Manitou SM - ME318 1 Di 4

REPAIR MANUAL
MANUEL DE RÉPARATION
REPARATURANLEITUNG
MANUAL DE REPARACIÓN
MANUALE RIPARAZIONE
This document has been printed from my e doc
MANITOU BF
Head office: 430, Rue de l’Aubinière
44150 Ancenis - FRANCE
Share capital: 39,548,949 euros
857 802 508 RCS Nantes
Tel: +33 (0)2 40 09 10 11
www.manitou.com
La présente brochure n’est fournie qu’à titre consultatif, toute reproduction, copie, représentation, captation, cession, distribution, ou
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This manual is for information purposes only. Any reproduction, copy, representation, recording, transfer, distribution, or other, in part
or in whole, in any format is prohibited. The plans, designs, views, commentaries and instructions, even the document organization
that are found in this document, are the intellectual property of MANITOU BF. Any violation of the aforementioned may lead to civil
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Il presente manuale è fornito esclusivamente a titolo di consultazione; è vietata qualsiasi riproduzione, copia, rappresentazione,
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diritti sono riservati.
GENERAL INSTRUCTIONS AND SAFETY NOTICE
GROUP 00 General characteristics and safety 1-1
AXLE ASSEMBLY - AXLE

GROUP 30 Axle 2-1
BRAKE
GROUP 40 Brake 3-1
MAST
GROUP 60 Mast 4-1
HYDRAULIC
GROUP 70 Hydraulic 5-1
ELECTRICITY
GROUP 80 Electricity 6-1
00
GENERAL CHARACTERISTICS AND SAFETY
- GENERAL INSTRUCTIONS AND SAFETY

NOTICE
- GENERAL CHARACTERISTICS AND

SPECIFICATIONS
- GENERAL LOCATION
- GENERAL CONTROL AND ADJUSTMENT

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GENERAL INSTRUCTIONS AND SAFETY NOTICE
pages
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MAINTENANCE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
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GENERAL INSTRUCTIONS AND
2 SAFETY NOTICE
00
FOREWORD
This chapter deals with the general instructions and safety notices during inspection and maintenance
work.
Other instructions and warnings are indicated in the chapters concerned.
In order to reduce accident risks, make sure to :
– Follow the instructions in the truck operating and maintenance manual.

 This manual should be found in all trucks.
– Please follow all safety instructions.
– Use the appropriate tools for any work to be performed.
– Use original LOC spare parts.
Any non-compliance increases the risk of accidents which may lead to grievous bodily harm and even
death.
An operator who obeys the safety instructions and a well-serviced machine will ensure safe, efficient
and profitable operation.
When you see this symbol:
It means: Warning! Be careful! Your safety, the safety of others or that of the lift truck is at risk.
The manufacturer cannot foresee all possible risky situations. Consequently, the safety instructions
given in the safety manual are not exhaustive.
At any time, as a repairer/operator, you must consider, within reason, the possible risk to yourself, to
others or to the lift truck itself when you repair, service or drive it.
Manitou cannot be held liable for the use of any lifting devices, tools or operating methods other than
those specified.
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SAFETY NOTICE 3
00
MAINTENANCE POSITION
2 4
1 3
Before any repair:
1 - Place the machine on a flat surface and chock the wheels.

2 - Turn off the engine and remove the ignition key.
3 - Let the machine cool down.
4 - Release all the pressure from the circuits concerned.
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RULES FOR MAINTENANCE
Do not carry out any work on the machine unless you have the
necessary training and knowledge to do so.
Make sure you have taken into consideration all the data plates on
the machine and in the instruction manual.
Be careful not to burn yourself when touching hot liquids or parts

when operations have to be done before the machine has had
time to cool down.
1
Before carrying out any operation on an electrically powered
2 component, activate the battery isolating switch.
If the truck does not have a battery isolating switch, disconnect
the battery terminals then group them together.
ECU b Remember to disconnect the computers before carrying

out any welding operations.
Machines operating in a contaminated environment (polluted or

damaging to health) should be specially equipped. Moreover, local
safety notices must indicate that maintenance and repair work is
being carried out on such machines.
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SAFETY NOTICE 5
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Never stand on a part of the machine that has not been designed
for that purpose.
Never wear clothes, jewelery or objects that could get caught during
work and cause accidents.
Always wear protective goggles, gloves, safety shoes as well as any

other protection required for the work to be carried out.
When carrying out maintenance operations near a mobile object,

always make sure it is secured.
When changing, or draining oils or fuel, or any other operation with

liquids, solids, or gases that are harmful to the environment, make
sure the necessary precautions are taken to avoid contaminating
the environment.
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When lifting or supporting a component of the machine, make

sure the equipment used is suitable for at least the load for which
it is subjected by the component and that it meets the national
standards for lifting devices.
Using a jack, make sure it is used on a flat, uniform surface, is sturdy

enough to support the load, that its lifting capacity is sufficient
and that it is correctly placed and positioned under the machine.
Make sure no object or tool which could cause an accident is left

in the machine.
Never check for any leaks with your hands.
max.
min.
MAX Never adjust a component to over the maximum capacity indicated

by the manufacturer.
MIN
00-00-M227EN (10/4/2013)
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GENERAL CHARACTERISTICS AND SPECIFICATIONS
pages
CHARACTERISTICS, LOADS AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– ME315 / ME316 / ME318 / ME320 SERIES 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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GENERAL CHARACTERISTICS AND
2 SPECIFICATIONS
00
CHARACTERISTICS, LOADS AND DIMENSIONS

ME315 / ME316 / ME318 / ME320 Series 2
1.1 MANUFACTURER MANITOU

1.2 MODEL TYPE ME315-48V ME316-48V ME318-48V ME320-48V
DESIGNATION
1.3 Propulsion: battery, diesel, petrol, LPG, mains Battery
1.4 Type of operation: manual, pedestrian, standing, seated Seated
1.5 Rated capacity/load on fork (basic capacity) Q (t) 1,5 1,6 1,8 2
1.6 Center of gravity of load c (mm) 500
Distance from the load bearing surface to the center of
1.8 x (mm) 355
the front axle
1.9 Wheelbase y (mm) 1250 1358 1358 1465
2.1 Kerb weight of truck kg 3050 3070 3090 3440
WEIGHT
2.2 Front axle load laden kg 3993 4155 4305 4893

2.2.1 Rear axle load laden kg 557 515 585 547
2.3 Front axle load unladen kg 1400 1565 1668 1662
2.3.1 Rear axle load unladen kg 1650 1505 1422 1778
Tire equipment: bandage (V), super-elastic (SE),
3.1 SE
pneumatic (L)
CARRIAGE
RUNNING
3.2 Size of front wheels “ or mm 18 x 7 - 8 18 x 7 - 8 18 x 7 - 8 200/50-10

3.3 Size of rear wheels “ or mm 15 x 4,5 - 8
3.5 Number of front wheels (x = drive wheel) 2x
3.5.1 Number of rear wheels (x = drive wheel) 2 twinned
3.6 Front wheel gauge (middle of wheels) b10 (mm) 902
3.7 Rear wheel gauge (middle of wheels) b11 (mm) 175
4.1 Tilt of mast forward α(°) 6
4.1.1 Tilt of mast backward β (°) 6
4.2 Height of mast lowered h1 (mm) 1995
4.3 Free lift h2 (mm) 145
4.4 Lift height h3 (mm) 3000
4.5 Height mast extended h4 (mm) 3565
4.7 Height of driver protection (cab) h6 (mm) 2020
4.8 Height of seat h7 (mm) 930
DIMENSIONS
4.12 Height of towing coupling h10 (mm) 473

4.19 Total length l1 (mm) 2862 2970 2970 3082
4.20 Length of fork at heel l2 (mm) 1792 1900 1900 2012
4.21 Overall width b1 (mm) 1060 1060 1060 1116
4.22 Section of fork arms e / s (mm) 100 / 35 100 / 35 100 / 35 100 / 40
4.22.2 Length of fork arms l (mm) 1070
4.23 Fork carriage to DIN 15173 A/B FEM 2A
4.24 Width of fork carriage b3 (mm) 1000
4.31 Ground clearance of mast m1 (mm) 100
4.32 Ground clearance at center of wheel-base m2 (mm) 90
4.33 Aisle width for 1000x1200 pallet widthways Ast (mm) 3161 3271 3271 3380
4.34 Aisle width for 800x1200 pallet lengthways Ast (mm) 3260 3370 3370 3480
4.35 Turning radius Wa (mm) 1440 1550 1550 1658
4.36 Inner turning radius b13 (mm) 0
5.1 Speed of travel laden km/h 13 13 12.5 12.5
5.1.1 Speed of travel unladen km/h 14
5.2 Rate of lift (laden) m/s 0,29 0,28 0,27 0,25
PERFORMANCE
5.2.1 Rate of lift (unladen) m/s 0,44 0,44 0,43 0,4

5.3 Speed of lowering laden m/s 0,43 0,44 0,45 0,47
5.3.1 Speed of lowering unladen m/s 0,42 0,43 0,43 0,46
5.5 Nominal towing power laden N 7000 7500 8000 9000
5.5.1 Nominal towing power unladen N 7250 7720 8300 9300
5.7 Slope laden % 14 13 13 11
5.7.1 Slope unladen % 15 14 14 12
5.9 Acceleration time laden s 5,2 5,2 5,3 5,7
5.9.1 Acceleration time unladen s 4,6 4,6 4,7 4,7
5.10 Service brake Oil-immersed multi-disc
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SPECIFICATIONS 3
00
6.1 Drive motor power rating kW 2 x 4,5
ENGINE 6.2 Lifting motor power rating kW 8,6
Size of battery compartment
6.3 DIN 43531 A
as per DIN 43 531/35/36 A,B,C, no
6.4 Battery voltage / capacity V / Ah 48 /460 48 / 575 48 / 575 48 / 690
6.6 Energy consumption according to VDI cycle kWh / h 4,3 4,3 4,3 4,7
MISCELLANEOUS
8.1 Speed control Electronic

8.2 Working hydraulic pressure for attachments Bar 145
8.3 Oil flow rate for attachments L / min 65
Sound level at driver's ears according
8.4 dB (A) 71 72 72 72
to EN 12053
8.5 Traction controller Kollmorgen AC
8.6 Hydraulic movement controller CURTIS DC
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GENERAL LOCATION
pages
LOCATION OF NAME AND IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
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LOCATION OF NAME AND IDENTIFICATION PLATE

Key:
1 - Load chart
2 - Driver's seat plate
3 - Traction controller plate
4 - Rear axle plate
5 - Pump motor plate
6 - Traction motor plate
3 CAPACITE NOMINALE
RATED CAPACITY
NENNKAPAZITÄT
CAPACIDAD NOMINAL kg
CAPACITÀ NOMINALE
CAPACITES EFFECTIVES
ACTUAL CAPACITIES
EFFEKTIVE KAPAZITÄT SUIVANT NORME EN 1726-1 ISO 1074.
CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA
1- Jusqu'à hauteur de levée

Up to height of
Bis zur hubhöhe
Hasta altura de elevación
- mm
Sino ad altezza di sollevamento
2- Pour hauteur maximale de
For maximum height of
Für maximale Höhe
Para altura máxima de mm
Per altezza massima di
MAT VERTICAL - -
VERTICAL MAST
VERTIKALER MAST
1 -
MASTIL VERTICAL
RAMPA VERTICALE
1 Q : kg 2
D
D : mm
EQUIPEMENT
ATTACHMENT
ZUBEHÖR
EQUIPO -
ATTREZZATURA
-
CAPACITES EFFECTIVES
ACTUAL CAPACITIES
- -
EFFEKTIVE KAPAZITÄT 1 -
CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA
2
n$:
5
4
00-03-M227EN (11/14/2013)
GENERAL LOCATION 3
00
Key:
7 - Mast identification
8 - Front wheel reducer plate
9 - Manufacturer's plate
HANGZHOU MANITOU MACHINERY EQUIPMENT CO.,LTD
398 SHIQIAO ROAD, HANGZHOU, P.R.C.
8 MODELE SERIE
N° dans la série Année de fabrication
9
N° de châssis
Poids sans la batterie Poids de la batterie mini
kg kg
Tension nominale Poids de la batterie max
V kg
Pression des pneumatiques (Bar)

Avant Arrière
N°267138
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4 GENERAL LOCATION
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00-03-M227EN (11/14/2013)
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GENERAL CONTROL AND ADJUSTMENT
pages
STANDARD TIGHTENING TORQUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
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2 GENERAL CONTROL AND ADJUSTMENT
00
00
STANDARD TIGHTENING TORQUES

Standard tightening torque to be used when not otherwise indicated in the removal and refitting
operations:
- The following tightening torques are given for hexagon head screws without flanges and
cylinder head hexagon socket screws.
- The torques are given for a friction coefficient μ = 0,20 corresponding to dry-fitted zinc-plated
fasteners and for torque tools having a ± 20 % class C tightening torque accuracy (equivalent
to pneumatic screwdrivers).
NF E 25-030-1 Screw / Nut connection :

Tightening torque in N•m (±20%)
Ø x “coarse” pitch Grade 8.8 Grade 10.9 Ø x “fine” pitch Grade 8.8 Grade 10.9
M3 x 0,5 1 1,5 - - -
M4 x 0,7 2,4 3,5 - - -
M5 x 0,8 4,8 7,1 - - -
M6 x 1 8,2 12,1 - - -
M8 x 1,25 20 30 M8 x 1 22 32
M10 x 1,25 43 63
M10 x 1,5 40 59
M10 x 1 46 68
M12 x 1,5 74 108
M12 x 1,75 69 102
M12 x 1,25 78 115
M14 x 2 111 163 M14 x 1,5 123 181
M16 x 2 175 256 M16 x 1,5 190 279
M18 x 2,5 240 352 M18 x 1,5 279 410
M20 x 2,5 341 501 M20 x 1,5 391 574
M22 x 2,5 470 691 M22 x 1,5 531 780
M24 x 3 588 864 M24 x 2 659 967
M27 x 3 874 1284 M27 x 2 965 1418
M30 x 3,5 1181 1735 M30 x 2 1351 1984
M33 x 3,5 1614 2371 M33 x 2 1821 2674
M36 x 4 2068 3037 - - -
b For hexagon screws with flanges:

Apply an increased torque of +10%.
(Standard NF E 25-030-1)
b Where washers are used, the following coefficient is to be applied (FD E 25-502) :
- Smooth tapered washer (CL): +5%
- Spring (or Grower) washer without jaws (W) : +10%
- Conical, internal teeth (CDJ-JZC) : +15%
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GENERAL CONTROL AND ADJUSTMENT 3
00
00
t IMPORTANT t
USE THE RECOMMENDED LUBRICANTS AND FUEL:
- For topping up, oils may not be miscible.
- For oil changes, MANITOU oils are perfectly appropriate.
DIAGNOSTIC ANALYSIS OF OILS
If a service or maintenance contract has been organized with the dealer, a diagnostic analysis of engine,
transmission and axle oils may be requested depending on the rate of use.
(*) RECOMMENDED FUEL SPECIFICATION
Use a high-quality fuel to obtain optimum engine performance.
• Type of diesel fuel EN590
• Type of diesel fuel ASTM D975
FRONT WHEEL REDUCERS

UNITS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBER
2l 62148
MANITOU oil 20 l 546332
FRONT WHEEL REDUCERS 0,35 Liters
Automatic transmission 55 l 546217
209 l 546195
MAST
UNITS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBER
MANITOU Lubricants
MAST LIFTING CHAINS 400 MI. 554271
Chain special (aerosol)
400 g. 545996
MANITOU grease
GREASING OF THE MAST 1 Kg. 161590
BLACK multi-purpose
5 Kg. 499235
HYDRAULICS
HYDRAULIC OIL TANK 5l 545500
MANITOU oil 20 l 582297
ME 315 Series 2 / ME 318 Series 2 25 Liters
Hydraulic ISO 46 55 l 546108
ME 318 Series 2 / ME 320 Series2 30 Liters
209 l 546109
BRAKE
0,5 l 473013
MANITOU fluid 1l 473014
BRAKE SYSTEM 1,5 Liters
DOT 4 brake fluid 5l 486363
30 l 486364
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4 GENERAL CONTROL AND ADJUSTMENT
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00
(11/15/2013)
AXLE
- AXLE COMPONENTS LOCATION
- AXLE CONTROL AND ADJUSTMENT
30
AXLE COMPONENTS LOCATION
30
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2 AXLE COMPONENTS LOCATION
30
Front left-hand
wheel motor
Pump motor
Fro n t r i g h t -
hand wheel
motor
Rear axle
30-03-M227EN (9/10/2013)
AXLE CONTROL AND ADJUSTMENT
30
pages
DISASSEMBLY AND REASSEMBLY TRANSFERT BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
– SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– 1. DISASSEMBLY OF THE DRIVE UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– GENERAL INSTRUCTIONS FOR THE CORRECT DISASSEMBLY AND REASSEMBLY . . . . . . . . . 11
I - DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
– 1. DISASSEMBLY OF THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
– 2. DISASSEMBLY OF THE HOUSING COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
II - REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
– 1. REASSEMBLY OF THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
– 2. REASSEMBLY OF THE HOUSING COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
– 3. REASSEMBLY AND ADJUSTMENT OF THE BRAKE LEVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CONTROL AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
– 2 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
– 3 PRODUCT SAFETY AND DANGER ZONES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
– 4 GENERAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
– 4.5 STANDARD TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
– 5 PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
– 6 MOTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
– 7 ATTACHMENT OF MOTOR-TRANSMISSION UNIT TO THE VEHICLE FRAME . . . . . . . . . . . . . 35
– 8 MOUNTING OF THE DRIVE WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
– 9 CONNECTION OF THE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
– 10 REPLACEMENT OF THE DISC PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
– 11 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
– 12 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
– 13 FAILURES, POSSIBLE CAUSES AND ELIMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
(06/09/2013) 30-04-M227EN
30
30-04-M227EN (06/09/2013)
AXLE CONTROL AND ADJUSTMENT 3
DISASSEMBLY AND REASSEMBLY TRANSFERT BOX
INTRODUCTION
This documentation was issued for maintenance specialists.

Due to further technical developments of the product a repair of the existing unit may require varying processes as well as
different setting and test data. Therefore we recommend you to give your axle product in the hands of masters and fitters
whose practical and theoretical training is continuously updated in our after-sales services training center.
We recommend to read the entire manual before beginning of repair work, since some procedures are very complex.
This manual is based on the technical satuts at printing date.
30
It was most carefully prepared to avoid mistakes.
However, we are not liable for possible errors in representation, errors in description or omission.
We reserve us the right to modification without prior notice.
The owner and user are liable for observing the safety instructions and to perform the maintenance work in accordance
with the specifications.
We are not liable for fautly installation, inadequate handing, insufficient maintenance, improperly as well as incompetently
performed work and the resulting consequential damages.
This is aslo applicable if no original spare parts are used.
We did not go into detail for disassembly, reassembly and repair of accessory parts.
Please observe the respective instructions and manuals of the vehicle manufacturer.
Important information with reference to technical reliability and operational safery are outlined by the following
symbols :
Is applicable for instructions which have especially to be observed for execution of the work.
Is indicated for working- and operating processes which must strictly be observed to avoid a damage or
destruction of the unit.
Is indicated for working- and operating processes which must strictly be observed to avoid risks for persons.
(06/09/2013) 30-04-M227EN
4 AXLE CONTROL AND ADJUSTMENT
SAFETY INSTRUCTIONS
• The use as directed requires the strict observance with the manufacturer’s specifications for installation,
disassembly and reassembly, initial operation and maintenance.
• Every person concerned with installation, disassembly and reassembly, initial operation and maintenance
in the user plant must have read and understood the whole instructions and in particular the safety
instructions.
• Any working method which endangers the safety of the transmission is prohibited.
30
• Modifications and changers without the proper authority are affecting the safety of the transmission
and are not allowed.
• Only original spare parts or spare parts approved are allowed to be used. It is explicity pointed out to
the fact that spare parts and accessories, wich were not supplied by us are not checked and approved
by us either. We do not accept any liability or admit any warranty for damages caused by the use of
spare parts and accessories which are no original parts.
• The described work is only allowed to be made by autorized, trained and instructed staff.
• The proper repair of these products requires adequately trained specialists.

The repairer is responsible for the training!
• Keep away aggressive cleaners from your skin, do not drink it or inhale its vapours!
Always wear safety gloves and goggles. If by mistake cleaner was swallowed, call medical
aidimmediately!
Strictly observe manufacturer instruction.
• Do not drain cleaners or transmission oil into the sewerage system or into the soil.
• Prior to start working on installed or mounted transmission, the wheels must be blocked.
• Prior to any work on the intalled transmission (e.g. oil change) or its mounted-on parts the engine
must always be switched off.
• The local regulations for safety and prevention of accdients must be observed!
30-04-M227EN (06/09/2013)
GENERAL DATA
1. DISASSEMBLY OF THE DRIVE UNIT
Drain oil from the transmission before disassembly of the drive unit.
Loosen and remove the wheel nuts as well as take off the drive whell. (see Fig. 1)
For further work on the transmission of the drive unit see Chapter II, Section 1.
1.1 REMOVAL OF THE DRIVE UNIT
30
a) E-motor and accessories mounted to the E-motor have to be disconnected.
b) Loosen the 7 fixing boltd (Pos. 1) on the vehicle frame and remove cautiously the drive unit.
(see Fig.1)
E-motor
Drive wheel
Wheel nut
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1.2 REMOVAL OF THE E-MOTOR (SEE FIG. 2)
a) Removal the three hexagon screws (1x M8x50

and 2x M8x75, Pos. 1 and 2) for E-motor.
b) Take off cautiously the E-motor from the

transmission.
30
Do not damage the teeth of the motor

pinion and the spur gear!
Damages can cause louder running noises.
Attention
In case of an inadequate removal of the E-motor from the transmission there is the danger
to damage the sealing surface for the O-ring in the housing!
If only the E-motor is removed, the released transimission opening is to be sealed in order
to avoid that dirt can get inside the transmission.
1.3 DISASSEMBLY OF THE INPUT PINION (SEE FIG. 3)
a) Hold the input pinion (Pos.2) with a suitable

strap wrench (e.g. as shown in Fig. “A”) and
remove the slotted nut (Pos.4) with slotted
nut wrench “B”.
b) Pull off the input pinion (Pos.2) by means

of pull “C”.
a) Take off the fitting key (Pos.3) from the

motor shaft (Pos.1).
b) Remove cautiously the O-ring (Pos.5) from

the centering seat of the motor.
30-04-M227EN (06/09/2013)
1.4 AUXILIARY TOOLS FOR DISASSEMBLY OF THE INPUT PININON
Strap wrench “A” for holding the input pinion in

place
30
Slotted nut wrench “B” (Ident No. 618846)
for removal of the stop nut.
Puller “C”
(Ident-Nr. 662244) to pull off the input pinion
(06/09/2013) 30-04-M227EN
SPECIAL TOOLS
Illustrations are not binding for the design!
Ident No. 618845

“H” Sleeve
To press the bearing inner ring onto the gear shaft
and the planet carrier
Ident No. 610060

30
“I” Assembly drift

To install radial shaft seal for the gear shaft
Ident No. 610390
“J” Striker mandrel

To install the planet gears
Ident No. 450971
“K” Peening mandrel

To peen the planet gears
30-04-M227EN (06/09/2013)
Ident Nr. 4699 395 001
“L” Puller
To pull off the planet gears from the planet carrier
30
Ident Nr. 4699 395 002
“M” Press device

To preassemble the wheel bolts
Ident Nr. 4699 395 003
“N” Slotted nut wrench

To loosen and to tighten the slotted nut on the
gear shaft bearing
Ident Nr. 4699 295 001
“O” Measuring fixture

To measure the housing dimension for bearing
preaload of the gear shaft bearing
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Ident Nr. 4699 295 002
“P” Measuring fixture

To measure the planet carrier and gear shaft for
bearing preload of the gear shaft bearing
30
Ident Nr. 4699 395 004
“Q” Assembly dritf

To install the bearing outer ring into the housing
seat
30-04-M227EN (06/09/2013)
GENERAL INSTRUCTIONS FOR THE CORRECT DISASSEMBLY AND REASSEMBLY
Cleanliness is essential for a correct work.

Transmission removed from the vehicle have to be cleaned prior to opening.
Special care and cleanliness are essential for a correct disassembly and reassembly of the unit as well
as for the installation of each spare part. A fault during installation can result in an early wear and chips
as well as foreign particles in the unit could cause fatal damage in the transmission.
Prior to reassembly all parts must be cleaned and inspected for wear and orther defects.
It would be a false economy to reinstall parts which are not in a perfect condition.
All parts have to be oiled carefully during reassembly. Apply a sealing compound onto housing- and
cover faces, which must be tight towards the outside.
30
For heating of bearings ect. use heating plates, heating elements to heating furnaces.
Never heat directly with an open flame!
This avoids damage to the bearings.
If not otherwise indicated heat ball bearings, gears, flanges ect. to approx. 90 - 100°C.
Parts which have been mounted in a warm condition must be subsequently installed after cooling
down to ensure
a perfect contact.
Lubricate both parts before shafts, bearings ect. are pressed into position.
For reassembly all of the indicated setting values, test data and tightening torques must be observed.
This units will be filled with oil after repair work.
The following description of disassembly and reassembly serves to inform both the
after-sales service centers and of the vehicle manufacturer, where adequate
workshop facilities and trained specialists are present.
(06/09/2013) 30-04-M227EN
I - DISASSEMBLY
Introduction
Prior to disassembly clean transmission carefully.

A great help is a bright, spacious working place, free of dirt and chips.
The necessary working steps are described and illustrated in the correct sequence.
Part only available as assembly group will not be stripped any further.
Pleased observe strictly the instructions of the vehicle manufacturer for removing the gearbox
from the vehicle.
1. DISASSEMBLY OF THE TRANSMISSION

30
Loosen and remove the two retaining rings (Pos.5).

Beat out the cylindrical pin (Pos.1) and remove the
brake lever (Pos.2) from the cover.
Loosen the 8 cap screws M6x16 (Pos.13) and press
off cautiously the cover (Pos.4) from the basic transmission.
Before loosening of the cap screws beat

slightly onto the same to loosen the LOCTITE-
connection!
Keep the housing cover on a clean place.

Further details on disassembly of the housing
cover are indicated in Section 2.
At removal of the housing cover, the spur

gear will remain connected by screws with
the inner disc carrier as one unit!
Pull out the disc pack including 4x outer clutch

discs and 3x inner clutch discs as well as the
thrust washer from the ring gear and keep it
on a clean place.
30-04-M227EN (06/09/2013)
By means of the puller “L” pull off cautiously the

three planet gears from the planet carrier.
The planet gears are pulled off with the bearing

completely.
30
Lock the gear shaft agains torsion.
Unlock the slotted nut the gear shaft.
Loosen and remove the slotted nut for the gear
shaft bearing.
Use slotted nut wrench “N”.
Expel and remove the gear shaft ( with taper roller

bearing inner ring) by means of a copper mandrel
and a hammer.
Pay attention that the gear shaft is not damaged

at removal.
Take out the planet carrier (with taper roller bearing

inner ring) from the bearing seat of the housing.
Keep the planet carrier and the gear shaft on a
clean place.
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Loosen the 10 internal Torx screws M 10x35 (Pos.1) and

take out the ring gear assy from the housing.
The Feyring will remain mounted to the ring gear.
Note
Dis- or reassembly of the ring gear is only required when
the teeth are damaged, so that no details are indicated
for ressembly.
Fastening with LOCTITE 270, as well as the tightening
torque of M = 67 Nm is absolutely necessary to tighten
30
the internal Torx screws.
On both sides the bearing outer rings for supporting the

gear shaft and the planet carrier have to be removed
cautiously from the houding by means of a copper mendrel
and a hammer.
When the bearing outer ring in the gear side is expelled,
pay attention not to damage the shim rings.
When the outer ring on the gear side is expelled,

the radial shaft seal is removed together with
the bearing! For reassembly a new radial shaft
seal has to be used!
2. DISASSEMBLY OF THE HOUSING COVER
Put the houding cover of the transmission onto a level

support.
Loosen and remove the six hexagon screws M8x35 (Pos.1).
30-04-M227EN (06/09/2013)
Remove the fixing plate (Pos.4) with the

compression spring (3 pcs., Pos.3) underneath
and keep te same on a clean place.
Then take off the inner disc carrier (Pos.2) with
the pressure disc (Pos.5) from the spur gear.
30
By means of pliers remove the retaining ring 30x1,5
(Pos.6) on the bearing seat of the cover.
Press off the spur gear (with the bearing) from the
bearing seat of the cover.
Use the threads M8 (6 pcs.) on the spur gear

for fastening of the inner disc carrier.
By means of pliers remove the axial slide bearing

from the bore seat of the cover.
Do not damage the surface of the axial slide

bearing.Pay attention to the installation
position of the axial slide bearing!
(06/09/2013) 30-04-M227EN
II - REASSEMBLY
INTRODUCTION
Clean all parts with a suitable cleaning agent and remove residues of LOCTITE.
Keep away cleaning agent from your skin, do not drink it or inhale its vapours!
Wear safety gloves and goggles! In case of the skin contact rinse immediately with a
lot of water!
If by mistake the cleaning agent was swallowed, call medical aid immediately!
Observe regulations for prevention of accidents!
30
Check all parts for wear, damages and cracks, if required replace them.
In case of damaged running teeth, the gear set parts have to be replaced per sert.
Always replace damaged tapered roller bearings (inner- and outer ring).
Do not reuse deformed shim ring and worn thrust washers.
Touch up seal faces or smoothen with a fine file.
For reassembly the following parts should only be used as new:
• Radial shaft seals, round sealing rings (O-rings)

• Slotted nut for gear shaft fastening
• Deformed or damaged shim rings
• Sealing rings on oil drain- and oil filler plug
30-04-M227EN (06/09/2013)
1. REASSEMBLY OF THE TRANSMISSION
1.1 PREASEMBLY OF GEAR SHAFT AND PLANET CARRIER
By means of a press and the press device “M”

press in the wheel bolts (Pos.1) into the gear shaft
until contact.
For pressing-in attention is to be paid that the flattened
30
collar of the bolt shows towards the middle of the gear
shaft.
Do not jam the wheel bolts at pressing-in of the same.
Fig. II- 1
Push the NILOS-ring (Pos.2) onto the gear shaft until contact and grease it with
SHELL Alvania R3.
Press the taper roller bearing inner ring (Pos.3) by means of the sleeve “H” with the NILOS-ring
onto the gear shuft until contact.
Fig. II-2
Only upon setting of the bearing fill up the taper roller bearing and
the roller gaps with grease SHELL Alvania R3.
Planet carrier is to be preassembled with the taper roller bearing.

(also see Chapter I, Section 1., Fig. I-7)
Press the taper roller bearing inner ring (like in Fig. II-2) onto the planet carrier.
(06/09/2013) 30-04-M227EN
1.2 INSTALL RADIAL SHAFT SEAL INTO THE HOUSING
Apply a thin layer of LOCTITE 574 onto the outer

diameter of the radial shaft seal (Pos.1). By means
of the assembly drift “I” install the radial shaft
seal into the housing seat until contact.
Do not damage the sealing lip of the adial

shaft seal!
30
1.3 MEASUREMENT AND ADJUSTMENT OF BEARING

PRELOAD ON THE GEAR SHAFT
Measurement of housing dimension (without bearing

outer rings)
Measure the housing dimension as follows:
Bring fixture part with the dial gauge to position “zero”.

(Zero position on the dial gauge = 29,0mm)
(O) Measuring fixture 4699 295 001
• Insert complete fixture into the housing until contact

and hand-tighten it.
• Determine the dimension and add it to dimension 29mm.
Example:
Dim. A 29,00 mm
Dim. B + 0,36 mm
Suma = Dim. housing 29,36 mm
Measure planet carrier (with taper roller bearing)
Measure the planet carrier as follows:
• Bring fixture part with the dial gauge to position “zero”.

(Zero position on the dial gauge = 7,40mm)
(P) Measuring fixture 4699 295.002

30-04-M227EN (06/09/2013)
• Put the planet carrier (Pos.1) onto the fixture until

contact.
30
• Put on the fixture part (with dial gauge) and by
turning motions roll in the taper roller bearings on
the planet carrier.
• Hand-tighten it at the same time as well as determine
the dimension.
• Add this dimension to 7,40 mm.
Example:
Dim. A 7,40 mm
Dim. B + 0,43 mm
Suma = Dim. planet carrier 7,83mm
Measure gear shaft (with taper roller bearing)
Measure the gear shaft as follows:
• Bring fixture part with the dial gauge to position

“zero”. (Zero position on the dial gauge = 21,56mm)
(P) Measuring fixture 4699 295.002
• Put the gear shaft (Pos.2) onto the fixture until contact.
• Put on the fixture part (with dial gauge) and by turning
motions roll in the taper roller bearing on the gear shaft.
• Determine dimension and add it to dimension
21,56mm
Example:
Dim. A 21,56 mm
Dim. B + 0,46 mm
Suma = Dim. gear shaft 22,02 mm
(06/09/2013) 30-04-M227EN
Determination of the shim rings

to be added
The following method can be applied

to determine the thickness of the shim
ring. (Pos.1).
Dim. D, Dimension housing =

30
Distance from contact plane face bearing

outer ring to contact plane bearing outer
ring.
Dim. E, Dimension planet carrier =

Distance from plane face bearing outer
ring to plane face planet carrier.
Dim. F, Dimension gear shaft =

Distance from plane face bearing outer
ring to plane face gear shaft.
The shim ring thickness (Pos.1) can be

calculated by means of equation
Z=E+F-D
Add shim ring according to thickness Z.
Example: E= 7,83 measure on the planet carrier

F= 22,02 measure on the gear shaft
D= 29,36 measure on the housing
Z = 7,83 + 22,02 - 29,36 = 0,49 mm
As per experience 0,1 mm will be deducted from dimension Z, so that a more favourable
bearing preload adjustment is obtained for operating conditions.
Z = 0,49 - 0,1 = 0,39mm
30-04-M227EN (06/09/2013)
The shim ring thickness determined in Section 1.4 is to

be combined with shim rings of a different thickness.
Put the shim ring (Pos.1) and the bearing outer ring
(Pos.2) into the bearing seat.
30
By means of assembly drift “Q” install the bearing outer
ring (Pos.2) with the shim ring (Pos.1) into the bearing
seat of the housing until contact.
Install the bearing outer ring on the opposite side, as
shown in Fig. II-13.
Grease the taper roller bearing inner ring and the roller
gap on the preassembled wheel hub with grease SHELL
Alvania R3.
Join the preassembled gear shaft (Pos.3) to the taper

roller outer ring of the housing.
Lock the gear shaft against slipping and torsion.
(06/09/2013) 30-04-M227EN
Apply a thin layer of LOCTITE 270 on the internal grearing

of the planet carrier (Pos.4) ans assemble it cautiously into
the gear shaft teeth.
By means of a suitable drift install the planet carrier until
contact.
LOCTITTE is only to be metered into the

internal gearing of the planet carrier!
Spilled LOCTITE is to be removed with a
clean cloth.
30
Wet the thread of the slotted nut slightly with LOCTITE 270.
Put on the slotted nut, fasten it with screws and tighten it.
Tigthen the slotted nut only with the slotted nut wrench
“N”, so that the wheel hub bearing is located tightly.
Slotted nut is to be tightened with a

tightening torque of 535 Nm, Cat. 2.2 ZFN
148!
Hit collar of the slotted nut with a chisel (Edge of

the chisel has to be a radius!) into the 2 recesses
of the gear shaft
Lock the slotted nut by 2-fold peening!
Rotate gear shaft several times in order to have aligned

the taper rollers in the bearing rings.
No bearing play must be measurable during the check!
However, the gear shaft must be rotatable by hand.
The bearing preload is correctly adjusted, when a total
earing friction torque of 1,5 ... 5,0 Nm is obtained.
Use an electronic torque spanner (Pos.5) to check the
bearing friction torque.
If the bearing friction torque is beyond the requested value a new adjustment is
required.
The final value has to be obtained by adding or removing of shim rings (see Fig. II-19)
30-04-M227EN (06/09/2013)
30
1.4 REASSEMBLY OF THE PLANET GEARS WITH THE PLANET CARRIER
Put the planet gear (Pos.1) straight onto the axle stub of the planet carrier, do not jam it, and press
ot on whit the striker mandrel “J” until contact.
Attention!
Pay attention to the installation position of the planet gear. The radius of the inner ring must
always be on the stop of the axle stub.
Repeart this procedure for the two remaining planet gears analogously.
(see Fig. II-21 y la Fig. II-22)
Lock the three planet gears againts axial displacement by means of peening mandrel “K”.
For this purpose expand the blind hole to such an extent that the bearing inner ring of the planet
gears cannot be displaced any more.
(see Fig. II-22).
(06/09/2013) 30-04-M227EN
1.5 DISC PACK ASSEMBLY OF THE TRANSMISSION
Two steps have to be oberved for disc pack assembly:
Step 1
• if for wearing reasons only the disc pack (Pos.1) is

replaced, the previous pressure disc (Pos.2) can be reused.
• place the clutch discs into the ring gear in the following
sequence:
-pressure disc
30
-outer clutch disc/inner clutch disc/outer clutch disc/inner clutch disc/outer clutch disc/inner clutch
disc/outer clutch disc (Fig. II-23)
The sine clutch discs have to be aligned regularly depending on the undulations.
(see Figures II-24 y II-25)
A rapid and exact method is the alignement and the centering respectively with an inner clutch disc
carrier which is not used for the assembly of the transmission.
The inner disc carrier (Pos.3) will be brought into the installation position as shown in Figure II-25.
By slight rotations and movements respectively of the inner disc carrier the position of the discs is fixed
clearly now.
Following to this, the inner disc carrier is to be removed cautiously from the installation position,
so that the position of the discs is not changed any more.
For assembly the direction
of the sine inner clutch discs
must ne observed!
30-04-M227EN (06/09/2013)
Step 2
If several parts of the transmission (e.g.cover

or pressure disc) are changed or replaced, the
required thickness of the pressure disc has to
be determined as follows.
Fig. II-26
30
The following method is used to determine the thickness
of the pressure disc.
Dim. X = Determine the distance from the plane cover

to plane face pressure disc.
Dim. Y = Measure thickness of the disc pack in
compressed condition.
Dim. W to be calculated as follows W = X + Y
Dim. V = Determine distance from plane face housing until contact of pressure disc in the ring gear.
Dim. Z to be calculated as follows: Z=V-W
Example: X = 23,23 mm measure

Y = 12,6 mm thickness of the disc pack
W = 23,23 + 12,60 = 35,83 mm
V = 41,93 mm measured in the housing
Z = 41,93 mm - 35,83 mm = 6,10 mm
The required thickness of the pressure disc can be read in Table 1.
Dimension Z Pressure disc C
5,58 a 6,10 4,8 mm thick required pressure disc 4,80mm
6,10 a 6,70 5,3 mm thick
6,70 a 7,22 5,8 mm thick

Table 1
(06/09/2013) 30-04-M227EN
2. REASSEMBLY OF THE HOUSING COVER
The housing caver will in principle be reassembled in reverse order of the diassembly.
(see Chapter I, Sect. 2.)
For reassembly is has to be observed as follows:
Place the axial slide bearing into the bore seat of the cover.
30
For assembly of the axial slide bearing the

correct installation position has to be
observed!
Put the spur gear (Pos.7, with preassembled bearing) onto

the bearing seat of the cover and install it until contact.
Install the retaining ring (Pos.6) with the aid of pliers and
lock the spur gear.
Put the pressure disc (Pos.5) and the inner clutch disc carrier
(Pos.2) onto the the spur gear.
Place the 3 compression springs (Pos.3) into the bore hole of
the inner clutch disc carrier (Pos.2) and put the fixing plate
(Pos.4) with the recesses on to the compression springs.
Align fixting plate on the inner disc carrier

depending on the gearing, so that the
assembly of the cover is not hindered.
30-04-M227EN (06/09/2013)
Connect the inner clutch disc carrier with the spur gear
by means of hexagon screws 6x M8x35 (Pos.1).
Put one drop each of LOCTITE 243 on the thread of the
screws and tighten the same.
Tightening torque: M = 34 Nm
30
The sealing face of the cover has to be sealed with
LOCTITE 574.
Place the cover coutiously and install it until contact

by beating slighty with a plastic hammer.
By means of 8 cap screws M6x16 (Pos.3) fasten the cover
to the basic transmission.
Put one drop each of LOCTITE 234 onto the threads.
Tightening torque. M = 9,6 Nm
(06/09/2013) 30-04-M227EN
3. REASSEMBLY AND ADJUSTMENT OF THE BRAKE LEVER
Put the brake lever (Pos.2) into the bracker (Pos.7) of the
cover and pay attention to the installation position!
By means of a drift install the cylindrical pin (Pos.1) into the
bracket and the brake lever at the same times.
With the two retaining rings (Pos.5) lock the cylindrical pin
agrainst loosening from the bracket.
Fig. II-33 / Fig. II-34
Thus the brake lever is installed and the Adjusting dimension “A” has to be checked and set.
30
The adjusting dimension “A” for the brake lever is between 0,4 mm – 1,0 mm. (Fig. II-34)
The adjusting dimension has to be checked with a dial gauge.
For this purpose position the feeler of the dial gauge on the brake lever in the specified measuring point
range. Press the brake lever againts the cover and read the deflection on the radial gauge. (Fig.II-35 / II-36).
If the adjusting dimension should not be within the specified range, it has to be obtained and set with the
pressure pin (Pos.6). (Fig. II-34)
Several pressure pins can be selected. (see spare part list, pressure pin Pos. 308 on page 3)
If the pressure pin is replaced the brake lever has to be removed again, as described in Chapter I, Sect. 1
Fig. I-1.
Then it is possible to pull out the pressure pin from the bore of the cover.
When installing the pressure pin do not damage the radial shaft seal.
Wet the sealing lip of the radial shaft seal (Pos.8) slighty with grease!
After installation of the brake lever, check the adjusting dimension applying the same steps as describe
above.
Measuring
point
Adjusting
dimension
for assembly
30-04-M227EN (06/09/2013)
CONTROL AND ADJUSTING
1 INTRODUCTION • insufficient maintenance
• improperly and incompetently performed work

This operator’s manual describes the installation and the resulting consequential damages
and maintenance as well as the elimination of
failures for the GP 20 and GP 21 transmissions. The • faulty operation
herein described work is only allowed to be made
by specialists. It is absolutely required that design We reserve further technical development of their
and function of the mentioned transmission types products. It is possible that procedures can become
are known. necessary which differ from those described in
the original version of this manual. In this case the
30
Prior to start work read this manual carefully. Carry customers are informed by us and the changed
out the single working steps as described and do pages of this manual will be made available to them.
not change them without permission. Observe
the safety instructions. If you do not understand a The customer is responsible to replace the changed
procedure or cannot follow it doubtlessly, do not pages and thus to keep this operator’s manual
act on your own without permission, but consult updated. The respective version is indicated on the
the Technical After-Sales Service. bottom of every page for information. The current
version of this manual can be requested from the
For the work described in this manual only original Technical Service.
spare parts or spare parts approved are allowed to
be used. If no original parts are used the optimum Keep this manual in such a way that it can always
function of the transmission can be negatively be found by persons concerned with the product.
affected and the warranty claim will lapse.
For an optimum maintenance and repair of the
product we recommend to have made the repair
We do not accept any liability for damages and and maintenance work by our service technicians.
failures caused by :
Maintenance and repair work made by us are also
• faulty installation covered by a warranty within the applicable terms
of contract.
• modifications on the transmission or the drive
unit without permission
• inadequate use of the transmission or the drive unit
For all publications we reserve us the right disclosure of its contents are forbidden without
of modifications due to technical reasons in our permission. Infringements are liable for
production, processing and appearance. damages. All rights reserved for the grant of
Transmittal of this manual, reproduction and a patent or registration of a utility model.
copying – even partially –, making use and
(06/09/2013) 30-04-M227EN
2 SAFETY INSTRUCTIONS
2.1 APPLIED TERMS AND WARNING SYMBOLS
If the below described work is hazardous, you will be warned by means of safety instructions.
Please observe and follow these instructions.
The following terms and symbols are used:
„CAUTION“ refers to possibly dangerous situations which can cause minor injuries.
„ATTENTION“ refers to situations which can cause damage to the product or material.
This symbol refers to dangers for the environment.

30
This symbol refers to dangers by substances which are harmful to health.
This symbol refers to important instructions. If these are not followed by you, the
transmission or add-on parts can be damaged.
This symbol is used for additional information.
3 PRODUCT SAFETY AND DANGER ZONES
This product was made with utmost care and corresponds to the state of technology and the recognized
safety rules. But nevertheless, this product might cause dangers which can be of
• mechanical nature (transmission mechanism, drive)
• thermal nature (hot transmission oil)
• chemical nature (cleaning agents, adhesives).
Please read the safety instructions and the procedures of this manual carefully prior to start the work
and observe all safety rules and instructions. If there is anything you do not understand or you are not
sure, please consult your superior or ZF GOTHA’s After-Sales Service.
Please observe the accepted rules of industrial safety and the regulations for the prevention of accidents.
Modifications or changes on the transmission without the proper permission are not allowed and can
cause hazards or damages.
3.1 IMMEDIATE ACTIONS AT CONTACT WITH CLEANING AGENTS
In case of skin contact rinse immediately with a lot of water! If swallowed, call medical
aid immediately!
30-04-M227EN (06/09/2013)
4 GENERAL DATA
4.1 SAFETY INSTRUCTIONS
During work on movable transmission parts in the installed transmission, these

could start unexpectedly and cause injuries to you. Prior to all work on the installed
transmission (e.g. oil change) or its add-on parts disconnect the power source feeding
the motor.
During work on the installed or mounted transmission the vehicle might suddenly
move and cause injuries to you. Block the wheels prior to start the work. The vehicle
must be standing on even and not on steep ground.
You might get injured by aggressive cleaning agents and adhesives at contact with
30
the skin and the eyes or when inhaled or swallowed. Always wear safety gloves and
goggles working with cleaning agents and observe the manufacturer instructions.
Do not eat, drink and smoke.
You can get burned by transmission oil when the transmission was in operation
before and the oil is still hot. Have the transmission cooled down prior to start work.
Cleaning agents and transmission oil can cause environmental damages, when these
get into the sewerage system or the environment. Never drain cleaning agents and
oil into the sewerage system or into the soil. Collect it and take care of an adequate
disposal in compliance with the disposal regulations of your company.
4.2 GENERAL INSTRUCTIONS
• Pay attention to cleanliness and expert like manner for all work to be carried out. Transmissions
removed from the vehicle have therefore to be cleaned prior to opening. Both utmost care and
cleanliness are essential conditions for a correct disassembly and reassembly of the unit.
• Special devices and special tools are necessary besides the standard tools. Their use is unavoidable
for a technically adequate assembly!
• All screws and threads in this transmission have metric dimensions. Only spanners and socket spanners
with metric sizes are allowed to be used.
• For assembly work all of the indicated setting values, test data and tightening torques must be
observed.
(06/09/2013) 30-04-M227EN
4.3 TORQUE LIMITS IN NM FOR SCREWS TO ZF STANDARD 148
Torque limits, if not especially indicated, can be taken from the following list:
30
Friction value: μ tot. 0.12 for screws and nuts without after-treatment, as well as phosphatized nuts.
Tightening by hand!
4.4 CONSUMABLES
Suitable cold cleaners, e.g. LOCTITE.

„WARNING“
Only use suitable agents which are non-toxic, non-combustible and permissible on the
market. Never use benzene, solvents or other combustible agents.
Description To be used for

LOCTITE No. 243 Screw lock up to Size M10
LOCTITE No. 574 for application onto the sealing face of the housing cover
LOCTITE No. 706 Cleaning of ground surfaces
Transmission oil according to the Chapter: „Transmission Oil Data“
4.5 STANDARD TOOLS
- Open jaw spanner/Ring spanner : 6, 8, 10, 13mm

- Torque spanner Adjustable up to 200 Nm
- Torx socket spanner : 15mm and 20mm
- Hexagon socket spanner : 8, 13, 17mm female; 5, 6, 8, 10, 14mm male.
- Dead-blow soft-face hammer 1000 g
- Impact-resistant screwdrivers
- Flat-head pliers
30-04-M227EN (06/09/2013)
4.6 SPECIAL TOOLS
Description Use Reference Number Illustration
For motor shaft 0 20mm

618 851
For tightening and removal
Slotted nut wrench “A” For motor shaft 0 25mm
of the slotted nut
618 846
5 PRODUCT DESCRIPTION
30
5.1 COMPONENTS AND ACCESSORIES OF A HFS 507 OR
GP – TRANSMISSION
The transmission of the HFS 507 & GP Product Range

consists essentially of the following components:
Item 01 Transmission housing
Item 02 Transmission cover
Item 03 Wheel shaft
Item 04 Model Identification Plate
Item 05 Motor *
Not illustrated are for instance:

• Helical gear set, consisting of helical gear and drive
pinion
• Planetary gear stage
• Oil filler and oil level plug
• Brake system
* optional component
5.2 TRANSMISSION IDENTIFICATION

The model identification plate is fixed to the transmission
housing side.
Data indicated there are as follows:

• 01 Transmission Type
• 02 Serial No.
• 03 Total Ratio
• 04 ZF Parts List No.
(06/09/2013) 30-04-M227EN
6 MOTOR INSTALLATION
„ATTENTION“
The taper connection must be free from grease and oil.
„ATTENTION“
At an inadequate installation of the motor to the transmission the tooth flanks at the
drive pinion and the helical gear can be damaged, which will cause louder noises later!
„ATTENTION“
Keep away cleaning agent from your skin, do not drink it or inhale its vapours! Wear safety
gloves and goggles! In case of skin contact rinse immediately with a lot of water! If by
mistake the cleaning agent was swallowed, call medical aid immediately! Observe the
regulations for the prevention of accidents!
30
• Clean the motor shaft (Item 05) and the drive pinion
(Item 01) carefully e.g. with LOCTITE fast cleaner No. 706.
• Insert the curved washer (Item 04) into the slot of

the motor shaft and slid on the drive pinion.
• Tighten the slotted nut with a torque spanner and

the special tool „A“.
• Observe the tightening torque of the slotted nut:

M20x1 & Ø 25 Motor shaft taper: 55 Nm
M14x1.5 & Ø 20 Motor shaft taper: 68 Nm
• Wet the O-Ring (Item 03) with a little bit of transmission oil or grease, insert it into the slot of the
motor centering seat.
• Insert the motor cautiously into the transmission top section in vertical direction, slightly turning the
wheel shaft by hand to achieve that the tooth flanks of the drive pinion are aligned with the tooth
flanks of the helical gear.
• When the tooth flanks are aligned lower the motor

until stop.
• Turn the motor that boltholes of the motor and

transmission top section are aligned adequately.
Fasten the motor and the transmission top section
with the cap screws M8x50 (Item 01) and M8x75
(Item 02).
• Tightening torque of the screws: 23 Nm
30-04-M227EN (06/09/2013)
7 ATTACHMENT OF MOTOR-TRANSMISSION UNIT TO THE VEHICLE FRAME
7.1 INSTALLATION POSITION 45 °
The motor-transmission unit can be installed within a range of 40° min. to 50° max. relative to the
horizontal reference plane of the vehicle frame.
„ATTENTION“
Deviations of the installation position or of the admissible tolerance require a consultation
with the ZF Gotha GmbH.
The installation angle has a strong influence on the oil quantity and the transmission maintenance. One
oil filler plug and oil drain plug each are located at the housing bottom side. (See Figure 07)
30
The oil filler opening defines the oil quantity (e.g. overflow) to be filled in. Always unscrew the screw
plug located at the lowest point to drain the transmission oil!
Check the frame surface on the vehicle for damages and roughness. The max. admissible surface
roughness in the transmission mounting zone is 0.10 mm.
Fasten the drive unit with 7 hexagon screws M14 and the retaining rings to the vehicle frame. (See
Figure 07) Tightening torque of the screws: 135 Nm
(06/09/2013) 30-04-M227EN
8 MOUNTING OF THE DRIVE WHEEL
This chapter is only applicable for delivery without drive wheel or for drive wheel replacement
The wheel shaft is adapted to the commercially available drive wheels (Vulkollan or solid rubber).
„ATTENTION“
Prior to install the drive wheel pay attention that the wheel shaft and the rim mounting
face are clean, free from grease and undamaged.
Centering and fixing of the drive wheels is made as

follows:
• for Vulkollan and solid rubber drive wheels (Item

30
01) over the centering collar of the wheel shaft and

by means of flat collar nuts (Item 02) with spring
washers (Item 03).
• The hole pattern of the rim must be adequately
aligned with the wheel bolts and is then slid on the
drive wheel.
• Fix the drive wheel with flat collar nuts and spring
washers.
• Tightening torque of the nuts: 140 Nm
9 CONNECTION OF THE BRAKE
Hydraulic or mechanical actuation of the brake is possible. For this purpose the connections of the brake
hydraulics and brake cable are provided with the three mounting holes M10x1 in the brake lever.
9.1 CONNECTION OF THE BRAKE HYDRAULICS
Depending on the installation position the bleeder (Item 01 in Figure 10) is to be connected to the upper
tapped hole and the brake line / hydraulic line (Item 02 in Figure 10) to the lower tapped hole.
Tightening torque: 12 up to 16 Nm
„ATTENTION“
Pay attention to the maximum possible bend radii when installing the hydraulic lines to
ensure a quick resetting of the brake lever after braking.
9.2 CONNECTION OF THE BRAKE CABLE
Screw the brake cable (Item 03 in Figure 10) into the tapped hole.
Tightening torque: 50 Nm
„ATTENTION“
The installation dimensions acc. to Section A in Figure 10 have to be checked after mounting
and maintained. Pay attention to the maximum possible bend radii when installing the brake
cable to ensure a quick resetting of the brake lever after braking.
„ATTENTION“
30-04-M227EN
After refilling of the brake fluid bleeding of the brake system is required. (06/09/2013)
30
9.3 BRAKE SYSTEM BLEEDING
When the brake fluid is filled up bleeding of the brake system is required.
Also observe the technical data in Chapter „14.4“
„ATTENTION“
Leaking brake fluid must be collected in a suitable tank. Do not drain any brake fluid into
the sewerage system or into the soil.
• Remove the protection cap (Item 01) from the bleeder

(Item 02) and connect a suitable hose with collecting
tank.
• Pressurize the brake by actuating the brake pedal
and keep this position.
• With an open end wrench loosen the bleeder approx.
half a turn and have the air escape.
• Upon tightening of the bleeder release the brake
pedal.
• This procedure has to be repeated until bubble-free
brake fluid comes out. In the meantime the fluid
level in the compensating tank is to be checked and
refilled if necessary.
• When brake fluid coming out is bubble-free the
bleeder has to be retightened.
Tightening torque: 12 up to 16 Nm
• Remove the hose and put on the protection cap.
(06/09/2013) 30-04-M227EN
10 REPLACEMENT OF THE DISC PACK
„ATTENTION“
When replacing the disc pack in a transmission, the disc pack of the transmission at the
other vehicle side is to be replaced as well!
In case of non-observance there might be a strongly different braking effect between the
left and the right transmission. A longer braking distance is to be expected.
The transmission must be removed from the vehicle. The motor removal is to be made in reverse order like
the installation. (See Chapter 7)
10.1 DISASSEMBLY OF THE DISC PACK
„ATTENTION“
30
In vehicles without regenerative braking (motor brake) the disc pack is to be replaced
every 600 hours! Otherwise a replacement is required every 3000 hours.
• Loosen the two retaining rings (Item 01) by means of snipe

nose pliers and remove them.
• Beat out the cyl. pin (Item 02) and remove the brake lever
(Item 03) with sealing ring from the cover.
• Loosen the 8 screws M6x16 (Item 4) and press off cautiously

the cover (Item 05) from the basic transmission.
„ATTENTION“
Before detaching of the cap screws beat slightly
onto the same to loosen the LOCTITE-connection!
• Remove the housing cover and keep it on a clean place.

„ATTENTION“
At removal of the housing cover the helical gear
(Item 01) will remain connected by screws with
the inner disc carrier (Item 02) as one unit! (see
Figure 13)
• Pull out the disc pack - including 4x outer clutch discs and
3x inner clutch discs as well as the thrust washer - as pack from
the ring gear.
• Outer and inner clutch discs are to be scrapped
• Keep the thrust washer on a clean place.
30-04-M227EN (06/09/2013)

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REPAIR MANUAL

This document has been printed from my e doc

AXLE ASSEMBLY - AXLE

- GENERAL INSTRUCTIONS AND SAFETY

- GENERAL CHARACTERISTICS AND

- GENERAL CONTROL AND ADJUSTMENT

In order to reduce accident risks, make sure to :

– Follow the instructions in the truck operating and maintenance manual.

When you see this symbol:

Before any repair:

1 - Place the machine on a flat surface and chock the wheels.

RULES FOR MAINTENANCE

Be careful not to burn yourself when touching hot liquids or parts

ECU b Remember to disconnect the computers before carrying

Machines operating in a contaminated environment (polluted or

Always wear protective goggles, gloves, safety shoes as well as any

When carrying out maintenance operations near a mobile object,

When changing, or draining oils or fuel, or any other operation with

When lifting or supporting a component of the machine, make

Using a jack, make sure it is used on a flat, uniform surface, is sturdy

Make sure no object or tool which could cause an accident is left

Never check for any leaks with your hands.

MAX Never adjust a component to over the maximum capacity indicated

CHARACTERISTICS, LOADS AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

CHARACTERISTICS, LOADS AND DIMENSIONS

1.1 MANUFACTURER MANITOU

1.3 Propulsion: battery, diesel, petrol, LPG, mains Battery

1.4 Type of operation: manual, pedestrian, standing, seated Seated

2.2 Front axle load laden kg 3993 4155 4305 4893

3.2 Size of front wheels “ or mm 18 x 7 - 8 18 x 7 - 8 18 x 7 - 8 200/50-10

4.12 Height of towing coupling h10 (mm) 473

5.2.1 Rate of lift (unladen) m/s 0,44 0,44 0,43 0,4

8.1 Speed control Electronic

LOCATION OF NAME AND IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

LOCATION OF NAME AND IDENTIFICATION PLATE

1- Jusqu'à hauteur de levée

HANGZHOU MANITOU MACHINERY EQUIPMENT CO.,LTD

398 SHIQIAO ROAD, HANGZHOU, P.R.C.

N° dans la série Année de fabrication

Poids sans la batterie Poids de la batterie mini

Tension nominale Poids de la batterie max

Pression des pneumatiques (Bar)

STANDARD TIGHTENING TORQUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

STANDARD TIGHTENING TORQUES

NF E 25-030-1 Screw / Nut connection :

b For hexagon screws with flanges:

FRONT WHEEL REDUCERS

- AXLE COMPONENTS LOCATION

- AXLE CONTROL AND ADJUSTMENT

DISASSEMBLY AND REASSEMBLY TRANSFERT BOX

This documentation was issued for maintenance specialists.

This manual is based on the technical satuts at printing date.

We reserve us the right to modification without prior notice.

• The proper repair of these products requires adequately trained specialists.

1. DISASSEMBLY OF THE DRIVE UNIT

1.1 REMOVAL OF THE DRIVE UNIT

1.2 REMOVAL OF THE E-MOTOR (SEE FIG. 2)

a) Removal the three hexagon screws (1x M8x50

b) Take off cautiously the E-motor from the

Do not damage the teeth of the motor

1.3 DISASSEMBLY OF THE INPUT PINION (SEE FIG. 3)

a) Hold the input pinion (Pos.2) with a suitable

b) Pull off the input pinion (Pos.2) by means

a) Take off the fitting key (Pos.3) from the

b) Remove cautiously the O-ring (Pos.5) from