking: Generator brake when the brake pedal is pressed
Invers Braking: Braking when the travel direction is changed and the accelerator pedal pressed
Cut Back Speed: Creep speed
Max. Speed Fw: Maximum forwards speed
Max. Speed Bk: Maximum reverse speed
Imax Trac.: Travel motor armature current
Creep Speed: Minimum speed, slight deflection of accelerator pedal
Pump Imax: Pump motor current


(FPS)
Armature current behaviour
The FPS has a booster function for starting up

or changing the travel setpoint. The result is a I
higher starting torque. approx. 350 A Linear reduction
proportional to time
When the vehicle is started up, an armature approx. 273 A
equivalent to
current of approx. 350 A is initially set. parameter 5
After 10 seconds, this drops to the set approx. 120 A

parameter value (standard 273 A = parameter
10 sec. 120 sec. t
value 5).
Over a period of another 110 seconds, the

armature current decreases linearly to a value
of approx. 120 A, i.e., after 2 minutes the
current is still approx. 120 A, unless the

setpoint for the accelerator pedal changes.
If the armature current falls below the required

current (see characteristic curve) during the
linear reduction phase for longer than 500 ms,
the booster function is restarted. This can also
occur if the setpoint is altered.
reserved.
Measuring the armature current
- Jack up the vehicle securely

- Apply the handbrake
- Bridge the switch for the handbrake
- Press the accelerator pedal
- It should be possible to read off the set
armature current briefly after approx. 10
seconds.

Replaces issue: Manual FM Typ 429 M55.1
SAVE
For storing the parameters which are currently set and adjusting the operating hours counter
with the notebook.
A maximum of 500 different models can be set. Storage of the settings data is limited only by
the capacity of the hard disk. The storage format used is DBASE format. This means that the
data can be processed further on a different system. A customer name and model ID can also
be specified.
INIT CONNECTION
PROGRAM
SAVE CHOPPER NAME: COMBI WAG. VXX
CUSTOMER:
RESTORE
2 BROWSE MODEL
CONFIG. MENU
ALARMS
TESTER 6
PROGRAM VACC
MOTOR DATA
SPECIAL FUNCTION
SPECIA LMENU
TRACE FUNCTION
EXIT
ARE YOU SURE Y/N
7/0381
reserved.
1. Use the cursor keys (1) to select the menu point 5 4

SAVE (2). P Ü *
3 +
2. Press the Enter key (3).
L Ö Ä '
#
3. The information window (4) is displayed, the
cursor flashes (6). 1 : _ Bild
. -
4. Enter the customer name, max. 10 characters. Alt Gr Einf Entf
Bild
5. Press the Enter key (3).
6. Answer "Are you sure?" with "J" (yes) or "N"
(no) and press the Enter key (3) to confirm.
7/0380
7. Once the data has been read in automatically,
press any key to return to the main menu.

RESTORE
For transferring the settings (parameters and settings for the operating hours counter) back
out of the notebook for storage in the control system.
Selection of a stored setting and transfer back to the control system.
It is only possible to select settings which correspond with the same control system type.
INIT CONNECTION
PROGRAM
SAVE SELECT PROGRAM:
RESTORE
BROWSE MODEL
2 CONFIG. MENU COMBI WAG. VXX NAME
ALARMS
TESTER
PROGRAM VACC
MOTOR DATA
SPECIAL FUNCTION
SPECIA LMENU
TRACE FUNCTION
EXIT
ARE YOU SURE Y/N
7/0381
5 4
reserved.
RESTORE.
P Ü *
2. Press the ENTER key (3). +
3
3. The Rückspeicherabfragefenster (4) is displayed. L Ö Ä '
#
4. Use the cursor keys (1) to select the required
1 : _ Bild
setting or customer. . -
5. Press the ENTER key (3). Alt Gr Einf Entf
If a setting is selected which does not correspond Bild
with the same control system type, the selection is

not accepted!
6. Answer "Are you sure?" with "J" (yes) or "N" (no) 7/0380
and press ENTER (3). If "J" is entered, continue

with point 7. If "N" is entered, the ESC key must be
pressed to return to the main menu.
7. Once the data has been stored automatically, press
any KEY to return to the main menu.

BROWSE MODEL
List of contents for all the stored settings (customer).
Stored settings can be called up for viewing or, if necessary, deleted. It is not
necessary to make a connection with the control system to use this feature.
INIT CONNECTION
PROGRAM
SAVE SELECT PROGRAM:: (TO CANCEL PRESS DEL (ENTF))
RESTORE
BROWSE MODEL
CONFIG. MENU COMBI WAG. VXX NAME
2 ALARMS
TESTER
PROGRAM VACC
MOTOR DATA
SPECIAL FUNCTION
SPECIA LMENU
TRACE FUNCTION
EXIT
7/0381
reserved.
BROWSE MODEL (2). P Ü *

+
2. Press the ENTER key (3).
3 L Ö Ä '
3. The list of contents is displayed. #
: Bild
4. Use the cursor keys (1) to select the required _
. -
settings.
Alt Gr Einf Entf
5. Display or Edit (to delete, see sheet no. M59) Bild
Press the ENTER key (3).

All the settings stored under one name can be displayed 4
or edited. To enter Editing mode, press the ENTER key
(the wide cursor appears). Once the alterations have
been made, press the ENTER key to quit Editing mode. 1 7/0380
Remark: All the parameters are displayed which have

been saved under the stored name. A 5 ESC F1 F2 F3 F4
character for configuration of the operating
hours counter is also displayed in the last ! " § $ %
position (see sheet no. M62) 1 2 3 4 5
Q W E R
6. Press the ESC key (5) to return to the main menu.
A S D F
> Y X C

BROWSE MODEL (continued)

Function for deleting the stored settings.
INIT CONNECTION
PROGRAM
SAVE ARE YOU SURE? Y/N
RESTORE
BROWSE MODEL
CONFIG. MENU COMBI WAG. VXX NAME
2 ALARMS
TESTER 6
PROGRAM VACC
MOTOR DATA
SPECIAL FUNCTION
SPECIA LMENU
TRACE FUNCTION
EXIT
7/0381
1. Use the cursor keys (1) to select the settings you
reserved.
wish to delete. P Ü *
+
3 L Ö Ä '
3. Press the Delete key (4). #
: Bild
4. The confirmation window (6) appears. Answer with _
. -
either "J" (Yes) or "N" (No).
Alt Gr Einf Entf
5. Press the ENTER key (3). Bild
6. Press the ESC key (5) to return to the main menu. 4
1 7/0380
5 ESC F1 F2 F3 F4
! " § $ %
1 2 3 4 5
Q W E R
A S D F
> Y X C

CONFIC. MENU
This program point is used for programming the various different input and output functions of the
control system.
Remark: The menu points "SET MODEL" and "ADJUSTMENT" have no function.
INIT CONNECTION
4 PROGRAM PC SUPER CONSOLE
SAVE FOR CHOPPER B1-H6 - H2 - SEM1- SEM2
RESTORESET OPTIONS VXX COPYRIGHT (C) 1996
BROWSE MODEL ALL RIGHTS RESERVED
SET MENUGURA-
CONFIG. MODEL INC VIA PARMA 59, PORIGLIO (RE) ITALY
ADJUSTMENT TEL (0522) 96 00 50
ALARMS
ADJUST HOUR TELEFAX (0522) 96 02 59
2 TESTER
EXIT VACC
PROGRAM
MOTOR DATA
SPECIAL FUNCTION
SPECIA LMENU
TRACE FUNCTION
EXIT
?
ß ´
reserved.
P Ü *
1. Use the cursor keys (1) to select +
CONFIG. MENU (2)
L Ö Ä '
2. Press the ENTER key (3) 3 #
3. The option selection menu (4) is displayed. Bild
: _
. -
Continued on sheet no. M61 1 Alt Gr Einf Entf
Bild
7/0380
5 ESC F1 F2 F3 F4
! " § $ %
1 2 3 4 5
Q W E R
A S D F
> Y X C
CONFIG. MENU (Continued)
INIT CONNECTION
2 PROGRAM
SAVE SELECT CHOICE:
RESTORESET OPTIONS:
BROWSE MODEL HOUR COUNTER 4
SET MENU
CONFIG. MODEL
ADJUSTMENT
ALARMS
ADJUST HOUR
TESTER
EXIT VACC
PROGRAM
MOTOR DATA
SPECIAL FUNCTION
SPECIA LMENU
TRACE FUNCTION
EXIT
?
ß ´
reserved.
P Ü *
1. Use the cursor keys (1) to select SET OP- +
TIONS (2). L Ö Ä '
2. Press the ENTER key (3). 3 #
3. The selection menu (4) is displayed (setting : _ Bild
the operating hours counter). . -

1 Alt Gr Einf Entf
Continued on sheet no. M62 Bild
7/0380


Setting the operating hours counter
INIT CONNECTION
PROGRAM
SAVE
RESTORESET OPTIONS: <TO SELECT >
BROWSE MODEL
SET MODEL
CONFIG.MENU
7 ADJUSTMENT
ALARMS
ADJUST HOUR
TESTER * * * * HOUR COUNTER * * * *
EXIT VACC
PROGRAM
MOTOR DATA KEY ON
SPECIAL FUNCTION
SPECIA LMENU 4
TRACE FUNCTION
EXIT
ARE YOU SURE Y/N
?
4. Press the ENTER key (3). 6 ß ´
reserved.
5. The information window (4) is displayed with the P Ü *

current configuration of the operating hours counter. +
6. The configuration can be altered using the cursor L Ö Ä '
keys (1). 3 #
Possible configuration: Key on (is stored in the : _ Bild
program with number 1). . -
Travel and pump 1 Alt Gr Einf Entf
(number 0) Bild
Travel+pump+lowering
(number 2)
7. Press the ESC key (5)
8. Confirm the safety prompt (6) with "J"or "N" and 7/0380
press the Enter key (3). 5 ESC F1 F2 F3 F4

9. Press the ESC key (5) to return to the selection
menu (7).
! " § $ %
10. Use the cursor keys (1) to select EXIT and press 1 2 3 4 5
the ENTER key (3) to return to the main menu.
Q W E R
11. If you wish to continue in the options selection menu
(7), see sheet no. M63
A S D F
> Y X C

Setting the operating hours counter
INIT CONNECTION
PROGRAM
SAVE
2 SET OPTIONS
RESTORE SET HOUR COUNTER: 4
BROWSESET MODEL
MODEL
ADJUSTMENT
CONFIG. MENU
7 ALARMSADJUST HOUR
TESTER
EXIT VACC
PROGRAM
MOTOR DATA
SPECIAL FUNCTION
SPECIA LMENU 4
TRACE FUNCTION
EXIT
ARE YOU SURE Y/N
5
1. Use the cursor keys (1) to select ADJUST HOUR 6
reserved.
(2) and press the ENTER key (3). ? `

ß ´
2. The information window (4) is displayed,
P Ü *
3. Press the ENTER key (3). +
4. Delete the current operating hours with the space 3
Ö Ä '
bar or backspace key (5). #
5. Enter a new value and press the ENTER key (3).
: Bild
6. The safety prompt (6) appears. Confirm with "J"or _
. -
"N" and press the Enter key (3).
Gr Einf Entf
7. Use the Cursor keys (1)to select EXIT (7) and Bild
press the ENTER key (3) to return to the main me- 1
nu.
7/0380

ALARMS
This menu point is for calling up the control system error memory.
For error messages, see sheet nos. M23 to M28.
INIT CONNECTION
PROGRAM TO CANCEL PRESS DEL (Entf.)
SAVE
RESTORE
BROWSE MODEL ALARMS CNT.: TEMP.: HOURS: 7
CONFIG. MENU
ALARMS 1) ALARM NULL XX 16° 0 6
TESTER
PROGRAM VACC 2) ALARM NULL 5
2 MOTOR DATA
SPECIAL FUNCTION
3) ALARM NULL
SPECIA LMENU
TRACE FUNCTION
EXIT 4) ALARM NULL
5) ALARM NULL
7/0381
1. Use the cursor keys (1) to select ALARMS (2).
reserved.
2. Press the Enter key (3). P Ü *

3 +
3. The control system error memory is read out and
displayed. The last 5 errors which have occurred L Ö Ä '
1 #
are displayed. The display shows how often the
Bild
error occurred (5), the temperature (6) and the : _
. -
operating hours counter reading (7) in the control
system the last time the error occurred. Alt Gr Einf Entf
Bild
4. Return to the main menu by pressing the ESC key
(4).
8
5. To delete errors, press the DEL key (8). 7/0380
4 ESC F1 F2 F3 F4
! " § $ %
1 2 3 4 5
Q W E R
A S D F
> Y X C
TESTER
Test functions can be activated under this point, e.g., motor current, potentiometer
voltage, control-system temperature, etc.
INIT CONNECTION
PROGRAM <SELECT FUNCTION TESTER>
SAVE
RESTORE
BROWSE MODEL BATTERY VOLTAGE
CONFIG. MENU
ALARMS All available TE-
TESTER STER-points see
PROGRAM VACC sheet M66
MOTOR DATA
2
SPECIAL FUNCTION
SPECIA LMENU
TRACE FUNCTION
EXIT
7/0381
1. Use the cursor keys (1) to select TESTER (2).
reserved.
2. Press the ENTER key (3). P Ü *

3 +
3. Use the cursor keys (1) to select the required test
function. L Ö Ä '
#
4. Press the ENTER key (3). 1 : Bild
_
. -
5. To end the test function, press the ESC key (4).
Alt Gr Einf Entf
6. Select a new test function with the cursor keys (1) Bild
or
7. Press the ESC key (4) to return to the main menu.
7/0380
4 ESC F1 F2 F3 F4
! " § $ %
1 2 3 4 5
Q W E R
A S D F
> Y X C
TESTER (Continued)
Available test points Display
Battery voltage Battery voltage value ...V

TR V Motor PU Travel motor voltage - pump motor voltage . . V . .V
TR I Motor PU Travel motor current - pump motor current . . A . .A
Field current Field current ...A
VMN Clocked negative travel motor ...V
Tr. Chopper Temp. Temperature - travel output stage . . °C
Pu. Chopper Temp. Temperature - pump output stage . . °C
Accelerator Travel potentiometer voltage ...V

Enableswitch Accelerator pedal microswitch ON/OFF

Backwardswitch Travel direction switch, reverse ON/OFF
Forwardswitch Travel direction switch, forwards ON/OFF
Handbrake Handbrake microswitch ON/OFF
Brakeswitch Brake pedal microswitch ON/OFF
Deadmanswitch Deadmanswitch ON/OFF
reserved.
Cutbackswitch Creep-speed switch ON/OFF

Batteryblock Battery lock microswitch ON/OFF
Tr. Motor Temp. Travel motor temperature monitor ON/OFF
(Off = Temperature OK)
Brushes Trac. Travel motor carbon brush monitor ON/OFF
(Off = Carbon brush OK)
Pu. Motor Temp. Pump motor temperature monitor ON/OFF
(Off = Temperature OK)
Brushes Pump. Pump motor carbon brush monitor ON/OFF
(Off = Carbon brushes OK)
Steerangle Microswitch for central wheel position +0°/255°
(+0° = wheel in straight-on position)
Speed Pump Pump setpoint (from electr. evaluation sys.) & pump motor speed
0.00V Perc. = 0%
Enable Pump Pump enable (from electr. eval. sys.) ON/OFF
(ON = Enabled)
Loweringswitch Lowering counter information (from electr. eval. sys.)ON/OFF
(ON = Lowering information available)

PROGRAM VACC
Automatic potentiometer adaptation to the control system. This function is used for
adaptation of the travel potentiometer to the minimum and maximum motor current.
INIT CONNECTION
PROGRAM <PROGRAM VACC WINDOW>
SAVE
RESTORE
BROWSE MODEL MAX V = 8,8V MIN V = 4,9V
CONFIG. MENU
ALARMS PRESS ENTER TO CONTINUE (ESC TO EXIT)
TESTER
PROGRAM VACC 4
MOTOR DATA
SPECIAL FUNCTION
2 SPECIA LMENU
TRACE FUNCTION
EXIT
7/0381
1. Use the cursor keys (1) to select PROGRAM
reserved.
VACC (2). P Ü *
3 +
L Ö Ä '
#
3. The voltage values which are currently in use are
displayed (4). 1 : _ Bild
. -
4. Press the ENTER key (3) to change to Alt Gr Einf Entf
programming mode. Bild
5. Select no travel direction and push the accelerator

pedal down slowly as far as it will go.
6. Release the accelerator pedal. 7/0380
7. Press the ESC key (5). 5 ESC F1 F2 F3 F4

8. Confirm the safety prompt "Are you sure?" (6)
with "J"or "N" and press the Enter key (3)to ! " § $ %
1 2 3 4 5
return to programming mode.
Q W E R
A S D F
> Y X C

Closing the superconsole software
INIT CONNECTION
PROGRAM
SAVE CHOPPER NAME: COMBI WAG. VXX
RESTORE BATTERY VOLTAGE: 48V
BROWSE MODEL MAX CURRENT: 300 AMPERE
CONFIG. MENU HOURS: xh
ALARMS
TESTER ALARMS:
PROGRAM VACC
MOTOR DATA
SPECIAL FUNCTION
SPECIA LMENU NO ALARMS
TRACE FUNCTION
EXIT
7/0381
reserved.
1. Use the cursor keys (1) or key (2) to select the P Ü *

menu point EXIT (4). 3 +
L Ö Ä '
2. Press the Enter key (3). #
1 : _ Bild
3. Switch off the notebook. . -

Alt Gr Einf Entf
Bild
7/0380

(FPS)
Electronic evaluation system (AWE)
Id. Nr. W8 406 860

Id. Nr. W8 407 465 (exchange)
General
The electronic evaluation system (1) acts as

a fix-programmed miniature control unit.
Logical connections and parameter sets for
the various different vehicle models are
stored in an EPROM.
These parameter sets can be modified with a

PSION manual programming unit, to optimise
the individual hydraulic movements (reach,
tilting, mast side shift, additional hydraulics,
reach damping function)
(see sheet no. M 99-100).
7/0454
These modified values are stored in an

reserved.
E2PROM. 1
The electronic evaluation system derives the

control signals for the travel and pump con-
troller, the console display and the hydraulic
valves from the digital input signals (keys, li- Functions
mit switches, etc.), the information provided
by the travel and pump controller (serial data
transmission) and the analogue hand lever Hydraulic-
settings (main lift and ancillary movements). Display
functions
The 24 V power supply is provided by the

voltage transformer via the logic board.
Diagnostic Options

(FPS) 1
(AWE)
Control of the hydraulic system
A mechanically coupled potentiometer (1) on

each of the hydraulic directional valves sends
an analogue signal to the electronic evaluation
system, for the setpoint main lift (SH) and set- 5/0099
point ancillary movements (SN) (idle position 6
V, approx. 0.5 V - 11.5 V by max. deflection).
The voltage level generated in this way serves

as the speed setpoint for the hydraulic pump
(SP).
On the basis of the selected hydraulic function

and the stored parameter, the electronic 2
evaluation system (AWE) sends a speed
setpoint to the travel and pump controller,
which in turn controls the motor,on condition
that the AWE also emits the "enable pump"
signal (0V, FP). 5/0100
reserved.
Remark: It is very important that the idle

position when the valve is not
activated is 6 V, as otherwise SH SN AZ AN AQ
individual movements may be ..
inaccurate or not function correctly.
12V 0V 12V 0V 0V
The course of the ancillary movements (tilting, X10.1 2 3 4 5 6 X13.15 9 8

X10.7
reaching, mast side shift and additional
hydraulics) is selected with electrical switching Electronic evaluation system
valves or selection keys in the "ancillary X20 X20 X11.1,3
2,4,5,6
movements" operating lever (2), which are FP 0V 24V
SP
switched by the power outputs of the electronic
evaluation system. These power outputs have 4 power outputs
a short-circuit, line breakage and excess
X20 X20
temperature monitoring facility.
If an error occurs, the electronic evaluation (FPS)
system issues an error code on the console
display. 5/0101

Block diagram
Main lift Ancill. movem. Ancillary movem. Steering Shift Hydraulic

potentiometer potentiometer selection contr. error damper option
• •
AWE
Shift
Power outputs damper
Red.
setpoint
Valves
Setpoint 0V 24V
generation Power Settings
supply
*TXD Pump Pump Lower- Konfiguration

RXD setpoint enable ing (Configuration)
(SP) (FP) counter
Inbetriebnahme
Logic board (Commissioning)
Parameter
(Parameters)
Optionen
(Options)
Display
reserved.
Fehlerliste
(Error list)
* The following information is sent Wartungs-
from the logic board to the intervall
electronic evaluation system as data (Maintenance
for the display. interval)
• Logic board software version
• Battery charge
• Operating hours
• Straight-on steering (bogie switch) Notebook
• Travel direction
• Creep speed ON/OFF
• Battery lock
• Handbrake
• Error code


Continued
The input and output signals of the hydraulic control system are explained in the following table
Input information Output information
Function SOK SH SN AN AQ AZ FP SP LS LN LQ ZH
Lift 1 > 6.2 V 6V - - - 1 0-10 V - - - -

Shift forwards 1 6V > 6.2 V - - - 1 0 parameter val. 1 - - -
Shift backwards 1 6V < 5.8 V - - - 1 0 parameter val. 1 - - -
Tilt backwards 1 6V > 6.2 V 1 - - 1 0 parameter val. - 1 - -
Tilt forwards 1 6V < 5.8 V 1 - - 1 0 parameter val. - 1 - -
Side shift, left 1 6V > 6.2 V - 1 - 1 0 parameter val. - - 1 -
Side shift, right 1 6V < 5.8 V - 1 - 1 0 parameter val. - - 1 -

Lift/shift forwards 1 > 6.2 V > 6.2 V - - - 1 0-10 V 1 - - -
Lift/shift backwards 1 > 6.2 V < 5.8 V - - - 1 0-10 V 1 - - -
Lower/shift forwards 1 < 5.8 V > 6.2 V - - - 1 0 parameter val. 1 - - -
Lower/shift backwards 1 < 5.8 V < 5.8 V - - - 1 0 parameter val. 1 - - -
Lift/tilt backwards 1 > 6.2 V > 6.2 V 1 - - 1 0-10 V - 1 - -
Lower/tilt backwards 1 < 5.8 V > 6.2 V 1 - - 1 0 parameter val. - 1 - -
Lower/tilt forwards 1 < 5.8 V < 5.8 V 1 - - 1 0 parameter val. - 1 - -
reserved.
Addit. hydraulics, left 1 6V > 6.2 V - - 1 1 0 parameter val. - - - 1

Addit. hydraulics, right 1 6V > 5.8 V - - 1 1 0 parameter val. - - - 1
Input information: Output information:

FP = Pump enable (0 volts)
SOK= Control system OK (see sheet M37) can be read off in the tester menu
Signal enquiry is possible (see M96) (see M65)
SH = Setpoint, lift SP = Pump setpoint
SN = Setpoint, ancillary movements can be read off in the tester menu
AN = Tilt selected (0 volts) (see M65)
AQ = Side shift selected (0 volts) Remark: It is, however, only possible to read off
half the value here (see M73)
AZ = Addit. hydraulics selected (optional) LS = Power output, shift valve (+24V)
(0 volts) LN = Power output, tilt valve (+24V)
LQ = Power output, side shift valve (+24V)
ZH = Power output, addit. hydraulics (0 volts)
Remark: The idle position area of the setpoint potentiometers SH and SN is defined with
±0.3 V, i.e., a valid function is recognised from 6.3 V or 5.7 V!

Block diagram for pump setpoint
Main lift Ancill. movements

potentiometer potentiometer
6.0 ±5.5 V 6.0 ±5.5 V

Electronic
Setpoint Conversion to parameters
evaluation
generation Ancillary movements system
Setpoint, pump for for ancillary movements, dependent on the set parameter 0-5.4V
Setpoint, pump for main lift 0-10 volts
R1 Logic circuit board
0 - 5V Logic
• 0 - 2.7V
•
reserved.
R2 Example
Interface
*Speed Pump Notebook

0-5V 100%
Menu tester
*Speed Pump
0-2.7V 20%

(FPS)
(AWE)
Simultaneous movements Max. setpoint = Lift setpoint (10 V)

reduced to 50 % during damping phase
It is possible to carry out the following
functions simultaneously: lift/lower lift with for-
wards/backwards reach, or lift while tilting
backwards, and lower while tilting back-
wards/forwards.
When the lift is lifted at the same time as rea-

ching backwards/forwards, the maximum set-

point is that of the lift (limitation of shift speed
by 2-way flow regulator valves, see hydraulic
system, section N7).
Max. setpoint = Reach setpoint
(dependent on paramter)
During reach damping, the speed is reduced to
50% and after a slight delay time, the
movement continues at the setpoint for the lift.
reserved.
When the lift is lowered at the same time as

reaching forwards/backwards, the maximum
setpoint is taken directly from the maximum
setpoint for reaching.
If the lift is raised at the same time as tilting

backwards, the maximum setpoint = lifting set-
point .
Max. setpoint = Lift setpoint (10 V)
If the lift is lowered at the same time as tilting
forwards or backwards, the maximum setpoint
= tilting setpoint.
The maximum tilting speed is also limited by

an orifice (see hydraulic system, section N12).
5/0102
Max. setpoint = Tilt setpoint
(dependent on paramter)

(FPS)
Electronic evaluation system 1
(AWE)
Compulsory reset
All movements can only be started from home
position. When a transition is made from one
type of movement to another (e.g. from rea-
ching to tilting), a reset is always required first,
which means that the hand lever must always 5/0103
be set to its idle position before the next move-
ment can be started.
The reset position is defined between a

"bottom" and a "top" value

(Reset position 6 V ± 0.3 V
Reach damping function 6/0026
A ramp is used to cushion the end of each

movement, i.e. the output value for the pump
setpoint (SP) is reduced proportionally,
reserved.
according to the parameter value entered.
The input information (0 V signals) is provided

by inductive proximity switches with a two-wire
system (1) which are attached to the slide car-
riage.
Practical measured values:

Switch not activated, SDV/SDH 19.5 V
Switch activated, SDV/SDH 6.8 V
Function SDV SDH SP

Reach damping 1 - max. red. value
function, front
Reach damping - 1 max. red. value
function, rear

(FPS)

(AWE)
Hydraulic options
A notebook can be used to activate various

options in the electronic evaluation system,
which extend the hydraulic functions.
These options are:
1.Lift cut-out
Input information
-X13.8(HB1) --> Intermediate lift limit
-X13.10 (HB2) --> End lift cut-out

-X13.12(EHA) --> Intermediate lift limit
release
Output information
-X20.10(FP) --> Enable pump
-X20.9 (SP) --> Pump setpoint
An intermediate lift limit can be activated via

reserved.
input HB1. As long as there is a 0V signal at

X13.8 the lift is deactivated (setpoint and
enable pump).
This cut-out is cancelled with a 0V signal at
X13.12 (EHA).
An end lift cut-out can be brought about via

input HB2 (X13.10). As long as there is a 0V
signal here, the main lift remains switched
off. This cut-out cannot be cancelled via
input "EHA".

(FPS)
(AWE)
Continued
Hydraulic options
2. Shifting and lowering lock

Input information
If the load carriage is retracted and is lowered
below a defined height (0.4 m) (0V signal at -X13.2 (SSP) --> 400 mm lowering lock
X13.2 SSP), the movement is blocked. The -X13.4 (SEV) --> Shift end position
load carriage can be lowered further if a -X13.6(ESP) --> Release of shifting and
transient 0V signal is sent to X13.6 (ESP) by lowering lock
means of the release key.
Output information
If the load carriage is extended, it can be
lowered without an intermediate stop. This -X11.6 (LSP) --> Lowering lock valve
movement is monitored with a 0V signal from

the "Shift end position" switch (SEV)" at X13.4.
If the load carriage is extended and lowered to

below the defined height, the forwards shift
function is locked. This locking function can
also be cancelled with the release key.
If the fork holder enters the locked area and

reserved.
this is unlocked with the release key, the mast

side shift function is deactivated.
3. Additional hydraulics
If this option is selected, an additional Input information

hydraulic function (e.g. fork tilt, bale
carrier) can be controlled with the -X13.5 (AZ) --> Selection of
electronic evaluation system. additional hydraulics
The input signal is a 0V signal at X13.5 (AZ). Output information
When the operating lever is displaced, output
X12.2 (ZH) is activated. This is not -X12.2 (ZH) --> Additional hydraulics
a 24 V valve power output, but a 0V relay
switch output. For this reason, a
micro-relay (Id. no. W8 014 372)
must be inserted.

(FPS)

(AWE)
Control of the console display

1 7 8 2
Id. no. W8 406 522, basic EMC version
The following information is provided on the flat

LEDs:
- Maintenance (1) 3
- Travel direction forwards/backwards (2) OOOOOOOO OO
O
- Handbrake applied (3) O
- Vehicle ON (4) 4 OO
- Creep speed (5) O
- Heating ON (6), only for cold-store FM 5 O
OO
The 6-digit, 7-segment display (7) indicates the
operating hours and the coded error messages. 5/0110
6 9
Commissioning and diagnosis information is also
shown on this display.
The 8-digit LED strip (8) shows the battery charge
level (see sheet no. M81)
In the standard model, the wheel position display
(9) only indicates the central wheel position (the
two LEDs in the middle light up).
As an optional extra, a semi-circle can be added
reserved.
which represents the position of the wheels (not

currently available).
The logic circuit board sends the following signals
to the electronic evaluation system to control the
display:
Serial data transmission from the FPS

- Travel direction forwards/backwards (FV/FR)
- Handbrake (HB)
- Creep speed (SF)
- Central wheel position (RM)
- Battery capacity
- Operating hours
- Maintenance
- Error messages
The signal for "vehicle ON" is evaluated with the

applied supply voltage (24 V).
When the vehicle is switched on with the key-

operated switch, information about the software
version and settings is displayed (see sheet no.
M80).

(FPS)

(AWE)
Continued
Display
The signals received from the AWE are transmitted
to the display.
- Maintenance LED
- Handbrake LED
- Vehicle ON LED
- Creep speed LED
- Forwards travel LED
- Reverse travel LED
- Heating ON LED
- Battery capacity
- Operating hours
5/0112
- Wheel position display
- Error messages
1
The signals can be tested on the display circuit
board as follows:
1. Remove the circuit board from the cover, so X 900

that the solder spots of the X900 connector (1)
reserved.
are accessible. 2 4 6 8 10 12 14 16 18 20 22 24 26
2. Measuring the signals at connector X900:
Pin 1: 5V Pin 13: free 1 3 5 7 9 11 13 15 17 19 21 23 25

2: 5V 14: free 5/0113
3: 0V 15: free
4: 0V 16: 5 V maintenance
5: Serial data to 17: 5 V handbrake
evaluation module
(~ 0.6 V DC measurement)
6: 0V 18: 5 V vehicle ON X100
7: Start signal for 19: 5 V creep speed
loading serial 20: 5 V forwards
data (can only be 21: 5 V heating ON
measured with oscilloscope)
8: 0V 22: Reserve LED AWE
9: Timing generator, 23: Reserve LED
evaluation module 24: 5 V reverse
(~ 0.24 V DC measurement)
10: 0V 25: 24 V
11: 0V 26: 24 V
12: 0V

(FPS)
(AWE)

1
Software version display
• Key-operated switch on 02
O
OOOOOOOO OO
- The programmed parameter type O
number (1) is displayed on the AWE OO
O
- The code number for the battery O
OO
discharge characteristic curve (2) and
the software version of the electronic 5/0110
evaluation system software version (3) is

displayed.
2 3
- The software version (4) for the travel
and pump control system is then
displayed, followed by the current
number of operating hours. 2 20.3
O
OOOOOOOO OO
Remark: If the data line between the
reserved.
O
electronic evaluation system and OO
O
the logic circuit board is O
OO
interrupted, the display stops at
the software version of the 5/0110
electronic evaluation system (3).

4
96011.2
O
OOOOOOOO OO
O
OO
O
O
OO
5/0110

(FPS)

(AWE)

2
Battery charge level
1
The battery charge level is displayed on the O
OOOOOOOO OO
8-digit LED strip (1). O
OO
O
O
OO
5/0110
Charge level Display

100% - 90%
= red, lights up
80%
70% = yellow, lights up
reserved.
60% = red, flashes

50%
40%
30%
24%
19%
• Lift cut-out, i.e. no setpoint and pump is not

enabled.
• The maintenance symbol (2) lights up.

Error list
Errors
The electronic evaluation system has various monitoring 2 1

tasks. When the vehicle is switched on, an error check is
carried out. First, possible errors in the electronic evaluation FE 01
system are checked, and then the messages sent by the
travel and pump controller. O
OOOOOOOO OO
O
If errors are identified, they are allocated to a specific error OO
class. Irrespective of how they are classified, they are O
O
entered in the event time memory, which can be read and OO
deleted again whenever necessary using the diagnosis
interface. 5/0110
Errors which occur during operation are treated in the same

way.
The error situation is indicated with a specific error number,
and the maintenance symbol appears in the 7 segment
display on the console (1).
Error class 1:
An error is displayed if, for example, an operator tries to drive
the vehicle, but travel is not possible because the battery
lock is is not activated. The error is displayed until it is
eliminated. The maintenance symbol flashes (2) when the
reserved.
vehicle is in error mode. The error is not stored.
Error class 2:
The error is displayed and remains on the display until the
cause has been rectified or the vehicle returns to an error-
free condition, e.g. when excess temperature has dropped.
When the error occurs for the first time, the status of the
operating hours counter is recorded in the event time
memory. The maintenance symbol (2) flashes when the vehi-
cle is in error mode.
Error class 3:
The error is displayed. Every time the vehicle is switched on
again, the error is displayed for between 10 and 15 seconds,
on condition that the cause has not meanwhile been
eliminated, e.g. carbon brushes.
The first time the error occurs, the error is indicated on the
display until it is acknowledged with the key-operated switch.
The status of the operating hours counter is recorded in the
event time memory. The maintenance symbol flashes until
the error is rectified.
Continued on next sheet


Error list
If more than one error occurs at the same time, they are indicated in order of urgency (error classes).
For a more detailed description of the logic circuit board, see sheet no. M23 ff. To delete errors in the
electronic evaluation system, see sheet no. M101
Class Affected components

Error messages AWE Logic board FE
Batterylock X 01 1 see M23

Valves:Shortcut/broken wire X 02 2 Valve wiring
No Telegram X 03 2 Logic board, AWE, ribbon cable
Telegram error X 04 2 Logic board, AWE
Forw. + Backw. X 05 2 see M23
Incorrectstart X 06 1 see M23

VACC not o.k. X 07 1 see M23
VACC out of range X 08 2 see M23
EEPROM k.O. X 10 3 see M24
Driver shorted X 11 2 see M24
Logic failure X 11 2 see M24
Contactor driver X 11 2 see M24
Micro ST 6215 k.O. X 11 2 see M24
No Field current X 12 2 see M24
High Field current X 13 2 see M24
reserved.
Pump I=0 Ever X 14 2 see M25

Pumpstyb I high X 14 2 see M25
Capacitor charge X 15 2 see M25
VMN not o.k. X 16 2 see M25
V Field not o.k. X 17 2 see M25
Stby I high X 18 2 see M26
I=0 Ever X 18 2 see M26
Contactor closed X 19 2 see M26
Coil shorted X 19 2 see M26
Traction Motor Temp X 20 2 see M26
Traction Brushes X 21 3 see M26
Th. Protection X 22 2 see M27
Pump Motor Temp. X 30 2 see M27
Pump Brushes X 31 3 see M27
Pump Temperature X 32 2 see M27
Error steering controller X 40 2 Steering controller/sensor
Brushes steering motor X 41 3 Steering motor
SOK kO X 42 2 see M28
Battery kO X 43 2 see M28


(FPS)
(AWE)
Maintenance intervals 1
It is possible to define a specific timescale for

a maintenance interval (see sheet no. M102).
O
OOOOOOOO OO
When the interval reaches its end (which is O
OO
registered by the travel and pump controller
O
from the operating hours), a flag is set which O
OO
causes the maintenance symbol to light up (1).
5/0110
To reset the flag, a new interval must be enter-

ed (which is greater than the current number of
operating hours) and the key-operated switch
must be switched OFF/ON.
The interval counter then starts again.

reserved.

(FPS)
(AWE)
TEWAK interface software
General
There are certain hardware and software

requirements for using a notebook to make
changes to the parameters in the electronic
evaluation system (AWE).
Software requirements:
- Operating system MS-DOS 3.1 or

higher
- Graphics operating system extension
WINDOWS 3.1/3.11
- Tewak program installed
(Id. no.1099649)
reserved.
Installation instructions are provided on

the diskette, or refer to sheet no. M86
Hardware requirements:
- 80286 processor or higher

- Minimum memory 1 MB RAM
- Hard disk with at least 40 MB free
capacity (needed for WINDOWS
3.1/3.11)
- VGA monitor or equivalent LCD monitor
on notebook.
- Mouse or trackball
- Interface adapter

(FPS)
5 1 3 6
(AWE)
TEWAK interface software C:\A:
A: INSTALL
Installing the TEWAK program
1. Switch on the notebook.

The following prompt appears: C:\(1)
2. Insert the installation diskette in disk drive
A (2). ESC F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12
3. Enter A: (3) and press the enter key (4). !

1
"
2
§
3
$
4
%
5
&
6
/
7
(
8
)
9
=
0
?
ß
`
´
You will now see: A: (5) Q W E R T Z U I O P Ü * 4

+
4. Enter INSTALL (6) and press the enter key A S D F G H J K L Ö Ä '
#
(4). The installation process then begins. > Y X C V B N M ; : _ Bild
< µ , . -

^ Bild
Opening the TEWAK program

7/0380
10 12
Remark: -Switch on the vehicle.
-Check the interface settings, 7 8 2
see M112.
-Plug in the interface adapter,
reserved.
see M112.
5. Enter: C: and press the enter key (4). C:\TEWAK
6. C:\ is displayed.
7. Enter: TEWAK (8) and press enter key (4).
8. The terminal program starts.
9. A "terminal window" is displayed (9)
10. Enter: press the shift key (10) and
type PP (11).
Remark: If the notebook is restarted, step 5

can be omitted.
Symbol Key combination

: Key (10) and (12) 11
7/0395

(FPS)
(AWE)
TEWAK interface software
Closing the TEWAK program
1. Move the arrow (2) onto the field (3) with 3 2

the trackball or mouse (1).
2. Click twice quickly on the field (3) with the 7/0395
key (4).
3. Press the ALT (6) and F4 (7) keys
5. Switch off the notebook (5)
ESC F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 8

! " § $ % & / ( ) = ? `
1 2 3 4 5 6 7 8 9 0 ß ´
Q W E R T Z U I O P Ü *
reserved.
7 A S D F G H J K L Ö Ä '
#
> Y X C V B N M ; : _ Bild
< µ , . -
^ Bild
6/0330
7
4 1

(FPS)

(AWE)
Diagnosis and
commissioning software 1 2
General
The AWE includes software for adjustment and

diagnosis purposes which is menu guided and can
be activated using the PSION manual programming
unit.
The menu contains the following points:
- Versionsnummer (see block 2, sheet no. M90) 5/0110

- Konfiguration (see sheet no. M91-94)

(Configuration)
- Inbetriebnahme (see sheet no. M95-98)
(Commissioning)
- Parameter (see sheet no. M99-100)
(Parameters)
- Fehlerliste (see sheet no. M101)
(Error list)
- Wartungsintervall (see sheet no. M102)
(Maintenance intervall)
reserved.
When the software is activated, the AWE goes into

"STOP mode", so that it is no longer possible to use
the vehicle functions.
This is indicated by the maintenance LED (1) and

vehicle ON LED (2) on the console display lighting
up.


Diagnosis and commissioning software
Menu structure and use
The software installed in the AWE is menu guided and can be activated and used with a
notebook.
In order to use the software, the vehicle must be switched on, the interface adapter set to AWE
(see sheet no. M112) and the notebook connected with the AWE (the TEWAK software must be
installed in the notebook).
The TEWAK software must then be called up in the notebook and started by entering "PP" on
the notebook keyboard (see also sheet no. M86).
Die Menüführung erlaubt folgende Befehle:

(shift)
- (1) and W Continue in a menu level
(shift)
- (1) and Continue to the next menu level down

(shift)
- (1) and X Back to the next menu level up
(shift) ESC F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F
- (1) and S Save changed values !

1
Q
"
2
W
§
3
E
$
4
R
%
5
T
&
6
Z
/
7
U
(
8
I
)
9
O
=
0
P
?
ß
Ü
A S D F G H J K L Ö
> Y X C V B N M ; :
- + Change values / settings < µ , .

1 Strg Alt Fn ° Alt Gr Einf
reserved.
-
7/0380
The symbols used in the menu flowchart indicate the following:
- Press the appropriate key on the notebook.
- The menu continues from or goes to this point.
- Display on the notebook screen
- Further sequence dependent on conditions

Continued
For instructions on calling the terminal interface, see M86
When "PP" is entered on the notebook, the AWE software registers on the notebook display with
the following main menu:
WAGNER Service
Terminal Remarks:
= shift key (see M89)
Menu continues automatically

(W)eiter
ID406860 Vxxx xxx Current software version
displayed
+
Electronic evaluation system is
x or
W
switched off. Only the symbols
+ x for maintenance and the key-
(W)eiter (J)a + J operated switch on the console
1 Contd. on display continue to be
Konfiguration 1 sheet no. illuminated.
M91
+ W
+ x
.
(W)eiter (J)a + J If the power supply fails during
reserved.
2 Contd. on
Inbetriebnahme programming, the battery plug
2 sheet no.
M95 should be pulled out briefly and
the system then reset with the
+ W
key-operated switch (Reset).
Restart the notebook.
(W)eiter (J)a + x
.
+ J
3 Contd. on
Parameter
3 sheet no.
M99
+ W
Weiter = Continue
(W)eiter (J)a + x
. Ja = Yes
Fehlerliste
+ J
4 Contd. on
Konfiguration = Configuration
4 sheet no.
Inbetriebnahme = Commissioning
M101 Parameter = Parameters
+ W Fehlersiste = Error list
Wartungsintervall = Maintenance
interval
(W)eiter (J)a + x
.
Wart. Intervall
+ J
5
5 End of
+ W Contd. on program
sheet no. Start with 'PP'
M102

Continued
Configuration submenu: (see also M92-94)
Continued from sheet no.90 Remarks:
1 1
Change the type
number with
+
(W)eiter (J)a
x
. +J (S)ich
Typ (type) +x or Typ: xx xx: Display
+ s depends which
type stored.
(S)ich = Save
+ W (W)eiter = Continue + x Back without
saving the
altered value
+ x
(W)eiter (J)a + J (W)eiter (S)ich + S Back/

HUBAB OFF continue and
Optionen (Options) (Lift cut-out) save altered
value
+ W
+ x or + S
+ W Continue in
menu without
reserved.
Selected value not

saving the
saved (old setting
retained)
+ W
altered value
To change
(W)eiter (S)ich +W ON/OFF:
+ x
SS-SPERRE OFF
(Reach and lowering lock)
= Shift key
+ W S
(see M89)
+ x or + S
Continued on
sheet no. M93
(FPS)

(AWE)
Diagnosis and
commissioning software
Continued Table of standard parameter sets

Menu point functions
Konfiguration Parameter Type

0 1 2 3
With this menu point, the vehicle can be
programmed for specific tasks, and retrofitted Reach forw 4.0V 4.4V 4.4V 4.4V
elements on the vehicle can be adapted to the
software. Reach back 5.0V 5.0V 5.0V 5.0V
This feature is required because there are various Tilt forw. 4.5V 4.6V 4.5V 4.2V
different basic versions of the vehicle (load
Tilt bachw. 4.2V 4.5V 5.2V 4.2V
carriage/pump variations) and because the vehicle
may already be, or is going to be, fitted with optional Side shift 5.0V 4.3V 4.3V 4.0V
extras (e.g. shifting and lowering lock, intermediate
lift limit, etc.). shift damp fw 65 65 65 65
In the "Type" submenu, entering a type number shift damp bw 55 55 55 55
activates a standard set of parameters which is
reserved.
responsible for the different pump speeds. Add. hydr. 4.0V 3.5V 3.5V 3.5V
There are currently 4 different parameter sets (types

0, 1, 2 and 3). The parameter set can be altered Reach forw. to Sideshift can be altered: +/- 1V
within a certain range.
shift damp forw./back can be altered: +/- 20%
Add. hydr. can be altered: 0-10V
Remark: When the vehicle is switched on with
the key-operated switch, the
programmed type no. appears briefly on Type: 0 no application
the display, e.g., ---02 = type no. 2 (see Type: 1 FM 14/17
sheet no. M80)
Type: 2 FM 20
Type: 3 FM with fork tilt
In the "Options" submenu, additional appliance
functions can be activated, and if modifications have
been made to the vehicle, the AWE is adapted here.


Continued
Configuration submenu
Continued from sheet no. M91
+ + (W)eiter (S)ich
. x or S
ZUS_HYDR OFF
(Add. Hydraulics) Remark:
+ W = Shift key
(see M89)
+ + (W)eiter (S)ich
. x or S
LR_NEU OFF
(New steering controller)
* For steering
controller with
Id.no. W8 407
010 and later, this
must be set to
+ W
ON. See also
remark on sheet
reserved.
no. B20.
+ + (W)eiter (S)ich
. x or S
WARNLICHT OFF
(Warning light)
+ W
+ x or + S (W)eiter (S)ich
QUERSCHUB ON
(Side shift)
+ W
Remark: If the "Standard-Param!" command is used in the

parameter submenu, all option points return to the basic
setting, i.e. they are "OFF"!
The only exception here is the "Side shift" option point.
This is "ON" in its basic setting!

(FPS)

(AWE)
Diagnosis and commissioning
software
Configuration submenu
Continued
Options Basic setting
1. Lift cut-out ("HUB AB", see sheet no. M76).

(Lift cut-off) OFF
2. Schub- und Senksperre (Reach and lowe-

OFF
ring lock) ("SS-SPERRE", see sheet no.
M77).
3. Zusatzhydraulik (Add. Hydraulics) OFF

("ZUS.HYDR.", see sheet no. M77).
4. WARNLICHT (Warning light)

For controlling a flashing or all-round light OFF
reserved.
during travel or lowering of the lift.

Because this is a "low-power" output, a flas-
her relay or a switching relay must be inser-
ted here.
5. LR_NEU (New steering controller) Adapta- ON or OFF*

tion to modified steering controller.
6. Mastquerschub (Side shift). The mast side

shift function is available as an optional ex- ON
tra. It is preset to "ON"
* For steering controller with

Id.no. W8 407 010 and
later, this must be set to
ON. See also remark on
sheet no. B20.

Menu structure and use / Inbetriebnahme submenu: (see also M96-98)
Continued from
2 2 Remarks:
sheet no. M90
+ X
The voltage level
(W)eiter (J)a . + J (W)eiter of the relevant
Analog - In Hfaupthub
(Analogue-In) .+ X
(Main lift)
potentiometer is
shown on the
console display.
+ W
+ (W)eiter
W + X
Nebenhub
(Ancillary lift)
+ W 'E1' appears on
the console
+ X display. The 7-
(W)eiter (J)a + J (W)eiter segment display
Digital - E/A DIG-IN: Ø1 provides
information about
+ W the input signals:

+X + W
. (see also M97)

+X
. . (W)eiter
= Shift key
DIG-IN: Ø2
(W)eiter (J)a (see M89)
Kommunikation
(Communication) + W
reserved.
+ W + J
(W)eiter
. DIG-OUT-BIT: Ø1
'A X' appears on
the console display,
where 'X' can be
either 0 or 1.
(D)aten + W 1 = Output set
(Data) 0 = Output not
set.
+ X
+X (W)eiter Change using
. The data from the DIG-OUT-BIT: 10 '1'
'0'
FPS to the AWE
can be read out
here (see sheet 'A2 X' appears on
no. M106) the console display
(see above)
(W)eiter = Continue
(J)a = Yes

(FPS)

(AWE)
Diagnosis and
1
Continued
Inbetriebnahme (Commissioning)
The "Commissioning" point in the menu simplifies

error detection and makes adjustment work easy to
carry out.
'The "Analog-IN" (Analogue-In) submenu can be

used to display the voltage levels of the hydraulic
potentiometer on the 7 segment display on the con-
sole (1). This
makes mechanical adjustment very easy (idle
position 6 V).
LED 8..................LED 1
With the "Digital E/A" (Digital I/O) submenu, the
switched
input/output signals at the AWE can be displayed.
reserved.
They are displayed on the console display in groups

of 8.
O
Display of the switched input signals: OOOOOOOO OO
O
The input signals are displayed on the vertical bar
OO
LEDs (LED1 to LED8) on the seven-segment
O
display, i.e. when the AWE receives an input signal O
OO
(0V signal), the corresponding bar LED lights up.
5/0110
The serial connection between the electronic
evaluation system and the FPS can be checked in
the Communication (data) submenu.
For division of the groups of 8, see sheet no. M 97.


Continued
Menu point functions, Inbetriebnahme
(Commissioning)
8 7 6 5 4 3 2 1
Input group 1
LED 8 7 6 5 4 3 2 1
Steering motor carbon br. ( KLR)
Steering controller error (FLR)
Shift damper function, back. (SDH)

Shift damper function, forw. (SDH)
Reserve input 1 (RES1)
Select additional hydraulics (AZ)
Heating on (KHA)
reserved.
Release interm. lift limit (EHA)
Input group 2
LED 8 7 6 5 4 3 2 1
End lift cut-out (HB2)
Intermediate lift cut-out (HB1)
Release shift/ lowering lock (ESP)
Shift end position (SEV)
400mm lowering lock (SSP)
Control system OK (SOK)
Select tilt
Select side shift


(AWE)
Continued
Menu point functions, Inbetriebnahme
(Commissioning)
Displaying the switched output signals:

A notebook can be used to set and reset the AWE
outputs. The output statuses are shown on the
console on the 7 segment display, e.g.,
AI 0 means: Output 1 not set,
AI 1 means: Output 1 set.
Caution:
This process releases safety-related

locks in the AWE, since the outputs
are switched directly!
For this reason, the vehicle must be
jacked up!
Once work with the diagnosis and commissioning

software is completed, the outputs return to the
status which is correct according to the signal
reserved.
settings of the vehicle.
Output assignmnt:
A1 Shift valve (LS)

A2 Tilt valve (LN)
A3 Side shift valve (LQ)
A4 Lowering valve (LSP) (optional)
A5 Enable pump (FP)
A6 Lowering information to FPS (SZ)
A7 Warning light (WL) - low-power
A8 Addit. hydraulics (ZH) - low-power
A9 Reserve X6.3 - low-power
A 10 Reserve X6.6 - low-power

Menu structure and use / Parameter submenu (see also sheet no. M100):
3 Continued from 3
sheet no. M90 Remarks:
+ X
= Shift key (see M89)
(W)eiter (J)a +J (W)eiter (S)ich
S - vor
(Reach forwards) .
back, no changes X
S - vor x.xxV If the value is outside the
'window', it cannot be
+W + W or S saved with the S
+ 3
do not save/save
key.
(W)eiter (J)a X Change using
S - rueck +J (W)eiter (S)ich
(Reach backwards) +X S - rueck x.xxV Current value x.xx is
displayed in volts (is
+W + W or S determined by processor
+ 3 continually).
(W)eiter (J)a X Change with
N - vor +J (W)eiter (S)ich
(Tilt forwards) +X N - vor x.xxV
+W Premissible alteration
+ W or
S ± 1 V from the standard

+ 3
parameter
(W)eiter (J)a X
N - rueck +J (W)eiter (S)ich (in steps of 0.1 V).
(Tilt backwards) +X N - rueck x.xxV
+W +W or S
+ 3 Current value xx in %.
(W)eiter (J)a X Permissible alteration
+J (W)eiter (S)ich ± 20% from the standard
OS
(Side shift) +X QS x.xxV parameter.
reserved.
+W +W or S
+ 3
(W)eiter (J)a X The "Add_Hydr"
+ J (W)eiter (S)ich parameter is only
SDF vor
(SDF forwards) + X SDF vor xx displayed if it has been
set to "ON" under
+W + W or S "Option"!
+ 3
(W)eiter (J)a X
Values in the E2PROM
SDF vor + J (W)eiter (S)ich
are set to zero! All the
(SDF backwards) +X SDF rueck xx option points are then
+W also set to "OFF" again
+ 3
+ W or S
and the mainenance
(W)eiter (J)a X interval set to 500 hours.
+ J (W)eiter (S)ich
Zus_Hydr.
(Add. Hydr) + X Zus_Hydr. xx
+W 3 +W or S
+X
(W)eiter (J)a +J Standard Param.
Continues
Standard-Param! automatically
+W Function aktiv
. Continues
automatically


(FPS)

(AWE)
Diagnosis and
Continued
Menu point functions, Inbetriebnahme (Com-
missioning)
Parameter
Under this menu point it is possible to alter within Table of standard parameter settings
certain limits the preset standard parameters that are
called by entering the type no. (see sheet no. M92).
In this way, the speed of the following hydraulic

functions can be adapted: Parameter Type
- S - vor (reach forward) 0 1 2 3

- S - rueck (reach back) S - vor 4.0V 4.4V 4.4V 4.4V
- N - vor (tilt forward)
- N - rueck (tilt back) S - rueck 5.0V 5.0V 5.0V 5.0V
- QS (mast side shift)
- SDF vor (reach forward dampening) N - vor 4.5V 4.6V 4.5V 4.2V
- SDF rueck (reach back dampening)
reserved.
- Zus. hydr. (add hydr. functions) N - rueck 4.2V 4.5V 5.2V 4.2V
QS 5.0V 4.3V 4.3V 4.0V

It is also possible to call the original standard SDF vor 65 65 65 65
parameter set again with the "Standard parameter"
command. SDF rueck 55 55 55 55
This deletes the contents of the E2PROMS.
Zus.Hydr. 4.0V 3.5V 3.5V 3.5V
The parameters for shifting, tilting, mast side shifting
and additional hydraulics can be altered within a
range of ± 1 V (in steps of 0.1 V).
The parameters for the shift damper function are

given as percentages and can be altered within a
range of ± 20 % in steps of 1%.

Fehlerliste submenu: Fehlerliste (for guide to errors, see M83)
When errors and faults of class 2 and 3 occur, the status of the
operating hours counter is stored with the error number the first time the
fault happens.
This counter status can be read off and deleted as required.

4
4
+
Are there No (W)eiter X or W
any errors?
Keine Fehler
Yes
No
Remarks:
reserved.
4
= Shift key
+ X
(see M89)
(W)eit (S)torno Are there
FE: xx xh
+ S any more xx = Error number
errors stored? x = Operating hour
during which the
+ W error occurred for
the first time.
Yes S
List of all further errors (see
above for illustration) or, if no = Operating hours
more errors in memory: reset to zero
(W)eiter
Keine Fehler
(No errors) (W)eit = Continue
(S)torno = Cancel
4


Wartungsintervall submenu:
Wartungsintervall
It is possible to define a set timescale (passed operating hours) for the

next maintenance interval.
The interval can be set using this menu.
When the programmed number of operating hours is reached, a marker
is set which causes the maintenance symbol to be displayed in the
console display.
To reset the marker and consequently the maintenance symbol, an
operating hours value must be programmed which is larger than the
current number of operating hours. The key-operated switch must also

be switched "ON/OFF".
If the maintenance interval is set to zero, the maintenance symbol is
illuminated continuously.

reserved.
5 5
+
Remarks:
(S)ichern (Save) S or X
= Shift key
Wartung: xxxxxh (see M89)
(Maintenance)
Use to change value in steps
of 50!
Default value for 1st maintenance interval is

500 h.
To save the value, press the S key. If the

value saved is zero, the maintenance
symbol on the console display is illuminated
continuously.
If the "Standard param!" command is used

in the parameter submenu, the default value
of 500 h is set here.


(FPS)
Replacing the software
The software for the electronic evaluation system 1

is stored in an EPROM (Eraseable Programable
Read Only Memory).
This means that to replace the software, the

EPROM used must also be replaced.
Procedure

Remark: The console display is integrated

in the cover. Take care when

removing the cover not to
damage the control unit for the
display.
2. Use the notebook to read off and make a note 7/0453

of the programmed type number, parameters
and options.
reserved.
3. Remove the notebook and disconnect the

electrical connections to the AWE.
4. Remove the cover from the FPS (see M38).
5. Carefully lever the EPROM (1) out of the IC
OOOOOOOO
base with a suitable tool.
O O
6. Carefully insert the EPROM with the new
OOOOOOOO
software in the IC base. 2 6/0005
2
Remark: Always wear antistatic protection
when handling the components
Take care not to bend any contact
vanes on the IC!
Observe the markings on the IC
and IC base (2). These must both
be on the same side.


(FPS)
Continued
Replacing the software, procedure
7. Activate the software using the notebook.
8. Under "Type" in the configuration menu, first

save type 0 and then save the relevant type
number.
9. Set the options and parameters as they were

before the software exchange, or set them
correctly for new vehicle adaptations.
10. End the program, make the electrical

connection for the console display and
replace the cover.
reserved.


(FPS)
Serial communication between logic circuit
board and the electronic evaluation system
The AWE polls data from the logic circuit board in

a fixed cycle via the RS232 serial interface.
The data is transmitted in ASCII-code format. Electronic evaluation system
When ASCII code "D" is transmitted along the TxD

lead of the AWE (TxD = Transmit Data), the logic
circuit board also sends its data along its TxD lead
RxD TxD
to the RxD terminal (RxD = Receive Data) of the
AWE.
If the logic circuit board does not respond to an

AWE data enquiry, this is registered and error code

FE03 is shown on the console display (e.g. in the TxD RxD
event of wire breakage).
In order for the data flow to be displayed, the
"Data" submenu must be selected under the menu Logic circuit board
point Commissioning (see sheet no. M106)
Explanation of telegram bytes (see sheet no.

M106) 5/0111
reserved.
Travel and pump control system


Serial communication
Continued
Meaning of telegram bytes
Positions Information Range of values

1-2 Error from control sys. 01 - 49 or none
3-4 Battery capacity 90 - 80 - 70 - 60 - 50 - 40 - 30 - 24 - 19
5 - 10 Operating hours 0.0 - 63999.9 represents operating hours.
11 Steering angle prefix + or none
12 - 13 Steering angle 00 or none
14 Travel direction V = forwards R = reverse or none
15 Travel status D = travel P = handbrake applied or none
16 Deceleration S = creep speed B = battery open or none
Example of a telegram
20 90 000012 +00 V P S
Error
Battery
reserved.
capacity
Operating
hours
Steering
angle
Travel
direction
Travel
status
The following is displayed:
1 - 2: Error 20 Creep
3 - 4: Battery capacity 90 speed
5- 10: Operating hours 1.2
11: Steering angle +
12 -13: Steering angle 00
14: Travel direction forwards
15: Travel status, handbrake applied
16: Deceleration, creep speed active


Setting the battery discharge
characteristic curve
Adjustment procedure
The ancillary movements lever (1) must be pulled and

the ancillary movement selection keys (2) pressed at 1
the same time as the key-operated switch is switched.
The maintenance symbol then flashes and a number
appears at the left of the display with a value of
between 0 and 7.
Continue pulling the ancillary movements lever and
release the selection button. The number can be
increased by pressing the right-hand button several
times and decreased by pressing the left-hand button.
Once the required characteristic curve has been set,
the lever can be released, and the value is stored.

The set value and the word "end" now appears in the
6/0063
display. Before travel is possible, the key-operated
switch must be switched off and on again. 2
Every time the vehicle is started, the set code for the
characteristic curve is displayed to the left, next to the
current Eprom version for the electronic evaluation
system (see sheet no. M80).
reserved.
The codes stored are:
0 = Wet-cell battery and power increased to 360 Ah

4 = Dry battery to 360 Ah

Guide to pin assignment
Travel 1 (inputs) X2 (logic circuit board)
X2.1 Travel potentiometer +10V X2.11 Brake pedal microswitch supply 0V

X2.2 Setpoint potentiometer * I/A X2.12 Brake pedal microswitch 0V I/D
X2.3 Travel potentiometer 0V X2.13 ------ 0V
X2.4 Accel. pedal microswitch 0V I/D X2.14 ------
X2.5 Accel. pedal microswitch
X2.6 Travel direction reverse 0V I/D
X2.7 Travel direction supply 0V
X2.8 Travel direcion forwards 0V I/D
X2.9 Handbrake supply 0V
X2.10 Handbrake 0V I/D
* Setpoint is approx. 4.8 - 8.7V, depending on I/D = Digital input

the value read in during commissioning).

I/A = Analogue input
Travel 2 (inputs) X3 (logic circuit board)
X3.1 Foot-switch supply 0V

X3.2 Foot-switch 0V I/D
X3.3 Creep speed supply 0V
X3.4 Creep speed 0V I/D
X3.5 Battery lock supply 0V
reserved.
X3.6 Battery lock 0V I/D

X3.7 free 0V
X3.8 free I/D
X3.9 free 0V
X3.10 free I/D
Input wiring on logic circuit board
+24V
+5V

Continued
Sensor system X4 (logic circuit board)
X4.1 Travel motor temperature supply 0V

X4.2 Travel motor temperature switch 0V 0V=ok I/D
X4.3 Travel motor carbon brush supply 0V
X4.4 Travel motor carbon brushes 0V 0V=ok I/D
X4.5 Pump motor temperature supply 0V
X4.6 Pump motor temperature switch 0V 0V=ok I/D
X4.7 Pump motor carbon brushes 48V I/D
X4.8 Pump motor carbon brushes 0V I/D
X4.9
X4.10 Seat adjustment motor 0V Output

X4.11
X4.12
X4.13
X4.14
X4.15
X4.16 Central wheel position 10V I/D
X4.17 Central wheel position supply 10V
X4.18
reserved.
I/D = Input Digital
Diagnosis interface X5
X5.1
X5.2 RXD FPS or AWE
X5.3 TXD FPS or AWE
X5.4
X5.5 GND FPS or AWE
X5.6
X5.7
X5.8
X5.9
X5.10
FPS = Travel and pump control system

AWE = Electronic evaluation system

Continued
X8 Control current fuses (separate connectors)
X8.1 F2 for key-operated switch 48V /10A

X8.2 3F1 for steering controller 48V / 20A
X8.3 3F1 for steering controller 48V / 20A
X8.4 4F1 for horn 48V / 5A
X8.5 5F7 (optional) 10A
X8.6 5F7 (optional) 10A
X8.7 Key-operated switch
X10 Hydraulic lever inputs (electronic evaluation system)

X10.1 Main lift potentiometer supply 12V
X10.2 Setpoint input 6 Volt +/- 5,5
X10.3 Main lift potentiometer supply 0V
X10.4 Ancillary movement potentiometer supply 2V
X10.5 Setpoint input 6 Volt +/- 5,5
X10.6 Ancillary movement potentiometer supply 0V
X10.7 Select tilt 0V
reserved.
X10.8 --------------------- 0V
X10.9 Select side shift 0V
X10.10 Tilt / side shift supply 0V
X11 Power valve outputs (24 volts/1.6 A) (electronic evaluation system)
X11.1 Shift value supply 0V

X11.2 Shift power output 24V
X11.3 Tilt valve supply 0V
X11.4 Tilt power output 24V
X11.5 Side shift power output 24V
X11.6 Lowering power output (optional) 24V
X12 Low-power outputs (electronic evaluation system)

X12.1 Warning light
X12.2 Additional hydraulics
X12.2 Reserve
X12.2 Reserve

Continued
X13 Option inputs (electronic evaluation system)
X13.1 0V
X13.2 400mm Lowering / shift lock
X13.3 0V
X13.4 Fork end position
X13.5 0V
X13.6 Lowering / shift lock release
X13.7 0V
X13.8 Intermediate lift cut-out
X13.9 0V
X13.10 Lift cut-out

X13.11 0V
X13.12 Lift cut-out release
X13.13 0V
X13.14 Cold-store heating
X13.15 0V
X13.16 Additional hydraulics selection
X13.17 0V
X13.18 Reserve input
reserved.
X14 Steering / shift damper function (electronic evaluation system)
X14.1 0V
X14.2 Shift damper function, forwards
X14.3 0V
X14.4 Shift damper function, backwards
X14.5 0V
X14.6 Steering controller error
X14.7 0V
X14.8 Steering motor carbon brushes
X14.9 --
X14.10 --

Interface adapter
Id. no. W8 406 464
Setting the interface
This interface adapter (1) is used to alter parameters in the travel and pump control system (FPS) and
AWE using the notebook.
The interface adapter must be selected at the relevant interface with a slide switch (2).
Slide switch position 2 : for travel and pump control (FPS-logic circuit board) and AWE
To connect the interface adapter:

Input side: Connect notebook.
Output side: Connect to FPS control system with 9-pin ribbon cable (see diagram below)
Adjustment: Set the interface switch (4) to AWE or FPS, depending on which parameters you
wish to adjust.
Power supply: the interface adapter is connected to the power supply with 2 terminals (3)
Red terminal +
Black terminal -
Note: The ribbon cable (5) may only be connected/disconnected when the power supply
is switched off.
The interface switch (4) may only be switched over when the vehicle is switched off.
reserved.
Interface 6/0326
adapter - 4
Notebook
AWE FPS
5 (logic circuit
board)
1
3 +
6/0667
24 V
6/0634 6/0633

Interface adapter
Functional elements
1 Interface
+
24 V
} adapter }
6
10 11
9
4
3
5 6/0634 6/0633
2 1 7 8
reserved.
1: Power supply
2: 25-pin notebook connection
3: 10 V power supply O.K.
4: LED lit up - notebook sending data
5: LED lit up - notebook receiving data
6: 17 volt power supply for notebook.
If a different voltage is required, this can be set via an internal potentiometer
(max. load 2.5 A) (see M114).
7: Interface connection to MUX-SPS (9-pin)
8: Interface connection to FPS control system (9-pin) and electronic evaluation system
9: Slide selector switch for interface adaptation
Position 1: MUX-SPS
Position 2: Travel and pump control system
10: Interface connection for SPS digsy 04
11: Control LED on = programming voltage for SPS digsy 04 is switched on.

Interface adapter
Adjusting the notebook power supply
1. To open, take the box in your hands as

illustrated in fig. 1 and press on the closed
5
element under the ventilation slot with your
thumb, pressing the inner catches (5) down
7/0455
and pulling the two housing elements apart at
the same time.
Notebook
2. Connect the notebook at the power supply
socket (1).
3. Connect the interface adapter to the voltage 1
converter (2) (see M15).
4. Connect the voltmeter (3)

5. Switch on the notebook and start up the
vehicle.
6/0634
6. Set the required voltage at the trimmer (3).
Remark: The voltage supply required for the 2

notebook is indicated in the +24V
documentation provided by the
+
reserved.
notebook manufacturer.
DC DC
DC/DC converter
Notebook
3

Assembly N Hydraulic system
Contents Sheet n o.
Functional characteristics of the hydraulic system ..........................................N 2

Block diagram of the hydraulic system............................................................N 3
Manually-operated double directional valve block...........................................N 4
Setting the maximum pressure........................................................................N 6
2-way flow regulator valve...............................................................................N 7
Directly operated directional valves
- Shift function 2Y25 .................................................................................N 9
- Tilting and mast side shift functions 2Y29/44.........................................N 10
- Guide to identification numbers.............................................................N 10.1
Back-pressure valve for tilting .........................................................................N 11
Tilting diaphragm.............................................................................................N 12
Lowering brake valve ......................................................................................N 13

Line break protection.......................................................................................N 14
Pump unit
- General ..................................................................................................N 16
- Removing ...............................................................................................N 17
- Pump motor, general..............................................................................N 18
• Removing the motor.............................................................................N 19
reserved.
• Replacing the carbon brushes .............................................................N 20

• Motor maintenance ..............................................................................N 21
- Hydraulic pump ......................................................................................N 22
Tank display and tank .....................................................................................N 24
Runback filter ..................................................................................................N 25

Replaces issue: Manual FM Typ 429 N1
Functional characteristics of
the hydraulic system
When the hydraulics levers (1) are activated

or the selector switch (2) for hydraulic
ancillary movements is pressed, electrical 1
signals are sent to the electronic evaluation
system (AWE).
This controls the electromagnetic on/off

valves accordingly, to initiate the selected
hydraulic function.
In addition, the AWE determines the deflec- 2

tion and directional values of the levers from
the potentiometers mounted on them.
6/0063
This forms the control signals sent to the

travel and pump controller, which then con-
trols the stepless speed of the pump unit (see
also block diagram on sheet no. N3).
Remark: The maximum speed of the

movements depends on the de-
reserved.
flection value (setpoint) and the

maximum values programmed in
the AWE.
These maximum values can be
modified using a notebook (see
sheet no. M88).

reserved.
Main lift and special

clearance cylinders
with integrated
Issue: 9/97
ine break protection
Replaces issue:
Distributor block with
Double directional valve lowering brake valve
block with potentiometer
Assembly N
for speed control Tilt cylinder
Distributor
Electrical block
signals to
electronic
evaluation
system 6/0060 Directional valve block
with 4/2-way on/off
7/0444 valves, back-pressure
valve and diaphragm
2-way flow 7/0441 for tilting
regulator valve 7/0442
Manual
Workshop
..
Block diagram of the hydraulic system
Pump unit Electrical control

by electronic
Stepless evaluation system
speed Runback filter
control
between 0
and max
1/min
Electrical
7/0443
FM Typ 429
control by
travel and 4/2-way on/off valve for
pump shifting
control
system
7/0445 6/0059
Sheet no.
Mast side shift
cylinder
Tank Shift cylinder
(optional)
N3
Hydraulic system
Manually-operated
double directional valve block
Id. no. W8 415 882 new
Id. no. W8 417 022 exchange
General
The DS directional valve block consists of a

mounting block (1), an intermediate plate (2), an
add-on valve (3) and an end plate (4). It can be
accessed by removing the "valve" cover.
The mounting block accommodates the

connecting threads for the pressure pipe (P, 3/4
inch), the return pipe (R, 1/2 inch) and the
working pipe (H, 3/4 inch).
The block can be used to control a single-acting

cylinder (N-valve).
A max. pressure relief valve (5) for setting the
6/0034
maximum pressure in the hydraulic system is also
integrated in the mounting block (for adjustment
instructions see sheet no. N6).
A mini test connection (6) for testing the pressure

is integrated in the intermediate plate.
6 1 5
reserved.
The add-on valve (G-valve) is used to control a

double-acting cylinder via the two working pipes
(A, B, 3/8 inch). 2
The directional valve block only controls the oil
flow direction, i.e. lifting/lowering main lift, tilting
forwards/backwards, reaching forwards/back-
wards or mast side shift to left/right. R
3
The speed is dictated by the rotational speed of H
the pump, which is controlled by the setpoint of P
the potentiometer on the directional valve. 4 A 6/0064
B
The entire block is mounted on the chassis with
rubber buffers to minimise noise and vibrations.
Remark: A sealing set is available for the

double directional valve block,
Id. no. W8 417 047.

Continued
Manually-operated
double directional valve block
1
Designation of the
DS directional valve block R
The designation provides extensive information P

A
about the type of directional control block. 6/0064
It is embossed on the end of the block B

(Fig. 1, no. 1), DS 34N-2-X50-G-F93/E1-1-200.
Meaning
DS34N = Basic block with 3/3way valve for Durchflußbilder

lifting/lowering (single-acting
cylinder) G B* D E N
2 = Connecting thread for add-on valves

2 = 3/8 inch; 3 = 1/2 inch
X50 = Width of intermediate plate = 50 mm
G = Flow type for add-on valves

Bild 2
(see Fig. 2) 6/0066
* mit Drosselung in Rücklaufleitung

F = Activation with weak spring
reserved.
93 = With fastening for attaching the

potentiometer, without hand lever;
92 = with hand lever
Montageart der Betätigung
E1 = Actuator mounting method
(see Fig. 3) Schalterstellungen alle Baugrößen nur Baugröße 2 u. 3
Schalthebelsauslenkung 0 0 0 0
b a a b a b b a
bei
1 = With end plate a = drückt den Schieber-
kolben in das Gehäu-
se
200 = Pressure relief valve setting b = zieht den Schieberkol-
ben aus dem Gehäu-
se
Kennzeichnung E1 E2 F1 F2
Remark: It is especially important to note the Montagerichtung z.B. E1 z.B. F1
designation for the flow type of the

directional valve (N, G, D, E) since
this influences the performance of
the hydraulic device.
The letters are embossed in the Anschlüsse weisen nach hinten nach vorne
directional valve block.
Bild 3 6/0067

Setting the maximum pressure
The system pressure for the hydraulic system is

set at the maximum pressure valve (1).
This setting can be checked at the test connection

point (2). 2 4
3
The maximum pressure valve is set to 200 bar by
the manufacturer and does not usually need to be
adjusted. 1
Exception: if the pressure is insufficient for
special equipment (e.g. add-on appliances), the
system pressure should be set at the highest
required operating pressure plus 15 bar. R
The FM 14/17 models with a load carriage which H

is ≤ 2.9 m high (1.7 t mast) also require a higher P
pressure setting than 200 bar (approx. 220 bar or A 6/0064
250 bar). B
Setting
1. Connect the pressure gauge at no. 2 on the

diagram.
2. Actuate the lift with a rated load and read off
the working pressure.
If this pressure is lower than 200 bar, no set-
ting or adjustment is required at the valve. The
reserved.
pressure then remains set at 200 bar.

3. If a working pressure greater than 200 bar
is required, determine the working pressure
with the rated load by releasing the lock nut
(3) and slowly turning in the adjuster screw
(4). The working pressure determined +15 bar
is the correct setting for the maximum pressu-
re.
4. Set the maximum pressure with the adjuster
screw by moving the lift to the mechanical end
stop.
5. Tighten the lock nut (3) again.

2-way flow regulator valve
Id. no. W8 417 379 18 l version

Id. no. W8 420 208 21 l version (with
add. hydraulic)
This valve is located in a hexagonal cartridge

at the add-on valve of the double directional
valve block (1).
1
Its purpose is pressure-independent regula-
tion of the oil quantity in both flow directions.
6/0080
If the hydraulic ancillary movements are ma-

de individually, the valve does not enter the
regulating position, since the quantity of oil

remains lower than the amount required to

activate the valve.
However, if lift and reaching or lift and tilting

movements are carried out simulaneously,
the valve limits the quantity of oil to the cor-
rect litre value. This creates a "hydraulic resi-
reserved.
stance" for the oil flow to the ancillary move-

ments, so that the simultaneous functions are
carried out at the same time, and the maxi-
mum speed of the ancillary movements is not
exceeded.
6/0081
Continued on sheet no. N8
Sinnbild
vereinfacht
6/0083
6/0082

Continued
2-way flow-regulator valve
Removing
1. Remove the valve cover.

2. Lay an absorbent cloth under the valve to 1
catch any escaping oil.
3. Mark the electrical connectors in this area
Remove the upper hydraulic connection Bild 1 5-04 25
at the add-on valve of the directional
valve block (spanner size 17).
2
5. Remove the lower hydraulic connection
at the hexagonal cartridge (spanner
size 17).
6. Remove the hexagonal cartridge with the
2-way flow regulator valve (spanner
size 22).
Bild 2 5-04 27
7. Clamp the hexagonal cartridge in a vice
and unscrew the straight screwed joint
(Fig. 1, no. 1).
reserved.
8. Unscrew the 2-way flow regulator valve

from the hexagonal cartridge with a
screwdriver (Fig. 1).
To mount the valve, follow the instructions

Remark: When inserting the valve in the

hexagonal cartridge, ensure it is
screwed in in the right direction!
Turn screwdriver bit in the
direction of the outer thread of
the hexagonal cartridge (Fig. 2,
no. 2).
Only screw in hand-tight.

Directly operated
directional valves
Shift function 2Y25

Id. no. W8 420 760 (Standard)
Id. no. W8 420 761 (Cold store)
3
This 4/2-way valve (1) is located on the
chassis floor below the travel transducer and
is fastened in place with 2 screws (2). 6/0034
The valve is easy to reach through the moun- 2

ting opening (3). The mounting opening can be
accessed by removing the battery.
1
Electrical control is carried out by the electro-

nic evaluation system.
6/0084
reserved.
Flow-through
diagram
1 4
3 2
6/0088
1
3
2
4
6/0084

5
Directly operated
directional valves
Tilting and mast side shift functions
2Y 44 (optional)
See table on next page

5/0103
This 4/2-way valve (1) is located in the slide
carriage and can be accessed by pushing out B3 A3
the mast and removing cover plate (5). The 3
valve block is screwed to the guard plate (3) 4
from below with 2 screws.
Electrical control is carried out by the electro-

nic evaluation system. 2
7/0442
7/0447
1
A1 B1
Integrated in this valve block are:
(1) Tilt valve
(2) Mast side shift valve (optional) 3
(3) Back-pressure valve (SBV) for tilting
reserved.
(4) Diaphragm (1,3/1,2/1,0)
The SBV setting is 120 bar (see also N11) and

must not be changed.
7/4006
3 1 1

Replaces issue: Manual FM Typ 429 N 10
Directly operated
directional valves
Guide to identification numbers
Standard version (tilting only)

W8 420 577 /Cold store W8 420 578
SH 5 version with tilting and mast side shift

W8 420 579 /Cold store W8 420 580
SH 5,1 version with tilting and mast side shift

and additional hydraulics
W8 420 581 /Cold store W8 420 582
SH 3 Fork tilt with side shift

W8 421 442 /Cold store W8 421 444
reserved.
SH 4 Fork tilt appliance

W8 421 441 /Cold store W8 421 443

Replaces issue: Manual FM Typ 429 N 10.1
1
Back-pressure valve for tilting
(SBV)
Id. no. W8 416 040
The back-pressure valve (1) is located in the

distributor block (see sheet no. N10).
7/0442
This valve block can be accessed when the

mast is pushed out and the cover plate 1
removed (see sheet no. N10, (2)).
Note: The valve is preset to 120 bar and

must on no account be adjusted!
Function
The valve consists essentially of the valve 7/0446

body, a non-return valve piston, a return
spring, an adjuster spring, an adjuster device
for adjusting the spring preload and a
hardened and ground regulating piston.
To lift a load, pneumatic fluid flows through the

reserved.
valve from connection 2 to connection 1 via

the integrated non-return valve. The non-return
valve piston is moved against the return
spring, forming the correct cross-section for
economical through-flow.
When the valve is in the locked position, the

consumer is held in position. The non-return
valve piston is pressed against the regulating
piston by the load pressure which builds up
and forms a seal around the seating edge. It is
important to ensure that the control connection
3 is pressure-relieved in the locked position.
7/0722
Continued on sheet no. N11.1 B Adjuster device
C Adjuster spring
D Valve body
E Regulating piston
F Non-return valve piston
G Return spring

Continued
Back-pressure valve for tilting

(SBV)
Function (Continued)
The consumer pressure (load pressure) on

connection 1 is applied to the surface of a
regulating piston ring A2 inside the valve, and
consequently against the force of the adjuster
spring. This makes it possible to limit the
consumer pressure (load pressure). The
setting for maximum consumer pressure
should be at least 20 % higher than the
greatest load pressure which occurs in normal
operation.
When the load is tilted (volume flow from

connection 1 to connection 2), the valve is
controlled by the approach pressure at control
connection 3. The load volume flow is
regulated at the metering notch of the
regulating piston in accordance with the
approach pressure of the consumer (aproach
reserved.
7/0722
volume flow). In this way, the load is prevented B Adjuster device
from moving too fast. C Adjuster spring
D Valve body
E Regulating piston
F Non-return valve piston
G Return spring

Replaces issue: Manual FM Typ 429 N11.1
Tilting diaphragm
Id. no.: see table
The diaphragm (1) is located in the distributor Symbol

block (2) which is fastened in the slide carriage.
The diaphragm is used for maximum flow-through

limitation and therefore limitation of the maximum
6/0095
tilting speed.
One of three different diaphragms may be used,

2
depending on the height of the load carriage:
1
Diaphragm Height of Id. no. Id. no.
diameter load carriage of of diaphragm
A h1 diaphragm w. hollow bolt
1.3 mm <2900 mm W8 260 288 W8 370 384

7/0442 7/0447
1.2 mm ≥2900 mm W8 260 134 W8 350 157

<3600 mm
1.0 mm ≥3600 mm W8 260 132 W8 370 155

reserved.
The tilting times or speeds are therefore dependent

on the load carriage and the diaphragm used. They
are:
Forwards tilting: 2-4s

Backwards tilting: 1.5 - 3 s
The higher the load carriage, the lower the tilting

speed. 7/0446
Remark: Since 3/96 a 1.3 mm diaphragm has

been used for load carriages with a
height h1 = 2900 mm, i.e. do not
change to a 1.2 mm diaphragm unless
the load carriage is higher than
2900 mm!

Lowering brake valve

Id. no.: see table
The lowering brake valve (1) is located in the

distributor block on the load carriage.
This is a 2-way flow regulator valve for lowering

single-acting cylinders at a constant lowering
speed, which is largely independent of the size of
the load. The maximum lowering speed must not
exceed 60 cm/s and is limited by this valve.
Note: The valve is preset. On no account

should any of its settings be altered!
7/0448
2
Used Valve Id. no.
in type
reserved.
1
FM 14/17 SB 31C-43 W8 421 546
to height of 2700/2900 mm
FM20 and FM 14/17 SB 33C-59 W8 421 545 Symbol
from height of 2950 mm
5-cylinder SB 27C-40 W8 017 448
lifting device
6/0100
6/0099
Operating direction Reverse direction
6/0101
Metering Shift diaphragm Shift diaphragm
notches in regulating in free flow-through
position direction

Line break protection

Id. no.: see table on sheet N15 1
General
The line break protection (1) prevents an un-

controllable, accelerated movement of a 6/0102 6/0103
loaded hydraulic device (crash) should

hydraulic back pressure be lost due to
breakage of the pressurized lines or line
connection. Symbol
It is screwed directly into the hydraulic oil
Simplified
inlet or outlet of the hydraulic device it is to
protect (see also plan of hydraulics, Id. no. (F) (B)
367 544). • •
v
v
The LB type is a disc valve whose valve
screw is raised in its idle state by a spring
from the valve seat, so maintaining a flow-
through cross-section of adjustable width. Detailed
The force of the flow resistance and the

damming effect at the valve screw in the flow
reserved.
o
direction B --> F (working or release F B
direction) is not as high in normal operation • •
as the counterforce of the spring, and so the 6/0106
valve remains open.
If, in an emergency situation, the flow volume

increases due to the higher driving force, the
flow forces overcome the spring force and
the valve shuts instantaneously .
2
Remark: A special tool (2), Id. no. W8 044
065 is needed to remove the line
break protection from the lift
cylinder.
6/0104

Continued
Line break protection
Valve for lowering load slowly

The valve plate contains a orifice hole (1),
through which oil can flow if the valve is triggered,
at a rate relative to the size of the load, so that
the load is lowered slowly to the floor.
6/0102
The fault can then be remedied.
Remark:
The gap width determines the response point of

the valve. The setting is made by the
manufacturer and may not be altered under any 1 6/0105
circumstances. Specification of the gap width is

only provided to help you decide whether the
correct line break protection is mounted.

Different line break protection types are fitted in

different types of lifting device (see table).
6/0107
reserved.
Used in Hydraulics Valve type Id. no. Gap width

designation S in mm
3 cyl. mast S15 LB3C-0.5-52 W8 417 847 1.2

(1.7 t) S16 LB3C-0.5-35 W8 417 848 0.7
S17 LB3C-1.0-48 W8 417 845 1.1
S18 LB3C-2x1.2-70 W8 417 898 1.9
3 cyl. mast S9 LB3C-0.8-40 W8 414 776 0.8

(2.5 t) S10 LB4C-1.5-90 W8 414 779 1.5
S12 LB3C-1.2-63 W8 415 310 1.7
S13 LB3C-0.8-80 W8 417 844 2.4
5 cylinder S6 LB3C-1.0-37 W8 416 871 0.8

mast S7 LB4C-1.0-78 W8 416 864 1.3
Remark: Valve type LB3C has a 1/2 inch thread

Valve type LB4C has a 3/4 inch thread

Pump unit
General
The pump unit (1) is located under the driver's

seat in the front corner.
It can be accessed by removing the front co-
ver.
If you wish to remove the unit, the two cover

sheets (2) must also be removed. 6/0109
The pump unit consists of a self-ventilated 1

48V series-wound motor (3) (see also sheet
no. N18), the speed of which is controlled by
the traction and pump controller.
3
As a result, the quantity of oil delivered by the

flange-mounted, external toothed gear pump
(4) (see also sheet no. N22) is proportional to
the speed of the pump motor. 7 5
6
The rotational speed is transferred from the
motor to the pump by a capstan coupling (5).
The coupling between the motor and pump is 4
reserved.
sealed by an O-ring (6). Saugseite
The pump unit is fastened to the chassis with Druckseite 6/0110
4 rubber bearings (7) to minimise noise.

6/0111

Continued
Pump unit
Removing
1. Make the pump unit accessible, as described

on sheet no. N16.
2. Position the electrical seat adjuster so that
the oil filler cap (1) on the tank is easily 1
accessible.
3. Push the mast right out. 6/0109 6/0112
4. Pump the hydraulic oil out of the tank through

the oil filler cap with a pump, Id. no. W8 413
061 (approx. 25 l oil). 3
5. Move the electrical seat adjuster to the top
position.
6. Isolate the vehicle from its power supply.
7. Remove the side covers (2) by removing the
2
3 nuts M8 (3).
6/0113.1
Remark: The 3 nuts can be reached from
the inside of the chassis. One of
them is located below the pump 5
unit.
8. Lay absorbent cloths underneath the pump
unit.
6/0113
9. Remove the intake side of the pump,
complete with the angled flange socket (4).
reserved.
10. Through the installation opening on the left 4

(5), remove the delivery side of the pump,
6
complete with angled flange socket (6).
11. Mark the electrical connections on the motor
6/0110.1
12. Remove the countersunk screw M8 x 20 (7)
from the fan impeller and screw in an eyebolt
(9) in its place. 7 MA = 18 Nm
48
48
Remark: When replacing the countersunk
screw M8 x 20 (7) secure with
Loctite no. 242 again!
41,5
41,5
13. Release the pump unit at the 4 rubber
bearings (10).
14. Remove the pump unit vertically upwards, 9
using the "travel motor suspension principle" M8x25
(see section Z). 6/0114
6/0110.2
To mount the pump unit, follow the instructions
above in reverse order. Ensure that all screws are
fastened with the correct tightening torque (see
illustration).
10
Continued
Pump unit
Pump motor, general
Id. no. W8 405 521
The pump motor (1) is a 48 V self-ventilated Air

series-wound motor. exit A1 D2
A1 o o
The motor is equipped with carbon brush monitor
and temperature sensor features (see sheet nos. D2
M129-130). The air flows from the bottom to the 1 M
top of the motor.
The motor speed is controlled by applying 6/0110.2
different voltages to terminals A1 and D2.

Air
Typical approximate values are as follows: intake
Remark: the values listed below can be read

off in the tester menu (see sheet no.
M65.
Function Motor Setpoint
voltage
Main lift, lifting 45 V 10.0 V

X15
Backwards shift 15 V 6.o V 2
reserved.
Forwards shift 15 V 5.5 V

Backwards shift damping 3.5 V 3.0 V
Forwards shift damping 5.0 V 3.9 V
Forwards tilt 9.0 V 4.5 V
6/0115
Backwards tilt 15.0 V 4.2 V
Mast side shift 9.5 V 4.0 V
Pin assignment
The temperature sensor and carbon brush 1 Temperature sensor
monitor signals are transmitted to the combined
travel and pump control system via connector 2 Carbon brush +
X15 (2). 3 --
The motor is supported by ball bearings on both 4 Temperature sensor
sides. The shaft end is sealed at the pump end 5 Carbon brush -
with a shaft sealing ring.
6 --

Continued
Pump unit
Removing the motor
1. Remove the pump unit (see sheet no. N17).

2. Remove the hydraulic pump (1) by
releasing the 4 screws M10x110 (2).
3. Remove the tensioning belt (3). 1
4. Disconnect the electrical connection

between the field winding (4) and the brush 2
bridge (5).
5. Release the countersunk screw M8x20 (6)
6/0110
(secured with Loctite no. 242 ) and remove
the fan impeller (7).
6. Remove the two circlips (8). 18
15
17
7. Release the 4 B-side bearing end-shield
screws M6x20 (9) and pull the rotor (10) out 10
of the stator and A-side bearing, complete
with B-side end shield (11).
8. Pull the B-side end shield (11) off the rotor 14
shaft with a puller device.
16
9. After the circlip (13) has been removed, the
B-side deep-groove ball bearing (12) can be
reserved.
pushed out. 4
10. Release the 4 screws M6x20 (14) and
remove the A-side end shield (15) from the 12 11
stator (16). 13 8
11. Push the A-side deep-groove ball bearing 7
(17) and the shaft sealing ring (18) out of the 6
end shield.
9 5 6/0116
3
To mount the motor, follow the instructions above
in reverse order.
When fitting or exchanging the shaft sealing ring
(18), ensure that it is inserted in the correct
position.
The sealing lip must face towards the pump (see
no. 19).
19
Secure the countersunk screw M8x20 (6) with
Loctite no. 242.
6/0117

Continued
Pump unit
Min. 16 mm
Exchanging the carbon brushes
Id. no. W8 400 447
The carbon brushes must be replaced when

they reach a minimum length of 16 mm,
which is equivalent to wear of about 50 %.
The carbon brush monitor is activated when
the carbon brush reaches a length of 15 mm. 5/0034
Length of a new carbon brush: 32 mm

Always replace the complete set of four
carbon brushes.
Removing the brushes

1
2. Make the pump unit accessible (see
sheet no. N16).
3. Remove the side covers on the left (see
sheet no. N17, point 7), so that the
installation opening for the carbon 6/0110.2
brushes can be reached.

reserved.
4. Remove the pump motor tensioning belt

(1).
5. Lift off the brush spring (2) and pull out
the carbon at the connecting cable (3). 2 4 3
6. Disconnect the connecting cable (4)
7. Clean out the commutator compartment
with compressed air.
Caution: Never breathe in carbon

dust.
8. Mount the new carbon brushes.
Remark: After exchanging the

brushes, do not run the
motor straight away under
full load. The carbon
brushes run in relatively 6/0118
quickly under minimal
loads.

Continued
Pump unit
Checking the brush springs
Id. no. W8 403 752
Brush springs with insufficient pre-tension

lead to burning of the commutator.
Ensure that the carbon brushes run easily in

the shaft.
reserved.

Continued
Pump unit
A A
Hydraulic pump
Id. no.: see table
The pump (1) is an anti-clockwise rotating, B B

externally toothed gear pump. Once the pump
3
unit has been removed from the vehicle (see
sheet no. N17), the pump can be removed from C C
the motor by releasing the 4 fastening screws
M10x110 (2).
Delivery
side
Pumps with different delivery outputs are used
(cm3/revolution), depending on the vehicle
mast type:
Delivery
6/0119
Mast type/Vehicle Pump type Id. no. output Intake
in side
3
cm /rev.
3 cylinder mast
1,7t, height ≤2900 SNP2/11S FR03 W8417479 11
reserved.
FM 14/17
3 cylinder mast
2,5t, FM20
oder SNP2/14S FR03 W8417301 14
5 cylinder mast
height ≤2480;
FM14/17/20
3 cylinder mast
2,5t, height ≥2950 SNP2/17S FR03 LFW W8 417300 17 1
FM14/17
6/0110

Continued
Pump unit
Mounting and commissioning
- Before mounting, fill the pump with hydraulic

oil.
- Grease the O-ring (1) on the neck of the
pump.
- When fitting a new pump, replace the O-ring
under the angle flanged socket.
- Before installing, clean pipes of dirt, scale,
sand and chips. Welded pipes, in particular,
must be pickled or rinsed.
- When first commissioning, we recommend 1

slightly releasing the pressure connection to
vent the system.
- Ensure that the fastening screws are
tightened with the correct tightening torque.
6/0110
Remark:
reserved.
The most frequent cause of

premature failure in gear pumps is
soiled hydraulic oil. For this
reason, particular care must be
taken to keep the hydraulic
system clean, and the filters must
be changed regularly (see sheet
no. N25). If the pump produces
noises or the oil forms bubbles:
check for leaks between the pump
and motor or at the hydraulic
connections.

Tank display
Id. no. W8 411 677
Beneath the driver's seat is the tank with an oil

sight glass (1). The level of oil in the tank can be
read off here once the upper front cover has been
removed.
Use an electric torch when taking the reading.
Check the display without fail:

1
1. On commissioning, after vehicle assembly
2. During scheduled servicing
3. When the hydraulic system has been opened
at any point
Remark: To take a reading, lower the lifting

device completely. Retract the
reach carriage completely and tilt
the load carriage as far forward

as possible.
On commissioning, fill the tank to the centre of

the sight glass and carry out all the hydraulic
movements with maximum lift, to fill the cylinders
and pipes. Then return the hydraulic equipment
to its home position, bleed the cylinders and fill
the tank to the centre of the sight glass again.
reserved.
Maximum oil level: Centre of sight glass 7/0456
Minimum oil level: Bottom edge of sight 4 3 2

glass
Tank
Id. no. W8 380 465
The tank for the hydraulic oil is located under the

driver's seat. It is screwed directly onto the
chassis (2). The tank holds 25 l (to the centre of
the sight glass), which is sufficient for all mast
movements.
At the bottom of the tank there is an oil drainage Oil types used Id. number
screw (3), which can be reached once the battery
has been pulled out. HLP46 W8 036 912
HVLP32 *W8 036 216
After draining oil, use a new aluminium sealing HVI32 *W8 036 216
ring (4) over this screw (Id. no. W8 006 197).
*cold storage model
Remark: The oil should be changed once a
year or every 2000 operating hours.

Runback filter
Id. Nr. W8 421 273 or
Id. Nr. W8 421 656
Application
1. Filtration of runback oil
2. Filtration of the air entering and leaving the
tank
The filter is mounted on the upper side of the oil 4

tank (6). The filtered oil leaves the tank below the
oil level through a hose mounted on the filter bell
(1), which prevents bubbles forming in the oil.
3
On the other side to the hose connection is an air 2
filter (2) made of pressed aluminium fabric. This 5
is used for aeration of the tank.
The filter cartridge used (3) consists of a paper
filter (filter mesh gauge 10 µm). This cannot be 1

cleaned.
If the filter is too heavily soiled, the oil can run

back into the tank unfiltered through a bypass 7/0456
valve in the lid (4).
Exchanging the filter

reserved.
4
1. Switch off the hydraulic system. Pressure on
the filter must be relieved on the delivery side.
2. Unscrew the lid (4), first removing the seat
(see sheet no. U3).
3. Pull out the filter cartridge (3).
4. Clean the filter bell (5), using a substance 6
such as washing benzene or petroleum.
5. Insert the new filter cartridge.
6. Check the sealing rings and replace if neces-
sary.
7. Oil the lid lightly and screw back on.
Remark: The filter should be changed after

500 operating hours/once a quarter
at the latest. The filter element is
identical for both types of filter.
6/0123

Pump motor specifications
Model GP 116 - 14/7.9

Motor type Series-wound motor
Voltage 48 V
Current 230 A
Output 9 KW
Speed 2900 min-1

Protection class IP00/22
Insulation class B/F
Id. no. W8 405 521

reserved.

Assembly R Lubrication plan
Contents Sheet no.
Lubrication plan .............................................................................................R 2

Lubricants ......................................................................................................R 3
Lubrication card .............................................................................................R 4
reserved.

Replaces issue: Manual FM Typ 429 R1
Lubrication plan
1 Lubricate the steering chains and gears with
al-purpose grease
every 3 months
2 Lubricate the fith wheel bearing with multi-

purpose grease
every 12 months
3 Lubricate all moving parts with oil

every 3 months
9
4 Change the brake fluid
every 12 months
5 Change the hydraulic oil 3

every 12 months
6 Change the transmission oil

every 12 months
7 Chain spray
every 3 months
6/0596
8 Grease the swivel bearings

every 12 months
reserved.
9 Keep sliding surfaces of the mast sections 7

free of corrosion with a film of grease
every 3 months
4
10 In case of mast or fork side shift: Grea- 1 10
se sliding surfaces with multipurpose
grease
every 3 months
2
11 Grease sliding surface of the battery 7/0458
frame with multi-purpose grease
every 3 months
6 5 11 8

Lubricants
Remark: The lubricant types used in the vehicle are marked on the lubrication card on
the vehicle (see sheet no. R 4).
Hydraulic oil HLP 46 DIN 51524/T2 Id. no. W8 036 912

or
Hydraulic oil HVLP 32 DIN 51524/T3 Id. no. W8 036 216
(Cold store) HVI 32
Quantity: approx. 25 l
Gear oil SAE 80 Id. no. W8 036 925
Gear oil
(Cold store) SAE 75W - 90 (partly synthetic) Id. no. W8 036 929
Quantity: approx. 3.6 l
Chain lubricant Stabylan 2001 Id. no. W8 010 100
Chain lubricant Syntesco Id. no. W8 036 220

(Cold store)
reserved.
Lubricants for roller bearings and other lubrication points
Beacon 2 Id. no. W8 010 107
Acedo X 2 (Cold store) Id. no. W8 050 076
Profile spray for lifting device, sliding surfaces and toothed racks
Ceplattyn 1612 (also for cold store) Id. no. W8 052 125
Brake fluid
ATE SL DOT 4 / DOT 3 Id. no. W8 034 957
Further special lubricants for cold store:

For all moving parts Kompranol Spray N74 Id. no. W8 050 077
For screwed joints,
Union nuts Rivolta antiwear Id. no. W8 050 078
Issue: 9/97 Workshop FM Typ 429 Sheet no.

Replaces issue: Manual R3
Lubricants
Lubrication card 1
Id no. W8 150 545 (1 pack =100 cards)
The lubricants used in the vehicle are all

marked on a card which can be hung on
the vehicle. This card is attached close to 2 6/0596
the filler opening of the oil tank.

The filler opening for hydraulic oil is
Nächster Wechsel
marked with the symbol shown in Fig. 1. Next Change
Datum
Date 3
Whenever the oils are replaced, a cross
should be made against the types used (2) HYDRAULIKÖL
HYDRAULIC OIL
and a date entered for the next oil change
(3) andbrake-fluid change (4) in

accordance with the vehicle lubrication
plan.
Decommissioning,
GETRIEBEÖL
disposal
reserved.
GEARBOX OIL
In the event that the vehicle described in

this manual has to be decommissioned, it
is important to ensure that all its
components are disposed of in accordance BREMSFLÜSSIGKEIT
BRAKE FLUID
with the applicable regulations.
ÖL-und LUFTFILTER 4
it is particularly important to ensure that the
OIL and AIRFILTER
fuels and lubricants used are recycled or
disposed of in the correct manner. 6/0598
6/0597


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Workshop Manual FM Type 429

Copyright protected. No part of this manual

First issued: 9/97 Workshop

This workshop manual provides specifications

This provides you with a comprehensive

The workshop manual is always updated by

Updating of workshop manuals

The industrial truck range is subject to

that certain components or assemblies are

To ensure that the holder of this manual always

Issue: 9/97 Workshop Sheet no.

Updating workshop manuals

1. Exchanging faulty sheets

Page baseline of the first sheet

hand and right-hand page baseline (5+6).

Issue: 9/97 Workshop Sheet no.

No guarantee claims arise as a result of

This does not affect the guarantee stipula-

We are continuously involved in the further

to alteration and error, and that no claims

Issue: 9/97 Workshop Sheet no.

Production number and consecutive identification numbers

Issue: 9/97 Workshop Sheet no.

Issue: 9/97 Workshop Sheet no.

Definition of movement directions

Issue: 9/97 Workshop Sheet no.

Issue: 9/97 Workshop Sheet no.

Motor, general ................................................................................................A 2

Issue: 9/97 Workshop Sheet no.

The travel motor used is a 48 V shunt motor.

the battery voltage, the field current is

For adjustment of the travel motor, see sheet

Issue: 9/97 Workshop Sheet no.

Terminal markings at the motor

Marking at the motor Meaning

Main current terminals

A1 Start of the rotor winding

X15.1 0 V signal, temperature sensor

X15.4 0 V supply, temperature sensor

Issue: 9/97 Workshop Sheet no.

Exchanging the carbon

The carbon brushes must be replaced when

Always replace the complete set of four

Removing the brushes

carbon at the connecting cable (3).

brushes, do not run the

Checking the brush springs

Ensure that the carbon brushes run easily in

Issue: 9/97 Workshop Sheet no.

Changing the drive wheel

New dimensions: Ø 343 mm/136 mm 230 mm

It is necessary to change the drive wheel Bild 1

- the running surface is pitted or

Removing the drive wheel

1. Pull out the battery plug.

4. Apply the handbrake.

Tightening torque: 140 Nm

Issue: 9/97 Workshop Sheet no.

Removing the travel drive

1. Pull out the battery plug.

3. Remove the covers.

8. Remove the steering chain (see sheet

M12x50 (Fig. 3, no. 1).