Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Table of contents
Page
1
2
(1)
01
385 Nm
Weights of counterweights:
6030/6031/6033/6034
> 818 kg
6032/6035
> 936 kg
6031/34
6032/35
788 3
788 3
788 3
1040 2
1040 2
1040 2
580 3
580 3
580 3
) (2)
01
) (3)
02
Page
Steering axle
Table of contents
02
Workshop manual
6030 - 35
Steering axle
Technical service data
L en kach se
80 - 82
Vorspur
0 1 mm
Radsturz
Nachlauf
Anz ugsmomente
MA=145 Nm
Radmutter
MA=210 Nm
Achslager
MA=195Nm
MA=210 Nm
SKM am Achsschenkelbolzen
MA=290 Nm
Schmiermittel
Radnabenlagerung
Radnabe
Achsschenkellagerung
02
Steering axle
02
Workshop manual
6030 - 35
Steering axle
Removing the wheel hub
1
2
3
4
5
6
7
8
9
10
11
12
Axle body
Stub axle
Radial seal
Taper roller bearing
Wheel hub
Pin
Wheel cap
Hexagon nut
Washer
Taper roller bearing
Wheel bolt
Nut
5 10
6
7
2
11
12
9 8
02
Steering axle
Checking the steer angle
The steer angle a must be 80 - 82. To facilitate
measurement, the complementary angle b can be
used.
It must be 98 - 100.
ATTENTION: It must be ensured that the steer angle
is clearly limited by the stop bolts (1). The stop must
not take place at the steering cylinder.
Rechtskurve
- Adjust the left and right steer angle with the stop
bolts (1) to 80 - 82.
- Check opposite angle.
- Check for free movement at narrow points.
- Check that the steer angle does not take place in
the steering cylinder.
Linkskurve
= 82
+0/
-2 Lenkeinschlag
02
Workshop manual
6030 - 35
Steering axle
Removing the stub axle
1 Hexagon bolt
2 Washer
3 King pin
4 Plug
5 Stub axle
6 Hexagon bolt
7 Hexagon bolt
8 Spacer
9 Scraper ring
10 Taper roller bearing
11 Spacer
12 Nipple
13 Taper roller bearing
14 Scraper ring
15 O-ring
16 Spacer
16
15
4
14
13
12
11
10
6
7
9
8
- Remove wheel.
- Unscrew bolt between tie rod and press out stub
axle.
- Losen hexagon bolt (1).
- Remove washer (2).
- Press out king pin (3) downwards.
- Remove stub axle from the axle.
- Remove spacers, O-ring, scraper rings, taper roller
bearings and spacers (8 - 16) from stub axle.
02
Steering axle
Fitting the stub axle
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Hexagon nut
Washer
King pin
Plug
Stub axle
Spacer
Scraper ring
Taper roller bearing
Spacer
Taper roller bearing
Scraper ring
O-ring
Spacer
Bolt
1
2
3
12
13
14
11
10
02
Workshop manual
6030 - 35
Steering axle
Removing the tie rods
The steering axle has two tie rods, which are seated
between the steering cylinder and both stub axles.
1 Stub axle
2 Piston rod
3 Seal
4 Pins
5 Bolt
6 Tie rod
7 Ball socket
5
4
02
Steering axle
Removing the steering cylinder
Remove tie rods.
Unscrew hydraulic connections and mark.
ATTENTION:
Workshop manual
03
6030 - 35
Table of contents
Technical service data
Description of the drive axle
Oil level check in wheel gear
Components of wheel drive 1 (left)
Components of wheel drive 2 (right)
Fitting and removing wheel drive
Replacing shaft seal on left wheel drive
Replacing shaft seal on right wheel drive
) (1 )
03
A D 20
Axle on chassis
Gear oil
Slotted nut
DIN 981 KM 12
Tightening torque 650 +20 Nm
) ( 2)
5.8
03
Wheel drive
Note:
The left and right wheel drive are not identical (see
pages 4 and 5).
Note:
The only repairs permitted is the replacement of the
shaft seal at the wheel drives. A complete wheel
gear repair can only be carried out with special tools
and appropriate clamping device. In the event of
damage to the axle body (e.g. faulty drive motor), the
complete drive axle must be replaced.
) (3 )
03
Wheel drive
Oil level check in wheel gear
1
) (4)
03
Wheel drive
Components of wheel drive 1 (left)
Item Designation
1
2
3
4
5
6
6
6
6
6
6
6
6
6
6
6
7
8
9
Wheel shaft
Screw plug
DIN 908 M10x1-5.8
Seal DIN 7603
A10x13, 5-CU
Taper roller bearing
DIN 720 32012X
Shaft seal DIN 3760
AS-110x125x7-V80
Ring 37.30*
Ring 37.33*
Ring 37.36*
Ring 37.39*
Ring 37.42*
Ring 37.45*
Ring 37.48*
Ring 37.51*
Ring 37.54*
Ring 37.57*
Ring 37.60*
Transmission case
Screw plug
M18x1.5-A3C
O-ring 185x3 -V80
Item Designation
Remark
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
) (5 )
Remark
03
Wheel drive
Components of wheel drive 2 (right)
Item
D esignation
R emark
Item
D esignation
10
11
locked wi th Locti te
243
10
Internal gear
11
Internal gear
12
Planetary carri er
12
Planetary carri er
13
Planetary gear
13
Planetary gear
14
Roller beari ng
18x30.86x13
14
Roller beari ng
18x30.86x13
15
Lock ri ng D IN 471
18x1.2
15
Lock ri ng D IN 471
18x1.2
16
Washer
16
Washer
17
C heese-head screw D IN
912
M8 x 20 8.8 A2C
17
C heese-head screw D IN
912
M8 x 20 8.8 A2C
18
C heese-head screw D IN
912
M10x30 10.9
18
C heese-head screw D IN
912
M10x30 10.9
) (6)
R emark
locked wi th Locti te
243
03
Wheel drive
Fitting and removing the wheel drive
Removing:
- Loosen wheel fixing bolts
- Jack up the vehicle, lower on to wooden blocks
and secure.
- Disconnect battery cable.
- Remove wheel fixing bolts and remove wheel.
- Drain gear oil from wheel drive to be changed (drain
screw at the bottom of wheel drives)
- Detach wheel drive from drive motor casing (16
cheese-head screws M10 x 35)
- Force off wheel drive with 2 bolts M8 through the
tapped holes in wheel drive casing (5 and 11
oclock position) from drive motor casing.
Attention:
-
Note:
The only repair permitted is the replacement of the
shaft seals on the wheel hubs. A complete wheel
gear repair can only be carried out with special tools
and appropriate clamping device.
Fitting:
- Fit wheel gear with new O-ring on drive motor casing
(filler opening must point upwards).
- Screw in fixing bolts (16 cheese-head screws M10
x 35) and tighten with a torque of 64 Nm.
- Fill gear oil through top filler opening.
Note:
For oil capacity and oil quality, see technical service
data.
-
) (7)
03
Wheel drive
Attention:
The lips of the seal must point towards the outside of
the axle.
-
Attention:
The lips of the seal must point towards the outside of
the axle.
-
) (8)
Note:
While screwing on the slotted nut, turn the hub so
that the bearing halves fit evenly.
-
03
Wheel drive
) (9)
Workshop manual
04
6030 - 35
PR
Air
pressure
Disc wheel
Side ring
Collar
Manufacturers
designation
v.18x7-8
16
10 bar
6379 -2 -0
h. 16x6-8
16
8,0 bar
4.33 R8 ET14
3960
3923 - 2
Side ring
Collar
Disc wheel
v. 18x8x12 1/8 Z
Ri m
h.16x5x10 1/2 KS
Ri m
v. 18x8x12 1/8 Z
Nat ural
Ri m
h.16x5x10 1/2 KS
Nat ural
Ri m
Scheibenrad
Manufacturers designation
v. 18 x 7 - 8
4.33 R 8 ET 0
h. 16 x 6 - 8
4.33 R 8 ET 14
v. 18 x 7 - 8
Nat ural
4.33 R 8 ET 0
h. 16 x 6 - 8
Nat ural
4.33 R 8 ET 14
v. 200 / 50 - 10
6.50 F 10 ET 52,5
h. 16 x 6 - 8
4.33 R 8 ET 14
v. 200 / 50 - 10
Nat ural
6.50 F 10 ET 52,5
h. 16 x 6 - 8
Nat ural
4.33 R 8 ET 14
) (2)
06
Table of contents
Page
Technical data
Mode of operation
Functional description
Steering column
Steering unit
Priority valve
Steering cylinder
) (1)
06
Fabri kat
D anfoss
Typ
Frderlei stung
40 cm3 /Umdrehung
berdruckventi l
90 +5/0 bar
Schockventi l
Fabri kat
D anfoss
Typ
Vorspanndruck
7 bar
Priorittsv entil
06
Steering
Mode of operation
The vehicle is equipped with a load-sensing (LS)
power-assisted steering system. This system acts
on the steering cylinder (7) on the steering axle.
Flanged on to the bottom end of the steering column
(2) is a steering unit (3). This unit consists of a
distributor valve and a measuring pump. When the
steering wheel is turned, the measuring pump
supplies a quantity of oil to the steering system,
which is proportional to the rotation of the steering
wheel. The distributor valve transfers this oil quantity
to the required side of the steering cylinder.
In LS systems, the steering and hydraulics are
supplied from a common pump unit (1). Oil flow
distribution between both systems takes place in the
priority valve (4), whereby the steering system always
has priority, i.e. a sufficient oil flow is supplied to the
<---------P
R
7
EF
8
6
CF
Rechts
LS
L inks
2
P
LS
3
L R
1 Pump
2 Steering column
tank
3 Steering unit
5 Slider bank
6 Hydraulic
4 3 Prority valve
8 Suction filter
7 Steering cylinder
Fahrtricht ung
06
Steering unit
ATTENTION:
When unscrewing the hydraulic connections,
hydraulic oil will discharge. Collect the hydraulic
oil and dispose of properly.
Loosen the four cheese-head screws and
remove the hand pump.
Whle loosening the screws, the steering wheel
with steering column must be tilted back or
forward.
06
Workshop manual
6030 - 35
Steering unit
Fitting the steering unit
Fitting takes place in reverse order to removal.
No
1
2
7
8
9
10
11
Designation
Remarks
Cheese-head scr. MA = 46Nm
Washer
Steering
column
Tilt back and forward
Union
Reducing union
HP hose
Relief valve
4
3
Installed in steering
unit
10
12
12
Copyrighted. Reproduction in any form
forbidden.
Copyright reserved.
11
14
15
17
16
ATTENTION:
The previously marked
hydraulic lines must be screwed back in the
same position again to avoid the risk of accident.
13
06
Priority valve
Priority valve
The priority valve is mounted on the right side wall
below the floor plate. The valve is a hydraulic control
unit and serves to provide oil for supplying the
steering in all operating states with priority.
When connecting the hydraulic lines to the priority
valve, the correct tightening torques must be used.
CF: MA =100 Nm
EF: MA =100 Nm
P : MA =100 Nm
LS: MA = 45 Nm
LS
EF
CF
12
3
6
06
Workshop manual
6030 - 35
Steering cylinder
Dismantling the steering cylinder
1
Steering cylinder
2
Threaded pipe
3
Hexagon bolt
4 - 8 Seal kit
9
Bushing
10
Circlip
11
Piston rod
CAUTION:
When unscrewing the hydraulic connections and
opening the steering cylinder, hydraulic oil will
discharge. Collect the hydraulic oil and dispose
of properly!
-
2
3
4
12
5
6
7
9
10
11
10
07
Table of contents
Page
Brake view
2/3
Parking brake
Pedal adjustment
) (1)
07
) (2)
07
Brake view
5
1
4
2
) (3)
07
Brake view
3
2
8
1 - Disk (7 pieces)
2 - Disk (5 pieces)
3 - Washer
4 - Ring gear
5 - Thrust washer
6 - Brake piston
7 - Pressure sender
8 - Bleeder
9 - Baffle
STILL GmbH Position as per: 2/2000 (Replaces version:
Baffle (9)
During assembly, it must be ensured that the nose
at the baffle is located at the top!
The nose at the baffle collects spray oil and supports
lubrication of the needle bearing and toothing.
(4)
07
Parking brake
Parking brake
Adjustment:
- Brake pedal depressed
- Parking brake released
- Adjust dimension X = 5 +0.5 at adjusting screw (1)
and lock adjusting screw with nut.
X
1
Pedal adjustment
- By positioning the pad (2), adjust the pedal height
E = 101 2.
4
2
Adjust clearance between main cylinder and
piston rod (1mm).
- By turning the piston rod (1), adjust 1mm clearance
at the pad (2).
3
E
1mm
) (5)
08
Table of contents
Page
2
3
5
6
Console, general
Console, operation
Console, password level
Console, plane text parameter
7
8
10
12
Keyswitch
Battery connector
Accelerator pedal
Accelerator pedal transmitter
Accelerator pedal, two-pedal control
Signal horn
Brake pedal transmitter
Parking brake switch
Seat switch
Pressure pick-up, hydraulics
Drive and pump motor temperature sensors
Drive motor speed sensors
Pump motor speed sensor
15
16
17
17
18
19
20
21
22
23
BG11
24
25
Battery
STILL contactor
Main fuse
26
27
27
Fuse carrier
Control fuses
Relay
29
29
29
30
31
32
33
Console
Replacing the console
Cold store version
FleetManager
34
34
34
35
37
(1)
08
Accelerator pedal
Brake pedal transmitter for el. braking
Transmitters, hydraulic
Potentiometer 4 kOhm
Potentiometer 4 kOhm
Electric pressure pick-ups
Rated voltage
80 Volt
Speed
Speed reduction
STILL contactor
1K 1
C oi l
Contact tips / contact tip material
Relays
K 1, K 2
Fuses
Power circuit fuses
Control circuit fuses
Traction battery
1F 2
( 300 A )
F 1, F 2, F 3, F 5, F 7, F 8 ( 5 A )
F9
( 10 A )
F6
( 15 A )
F4
( 20 A )
G1
80 Volt / 420Ah
Insulation resistance
Electrical installation
Electrical machines
G1 traction battery
Electrical protection
Electrical installation
Electrical machines
IP 23
FM IP 22
HM IP 20
IP 23
Controller
(2)
approx. 80 kOhm
approx. 80 kOhm
08
Electrical installation
Mechanical configuration
The electrical installation consists of:
Controller A9
Fuse carrier A7
Main or line contactor 1K1
Power circuit fuse 1F2
Console
Transmitters, switches & sensors
Drive motor FM1
Hydraulic motor HM
item 1
item 2
item 3
item 4
item 5
item 6
item 7
Controller A9
Control and regulating electronics
Power electronics for FM1 and HM
Fuse carrier
Control fuses, various
Relays
K1, K2
Dash panel
Keyswitch
S1
Accelerator pedal transmitter switch 1S16
Hazard flasher switch
direction indicator switch (where fitted)
Display, various keypads
In front part of truck/foot area:
Horn push (floor plate)
Accelerator pedal transmitter
Brake pedal transmitter
Pressure pick-up, hydraulic
Relay board, front (optional)
6
7
4S1
1B1
1B2
2B1-B5
4H1
1S4
7S1
In the counterweight
Controller
Main contactor
Power circuit fuse (300A)
Fuse carrier
Power supply (optional)
Relay board, rear (optional)
A9
1K1
1F1
A7
U1
(3)
3/4
08
Electrical installation
General
The vehicle has a variable-speed front-wheel drive with
separately excited shunt-wound motor.
The circuit-breakers in the controller A9 are protected
by overcurrent limitation.
The control electronics are supplied from an
internal10V voltage transformer in the controller A9.
Additional electrical consumers are supplied directly
with 80V or via the voltage transformer U1 with 24V.
The cables between the controller and exciter windings
of the electric motors are two-pole and installed
isolated.
A1
1M1
1M2
D2
A1
F2
A2
5
1
X17
A9
14
A1
24
A1
13
23
14
24
13
23
G1
40 0A
1K1
A2
7 K2
A2
X2 6
4
X 17
1F2
F1
)(4)
08
(5)
08
Insulation test
Procedure
Disconnect the battery.
Disconnect all insulation displacement type
connectors at base plate of controller A9.
Disconnect leads at voltage converter U1.
Disconnect leads at relay boxes.
Disconnect drive motor, hydraulic pump motor and
battery leads at controller A9.
Isolavi 8
METRISO 500D
Metra Hit 16i
(6)
08
Console
The forward-reverse control switches, direction
indicator switch, hazard flasher switch (if fitted),
display and keypads are mounted on the console.
A CAN bus system interconnects the console and
the controller.
Direction of travel
Direction of travel is controlled by one or two touch
sensitive levers (depending on equipment level)
positioned on the console, on the left and right sides
of the steering wheel. The forward-reverse lever
automatically returns to neutral upon being released.
It can be converted to a 3-position engaging type lever,
in which case only the LH forward-reverse control lever
is needed, whereas the RH lever is replaced by a
cover.
Indication of direction of travel
The selected direction of travel (forward or reverse) is
indicated by forward-reverse lights located in the
middle of the dash panel.
Direction (turn) indicator switch
A direction indicator switch is only fitted in conjunction
with flashing indicators. It is located on the dash panel,
above the RH forward-reverse lever.The direction
indicator switch normally functions as an engaging
type switch, can however be converted to a touch
sensitive switch. The direction indicator lights are
arranged on the dash panel, on the left and right sides
of the forward-reverse lights.
Converting touch sensitive levers to engaging
type levers
Procedure:
Detach the small plastic cover plate glued on the
forward-reverse control lever.
Loosen the screw at this stage exposed.
Remove the RH forward-reverse lever and install a
cover in its place.
Slightly lift the LH forward-reverse control lever,
allowing it to be released from its catch but still
remain engaged with the hex. pin, which must be
turned approx. 60 clockwise.
Completely lift off the lever and replace it after having
turned it 60 anti-clockwise.
Secure the lever with the screw. Glue the small
plastic plate into place again.
Hazard flasher
The hazard warning system is activated with the
hazard flasher keypad in the console at the left.
Electrical connections
From battery G1 to the hazard flasher key
G1 (x) X40 F9 X53/1,2 X47/1
From hazard flasher keypad to controller A9
X47/3 X11/16 (A9)
(7)
08
Console
DISPLAY 1 (5)
DISPLAY 2 (6)
PRG
DISPLAY 3 (7)
DISPLAY 4 (8)
PRG
F2
F1
1
Panel keypads
for selecting the displays directly
PRG
scrolling/counting up
scrolling/counting down
O PRG
(8)
simultaneously.
08
Console
Display
The indications are via an LCD display in the dash
panel.
PRO G 1
BA T T
PRG
F1
S E R VI CE
I N
00000 , 0h
49h
PRG
PRG
F2
F1
Keypads
14 keypads are integrated into the RH section of the
dash panel for operating electrical consumers,
presetting driving characteristics, auxiliary functions
as well as for parametrization via addresses a certain
number of truck functions.
1 Without function
2 Hare
Fast acceleration (drive program 1...5)
3 Tortoise
Slow acceleration (drive program 5...1)
4 / 10 Spotlight (working light), rear/front
Switching spotlight on/off
5 Flashing beacon
Switching flashing beacon on/off
6 / 12 Screen wipers rear/front
Pressing keypad momentarily: Intermittent wiper
action, permanent wiping action, switching off.
Pressing keypad and holding: Electric washer
action then reverting to the last operating status
7 Without function
8 Parking light
Switching parking light on/off
9 Headlights
Switching headlights on/off
11 Heater / demister
Switching heater/demister on/off
13 Return
Switchover between display levels 1 and 2
13 Return
Parameterization
14 Zero
Parameterization
)
PRG
F2
0 9: 4 2
O V E R HE A T I N G
PRG
E R R OR
PRG
XXX
F2
F1
PRG
PRG
F2
F1
(9)
7 2 8 3 9 4 10 5 11 6 12
14
13
08
Console
DISPLAY 1 (5)
DISPLAY 2 (6)
PRG
DISPLAY 3 (7)
DISPLAY 4 (8)
PRG
F2
F1
1
Displays 1 to 4:
1 to 4 and PRG
Pressing PRG
and O PRG at the same time:
Activating and terminating the programming mode.
Note
Changes are stored in the truck controller when
the console is switched off with the keypad switch
and has switched off completely (after approx.
50 sec) or the battery plug was disconnected.
After the truck is switched on, display level 1 with
the selected drive program, time and battery indication
is shown:
PROG 3
BATT:
14:37
999h
ENGLISH
14:37
LANG.
( 10 )
08
3 $ 6 6: 25 ' / ( 9 ( /
35*
35*
&2' (
)
)
1
16.0km/h
1
100%
COUNTER MODE
1
V1.17
SERVICE ADDR
VALUE
NO
1
000
00
PASSWORD LEVEL
2
NEW CODE
XXXX
PASSWORD LEVEL
1
NEW CODE
XXXX
( 11 )
08
( 12 )
DISPLAY 1
DISPLAY 2
PRG
DISPLAY 3
DISPLAY 4
PRG
F2
F1
Travel speed
km/h
16
16
16
16
16
Acceleration
position
80
90
Deceleration
position
80
90
Reverse
forward / backward
80
90
Brake delay
position
60
70
80
90
100
08
PRG
DISPLAY 4
PRG
F1
HYDRAULICS settings
The motor rpm can be preset for each hydraulic
function.
HYDRAULICS
LIFTING
100 %
By scrolling up with keypad, the following will appear
in the lower line:
LIFTING
100 %
TILTING
500 / min
EXT1
2550 / min
EXT2
500 / min
Vehicle reset
RESET
NO
can change between YES and No. A YES initiates a
vehicle reset, where the main contactor 1K1 opens
briefly and closes again.
Note:
Parameter changes are only effective after a vehicle
reset!
LIFTING
Presetting motor speed for maximum hoisting speed
in % (100% = 2550 rpm).
TILTING
Presetting motor speed for maximum tilt speed in
rpm (setting range = 300/min....2550/min).
EXT 1
Presetting motor speed for maximum operating rpm
of auxiliary hydraulic function 1
(setting range = 300 rpm....2550 rpm).
EXT 2 (4th hydraulic function)
Presetting motor speed for maximum operating rpm
of auxiliary hydraulic function 2
(setting range = 300 rpm....2550 rpm).
Note:
If the keypads 5 or 6 are kept pressed, scrolling will
be in steps of 5, 10 and 50 to accelerate scrolling.
)
DISPLAY 2
DISPLAY 3
F2
DISPLAY 1
( 13 )
08
( 14 )
DISPLAY 1
DISPLAY 2
PRG
DISPLAY 3
DISPLAY 4
PRG
F2
F1
08
Keyswitch
Keyswitch S1
Keyswitch S1 is located on the right-hand side of
the steering column. It is operated with a removable
key.
The keyswitch secures the truck against unauthorized
use.
Keyswitch S1 turns on the controller and the supply
voltage for the console, signal horn and lighting as
well as the fan motors for the drive and pump motors.
Keyswitch S1 has 2 positions:
0 = ON
1 = OFF
( 15 )
08
Battery connector
Battery connector X1/X2
The battery connector consists of two parts:
battery connector X1 (socket half)
battery connector X2 (pin half)
Type: Schaltbau 160 A
Battery connector X1 is provided with a handle and it
is firmly connected to the battery. It also provides a
breaking point for connecting the battery to a charger.
The truck operator can at any time reach the connector
with his left hand and disconnect it in an emergency.
Battery connector X1 serves as an emergency
cut-out.
80V
terminal 2/A9
Batt.()
terminal 1/A9
Truck
( 16 )
08
1S16
1B1
X16
against
green X16/8 (+)
= approx.10 Volt
1B1
Removal
Lift floor plate from the LH side
Pull out connector X16 from accelerator pedal
transmitter
Lift out floor plate
Slacken locknuts
Remove accelerator pedal transmitter from under
the floor plate
2
STILL GmbH Stand: 2/2000 ( Ersatz fr Stand:
( 17 )
08
X16/1
Set value
X16/2
GND
X16/5
Sender 1B4:
+10Volt
X16/8
Set value
X16/3
GND
X16/4
Basic adjustment
Basic adjustment of threaded rod: 28mm
Adjust forward pedal to a height of 81mm. Adjust
reverse pedal to a height of 79mm. (Note material
thickness of floor covering). Make fine adjustment
via hexagon bolt X.
Attach Mark II plus measuring adapter to connector
X16 below the floor plate.
Set lock switch to ON
Measure voltage at measuring adapter:
Sender 1B3:
X16/2 (+) X16/5 ()
Sender 1B4:
X16/3 (+) X16/4 ()
Pedals not depressed, potentiometers in centre
position:
Voltage: 4.7 5.3 V per
potentiometer.
Reverse pedal, fully depressed:
X16/2 (+) X16/5 (), voltage 8.8 9.3 V
X16/2 (+) X16/4 (), voltage 0.7 1.4 V
Forward pedal, fully depressed:
X16/2 (+) X16/5 (), voltage 0.7 1.4 V
X16/3 (+) X16/4 (), voltage 8.8 9.3 V
Adjustment of forward pedal
This adjustment is necessary if the voltage is >
9.3V and < 0.7V
Reduce the dimension 81mm.
Reduce threaded rod U, dimension 28mm by
actuating the angular joint.
Readjust centre position of potentiometer
This adjustment is necessary if the voltage is <
8.8V and > 1.4V
Increase the dimension 81mm.
Increase threaded rod U, dimension 28mm by
operating the angular joint
Readjust centre position of potentiometer
STILL GmbH Position as per: 2/2000 (Replaces version:
) (18)
08
4S1
( 19 )
08
1B2/3 green
1B2/2 red
1B2/1 yellow
1B2
X11/42
X50/5
6S4/1
6S4/2
6S4
) (20)
08
Brake operated
switch open
1S3
X11/26
GND
Note
Application of the parking brake cuts out the traction
circuit.
If the truck is parked on an incline, apply the
parking brake firmly.
Brake unoperated
switch closed
( 21 )
08
Seat switch
Seat switch 7S1
The mechanically operated switch is glued on the
seat pan underneath the cushion. The seat switch
will close even if only a light load is placed on it.
Seat switch 7S1 is caused to close immediately the
driver sits on seat in which case the truck will be
released by the controller for driving.
Electrical connections
Seat switch 7S1 is connected directly to controller
A9.
7S1/3 X27/3
X11/13
7S1/1 X27/4
GND
CAUTION
The seat switch is a safety device which may
not be bridged. The seat switch will close even
if only a light load is placed on it.
Seat switch removal
Disconnect and remove the connector under the
battery cover and remove the seat.
Remove the cable ties (cut).
Mount the mechanical switch at the scissors of
the seat. The switch must be be tightened slightly
when no load is on the seat so that the switch
lever still has a stroke of approx. 2-3 mm (see
arrow).
Place the seat on the four mounting pins and set
the weight adjuster to the lowest weight.
Place a light load of approx. 40 kg on the seat and
remove it again. When the load is on the seat, the
switch must be able to operate.
( 22 )
08
2B2
2B3
Test
points
Transmitter
Voltage
in volts
P o s.
Neg.
2B1 hoisting
2B2 tilting
2B3 a. h. f. 1
2B4 a. h. f. 2
Lever
pulled
b a ck
Lever
moved
forward
7.5
2.5
( 23 )
2B1
08
X11/11
X11/12
X11/25
X11/7,8
+10 Volt
Signal
Signal
GND
Adapter, Pin 2
) (24)
08
Electrical connections
The pulse generator is supplied with +10V by the
controller.
Sender (br) X14/1
Sender (sw) X14/2
Sender (bl) X14/3
X11/11
X11/40
X11/7/8
+10Volt
Signal
GND
1
4
Function test
2 1
4 3
Mark II - Adapter
Attention
The motor must be voltageless, disconnect
armature cable!
(25)
08
Battery
Battery servicing
The specific gravity of the filled battery is 1.28 kg/l.
In the discharged state, the specific gravity must not
be lower than 1.4 kg/l.
Check the specific gravity with an acidimeter. The
specific gravity can be read directly on the acidimeter.
After charging, it takes a certain time until the acid
above the plates has balanced and mixed with the
acid between the plates. Measurement should
therefore initially take place about 30 minutes after
charging has ended.
Check the acid density regularly. When the
minimum mark is reached, replenish with
distilled water only.
( 26 )
08
STILL contactor
Main line contactor 1K1
As main line contactor, contactor 1K1 switches the
power supply for the power electronics in the
controller. It is located along with main line fuse 1F2
in the counterweight.
Control voltage
The contactor coil has been designed for 24Volt
operating voltage. Controlled by controller A9, by
which it is fed with regulated current, the contactor
coil is thus not supplied with full operating voltage.
Mechanical configuration:
The contactor frame is made of impact resistant
plastic; four M8 studs are embedded in the plastic
material. The contact screws/tips are screwed from
the inside into the top studs. The lower screws serve
as terminals for connecting the contact bridges of
the armature by means of contact bridges.
The coil assemblyncomprises:
coil
magnetic core
frame
protective circuitry
The protective ciruitry connected in parallel to the coil
consists of a resistor wired in series with a diode
with the following data:
24 V
Resistor
Diode
47 Ohm
1N4005
Coil resistor
approx. 20 Ohm
at 24 Volt operating voltage
60
( 27 )
1K1
24 Volt
08
STILL contactor
Contact pressure
Contact pressure of contactor in the fully operated
state:
Required value 9,0 N for each contact, centre of
contact taken as a reference.
Adjustment
Fully actuate contactor (electrically or
mechanically).
Attach contacts centrally to a spring balance or
scale and apply a load of 9.0 N.
Contact pressure can now be accurately adjusted
by operating on the hex. head screw passing
through the contact spring. Rotating the hex. head
screw in a clockwise direction will increase the
pressure.
NOTE:
The contact spring is subjected to a certain degree
of friction. The contact pressure is therefore correctly
adjusted if when applying a pressure load of
10...10.5N the contact during slow approach does
not yet close, but in the case of a rapid approach
makes contact and remains closed.
60
Pull-in stroke
Provided the contactor is correctly assembled, a
spacing of 1.3 to 2.7 mm between contact bridge
and support finger must be achieved with contactor
being pulled in.
Torque loadings
The contact screws must be tightened to a torque of
10 +1 Nm. To achieve this torque loading without using
a torque wrench, the contact screws must be screwed
fully home and then rotated through a further 60.
Mounting the arc blow-out magnets
To install the arc blow-out magnets or arc suppression
chambers on the contactors, a screwdriver must be
passed through a hole in the leaf spring. By exerting
a light pressure on the leaf spring the latter is pressed
inwards until the arc blow-out magnet has reached
its final position. After withdrawal of the screwdriver
the leaf spring will retain the arc blow-out magnet in
position.
( 28 )
08
D es.
Value
Connection
F1
5A
F2
5A
F3
5A
Brush wear
F4
20 A
F5
5A
F6
15 A
F7
5A
Hydraulic controller
F8
5A
F an
F9
10 A
K1
24 V
255Ohm
auxiliary loads,
equipment A
K2
24 V
255Ohm
auxiliary loads,
equipment A
( 29 )
08
Controller
SAAB-connector, 42 pins
&DQ%XV
;
;
A9, left
A9, right
Controller A9
The controller is the central switchboard for nearly all
electrical components. Provided with a
microprocessor control, it assumes most of the
control, switching and monitoring functions.
The controller includes the main groups:
Power electronics
Armature regulator for drive and hydraulic motor
Field regulator for drive motors
Control electronics (casette insert)
The signals for:
Keyswitch
Accelerator pedal transmitter
Accel. pedal transmitter switch
Brake pedal transmitter
Transmitters
for hoisting / tilting / auxiliary
Speed sensors
Motor brush monitors
Temperature sensors
are monitored and evaluated.
2B1 2B5
Main connections
Connector X17
X17/1
not used
X17/2
not used
X17/3
not used
X17/6
not used
Terminal
1
2
3
4
5
6
7
8
S1
1B1
1S16
1B2
Batt () 80 Volt
Batt (+) 80 Volt
not used
not used
B1 / armature for 1M1
A2 / armature for 1M1
A1 / armature for 2M1
D2 / armature for 2M1
24 Volt
4
GND
( 30 )
08
PRG
NO
PRG
YES
D - E E P ROM V A L I D ?
PRG
PRG
F2
F1
A RE
Y OU S U R E
PRG
PRG
F2
F1
P LE AS E WA I T
PRG
PRG
F2
F1
( 31 )
08
CAN-Bus
X11
Ribbon cable
(64 pins)
Controller A9
Note
If a control card with truck-specific parameters is
installed, the query DEEPROM VALID ? must be
acknowledged with NO, otherwise the console will
overwrite the control card parameters.
( 32 )
08
Field regulator
Field regulator
The power electronics of the controller A9 include one
field regulator for the drive motor.
The field regulators consist of 4 MosFet transistors,
which are controlled via measurement and control
electronics. The field regulator operates as switched
H-bridges and supplies the shunt field of the drive
motor via the control electronics.
If the result of a vehicle diagnosis or console error
message (error 174) refers to a faulty field regulator,
only this regulator needs to be renewed. The modular design of the controller enables easy fitting and
removal.
Removal and fitting of the field regulator
( 33 )
08
PRG
PRG
NO
Procedure
Safely park the truck on level ground.
Disconnect the batteries.
Remove steering column shroud
Remove the faulty console and replace it with a
new one.
Note:
To ensure perfect transmission of the angle lock
pulses, the console must be adjusted.
Refit the shroud.
Reconnect the batteries.
Turn keyswitch S1 ON.
PLEASE WAIT
will appear on the display panel of console.
The complete data information stored in the
controller memory is at this stage transferred to
the console.
After that a reset is effected automatically.
The console is now ready for operation.
If a console from a different truck, i.e. already
containing a software, is used as a substitute (which
is feasible), proceed as follows:
Turn keyswitch S1 ON.
D EEPROM VALID ?
>>are the parameters stored in the console valid?<<
will appear on the display of the console.
As the console has been removed and as the
operating parameters programmed into the
controller are required for transfer to the console,
answer NO (press upper PRG keypad)
ARE YOU SURE ?
is displayed.
Answer YES (PRG
). The information data
stored in the controller is now transmitted to the
console without display
After that a reset is effected automatically.
By calling the truck number (which will be
displayed), it is possible to check whether the
correct drive parameters have been loaded.
Turn keyswitch S1 OFF.
Cold store version
Heater cable terminals:
Batt(+) X47/2 in the console to S1.
Batt() X41on the fuse board in the counterweight.
( 34 )
YES
P LE A S E WA I T
PRG
PRG
F2
F1
D - E E P ROM V A L I D ?
PRG
PRG
F2
F1
A RE
Y OU S U R E
PRG
PRG
F2
F1
08
FleetManager
FleetManager
FleetManager is an operating data management
(ODM) and analysis ODA) system that supports the
fleet manager in the control, management and
analysis of an industrial truck fleet.
FleetManager generally fulfils 4 main tasks:
- Acquisition of regular and event-orientated vehicle
operating data
- Acquisition of special operating data in the event of
an accident via accident recorder
- Access control to the vehicle via freely
programmable data card
- Basic data management as well as the evaluation
and display of all acquired operating data in
FleetManager software in the evaluation PC of the
fleet manager
Data transfer between the vehicle and evaluation PC
takes place via a contactless data card. On the
vehicle, the data card is read and written via a card
reader (card device).
The card reader is an integral part of the console; a
precondition is the FleetManager option.
Delivery condition
Vehicles with the FleetManager option are originally
parameterised so that they cannot be moved without
card. On switching on the vehicle via the keyswitch,
the usual status indications appear on the console
display.
Deactivate FleetManager
After configuration by the fleet manager, a vehicle
can only be operated with cards with appropriate
authorisation.
After starting the vehicle via the switchlock, the
following message appears on the display:
PLEASE INSERT
CARD
FleetManager can be deactivated by changing
specific parameters in order to operate the vehicle
without card for service and diagnostic purposes.
Address 144 Enable FleetManager function
Value
00 FleetManager is deactivated
FF FleetManager is activated
Attention:
FleetManager must be reactivated following
service or diagnostic routines in any event!
( 35 )
08
FleetManager
Card reader write and read test
To carry out an internal card reader write and read
test, a blnak card can be used as a test card. A blank
card is a card that has not yet been configured via
the FleetManager PC program.
A test can only be carried out with FleetManager
activated. During the test, the following messages
appear on the display:
TESTING CARD
If the test was successful, the following message
appears on the display:
CARD
OK
After removing the test card, the normal display
reappears.
In the event of a fault, the displays constantly shows
the message CHECKING CARD or the following
message is displayed:
CARD
FAULT
Both types of faults indicate a write or read fault of
the card reader (the test should be repeated with a
second test card if necessary).
If the card reader is faulty, the console must be
removed.
( 36 )
08
Table of contents
Page
38
39
Horn control
40
Hydraulic controller
41
42
Parameterisation
43
Controller renewal
44
45
( 37 )
08
Joystick
The joystick includes the following electronic components:
Integrated evaluation electronics
CAN bus controller
Emergency Stop switch (connections directly on
A9)
Joystick heating (connections directly on 2A7)
The following control functions are combined in the
joystick and can be actuated by the driver with the
right hand.
Forward/Reverse
7
Left/Right
7
Balance
1
Fine control (Zoom)
4
Direction switch
3/6
Horn button
2
Function button
5
Emergency Stop switch 7S2
Red Emergency Stop switch, right next to the joystick
All vehicle functions can be deactivated by actuating
the switch
Functions can be reactivated by pulling out the
Emergency Stop switch
The Emergency Stop switch is jointly connected
at the heater for the joystick via the 4-pole connector
X49 to the hydraulic controller 2A7
The actuated/closed switch simultaneously applies
+48 V to:
- terminal 2X1/4 of the hydraulic controller 2A7
> disabling of hydraulic function
- terminal X11/2 of vehicle controller A9
> stopping of drive
7S2
( 38 )
08
2A7
Safety relay K1
Controlled via seat contact switch 7S1 it prevents
lowering of the load when the drivers seat is
unoccupied.
Since October 1999
Safety relay K1 omitted, function integrated into
hydraulic controller.
( 39 )
08
Horn control
Horn control 4A1
The control 4A1 enables the horn to be actuated from
both the jostick and the horn button in the centre of
the steering wheel or in the floor plate - without
switching over or rearrangement.
The horn control is a closed block with three plug-in
connections. It is installed below the floor plate on
the chassis.
The block includes a 12-24V relay and semiconductor
for switching.
Function
Via the horn button on the joystick, the relay coil is
connected to operating voltage via connector X61. The
relay contact is connected to the terminals of
connector X48 and so arranged in parallel with the
horn button in the floor plate.
In the event of failure of the control 4A1, connectors
X48 can be disconnected from the block and directly
interconnected.
X48
X61
X48
( 40 )
08
Hydraulic controller
2A7
2X1
2X2
2X3
( 41 )
08
Safety function
The CAN bus cable 2X3 serves solely for the 24V
supply and does not transfer any information.
Interchanging the CAN bus cables 2X2 and 2X3 at
the controller is safe.
Communication
The control commands for the driving direction and
the set value for the hydraulic speed are output by
the joystick and sent via the CAN bus 2X2 to the
hydraulic controller 2A7.
From the hydraulic controller 2A7, this information is
passed on to the vehicle controller A9 via the following
cables:
- Forward
2A7 2X1/16
A9
X11/18
- Reverse
2A7 2X1/13
A9
X11/33
- Hydraulic speed
2A7 2X1/12
A9
X11/19
A9 X11/9
Note
For controlling the relay K1, the output of the optional relay K1 is used. In this variant, the relay K1
cannot be used for the additional electronics.
Integrated safety function
Since October 1999, the safety function is integrated
into the hydraulic controller 2A7.
Depending on the switching status of the seat switch
7S1, a voltage level between 0V and 24V is output to
the hydraulic controller 2A7 by the vehicle controller
A9. The hydraulic controller 2A7 evaluates the voltage
level and shuts down the hydraulics when the seat
switch is not actuated.
- Emergency Stop circuit
2A7 2X1/6
A9
X11/32
Note
In this variant, the relay K1 is unnecessary, so that
the relay K1 can be used for the additional electronics.
( 42 )
08
Parameterisation
Parameterisation
All parameter changes for the hydraulic
controller 2A7 and joystick can only be made
via parameterisation of the service notebook.
As no CAN bus connection to the console exists,
all changes made here are without effect.
H Y DRA U L I K
HYDRAULIC
LIFT
TILT
AUX.1
AUX.2
F2
F1
100 %
500/min
2550/min
500/min
Conversion to joystick
If a vehicle is subsequently converted to the joystick
system, the following addresses must be changed
in the vehicle software.
Hydraulic speeds
The set value for the hydraulic speeds is transferred
by the hydraulic controller 2A7 to the vehicle
controller A9 via the additional hydraulics1
connection.
2A7 2X1/12
1 0 0%
HE B EN
Note:
In the console, the usual indications can be selected
in the display. However, the indicated speed values
bear no real relation to the actual hydraulic speeds.
PRG
PRG
A9
X11/19
Address 128
Value
40
Hydraulic configuration
Hydraulic speed via
hydraulic controller
Address 12A
Value
FF
Hydraulic limitation
Via vehicle parameterisation, further hydraulic
limitations can be parameterised. However, the
parameterised hydraulic limitation is then active for
all hydraulic functions, as the vehicle controller A9
only processes one speed signal.
Forward
2A7 2X1/16
A7
X11/18
Reverse
2A7 2X1/13
A7
X11/33
Error messages
At transmitter voltages less than 2.0V and above
7.89V, the vehicle controller A9 detects a fault and
generates an error message.
Note:
Parameterised hydraulic limitations are always active
for all hydraulis functions!
Direction preselection
only 2-pedal
only 1-pedal
via console and joystick
via joystick
Note:
To ensure reliable operation, the standard value for
the additional hydraulics1 should be set in vehicle
parameterisation to the maximum permissible speed.
Address 08A
Value
00
01
03
04
( 43 )
08
Controller renewal
Replacement of hydraulic controller 2A7
( 44 )
08
2Y1
2Y2
2Y3
2Y4
2Y5
2Y6
2Y7
2Y8
2Y9
2Y10
2Y2
2Y1
2Y9
2Y3
2Y4
When a hydraulic function is actuated via the joystick, a current of 0 1.5A is applied to the magnet
coil. The produced magnetic field moves a magnet
core in the pressure pipe, which opens the proportional valve. The current of 0 - 1.5A corresponds to an
actuator travel of 0 - 100%.
Electrical connection of the lifting magnets
respectively takes place via a 2pole timer plug.
PIN 1: Transformer
PIN 2: Pulse width modulator
The lifting magnets are connected to the controller
2A7 via the connector 2X1.
Test
An extensive electrical test is onl possible with
the aid of the diagnostic system!
Release valve 2Y9
The release valve 2Y9 is a safety valve which prevents
accidental actuation of the way valves
(e.g. accidental actuation of the joystick when
opening the hood)
The release valve is only active when the drivers seat
is occupied and the seat contact switch 7S1 is
actuated.
Function/Adjustment/Replacement
A detailled description of the proportional way valves
is provided under Group 10.
( 45 )
2Y5
2Y6
2Y7
2Y8
08
Table of contents
Page
Introduction
Basic principles
Induction of movement
Generation of the magnetic field
Generation of three-phase voltage
3
4
5
6
Electrical installation
Converter
Block diagram
Fitting and removing the converter
8
9
10
Battery computer
11
Central computer
Overview
Fitting/removal
12
13
Speed sensors
14
Fuse panel
Fuse panel, rear
Fuse panel, front
15
16
) (1)
08
Accelerator pedal
Brake pedal transmitter for el. braking
Transmitters, hydraulic
Potentiometer 4 kOhm
Potentiometer 4 kOhm
Electric pressure pick-ups
Rated voltage
80 Volt
320 A
Speed
Speed reduction
STILL contactor
1K 1
C oi l
Contact tips / contact tip material
Relays
K 1, K 2
Fuses
Power circuit fuses
Control circuit fuses
Traction battery
1F 2
( 300 A )
F 1, F 2, F 3, F 5, F 7, F 8, F 10
F9
( 10 A )
F6
( 15 A )
F4
( 20 A )
F11
( 30 A )
G1
80 Volt / 420Ah
Insulation resistance
Electrical installation
Electrical machines
G1 traction battery
Electrical protection
Electrical installation
Electrical machines
Battery / Central Computer
Converter
IP 23
FM IP 64, HM IP 64
IP 23
IP 23
(5A)
)(2)
approx. 80 kOhm
approx. 80 kOhm
08
Introduction
Basic principles
When the asynchronous motor (induction motor) was
introduced in 1880, it quickly became the workhorse
of the industry.
This was due to its simple design, simple mechanical
construction, low price, good electrical data, high
efficiency and an unexcelled low-maintenance
standard.
In the simplest case, the asynchronous motor
consists of a stator with three identicaI phase windings
composed of 120 staggered pole pairs.
Figure 1
Block diagram of a two-pole stator.
Figure 1
Figure 2
Block diagram of a rotor with short-circuited bars
(rings).
Magnetic lines
of rotary field
Direction of
rotation of
rotary field
Figure 2
Figure 3
Technical design of the R60i motor rotor.
The slanted arrangement of the short-circuit bars
improves the breakaway torque.
Figure 3
08
Introduction
Induction of movement
Figure 1
When a conductor is moved in a magnetic field so
that it intersects magnetic lines of forces, a voltage
is induced in the same. The same applies when
moving magnetic lines of force intersect a conductor.
The induced voltage increases with the speed of the
magnetic field.
If the conductor is formed to a loop and closed briefly,
a short-circuit current is induced, which increases
with the speed of the magnetic lines of force
intersecting the loop.
Rotary axis
Figure 1
Figure 2
The short-circuit current flowing in the coil loop
generates a magnetic field, the polarity of which
depends on the direction of rotation of the rotating
field.
Figure 3
Where the magnetic lines of force of the coil and those
of the rotating field move in the same direction, they
repel each other. This causes a moment to act on
the coil, which then rotates in the direction of the
arrows.
In the illustrated example, the magnetic field rotates
counterclockwise and, at a frequency of 50 Hz, at a
speed of 3000 rpm. The short-circuited coil former
similarly rotates counterclockwise at a speed reduced
by the slip. The slip is unavoidable, as the coil must
intersect the magnetic lines of force in order to induce
a voltage in the coil former. Only then can a shortcircuit current generate the magnetic field.
= 3000 rpm
Figure 2
Magnetic lines of
force moving in
the same
direction
Magnetic lines of
force moving in
the same
direction
Figure 3
08
Introduction
Fig. a
Fig. b
Generation of the rotating magnetic field
The block diagram shows a two-pole machine. With
higher pole numbers, the magnetic field and phase
angle change (with a four-pole machine, the phase
angle is 15).
Instant a Fig. a
- The phase current U has reached its maximum
value.
- The magnetic field around winding U has also
reached its maximum.
- The phase currents V and W have are I/2 their
maximum value.
- The magnetic fields around windings V and W are
accordingly weaker.
- The resulting magnetic field is shown in Fig. a
Instant b Fig. b
- Precisely 30 later, the phase currents U and W
3/2 of their maximum value.
- The phase current V has reduced to 0.
- The magnetic field forms only around the windings
U and W and has rotated a further 30 .
Bild c
Instant c Fig. c
- Again 30 later, the same constellation as for Instant a can be seen.
- The current in winding W has reached its maximum
strength.
- In U and V the currents are I/2.
- The magnetic field develops accordingly, however,
by 60 out of phase with respect to Instant a.
08
Introduction
Three-phase current generation
The control of a three-phase asynchronous motor
differs fundamentally from that of a direct-current
motor, as here a alternating voltage with three phases
must be provided from a direct voltage. This takes
place by the direct voltage being chopped by means
of an electronic circuit, thus resulting in the generation
of pulses of varying duration.
Figure 1
The basic principle of this circuit, a half-bridge, is
shown with single bipolar transistors for improved
clarity. (see Figure 1)
Figure 1
Figure 2
The applied direct voltage pulses generate in the motor
an almost sinusoidal alternating current.
In order to vary the speed of an asynchronous motor,
not only the frequency, but also the level of the
atlernating current must be changed. This takes
place in that the pulse width is varied more quickly or
slowly, whereby the pulse frequency itself remains
constant.
In order to therefore generate an alternating current
with a higher frequency, variation of the pulse
width takes place more quickly (see Figure 2 top).
In order to generate a low alternating current, the
pulse width is reduced. The pulse frequency itself
always remains constant (see Figure 2 bottom).
Figure 2
Figure 3
Figure 3 shows the output stage of the converter used
in the R60.
B-
Figure 3
) (6)
08
Electrical installation
Electrical installation
The vehicle has front-wheel drive and is driven via a
mechanical differential by a variable-speed
asynchronous machine.
The hydraulic pump is similarly connected to a variable-speed asynchronous motor.
Two separate, identical 80V converters, which supply
the asynchronous machines (see Figure 1), are
controlled by a high-speed Can-Bus (250kB/s) via the
battery computer from the central computer. Figure
2 shows how the individual components are
interconnected.
The additional electrical consumers are supplied with
electrical energy by the voltage transformers U1/U2
via the fuse panels and relay boxes in the rear body
and cowl.
Figure 2
Legend
Vehicle sender:
Travel sender
Brake sender
Vehicle sender (Battery potential):
Shunt
Motor sender:
Speed sensor bearing
Temperature sensor
HSK:
Main contactor 1K1
STILL GmbH Position as per: 2/2000 (Replaces version:
(7)
Figure 1
08
Converter
Converter
LED
X150/151
No indication:
Flashing at 1Hz:
Fault status!
The converter stops all
movements, assumes an inactive
state and generates an error
code.
The error code can be output via
the display, see error list.
Figure 1
13
12
11
Pin10:
Pin11:
Pin12:
Pin13:
(8)
10
Figure 2
Battery computer
08
Converter
CAN
communication
CAN-Bus
Monitoring of U and V
d.c. link
80V supply
Power
supply
Motor temperature
sensor
Measuring
circuit
Bearing
sensor
Contactor control
Battery current
measurement
Shunt
08
Figure 1
08
Battery computer
Battery computer
The battery computer is located in the rear
compartment on the right next to the hydraulic
converter and has the following interfaces:
4 Digital inputs
2 Analog inputs
CAN 1 - 250 KB to central computer
CAN 2 - 250 KB to converters
(11)
08
Central computer
Central
computer
Stroke limiter
Lift
Tilt
Additional 1
Additional 2
Additional 3
Master-Reset
Dead mans switch (Res4)
Travel sender
Brake fluid switch
Travel sender switch
Steering transmitter
Brake sender
08
Figure 2
Figure 3
08
Speed sensor
Drive and hydraulic motor speed sensor
X151/3
X151/5
X151/6
X151/4
+10 Volt
Signal
Signal
GND
X150/3
X150/5
X150/6
X150/4
+10 Volt
Signal
Signal
GND
08
) (15)
08
F4 - 20A:
F5 - 5A:
F7 - 5A:
F10 - 5A:
) (16)
09
Table of contents
Page
2
2
2
Transformer
Relay box
Distributor card/panel
CAN-Bus connections R6030 - 32
CAN-Bus connections R6033 - 35
3
4
5
6
7
) (1)
09
Variants
Variant A
80 Volt version:
Controller A9, fuse carrier A7 with relays K1 and K2
and/or distributing circuit board (front scuttle)
24 Volt version:
Controller A9, fuse carrier A7 with relays K1 and K2,
voltage converter U1 and/or distributing circuit board
(front scuttle).
Variant C
Controller A9, fuse carrier A7, voltage converter U1,
control relay boards (counterweight and front scuttle).
09
Transformer
Transformer
For supplying the electricala consumers with 24 V, a
150/240/400W transformer is installed as required.
The transformer is located behind the converter in
the counterweight or on the left next to the controller.
On the underside of the transformer is an aluminium
block as a heatsink. The heatsink serving for heat
removal is bolted to the counterweight.
Electrical connection takes place via screw terminals
below the cover.
Technical data of transformer
Technical D ata
Type
80V/24V
35V....120V
Output voltage
24V regulated
16.7A
400 W
Overload capabi li ty
Short-resi stant
20 mVRMS
C urrent
li mi tati on at
approx. 23 A
C ut-off at
approx. 140 V
C ut-off at
approx. 33 V
400 V
Insulati on voltage
500 V
Effecti vi ty
81% at IRATED
Frequency
25 kHz
Idle power
approx. 3 W
Temperature protecti on
C ut off at heat
si nk temp.
approx. 80C
yes
yes
Type of protecti on
IP 55
400W Transformer
Note:
In the event of failure of the 240W or 400W transformer,
the same can be opened and the fuse checked (see
picture on right).
The 240 V/200 mA fuse is also used in the R70 digi
controller.
) (3)
09
Relay box
Relay box
The relay box consists of a control unit, three slots
for relays (24Volt) and 10 switching transistors for
switching the consumers.
Control unit
The control unit is connected to the controller A9 via
the CAN-Bus. The relay box receives the instruction
from the controller A9 to switch a consumer on or off
via the CAN-Bus.
Relay box login via console:
rear: 0A5
0B
01
X71 / 1 , 3
0C
02
X70 / 1 , 3
0D
03
X69/ 3
0E
04
X69/ 1
0F
05
X67 / 4 , X68 / 4
10
06
X67 / 3 , X68 / 3
11
07
X68/ 2
12
08
X68 / 1 , 5
13
09
X67/ 2
14
0A
X67/ 1
18
15
X66
19
16
X65
1A
17
X62
Load values
Input value front/rear
Channel 01: 7A
0B/01
Channel 02: 7A
0C/02
Channel 03: 3A
0D/03
Channel 04: 3A
0E/04
Channel 05: 3A
0F/05
Channel 06: 3A
10/06
Channel 07: 3A
11/07
Channel 08: 3A
12/08
Channel 09: 3A
13/09
Channel 10: 3A
14/0A
Channel 11: 5A (fuse value)
18/15
Channel 12: 5A (fuse value)
19/16
Channel 13: 15A (fuse value)
1A/17
STILL GmbH Position as per 2/2000 (Replaces version:
) (4)
09
Distributing card
Distributing card
The distributing card replaces the distributing circuit
board and takes over its functions since October 1999.
The distributing card consists of an angled holding
plate with inserted connectors and takes over the
distribution of the powr supply for the consumers.
(5)
09
Diagnose
Diagnose
A9
A9
2A7
2A7
Joystick
Joystick
* T-Stck fr Diagnose,
24V-Busversorgung
A9
A9
(6)
09
)(7)
09
Registering a consumer:
First the 3-digit SERVICE ADDR. for the input of a
function block and the VALUE of the desired switch
are entered. Then the 3-digit SERVICE ADDR. for
the output of this function block and the VALUE of
the input channel from the control relay board or
relays is entered.
Note
The VALUE will only be stored in memory when both
characters are confirmed with PRG
and the
entire line is flashing.
SE RV I CE ADDR 0 0 0
FF
V AL UE
PRG
PRG
F2
F1
STILL GmbH Stand: 2/2000 ( Ersatz fr Stand:
(8)
SE R V I C E AD DR 0 0 0
FF
V AL UE
F2
1E
0D0
parking light
parking light
0D1
0D2
main beam
head light, LH
0D5
rear light
head light, RH
0D3
0D4
0D6
0D7
rear light, LH
1D
rear light, RH
Lighting
20
(9)
21
F1
19
1A
X71 / 1 , 3
X70 / 1 , 3
0D
X69/ 3
0E
X69/ 1
0F
X67 / 4 , X68 / 4
10
X67 / 3 , X68 / 3
11
X68/ 2
12
X68 / 1 , 5
13
X67/ 2
14
X67/ 1
18
X66
X65
X62
0D 0
0D 2
0D 5
0D 1
0D 3
0D 4
0D 6
0D 7
09
1B
1F
0B
0C
41
42
0D8
IN
OUT
in = out
0 D9
stop light
3C
3F
N
)
3D
3E
(10)
40
2A
0 E 1 IN 1
0 E 2 IN 2
1B2
4A
4B
1B1
48
49
1S4
44
in1
0
0
1
1
in2
0
1
0
1
out OUT
X71 / 1 , 3
02
X70 / 1 , 3
03
X69/ 3
04
X69/ 1
05
X67 / 4 , X68 / 4
06
X67 / 3 , X68 / 3
07
X68/ 2
08
X68 / 1 , 5
09
X67/ 2
0A
X67/ 1
15
X66
X65
X62
0E3
0
1
1
1
flashing beacon
fuse buard
1B
45
1C
7S1
46
47
57
58
K2
09
K1
01
SE R V I C E AD DR 0 0 0
FF
V AL UE
F2
0DF
IN
1E
OUT
in = out
0E0
Spotlight, front
1D
)
0DC
0DD
IN 1
IN 2
20
(11)
in1
0
0
1
1
in2
0
1
0
1
out
0
1
1
0
OUT
0DE
21
Spotlight, rear
F1
0 DA
IN
in = out
OUT
0DB
Reversing light
19
1A
0D
X69/ 3
0E
X69/ 1
0F
X67 / 4 , X68 / 4
10
X67 / 3 , X68 / 3
11
X68/ 2
12
X68 / 1 , 5
13
X67/ 2
14
X67/ 1
18
X66
X65
X62
09
1B
X71 / 1 , 3
X70 / 1 , 3
1F
0B
0C
41
42
0E4
IN
in = out
OUT
0E5
Reserve 1
0E6
IN 1
0E7
IN 2
3C
3F
N
)
3D
3E
rev. and driver seated
(12)
1B2
4A
4B
1B1
48
49
1S4
44
45
out1
1
0
0
1
out2
1
0
0
1
Reserve 2
40
2A
in2
0
1
0
1
0 EA
0EB
OUT 1 0 E C
OUT 2 0 E D
IN 1
IN 2
in1
0
0
1
1
in2
0
1
0
1
out1
1
0
0
1
0EE
IN
in = out
OUT
0EF
58
X69/ 3
04
X69/ 1
05
X67 / 4 , X68 / 4
06
X67 / 3 , X68 / 3
07
X68/ 2
08
X68 / 1 , 5
09
X67/ 2
0A
X67/ 1
15
X66
X65
X62
fuse buard
1B
K1
K2
09
03
1C
47
57
X71 / 1 , 3
X70 / 1 , 3
Reserve 3
46
01
02
out2
1
0
0
1
Reserve 4
7S1
in1
0
0
1
1
OUT 1 0 E 8
OUT 2 0 E 9
S1
SE R V I C E AD DR 0 0 0
FF
V AL UE
F2
0F3
1E
1D
Wiper/washer 1
0FF
Wiper
0F7
Washer
0F8
IN
Wiper
IN
0FD
20
Wiper/Washer 2
0F9
Washer
Wiper
IN
0FE
103
(13)
Wiper/Washer 3
21
0
1
2
3
F1
0F0
19
1A
Washer
OFF
ON
INTERVAL
WASH
IN
OUT 1
OUT 2
in
0
1
2
104
out1
0
1
1
X71 / 1 , 3
X70 / 1 , 3
0D
X69/ 3
0E
X69/ 1
0F
X67 / 4 , X68 / 4
10
X67 / 3 , X68 / 3
11
X68/ 2
12
X68 / 1 , 5
13
X67/ 2
14
X67/ 1
18
X66
X65
X62
0F1
0F2
out2
0
0
1
Heater
09
1B
1F
0B
0C
41
42
3C
3F
N
)
3D
3E
(14)
0C9
0C7
0C8
0 CA
RH / LH
front/right
front
front/left
hinten
warning
flasher
rear/right
rear/left
0CC
0CD
0CE
0CF
40
2A
1B2
4A
4B
1B1
48
49
1S4
44
Flasher
01
X71 / 1 , 3
02
X70 / 1 , 3
03
X69/ 3
04
X69/ 1
05
X67 / 4 , X68 / 4
06
X67 / 3 , X68 / 3
07
X68/ 2
08
X68 / 1 , 5
09
X67/ 2
0A
X67/ 1
15
X66
X65
X62
fuse buard
45
1B
7S1
46
1C
47
57
58
K2
09
K1
S1
09
(15)
09
Spotlight, front
Input signal
for button/switch
Function block
1F
0DF
Output signal
for consumers
0E0
in
1C
S E R V I C E A D D R 0 DF
K2
1C
SE R V I C E AD DR 0 E 0
1C
1 F V AL UE
V AL UE
K1
1B
out
Spotlight, rear
Input signal
for button/switch
19
Connecting block
108
in1
in2
AND
04
0
1
0
1
0DC
0
0
0
1
Output signal
for consumers
0DE
in 1
in 2
in1 in 2 out
0
0
1
1
Function block
1B
out
1B
1C
K1
K2
R
3E
109
0DD
SE R V I C E AD DR 1 0 8
V AL UE
1 9 V AL UE
SE R V I C E AD DR 1 0 9
V AL UE
S E R V I C E A D D R 0 D C SERV I CE ADR.
0 4 WERT
S E R V I C E A D D R 0 DD
3 E V AL UE
00
(16)
0 DE
1B
09
F2
RH / LH
front
1E
front, RH
front, LH
rear, RH
rear, LH
rear
Warnblinker
1D
2D
2C
2F
2E
FL ASHERS
1F
Parking light
Headl. dip beam
Tail lamp
Parking light
Headlamp LH
Headlamp RH
Tail lamp LH
Tail lamp RH
20
31
32
--33
---
LIGHTIN G
21
in
out
12
out 1
out 2
13
---
out 1
out 2
14
---
out
15
out
34
out
35
out
37
out
38
RESERVE 1
F1
in 1
in 2
RESERVE 2
Exclusiv e OR, inv ertedv alue
in 1
in 2
19
RESERVE 3
Exclusiv e OR, inv ertedv alue
1A
in
RESERVE 4
1B
in
S1
N
Fwd
STOP LIGHT
41
42
3C
3F
3D
in
REVERSING LIGHT
in
Rev
Flasher
3E
in 1
in 2
2A
1B2
4A
1B1
48
1S4
44
4B
in 1
in 2
49
out
36
out 1
out 2
3A
3B
Flashing beacon
OR
45
Seat
dead man function
lift cut off
in 1
46
47
57
HEATER
58
(17)
09
FF
V AL UE
105
106
107
in1
in3
AND
108
109
0
0
0
0
1
1
1
1
in1
0
0
1
1
0
0
1
1
0
1
0
1
0
1
0
1
0
0
0
0
0
0
0
1
0
0
1
1
AND
0
1
0
1
0
0
0
1
front, RH
front, LH
rear, RH
rear, LH
rear
Warnblinker
02
03
0CC
0DD
RELAY BOX, front
0CE
X71 / 1 , 3
0B
0CF
0C
FL ASHERS
0D0
0D2
0D5
in1 in 2 out
in2
RH / LH
front
0C9
0C7
0C8
0CA
in1 in 2 in 3 out
in2
Parking light
Headl. dip beam
Tail lamp
Parking light
Headlamp LH
Headlamp RH
Tail lamp LH
Tail lamp RH
04
05
0D1
0D3
0D4
0D6
0D7
LIGHTIN G
in
0E4
out
0E5
out 1
out 2
0E8
0E9
X70 / 1 , 3
0D
X69/ 3
0E
X69/ 1
0F
X67 / 4 , X68 / 4
10
X67 / 3 , X68 / 3
11
X68/ 2
12
X68 / 1 , 5
13
X67/ 2
14
X67/ 1
18
X66
19
X65
1A
X62
RESERVE 1
10A
10B
10C
in1
in1 in 2 in 3 out
in2
0
0
0
0
1
1
1
1
in3
OR
10D
10E
0
0
1
1
0
0
1
1
0
1
0
1
0
1
0
1
0
1
1
1
1
1
1
1
06
07
in 1
in 2
0E6
0E7
RESERVE 2
in 1
in 2
0EA
0EB
in1
in1 in 2 out
in2
0
0
1
1
OR
0
1
0
1
0
1
1
1
out 1
out 2
0EC
0ED
RESERVE 3
08
09
in
0EE
out
0EF
RESERVE 4
in
0D8
10F
110
in1
in2
OR
0
0
1
1
0
1
0
1
0
1
1
01
0D9
out
0DB
0A
0B
in
0DA
REVERSING LIGHT
in
0DF
in
T ON
pulse generator
T = 60 ms
T OFF
out
0E0
03
X69/ 3
04
X69/ 1
05
X67 / 4 , X68 / 4
06
X67 / 3 , X68 / 3
07
X68/ 2
08
X68 / 1 , 5
09
X67/ 2
X67/ 1
0A
15
X66
16
X65
17
X62
in 1
in 2
0DC
0DD
10
11
out
0DE
SPOTLIGHT, rear
in 1
in 2
0E1
0E2
0E3
out 1
out 2
0F1
0F2
OR
in 1
00 = permanently OFF
FF = not used
HEATER
out
Flashing beacon
0F0
(18)
1B
1C
X70 / 1 , 3
Fuse board
X71 / 1 , 3
02
STOP LIGHT
in1 in 2 out
Exclusive
out
01
K1
K2
10
Table of contents
Page
2
3
4
5
6
7
8
Control valve
Lifting/lowering
Lifting/lowering
Tilting
Tilting
Additional hydraulics
Additional hydraulics
9
10
11
12
13
14
17
Pressurising valve
Single lever control function variant
Checking/dismantling
18
19
Lowering brake
Function
20
Hydraulic pump
Function
21
Hydraulic tank
Removal and fitting
Hydraulic oil change, capacities, breather filter
22
23
Air filter
Function and maintenance
24
15
16
Hydraulic unions
Fitting
25 -27
Speeds
Lift - lower - tilt
28
Hydraulic diagram
Circuit diagram
Legend
29
30
Joystick
31
(1)
10
14cm / Revoluti on
D i recti on of rotati on
50 + 10 Nm
500 1/ mi n
Li fti ng
Ti lti ng
25 + 8 Nm
Threaded connecti on
Ti lt cross-secti on reducer
Air filter
Fi lter fi neness
20 ( absolute )
H ydraulic tank
C apaci ty
Hydrauli c oi l ( OZ )
S p eed s
Tele / N iho
Triple
6030/31/33/34
6032/35
0.53 m/sec
0.45 m/sec
0.50 m/sec
0.43 m/sec
Tolerance 12 %
0.45 - 60 m / sec.
(2)
10
Hydraulic system
Functional description of lift and tilt hydraulics
The hydraulic oil drawn out of the tank (4) by the gear
pump (5) via the filter flows to a priority valve (6)
connection P.
The oil volume required for the steering is supplied to
the steering unit at this point.
The residual oil volume is supplied via connection EF
to the control valve block (2) connection P.
With only minor actuation (displacement) of a valve,
the oil flows with low circulation pressure through the
control valve block from connection R back into the
tank.
With further actuation, an oil volume corresponding
to the valve displacement flows from connection A1
to the lift cylinders (7) and from A2 and B to the tilt
cylinders (9) and an attachment (1) in the additional
hydraulics.
Attention
Before carrying out any work on the
hydraulic system, fully lower the fork
carriage and disconnect the battery
connector.
(3)
10
The balancer (3) with hood (9) and control lever (8)
are supported rotatable on the valve carrier (14).
To open the battery hood, the hood (9) must be tilted
forward after releasing the pin.
Removing control valve block
- Fully tilt mast forward and lower fork carriage.
- Disconnect battery connector.
- Unscrew covering
- Disconnect all electrical and hydraulic connections.
- Unscrew fixing bolts (1) of valve carrier (14) and
remove complete valve carrier from the chassis panel.
- Remove all bolts (13) between levers (10)
and valves (3).
- Separate control valve block (7) from valve carrier
by loosening screws (11).
Maintenance information
The following bearing points must be greased:
- Bolts (13) for valve and lever connection (10).
- Levers (10) on axle (6).
(4)
10
(5)
10
Sender/Sensor (9 a-d) :
ATTENTION
To prevent the senders mutually influencing each
other, senders with different frequencies will be
installed at the control valve block from January
2000.
1. Valve slider
2. Relief valve
3. Plug - Stop valve/lift
4. Connection A1 - (lift/lower)
5. Connection P - (pump line)
6. Connection A2 - (backward tilt)
7. Connection B - (forward tilt)
8. Connection R - (return tank)
9a-d. Sender (inductive sensor)
10. Shroud with wiper
11. Shroud fixing bolts
12. Sender fixing bolts
13. Block bolts
14. Connections - additional hydraulics 2
15. Connections - additional hydraulics 1
16. Plug - pressurising valve - tilt
The slider bank (I) includers the slider (1) for the lift
and tilt hydraulics. If no further control valves are
provided for additional hydraulics, a plate is fitted at
this block downstream of the tilt valve.
T h e
control valves (II) and (III) for the additional hydraulics
are generally identical in terms of function and design.
The control valve (III) for the additional hydraulics is
simultaneously designed as a plate.
If the control valve block only has one additional
hydraulics, the control valve (II) is replaced by the
control valve (III).
Sealing of the control valve blocks with respect to
each other takes place with O-rings and retaining
rings in the flange surfaces.
Installation information
- Any repairs to the slider bank must be carried out
with particular care, as any fouling and damage to
sealing surfaces can result in malfunctions and leaks.
- The tightening torques, particularly for the block
bolts (15) must be observed.
- The lift/lower valve (arrow) must not be turned more
than 55 to each side.
) ( 6)
: 250 bar
=
=
=
=
=
46
29
5.5
3.5
25
+
+
+
+
+
15
10
1.8
1.2
8
Nm
Nm
Nm
Nm
Nm
10
(7)
10
A1
A2
B
A+B
= Connection - lift/lower
= Connection - backward tilt
= Connection - forward tilt
= Connections - additional hydraulics
P
R
1. Relief valve
2. Check valve
3. Valve
4. Stop valve - lift/lower
5. Sender (inductive sensor)
6. Control valve
7. No-load channel
8. Pressurising valve - tilt
Function
On actuation of a valve (3), the pump motor speed
and in turn the delivery capacity of the hydraulic pump
is regulated proportional to the valve stroke via the
sender (5).
With only minor valve displacement, the oil entering
P flows via the no-load channel (7) through the control
valve up to the plate or valve and from there via the
return channel R back into the tank.
The no-load channel is closed with increasing valve
displacement and the oil flows via the pump channel
P to the load.
On activation of a load, the relief valve opens when
the set final pressure is exceeded in the pump channel
and the oil flows via the return R into the tank.
(8)
10
1
26
25
3
4
24
R
23
A1
22
21
5
20
19
18
10
11
17
12
13
16
14
15
(9 )
6
7
8
9
10
Control valve
Lifting/lowering
1. Valve
2. Wiper
3. Shroud
4. O-ring
5. Ball
6. Spring
7. Plug
Check valve
8. O-ring + retaining ring
9. Circlip
10.Thrust washer
11. Return spring
12.Spacer
13.Sleeve holder
14.Sleeve
15.Sender (inductive sensor)
16.Sender fixing bolt
17 +18. Spring washer
19.Retaining ring
20.O-ring
21.Valve cone
22.Bore
23.Spring
Stop valve
24.Screw plug
25.O-ring
26.Bore
Function
On downward actuation of the valve (1) (lifting), the oil
flows from the pump channel P via the ball (5) of the
check valve and via the raised valve cone (21) of the
stop valve for connection A1 to the lifting cylinders.
Tightening torque:
Item 16 = 3.5 + 1.2 Nm
Item 24 = 29 + 10 Nm
(10 )
10
(11 )
10
Control valve
Tilting
The oil discharged from the front tilt cylinder chambers
flows via the connection A2 to the pressurising valve.
When the set pressurising pressure is reached, the
valve cone (25) is opened and the oil can flow via the
bores in the valve disk (26) and via the slider opening
into the return R.
Function
On downward actuation of the slider (1) (backward
tilt), the oil flows from the pump channel P via a
control and check valve (5-14) lifted from its seat and
via the valve disk (26) of the pressurising valve lifted
from its seat to connection A2 to the front tilt cylinder
chambers.
The oil discharged from the rear tilt cylinder chambers
can flow via connection B into the return R.
( 12)
+ 1,2
Nm
10
Control valve
Additional hydraulics
P
R
(13 )
10
Control valve
Additional hydraulics
ATTENTION
The sleeve (14) mounted on the sleeve holder (13)
must not be shifted, as this will change the output
voltage of the sender.
A + B = Attachment connection
1.
Valve
2.
Wiper
3.
Shroud
4.
O-ring
5.
Ball
6.
Spring
7.
Plug
8.
O-ring + retaining ring
9.
Circlip
10. Retaining ring
11.
Return spring
12. Spacers
13. Sleeve holder
14. Sleeve
15. Sender (inductive sensor)
16. Sender fixing bolt
17+18. Spring washer
19. Retaining ring
20. O-ring
Function
There are two types of control valve for the additional
hydraulics.
(14 )
10
1
2
3
4
5
6
7
8
9
10
P
1
ATTENTION
Do not remove any washers (3).
Do not set the pressure higher than 250 bar.
NOTE
If fouling of the valve cone seat is suspected (e.g.
with reduced lift or tilt), unscrew valve housing (7),
remove spring (6) and valve cone (10) and check valve
seat for foreign bodies.
In case of damage, renew the complete relief valve
and set the pressure to 250 bar.
Tightening torques:
Valve housing (7) : 46 + 15 Nm
Lock nut
(2) : 13.5 + 4.5 Nm
Block seal
Pump channels P and return channels R are sealed
on the flange surfaces of the control valves and plate
by means of O-rings (1) and retaining rings (2).
1
Installation note: Do not clean flange surfaces with
cloths or paper cloths. Fibres on the O-rings can
impair the tighteness of the seal.
Recommended: Wipe sealing surface with the palm
of the hand.
In case of leaks at the gaskets, check tightening
torques of the tie rods.
P
P
1
2
1
R
(15 )
10
Adjustment
At a supply voltage of 10 V (measured between
connection A and C), an output voltage of 4.4 5.6 V must be present at the sensor in a neutral
position of the valve at connection B (measured
between connection B and C) .
The output voltage must be corrected if necessary
by moving the sleeve (5) through the cover opening
(7).
NOTE
Only use antimagnetic and electrically insulating
material (plastic or ceramic) as a tool (do not use
steel, copper, etc).
1. Valve
2. Collar screw
3. Spacer
4. Sleeve holder
5. Sleeve
6. Sensor
7. Cover
8. Fixing bolts
A = Supply voltage ( + )
B = Output voltage
C = Ground ( - )
Tightenting torques:
2
3
4
Removal
- After removing the bolts (8), carefully remove the
sender (6) from the sleeve holder (4), taking care not
to lose any spacers (3).
- The sleeve holder is screwed with Loctite into the
collar screw (2). If the sleeve holder has to be removed
(normally unnecessary), the adhesive point must be
heated for unscrewing if necessary (remove control
valve block).
- Thoroughly clean the collar screw thread and fit
sleeve holder with Loctite 243.
- If readjustment of the sender should be necessary,
the sleeve (5) must be removed to the extent that the
end protrudes about 1 mm above the sleeve holder
and the cover (7) removed.
8
5
6
Installation
Carefully slip sensor with fitted spacers over the sleeve
holder and screw to valve block.
Alternately tighten bolts (8) with the prescribed
tightening torque.
3000 rpm
Tilting
up to rated stroke 3500 mm
up to rated stroke 5000 mm
up to rated stroke 5000 mm
1100 rpm
650 rpm
500 rpm
(16 )
See group 13
Workshop manual
10
6030 - 35
2
1,2 mm
17
10
Pressurising valve
Single lever actuation variant
With single lever actuation for lifting and lowering, the
pressurising valve integrated in the control valve block
is omitted in connection A.
Installed between the control valve block (2),
connection B and tilt cylinder (3) (front cylinder
chambers), a pressurising valve (1) in the piping
prevents automatic forward tilting of the mast.
The pressurising valve only allows tilting with pump
pressure.
The pressurising valve is marked -P- and -R- at the
connection points.
R > P
P > R
= Free flow
= Pressurised
R
Design
1. Housing
2. Valve screw
7
8
3. Freewheel balls
4. Seal
5. Cone with damping
6. Spring
7. Adjusting screw
5
4
3
2
8. Plug
9. Seal
9
1
P
STILL GmbH Position as per: 10/1999 (Replaces version:
(18 )
10
Pressurising valve
Check pressurising valve (UVV) :
- Note rated load
- Park vehicle on a horizontal plane and place mast
vertical.
- Attach an angle-measuring instrument (spirit level)
(1) to the mast (2).
2
Dismantling
6
Note
After dismantling twice, the action of the plug (8) is
no longer ensured.
5
4
3
2
9
1
P
(19 )
10
Lowering brake
1. Restrictor
3 Valve housing
2. Hexagon housing
4. Control piston
(lowering brake valve)
6. Nut
8. Adjusting nut
5. Spring
7. Spring washer
F
2
Function
A lowering brake valve (3) screwed into the hexagon
housing (2) ensures a constant lowering speed,
largely independent of the size of the load.
The lowering brake is installed in the feed pipe to the
mast directly at connection B of the lifting/lowering
control valve block.
An arrow on the housing (2) indicates the free flow in
the direction of the mast with correct installation.
3
4
5
6
7
Lifting
(direction of flow F ---> B)
The oil flowing from the control valve to the lift cylinders
can flow unhindered through the lowering brake, as
the restrictor (1), pushed out of the control piston (4),
does not produce any flow resistance.
SS 3 36 / 170
6032/35
SS 3 42 / 170
Example :
Type = SS3
Operating flow = 36 Liter
Operating pressure = 170 bar
ATTENTION
The maximum permissible lowering speed is
0.6 m/sec.
B
)
(20 )
10
Hydraulic pump
Installation
Type
: Gear pump
Delivery
: 14 cm 3 /per revolution
Direction of rot . : Counter-clockwise (arrow on pump)
Drive
: Pump motor (1) via pump
shaft and catch (2)
Seal
: Radial seal in pump motor
and O-ring (3)
Function
The hydraulic oil sucked out of the tank by the pump
(4) via the line (11) flows under pressure via the line
(7) to the priority valve.
NOTE
Pump removal and installation is easier with the
battery removed.
NOTE
In the event of pump noise, oil foaming in the tank,
delayed or no load movement, a check must be made
to see whether there are any leaks at the radial seal
in the motor, at the O-rings (3 + 9) or at other air
intake connections (10 + 11).
(21 )
10
Hydraulic tank
The metal hydraulic tank is located in the cowl below
the plate. The tank is supported in rubber pads, bolted
to the chassis partition and floor plate.
1. Hydraulic tank
2. Floor plate fixing
3. Air filter
4. Chassis partition fixing
5. Screw plug
6. Return - steering
7. Return - control valve block, connection R
8. Breather filter with dipstick
9. Bush
10. Pipe for filter cartridge
NOTE
- The tank can only be removed with the battery
removed in order to loosen the fixng (4) on the chassis
partition.
- The tank can be removed with oil filling.
Removal
- Tilt mast back and fully lower fork carriage.
- Remove battery.
- Jack up right vehicle side and remove right front
wheel.
- Remove plate.
- Remove return hoses (6+7) and disconnect air
intake hose from air filter (3).
- If the hydraulic oil is to be drained, unscrew screw
plug (5) and discharge oil into a collecting container.
- Loosen fixing (4) on chassis partition.
- Loosen fixing on floor plate (2) on the right side of
the tank (on the left side, the tank is suported on ly
one one rubber pad).
- Remove drained tank upwards.
With the tank filled, screw one M8 eye bolt into
the bush (9) and remove tank with lifting gear.
Installation
- Prior to installation of the tank, ensure that the
rubber pad on the left side is placed in the hole in
the floor plate.
(22 )
10
Hydraulic tank
1. Hydraulic tank
2. Floor plate tank fixing
3. Air filter
4. Battery partition tank fixing
5. Oil drain screw
6. Return - steering
7. Return - control valve block, connection R
8. Breather filter
Hydraulic oil change
Every 3000 operating hours, however, minimum every
two years.
-
6032/35
Tele
up to 3260
21
21
Niho
up to 2710
21
21
Triple up to 3260
21
23
Mast
Overall height (mm)
Marking
6030/31/33/34
6032/35
Tele
up to 3260
II
II
Niho
up to 2710
II
II
Triple
up to 3260
II
Breather filter
The breather filter (8) with a filter fineness of 25
prevents dust and dirt entering the hydraulic tank.
The breather filter must be renewed every 3000
operating hours.
(23 )
10
Air filter
Function and maintenance
Type : Air filter with paper filter cartridge withg bypass
valve and strainer.
Paper filter cartridge (3) :
Filter fineness = 15 (nominal)
Bypass valve(1) : Operating pressure: 0.25 0,05 bar
Strainer
(2) : 200
1. Bypass valve
2. Strainer
3. Paper filter cartridge
4. Seal
5. Air intake to pump
6. O-ring
7. Filter cover
8. Nut (4)
9. Hydraulic tank
10. Pipe
11. Notch
The oil sucked out of the tank by the hydraulic pump
flows through the filter cartridge (3) from the outside
to the inside.
.
For protection of the hydraulic pump, the bypass valve
(1) opens at a low pressure of 0.25 0.05 bar (filter
cartridge clogged) and allows the oil to flow via a
strainer (2).
The insertion depth of the paper filter cartridge (3) is
limited by notches (11) in the pipe.
NOTE
In the event of jerky load movements or none at all,
loud pump noise or foaming oil, the packing Items
Pos. 4 and 6 and the connection of the filter cover
Item 7 to the air intake hose must be checked for air.
Paper filter cartridge (3) replacement
- Loosen nuts (8).
- Lift cover (7) and remove from filter cartridge (3).
- Remove filter cartridge.
- New seal (4) at pipe (10).
- Fit new filter cartridge (3) in pipe (10).
- Fit cover (7) and tighten with nuts (8).
NOTE : Do not clean paper filter cartridges.
Replace if clogged.
Maintenance intervals
Change paper filter cartridges (3) minimum every 3000
operating hours.
(24 )
10
Hydraulic unions
Tilt cylinder unions
The threaded pipes are plastic coated for sealing in
the cylinder barrel at the thread (arrow).
Fitting :
After positioning the union in the cylinder barrel
(maximum one full turn), the following screwing depth
limits must be maintained :
minimum = 4 full turns
maximum = 5 full turns
NOTE
The correct position of the union must be achieved
when screwing in. Any unscrewing during or after
screwing will result in leaks.
In the event of leaks of the union, do not continue to
screw in any further, but renew instead.
180 o
(25 )
10
Hydraulic unions
Pipe union with soft seal (EO2)
Screw function nut (1) with retaining ring (3) and seal
(2) hand-tight to the threaded pipe.
Insert pipe end into the union and fully push into the
internal cone.
ATTENTION:
Installation may be unsuccessful if the pipe is not
fully inserted.
6
Tighten function nut (1) until an increase in force can
be noticed (about 1 to 1 1/2 turns).
For this purpose, mark (6) the pipe and function nut.
(26 )
10
Hydraulic unions
Check
After installation, slacken function nut (1) and check
whether the gap between the seal (2) and retaining
ring (3) is closed.
2 3
Repeat installation
After each slackening of the function nut (1), repeat
installation must take place with the same torque as
in initial installation.
The threaded pipe (7) must be countered.
1
Seal replacement
In the event of leaks at the union, the seal (2) can be
removed from the free pipe end, checked for damage
or hardening and replaced if necessary.
(27 )
10
Speeds
The vehicles are delivered with the following working
speeds, measured with rated load:
Lifting:
( Tolerance 12 % )
Rated stroke - h3
above
to
6030
6031
6033
6034
6032
6035
Tele
0.53 m/sec.
0.45 m/sec.
Niho
Triple
0.50 m/sec.
0.43 m/sec.
3500
5000
Seconds per
degree
Tilt angle
3500
5000
NOTE:
For Niho and triple masts, the mean value from the
measured speeds in stroke I and stroke II is decisive.
Lowering:
Tele mast
Niho/triple mast
NOTE
Special equipment on the vehicles may produce
deviating values.
ATTENTION:
0.60 m/sec. must not be exceeded!
Tilting:
3500
5000
Seconds per
degree
Tilt angle
3500
5000
(28 )
10
Hydraulic diagram
(29 )
10
Hydraulic diagram
1
Steering cylinder
Mast type
2. Steering unit
3. Oil tank
6030 - 35
4. Intake filter
5. Pump unit
6. Control valve block
7. Control valve block (double additional
hydraulics)
8. Control valve block (single additional hydraulics)
9. Pressurising valve 125 bar
10. Tilt cylinder
11. Lowering brake
12. Hose failure safety device
13. Lift cylinder
14. Sender (electric sensor for pressure indication)
15. Relief valve
16. Breather filter
17. Priority valve
18. Pressure switch
19. Hydraulic accumulator
20. Relief valve
Variants:
A = Pressure regulator with single additional
hydraulics
B = Pressure regulator with double additional
hydraulics
C = Hydraulic accumulator
(30 )
Tele
Niho
Triple
10
Table of contents
Page
32
Hydraulic system
Functional description of lift and tilt hyraulics
33
Actuation
Joystick/Function
Joystick/Function, installation information
Emergency lowering
34
35
36
37
38
39
40
Control valve
Connection block - lifting/lowering
Connection block - lifting/lowering
Tilting
Tilting
Additional hydraulics - end valve
Additional hydraulics - end valve
41
42
43
44
45
46
47
48
Hydraulic diagram
Diagram
Legende
49
50
(31 )
10
14cm / revoluti on
D i recti on of rotati on
50 + 10 Nm
500 rpm
wi thout load about 3000 rpm/ wi th load about 2550 rpm
Ti lti ng
Threaded connecti on
Ti lt cross-secti on reducer
20 ( absolute )
H ydraulic tank
C apaci ty
Hydrauli c oi l ( OZ )
S p eed s
Tele / N iho
Triple
6030/31/33/34
6032/35
0.53 m/sec
0.5 m/sec
0.50 m/sec
0.43 m/sec
Tolerance 12 %
0.45 - 60 m / sec.
)
(32 )
10
Hydraulic system
Functional description of lift and tilt hydraulics
The hydraulic oil drawn out of the tank (4) by the gear
pump (5) via the filter (3) flows to a priority valve (6)
connection P.
The oil required for the steering is supplied to the
steering unit.
The residual oil flows via the connection EF to the
control valve block (2) connection P.
The control valve sliders are controlled by lifting
magnets via an electrical signal proportional to
actuation of the joystick (1).
With only slight actuation of the joystick and minor
displacement of a valve slider, the oil flows with low
circulation pressure through the control valve block
from connection R back into the tank.
On further actuation of the joystick, an oil volume proportional to the valve displacement flows from
connection A to the lift cylinders (7) and from A and
B to the tilt cylinders (9) and to an attachment (10) in
the additional hydraulics.
Attention
Before carrying out any work on the hydraulic
system, fully lower the the fork carriage and
disconnect the battery connector.
(33 )
10
Actuation/Joystick
The joystick (1), which can be moved to all sides, is
screwed to the armrest (2).
The armrest can be adjusted for height and moved
forward by loosening the locking wheel (3).
CAUTION
To prevent damage to the joystick, before opening
the battery hood:
- Move the seat right back
- Fully lower the armrest
(34 )
10
Actuation/Joystick
The following basic settings are provided for actuation
of the attachments.
Moving joystick to the left or right:
- Turn rotating head or roller clamp to the left or right
- Move sideshift to the left or right
Moving joystick to the left or right with F function
button depressed:
- Open or close sideshift
- Open or close clamp
Emergency lowering
If in the event of failure of the valve control a lifted load
can no longer be lowered, it is possible to lower the
load manually.
- Open valve cover (1)
- Push in upper solenoid valve (3) with a screwdriver
or similar.
The lowering speed can be regulated by the amount
of pressure applied.
Removal of joystick
For this purpose, the joystick, emergency switch and
cover are screwed to the underside of the armrest.
1 = Screws for joystick housing
2 = Screws for joystick cover
3 = Screws for armrest cover
2
1
2
1
2
2
1
3
(35 )
10
1. Rubber pad
2. Valve carrier fixing bolts
3. Control valve block fixing bolts
4. Valve carrier
5. Control valve block
6. Pin
7. Valve bonnet
8. Emergency lowering
9. Valve bonnet fixing screw
Design
- The control valve block is fixed to the valve carrier
(4) with three bolts (3).
- The valve carrier id flexibly fixed in three rubber pads
(1) to the chassis partition (7).
- The valve bonnet (7) is mounted rotatable on the
valve carrier (4).
- To open the battery hood, the valve bonnet must be
tilted forward after releasing the pin (6).
- Attached to the upper side of the valve bonnet is a
sign with the control symbols of the hydraulic
functions.
NOTE
Removal of the valve bonnet (7) from the valve carrier
(4) is only possible with the control valve block
removed.
- Remove screw (9) and remove valve bonnet (7)
laterally.
(36 )
10
(37 )
10
Installation information
10. Cap
11. Control magnet - lowering
12. Connection P (pump line)
13. Connection A (lifting/lowering)
14. Relief valve 250 bar
15. Travel adjustment - lift valve
16. Connection A (forward tilt)
17. Connection B (backward tilt)
18. Screw plug - pressurising valve 125 bar
19. Screw plug - pressurising valve 25 bar
20. Connections additional hydraulics 1
21. Connections additional hydraulics 2
22. Screw plug - Pressure regulator
Function
The magnet coils (4) push the valve slider downwards
and open the connections B to the connection P,
as well as the connections A to the return R.
The magnet coils (5) pull the valve sliders upwards
and open the connections A to the connection P,
as well as the connection B to the return R.
STILL GmbH Position as per: 2/00 (Replaces version:
38
10
B
A
IV
B
A
III
3
B
A
5
7
3
8
9
10
5
4
II
11
12
Y1
Y
13
2
1
R
39
10
I
= Control valve block - lifting/lowering
II
= Control valve - tilting
III
= Control valve - additional hydraulics 1
IV
= Control valve - additional hydraulics 2
A + B = Load connections
P
= Pump connection
R
= Return tank
Y
= Control channel
Y1
= Control channel - load
1. Solenoid valve
2. Relief valve
3. Shuttle valves
4. Lower valve
5. Check valve
6. Control valve - lowering
7. Control valve - tilting
8. Pressurising valve 125 bar
9. Pressurising valve 25 bar
10. Control magnets
11. Check valve - lifting
12. Lift valve
13. Pressure regulator
Function
The control valve block functions on the three-way
flow control principle.
In a neutral position of the valve, no pressure from
the load side is active.
The control channels -Y1- and -Y- are therefore
pressureless.
The oil entering at P can therefore open the pressure
regulator (13) against spring force and the oil pumped
by the pump flows virtually pressureless at R directly
back into the tank.
On displacement of a valve, the pressure produced in
the load is applied via the control channels Y1 and Y
to the pressure regulator and is closed by spring
force.
The oil is thus supplied to the load. The oil flow is
rgulated via permanently set pump motor speeds and
by actuation of the joystick.
40
10
41
10
Control valve
Connection block - lifting/lowering
A = Load connection - lifting
P = Pump channel
R = Return channel
Y = Control channel
1. Cap
2. Control magnet - lifting
3. Control magnet - lowering
4. Plug connections
5. Control magnet plunger
6. O-ring
7. Lower valve
8. Lift valve rod
9. Valve housing
10.+11. Spring
12. Locking and adjusting screw
13. O-ring
14. Screw plug
15. O-ring
16. Stop
17. Spring
18. Valve rod
Regulator
19. Bore
20. Distance spacers
21. Dowel pin
22. O-ring
23. Screw plug
24. Flange for pressure pipe
25. Flange fixing bolt
26. Lower valve lock screw
27. Tilt valve flange
28. Valve seat
29. Vealve with spring
Lift check valve
30. Scheibe
31. Seege circlip ring
32. Seeger circlip ring
33. Cross-section reducer
34. Sleeve
35. Spring
Lower control
36. Washers
valve
37. O-ring
38. Screw plug
Functions
Pressure regulator (14 - 23)
The oil entering the pressure regulator at P flows
via the bore (19) into the upper chamber between the
valve rod (18) and screw plug (23). If no valve is
actuated, the rod (18) is pushed downwards against
the spring (17). The oil flows from P virtually
pressureless into the return R.
42
10
3
4
5
6
7
23
24
25
P
26
A
27
28
27
Y1
9
10
11
12
13
14
15
16
26
25
24
23
17
18
19
20
21
22
43
10
Control valve
Tilting
A = Connection - forward tilt
B = Connection - backward tilt
P = Pump channel
R = Return channel
Y = Control channel
Y1 = Control channel - load
1. Union nut
2. Magnet coil (backward tilt)
3. Magnet coil (forward tilt)
4. Pressure pipe
5. O-ring
6. O-ring
7. Pull rod (magnet core)
8. Slider
9. Valve rod
10. Cross-section reducer
11. Valve cone
12. Bores
Control and
13. Spring
check valve
14. O-ring + retaining ring
15. Circlip
16. Screw plug
17. Washer
18. O-ring + retaining ring
19. Spring
20. Spring
21. Nut
22. Slider screw plug
23. Pressurising valve screw plug
24. Spring
25. O-ring
26. Spring
27. Valve disk
Pressurising
28. Valve cone
valve
Function
Proportional to joystick actuation, the slider (8) is:
- Pulled upwards by the magnet coil (2) via the pull
rod (7) and opens the connection A (forward tilt)
to the pump channel P.
- Pulled downwards by the magnet coil (3) via the
pull rod (7) and opens the connetion B (backward
tilt) to the pump channel P.
The oils flows from P via the cross-section reducer
(10), the valve cone (11) lifted from its seat, the slider
opening and the valve cone (27) of the pressurising
valve lifted from its seat to the load connection A or
B.
The oil discharged from a tilt cylinder flows via one of
the load connections A or B to the pressurising
valve (26 - 28).
= 25 bar
= 125 bar
44
10
3
4
5
6
7
Y1
10
11
12
13
14
15
16
17
18
19
STILL GmbH Position as per: 2/00 (Replaces version:
45
10
Control valve
Additional hydraulics/end valve
A = Connection - attachment
B = Connection - attachment
P = Pump channel
R = Return channel
Y1 = Control channel - load
1. Union nut
2. Magnet coil
3. Magnet coil
4. Pressure pipe
5. O-ring
6. O-ring
7. Pull rod (magnet core)
8. Slider
9. Ball
10. Spring
11. O-ring + retaining ring
Check valve
12. Circlip
13. Screw plug
14. Washer
15. Spring
16. Spring
17. Adjusting screw
18. Screw plug
19. O-ring + retaining ring
Function
Proportional to joystick activation, the slider (8) is:
- Pulled upward by the magnet coil (2) via the pull
rod (7) and opens the connection A to the pump
channel P.
- Pushed downward by the magnet coil (3) via the
pull rod (7) and opens the connection B to the
pump channel P.
The oil flows from P via the ball (9) lifted from its
seat and via the slider opening to the load connection
A or B.
ATTENTION
The slider screw plug (18) and also the nut (17) must
not be loosened in any event otherwise the slider travel
set by the manufacturer will be altered and
malfunctions will result.
Resealing at the O-ring (6) and (19), as well as removal of the pressure tube (4) and slider (8) is therefore
not possible.
46
10
11
10
9
8
Y
7
6
1. O-ring
2. Retaining ring
3. Shuttle valve
4. Block bolt bores
5. Aluminium plate
INSTALLATION INFORMATION
- For resealing, two additional aluminium plates (5)
must be bonded to the flange surface of the control
valves according to the dimensionally specified
position.
- Do not clean flange surfaces with a cloth or paper
cloths. Fibres on the O-rings can impair the
tightness.
It is recommended to wipe the surface with the
palm of the hand.
- Observe tie rod (4) tightening torques.
Block seals
Pump channel P, return channels R and control
channel Y are sealed on the flange surfaces of the
control valve by means of O-rings and retaining rings.
47
2 1
10
48
10
Hydraulic diagram
49
10
Hydraulic diagram
Mast type
1. Steering cylinder
2. Steering unit
3. Oil tank
6030 - 35
4. Intake filter
5. Pump unit
6. Control valve block lift/tilt
7. Control valve block (single additional hydraulics)
8. Control valve block (double additional hydraulics)
9. Pressurising valves
10. Tilt cylinder
11. Lowering brake
12. Hose fracture safety device
13. Lift cylinder
14. Sender (electric sensor for pressure indication)
15. Relief valve
16. Breather filter
17. Priority valve
18. Pressure switch
19. Hydraulic accumulator
20. Relief valve
VARIANTS :
A = Pressure regulator with single additional
hydraulics
B = Pressure regulator with double additional
hydraulics
C = Hydraulic accumulator
50
Tele
Niho
Triple
Workshop manual
Table of contents
Page
4
4
4
5
5
6
6
7
7
8
9
Pump motor
Motor type
Position of motor terminals
Circuit diagram
Removing the motor
Fitting the motor
Checking and replacing carbon brushes
Speed sensor
Independent air cooling
Carbon brush monitor
Temperature monitor
Motor (exploded drawing)
Motor (sectional view)
Insulation test
General notes
10
10
10
11
11
11
12
12
13
14
15
16
17
18
11
6030 - 32
11
Type
GF 148 - P8
Manufacturer
JULI
Motor type
Voltage (V)
80
Current (A)
165
Excitation
12 V/16 A
2500
3800
6500
Power (kW)
11
Mode
S2 (60min)
Degree of protection
IP 23
Insulation class
Carbon brushes
EG34D-J
a) Dimensions
12.5 x 25 x 40
b) Wear limit
c) Quantity (units)
yes (isolated)
Weight (kg)
146
Ventilation
Group 11
Drive motor
Workshop manual
11
6030 - 32
Type
GP 116 - Q2
Manufacturer
JULI
Motor type
4-pole d.c.motor
Voltage (V)
80
Current (A)
132
3000
4000
5000
Power (kW)
12
Mode
S3 (20%)
Degree of protection
IP 23
Insulation class
Carbon brushes
A121
a) Dimensions
12.5 x 40 x 40
b) Wear limit
c) Quantity (unit)
yes (isolated)
Weight (kg)
35
Ventilation
11
Drive motor
Drive motor type
The four-pole separately excited machine with
commutating poles is integrated into the front axle.
It has a carbon brush and temperature monitor.
Independent air cooling supplies the machine with
cooling air.
(-)
(+)
A2 B1
F2
F1
(-)
A2 B1
F2
Circuit diagram
A1 / A2 = Rotor
M
A1/B2
A1/B2
F1 / F2 = Field winding
Rechtslauf
right
rotation
F1
F2
Linkslauf
left rotation
Terminals
F1
(-) (+)
Workshop manual
6030 - 32
11
Drive motor
11
Drive motor
Removing the armature
Removal:
- Jack up the vehicle
- Remove both drive wheels
- Drain gear oil on both sides of the wheel gear
- Loosen fixing bolt of left wheel hub (16 hexagon
socket screws M8) and remove the hub
- Remove planetary gear
(Note fitting position!)
- Remove circlip and washer in front of the speed
sensor disk
Attention
Do not force off against the sensor bearing!
4
7
5
2
Workshop manual
11
6030 - 32
Drive motor
Checking/replacing carbon brushes
1
CARBON BRUSHES
x12
The speed sensor bearing can be tested with 10 V
d.c. (voltage of vehicle electronics is applied on
contacting via connector x12!). The measuring
instrument must be connected to terminals 4 and 2
or 3. If the sensor is intact, a voltage jump (from
about 0V to about 8 V) must be measured, turning
the rotor slightly.
1 = Positive 10V (red)
2 = Spur B (blue)
3 = Spur A (white)
4 = Negative 10V (black)
2
1
3
4
11
Drive motor
Workshop manual
11
6030 - 32
Drive motor
1 = Ball bearing
2 = Bellville springs
3 = Shaft seal (secured with Loctite 243)
4 = Insulator (secured with Loctite 243)
11
Pump motor
Pump unit
The pump unit is located below the floor plate on the
right-hand side and is arranged horizontally on rubber
mountings. The catch connects the drive to the gear
pump.
Motor terminals
The motor terminals are laterally arranged. These are
the terminals A1 and D2.
Position as per: November 1999
(Replaces version:
)
Speed sensor
The speed sensor is connected to the electrical
installation via connector x14 (four-pole).
Circuit diagram
+
A1
X14
D2
X15
Neutral zone
The brush yoke ring is not adjustable. The neutral
position is ensured due to the design.
10
(D1)
( A2)
Armature support
11
Pump motor
Removing the pump motor
The pump motor can be removed by first removing
the floor plate and subsequently disconnecting the
electrical connections from the pump motor (A1 and
D2, as well as the connectors x14 and x15).
The hydraulic connection must now be disconnected
from the hydraulic pump. This procedure is described
in more detail in Group 10 of this manual.
In order to lift the motor out of the vehicle contour, the
three mountings (rubber) must be removed (see Fig.
Item 1).
By removing the speed sensor guard on the machine
(top cover 2), the eyebolt can be screwed into the
shaft end. The machine can subsequently be lifted
out with lifting gear.
2
Fitting the pump motor
Fitting of the pump motor takes place in reverse order.
The tightening torques for the hydraulic hose
connections and pump must be noted (if removed).
11
11
Pump motor
Speed sensor
The speed sensor for the pump motor is located on
top of the pump motor in way of the brush-sided
bearing retainer plate.
On the rotor shaft, a ring rotates at motor speed.
This ring is scanned by the speed sensor. The speed
sensor is accessible from above after removing the
cover.
The ring is seated on the rotor shaft and can only be
removed from the rotor shaft together with the bearing
retainer plate.
Removing the speed sensor
2,80,2
12
Workshop manual
6030 - 32
11
Carbon brush monitor
Functional principle
The brush yoke rings in the drive and pump motor are
equipped with monitoring switches (normally-closed
contacts).
When the brush remaining length is reached, these
switches are opened by the brush spring.
If an interruption is caused by the opening of the switch
or wire break, this is shown on the display of the
instrument panel.
13
11
Temperature monitor
Functional principle
X 11
X 13
1
2
3
4
5
6
22
23
38
15
1
2
3
4
1
2
3
4
1
2
3
4
14
Workshop manual
6030 - 32
11
Pump motor
15
16
11
Pump motor
Workshop manual
6030 - 32
11
Insulation test
Drive motor
A2 or B1 to F1 /F2
The following are tested:
Armature and field winding of the drive motor and
pump motor, as well as the associated connecting
cable.
The test takes place with a direct voltage of
minimum 500 V at a test current of minimum 1 mA
(measuring instrument = Isolavi or Metriso).
17
11
General notes
Commutator resurfacing
Permissible commutator eccentricity
up to Rated speed 3.000 rpm 0.02 mm
over Rated speed 3.000 rpm 0.02 mm
To eliminate the commutator eccentricity, the
removed rotor must be skimmed on the lathe. A
good surface condition is achieved at high speed
and a low feed rate.
Permissible minimum commutator diameter
The commutator may only be skimmed to a
minimum dimension.
6030 - 32
Drive motor
100 mm
Pump motor
78 mm
Removal of commutator mica insulation
1=
18
Werkstatt-Handbuch
Table of contents
Page
20
Drive motor
Asynchronous motor
Mode of operation
Position of axle terminals
Removing the drive motor
Fitting the drive motor
Replacing the sensor bearing
Sectional view/Area of sensor bearing
Drive motor (exploded drawing)
Drive motor (sectional view)
22
22
23
23
23
24
25
26
27
Pump motor
Motor type
Position of electrical terminals
Removing the pump motor
Fitting the pump motor
Pump motor (exploded drawing)
Speed sensor
Temperature sensor
Insulation test
28
29
29
29
30
31
31
32
11
6033 - 35
19
11
Workshop manual
6033 - 35
6033/34/35
Type
A F 128 - K 1
Motor type
Manufacturer
Voltage (V)
~ 45 V Y
Current (A)
200
2400
6250
Rating (kW)
11.8
Mode
Insulation class
Weight (kg)
Ventilation
Speed sensor
Temperature sensor
I P 64
F
Axle 230 Kg
Surface cooling
Sensor bearing 80 pulses/rev.
Philips KTY 84-130
Degree of protection
S2 - 60 min
20
11
6033/34/35
Type
A P 124 - K 1
Motor type
Manufacturer
JULI
Voltage (V)
~ 45 V Y
Current (A)
200
3000
3100
3900
Rating (kW)
12.6
Mode
Degree of protection
S 3 - 20%
I P 64
Insulation class
Weight (kg)
50
Ventilation
Speed sensor
Temperature sensor
Surface cooling
Sensor bearing 64 pulses/rev.
Philips KTY 84-130
21
11
Workshop manual
6033 - 35
Drive motor
Asynchronous motor
The asynchronous motor, here four-pole type, as used
in this vehicle, is the most frequently built three-phase
motor. The various types of asynchronous machines
differ, for example, in the design of the rotor.
This machine has a squirrel-cage. It is a squirrelcage rotor with aluminium conductors fitted in the
laminated core slots. The conductors are shortcircuited on both sides of the laminated core with
short-circuiting rings. Conductors and short-circuiting
rings form the rotor cage, which simultaneously holds
the laminated core together.
The stator consists of the housing, laminated stator
core and star-connected stator winding.
The electric machine is cooled with cooling air and
is integrated into the drive axle.
Mode of operation
In the rotor a voltage is induced, which induces
currents in the cage bars due to the design of the
rotor. The stator rotating field produces with the rotor
current a torque. Machines that operate in this way
are called induction motors.
In the case of this installed machine, an inclined
arrangement of the conductors in the rotor was
selected. This arrangement counteracts a reduction
of torque in the lower speed range.
The machine in this vehicle is controlled via an inverter.
This control operates on the pulse width modulation
principle at a cycle frequency of about 13 kHz (see
Group 08 - Control principle).
Speed variation of the asynchronous machine takes
place via a change in the frequency of the employed
alternating voltage.
22
11
Drive motor
Position of electrical terminals at the axle
The three main supply terminals U, V and W are
arranged on the left side on the terminal board.
The connectors x12 (speed sensor) and x13
(temperature monitor) are arranged immediately
next to the terminal board.
W V U
x13
x12
23
11
Workshop manual
6033 - 35
Drive motor
Replacing the sensor bearing
24
11
Drive motor
1 = Connector
2 = Contact plate bolts
3 = Contact plate
4 = Contact shaft
5 = Wheel rim/Wheel
6 = Gear oil
7+8 = Wheel gear
9 = Gear
18 = Sensor bearing
19 = Thrust washer
20 = Shaft seal
21 = Washer
22 = Seal
23 = Inner shaft
24 = Ring gear
25a = Filler screw
10,5
10,5
25
26
w
v
u
6033 - 35
Workshop manual
11
Drive motor
Ju
li
11
Drive motor
27
11
Workshoop manual
6033 - 35
Pump motor
Asynchronous motor
A three-phase motor was also used here as a drive
for the hydraulic pump. The pump motor corresponds
from electrical aspects to the drive motor of this
vehicle, i.e. the three-phase motor is controlled by a
separate inverter. This control also operates on the
pulse width modulation principle.
Pump unit
28
11
Pump motor
Position of pump motor terminals
The three main supply terminals (U,V and W) are
laterally arranged in the upper third of the horizontal
pump motor.
The connectors x14 (speed sensor/4-pole) and x15
(temperature monitor/3-pole) are also laterally fixed
to the pump housing.
Removing the pump motor
- Remove floor plate
- Disconnect 3 main supply cables from pump
motor
bottom
top
x15
x14
29
30
6033 - 35
Workshop manual
11
Pump motor
11
Temperature (C)
Resistance (Ohm)
-40
355
-30
386
-20
419
-10
455
493
10
533
20
576
25
598
30
621
40
668
50
718
60
769
70
824
80
880
90
939
100
1000
110
1063
120
1129
130
1197
140
1268
150
1340
160
1415
170
1493
180
1572
190
1654
200
1739
210
1825
220
1914
230
2006
240
2099
31
11
Workshop manual
6033 - 35
Insulation test
Preparations for testing
Prior to testing, all connectors and screw
terminals must be disconnected from the
machine to be tested.
Insulation test
The insulation test should be carried out prior to fault
location at the vehicle, so that no false values are
obtained during fault location.
On completing repairs on electric groups and/or
electric machines (pump motor/drive motor) of the
vehicle, a test of the insulation resistance must be
carried out prior to installation or recommissioning.
Insulation values of the electric machines should be
minimum 1kW per volt for the drive motor and pump
motor, i.e. with an 80V installation, the insulation
value must be minimum 80kW.
Pump motor
U, V and W to frame (ground)
The following are tested:
Field windings of the drive motor and pump motor, as
well as the associated connecting cable.
The test takes place with a direct voltage of minimum
500V at a test current of minimum 1m A (measuring
instrument = Mtetra hit 16i, Isolavi or Metriso).
Drive motor
U, V and W to frame (ground)
32
13
Table of contents
Page
Pressure regulator
Relief valve, Pressure gauge
Joystick
13
Setting range
0 - 160 bar
Cross-section reducer
1.2 mm
No cross-section
reducer
Motor speed
(additional hydraulics
against excess pressure)
Sideshift functions
Other functions
=
500 rpm
= up to 2550 rpm
13
I = Additional hydraulics 1
II = Additional hydraulics 2
1. Relief valve
2. Connections for attachment
3. Sender
4. Return to tank
5. Control valve block
Function
For protection of the attachment and transported
goods, a pressure regulator with manually controllable
relief valve (1), e.g. for using a clamp function, is
installed upstream of the control levers for the
hydraulics.
The pressure set at the relief valve is measured by a
sender (3) and shown on the instrument panel display.
Connection of the pressure regulator takes place at
the lower connection bores B of the control valve
block, e.g. for the close clamp function.
(3)
13
Pressure regulator
Relief valve
- Setting range: 0 - 160 bar
- Manually controllable
1 = Handle
2 = Wing nut
3 = Distance spacer
4 = Housing
5 = Lock washer with screws
6 = Spring
7 = Washer
8 = Ball
9 = Damping piston
10 = Damping spring
2
3
4
5
7
8
9
10
ATTENTION
For setting purposes, the maximum pressure loading
capacity of the attachment specified by the
manufacturer must be observed (see attachment
identification plate).
P
Pressure gauge/Instrument panel
The pressure set at the relief valve is shown on the
the instrument panel display.
NOTE
A pressure drop indicated on the display, e.g. after
clamping a load and a neutral position of the valve, is
caused by leakage oil at the valve and does not signify
a pressure drop at the attachment.
The attachment must be provided with a stop valve
for the load holding function.
Druck : 140 b ar
13
1,2 mm
An b au g ertetyp
F ab rikat
P u mp en mo to rd reh z ah l
1/min
1. Zu satz h yd r. 2. Zu satz h yd r.
B e i A usli e fe rung o hne A nb a ug e r t
D re hg e r t
S e i te nschi e b e r
500
1u.2 T 351 E
K a up
2550
1 T 151 P 2 / P 3 / P 4
K a up
500
2550
ja
C a sca d e
700
S e i te nschi e b e r
S L4
S a co / B o lzo ni
500
K a up
2550
K a up
500
K a up
2550
K a up
500
2550
K a up
500
2550
K a up
500
800
S e i th
2550
u. 2 T 409
2 T 163
ja
ja
55 F
1,5 T 409 -2
ja / n ein
ne i n
S e i te nschi e b e r
D o p p e lkla mme r
B len d en 1,2
1. Zu satz h yd r.
ja
ne i n
2550
ja
ne i n
ja
ja
ja
ne i n
13
13
Table of contents
Page
Additional hydraulics
Pressure regulator I and II
Installation of attachments
Additional hydraulics
Cross-section reducers and pump
motor speeds for attachments
13
Pressure regulator
Installation of attachments
For the installation or removal of attachments, the
additional hydraulic system can be rendered
pressureless for disconnecting the hydraulic
connection (couplings at fork carriage).
For this purpose, the buttons 5 to 8 on the joystick
must be pressed simultaneously with the keyswitch
switched on.
Function
For protection of the attachment and transported
goods, a pressure regulator with manually controllable
relief valve (4), e.g. for using a clamp function, is
installed above the control valve block.
The pressure occurring at the relief valve at P is
measured by a sender (5) and shown on the
instrument panel display.
Connection of the pressure regulator takes place at
the upper connection bores A of the control valve
block, e.g. for the close clamp function.
For single additional hydraulics ( I ), connection takes
place at the third control valve. For double additional
hydraulics ( II ), connection takes place at the fourth
control valve.
13
Additional hydraulics
Cross-section reducers for attachments
1. Threaded pipe with cross-section reducer bore
2. Screw with cross-section reducer bore
3. Cross-section reducer marking
Cross-section reducers (1) for attachments with
sideshift
For reduction of the sideshift speed and, in the event
of a possible malfunction of the pump motor control
(excessive pump motor speed), to counteract any
rapid sideshift movement (stability), attachments with
sideshift in both connections A and B of the control
valve of additional hydraulics 1 are installed in the
threaded pipe (1) with a cross-section reducer bore
of 1.2 mm diameter.
ATTENTION
When retrofitting an attachment with sideshift, it must
be ensured that the cross-section reducer unions are
installed.
See chapter Pump motor speeds and cross-section
reducers for attachments.
Vehicles with additional hydraulics, which are delivered
without attachment, are provided with cross-section
reducer unions for safety reasons.
Cross-section reducers (2) for attachments with
pressure regulator
For attachments to be operated with reduced or variable pressure, as special equipment, in conjunction
with a pump motor speed reduction, screws (2) with
cross-section reducer bore can be used in both swivel
unions of connections A and B of additional
hydraulics 1 or 2 for safety purposes.
NOTE
The installation of a cross-section reducer union 1
and 2) is recognisable by the outer recess (3) on the
hexagon.
Workshop manual
6030 - 35
Page
3
5
6
9
12
15
16
18
21
22
23
Group 22
Removing fork carriage
Replacing support roller bearing
25
26
Group 24
Mast bearing
27
Group 25
Removing tilt cylinder
Fitting tilt cylinder
Mast tilt
29
30
31
Table of contents
Group 20
Technical service data
Mast types/removal
Telescopic mast
Niho mast
Triple mast
Stop/Chain safety device
Support rollers
Lift cylinder
Lowering brake valve
Check valve
Buffer
20-25
Workshop manual
6030 - 35
20-25
Technical service data
Tightening torque = 20 Nm
Chains
Lowerieng speed
Workshop manual
20-25
6030 - 35
Mast
Telescopic mast
When lifted, the inner mast is
higher than the load. With a low
ceiling height, the inner mast stroke
must be taken into account.
Niho mast
When lifted, the mast to be extended in stroke 1 is not higher than
the load. With low ceiling heights,
the inner mast stroke does not need
to be taken into account.
Triple mast
As for the Niho mast, only extended lift hieght with same overall
height. With low ceiling heights, the
inner mast stroke does not need to
be taken into account.
Note:
In order to reduce wear, the roller tracks must be
greased as required with :
High-pressure adhesive lubricant
STILL Part No. 147873
20-25
Telescopic mast
Functional description
The two cylinders are located in the outer mast
section.
The cylinders are hydraulically connected via a hose
line.
The two pistons are connected at the top to the crossmember of the inner mast.
When the cylinders are pressurised with oil, both
pistons extend and lift the inner mast.
The end stop takes place in the cylinder.
The chains are attached to the outer mast, are guided
via chain rollers at the inner mast and are connected
at the other end to the fork carriage.
The mast extends towards the fork carriage in a ratio
of 1 : 2.
Workshop manual
20-25
6030 - 35
Telescopic mast
20-25
Telescopic mast
Chain adjustment
The chains must be evenly adjusted at the bail screws
(1).
The centre of the upper fork carriage rollers (4-roller
fork carriage) or the centre fork carriage rollers (6roller fork carriage) must remain in the inner mast
section with the lift cylinder piston fully extended
(stop in cylinder) min. --> dimension X.
Never compensate tyre wear by retensioning the
chain.
Attention:
The chains must be inspected for wear, damage and
elongation according to UVV.
Dimension X
6030/6031/6033/6034 X = 25
6032/6035
X = 15
Insertion depth E
6030/6031/6033/6034 E = 336
6032/6035
E = 369
Workshop manual
20-25
6030 - 35
Niho mast
Functional description
1 - Stop
The stop prevents the fork carriage falling out
(Adjustment, see page 15).
20-25
Niho mast
3
1
10
Workshop manual
6030 - 35
20-25
Niho mast
Chain adjustment
The chain is adjusted at the bail screw (1).
The centre of the upper fork carriage rollers (4-roller
fork carriage) or the centre fork carriage rollers (6roller fork-carriage) must remain in the inner mast
section with the centre cylinder piston fully extended
(stop in cylinder) min. --> dimension X.
Never compensate tyre wear by retensioning the
chain.
When making the chain adjustment, it must be
ensured that the minimum distance of 2mm to the
stop is maintained (see adjustment, page 15).
1
Attention:
The chains must be inspected for wear, damage and
elongation according to UVV.
Dimension X
6030/6031/6033/6034 X = 20
6032/6035
X = 15
Insertion depth E
6030/6033
6031/6034
6032/6035
E = 321
E = 371
E = 369
11
20-25
Triple mast
Functional description
The mast has 1 centre cylinder (stroke 1) and 2 outer
cylinders (stroke 2).
The centre cylinder has a telescopic action within
the inner mast providing the high free lift, but not
exceeding the overall height of the truck.
The two outer cylinders are located within the double
T-section of the outer mast.
The outer cylinder pistons are connected to the centre
mast.
The chains for stroke 2 are attached to the top of the
outer mast and to the bottom of the inner mast.
When the cylinders are pressurised with oil, the centre
cylinder piston extends first, due to its larger area.
The two outer cylinder pistons subsequently extend
and lift the centre mast. The centre mast lifts due to
the chain connection in the inner mast in a ratio of 1
: 2.
1 - Stop
The stop prevents the fork carriage falling out
(adjustment, see page 15).
12
20-25
Triple mast
13
20-25
Triple mast
Chain adjustment
Outer chains:
The outer chains must be evenly adjusted at the bail
screws (1), until the three mast sections are in
alignment.
Centre chain:
The chain is adjusted at the bail screw (2).
The centre of the upper fork carriage rollers (4-roller
fork carriage) or the centre fork carriage rollers (6roller fork carriage) must remain in the inner mast
section with the centre cylinder piston fully extended (stop in cylinder) min. --> dimension X.
Attention:
The chains must be inspected for wear, damage and
elongation according to UVV.
Dimension X
6030/6031/6033/6034 X = 20
6032/6035
X = 15
Insertion depth E
6030/6033
6031/6034
6032/6035
E = 381 to BH 2360
E = 481 from BH 2460
E = 431 to BH 2360
E = 531 from BH 2460
E = 419
14
Workshop manual
20-25
6030 - 35
Chain/Stop
Chain adjustment
The centre chain of the Niho and triple mast and the
outer chain of the telescopic and triple mast are
secured as shown in the diagram opposite.
1 - Cap
2 - Cheese-head screw M6 with Tuflok coating
Stop
For chain adjustment, it must be ensured that with
the mast fully extended, the stop takes place in the
cylinder, i.e. stop (1) and stop (2) must not make any
contact.
Note:
In the case of high masts, it can easily be determined
how large the gap is by applying some plasticine to
the stop (1), lifting the fork carriage up to the stop
and subsequently measuring the thickness of the
plasticine with a sliding vernier caliper.
15
20-25
Support rollers
Fitting
1.6t/1.8t
Roller
diameter
75.3
75.6
75.9
76.2
Dimension A Dimension X
above
up to
-75.9
0.6
-76.2
0.6
-76.5
0.6
76.5
--
2.0t
Dimension A
above
up to
-81.5
-81.8
-82.1
82.1
--
Dimension X
0.6
0.6
0.6
lateral clearence
seitliches Spiel
Note:
Dimension A must be measured where the support
track changes to the radius.
Dimension A for new profile --> 75.4 +0.8 (1.6t/1.8t)
81.0 +0.8 (2.0t)
Roller
diameter
80.9
81.2
81.5
81.8
1 - Support roller
2 - Washer
3 - Countersunk screw
Tightening torque = 60 Nm
fork
carriage
Gabeltrger
16
Workshop manual
6030 - 35
20-25
Support rollers
Check
Determine the lateral clearance and dimension X
with a feeler gauge.
The value of dimension X = 0.6 mm is a guide value
for fitting the next larger support roller during the
running-in period, i.e. for the new profile (dimension
A = 75.4 +0.8 or 81.0 +0.8), the profile material will
slightly compress in the beginning at the points where
the support rollers run.
17
20-25
Lift cylinder
Removing outer cylinder Niho/Triple
- Set mast vertical
- Raise fork carriage
- Extend outer cylinder piston about 20cm
- Place wooden block between upper outer mast
cross member and inner mast cross member (for
triple centre mast cross member)
- Remove lock ring from upper piston mounting (cross
member)
- Fully lower mast so that the hydraulic system is
rendered pressureless
- Disconnect upper and lower hydraulic connection
- Loosen clamp
- If the piston should not lower by itself, then, e.g.
use a screwdriver
2
3
4
Note:
The adapter (1) is secrued with Loctite 275 (524199).
18
Workshop manual
20-25
6030 - 35
Lift cylinder
Removing telescopic mast cylinder
- Set mast vertical
- Extend lift piston (about 20cm) until upper mount is
accessible for removal of the lock ring
- Remove lock ring of upper piston mount
- Place wooden block between upper outer mast cross
member and inner mast cross member
- Fully lower mast, so that the hydraulic system is
rendered pressureless
- Disconnect lower hydraulic connection
- Loosen clamp
1
Seal kit replacement
2
3
6
7
1 - Double wiper
2 - Grooved ring
3 - Cylinder head
4 - Bleeder
5 - O-Ring
6 - Piston
7 - Cylinder barrel
8 - Circlip
9 - Bushing
8
9
19
20-25
Lift cylinder
Centre cylinder Niho/Triple
The cylinder is a single-action cylinder (plunger
piston).
The cylinder barrel and cylinder liner are welded
together.
The cylinder head is screwed to the cylinder barrel
and secured with Loctite 243.
Cylinder barrel-cylinder head sealing takes place with
an O-ring.
Cylinder head-piston sealing takes place with a
grooved ring.
A check valve screwed into the cylinder liner prevents
the load being lowered too quickly in the event of
pipe fracture.
The centre cylinder has end position damping (bores
A and B).
1
2
3
4
5
6
1 - Double wiper
2 - Grooved ring
3 - Bleeder
4 - Cylinder head
5 - Seal
6 - Piston
7 - Cylinder barrel
8 - Piston cover
9 - Seal
10 - Guide
20
A
8
9
10
20-25
Function
When the load is lowered, the diaphragm is regulated
by the flow of hydraulic oil and forms in the control
piston a annular diaphragm, the flow resistance of
which determines in conjunction with the bias
(adjusting length) of the piston spring, the size of the
controlled flow.
Note:
The permissible lowering speed at rated load is 0.6
m/sec.
Lift --> Flow direction F--->B
Free, unhindered flow with low resistance due to the
diaphragm leaving the normal position (diaphragm
action cancelled).
Lower --> Flow direction B--->F
Virtually constant flow due the automatic equilibrium
between the inner pressure gradient and bias of the
control piston spring.
3
1 - Diaphragm in free flow direction
2 - Piston spring
3 - Control piston
4 - Guiding edges
5 - Diaphragm in normal position
4
F
21
20-25
Check valve
Function :
The check valve prevents a load being lowered too
quickly and uncontrolled in the event of a pipe
fracture.
3
1 - Piston cover
2 - Cylinder liner
3 - Check valve
4 - Valve disc
The diagrams show the position of the check valve
(LBS) :
2
3
22
Workshop manual
20-25
6030 - 35
Lift cylinder
B
A
1 - Piston cover
2 - Piston
3 - Diaphragm
4 - Spring
5 - Circlip
Function
When the piston rod is pressurised with oil when the
mast is lifted, the piston (2) is moved by the force of
the spring (4) in the direction of the cylinder liner,
until the circlip (5) on the piston cover (1) makes
contact. The oil flows via the diaphragm bore (3) from
chamber A to chamber B, until a pressure balance
has taken place.
When the mast is lowered, the first piston (2) makes
contact with the cylinder liner (2) before the piston
rod reaches its end position. The piston (2) is moved
in the direction of the piston rod, whereby the oil from
chamber B flows via the diaphragm bore (3) into the
chamber A. The mast is thus hydraulically retarded
by this pressure balance.
23
Workshop manual
20-25
6030 - 35
Fork carriage
Removing the fork carriage
- Set the mast vertical.
- Remove fork/attachment.
- Slightly lift the fork carriage so that the chain can
be hung out and support the fork carriage.
- Fully lower the inner mast hydraulically.
- Hang out chain at fork carriage.
- Remove screw at the stop on the inner mast.
- Remove fork carriage upwards from the inner mast.
Stop adjustment:
See page 15
2
1
25
20-25
Roller retainer
Replacement of support roller bearing
A
D
Position as per: November 1999
(Replaces version:
)
50 91
26
2
Copyrighted. Reproduction in any form
forbidden.
Copyright reserved.
Tolerance
A = 0.2 C = 0.5
B = 0.5 D = 0.8
Workshop manual
20-25
6030 - 35
Mast bearing
1 - Mast bearing
2 - Ball socket GE 35 DO - 2RS
3 - Hexagon bolt M16x45 10.9
4 - Hexagogn bolt M16x110 10.9
5 - Lubricator DIN 71412 - BS6
6 - Detent ring
Tightening torque of 3 and 4 = 275 Nm
27
Workshop manual
20-25
6030 - 35
Tilt cylinder
Dismantling
Clamp cylinder in the vice at the cylinder liner.
Unscrew threaded pipe on the cylinder hear side
(threaded pipe protrudes into cylinder chamber).
Lightly drive in cylinder head (9) with mandrel.
Through the small hole in the cylinder barrel, push in
circlip (11) with mandrel and lever out circlip with a
screwdriver (see diagram).
Remove cylinder head from cylinder barrel by firmly
pulling on the piston rod.
14
X
13
1 - Hexagon nut
2 - Spacer
3 - Piston guide ring
4 - Seal
5 - Piston
6 - Piston rod
7 - Seeger V-ring
8 - Grooved ring
9 - Cylinder head
10 - O-ring
11 - Circlip
12 - Wiper
13 - Hexagon bolt for eyebolt clamping
14 - Eyebolt
12
11
10
9
Hub
L
6
4
5
3
29
20-25
Tilt cylinder
Assembly
Check all parts for wear.
The piston (5) is sealed on the piston rod (6) with
Loctite 270.
The hexagon nut (1) or spacer (2) is secured with
Loctite 270.
15
15 - Ring
for Tele/Niho fitted externally
for triple fitted internally
L
Position as per: November 1999
(Replaces version:
)
30
Workshop manual
20-25
6030 - 35
Tilt cylinder
a
h4
h3
h5
h2
h - Overall height
h2 - Free lift, Tele 150mm
h3 - Nominal lift
h4 - Maximum height
Stroke
Mast
Overall height
forward (degrees) backward (degrees)
333
333
71
71
3
3
5
5
Tele
Tele
up to 1910
for front windscreen
333
348
71
56
3
3
5
3
Niho
Niho
up to 1910
for front windscreen
309
309
91
91
3
3
8
8
Tele
Niho
1960 to 3260
1960 to 3260
333
71
Triple
1860 to 3260
31