Still STED Electric forklift truck Explosion-protected RX20-15 RX20-16 RX20-18 RX20-20 Workshop manu

Explosion-protected

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172391 [EN]

I

II

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Sheet 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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172391 [EN]

Sheet 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 17-21 - Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 01 - Cable routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 02 - Variants

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Sheet 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 22-27 - Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 01 - Cable routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 02 - Electric parking brake, joystick version . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Sheet 03 - Variants

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172391 [EN]

III

a

Working on a truck within potentially explosive areas can lead to explosions in the surrounding atmosphere.

No work may be performed on the truck in potentially explosive areas.

The person carrying out the repair must be "quali ed to work with explosion protection-related components".

Inform the safety of cer about the repair work.

Ask the safety of cer to allocate a safe working area away from the potentially explosive area.

Do not drive the truck out of the potentially explosive area yourself arrange for the truck to be driven away.

Do not perform any work on the truck within potentially explosive areas.

Switching off or manipulating any safety devices Changing the electrical system, including the repair of cables Conversion and retro tting Welding work of any type Modifying the software if this is not speci ed or recommended by the manufacturer If you have any questions regarding this matter, please contact the manufacturer.

Charging and replacing the battery Safety checks Repair work Con guring settings Transportation and loading

172391 [EN]

-1

The truck may be operated only in the potentially explosive areas for which it is approved.

Check the area of application by comparing it with the nameplate information.

If the area of application is not clear, ask a safety of cer.

An explosive atmosphere is a mixture of air and ammable gases, vapours, fumes or dusts, under atmospheric conditions in which the combustion process is transferred to the entire non-combusted mixture after being ignited. Atmospheric conditions refer to ambient temperatures of -20°C to 60°C with a pressure range between 800 hPa and 1100 hPa. An explosion may occur if an explosive atmosphere reaches a certain temperature (ignition temperature), or is ignited by an ignition source.

The aim of explosion protection on a truck is to implement technical measures to prevent the generation of ignition sparks or high temperatures.

This makes it possible to use explosion-protected trucks in certain potentially explosive areas. These areas or zones are designated and indicated within the work spaces.

A person quali ed to work with explosion protection-related components is someone who, thanks to his or her technical training, has a suf cient depth of knowledge regarding explosion-protected industrial trucks.

The quali ed person may only work on the industrial trucks for which he or she has received training.

The quali ed person must have a quali cation certi cate in accordance with EN 60079-17 and must attend training regarding new features no more than two years after rst qualifying.

The person quali ed to carry out explosionprotection testing must have at least one year s experience in manufacturing, assembling or repairing the systems or system components set

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172391 [EN]

out in §1 Para. 2 No.3 of the German Ordinance on Industrial Safety and Health (BetrSichV).

In addition, they must have at least one year s experience in manufacturing or repairing the devices, protection systems or safety, monitoring or control equipment set out in Article 1 of Directive 94/9/EC. The person quali ed to carry out explosionprotection testing must have the necessary speci c knowledge of explosion protection and be familiar with the relevant technical regulations.

They must also regularly refresh their knowledge.

Observe the national regulations for the country of use.

Working on a truck within potentially explosive areas can lead to explosions in the surrounding atmosphere. Repair work is forbidden in potentially explosive areas.

If it is necessary to tow the truck out of a potentially explosive area, the safety of cer must be informed.

Only a towing vehicle that complies with explosion-protection regulations may be used.

Do not perform any work on trucks in potentially explosive areas.

Inform the safety of cer.

Ensure that the towing vehicle is approved for the relevant explosionprotected area.

The truck must be towed by the operating company to the location allocated for this purpose by the safety of cer. This location for carrying out the repair work must be away from potentially explosive areas.

Do not tow the truck yourself truck to be towed.

arrange for the

172391 [EN]

-3

In potentially explosive areas, only use tow bars that are approved for use in potentially explosive areas.

Use an approved tow bar.

If the truck needs to be towed, the speci c notes in the operating instructions of the towing vehicle and of the truck to be towed are binding.

Observe the operating instructions of the truck to be towed and of the towing vehicle.

Once the repair work has been completed, ensure that the required level of explosion protection has been restored.

Trucks to be used in potentially explosive areas are designed for certain explosion groups, categories and temperature ranges. In potentially explosive areas, trucks that do not meet explosion-protection regulations may lead to explosions in the surrounding atmosphere.

Only explosion-protected trucks with electrical systems that correspond to Directives 94/9/EC and 1999/92/EC may be used. The proper condition of the electrical system of trucks used in potentially explosive areas must be monitored by a person quali ed to work with explosion protection-related components and checked whenever deemed necessary as long as this is on a regular basis.

Observe explosion protection regulations.

The scope of the checks is set out in the "Service instruction and spare parts list".

A test log book is to be kept if requested by the responsible authority.

System tests may only be carried out by a person quali ed to work with explosion protection-related components.

Observe the "Special requirements for operating electrical systems in potentially explosive operating areas".

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172391 [EN]

Observe the national regulations for the country in which the truck is being used.

In potentially explosive areas, wheels and tyres that do not meet explosion-protection regulations may lead to explosions in the surrounding atmosphere.

Only approved antistatic tyre types may be used.

Observe explosion protection regulations.

Ensure that antistatic tyres (1) are used.

1

5063_901-033

The category for which the truck is approved is used to determine the appropriate tyre selection.

Note the list of points below.

Category 2 Antistatic tyres are mandatory on all axles.

Category 3 Antistatic tyres are only mandatory on the drive axle.

Only one type of tyre may be tted on each axle, e.g. only superelastic tyres (SE). A mixture of pneumatic and SE tyres on each axle, for example, is prohibited.

Make sure that only one type of tyre is tted on each axle.

Risk of tipping!

Tyre quality affects the stability of the truck.

If you wish to use a different type of tyre on the truck from the tyres approved by the truck manufacturer, or tyres from a different manufacturer, you must rst obtain approval from the truck manufacturer.

172391 [EN]

-5

Risk to stability!

When using pneumatic tyres or solid rubber tyres, rim parts must never be changed and rim parts from different manufacturers must not be mixed.

Changes must only be made following consultation with the manufacturer. When changing wheels or tyres, always ensure that this does not cause the truck to tilt to one side (e.g. always replace right-hand and left-hand wheels at the same time).

If the type of tyre (e.g. SE tyres) is changed to a different type of tyre (e.g. pneumatic tyres) on only one axle, the load diagram must be changed accordingly.

Contact the manufacturer.

The truck may only be operated in the potentially explosive areas for which it is approved!

The truck is not approved for zones 0 and 20!

Check the area of application by comparing it with the nameplate information.

If the area of application is not clear, ask a safety of cial.

Areas with explosive atmospheres are divided into zones. Equipment is divided into equipment groups and equipment categories. The equipment category determines the zones in which the explosion-protected truck may be used.

Potentially explosive areas are divided into six zones. The divisions are based on the probable frequency and duration with which a dangerous explosive atmosphere can occur. A distinction is also made between ammable gases, fumes, vapours (G = gas) and dusts (D = dust).

Potentially explosive areas for ammable gases, vapours and fumes are divided into zones 0, 1 and 2: Description Zone Permanent, long-term or frequent dangerous explosive atmosphere.

0

-6

1

Occasional dangerous explosive atmosphere.

2

Infrequent dangerous explosive atmosphere.

172391 [EN]

Potentially explosive areas for ammable dusts are divided into zones 20, 21 and 22: Description Zone Permanent, long-term or frequent dangerous explosive atmosphere in the form of 20 a ammable dust cloud.

Occasional dangerous explosive atmosphere in the form of a ammable dust 21 cloud. Deposits or layers of combustible dust usually present.

Infrequent dangerous explosive atmosphere in the form of a ammable dust 22 cloud.

Equipment is divided into groups I and II: Group Description I II

Mining equipment (subterranean) endangered by exposure to pit gas/dust.

Equipment in all other areas with gas explosion protection and dust explosion protection outside of mining.

The equipment in group II is divided into equipment categories. The following table only shows the categories to which this explosion protected truck is assigned. The truck requirements depend on the zone in which it is intended and permitted to be operated.

Category Description Zone Occasional dangerous explosive atmospheres in the form of 1 II 2G ammable gases, vapours or fumes.

Occasional dangerous explosive atmosphere in the form of 21 II 2D a ammable dust cloud.

Infrequent dangerous explosive atmospheres in the form of 2 II 3G ammable gases, vapours or fumes.

Infrequent dangerous explosive atmosphere in the form of a 22 II 3D ammable dust cloud.

Zone 1 trucks are also automatically approved for zone 2. Zone 21 trucks are also automatically approved for zone 22. Depending on zone classi cation, the trucks operating and display elements may be enclosed in special housing.

The truck is not approved for zones 0 and 20!

Read the zone for which the truck is approved on the truck nameplate.

The ignition of potentially explosive atmospheres primarily depends on the ignition temperatures of the gases concerned. Certain ammable gases are listed in the following table in order of combustibility and divided into IEC groups.

Propane

Group II A

Ethylene

Group II B

Hydrogen

Group II C

172391 [EN]

Lowest Highest

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In accordance with the ATEX Directive 94/9/EC, the truck is equipped for use in the zone speci ed on the identi cation plate.

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172391 [EN]

If the surface temperatures on the truck exceed the permissible temperature for the surrounding medium, this may lead to explosions in the surrounding atmosphere. The maximum surface temperature must always be lower than the ignition temperature of the surrounding medium.

Only use the truck in areas with a temperature class for which the truck is approved!

In potentially explosive areas, only certain permissible surface temperatures may be reached on the truck, depending on the ignition temperature of the combustible media.

These temperatures are divided into classes T1 to T6, and are indicated along with the markings for the zones.

T1

> 450°C

450°C

T2

> 300°C to 450°C

300°C

T3

> 200°C to 300°C

200°C

T4

> 135°C to 200°C

135°C

T5

> 100°C to 135°C

100°C

T6

> 85°C to 100°C

85°C

.

The truck components are protected in various ways in order to avoid excessively high temperatures and to prevent ignition sparks from forming.

All components in the truck that are used for explosion protection are marked accordingly. The types of explosion protection and the corresponding markings to be used are listed in the following table.

Flameproof enclosure

EEx d

EN 60079-1

Increased safety

EEx e

Intrinsic safety

EEx i

Encapsulated

EEx m

EN 60079-7 EN 60079-11 EN 60079-25 EN 60079-18

172391 [EN]

-9

Energy limited

EEx n

EN 60079-15

Restricted breathing housing

EEx nR

EN 60079-15

.

Combustible gas/air mixtures can penetrate the ameproof enclosure, but an explosion cannot spread to outside the enclosure.

The ameproof enclosure is a steel or aluminium housing that can withstand the pressure of an explosion that occurs inside it. The housing is tted with a cover. The entire joining surface between the cover and the housing must have a speci c gap length (1) and the joining surface must be screwed onto the housing at a precisely de ned width (2). If an explosion occurs in the housing, the explosive pressure can be released to the outside of the enclosure through this gap.

In this case, the housing will not be destroyed.

1 2

6053-Service-018

Improper closing of the pressure-tight housing can cause a detrimental change to this gap.

The gap must be adjusted correctly in order for the explosive pressure to be released to the outside of the enclosure without the ignition temperature or an ignition spark being transferred.

If the gap is too large, the ignition temperature and/or an ignition spark may be transferred to the surrounding atmosphere and cause an explosion.

Only open pressure-tight housings away from potentially explosive areas.

The pressure-tight housing may be opened and closed only by a person quali ed to work with explosion protection-related components.

Never close the gap.

The gap is protected with aluminium-saponi ed grease to prevent corrosion and water ingress.

The gap must always be smooth and undamaged with no grooves. Cables that lead into the housing are equipped with cable inlets. These cable inlets are also enclosed in a ameproof housing and must always be rmly tightened.

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172391 [EN]

This type of protection reduces the risk of excessively high temperatures or sparks being generated in the internal and external parts of the electric components through the use of additional measures.

6053-Service-043

This type of protection is used to ensure that current circuits in which sparks or high temperatures occur under certain conditions cannot ignite a potentially explosive atmosphere. The voltages and currents are limited to such a low level that impermissible temperatures do not occur. If a circuit interruption or short circuit occurs, any sparks generated have so little energy that they are not suf cient to ignite a potentially explosive atmosphere.

R

L

V

C

Intrinsically safe cables and connections are blue and the installed components are marked in blue.

Intrinsically safe cables must not be laid next to conventional (not intrinsically safe) cables. Intrinsically safe cables must be routed separately from normal cables (at a distance of > 4 cm) and must be mechanically protected against damage.

The components with the "Intrinsic safety" type of spark protection protect or monitor the sensor system.

6053-Service-044

The sensor system includes: Transmitters Solenoid valves Temperature sensors

172391 [EN]

-11

Parts that could ignite a potentially explosive atmosphere are enclosed in a casting compound with a suf ciently high resistance to environmental in uences so that a potentially explosive atmosphere cannot be ignited by either sparks or heating.

The protected components are shifting devices and electronic circuits used in the truck electrics or the truck operating devices.

This simpli ed protection type is based on the concept of explosion prevention, in the same way as the intrinsic safety protection type. The difference is that the energy limitation in the current circuit guarantees that required levels of safety are reached during normal operation.

Any possible malfunctions are not taken into consideration.

000_Vergusskapselung (EEx m)

The restricted breathing housing protection type can be used in the following circumstances: For spark-producing components within housings that produce temperatures that exceed the external ambient temperature by no more than 10 K (Kelvin) The internal temperature may exceed the ambient temperature by up to 20 K if the drop in temperature when the device is turned off does not exceed 10 K/h For components that are installed inside housings and that do not produce sparks when the external surface temperature is restricted

Traction motor Pump motor Electronic controls Battery male connector Headlights and lamps Battery Battery connection box Terminal strips Solenoid valve connection box

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172391 [EN]

Zener barriers Intrinsically safe PCB Insulation-monitoring PCB Key switch Emergency off switch Reset button Sensor for hydraulic oil temperature Sensor for traction motor temperature Sensor for pump motor temperature Curve switch (for steering turntable and swing axle version) Switch for parking brake Switch for forward/reverse drive direction Buckle switch Seat switch Stop switch Windscreen wiper (variant) Heating system (variant)

Additional explosion-protection measures consist of tting components that cannot produce sparks or electrostatic charges thanks to their design or the materials used.

The following components are equipped with additional explosion-protection measures: Fork arms (coated) Driver s seat (antistatic cover) Tyres (antistatic) Antistatic belt with leak resistance (for nonmarking, light-coloured tires) Corona electrode with leak resistance Plastic parts (antistatic paint) Cable inlets (pressure-resistant) Floor covering (e.g. textured aluminium sheet) Floor mat (antistatic)

172391 [EN]

-13

1

2

3

The truck can be identi ed from the information on the nameplate.

When ordering spare parts or requesting plans, it is necessary to specify the job number (10).

The job number begins with a letter (E = electric forklift truck; D = diesel truck) followed by a sequential number. Specifying the job number enables the spare parts and plans to be selected reliably.

20 19

4

18

6

17

7 8

5

16 9

15 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

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13

12 11 10

6036_003-021_V3

Type Production number Year of manufacture Empty weight in kg Max. permissible battery weight in kg (for electric forklift trucks only) Min. permissible battery weight in kg (for electric forklift trucks only) Ballast weight in kg (for electric forklift trucks only) Address of manufacturer ATEX number Miretti job number Permissible surface temperature Permissible temperature class Explosion group Equipment category Explosion-protection symbol For more detailed information, refer to the "technical data in the operating instructions" CE mark Nominal drive power in kW Battery voltage in V Rated capacity in kg

172391 [EN]

a

During operation, the temperature, state of wear and insulation values of various components are monitored by sensors. If dangerous limits are detected, the truck controller automatically shuts down.

This automatic emergency shutdown indicates a serious malfunction. The safety of cer must be informed immediately. Only the safety of cer may decide whether the truck must be removed from the potentially explosive area. The cause of the automatic emergency shutdown must be determined and remedied.

Do not operate the truck if the warning light is illuminated.

Inform the safety of cer.

4 1 2

4

"Pump motor temperature"

2

1 6200_003-092

3

1

3

Warning light for "pump motor temperature" Warning light for "temperature of left-hand traction motor" Warning light for "temperature of right-hand traction motor" Warning light for "insulation monitoring"

The temperature of the pump motor is above the permissible value.

2

"Temperature of left-hand traction motor" The temperature of the left-hand traction motor is above the permissible value.

3

"Temperature of right-hand traction motor" The temperature of the right-hand traction motor is above the permissible value.

4

"Insulation monitoring" A short circuit to earth occurs.

172391 [EN]

-1

The driver s seat is equipped with a special antistatic textile cover that prevents electrostatic charge.

Do not use any additional seat padding such as blankets, cushions or furs.

Inside the cover is a network of ne copper wires that is conductively connected to the seat frame and the earth of the truck.

If holes or rips with a total size of more than 100 cm 2 (for category 2G equipment) are found in the cover, the corresponding part of the driver s seat must be replaced.

2045Wa-005

Contact your manufacturer for advice on this matter.

For category 2D equipment, the damaged surface must not exceed 400 cm2. For category 3G or 3D equipment, the seat must not be equipped with an antistatic cover.

If the entire driver s seat is to be replaced, the use of an explosion-protected driver s seat from the same manufacturer is strongly recommended.

The surface resistance must be less than or equal to 1 G (109 ) at a test voltage of 500 V.

Paint layers with a total damaged area of > 100 cm2 must be repaired immediately.

Otherwise, static discharge may occur, resulting in explosions in the surrounding atmosphere in potentially explosive areas.

For the repair, only antistatic paint with the same speci cation is permitted.

Only use antistatic paint of the same speci cation.

-2

172391 [EN]

Check the paint layer of the plastic parts (see the arrows) for damage and abrasion.

The plastic parts of the truck, e.g. consoles, steering column panelling, paper trays and trays, are coated with a special antistatic paint. This paint prevents the build-up of an electrostatic charge in plastic components.

3 1

8 6

75 % 9

2

2 234,7 h

7 5

0

12: 15

Damage to the paintwork must not exceed a total surface area of 100 cm2 (category 2G equipment) The surface resistance must be less than or equal to 1 G (109 ) at a test voltage of 500 V For the repair, it is absolutely essential that antistatic paint with the same speci cation from the same manufacturer is used Antistatic paint is supplied with the truck for touch-up purposes.

6200_901-056

For category 2D equipment, the damaged surface must not exceed 400 cm2. For category 3G or 3D equipment, plastic parts must not be coated with antistatic paint.

172391 [EN]

-3

-4

172391 [EN]

a

In potentially explosive areas, wheels and tyres that do not meet explosion-protection regulations may lead to explosions in the surrounding atmosphere!

Only use permitted tyre types.

6036_901-001_V3

Antistatic tyres are special tyres made from a rubber mix with low leak resistance.

The tyres feature an "antistatic"(1) marking.

These tyres are characterised by an especially high proportion of electrically conductive graphite and it is for this reason that they are speci cally selected and offered as antistatic tyres.

If "non-marking" tyres (non-marking, lightcoloured) are used, an antistatic belt with leak resistance must be attached beneath the truck and conductively connected to the earth of the truck, with the other end of the belt trailing along the ground.

Alternatively, a corona electrode with leak resistance must be tted.

The leak resistance ensures that high voltages are not discharged too quickly, thus reducing the energy that could generate arcs. Furthermore, it protects the electrical system from voltage surges.

1

5063_901-033

Check that the antistatic belt is in contact with the ground in all driving conditions.

"Non-marking" tyres are usually marked with a safety notice: "Safety warning: Tyres are not electrically conductive. Risk of re and explosion with electrostatic charging. The truck must therefore be earthed."

If the safety notice is missing, this is no guarantee of good discharge capacity.

172391 [EN]

-1

Observe explosion-protection regulations.

Ensure that permissible tyres are used.

Check the presence and condition of the antistatic belt/corona electrode.

If in doubt, speak to the safety of cer.

The tyres must not be dirty. The tread in particular must be kept free from adhesive dirt (greases, oils).

Always remove dirt from the tyres.

The maximum surface resistance must not exceed 1 G (10 9 ).

Set out an insulation plate (4) with a resistance of more than 1012 that matches the size of the truck.

Lay the conductive metal test plate (3) on the insulation plate. There must be a distance of at least 50 mm between the edges of the test plate and the edges of the insulation plate.

3

Drive the truck onto the test plate.

Remove any rust, grease, paint or other disruptive material from the measuring points on all metal parts of the truck and those on the conductive tyres.

4 6200_901-002

Measure the leak resistance using a test voltage of 500 V DC at a resistance less than or equal to 1 k (103 ).

3 4

Electrically conductive metal test plate Insulation plate

Apply the test voltage between the test plate and the measuring points on the truck (e.g. headlight brackets, mounting for the seat console, wheel nuts).

Carry out the measurements at a relative humidity of no more than 60%.

Take a measurement on all tyres.

Maximum leak resistance: 1 M (106 ).

-2

172391 [EN]

A

The leak resistance on each tyre can be measured separately.

Move or lower the corresponding wheel onto a sheet metal plate (B).

Measure the leak resistance between an untreated metal wheel nut (A) and the sheet metal plate (B).

The resistance must be measured at a voltage of 500 V and the result must be less than or equal to 1 M (106 ).

All wheels must be electrically conductive for CAT 2.

Only drive wheels must be electrically conductive for CAT 3.

172391 [EN]

B

5063_901-034

-3

-4

172391 [EN]

a

Working on a truck within potentially explosive areas can lead to explosions in the surrounding atmosphere.

Repair work is not permitted in potentially explosive areas.

Do not perform any work on trucks in potentially explosive areas.

The following work may only be carried out by a person quali ed to work with explosion protection-related components.

The diagnostic connector is located in a housing (1) under the panelling behind the driver s seat.

1

Switch off the key switch.

Actuate the emergency off switch.

Fold up the panelling behind the driver s seat.

Remove the cover (1) from the housing.

6200_901-003

172391 [EN]

-1

Connect the diagnostic device to the diagnostic connector (2).

Depending on the date of manufacture of the truck, it is possible that the diagnostic connector is not connected. This depends on the approval directive that was valid at the time and does not constitute a fault.

In this case, connect the diagnostic connector to the cables in the same way as for the series-production truck After the diagnostics procedure, disconnect the cables from the diagnostic connector and place the cables back in the housing as you found them

2

6200_901-004

When the key switch is switched on, it is possible that the truck may be moved unintentionally.

If any work is carried out on the truck when the key switch is switched on, the following instruction must be observed: Observe the safety regulations for maintenance.

Jack up the truck.

The remaining steps for diagnostics and parameterising of the settings are the same as those for the series-production truck.

Observe the information in the workshop manual for the series-production truck.

Risk of component damage!

When disassembling the panelling and when opening and closing the housing, the antistatic paint can be damaged.

Maintain the integrity of the antistatic paint and touch up any damage to the paint.

After the diagnostics procedure, close the housing again and reassemble the panelling.

The truck is only approved for the application speci ed on the nameplate when the truck is fully assembled.

-2

172391 [EN]

a

1

2

Working on a truck within potentially explosive areas can lead to explosions in the surrounding atmosphere. Repair work is not permitted in potentially explosive areas.

Do not perform any work on trucks in potentially explosive areas.

The following work may only be carried out by a person quali ed to work with explosion protection-related components.

1

2

5060_901-003

Risk of accident!

The battery male connectors are only protected against disconnection when the screws (1) are tightened.

Otherwise, the battery male connectors may work loose during operation. If this happens, the power supply of the truck is interrupted and it is no longer possible to operate the truck.

Always re-tighten the screws.

Do not operate the truck without these screws.

The battery male connectors are non-interchangeable.

The "plus" battery male connector is routed through two grooves.

The "negative" battery male connector is routed through one groove.

172391 [EN]

-1

1

Loosen the screws (1).

2

Unscrew the battery male connector along the grooves (2) and disconnect it.

Re-tighten the screws, to prevent them being lost.

Store the battery male connector securely to prevent it from being dropped and crushed.

Loosen the screws (1).

Screw in the battery male connector along the grooves (2) and connecting it.

1

Tighten the screws to secure the battery male connector in place.

2

1

The pressure-resistant housings are marked as such with a label. The data on the label corresponds to the approved area of application for the pressure-resistant housings. The label must be positioned so that it is always easy to read. Only the manufacturer is allowed to re-label the pressure-resistant housings.

5060_901-003

2

6 3

5

A note is printed on the label: "To avoid the ignition of combustible gases or vapours, do not remove the cover when the circuits are active or in potentially explosive areas."

4

5060_901-020

1 2 3 4 5 6

-2

Serial number CE mark Year of manufacture Approved area of application Inspection number Manufacturer

172391 [EN]

Improper opening and closing of the pressure-tight housings can cause a detrimental change to the gap.

The gap must be adjusted correctly in order for the explosive pressure to be released to the outside of the enclosure without the ignition temperature or an ignition spark being transferred.

If the gap is too large, the ignition temperature and/or an ignition spark may be transferred to the surrounding atmosphere and cause an explosion.

Only open and close the pressuretight housings away from potentially explosive areas.

The pressure-tight housings may be opened and closed only by a person quali ed to work with explosion protection-related components.

Do not use rust remover.

Loosen all mounting screws crosswise from the outside towards the middle and only then unscrew these mounting screws.

Make sure that none of the screws fall inside the truck.

Carefully fold up or set aside the cover.

Check the integrity of the threads of the pressure-tight housing and of the screws.

172391 [EN]

-3

In order to prevent corrosion damage, insert desiccant into the housing of the electronic control unit.

Check the contact surfaces of the housing (2) and the cover (1) for damage or score marks.

2

1

Check the thread of the pressure-tight housing.

If the pressure-tight housing is damaged, it must be replaced in its entirety.

6200_901-005

Repair work of any form on the pressuretight housing is not permitted.

If damage is detected in the form of unevenness of the ange, score marks or damaged threads, replace the pressure-tight housing in its entirety.

Do not perform any machining work such as shape grinding or threading.

As a basic principle, do not perform any welding work.

To clean the contact surfaces, use only ne, stainless-steel wool with a low proportion of ferrite.

Blow out the pressure-tight housing with oil-free, dry air at a low pressure.

Make sure that there is no dirt in the housing or on the contact surfaces.

Coat the contact surfaces with aluminiumsaponi ed grease.

Close the cover carefully and accurately.

Replace worn screws with new screws of the same standard, the same class and the same material.

-4

172391 [EN]

Screw all the screws (3) into the cover.

3

Uneven gap when the housing cover is distorted!

If the screws are not tightened crosswise from the middle outwards, this will lead to distortion of the housing cover and the gap will be uneven.

Ensure that all screws are screwed in.

Always tighten the screws crosswise from the middle outwards.

Apply the correct tightening torque.

6036_901-005

Tighten the screws crosswise from the middle outwards to the tightening torques speci ed in the table below.

6200_901-048

From

Up to

2.5 5

10

M5 M6

5

M8

10

20

M10

20

40

Check the gap between the cover and the housing.

The gap must be < 0.05 mm. It must not be possible to insert a 0.05-mm feeler gauge at any point around the circumference.

If necessary, check the tightening torque of the screws or replace the pressure-tight housing.

172391 [EN]

-5

The pressure-tight housings contain the components for the electronic control unit of the standard truck, as well as the explosion-protection-speci c components.

The housings themselves contain the STILL components and the housing covers contain the Miretti components.

Intrinsically safe connections, wires and cable ducts are marked in blue. There is no connection between intrinsically safe and non-intrinsically safe cable ducts. Under no circumstances may the markings be swapped or removed.

Failure to observe the following points will invalidate the truck s approval for use in potentially explosive areas.

For the control unit component in the pressure-tight housing, the following instructions must be observed: PCBs and components must be replaced and not repaired.

Do not take components from one truck and install them in another.

No soldering is permitted. The components are connected to each other by plug connections or screw connections.

Faulty cables must be replaced completely and not repaired.

In order to prevent corrosion damage, insert desiccant into the housing of the electronic control unit.

Replace desiccant at regular intervals.

-6

172391 [EN]

2

1

3

4

6200_901-058

6 1 2 3

5

Main fuse for pump motor Pump motor converter 2U03 Interface card

4 5 6

CAN-Power-Port (CPP) Supply unit (SU) Truck control unit (MCU)

A bag with desiccant must be available.

172391 [EN]

-7

1

7 1 2 3

2

6

Zener barriers SMZ5 Zener barriers SMZ2 Intrinsically safe PCB SSI1 Intrinsically safe PCB SSI2 (underneath)

-8

3

5 4 5 6 7

4 SD insulation monitoring PCB Intrinsically safe PCB SSI6 Zener barriers SMZ1 (underneath) Zener barriers SMZ3

172391 [EN]

6200_901-057

2

1

6200_901-060

1

Converter for right-hand traction motor, 1U06

2

Converter for left-hand traction motor, 1U07

A bag with desiccant must be available.

172391 [EN]

-9

1

3

2

6200_901-059

1 2 3

Housing temperature probe U1 Housing temperature probe U2 Zener barriers SMZ6

-10

172391 [EN]

1 8

7 2

6

3

5 1 2 3 4

4

Terminal strip J1, inputs Red LEDs Relays Terminal strip J2, outputs

6036_901-009

5 6 7 8

Terminal strip J3, power supply connection Yellow LED, 24-V power supply, PCB Green LED, 12-V power supply, relays Yellow LED, 5-V power supply, electronics

When the key switch is switched on, it is possible that the truck may be moved unintentionally.

If any work is carried out on the truck when the key switch is switched on, the following instruction must be observed: Observe the safety regulations for maintenance.

Jack up the truck.

172391 [EN]

-11

It is possible for intrinsic safety PCBs to be tted with different numbers of signal paths.

1 8

The intrinsic safety PCBs are often screwed into the cover in a double layer. Markings on the PCBs allow them to be assigned to the circuit diagrams.

These PCBs are known as contact repetition PCBs, meaning the signals from the intrinsically safe input are galvanically isolated from the nonintrinsically safe output. The control signals are connected to terminal strip J1 (1). The relays (3) ensure that the signals are galvanically isolated from the non-intrinsically safe area and transmit these at terminal strip J2 (4). When a signal is sent to one of the channels R1 R8, the assigned LED (2) must illuminate. The PCB s power supply is connected to terminal strip J3 (5) and can be checked using the 24-V (6), 12-V (7) and 5-V (8) LEDs.

7 2 3

6

5

6321_900-035

The yellow LED (6) must be illuminated for the 24-V power supply for the PCB. The green LED (7) must be illuminated for the 12-V power supply for the relays.

The yellow LED (8) must be illuminated for the 5-V power supply for the electronics.

If any of the LEDs is not illuminated, there is a problem with the corresponding power supply.

Replace the PCB.

Disconnect the wires from terminal strips J1 (1) and J2 (4).

The wires at terminal J3 (5) must remain connected.

To test the relay contacts, the relevant inputs must be short-circuited to terminal strip J1 (1).

-12

4

172391 [EN]

At terminal strip J2 (4), the closing of the relay contacts can be checked with an ohmmeter.

J1-10 to J1-1

Relay contacts to check J2-1 and J2-3

J1-10 to J1-2

J2-4 and J2-6

J1-10 to J1-3

J2-7 and J2-9

J1-10 to J1-4

J2-10 and J2-12

J1-10 to J1-5

J2-13 and J2-15

J1-10 to J1-6

J2-16 and J2-18

J1-10 to J1-7

J2-19 and J2-21

J1-10 to J1-8

J2-22 and J2-24

Short-circuiting input

The associated red LEDs (2) on the relays (3) must illuminate.

If one of the functions cannot be successfully tested, replace the entire PCB.

The truck is equipped with a monitoring device that switches off the power supply to the truck when an insulation fault (short circuit to earth) is detected.

172391 [EN]

-13

At the same time, the "insulation warning"(1) light illuminates.

The power supply is switched off in the following cases: Cables not correctly insulated Electromechanical components poorly insulated Condensation in the electronic control unit Electronics poorly insulated

1 If the truck controller automatically shuts down, this indicates that a serious malfunction has occurred.

6200_901-055

The safety of cer must be informed immediately. Only the safety of cer may decide whether the truck must be removed from the potentially explosive area.

The cause of the automatic emergency shutdown must then be determined and recti ed.

The equipment described below may only be operated once approved by the safety of cer.

Do not operate the truck if the warning light is illuminated.

Inform the safety of cer.

The emergency shutdown can be bridged to allow the truck to be driven out of the potentially explosive area.

In potentially explosive areas, authorised service personnel are not permitted to move the truck.

Arrange for the truck to be removed from the potentially explosive area.

The operator is able to bridge the emergency shutdown as follows:

-14

172391 [EN]

Simultaneously press the reset button (1) and actuate the accelerator pedal.

1

The truck will move in the preselected drive direction.

Arrange for the truck to be removed from the potentially explosive area and into a workplace authorised by the safety of cer.

Check the SD insulation monitoring PCB. See the corresponding section for more information.

6200_003-088

2

2

The insulation monitoring PCB monitors the insulation resistance of the electrical components to earth.

6

5

4

3

2

1

1

If the insulation resistance falls below 500 , the PCB switches off the power supply to the truck.

6036_901-011

1 2

172391 [EN]

Terminal strip Test resistance

-15

At the same time, the "insulation warning"(1) light illuminates.

For information on the procedure and countermeasures to be adopted in the event of emergency shutdown of the truck, refer to the section entitled "Insulation protection and emergency shutdown".

1

Working on a truck within potentially explosive areas can lead to explosions in the surrounding atmosphere. Repair work is not permitted in potentially explosive areas.

6200_901-055

Do not perform any work on trucks in potentially explosive areas.

The following work may only be carried out by a person quali ed to work with explosion protection-related components.

When the key switch is switched on, it is possible that the truck may be moved unintentionally.

If any work is carried out on the truck when the key switch is switched on, the following instruction must be observed: Observe the safety regulations for maintenance.

Jack up the truck.

Open the housing cover of the electronic control unit.

Unlock the emergency off switch.

Turn the key switch to position .

Terminal 5 must always be connected to the earth of the housing.

-16

172391 [EN]

Maintain a test resistance of < 500 (2) (recommendation: 390 ) between terminal 6 and terminal 5.

The electronics must switch off and the "insulation warning" light must illuminate.

2

2 6

5

4

3

2

1

1

If the "insulation warning" light does not illuminate, there is a fault in the monitoring circuit.

The truck must immediately be taken out of service and must not be operated in a potentially explosive area until it has been properly repaired.

Shut down the truck immediately.

Do not recommission the truck until it has been repaired.

If the electronics do not switch off, replace the PCB. Remove the test resistance and switch the truck on again.

Maintain a test resistance of < 500 (2) (recommendation: 390 ) between terminal 4 and terminal 5.

6036_901-011

The electronics must switch off and the "insulation warning" light must illuminate.

If the electronics do not switch off, replace the PCB.

172391 [EN]

-17

Maintain a test resistance of > 500 (2) (recommendation: 560 ) between terminal 6 and terminal 5.

The electronics must not switch off and the "insulation warning" light must not illuminate.

2

2 6

5

4

3

2

1

1

If the "insulation warning" light does illuminate, there is a fault in the monitoring circuit.

The truck must immediately be taken out of service and must not be operated in a potentially explosive area until it has been properly repaired.

Shut down the truck immediately.

Do not recommission the truck until it has been repaired.

If the electronics switch off, replace the PCB. Remove the test resistance and switch the truck on again.

Maintain a test resistance of > 500 (2) (recommendation: 560 ) between terminal 4 and terminal 5.

6036_901-011

The electronics must not switch off and the "insulation warning" light must not illuminate.

If the electronics switch off, replace the PCB. After nishing the work, lock the housing cover of the electronic control unit so that the housing cover is pressure tight.

3

Working on a truck within potentially explosive areas can lead to explosions in the surrounding atmosphere. Repair work is not permitted in potentially explosive areas.

Do not perform any work on trucks in potentially explosive areas.

The following work may only be carried out by a person quali ed to work with explosion protection-related components.

6200_901-007_V2

-18

172391 [EN]

3

Zener barriers in the pressure-tight housing on the counterweight

3

6200_901-008_V2

3

Zener barriers in the pressure-tight housing in the battery compartment

4

PCBs with various numbers of zener barriers can be tted.

12 11 10

9

8

7

Terminal rail J2 (1)

B1

B2

B3

250 mA fuse (2)

6+

18+

28+

F1

F2

F3

Zener barriers B1 B3 (3)

J1

3

Terminal rail J1 (4) The zener barriers (3) limit voltage and current intensity, and thus prevent high-energy currents from reaching the potentially explosive areas.

The inputs are connected to terminal strip J1 (4) and the outputs are connected to terminal strip J2 (1).

The fuses (2) protect the power supply to and signal monitoring of the barriers.

2 1

2

3

1

4

5

6

J2

6036_901-010

Test the conductivity of the fuses (2); replace any faulty fuses with fuses of the same type with the same nominal current.

Disconnect the wires to terminal rails J1 (4) and J2 (1).

Using an ohmmeter (with range up to approx.

2000 ), test between the neighbouring terminals to check that the barrier (3) is working properly.

172391 [EN]

-19

The result must match the resistance (+/- 5%) printed on the corresponding barrier.

Refer to the table below.

6+

33

18+

184

28+

273

J2-1 and J1-11 J2-3 and J1-9 J2-5 and J1-7 J2-1 and J1-23 J2-3 and J1-21 J2-5 and J1-19 J2-7 and J1-17 J2-9 and J1-15 J2-11 and J1-13 If the resistance is not within the speci ed range or is in nite, replace the PCB. Connect the wires to J1 and J2.

Close the pressure-tight housings.

Perform a functional check of the truck.

-20

172391 [EN]

2

1

2

Working on a truck within potentially explosive areas can lead to explosions in the surrounding atmosphere. Repair work is not permitted in potentially explosive areas.

Repairs on electric motors may be carried out only by personnel who have undergone special training for this purpose and who have been awarded the corresponding quali cation.

Do not perform any work on trucks in potentially explosive areas.

The following work may only be carried out by a person quali ed to work with explosion protection-related components.

6200_901-010

Restrict motor-related repair work on the truck to removing the motors.

Send the motors to the manufacturer to be repaired.

For the following tasks, also observe the instructions in the workshop manual for the series-production truck.

To remove the traction motors (2), open the pressure-tight housings.

Loosen all the cable connections and disconnect all transmitters from the motor.

Then remove the entire motor from the truck.

The motor can be ordered by specifying the "Miretti" job number.

To remove the pump motor (1), open the pressure-tight housing.

Loosen all the cable connections and disconnect all transmitters from the motor.

Then remove the entire motor from the truck.

The motor can be ordered by specifying the "Miretti" job number.

Install the motor.

172391 [EN]

-21

Connect all cable connections and all transmitters.

Close the pressure-tight housing again.

Working on a truck within potentially explosive areas can lead to explosions in the surrounding atmosphere.

Repair work is not permitted in potentially explosive areas.

Do not perform any work on trucks in potentially explosive areas.

The following work may only be carried out by a person quali ed to work with explosion protectionrelated components.

The information required to repair cables and inlets can be found in the chapter entitled "Special equipment/accessories".

Cables must be replaced only with cables of the same type and the same length. Repair work on cables is not permitted.

Replace cables; do not repair cables.

Use cables of the same type and length in accordance with the "spare parts list".

Screw the cable inlet (4) into the housing/component.

Cut the cable (7) to the required length.

1

3

2

Push the nut (1) and the thrust collar (2) over the cable.

4

Prepare the screening (6) of the cable as shown Push the conical ring (3) and the rubber ring (5) over the cable.

Insert the cable with the rubber ring into the cable inlet.

Connect all the parts as shown and screw the nut (1) onto the cable inlet (4).

7

Check that the cable is securely connected.

-22

6

5 6036_901-007

172391 [EN]

1 Working on a truck within potentially explosive areas can lead to explosions in the surrounding atmosphere. Repair work is not permitted in potentially explosive areas.

5

Do not perform any work on trucks in potentially explosive areas.

4

The following work may only be carried out by a person quali ed to work with explosion protection-related components.

2

3 If a light has a different power output from the power output indicated on the light s identi cation plate, the surface temperature may increase.

This can cause explosions in the surrounding atmosphere.

Only use lights with a power output that corresponds to the power output on the light s identi cation plate.

Risk of component damage!

5060_901-002

1 2 3 4 5

Dome Light PCB with interrupter unit All-round contact surface Screw

Tools can damage the surface and t of the components.

Do not use tools to unscrew the dome.

Loosen the screw (5).

Unscrew the dome (1) in an anticlockwise direction and place the dome in a safe location.

Remove and replace the light (2).

Apply a light protective layer of aluminiumsaponi ed grease to the contact surface of the dome (4).

Screw on the dome again and tighten the screw (5).

172391 [EN]

-23

1 Working on a truck within potentially explosive areas can lead to explosions in the surrounding atmosphere. Repair work is not permitted in potentially explosive areas.

5

Do not perform any work on trucks in potentially explosive areas.

4

The following work may only be carried out by a person quali ed to work with explosion protection-related components.

2

Loosen the screw (5) that prevents the ange from rotating.

3

Unscrew the dome (1).

Release the 3 screws securing the circuit board (3).

Disconnect the connecting cables.

Change the circuit board.

Reconnect the connection cable.

Secure the circuit board with 3 screws.

Apply a light protective layer of aluminiumsaponi ed grease to the contact surface of the dome (4).

5060_901-002

1 2 3 4 5

Dome Light PCB with interrupter unit All-round contact surface Screw

Screw on the dome again and tighten the screw (5).

Working on a truck within potentially explosive areas can lead to explosions in the surrounding atmosphere. Repair work is not permitted in potentially explosive areas.

Do not perform any work on trucks in potentially explosive areas.

The following work may only be carried out by a person quali ed to work with explosion protection-related components.

-24

172391 [EN]

If a light has a different power output from the power output indicated on the light s identi cation plate, the surface temperature may increase.

This can cause explosions in the surrounding atmosphere.

Only use lights with a power output that corresponds to the power output on the light s identi cation plate.

Risk of component damage!

Tools can damage the surface and t of the components.

Do not use tools to unscrew the ange.

Loosen the screw (1) and unscrew the ange (6) with the O-ring (2).

1 2 3

Carefully remove the locking ring (3).

Remove the parabolic mirror (4).

Remove the light (5) from the tting (9) and replace it with a light of the same speci cation.

4

Insert the parabolic mirror (4).

5

Insert the locking ring (3).

Ensure that the O-ring (2) is correctly seated.

Apply a light protective layer of aluminiumsaponi ed grease to the contact surface of the ange (7).

Screw on the ange (6) again with the O-ring (2).

9

8 7

6

5063_901-028

Reinsert and tighten the screw (1).

Also refer to the section entitled "Closing the pressure-tight housing".

172391 [EN]

-25

Working on a truck within potentially explosive areas can lead to explosions in the surrounding atmosphere. Repair work is not permitted in potentially explosive areas.

Do not perform any work on trucks in potentially explosive areas.

The following work may only be carried out by a person quali ed to work with explosion protection-related components.

If a light has a different power output from the power output indicated on the light s identi cation plate, the surface temperature may increase.

This can cause explosions in the surrounding atmosphere.

Only use lights with a power output that corresponds to the power output on the light s identi cation plate.

Risk of component damage!

Tools can damage the surface and t of the components.

Do not use tools to unscrew the ange.

Loosen the screw (1) and unscrew the ange (6) with the O-ring (2).

1 2 3

Carefully remove the locking ring (3).

Remove the diffusing lens (5).

Remove the light (4) and replace it with a light of the same speci cation.

Insert the diffusing lens (5).

4

Insert the locking ring (3).

Ensure that the O-ring (2) is correctly seated.

5

Apply a light protective layer of aluminiumsaponi ed grease to the contact surface of the ange (7).

7

Screw on the ange (6) again with the O-ring (2).

5063_901-029

Reinsert and tighten the screw (1).

-26

6

172391 [EN]

Also refer to the section entitled "Closing the pressure-tight housing".

Working on a truck within potentially explosive areas can lead to explosions in the surrounding atmosphere. Repair work is not permitted in potentially explosive areas.

Do not perform any work on trucks in potentially explosive areas.

The following work may only be carried out by a person quali ed to deal with the risk of explosion.

If a lamp has a different power output from the power output indicated on the light s identi cation plate, the surface temperature may increase.

This can cause explosions in the surrounding atmosphere.

Only use lamps with a power output that corresponds to the power output on the light s identi cation plate.

Risk of component damage!

Tools can damage the surface and t of the components.

Do not use tools to unscrew the cover part.

172391 [EN]

-27

Release four screws (2) and remove the cover part (1) with O-ring (3).

1

Remove the lamp (7) from the socket (4) and replace it with a lamp of the same speci cation.

Ensure that the O-ring (3) is correctly seated.

Apply a light protective layer of aluminiumsaponi ed grease to the contact surface of the ange (8).

Place the cover part (1) in position and seal it by tightening the four screws (2).

2 3

8 7

4 5

Release four screws (2) and remove the cover part (1) with O-ring (3).

Unscrew the screw (5).

Loosen the connecting cable for the socket (4).

Remove and replace the socket (4) with the support (6).

Connect the connecting cable for the lamp socket and fasten the lamp socket to the body of the lamp with the screw.

6

Ensure that the O-ring (3) is correctly seated.

Apply a light protective layer of aluminiumsaponi ed grease to the contact surface of the ange (8).

5063_901-030

Place the cover part (1) in position and seal it by tightening the four screws (2).

-28

172391 [EN]

5

4 3

Working on a truck within potentially explosive areas can lead to explosions in the surrounding atmosphere. Repair work is forbidden in potentially explosive areas.

Do not perform any work on trucks in potentially explosive areas.

The following work may only be carried out by a person quali ed to work with explosion protection-related components.

1

2

6036_901-016

If a light has a different power output from the power output indicated on the light s identi cation plate, the surface temperature may increase.

This can cause explosions in the surrounding atmosphere.

Only use lights with a power output that corresponds to the power output on the light s identi cation plate.

Risk of component damage!

Tools can damage the surface and t of the components.

Do not use tools to unscrew the cover part.

Release the six screws (1) used to secure the ange.

Remove the ange/washer (5) without the use of tools.

Remove the light (3) and replace it with a light of the same speci cation.

Apply a light protective layer of aluminiumsaponi ed grease to the contact surface (4) on the body of the light (2).

Secure the ange on the body of the light and seal it by tightening the six screws (1).

172391 [EN]

-29

Working on a truck within potentially explosive areas can lead to explosions in the surrounding atmosphere. Repair work is not permitted in potentially explosive areas.

Do not perform any work on trucks in potentially explosive areas.

The following work may only be carried out by a person quali ed to work with explosion protection-related components.

When the key switch is switched on, it is possible that the truck may be moved unintentionally.

If any work is carried out on the truck when the key switch is switched on, the following instruction must be observed: Observe the safety regulations for maintenance.

Jack up the truck.

Fuses and various electrical components are located in the pressure-tight housing for the electronic control unit on the counterweight.

The location of the pressure-tight housing may differ in zone 1 and zone 2 trucks. In some trucks, the pressure-tight housing may be tted on the rear weight and/or in the battery compartment! If in doubt, please contact the manufacturer.

3

Open the housing cover of the electronic control unit (4) by loosening all screws (3).

4

The use of incorrect fuses can lead to short circuits, which can cause res and result in an explosion in the surrounding atmosphere.

6200_901-006

Use only fuses with the same specication and prescribed nominal current.

Locate faulty fuses or faulty electrical components using the electronic circuit diagrams.

Replace faulty fuses or faulty electrical components.

-30

172391 [EN]

Perform a functional check of the corresponding components.

After nishing the work, lock the housing cover of the electronic control unit so that the housing cover is pressure tight.

172391 [EN]

-31

-32

172391 [EN]

a

1

2

The fork arms (2) are coated and welded with non-sparking steel (1). The fork arms rarely feature copper or brass.

This coating must not wear through!

Check the entire circumference to make sure that the coating (3) has not worn through.

If the coating has worn through, do not operate the truck in explosionprotected areas.

3

Inform the safety of cer.

6036_901-022

Top Side Bottom

2 mm 4 mm

Full wear of the coating can be recognised from a difference in the colour and structure of the different materials.

Carefully check the coating on the top (3), bottom and side (5) for damage and wear.

If necessary, contact the safety of cer.

5

3

5 6036_901-024

172391 [EN]

-1

The area around the fork arm bend (4) is not coated to enable inspection for crack formation.

Risk of component damage!

The fork arm bend is checked for crack formation by means of a "dye penetration test".

The application of paint produces an incorrect result, and cracks therefore cannot be detected.

Do not repaint the area (4).

4 Damaged or worn coatings may be only repaired by the manufacturer or by a specialist welder.

6036_901-023

All straightening work (hot/cold) on deformed fork arms is forbidden.

Inform the safety of cer.

Hand over the fork arms to the manufacturer or to a specialist welder for repair.

In this case, we recommend handing over both fork arms to the manufacturer or to a specialist welder for repair because the level of wear is generally the same on the second fork arm.

It may be necessary for the specialist welder to ask for the exact material designation and for a welding procedure speci cation. The material used can be requested by specifying the Miretti job number.

-2

172391 [EN]

a

2 1

6036_901-031

1

-

1

2

R047011122

1

Original fork Coating for anti-spark protection; Material will vary; Thickness of the sheet metal: 2 mm

Request the exact material designation by specifying the Miretti job number.

Grey

B056025122

Black

B056027122

Antistatic paint is supplied with the truck for touch-up purposes.

Only use antistatic paint of the same speci cation.

172391 [EN]

-1

1 2

3

2

4

11

5

6

8

7

2

9

10

12

13

6036_901-034_V3

1

B004043111

1

Bush

2

VM0605X010

3

3

S170018111

1

Screw Bearing

4

C007056112

1

Body

5

P003027111

1

Guide pin

6

B004042111

1

Bush

7

B004044111

1

8

C007043111

1

Bush Body

9

B004045111

1

10

S133029111

1

11

P060001111

1

12

S133017112

1

Socket Plug unit

13

P060003112

1

Socket unit

Bush Plug

.

-2

172391 [EN]

1 2

3

2

4

11

5

6

8

7

2

9

10

12

13

6036_901-034_V3

1

B004043111

1

Bush

2

VM0605X010

3

3

S170018111

1

Screw Bearing

4

C007056112

1

Body

5

P003027111

2

Guide pin

6

B004042111

1

Bush Bush Body

7

B004044111

1

8

C007043111

1

9

B004045111

1

10

S133029111

1

11

P060001111

1

12

S133011112

1

Socket Plug unit

13

P060026112

1

Socket unit

Bush Plug

.

172391 [EN]

-3

1

2

3

4

6036_901-018

Quantity

Description

C012095122

1

L020050122

1

Dome Light

3

L010019122

1

4

C012095122

1

No.

Order no.

1 2

.

-4

172391 [EN]

PCB with interrupter unit Housing

8

9

1 2

7

3

4

6036_901-032_V3

5

6

1

VM0705X008

1

2

G033030121

1

3

P007006121

1

Screw M5x8 VSTEI O-ring OR 4500

4

L020029122

1

Parabolic mirror 24 V, 35 W light

5

P010010122

1

Fitting Screw TCEI M5x8 Support

6

VM0105X008

1

7

S160065121

1

8

P047047121

1

9

G034137121

1

Plate O-ring OR 00177

.

172391 [EN]

-5

7

9

8

1 2

3 3 4

6036_901-047_V2

5

6

1

VM0705X008

1

2

G033030121

1

Screw M5x8 VSTEI O-ring OR 4500

3

L020018122

2

24 V, 21 W light

4

L020005122

1

24 V, 5 W light

5

P007007121

1

Parabolic mirror

6

VM0105X008

1

7

S160065121

1

Screw TCEI M5x8 Support

8

P047047121

1

9

G034137121

1

Plate O-ring OR 00177

.

-6

172391 [EN]

9

1

2

8

3 7 6 4

5

6321_900-057_V2

1

VM0106X012

4

2

P010006122

1

3

VM0104X020

2

4 5

S170029111

1

Screw Support

P002001112

1

Screw joint

6

VM0604X016

1

Screw

7

D003003121

1

8

L020021122

1

Nut 24 V light

9

G012011121

1

Lens

Screw Fitting

.

172391 [EN]

-7

Cable inlet C in the example on the right can be determined from the table of cable types as follows:

AD2

C

The suf x 2 after AX indicates the length of the cable, in this case 4 m.

B

Look up the cable type in the table, e.g. AX2.

Find the cable inlet in the same row.

The elds with a grey background refer to cable length sections 7-12.

6036_901-012

AA

C

2x1.5

C105002122

DM0.10

AB

C

3x1.5

C105003122

DM0.10

AC

C

4x1.5

C105004122

AD

C

8x1.5

C105008122

AE

C

12x1.5

C105012122

AF

C

14x1.5

C105014122

AG

C

19x1.5

C105019122

AH

C

1x2.5

C101002122

AI

C

1x4

C101003122

AJ

C

1x10

C101010122

AK

C

1x16

C101015122

AL

C

1x25

C101020122

DM0.10 DM1.13 DG1.13 DMD1.13.19 DGD1.13.19 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM2.18 DG2.18 DMD2.18.24 DGD2.18.24 DM0.7 DG0.7 DM0.7 DG0.7 DM0.7 DG0.7 DM0.10 DM1.10 DG1.10 DMD1.10.15 DGD1.10.15

-8

172391 [EN]

AM

C

1x35

C101025122

AN

C

1x50

C101030122

AO

C

1x70

C101035122

AP

C

4x2.5

CX105030122

AQ

C

4x6

C105040122

AR

C

4x16

C105055122

DM1.10 DG1.10 DMD1.10.15 DGD1.10.15 DM2.13 DG2.13 DMD2.13.20 DGD2.13.20 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM2.18 DG2.18 DMD2.18.24 DGD2.18.24 -

AS AT

SCH

2x0.75

C107004122

DM0.10

SCH

3x0.75

C107002122

DM0.10

AU

SCH

4x0.75

C107003122

DM0.10

AV

SCH

8x0.75

C107006122

5.0

AW

SCH

12x0.75

C107007122

AX

SCH

18x0.75

C107008122

4.0

4.0

AY

SCH

21x0.75

C107001122

AZ

SCH

25x1

C104083122

DM0.10 DM1.13 DG1.13 DMD1.13.19 DGD1.13.19 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20

BA

DI

2x1

C104004122

DM0.10

1.5

1.5

BB

DI

7x1

C104009122

DM0.10

5.0

3.5

.

172391 [EN]

-9

BC

DI

12x1

C104011122

BD

DI

18x1

C104013122

BE

DIFX

25x1

C104076122

BF

DI

1x10

C102059122

BG

DI

1x16

C102058122

BH

DI

1x25

C102057122

BI

DI

1x35

C102055122

BJ

DI

1x50

C102053122

BK

DI

1x70

C102054122

BL

DI

1x4

C102061122

BM

DI

1x95

C10104122

DM1.13 DG1.13 DMD1.13.19 DGD1.13.19 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM0.10

BN

DIFX

4x1

5491.15.001

DM0.10 DM1.13 DG1.13 DMD1.13.19 DGD1.13.19 DM1.13 DG1.13 DMD1.13.19 DGD1.13.19 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM2.18 DG2.18 DMD2.18.24 DGD2.18.24 DM0.7 DG0.7 DM2.18 DG2.18 DMD2.18.24 DGD2.18.24 DM0.10

BO

DIFX

2x0.75

C104002122

DM0.10

BP

DIFX

2x1.5

C104080122

DM0.10

BQ

DIFX

4x1.5

C104024122

BR

DIFX

12x0.25

C104026122

BS

DIFX

7x1.5

C104073122

DM0.10 DM1.13 DG1.13 DMD1.13.19 DGD1.13.19 DM0.10

BT

DIFX

7x1

C104079122

BU

DIFX

12x1

C104078122

-10

DM0.10 DM1.13 DG1.13 DMD1.13.19 DGD1.13.19

172391 [EN]

5.0 5.0 5.0 5.0 5.0 5.0 3.0 3.0

5.0

5.0 5.0

DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM2.18 DG2.18 DMD2.18.24 DGD2.18.24 DM2.18 DG2.18 DMD2.18.24 DGD2.18.24

BV

DIFX

18x1

C104075122

BW

DIFX

25x1

C104076122

BX

DIFX

34x1

C104081122

BY

DIFX

50x1

C104082122

CA

N

2x1.5

C103004122

DM0.10

CB

N

3x1.5

C103006122

DM0.10

CC

N

4x1.5

C103001122

DM0.10

CD

N

7x1.5

C103002122

CE

N

12x1.5

C103003122

CF

N

2x6

C103007122

CG

N

25x0.5

C104084122

CH

N

3x0.75

C103010122

CI

N

4x0.75

C103011122

CJ

N

8x0.75

C103012122

CK

N

5x6

C103050122

DM0.10 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM1.13 DG1.13 DMD1.13.19 DGD1.13.19 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM0.7 DG0.7 DM0.7 DG0.7 DM0.10 DM2.18 DG2.18 DMD2.18.24 DGD2.18.24

.

5.0

5.5

5.0

2.5 5.0

1.0

2.5

/

5.0

5.0

4.5

/

4.0

/

/

5.0

5.0

.

172391 [EN]

-11

Cable inlet C in the example on the right can be determined from the table of cable types as follows:

AD2

C

The suf x 2 after BI indicates the length of the cable, in this case 1.5 m.

B

Look up the cable type in the table, e.g. BI2.

Find the cable inlet in the same row.

6036_901-012

AA

C

2x1.5

C105002122

DM0.10

AB

C

3x1.5

C105003122

DM0.10

AC

C

4x1.5

C105004122

AD

C

8x1.5

C105008122

AE

C

12x1.5

C105012122

AF

C

14x1.5

C105014122

AG

C

19x1.5

C105019122

AH

C

1x2.5

C101002122

AI

C

1x4

C101003122

AJ

C

1x10

C101010122

AK

C

1x16

C101015122

AL

C

1x25

C101020122

DM0.10 DM1.13 DG1.13 DMD1.13.19 DGD1.13.19 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM2.18 DG2.18 DMD2.18.24 DGD2.18.24 DM0.7 DG0.7 DM0.7 DG0.7 DM0.7 DG0.7 DM0.10 DM1.10 DG1.10 DMD1.10.15 DGD1.10.15

-12

172391 [EN]

AM

C

1x35

C101025122

AN

C

1x50

C101030122

AO

C

1x70

C101035122

AP

C

4x2.5

CX105030122

AQ

C

4x6

C105040122

AR

C

4x16

C105055122

DM1.10 DG1.10 DMD1.10.15 DGD1.10.15 DM2.13 DG2.13 DMD2.13.20 DGD2.13.20 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM2.18 DG2.18 DMD2.18.24 DGD2.18.24 -

AS

SCH

2x0.75

C107004122

DM0.10

AT

SCH

3x0.75

C107002122

DM0.10

AU

SCH

4x0.75

C107003122

DM0.10

AV

SCH

8x0.75

C107006122

AW

SCH

12x0.75

C107007122

AX

SCH

18x0.75

C107008122

AY

SCH

21x0.75

C107001122

AZ

SCH

25x1

C104083122

TC

C

4x1.5

C104024122

DM0.10 DM1.13 DG1.13 DMD1.13.19 DGD1.13.19 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM0.10

BA

DI

2x1

C104004122

DM0.10

BB

DI

7x1

C104009122

DM0.10

.

172391 [EN]

-13

BC

DI

12x1

C104011122

BD

DI

18x1

C104013122

BE

DIFX

25x1

C104076122

DM1.13 DG1.13 DMD1.13.19 DGD1.13.19 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM0.10

BF

DI

1x10

C102059122

BG

DI

1x16

C102058122

BH

DI

1x25

C102057122

BI

DI

1x35

C102055122

BJ

DI

1x50

C102053122

BK

DI

1x70

C102054122

BL

DI

1x4

C102061122

BM

DI

1x95

C10104122

BN

DIFX

4x1

C104040122

DM0.10 DM1.13 DG1.13 DMD1.13.19 DGD1.13.19 DM1.13 DG1.13 DMD1.13.19 DGD1.13.19 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM2.18 DG2.18 DMD2.18.24 DGD2.18.24 DM0.7 DG0.7 DM2.18 DG2.18 DMD2.18.24 DGD2.18.24 DM0.10

BO

DIFX

2x0.75

C104002122

DM0.10

BP BQ

DIFX

2x1.5

C104080122

DI

2x35 + 1x2.5

C104033122

BR

DIFX

12x0.25

C104026122

BS

DIFX

7x1.5

C104073122

DM0.10 DM1.13 DG1.13 DMD1.13.19 DGD1.13.19 DM0.10

BT

DIFX

7x1

C104079122

BU

DIFX

12x1

C104078122

-14

DM0.10 DM1.13 DG1.13 DMD1.13.19 DGD1.13.19

172391 [EN]

1.5 1.5 1.5

1.5

2.5 2.5 2.0

2.0

1.5 1.5

DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM2.18 DG2.18 DMD2.18.24 DGD2.18.24 DM2.18 DG2.18 DMD2.18.24 DGD2.18.24

BV

DIFX

18x1

C104075122

BW

DIFX

34x1

C104081122

BX

DIFX

50x1

C104082122

CA

N

2x1.5

C103004122

DM0.10

CB

N

3x1.5

C103006122

DM0.10

CC

N

4x1.5

C103001122

DM0.10

CD

N

7x1.5

C103002122

CE

N

12x1.5

C103003122

CF

N

2x6

C103007122

CG

N

25x0.5

C104084122

CH

N

3x0.75

C103010122

CI

N

4x0.75

C103011122

CJ

N

8x0.75

C103012122

CK

N

5x6

C103050122

CL

SIL

1x35

C102090122

DM0.10 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM1.13 DG1.13 DMD1.13.19 DGD1.13.19 DM2.15 DG2.15 DMD2.15.20 DGD2.15.20 DM0.7 DG0.7 DM0.7 DG0.7 DM0.10 DM2.18 DG2.18 DMD2.18.24 DGD2.18.24 DM1.13

CM

SIL

1x95

C102093122

DM2.18

.

2.0

2.0

.

172391 [EN]

-15

6036_901-013

DM0.7

P106001122

4 7

M16x1.5

DM0.10

P106002122

7 10

M16x1.5

DM1.8

P106003122

5.5-8

M20x1.5

DM1.10

P106004122

8-10.5

M20x1.5

DM1.13

P106005122

10.5-13

M20x1.5

DM2.13

P106006122

10.5-13

M25x1.5

DM2.15

P106007122

13-15.5

M25x1.5

DM2.18

P106008122

15.5-18

M25x1.5

.

6036_901-013

DG0.7

P107001122

4 7

GK 3/8

DG1.8

P107002122

5.5-8

GK 1/2

DG1.10

P107003122

7 10

GK 1/2

DG1.10

P107004122

8-10.5

GK 1/2

DG1.13

P107005122

10.5-13

GK 1/2

DG2.8

P107006122

5.5-8

GK 3/4

DG2.10

P107007122

8-10.5

GK 3/4

DG2.13

P107008122

10.5-13

GK 3/4

-16

172391 [EN]

DG2.15

P107009122

13-15.5

GK 3/4

DG2.18

P107010122

15.5-18

GK 3/4

.

6036_901-080

P113001122

5-7/10-15

DMD0.10.15

P113002122

7-10/10-15

M16x1.5

DMD1.8.15

P113003122

5.5-8/10-15

M20x1.5

DMD1.10.15

P113004122

5.5-8/10-15

M20x1.5

DMD1.13.19

P113008122

10.5-13/14-19

M20x1.5

DMD2.13.20

/

10.5-13/15-20

M25x1.5

DMD2.15.20

P113010122

13-15.5/15-20

M25x1.5

DMD2.18.20

/

15.5-18/15-20

M25x1.5

DMD2.18.24

P113009122

15.5-18/20-24

M25x1.5

DMD0.7.15

M16x1.5

.

172391 [EN]

-17

6036_901-080

DGD1.18.15

P112006122

5.5-8/10-15

NPT 3/4

DGD1.10.15

P112007122

5.5-8/10-15

NPT 3/4

DGD1.13.20

P112008122

10.5-13/15-20

NPT 3/4

DGD2.8.15

/

5.5-8/10-15

NPT 3/4

DGD2.10.15

/

8-10.5/10-15

NPT 3/4

DGD2.13.20

/

10.5-13/15-20

NPT 3/4

DGD2.15.20

P112009122

13-15.5/15-20

NPT 3/4

DGD2.18.20

/

15.5-18/15-20

NPT 3/4

DGD2.18.24

/

15.5-18/20-24

NPT 3/4

.

6036_901-014

PG9.8

P100015122

4 8

PG9

PG11.10

P100003122

5 10

PG11

PG13.12

P100001122

6 12

PG13.5

PG16.14

P100004122

10 14

PG16

PG21.18

P100002122

13 18

PG21

.

-18

172391 [EN]

6036_901-015

a

PR14.6

P001080122

4-6.5

1/4

PR14.9

P001081122

6.5-9.5

1/4

PR38.9

P001079122

6.5-9.5

3/8

PR38.13

P001084122

9 13

3/8

PR12.13

P001082122

9 13

1/2

PR12.16

P001085122

12 16

1/2

PR12.18

P001083122

14 18

1/2

PR34.18

P001086122

14 18

3/4

.

172391 [EN]

-19

-20

172391 [EN]

Circuit diagrams Antistatic paint . . . . . . . . . . . . . . . . . . . . .

-1

Area of application for the truck . . . . . . . . .

-2

Sheet 01 . . . . . . . . .

-1, -37, -41, -89

Sheet 02 . . . . . . . . .

-3, -39, -43, -91

Sheet 03 . . . . . . . . . . . . . .

-5, -45, -93

Sheet 04 . . . . . . . . . . . . . . . . . .

-7, -47

Sheet 05 . . . . . . . . . . . . . . . . . .

-9, -49

Sheet 06 . . . . . . . . . . . . . . . . .

-11, -51

Sheet 07 . . . . . . . . . . . . . . . . .

-13, -53

Sheet 08 . . . . . . . . . . . . . . . . .

-15, -55

Sheet 09 . . . . . . . . . . . . . . . . .

-17, -57

Sheet 10 . . . . . . . . . . . . . . . . .

-19, -59

Sheet 11 . . . . . . . . . . . . . . . . .

-21, -61

Sheet 12 . . . . . . . . . . . . . . . . .

-23, -63

Sheet 13 . . . . . . . . . . . . . . . . .

-25, -65

-19

Sheet 14 . . . . . . . . . . . . . . . . .

-27, -67

Sheet 15 . . . . . . . . . . . . . . . . .

-29, -69

Designation . . . . . . . . . . . . . . . . . . .

-16

Sheet 16 . . . . . . . . . . . . . . . . .

-31, -71

DG ATEX . . . . . . . . . . . . . . . . . . . . .

-16

DGD . . . . . . . . . . . . . . . . . . . . . . . .

-18

DM ATEX . . . . . . . . . . . . . . . . . . . .

-16

DMD . . . . . . . . . . . . . . . . . . . . . . . .

-17

Eex e II . . . . . . . . . . . . . . . . . . . . . .

-18

Tables . . . . . . . . . . . . . . . . . . . . . . .

-16

Changing the interrupter unit . . . . . . . . .

-24

Checking the antistatic paint layer . . . . . . .

-2

Battery male connector . . . . . . . . . . . . . .

-1

Connecting . . . . . . . . . . . . . . . . . . . .

-2

Disconnecting . . . . . . . . . . . . . . . . . .

-2

Negative . . . . . . . . . . . . . . . . . . . . . .

-2

Positive . . . . . . . . . . . . . . . . . . . . . . .

-3

Spare parts list . . . . . . . . . . . . .

-3

-2

Cable inlet IP . . . . . . . . . . . . . . . . . . . . . . . . . .

Cable inlets

Sheet 17 . . . . . . . . . . . . . . . . . . . . . .

-73

Sheet 17-21 - Parts list . . . . . . . . . . . .

-33

Sheet 18 . . . . . . . . . . . . . . . . . . . . . .

-75

Sheet 19 . . . . . . . . . . . . . . . . . . . . . .

-77

Sheet 20 . . . . . . . . . . . . . . . . . . . . . .

-79

Sheet 21 . . . . . . . . . . . . . . . . . . . . . .

-81

Sheet 22-27 - Parts list . . . . . . . . . . . .

-83

Closing the pressure-tight housing . . . . . .

-4

Connecting the diagnostic device . . . . . . .

-1

Contact repetition PCB . . . . . . . . . . . . . .

-11

Driver s seat . . . . . . . . . . . . . . . . . . . . . . .

-2

Electronic control unit . . . . . . . . . . . . . . . .

-6

Electronic control unit - Structure

172391 [EN]

Components in the housing (battery compartment) . . . . . . . . . . . . . . .

-9

Components in the housing (counterweight) . . . . . . . . . . . . . . . . . . . .

-7

Components in the housing cover (battery compartment) . . . . . . . .

-10

Components in the housing cover (counterweight) . . . . . . . . . . . . . .

-8

Emergency shutdown . . . . . . . . . . . . . .

-13

Bridging . . . . . . . . . . . . . . . . . . . . . .

-14

Explosion groups . . . . . . . . . . . . . . . . . . .

-7

21

Explosion protection

Light FL 32

Equipment categories . . . . . . . . . . . .

-6

Repairing . . . . . . . . . . . . . . . . . . . . .

-27

Zones . . . . . . . . . . . . . . . . . . . . . . . .

-6

Spare parts list . . . . . . . . . . . . . . . . . .

-7

Explosion protection-speci c components on the truck . . . . . . . . . . . . . . . .

-12 Making a cable inlet . . . . . . . . . . . . . . . .

-22

Nameplate . . . . . . . . . . . . . . . . . . . . . . .

-14

-2

Flashing light Repairing . . . . . . . . . . . . . . . . . . . . .

-23

Spare parts list . . . . . . . . . . . . . . . . . .

-4

Fork arms Checking . . . . . . . . . . . . . . . . . . . . . .

-1

Coating . . . . . . . . . . . . . . . . . .

-1,

-1

Personnel quali ed to work with explosion protection-related components . . .

Repairing . . . . . . . . . . . . . . . . . . . . . .

-2

Pressure-tight housing

Spare . . . . . . . . . . . . . . . . . . . . . . . .

-1

General considerations . . . . . . . . . . . . . .

Identi cation . . . . . . . . . . . . . . . . . . .

-2

Open . . . . . . . . . . . . . . . . . . . . . . . . .

-3

Repairing the working spotlights FL 150 .

-29

Replacing the electric motors . . . . . . . . .

-21

Installing the electric motors . . . . . . .

-21

Removing the pump motor . . . . . . . .

-21

Removing the traction motor . . . . . . .

-21

Replacing the fuses . . . . . . . . . . . . . . . .

-30

-1

Headlight EL 150 Repairing . . . . . . . . . . . . . . . . . . . . .

-24

Spare parts list . . . . . . . . . . . . . . . . . .

-5

Insulation monitoring PCB Safety information

Checking . . . . . . . . . . . . . . . . . . . . .

-15

Function checking . . . . . . . . . . . . . .

-16

Area of application for the truck . . . . . .

-2

Functional description . . . . . . . . . . .

-15

Working on the truck . . . . . . . . . . . . . .

-1

Insulation protection . . . . . . . . . . . . . . . .

-13

Emergency shutdown . . . . . . . . . . . .

-14

Functional description . . . . . . . . . . .

-13

Tables of cables used, CAT 2GD . . . . . . .

-8

Tables of cables used, CAT 3GD . . . . . .

-12

-11

Temperature classes . . . . . . . . . . . . . . . .

-9

Checking the contacts . . . . . . . . . . .

-12

Testing the electrical system . . . . . . . . . . .

-4

Functional description . . . . . . . . . . .

-12

Testing the MBZ zener barriers . . . . . . . .

-19

-12

Towing the truck out of potentially explosive areas . . . . . . . . . . . . . .

-3

Intrinsic safety PCB Checking . . . . . . . . . . . . . . . . . . . . .

Power supply . . . . . . . . . . . . . . . . . .

Leak resistance Measuring . . . . . . . . . . . . . . . . . . . . .

-2

Measuring individual tyres . . . . . . . . .

-3

Preparations for measuring . . . . . . . .

-2

Leak resistance testing . . . . . . . . . . . . . . .

-1

Light EL 160

22

Repairing . . . . . . . . . . . . . . . . . . . . .

-26

Spare parts list . . . . . . . . . . . . . . . . . .

-6

Types of spark protection . . . . . . . . . . . . .

-9

Encapsulated (EEx m) . . . . . . . . . . .

-12

Energy limited (EEx n) . . . . . . . . . . .

-12

Flameproof enclosure (EEx d) . . . . .

-10

Increased safety (EEx e) . . . . . . . . .

-11

Intrinsic safety (EEx i) . . . . . . . . . . . .

-11

Restricted breathing housing (EEx nR) . . . . . . . . . . . . . . . . . .

-12

172391 [EN]

Tyres Checking . . . . . . . . . . . . . . . . . . . . . .

-1

Description . . . . . . . . . . . . . . . . . . . .

-1

Safety principles . . . . . . . . . . . . . . . .

-5

Warning lights related to explosion protection . . . . . . . . . . . . . . . . . .

Working on the truck . . . . . . . . . . . . . . . . .

-1

Zener barriers . . . . . . . . . . . . . . . . . . . .

-19

Function checking . . . . . . . . . . . . . .

-19

Functional description . . . . . . . . . . .

-19

-1

172391 [EN]

23

STILL GmbH Berzeliusstrasse 10 D-22113 Hamburg Ident no. 172391 EN

Explosion-protected

a

172391 [EN]

6200_901-029_V2

-1

-2

1K1 7S2 A21 A43

Main contactor, 11-12 Emergency off switch, 11 Fuse box, 5-16 Supply Unit (SU), 6-10 :X42:1 - 12 V, L, current sensor, 7 :X42:2 - 48-V fuse, 9 :X42:3 - relay for signal horn, 10 :X42:4 - contactor A1, 8 :X42:5 - contactor A2, 9 BATT F01 F11

:X42:6 - U charge, 9 :X42:7 - signal transmitter, 10 :X42:8 - GND_F, 10 :X42:9 - current sensor, 8 :X42:10 - GND_L, current sensor, 8 :X42:11 - GND_F, relay for signal horn, 9 :X42:12 - GND_L, battery, 8 48-V battery, 2 400-A main fuse, 13 Fuse for SU/MCU, 14 K1 U10 V1 X1 X2

F12 F14 F15

5-A fuse for signal horn, 14 15-A/30-A fuse for voltage transformer (U1-2), 15 10-A fuse for CPP, front, 15 Voltage transformer U4, 10 A Solenoid valve on attachment, 10 A 24-V relay, 6 Current sensor, 8 24 V fan, 5 Positive battery male connector, 2 Negative battery male connector, 2 *

X20 X21 X22 X26 X27 X271

172391 [EN]

Plug for control cables to SU, 7-10 Plug for signal horn, 5 Plug for contactor coil, 11 Plug for signal transmitter, 5 Plug for voltage converter U1, U2, 16 Plug for voltage converter U4, feed to 5th hydraulics, 16 Optional

172391 [EN]

X52-3

X52-2 X52-1

6200_901-030_V2

-3

-4

F24 F25 F26 F27

F23

7A21 F22

Distributor plate, 2-7 50-A fuse for heating system, 5 Note: 5-mm cable shoes 10-A fuse for option board, solenoid valve on attachment, 5 10-A fuse for CPP, rear, 5 10-A fuse for proportional technology, 4 25-A fuse for CPP, roof, 5 25-A fuse for CPP, seat, 5 X52

X35 X37 X44

F28 F29

10-A fuse for CPP, front, 5 15-A fuse for Option Board, material management system (MMS), 3 Plug for feed to 5th hydraulic function, CPP, roof, 9 Plug for 12-V supply, 11 42-pin SAAB plug, switch and sensors for truck chassis, 12-3 X48:14 - 24 V, 13 X48:15 - GND_F, 12 Plug for supply voltage X66

X65

X52_1 X52_2 X52_3 X63 X64 X65

Plug for CPP, front, 14 Plug for CPP, roof, 15-16 Plug for CPP, seat, 17-18 Plug for Option Board, 3 Plug for CPP, rear, 3 Plug for Option Board, CPP, front, proportional technology, 3-4 Plug for Option Board, CPP, front, proportional technology, 12-13 Plug for CPP, roof, 3

X66 X66 X67 X81 X81 X82 X83 *

172391 [EN]

Plug for CPP, roof, 9 Plug for CPP, roof, 15-16 Plug for CPP, seat, 3 Plug for voltage converter U1, U2, 6 Plug for voltage converter U1, U2, 8 Plug for voltage converter, 6-7 Plug for voltage converter, 6-7 Optional

172391 [EN]

WH BK

RD

BU

WH

RD BK

BU

6200_901-031_V2

-5

-6

1U07

1M1 1M2 2M1 1U06

Right-hand traction motor, 15-19 Left-hand traction motor, 2-7 Pump motor, 9-13 Converter for right-hand traction motor, 14-19 :X151:2 - GND_F, 18 :X151:3 - A FM1, 16 :X151:4 - CAN_H, 17 :X151:5 - B FM1, 17 :X151:6 - CAN_L, 18 :X151:7 - 10 V, DZS, 17 :X151:8 - 24 V switched, 18 :X151:8 - GND_L, 18 :X151:9 - U 1M1, 16 :X151:10 :X151:11 - converter enable command, 15 :X151:12 - temperature sensor FM1 +, 18 :X151:14 - temperature sensor FM1 , 19 Converter for left-hand traction motor, 1-7 :X152:1 - GND_L, 5 :X152:2 - GND_F, 6 :X152:3 - A FM2, 3 :X152:4 - CAN_H, 5 :X152:5 - B FM2, 4 A43

2U03

:X152:6 - CAN_L, 6 :X152:7 - 10 V, DZS, 4 :X152:8 - 24 V switched, 6 :X152:9 - U 1M2, 5 :X152:10 - converter enable command, 5 :X152:11 - V FM2, 2 :X152:12 - temperature sensor FM2 +, 6 :X152:14 - temperature sensor FM2 , 6 Pump motor, 7-13 :X150:1 - V 2M1, 9 :X150:2 - GND_F, 13 :X150:4 - CAN_H, 12 :X150:5 - speed 1, 10 :X150:6 - speed 2, 10 :X150:6 - CAN_L, 12 :X150:7 - 10 V, DZS, 10 :X150:8 - GND_L, 11 :X150:8 - 24 V switched, 12 :X150:10 - converter enable command, 11 :X150:12 - temperature sensor for pump motor +, 12 :X150:14 - temperature sensor for pump motor , 14 Supply Unit (SU), 2-7 :X44:1 - GND_F, 1U07, 6 :X44:2 - 24 V, 1U07, 6 A43

A43

:X44:3 - CAN_H, 1U07, 6 :X44:4 - CAN_L, 1U07, 6 :X44:5 - enable command, 1U07, 5 :X44:6 - V FM2, 1U07, 2 :X44:7 - A FM2, 1U07, 3 :X44:8 - B FM2, 1U07, 4 :X44:9 - U FM2, 1U07, 5 :X44:36 - track A, FM2, axle, 7 :X44:37 - track B, FM2, axle, 7 Supply Unit (SU), 10-13 :X44:15 - GND_F, 2U03, 13 :X44:16 - 24 V, 2U03, 12 :X44:17 - CAN_H, 2U03, 12 :X44:18 - CAN_L, 2U03, 12 :X44:19 - enable command, 2U03, 11 Supply unit (SU), 15-20 :X44:21 - track A, FM1, 1U06, 16 :X44:22 - track B, FM1, 1U06, 16 :X44:23 - track A, FM1, axle, 20 :X44:24 - track B, FM1, axle, 20 :X44:29 - GND_F, 1U06, 18 :X44:30 - 24 V, 1U06, 18 :X44:31 - CAN_H, 1U06, 18 :X44:32 - CAN_L, 1U06, 18 BK BN BU GNYE RD WH

FM1 FM2

X15 +

X12 X13

L1M1 L1M2 X10 X11

172391 [EN]

Black Brown Blue Green/yellow Red White

Right-hand traction motor Left-hand traction motor

:X44:33 - V FM1, 1U06, 17 :X44:34 - enable command, 1U06, 15 :X44:35 - U FM1, 1U06, 17 Rev sensor for right-hand traction motor, 17-18 Rev sensor for left-hand traction motor, 4-5 Plug for rev sensor for right-hand traction motor, 17-18 Plug for temperature sensor for right-hand traction motor, 18-19 Plug for rev sensor for left-hand traction motor, 4-5 Plug for temperature sensor for left-hand traction motor, 6 Plug for temperature sensor for pump motor, 12-13 Optional

RD

BU

172391 [EN]

BU

BN

BK

1

6200_901-032_V2

-7

-8

1 3B1 4H2 A21 A43

Intrinsically safe side Steering angle sensor, 14-16 Signal transmitter, 17 Fuse box Supply Unit (SU), 5-8 :X41:3 - track A, FM2, 7 :X41:4 - track B, FM2, 7 :X41:7 - CAN_L, 7 :X41:9 - MCU reset, 7 A44

:X41:11 - track A, FM1, 7 :X41:12 - track B, FM1, 6 :X41:14 - converter enable command, 6 :X41:15 - CAN_H, 6 Main Control Unit MCU (truck control unit), 9-12 :X47:10 - CAN_H, 11 :X47:11 - MCU reset, 10 :X47:12 - track B, FM1, 11 :X47:13 - track A, FM2, 10 :X47:24 - CAN_L, 10 L2M1

A44

:X47:25 - converter enable command, 11 :X47:26 - track B, FM2, 10 :X47:27 - track A, FM1, 11 Main Control Unit MCU (truck control unit), 14-18 :X46:23 - GND_S, steering angle sensor, 16 :X46:35 - steering angle sensor, track B, 16 :X46:36 - steering angle sensor, track A, 15 :X46:37 - steering angle sensor, track NN, 16 :X46:38 - 12 V, S, steering angle sensor, 15 Impulse transmitter for pump motor, 3-4 Black Brown Blue Red

BK BN BU RD

172391 [EN]

Card for zener barriers, 2-5 Card for zener barriers, 14-18 Plug for impulse transmitter for pump motor, 2-4 Plug for signal transmitter, 16-7 Optional

SMZ1 SMZ2 X14 X26 *

RD

172391 [EN]

GNYE

GNYE

BU

GNYE

RD

GNYE

BU

YE

GN

RD

BU YE

GN

YE

GN

RD

1

6200_901-033_V2

-9

.

6V

-10

6V

V70-71

Intrinsically safe side Accelerator, 15-17 Brake sensor, 18-19 Drive direction switch, 5 Parking brake switch, 4-5 Steering switch (diaphragm pressure switch), 4-5 Oil level switch, 4-5 Supply Unit (SU), 6 :X41:6 - switch lock, 6 :X41:10 - U battery 48 V, 6 Supply Unit (SU), 11-12 :X43:3 - oil level, 11 :X43:11 - GND_L oil level, 12

V69-71

A43

1 1B1 1B2 1S1 1S3 6S3 6S12 A43

A44

Main Control Unit (MCU - truck control unit), 7-11 :X46:3 - parking brake, 7 :X46:11 - accelerator 2, 9 :X46:16 - GND_S accelerator 1 and 2, 8 :X46:17 - GND_S parking brake switch, 7 :X46:18 - GND_S drive direction switch, 10 :X46:19 - GND_S steering switch (diaphragm pressure switch), 8 :X46:30 - drive direction switch actuated, 9 :X46:31 - drive direction switch for reverse, 10 :X46:32 - drive direction switch for forwards, 10 :X46:33 - steering switch (diaphragm pressure switch), 7 :X46:40 - 12 V -S accelerator, 8 F2 RV SMZ3 SSI1 U1

A44

Main Control Unit (MCU - truck control unit), 15-18 :X46:11 - accelerator 2, 16 :X46:12 - accelerator 1, 16 :X46:13 - brake sensor, 17 :X46:26 - GND_S accelerator 1 and 2, 17 :X46:27 - GND_S brake sensor, 16 :X46:40 - 12 V -S accelerator, 15 :X46:41 - 12 V -S brake sensor, 16 :X46:41 - 12 V -S brake sensor, 18 10-A fuse for clamp light, 1 DC/DC voltage transformer, 12-13 Card for zener barriers, 14-19 Intrinsically safe PCB, 4-11 Voltage converter, 1-2 Blue Green Green-yellow Red Yellow

BU GN GNYE RD YE

172391 [EN]

Voltage converter, 3-4 Optional

U2 *

172391 [EN]

1

6200_901-034_V2

-11

-12

A44

1 4S1 6S4 7S1 7S17 A43

Intrinsically safe side Horn button, 3-4 Brake uid switch, 3-4 Seat contact switch, 3-4 Switch for buckle, 3-4 Supply Unit (SU), 15 :X41:13 - emergency off switch, 15 Main Control Unit (MCU - truck control unit), 3 A44

A44

:X47:1 - K2, 3 Main Control Unit (MCU - truck control unit), 6-8 :X46:9 - brake uid switch, 8 :X46:10 - signal horn button, 7 :X46:20 - GND_S, switch for buckle, 7 :X46:22 - GND_S, brake uid switch, 8 :X46:25 - GND_S, signal horn button, 7 :X46:34 - switch for buckle, 6 Main Control Unit (MCU - truck control unit), 9-10 F18 F19 K2 K2 PR S1M1

:X46:8 - seat contact switch, 9 :X47:8 - digital res2, 8 :X46:21 - GND_S, seat contact switch, 10 1.6-A fuse for V1 fan, 18 1.6-A fuse for V2 fan, 19 Relay, 3 Relay, 4 Reset button, 3-4 Temperature sensor for left-hand traction motor, 3-4

S1M2 S2M1 SD SSI2 ST12 V1 V2 *

172391 [EN]

Temperature sensor for right-hand traction motor, 3-4 Temperature sensor for pump motor, 3-4 Insulation monitoring PCB, 13-14 Intrinsically safe PCB, 5-12 Temperature sensor in pressure-tight housing, 13-14 Fan, 17-18 Fan, 19 Optional

172391 [EN]

YE

GN

RD

1

6200_901-035_V2

-13

-14

1 1S27 6S10 5S19 7S13 7S15 7Y08

Intrinsically safe side Battery door sensor, 3 Oil temperature transmitter, 6 Switch for interior lighting, 9-10 Dead man switch, 9-10 Switch for 5th hydraulic function, 9-10 Solenoid valve on attachment, 17 A43

7Y09 A43

Solenoid valve for lift limitation, 17 Supply Unit (SU), 2-3 :X44:11 - 12 V, L, battery door, 3 :X44:25 - battery door, 3 :X44:39 - GND_L, battery door, 2 Supply Unit (SU), 5-7 :X44:14 - 12 V, L, oil temperature transmitter, 5 :X44:38 - oil temperature transmitter, 6 Fx KV MV

A44

:X44:40 - GND_L, oil temperature transmitter, 6 Main Control Unit MCU (truck control unit), 13-14 :X47:1 - GND_F, 13 :X47:17 - 5th hydraulic function, 13 :X47:35 - dead man switch, 14 15-A fuse for solenoid valve on attachment 3, 17 Relay, 12 Fan, 10 Green Red Yellow

GN RD YE

172391 [EN]

Card for zener barriers, 5-7 Intrinsically safe PCB, 9-15 Optional

SMZ4 SSI3 *

A

172391 [EN]

BU

BN

BK

BU

BN

BK BU

BN

BK

1

6200_901-036_V2

-15

-16

1 2B1 2B2 2B3 2B4 3B28 3B29 7B43 2Y46 A A43

Intrinsically safe side Hydraulic transmitter for lifting, 3 Hydraulic transmitter for tilting, 4 Hydraulic transmitter for auxiliary hydraulics 1, 6 Hydraulic transmitter for auxiliary hydraulics 2, 7 Curve switch for right-hand curves, 10 Curve switch for left-hand curves, 8-9 Fork carriage monitoring, 12-3 Check valve, 3 Valve block, 3-8 Supply Unit (SU), 9-11 A44

:X44:10 - left-hand curve switch (digital), 10 :X44:12 - 12 V, L position, steering axle, 11 :X44:27 - right-hand curve switch (digital), 11 :X44:41 - GND_L position, steering axle, 10 Main Control Unit MCU (truck control unit), 2-8 :X46:2 - lowering off, 3 :X46:4 - auxiliary hydraulics 1, 5 :X46:5 - auxiliary hydraulics 2, 5 :X46:6 - lifting, 4 :X46:7 - tilting, 5 :X46:24 - GND_S, valve block, 5 :X46:39 - 12 V, S, valve block, 6 L3

F1 FY46 L1 L2

A44

:X47:1 - GND_F, 7 :X47:15 - 12 V, S, distributor plate, 8 Main Control Unit MCU (truck control unit), 12-13 :X47:16 - fork carriage S2, 12 :X47:30 - fork carriage S1, 12 5-A fuse, 6 15-A fuse for check valve 3, 3 Warning light for insulation monitoring, 16 Warning light for temperature of right-hand traction motor, 16 Warning light for temperature of left-hand traction motor, 17 Black Brown Blue

BK BN BU

172391 [EN]

Warning light for pump motor temperature, 17 Warning light for heating system, 18 Card for zener barriers, 9-13 Card for zener barriers, 15-19 6-pin SAAB plug, 3-8 Optional

L4 L5 SMZ5 SMZ6 X19 *

A

172391 [EN]

BK

YE

RD

BN

GY

ABEII

6200_901-037_V2

-17

-18

ABEII

A

Diagnostic connector, 1-3 :X50:1 - CAN_H red, 2 :X50:2 - CAN_L red, 2 :X50:3 - 24 V, 3 :X50:4 - GND_F, 2 Display and operating unit, 8-18 :X49:1 - 24 V, 10 :X49:2 - GND_F, 11 :X49:3 - CAN_H red, 11 :X49:4 - CAN_L red, 11 :X49:5 - 48 V, 11 A43

A43

:X49:6 - warning light Supply Unit (SU), 2-5 :X40:1 - CAN_H, 3 :X40:2 - CAN_L, 3 :X40:3 - 24 V, 3 :X40:4 - GND_F, 3 :X41:1 - GND_F, 4 :X41:2 - 24 V CAN bus, 5 :X41:16 - CAN_H red, 4 :X41:18 - CAN_L red, 5 Supply Unit (SU), 12-13 :X41:5 - warning light, 12 A44

A44

Main Control Unit (MCU - truck control unit), 8-11 :X45:1 - CAN_H red, 9 :X45:2 - CAN_L red, 9 :X45:3 - 24 V, 9 :X45:4 - GND_F, 10 :X46:1 - CAN_H red, 11 :X46:29 - CAN_L red, 11 :X47:14 - 24 V, 9 :X47:28 - GND_F, 10 :X47:31 - GND_F, 11 Main Control Unit (MCU - truck control unit), 14-15 :X47:20 - , CAN_H red, 15 X49 X51 * **

CPP

172391 [EN]

:X47:21 - CAN_L red, 14 :X47:36 - GND_F, 14 CAN Power Port, 14-15 :1 - CAN_H red, 15 :2 - CAN_L red, 14 :3 - GND_F, 14 6-pin MARK II plug, 10-12 Plug for CAN bus to CPP, 14-15 Optional Heating system (optional)

172391 [EN]

BU

BU

BK

BN

BN

BK BU

BN

BK BU

BN

BK BU

BN

BK

1

6200_901-038_V2

-19

-20

7B45

1 7B41 7B44

Intrinsically safe side Sensor for lift limitation, 8-9 Cylinder detection sensor for load measurement, 11-12 Load sensor, 13-14 A44

9S8 9S9 A44

Left-hand door sensor, 2-3 Right-hand door sensor, 4-5 Main Control Unit MCU (truck control unit), 3-5 :X47:7 - left-hand door switch, 4 :X47:22 - right-hand door switch, 3 Main Control Unit MCU (truck control unit), 8 SMZ7 SMZ8

A44

:X47:29 - lift limitation, 8 Main Control Unit MCU (truck control unit), 12-13 :X47:2 - load measurement, 12 :X47:6 - load sensor, 13 Card for zener barriers, 2-6 Card for zener barriers, 7-9 BK BN BU

172391 [EN]

Black Brown Blue

SMZ10 Card for zener barriers, 11-15 * Optional

top

172391 [EN]

6200_901-039_V2

-21

-22

top CPP 5E1 5E2 5E5 5E6 5E10 5E11 5E17 5E18 5E19 5E21 5E28

Top CAN power port, 4-17 Front right-hand headlight, 17 Front left-hand headlight, 10 Front right-hand side light, 14 Front left-hand side light, 7 Front left-hand direction indicator, 5 Front right-hand direction indicator, 13 Front right-hand spotlight, 4 Front left-hand spotlight, 8 Interior lighting, 3 Rear rotating beacon, 19 Rear left-hand spotlight, 11 X53

X52

5E29 7A21 X51

Rear right-hand spotlight, 16 Distributor card, 3 Plug for CPP, CAN, red, 15-17 :1 - GND_H, red, 16 :2 - GND_L, red, 16 :3 - GND_F, C, 15 Plug for CPP supply voltage, 5-6 :1 - 24 V, 6 :1 - 24 V, 5 :2 - GND_F, 5 :2 - GND_F, 5 2 x 2-pin plugs for CPP, 2 switching outputs, 13-14 :1 - roof wiper, OUTPW2, 14 :1 - roof wiper, OUTPW10, 14 X54

:2 - roof wiper, OUTPW1, 13 :2 - roof wiper, GND-F, 14 10 x 2-pin plugs, 14 slots for CPP, 8 switching outputs, 7-12 :1 - rear right-hand spotlight, GND_F, 12 :1 - rear right-hand spotlight, OUTPW4, 12 :2 - rear left-hand spotlight, GND_F, 12 :2 - rear left-hand spotlight, OUTPW4, 11 :3 - rotating beacon, GND_F, 11 :3 - rotating beacon, OUTPW4, 11 :4 - rotating beacon, GND_F, 11 :4 - rotating beacon, OUTPW4, 10 :5 - interior lighting, GND_F, 10 :5 - interior lighting, OUTPW6, 10 * **

172391 [EN]

Optional approx. 400 W

:6 - radio, GND_F, 10 :6 - radio, OUTPW5, 10 :7 - not in use, GND_F, 9 :7 - not in use, OUTPW8, 9 :8 - direction indicator, GND_F, 9 :8 - direction indicator, OUTPW7, 8 :9 - front right-hand spotlight, GND_F, 8 :9 - front right-hand spotlight, OUTPW9, 8 :10 - front left-hand spotlight, GND_F, 8 :10 - front left-hand spotlight, OUTPW9, 7

172391 [EN]

sheet metal cover counterweight

trade mark emblem

6200_901-040_V2

-23

-24

trademark emblem Brand emblem sheet metal cover counterweight Sheet metal cover on counterweight CPP CAN-Power-Port, 4-17 5E3 Right-hand rear light, 16 5E4 Left-hand rear light, 7 5E7 Right-hand stop light, 14 5E8 Left-hand stop light, 9 5E12 Left-hand direction indicator, 6 5E13 Right-hand direction indicator, 16 X52

5E24 5E25 7A21 X51

Left-hand back-up light, 10 Right-hand back-up light, 13 Distributor card, 3 Plug for CPP, CAN, red, 15-17 :1 - GND_H, red, 16 :2 - GND_L, red, 16 :3 - GND_F, C, 15 Plug for CPP supply voltage, 5-6 :1 - 24 V, 6 :1 - 24 V, 5 :2 - GND_F, 5 X54

X53

:2 - GND_F, 5 2 x 2-pin plugs for CPP, 2 switching outputs, 13-14 :1 - OUTPW2, 14 :1 - OUTPW10, 14 :2 - OUTPW1, 13 :2 -GND-F, 14 10 x 2-pin plugs, 14 slots for CPP, 8 switching outputs, 7-10 :1 - GND_F, 10 :1 - OUTPW6, 10 :2 - right-hand direction indicator, GND_F, 10 *

172391 [EN]

:2 - right-hand direction indicator, OUTPW5, 9 :3 - right-hand rear light, GND_F, 9 :3 - right-hand rear light, OUTPW8, 9 :4 - left-hand rear light, GND_F, 9 :4 - left-hand rear light, OUTPW7, 8 :5 - left-hand direction indicator, GND_F, 8 :5 - left-hand direction indicator, OUTPW9, 8 :6 - right-hand stop light, GND_F, 8 :6 - right-hand stop light, OUTPW9, 8 Optional

172391 [EN]

BU/BK BU BK

BK BN

front

BU/WH YE/GN GY

6200_901-041_V2

-25

-26

front CPP 5E1 5E2 5E5 5E6 5E10 5E11 7A21 9M2 X51

Front CAN-Power-Port, 4-17 Front right-hand headlight, 10 Front left-hand headlight, 6 Front right-hand side light, 11 Front left-hand side light, 7 Front left-hand turn indicator, 5 Front right-hand turn indicator, 9 Distributor card, 3 Front windscreen wiper motor, 16-19 Plug for CPP to CAN red, 15-17 :1 - GND_H red, 16 :2 - GND_L red, 16 X54

X53

X52

:3 - GND_F C, 15 Plug for CPP supply voltage, 5-6 :1 - 24 V, 6 :1 - 24 V, 5 :2 - GND_F, 5 :2 - GND_F, 5 2 x 2-pin plugs for CPP, 2 x switching outputs, 13-14 :1 - front windscreen wiper, OUTPW2, 14 :1 - front windscreen wiper, OUTPW10, 14 :2 - front windscreen wiper, OUTPW1, 13 :2 - front windscreen wiper, GND-F, 14 10 x 2-pin plugs, 14 x slots for CPP, 8 x switching outputs, 7-10 :1 - left-hand headlight, GND_F, 10 * **

:1 - left-hand headlight, OUTPW6, 10 :2 - left-hand turn indicator, GND_F, 10 :2 - left-hand turn indicator, OUTPW5, 9 :3 - left-hand side light, GND_F, 9 :3 - left-hand side light, OUTPW8, 9 :4 - right-hand side light, GND_F, 9 :4 - right-hand side light, OUTPW7, 8 :5 - right-hand turn indicator, GND_F, 8 :5 - right-hand turn indicator, OUTPW9, 8 :6 - right-hand headlight, GND_F, 8 :6 - right-hand headlight, OUTPW9, 8 Optional Approx. 238 W

172391 [EN]

BK Black BN Brown BU Blue BU/BK Blue-black BU/WH Blue-white GY Grey YE/GN Yellow-green

172391 [EN]

BU/BK YE/GN

BU/WH GY

BK BN

behind the seat

BU BK

6200_901-042_V2

-27

-28

behind the seat Behind the seat CPP CAN power port, 4-17 7A21 Distributor card, 3 7Y09 Solenoid valve for lift limitation, 12414 9M3 Rear windscreen wiper motor, 4-7 9M10 Windscreen washer motor, 8-9 9M11 Windscreen washer motor, 15-16 9R16 Rear window heating, 10-11 X51 Plug for CPP, CAN, red, 15-17 :1 - GND_H, red, 16 :2 - GND_L, red, 16 :3 - GND_F, C, 15 X52 Plug for CPP supply voltage, 5-6 X54

X53

:1 - 24 V, 6 :1 - 24 V, 5 :2 - GND_F, 5 :2 - GND_F, 5 2 x 2-pin plugs for CPP, 2 switching outputs, 13-14 :1 - rear washer, OUTPW2, 14 :1 - rear washer, OUTPW10, 14 :2 - rear washer, OUTPW1, 13 :2 - rear washer, GND-F, 14 10 x 2-pin plugs, 14 slots for CPP, 8 switching outputs, 7-12 :1 - rear window heating, GND_F, 12 :1 - rear window heating, OUTPW4, 12 :2 - rear window heating, GND_F, 11

:2 - rear window heating, OUTPW4, 11 :3 - seat heater, GND_F, 11 :3 - seat heater, OUTPW4, 11 :4 - seat heater, GND_F, 11 :4 - seat heater, OUTPW4, 10 :5 - rear washer, GND_F, 10 :5 - rear washer, OUTPW6, 10 :6 - front washer, GND_F, 9 :6 - front washer, OUTPW5, 9 :7 - roof washer, GND_F, 9 :7 - roof washer, OUTPW8, 9 :8 - solenoid valve for lift limitation, GND_F, 9 :8 - solenoid valve for lift limitation, OUTPW7, 8 :9 - blower/heating system, GND_F, 8

172391 [EN]

BK Black BN Brown BU Blue BU/BK Blue/black BU/WH Blue/white GY Grey YE/GN Yellow/green

* **

:9 - blower/heating system, OUTPW9, 8 :10 - blower/heating system, GND_F, 8 :10 - blower/heating system, OUTPW9, 7 Optional Max. 396 W

172391 [EN]

6200_901-043_V2

-29

-30

5E5 5E10 5E12 5E13

Front right-hand side light, 7 Front left-hand turn indicator, 5 Left-hand turn indicator, 4 Right-hand turn indicator, 6

7A21 F20 R * **

Distributor card, 9-10 10 A fuse, 3 4.7 resistor Optional Note: 5 mm cable shoes

172391 [EN]

172391 [EN]

6200_901-045_V2

-31

-32

A43 X40 X41 X42

Supply Unit (SU), 1-14 Plug for SU to CAN bus for CPP, 3-4 16-pin SAAB plug, 4-7 16-pin SAAB plug, 8-11

X44 A44 X46 X47 *

42-pin SAAB plug, 7-10 Main Control Unit (MCU - truck control unit), 2-11 42-pin SAAB plug, 5-10 42-pin SAAB plug, 5-10 Optional

172391 [EN]

ORIGINAL ORIGINAL ORIGINAL ORIGINAL 5704.25.010 5704.25.010 5704.25.010 5704.25.010

ORIGINAL ORIGINAL ORIGINAL

24 V 24 V 24 V 24 V 24 V

24 V 24 V 28 V, 3~ 28 V, 3~ 28 V, 3~

Right-hand side light Left-hand rear light Right-hand rear light Left-hand headlight Right-hand headlight Load sensor Cylinder detection for load measurement Fork carriage monitoring Lift limitation Steering angle sensor Hydraulic transmitter for auxiliary hydraulics 2 Hydraulic transmitter for auxiliary hydraulics 1 Hydraulic transmitter for tilting Hydraulic transmitter for lifting Brake sensor Accelerator Drive direction switch Curve switch for left-hand curves Curve switch for right-hand curves Rear window heating Front windscreen washer pump Rear wiper motor Front wiper motor Pump motor Left-hand traction motor

5E5

5E4 5E3

5E2

5E1

7B45

7B44

7B43

7B41

3B1

2B4

2B3

2B2

2B1

1B2

1B1

1S1

3B29

3B28

9R16

9M10

9M3

9M2

2M1

1M2

S042005122 F022070122 F022070122

Left-hand reverse light Right-hand reverse light Right-hand back-up light Left-hand back-up light Rotating beacon

5E29

5E28

5E25

5E24

5E21

24 V

L010039112

ORIGINAL

Signal transmitter

4H2

24 V

Right-hand traction motor Main contactor

1K1

ORIGINAL

ORIGINAL

ORIGINAL

F022070122

F022070122

F022070122 F022070122

F022001122

1M1

172391 [EN]

ORIGINAL

24 V

Left-hand side light

5E6

F022001122

24 V

Right-hand stop light

5E7

F022001122

24 V

24 V

Front left-hand direction indicator Left-hand stop light

5E8

5E10

-33

ORIGINAL

ORIGINAL ORIGINAL ORIGINAL P037038122

ORIGINAL ORIGINAL ORIGINAL ORIGINAL ORIGINAL ORIGINAL S0430211122 ORIGINAL R015010122 B003012122 R015010122 B003012122 24 V, 20 A 24 V

Pump motor converter Converter for left-hand traction motor Converter for right-hand traction motor Right-hand door sensor Left-hand door sensor Switch for buckle Switch for 5th hydraulic function Dead man switch Emergency off switch Seat contact switch Oil level Oil temperature transmitter Brake uid switch Steering switch (diaphragm pressure switch) Switch for interior lighting Horn button (bottom plate) Battery door sensor Parking brake switch Relay Relay Relay

2U03

1U07

1U06

9S9

9S8

7S17

7S15

7S13

7S2

7S1

6S12

6S10

6S4

6S3

5S19

4S1

1S27

1S3

KV

K2

K1

24 V

24 V

ORIGINAL

ORIGINAL

ORIGINAL

ORIGINAL

172391 [EN]

ORIGINAL

Check valve

2Y46

-34

ORIGINAL

Solenoid valve on attachment

7Y08

24 V

Solenoid valve for lift limitation

7Y09

F022001122

Fuse box

A21

ORIGINAL

Front right-hand direction indicator

5E11

24 V

Rear right-hand direction indicator

F022001112

F022001112

Rear left-hand direction indicator

24 V

Right-hand searchlight

5E17

F022001112

5E12

24 V

Left-hand searchlight

5E18

5E13

24 V

Interior lighting

5E19

Fuse

F20

10 A 10 A 20 A

Fuse Fuse for CPP, front

F16

F15

1.6 A

ORIGINAL ORIGINAL S026035122

Fuse for SU/MCU Fuse Fuse Fuse Main fuse Interface card Battery MCU (main control unit) SU (supply unit)

F11

F3

F2

F1

F01

CPP

BATT

A44

A43

5704.09.000 ORIGINAL 5704.25.030 5704.25.020 L032003122

24 V 24 V 24 V 24 V

Reset button Fan Impulse transmitter for pump motor Impulse transmitter for traction motor Impulse transmitter for traction motor Warning light for heating system Pump motor temperature warning light Warning light for temperature of left-hand traction motor Warning light for temperature of right-hand traction motor

PR

MV

L2M1

L1M2

L1M1

L5

L4

L3

L2

CAT 2G

Reset button

PR

L032003122

L032003122

L032003122

P037031122 C109036122

P037046122

R037031122

Voltage regulator Resistor

R

ORIGINAL

ORIGINAL

F047008122 M046046122

ORIGINAL

ORIGINAL

ORIGINAL

ORIGINAL

RV

CAT 2GD IP65

48 V

400 A

500 mA

20 A

10 A

10 A

5A

Fuse for signal horn

F12

ORIGINAL ORIGINAL

50 A

Fuse for voltage transformer Fuse

F13

ORIGINAL

ORIGINAL

ORIGINAL

I041014122 Z045009122 F047021122 M046046122 F047123122 M046046122

F14

15 A

Fuse Fuse

F17

10 A

24 V

F18/F19

172391 [EN]

Exposure

INT

-35

.

S020036122 S020037122 S100169112

S040042122 S021007122

67°C 24 V, 6 relays 24 V, 8 relays 6 modules 6+, 28+, 28+, 28+, 28+, 28+ 6 modules 6+, 18+, 18+, 18+, 18+, 18+ 6 modules 18+, 18+, 18+, 18+, 18+, 18+ 6 modules 18+, 18+, 18+, 6+, 28+, 28+ 3 modules 6+, 18+, 18+

48 V 85°C 85°C 85°C CAT 2GD IP65 CAT 2G

Temperature sensor in pressure-tight housing Intrinsically safe PCB Intrinsically safe PCB Zener barriers Zener barriers Zener barriers Zener barriers Zener barriers Light switch for drive direction Insulation monitoring PCB Temperature sensor for pump motor Temperature sensor for right-hand traction motor Temperature sensor for left-hand traction motor Key switch Key switch

ST12

SSI3

SSI1/SSI2

SMZ6

SMZ5

SMZ3

SMZ2

SMZ1

SF

SD

S2M1

S1M2

S1M1

S1

S1

-36

S120006122

80-48 V / 24 V

Housing temperature sensor

U1/U2

ORIGINAL

172391 [EN]

C060029122

S120010122

S120010122

S120010122

S100012112

S100075112

S100072112

S100126112

A060004122

V041035112

V041035112

24 V

Fan

24 V

Fan

V1

L032003122

V2

24 V

Warning light for insulation monitoring

L1

172391 [EN]

ABEII

ENCM A

=> 24

6200_901-046_V2

-37

-38

1B1 1B2 1M1 1M2 1S1 1S3 1S27 2B1 2B2 2B3 2B4 2M1 2Y46 3B28 3B29 4H2 4S1 5E1

Accelerator, 5 Brake sensor, 1 Right-hand traction motor, 10-12 Left-hand traction motor, 7-9 Drive direction switch, 3 Parking brake switch, 2 Sensor for battery door, 4 Hydraulic transmitter for lifting, 17-19 Hydraulic transmitter for tilting, 17-19 Hydraulic transmitter for auxiliary hydraulics 1, 17-19 Hydraulic transmitter for auxiliary hydraulics 2, 17-19 Pump motor, 12-14 Check valve, 18 Curve switch for right-hand curves, 3 Curve switch for left-hand curves, 4 Signal transmitter, 6 Horn button ( oor plate), 5 Front right-hand headlight, 10

5E2 5E3 5E4 5E7 5E8 5E12 5E13 5E21 5E24 5E25 5E28 5S19 6S3 6S4 6S10 6S12 7B41 7B43 7B44

Front left-hand headlight, 7 Right-hand rear light, 16 Left-hand rear light, 12 Right-hand stop light, 16 Left-hand stop light, 12 Left-hand direction indicator, 12 Right-hand direction indicator, 16 Rotating beacon, 18-19 Left-hand back-up light, 13 Right-hand back-up light. 16 Right-hand reverse light Switch for interior lighting, 5 Steering switch (diaphragm pressure switch), 2 Brake uid switch, 6 Oil temperature transmitter, 3 Oil level, 1 Sensor for lift limitation, 2 Fork carriage monitoring, 3 Cylinder detection for load measurement, 1 7B45 7S1 7S2 7S13 7S15 7S17 7Y08 7Y09 9M2 9S8 9S9 A ABEII BATT ENCM L1M1 L1M2 L2M1 L1

Load sensor, 2 Seat contact switch, 4 Emergency off switch, 4 Dead man switch, 2 Switch for 5th hydraulic function, 1 Switch for buckle, 4 Solenoid valve on attachment, 18 Solenoid valve for lift limitation, 18 Front windscreen wiper motor, 11-12 Left-hand door sensor, 3 Right-hand door sensor, 4 Lever/valve block, 17-19 Display and operating unit, 4-6 48-V battery, 18-19 Pressure-tight housing, 7-16 Impulse transmitter for right-hand traction motor, 9 Impulse transmitter for left-hand traction motor, 9 Impulse transmitter for pump motor, 6 Warning light for insulation monitoring, 3 L4 L5 PR S1 S1M1 S1M2 S2M1 SF V1 V2 X50 *

L3

L2

172391 [EN]

Warning light for temperature of right-hand traction motor, 4 Warning light for temperature of left-hand traction motor, 3 Warning light for pump motor temperature, 4 Warning light for heating system, 3 Reset button, 4 Key switch, 1 Temperature sensor for left-hand traction motor, 5 Temperature sensor for right-hand traction motor, 6 Temperature sensor for pump motor, 5 Drive direction switch, 1 Fan, 15 Fan, 14 Diagnostic connector, 20 Optional

23

top

172391 [EN]

23

front

6200_901-047_V2

-39

-40

5E6

front top 5E5

Front Top Front right-hand side light, 8 Front right-hand side light, 19 Front left-hand side light, 7 5E17

5E11

5E10

Front left-hand side light, 17 Front left-hand turn indicator, 9 Front left-hand turn indicator, 516 Front right-hand turn indicator, 9-10 Front right-hand turn indicator, 18 Front right-hand spotlight, 4 5E29 *

5E18 5E19 5E28

Front left-hand spotlight, 18 Interior lighting, 3 Rear left-hand spotlight, 5 Rear left-hand spotlight, 7 Rear right-hand spotlight, 5 Optional

172391 [EN]

172391 [EN]

6200_901-011_V2

-41

-42

1K1 7S2 A21 A43

Main contactor, 11-12 Emergency off switch, 11 Fuse box, 5-16 Supply Unit (SU), 6-10 :X42:1 - 12 V, L, current sensor, 14 :X42:2 - 48-V fuse, 16 :X42:3 - relay for signal horn, 17 :X42:4 - contactor A1, 15 :X42:5 - contactor A2, 15 BATT F01 F11

:X42:6 - U load, 16 :X42:7 - signal transmitter, 16 :X42:8 - GND_F, 17 :X42:9 - current sensor, 14 :X42:10 - GND_L, current sensor, 15 :X42:11 - GND_F, relay for signal horn, 16 :X42:12 - GND_L, battery, 14 48-V battery, 2 400-A main fuse, 13 Fuse for SU/MCU, 14 K1 U10 V1 X1 X2

F12 F14 F15

5-A fuse for signal horn, 14 15-A/30-A fuse for voltage transformer (U1-2), 15 10-A fuse for CPP, front, 15 Voltage transformer U4, 10 A Solenoid valve on attachment, 10 A 24-V relay, 6 Current sensor, 8 24-V fan, 5 Positive battery male connector, 2 Negative battery male connector, 2 *

X20 X21 X22 X26 X27 X271

172391 [EN]

Plug for control cables to SU, 7-10 Plug for signal horn, 5 Plug for contactor coil, 11 Plug for signal transmitter, 5 Plug for voltage converter, U1, U2, 16 Plug for voltage converter U4, feed to 5th hydraulics, 16 Optional

172391 [EN]

(GN/YE) (GY) (BK) (BN)

(GN/YE) (GY) (BK) (BN)

6200_901-012_V2

-43

-44

F24 F25

F23

F22

7A21 A44

Distributor plate, 2-7 Main Control Unit (MCU - truck control unit), 12-3 X48:14 - 24 V, 13 X48:15 - GND_F, 12 50-A fuse for heating system, 5 Note: 5-mm cable shoes 10-A fuse for option board, solenoid valve on attachment, 5 10-A fuse for CPP, rear, 5 10-A fuse for proportional technology, 4

25-A fuse for CPP, roof, 5 25-A fuse for CPP, seat, 5 10-A fuse for CPP, front, 5 15-A fuse for Option Board, material management system (MMS), 3 U1 Voltage converter U1, 18-19 U2 Voltage converter U2, 18-19 X35 Plug for feed to 5th hydraulic function, CPP, roof, 9 X37 Plug for 12-V supply, 9 X52 Plug for supply voltage X52_1 Plug for CPP, front, 14

F26 F27 F28 F29

X66 X66 X66

X65

X52_2 X52_3 X63 X64 X65

Plug for CPP, roof, 15-16 Plug for CPP, seat, 17-18 Plug for Option Board, 3 Plug for CPP, rear, 3 Plug for Option Board, CPP, front, proportional technology, 3-4 Plug for Option Board, CPP, front, proportional technology, 12-13 Plug for CPP, roof, 3 Plug for CPP, roof, 9 Plug for CPP, roof, 15-16 BK BN GNYE GY

X67 X81 X81 X82 X83 *

172391 [EN]

Black Brown Green/yellow Grey

Plug for CPP, seat, 3 Plug for voltage converter, U1, U2, 6 Plug for voltage converter, U1, U2, 8 Plug for voltage converter, 6-7 Plug for voltage converter, 6-7 Optional

172391 [EN]

BK

GY

BU

BK

RD

BN

BK

GY

BU

BK

RD

BN

WH

GN/YE

GN/YE

BK

GY

BU

BK

RD

BN

WH

GN/YE

6200_901-013_V2

-45

-46

1U07

1M1 1M2 2M1 1U06

Right-hand traction motor, 15-19 Left-hand traction motor, 2-7 Pump motor, 9-13 Converter for right-hand traction motor, 14-19 X151:1 - GND_L, 18 :X151:2 - GND_F, 18 :X151:3 - A FM1, 16 :X151:4 - CAN_H - 17 :X151:5 - B FM1, 17 :X151:6 - CAN_L, 18 :X151:7 - 10 V DZS, 17 :X151:8 - 24 V switched, 18 :X151:9 - U 1M1, 16 :X151:10 - enable converter, 17 :X151:11 - V 1M1, 15 :X151:12 - temperature sensor FM1 +, 18 :X151:14 - temperature sensor FM1 , 19 Converter for left-hand traction motor, 1-7 :X152:1 - GND_L, 5 :X152:2 - GND_F, 6 :X152:3 - A FM2, 3 :X152:4 - CAN_H, 5 :X152:5 - B FM2, 4 :X152:6 - CAN_L, 6 :X152:7 - 10 V DZS - 4 A43

2U03

:X152:8 - 24 V switched, 6 :X152:9 - U 1M2, 5 :X152:10 - enable converter, 5 :X152:11 - V FM2, 2 :X152:12 - temperature sensor FM2 +, 6 :X152:14 - temperature sensor FM2 , 6 Pump motor, 7-13 :X150:1 - GND_L, 9 :X150:2 - GND_F, 13 :X150:3 - speed 1, 11 :X150:4 - CAN_H, 12 :X150:6 - speed 2, 10 :X150:6 - CAN_L, 12 :X150:7 - 10 V DZS, 10 :X150:8 - V 2M1, 11 :X150:8 - 24 V switched, 12 :X150:10 - enable converter, 11 :X150:12 - temperature sensor for pump motor +, 12 :X150:13 - W 2M1, 9 :X150:14 - temperature sensor for pump motor, 14 Supply Unit (SU), 2-7 :X44:1 - GND_F 1U07, 6 :X44:2 - 24 V 1U07, 6 :X44:3 - CAN_H 1U07, 6 :X44:4 - CAN_L 1U07, 6 :X44:5 - enable 1U07, 5 L1M1 L1M2

A43

A43

:X44:6 - V FM2 1U07, 2 :X44:7 - track A FM2 1U07, 3 :X44:8 - track B FM2 1U07, 4 :X44:9 - U FM2 1U07, 5 :X44:36 - track A FM2 axle, 7 :X44:37 - track B FM2 axle, 7 Supply Unit (SU), 10-13 :X44:15 - GND_F 2U03, 13 :X44:16 - 24 V 2U03, 12 :X44:17 - CAN_H 2U03, 12 :X44:18 - CAN_L 2U03, 12 :X44:19 - enable 2U03, 11 Supply unit (SU), 15-20 :X44:21 - track A FM1 1U06, 16 :X44:22 - track B FM1 1U06, 16 :X44:23 - track A FM1 axle, 20 :X44:24 - track B FM1 axle, 20 :X44:29 - GND_F 1U06, 18 :X44:30 - 24 V 1U06, 18 :X44:31 - CAN_H 1U06, 18 :X44:32 - CAN_L 1U06, 18 :X44:33 - enable 1U06, 17 :X44:34 - V FM1 1U06, 15 :X44:35 - U FM1 1U06, 17 Speed sensor for right-hand traction motor, 17-18 Speed sensor for left-hand traction motor, 4-5 BK BN BU GNYE RD WH

FM1 FM2

172391 [EN]

Black Brown Blue Green-yellow Red White

Right-hand traction motor Left-hand traction motor

L2M1 Speed sensor for pump motor, 11 ST1M1 Temperature sensor for right-hand traction motor, 18-19 ST1M2 Temperature sensor for left-hand traction motor, 6 ST2M1 Temperature sensor for pump motor, 12-13 X10 Plug for speed sensor of right-hand traction motor, 17-18 X11 Plug for temperature sensor of right-hand traction motor, 18-19 X12 Plug for speed sensor of left-hand traction motor, 4-5 X13 Plug for temperature sensor of left-hand traction motor, 6 X14 Plug for speed sensor of pump motor, 11 X15 Plug for temperature sensor of pump motor, 12-13 + Optional

172391 [EN]

6200_901-061

-47

-48

A44

6S4 7S1 A43 A44

Brake uid switch, 4-5 Seat contact switch, 6 Supply Unit (SU), 2-4 :X41:6 - switch lock, 3 :X41:10 - 48-V U battery, 4 :X41:13 - emergency off switch, 3 Main Control Unit MCU (truck control unit), 4-7 :X46:8 - seat contact switch, 6 K4 K5 L1

A44

:X46:9 - brake uid switch, 5 :X46:21 - GND_S, seat contact switch, 7 :X46:22 - GND_S, brake uid switch, 5 :X47:8 - digital res2, 6 Main Control Unit MCU (truck control unit), 12-14 :X47:8 - digital res2, 13 Relay, 9 Relay, 10 Warning light for insulation monitoring, 11

PR S1 S1M1 S1M2 S2M1 STF SMT SMP *

Reset button, 11-12 Key switch, 3 Temperature sensor for left-hand traction motor, 9-10 Temperature sensor for right-hand traction motor, 9-10 Temperature sensor for pump motor, 9-10 Sensor for brake temperature, 9 Temperature sensor for traction motor, 9 Temperature sensor for pump motor, 9 Optional

172391 [EN]

172391 [EN]

YE

RD RD

YE

YE RD

BU

BN

6200_901-062

-49

-50

1B1 1B2 3B1 1S1 1S3 4H1 4S1 6S3 A21 A44

Accelerator, 11-13 Brake sensor, 14-15 Steering angle sensor, 16-17 Drive direction switch, 7-8 Parking brake switch, 5 Signal transmitter, 19 Horn button (bottom plate), 6-7 Steering switch (diaphragm pressure switch), 2-3 Fuse box, 19 Main Control Unit MCU (truck control unit), 2-19

:X46:3 - parking brake, 5 :X46:10 - signal horn button, 6 :X46:11 - accelerator 2, 7 :X46:11 - accelerator 2, 12 :X46:12 - accelerator 1, 12 :X46:13 - brake sensor, 14 :X46:16 - GND_S, accelerator 1 and 2, 7 :X46:17 - GND_S, parking brake switch, 5 :X46:18 - GND_S, drive direction switch, 9 :X46:19 - GND_S, steering switch (diaphragm pressure switch), 3

:X46:23 - GND_S, steering angle sensor, 18 :X46:25 - GND_S, signal horn button, 7 :X46:26 - GND_S, accelerator 1 and 2, 13 :X46:27 - GND_S, brake sensor, 14 :X46:30 - drive direction switch actuated, 9 :X46:31 - drive direction switch for backwards, 10 :X46:32 - drive direction switch for forwards, 10 :X46:33 - steering switch (diaphragm pressure switch), 2 :X46:35 - steering angle sensor, track B, 18 :X46:36 - steering angle sensor, track A, 17 Brown Blue Red Yellow

* BN BU RD YE

172391 [EN]

:X46:37 - steering angle sensor, track NN, 17 :X46:38 - 12 V, S, steering angle sensor, 17 :X46:40 - 12 V, S, accelerator, 7 :X46:40 - 12 V, S, accelerator, 11 :X46:41 - 12 V, S, brake sensor, 15 Optional

172391 [EN]

YE RD

YE

RD

6200_901-063

-51

-52

1S27 5S19 6S10 6S12 7S13 7S15 7S17

Battery door sensor, 4 Switch for interior lighting, 11 Oil temperature transmitter, 5 Oil level, 7 Dead man switch, 13 Switch for 5th hydraulic function, 14 Switch for buckle, 2

7Y08 7Y09 A43

Solenoid valve on attachment, 18 Solenoid valve for lift limitation, 18 Supply Unit (SU), 4-8 :X43:3 - oil level, 7 :X43:11 - GND_L, oil level, 8 :X44:11 - 12 V, L, battery door, 5 :X44:14 - 12 V, L, oil temperature transmitter, 6 :X44:25 - battery door, 4 A44

A44

:X44:38 - oil temperature transmitter, 6 :X44:39 - GND_L, battery door, 4 :X44:40 - GND_L, oil temperature transmitter, 5 Main Control Unit MCU (truck control unit), 2 :X46:20 - GND_S, switch for buckle, 2 :X46:34 - switch for buckle, 2 Main Control Unit MCU (truck control unit), 13-15 :X47:1 - GND_F, 13 Green Red Yellow

GN RD YE

172391 [EN]

:X47:17 - 5th hydraulic function, 14 :X47:35 - dead man switch, 14 Optional

*

172391 [EN]

6200_901-064

-53

-54

A43

Supply Unit (SU), 2-5 :X41:3 - track A, FM2, 4 :X41:4 - track B, FM2, 4 :X41:7 - CAN_L, 3

:X41:9 - MCU reset, 3 :X41:11 - track A, FM1, 3 :X41:12 - track B, FM1, 3 :X41:14 - converter enable command, 2 :X41:15 - CAN_H, 2

A44

Main Control Unit (MCU - truck control unit), 7-9 :X47:10 - CAN_H, 9 :X47:11 - MCU reset, 8 :X47:12 - track B, FM1, 9 :X47:13 - track A, FM2, 7

172391 [EN]

:X47:24 - CAN_L, 8 :X47:25 - converter enable command, 9 :X47:26 - track B, FM2, 8 :X47:27 - track A, FM1, 8

A

172391 [EN]

BU

BN

BK

BK BU

3B28

BN 3B29

6345_901-024

-55

-56

2B1 2B2 2B3 2B4 2Y46 3B28 3B29 A A43

Hydraulic transmitter for lifting, 3 Hydraulic transmitter for tilting, 5 Hydraulic transmitter for auxiliary hydraulics 1, 6 Hydraulic transmitter for auxiliary hydraulics 2, 7 Check valve, 3 Curve switch for right-hand curves, 14-15 Curve switch for left-hand curves, 16 Valve block, 3-8 Supply Unit (SU), 14-17 A44

:X44:10 - left-hand curve switch (digital), 15 :X44:12 - 12 V -L steering axle position, 11 :X44:13 - 12 V -L steering axle centre, 17 :X44:27 - Right-hand curve switch (digital), 16 :X44:41 - GND_L steering axle position, 14 :X44:42 - GND_L steering axle centre, 16 Main Control Unit (MCU - truck control unit), 2-11 :X46:2 - lowering off, 3 :X46:4 - auxiliary hydraulics 1, 5 :X46:5 - auxiliary hydraulics 2, 5

:X46:6 - lifting, 4 :X46:7 - tilting, 5 :X46:15 - GND_S lowering off, 3 :X46:24 - GND_S valve block, 5 :X46:39 - 12 V -S valve block, 6 :X47:39 - display for right direction, 11 :X47:40 - display for left direction, 10 :X47:41 - display for reverse direction, 10 :X47:42 - display for forwards direction, 10 :X47:37 - display minus, 9 Black Brown Blue

BK BN BU

172391 [EN]

:X47:38 - display for message, 10 6-pin SAAB-Stecker, 3-8 Optional

X19 *

172391 [EN]

A

X41:18

B

CPP

ABEII

6200_901-066

-57

-58

ABEII A43

A

Diagnostic connector, 3-5 :X50:1 - CAN_H, red, 4 :X50:2 - CAN_L, red, 4 :X50:3 - 24 V, 5 :X50:4 - GND_F, 4 Display and operating unit, 13-17 Supply Unit (SU), 4-8 :X40:1 - CAN_H, 4 :X40:2 - CAN_L, 5 :X40:3 - 24 V, 5 :X40:4 - GND_F, 4 A44

:X41:1 - GND_F, 5 :X41:2 - 24 V, CAN bus, 6 :X41:16 - CAN_H, red, 6 :X41:18 - CAN_L, red, 6 :X48:14 - 24 V, 7 :X48:15 - GND_F, 8 Main Control Unit MCU (truck control unit), 10-17 :X45:1 - CAN_H, red, 11 :X45:2 - CAN_L, red, 10 :X45:3 - 24 V, 10 :X45:4 - GND_F, 10 :X46:1 - CAN_H, red, 14 B

:X46:29 - CAN_L, red, 11 :X47:9 - CAN_H, red, 11 :X47:14 - 24 V, 10 :X47:20 - , CAN_L, red, 17 :X47:21 - CAN_H, red, 17 :X47:23 - CAN_L, red, 12 :X47:28 - CAN_L, red, 11 :X47:31 - GND_F, 14 :X47:36 - GND_F, 16 Joystick :X70:1 - CAN_H, red, 11 :X70:2 - CAN_L, red, 12 X49 X51 *

CPP

172391 [EN]

:X70:3 - 24 V, 11 :X70:4 - GND_F, 11 CAN-Power-Port, 16-17 :1 - CAN_H, red, 17 :2 - CAN_L, red, 17 :3 - GND_F, 16 6-pin MARK II connector, 13-15 Plug for CAN bus to CPP, 14-15 Optional

BU

BN

BK

172391 [EN]

BU

BN

BK

BU

BN

BK

BU

BU BK

BN

BN

BK

BU

BN

BK

6200_901-067

-59

-60

7B41 7B43 7B44 7B45 9S8

Sensor for lift limitation, 7 Fork carriage monitoring, 11-12 Cylinder detection for load measurement, 16 Load sensor, 17-18 Left-hand door sensor, 2 A44

9S9 A44

Right-hand door sensor, 4 Main Control Unit (MCU - truck control unit), 2-4 :X47:7 - left-hand door switch, 3 :X47:22 - right-hand door switch, 4 Main Control Unit (MCU - truck control unit), 7-8 :X47:29 - lift limitation, 7 A44

A44

Main Control Unit (MCU - truck control unit), 10-13 :X47:16 - fork carriage S2, 11 :X47:30 - fork carriage S1, 12 Main Control Unit (MCU - truck control unit), 16-18 :X46:6 - load sensor, 18 :X47:22 - right-hand door switch, 3 Black Brown Blue

BK BN BU

172391 [EN]

Optional

*

top

172391 [EN]

6200_901-039_V2

-61

-62

top CPP 5E1 5E2 5E5 5E6 5E10 5E11 5E17 5E18 5E19 5E21 5E28

Top CAN power port, 4-17 Front right-hand headlight, 17 Front left-hand headlight, 10 Front right-hand side light, 14 Front left-hand side light, 7 Front left-hand direction indicator, 5 Front right-hand direction indicator, 13 Front right-hand spotlight, 4 Front left-hand spotlight, 8 Interior lighting, 3 Rear rotating beacon, 19 Rear left-hand spotlight, 11 X53

X52

5E29 7A21 X51

Rear right-hand spotlight, 16 Distributor card, 3 Plug for CPP, CAN, red, 15-17 :1 - GND_H, red, 16 :2 - GND_L, red, 16 :3 - GND_F, C, 15 Plug for CPP supply voltage, 5-6 :1 - 24 V, 6 :1 - 24 V, 5 :2 - GND_F, 5 :2 - GND_F, 5 2 x 2-pin plugs for CPP, 2 switching outputs, 13-14 :1 - roof wiper, OUTPW2, 14 :1 - roof wiper, OUTPW10, 14 X54

:2 - roof wiper, OUTPW1, 13 :2 - roof wiper, GND-F, 14 10 x 2-pin plugs, 14 slots for CPP, 8 switching outputs, 7-12 :1 - rear right-hand spotlight, GND_F, 12 :1 - rear right-hand spotlight, OUTPW4, 12 :2 - rear left-hand spotlight, GND_F, 12 :2 - rear left-hand spotlight, OUTPW4, 11 :3 - rotating beacon, GND_F, 11 :3 - rotating beacon, OUTPW4, 11 :4 - rotating beacon, GND_F, 11 :4 - rotating beacon, OUTPW4, 10 :5 - interior lighting, GND_F, 10 :5 - interior lighting, OUTPW6, 10 * **

172391 [EN]

Optional approx. 400 W

:6 - radio, GND_F, 10 :6 - radio, OUTPW5, 10 :7 - not in use, GND_F, 9 :7 - not in use, OUTPW8, 9 :8 - direction indicator, GND_F, 9 :8 - direction indicator, OUTPW7, 8 :9 - front right-hand spotlight, GND_F, 8 :9 - front right-hand spotlight, OUTPW9, 8 :10 - front left-hand spotlight, GND_F, 8 :10 - front left-hand spotlight, OUTPW9, 7

172391 [EN]

sheet metal cover counterweight

trade mark emblem

6200_901-068

-63

-64

trademark emblem Brand emblem sheet metal cover counterweight Sheet metal cover on the counterweight CPP CAN Power Port, 4-17 5E3 Right-hand rear light, 16 5E4 Left-hand rear light, 7 5E7 Right-hand stop light, 14 5E8 Left-hand stop light, 9 5E12 Left-hand turn indicator, 6 5E13 Right-hand turn indicator, 16 X52

5E24 5E25 7A21 X51

Left-hand back-up light, 10 Right-hand back-up light, 13 Distributor card, 3 Plug for CPP CAN red, 15-17 :1 - GND_H red, 16 :2 - GND_L red, 16 :3 - GND_F C, 15 Plug for CPP supply voltage, 5-6 :1 - 24 V, 6 :1 - 24 V, 5 :2 - GND_F, 5 X54

X53

:2 - GND_F, 5 2 x 2-pin plugs for CPP, 2 x switching outputs, 13-14 :1 - OUTPW2, 14 :1 - OUTPW10, 14 :2 - OUTPW1, 13 :2 -GND-F, 14 10 x 2-pin plugs, 14 x slots for CPP, 8 x switching outputs, 7-10 :1 - GND_F, 10 :1 - OUTPW6, 10 :2 - right-hand turn indicator, GND_F, 10 *

172391 [EN]

:2 - right-hand turn indicator, OUTPW5, 9 :3 - right-hand rear light, GND_F, 9 :3 - right-hand rear light, OUTPW8, 9 :4 - left-hand rear light, GND_F, 9 :4 - left-hand rear light, OUTPW7, 8 :5 - left-hand turn indicator, GND_F, 8 :5 - left-hand turn indicator, OUTPW9, 8 :6 - right-hand stop light, GND_F, 8 :6 - right-hand stop light, OUTPW9, 8 Optional

172391 [EN]

BK BU/BK BU BN

YE

front

BU/WH BK

YE/GN

6200_901-069

-65

-66

front CPP 5E1 5E2 5E5 5E6 5E10 5E11 7A21 9M2 X51

Front CAN power port, 4-17 Front right-hand headlight, 10 Front left-hand headlight, 6 Front right-hand side light, 11 Front left-hand side light, 7 Front left-hand direction indicator, 5 Front right-hand direction indicator, 9 Distributor card, 3 Front windscreen wiper motor, 16-19 Plug for CPP, CAN, red, 15-17 :1 - GND_H, red, 16 :2 - GND_L, red, 16 X54

X53

X52

:3 - GND_F, C, 15 Plug for CPP supply voltage, 5-6 :1 - 24 V, 6 :1 - 24 V, 5 :2 - GND_F, 5 :2 - GND_F, 5 2 x 2-pin plugs for CPP, 2 switching outputs, 13-14 :1 - front windscreen wiper, OUTPW2, 14 :1 - front windscreen wiper, OUTPW10, 14 :2 - front windscreen wiper, OUTPW1, 13 :2 - front windscreen wiper, GND-F, 14 10 x 2-pin plugs, 14 slots for CPP, 8 switching outputs, 7-10 :1 - left-hand headlight, GND_F, 10 * **

:1 - left-hand headlight, OUTPW6, 10 :2 - left-hand direction indicator, GND_F, 10 :2 - left-hand direction indicator, OUTPW5, 9 :3 - left-hand side light, GND_F, 9 :3 - left-hand side light, OUTPW8, 9 :4 - right-hand side light, GND_F, 9 :4 - right-hand side light, OUTPW7, 8 :5 - right-hand direction indicator, GND_F, 8 :5 - right-hand direction indicator, OUTPW9, 8 :6 - right-hand headlight, GND_F, 8 :6 - right-hand headlight, OUTPW9, 8 Optional approx. 238 W

172391 [EN]

BK Black BN Brown BU Blue BU/BK Blue/black BU/WH Blue/white GY Grey YE/GN Yellow/green

172391 [EN]

BU/BK

BU/WH GY

BK BN

behind the seat

BU BK

YE/GN

6200_901-070

-67

-68

behind the seat Behind the seat CPP CAN Power Port, 4-17 7A21 Distributor card, 3 7Y09 Solenoid valve for lift limits, 12-14 9M3 Rear windscreen wiper motor, 4-7 9M10 Windscreen washer motor, 8-9 9M11 Windscreen washer motor, 15-16 9R16 Rear window heating, 10-11 VR Blower/heating system, 17-20 X51 Plug for CPP CAN red, 15-17 :1 - GND_H red, 16 :2 - GND_L red, 16 :3 - GND_F C, 15 X54

X53

X52

Plug for CPP supply voltage, 5-6 :1 - 24 V, 6 :1 - 24 V, 5 :2 - GND_F, 5 :2 - GND_F, 5 2 x 2-pin plugs for CPP, 2 x switching outputs, 13-14 :1 - rear window washer motor, OUTPW2, 14 :1 - rear window washer motor, OUTPW10, 14 :2 - rear window washer motor, OUTPW1, 13 :2 - rear window washer motor, GND-F, 14 10 x 2-pin plugs, 14 x slots CPP, 8 x switching outputs, 7-12 :1 - rear window heating, GND_F, 12 :1 - rear window heating, OUTPW4, 12

:2 - rear window heating, GND_F, 11 :2 - rear window heating, OUTPW4, 11 :3 - seat heater, GND_F, 11 :3 - seat heater, OUTPW4, 11 :4 - seat heater, GND_F, 11 :4 - seat heater, OUTPW4, 10 :5 - rear window washer motor, GND_F, 10 :5 - rear window washer motor, OUTPW6, 10 :6 - front window washer motor, GND_F, 9 :6 - front window washer motor, OUTPW5, 9 :7 - roof washer motor, GND_F, 9 :7 - roof washer motor, OUTPW8, 9 :8 - solenoid valve for lift limits, GND_F, 9 :8 - solenoid valve for lift limits, OUTPW7, 8

172391 [EN]

BK Black BN Brown BU Blue BU/BK Blue-black BU/WH Blue-white GY Grey YE/GN Yellow-green

* **

:9 - blower/heating system, GND_F, 8 :9 - blower/heating system, OUTPW9, 8 :10 - blower/heating system, GND_F, 8 :10 - blower/heating system, OUTPW9, 7 Optional Max. 396 W

172391 [EN]

6200_901-071

-69

-70

F20 6S5

Fuse, 16 Thermostat, 120°C, 8

6S6 9S18 KR

Thermostat, 120°C, 9 Blower switch, 12 Relay, 5

R1 R2 R3

Heating resistor, 47 Heating resistor, 47 Heating resistor, 47

, 7150 W, 7-8 , 7150 W, 7-8 , 7150 W, 7-8

VR *

172391 [EN]

Blower, 5 Optional

172391 [EN]

6200_901-072

-71

-72

5E10

Front left-hand direction indicator, 7

5E11 5E12

Front right-hand direction indicator, 16 Rear left-hand direction indicator, 8

5E13 SFR

Rear right-hand direction indicator, 15 Turn indicator switch, 9-13

*

172391 [EN]

Optional

172391 [EN]

VT VT BK RD GN RD BK

RD

A

BU

RD BN BN

BU

BU BU BU

6200_901-073

-73

-74

A FHV KR KR1 ST01

Connections for original 80-V heating system controller 5-A fuse, 14 Relay, 10-11 Relay, 2-3 Temperature sensor, 75°C, 2

Temperature sensor, 75°C, 2 Blower, 15 Optional Black

ST02 VR * BK

BN BU GN RD VT

Brown Blue Green Red Violet

172391 [EN]

A

BU

172391 [EN]

BU

BN BN BN

6200_901-074

-75

-76

9S18 9S27 A *

Blower switch, 5-9 Heating switch, 10-14 Connections for original 80-V heating system controller Optional

BN BU

Brown Blue

172391 [EN]

172391 [EN]

6200_901-075

-77

-78

1S3 ELF

Parking brake switch, 7-8 Electric parking brake, 1-10 :X506:1 - brake, 3 :X506:2 - GND, 7

:X506:3 - push button in, 5 :X506:4 - push button in, 3 :X506:5 - GND, 5 :X506:6 - status LED, 4 :X506:7 - status LED, 5

:X506:8 - U switch lock, 7 :X506:9 - CAN_H, 8 :X506:10 - CAN_L, 9 :X506:11 - GND_Bus, 9 :X506:12 - end position, 7 *

172391 [EN]

:X506:13 - GND, 10 :X506:14 - GND, 10 :X506:15 - battery +, 8 :X506:16 - battery +, 10 Optional

172391 [EN]

X48

6200_901-076

-79

-80

2B5 2Y1 2Y2 2Y3 2Y4 2Y5 2Y6 2Y7 2Y8 2Y9

Pressure sensor, 18-19 Solenoid coil for lifting, 4-5 Solenoid coil for lowering, 5-6 Solenoid coil for tilting backwards, 10-11 Solenoid coil for tilting forwards, 9-10 Solenoid coil for auxiliary hydraulics 1 positive, 7 Solenoid coil for auxiliary hydraulics 1 negative, 8 Solenoid coil for auxiliary hydraulics 2 positive, 12 Solenoid coil for auxiliary hydraulics 2 negative, 13 Check valve for hydraulics blocking function, 15-16

2Y10 2Y11 X48

Solenoid coil for load switching, 14 Solenoid coil for use of lowering function, 16-17 42-pin SAAB connector for servo hydraulics, 3-20 :X48:1 - GND_F, 3 :X48:2 - 24 V switched, 4 :X48:3 - lifting, 4 :X48:4 - 24 V switched, 5 :X48:5 - lowering, 6 :X48:6 - 24 V switched, 7 :X48:7 - auxiliary hydraulics 1 positive, 7 :X48:8 - 24 V switched, 8

:X48:9 - auxiliary hydraulics 1 negative, 8 :X48:10 - 24 V switched, 9 :X48:11 - tilting forwards, 9 :X48:12 - 24 V switched, 10 :X48:13 - tilting backwards, 10 :X48:14 - 24 V switched, 17 :X48:15 - GND_F, 18 :X48:16 - 24 V switched, 11 :X48:17 - auxiliary hydraulics 2 positive, 12 :X48:18 - 24 V switched, 12 :X48:19 - auxiliary hydraulics 2 negative, 13 *

172391 [EN]

:X48:22 - 24 V switched ,14 :X48:23 - load switching, 14 :X48:24 - 24 V switched,15 :X48:25 - check valve for hydraulics blocking function, 15 :X48:41 - 24 V switched, 16 :X48:42 - using lowering function, 17 Optional

172391 [EN]

A

6200_901-026_V2

-81

-82

A A43

Original 80-V heating system controller Supply Unit (SU), 1-14

X40 X41 X42

SU plug, CAN bus for CPP, 3-4 16-pin SAAB plug, 4-7 16-pin SAAB plug, 8-11

X44 A44 X46

42-pin SAAB plug, 7-10 Main Control Unit (MCU - truck control unit), 2-11 42-pin SAAB plug, 5-10

X47 *

172391 [EN]

42-pin SAAB plug, 5-10 Optional

ORIGINAL ORIGINAL ORIGINAL ORIGINAL ORIGINAL ORIGINAL ORIGINAL 5704.25.010 5704.25.010 5704.25.010 5704.25.010

ORIGINAL ORIGINAL ORIGINAL

24 V 24 V 24 V 24 V 24 V

24 V 24 V 75°C 75°C 28 V, 3~

Right-hand side light Left-hand rear light Right-hand rear light Left-hand headlight Right-hand headlight Position, steering axle, left Position, steering axle, right Load sensor Cylinder detection for load measurement Fork carriage monitoring Lift limitation Steering angle sensor Hydraulic transmitter for auxiliary hydraulics 3 Hydraulic transmitter for auxiliary hydraulics 2 Hydraulic transmitter for auxiliary hydraulics 1 Hydraulic transmitter for tilting Hydraulic transmitter for lifting Transmitter Transmitter Brake sensor Accelerator Drive direction switch Curve switch for left-hand curves Curve switch for right-hand curves Rear window heating Rear windscreen washer pump Front windscreen washer pump Rear wiper motor Front wiper motor Temperature probe Temperature probe

5E5

5E4 5E3

5E2

5E1

8B29

8B28

7B45

7B44

7B43

7B41

3B1/3B01

2B5

2B4

2B3

2B2

2B1

1B4

1B3

1B2

1B1

1S1

3B29

3B28

9R16

9M11

9M10

9M3

9M2

ST01

ST02

28 V, 3~ 28 V, 3~

Pump motor Left-hand traction motor Right-hand traction motor

2M1

1M2

1M1

172391 [EN]

ORIGINAL

24 V

Left-hand side light

5E6

S120006122

S120006122

ORIGINAL

ORIGINAL

ORIGINAL

ORIGINAL

ORIGINAL

F022070122

F022070122

F022070122 F022070122

F022001122

F022001122

24 V

Right-hand stop light

5E7

F022001122

24 V

24 V

Front left-hand direction indicator Left-hand stop light

5E8

5E10

-83

24 V

Interior lighting Left-hand searchlight Right-hand searchlight Rear right-hand direction indicator Rear left-hand direction indicator Front right-hand direction indicator

5E19

5E18

5E17

5E13

5E12

5E11

ORIGINAL

24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V

Check valve for hydraulics blocking function Solenoid coil for auxiliary hydraulics 2, negative Solenoid coil for auxiliary hydraulics 2, positive Solenoid coil for auxiliary hydraulics 1, negative Solenoid coil for auxiliary hydraulics 1, positive Solenoid coil for tilting forwards Solenoid coil for tilting backwards Solenoid coil for lowering Solenoid coil for lifting Pump motor converter Converter for left-hand traction motor Converter for right-hand traction motor

2Y9

2Y8

2Y7

2Y6

2Y5

2Y4

2Y3

2Y2

2Y1

2U03

1U07

1U06

-84

ORIGINAL

24 V

Solenoid coil for load switching

2Y10

ORIGINAL

ORIGINAL

ORIGINAL

ORIGINAL

ORIGINAL

ORIGINAL

ORIGINAL

ORIGINAL

ORIGINAL

ORIGINAL

ORIGINAL

ORIGINAL

24 V

Solenoid coil for lowering

2Y11

ORIGINAL

24 V

Check valve

2Y46

24 V

Solenoid valve for lift limitation Solenoid valve on attachment

ORIGINAL

172391 [EN]

F022001122

7Y08

24 V

24 V

F022001122

F022001112

F022001112

F022001112

7Y09

Front left-hand direction indicator

24 V

Rotating beacon

5E21

Fuse box

24 V

Left-hand back-up light

5E24

A21

24 V

Right-hand back-up light

5E25

5E10

F022070122

Right-hand reverse light

5E28

24 V

F022070122

Left-hand reverse light

5E29

L010028122

ORIGINAL S042031122

Signal transmitter

4H1

24 V

Main contactor

1K1

R037019122 R037019122 ORIGINAL ORIGINAL ORIGINAL S040042122 C109039122 ORIGINAL ORIGINAL ORIGINAL ORIGINAL

ORIGINAL ORIGINAL

Heating resistor Heating resistor Temperature sensor for right-hand traction motor Temperature sensor for left-hand traction motor Temperature sensor for pump motor Turn indicator switch Diagnostic connector Diagnostic connector Diagnostic connector Diagnostic connector Negative battery male connector Positive battery male connector Blower/heating system Right-hand door sensor Left-hand door sensor Switch for buckle

R2

R3

ST1M1

ST2M1

ST1M2

SFR

XK4

XK3

XK2

XK1

X2

X1

VR

9S9

9S8

7S17

P037038122

ORIGINAL ORIGINAL

Emergency off switch Seat contact switch Oil level Oil temperature transmitter Thermostat Thermostat Brake uid switch

7S2

7S1

6S12

6S10

6S6

6S5

6S4

ORIGINAL

S120064122

S120064122

ORIGINAL

ORIGINAL

Switch for 5th hydraulic function Dead man switch

7S13

ORIGINAL

7S15

172391 [EN]

R037019122

Heating resistor

R1

ORIGINAL

R015010122 Z045009122

Relay

KR1

+

ORIGINAL

Relay

KR 24 V

6280.25.005

Blower switch

9S18

6280.25.010

Heating switch

9S27

-85

S0430211122 ORIGINAL R015010122 B003012122 R015010122 B003012122

ORIGINAL ORIGINAL

24 V, 20 A 24 V 24 V

10 A 10 A 20 A 50 A 5A

Battery door sensor Parking brake switch Relay Relay Relay Exposure Fuse Fuse Fuse Fuse Fuse for CPP, front Fuse for voltage transformer Fuse Fuse for signal horn Fuse for SU/MCU Fuse Fuse Fuse Fuse Heating control Main fuse Interface card Battery MCU (main control unit) SU (supply unit) Interface card Voltage regulator

4S1

1S27

1S3

KV

K2

K1

INT

F20

F18/F19

F17

F16

F15

F14

F13

F12

F11

F3

F2

F1

FHV

CN1

F01

CPP

BATT

A44

A43

A22

RV

-86

ORIGINAL

Horn button (bottom plate)

5S19

48 V

400 A

5A

500 mA

10 A

10 A

10 A

15 A

1.6 A

10 A

ORIGINAL

Switch for interior lighting

172391 [EN]

S026035122

ORIGINAL

ORIGINAL

F047008122 M046046122 F047070122 P013004122

ORIGINAL

ORIGINAL

ORIGINAL

ORIGINAL

ORIGINAL

ORIGINAL

ORIGINAL

ORIGINAL

ORIGINAL

I041014122 Z045009122 F047021122 M046046122 F047123122 M046046122

ORIGINAL

ORIGINAL

Steering switch (diaphragm pressure switch)

6S3

ORIGINAL 5704.25.030 5704.25.020 L032003122

S120006122 S020036122 S020037122 S100169112

S040042122 S021007122

24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 80-48 V / 24 V 67°C 24 V, 6 relays 24 V, 8 relays 6 modules 6+, 28+, 28+, 28+, 28+, 28+ 6 modules 6+, 18+, 18+, 18+, 18+, 18+ 6 modules 18+, 18+, 18+, 18+, 18+, 18+ 6 modules 18+, 18+, 18+, 6+, 28+, 28+ 3 modules 6+, 18+, 18+

48 V 85°C 85°C 85°C

Impulse transmitter for pump motor Impulse transmitter for traction motor Impulse transmitter for traction motor Warning light for heating system Pump motor temperature warning light Warning light for temperature of left-hand traction motor Warning light for temperature of right-hand traction motor Warning light for insulation monitoring Relay Relay Fan Housing temperature sensor Temperature sensor in pressure-tight housing Intrinsically safe PCB Intrinsically safe PCB Zener barriers Zener barriers Zener barriers Zener barriers Zener barriers Light switch for drive direction Insulation monitoring PCB Temperature sensor for pump motor Temperature sensor for right-hand traction motor Temperature sensor for left-hand traction motor

L2M1

L1M2

L1M1

L5

L4

L3

L2

L1

K4/5

KF1/2

V1/2

U1/U2

ST12

SSI3

SSI1/SSI2

SMZ6

SMZ5

SMZ3

SMZ2

SMZ1

SF

SD

S2M1

S1M2

S1M1

172391 [EN]

5704.09.000

Fan

S120010122

S120010122

S120010122

S100012112

S100075112

S100072112

S100126112

A060004122

V041008122

R015010122 B003012122 R015010122 B003012122

L032003122

L032003122

L032003122

L032003122

P037031122 C109036122

P037046122

MV

CAT 2G

Reset button

PR

CAT 2GD IP65

Reset button

PR

R037031122

Resistor

R

-87

.

Current sensor

U10

-88

Key switch

S1 ORIGINAL

ORIGINAL

172391 [EN]

172391 [EN]

ENCM

=> 3

X50

ABEI

=> 3

A

6200_901-077

-89

-90

1B1 1B2 1M1 1M2 1U06 1U07 1S1 1S3 1S27 2B1 2B2 2B3 2B4 2M1

Accelerator, 16 Brake sensor, 17 Right-hand traction motor, 7-10 Left-hand traction motor, 4-7 Converter for left-hand traction motor, 8-9 Converter for right-hand traction motor, 5-6 Drive direction switch, 15 Parking brake switch, 15 Battery door sensor, 16 Hydraulic transmitter for lifting, 18 Hydraulic transmitter for tilting, 18 Hydraulic transmitter for auxiliary hydraulics 1, 19 Hydraulic transmitter for auxiliary hydraulics 2, 19 Pump motor, 10-13

2U03 3B28 3B29 4H2 4S1 5S19 6S3 6S4 6S10 6S12 7B41 7B43 7B44 7B45 7S1

Pump motor converter, 11-12 Curve switch for right-hand curves, 15 Curve switch for left-hand curves, 16 Signal transmitter, 17 Horn button (bottom plate), 16 Switch for interior lighting, 17 Steering switch (diaphragm pressure switch), 15 Brake uid switch, 1 Oil temperature transmitter, 17 Oil level, 15 Sensor for lift limitation, 15 Fork carriage monitoring, 16 Cylinder detection for load measurement, 15 Load sensor, 16 Seat contact switch, 1

7S2 7S13 7S15 7S17 9S8 9S9 9S18 9S27 A ABEI A43 A44 BATT ENCM FHv

Emergency off switch, 17 Dead man switch, 15 Switch for 5th hydraulic function, 16 Switch for buckle, 17 Left-hand door sensor, 14 Right-hand door sensor, 15 Blower switch, 11 Heating switch, 11 Lever/valve block, 18-19 Display and operating unit, 4-6 Supply Unit (SU), 11-12 Main Control Unit MCU (truck control unit), 13-14 48-V battery, 2-3 Pressure-tight housing, 4-10 Fuse, 11 L1 PR S1 S1M1 S1M2 S2M1 ST01 ST02 U1 VR V1 V2 X50 *

172391 [EN]

Warning light for insulation monitoring, 2 Reset button, 1 Key switch, 1 Temperature sensor for left-hand traction motor, 2 Temperature sensor for right-hand traction motor, 2 Temperature sensor for pump motor, 2 Temperature sensor, 9 Temperature sensor, 9 Housing temperature probe, 16 Blower/heating system, 17-20, 10 Fan, 15 Fan, 14 Diagnostic connector, 19 Optional

172391 [EN]

1 <=

1 <=

A

6200_901-078

-91

-92

1S3 2Y1 2Y2 2Y3

Parking brake switch, 10 Solenoid coil for lifting, 5 Solenoid coil for lowering, 6 Solenoid coil for tilting backwards, 5

2Y4 2Y5 2Y6 2Y7 2Y8

Solenoid coil for tilting forwards, 6 Solenoid coil for auxiliary hydraulics 1 positive, 5 Solenoid coil for auxiliary hydraulics 1 negative, 6 Solenoid coil for auxiliary hydraulics 2 positive, 5 Solenoid coil for auxiliary hydraulics 2 negative, 6

2Y9 2Y10 2Y11 A ELF

Check valve for hydraulics blocking function, 5 Solenoid coil for switching of load, 6 Solenoid coil for use of lowering, 5 Joystick version Electric parking brake, 9-12

172391 [EN]

Joystick Joystick * Optional

1 <=

top

172391 [EN]

1 <=

6200_901-079

-93

-94

CPP top 5E1 5E2

CAN-Power-Port, 3-12 Top Front right-hand headlight, 6 Front left-hand headlight, 7

5E5 5E6 5E10 5E11 5E12

Front right-hand side light, 8 Front left-hand side light, 8 Front left-hand direction indicator, 17 Front right-hand direction indicator, 18 Left -hand direction indicator, 19

5E13 5E17 5E18 5E19 5E21

Right-hand direction indicator, 20 Front right-hand spotlight, 4 Front left-hand spotlight, 4 Interior lighting, 3 Rear rotating beacon, 14

5E28 5E29 9M2 9M3 *

172391 [EN]

Rear left-hand spotlight, 5 Rear right-hand spotlight, 5 Front windscreen wiper motor, 14 Rear windscreen wiper motor, 14 Optional

Ident no. 172391 EN

STILL GmbH Berzeliusstrasse 10 D-22113 Hamburg