Still R60-16, 18 Y 20 (ingles 03-1999).pdf

01

Workshop manual 6030 - 35

Table of contents

Page

Chassis and counterweight Jacking-up fork truck

ã STILL GmbH Stand: 3/1999 ( Position as per:

1 2

)

(1)

01

Workshop manual 6030 - 35

Chassis and counterweight Chassis and counterweight The chassis is a welded construction. Chassis and counterweight are connected together with 4 hexagon bolts M20x70 8.8. Bolt tightening torque:

385 Nm

Weights of counterweights: 6030/6031/6033/6034

—> 818 kg

6032/6035

—> 936 kg

Battery compartment dimensions 6030/33

6031/34

6032/35

A

788 ±3

788 ±3

788 ±3

B

1040 ±2

1040 ±2

1040 ±2

C

580 ±3

580 ±3

580 ±3

A

C

B

ã STILL GmbH Position as per: 3/1999 (Replaces version:

) (2)

01

Workshop manual 6030 - 35

Jacking up fork truck Attention Before jacking up fork truck: Disconnect battery connector! Engage parking brake! The fork truck has to be jacked up for various maintenance work. When jacking up the fork truck, suitable means, e.g. wooden blocks must be used to prevent the fork truck slipping or tilting. It must always be ensured that only truck jacks with sufficient bearing capacity are used and that the fork truck is only jacked up on even surfaces and secured to prevent rolling. The fork truck must only be jacked up at the point shown in the diagrams, i.e. on the left or right of the mast and on the front or rear of the chassis. Do not jack up the fork truck at the counterweight! When jacking up the fork truck at the mast, the safety regulations for working on the mast must be observed.

Warning information for parking the fork truck on a slope and opening the hood. Danger: The fork truck can roll despite engaged parking brake. If the fork truck is parked on a slope, the hood may only be opened when the fork truck is secured with chocks to prevent rolling.

ã STILL GmbH Position as per: 3/1999 (Replaces version:

) (3)

02

Workshop manual 6030 - 35

Page

Technical service data

2

Steering axle construction

3

Removing the steering axle

3

Fitting the steering axle

3

Removing the wheel hub

4

Fitting the wheel hub

4

Adjusting the steer angle

5

Checking the steer angle

5

Removing the stub axle

6

Fitting the stub axle

7

Greasing the axle

7

Removing the tie rods

8

Fitting the tie rods

8

Removing the steering cylinder

9

Fitting the steering cylinder

9

Steering axle

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per August 1999 (Replaces version: )

Table of contents

1

02

Workshop manual

6030 - 35

Steering axle Technical service data L en kach se

Radei nschlagwi nkel

80 - 82 °

Vorspur

0 ± 1 mm

Radsturz

0°

Nachlauf

0°

Anz ugsmomente MA=145 Nm

Radmutter

MA=210 Nm

Achslager

MA=195Nm

Lenkzyli nderbefesti gung

MA=210 Nm

SKM am Achsschenkelbolzen

MA=290 Nm

Schmiermittel

Radnabenlagerung

Position as per August 1999 ( Replaces version January 1991)

Radnabe

Fett F nach D IN51825-KP2K -20, li tthi umversei ft Fett F nach D IN51825-KP2K -30, li tthi umversei ft

Achsschenkellagerung

Fett FL nach D IN51825-KPF2N -20, li thi umversei ft

2

Copyrighted. Reproduction in any form forbidden Copyright reserved.

STILL Ident.-Nr. 148659

Workshop manual 6030 - 35

02 Steering axle

Steering axle construction The steering axle is mounted with 2 buffer elements on the counterweight. The stub axles are supported in the axle body in taper roller bearings. Steer angle limitation takes place via stop bolts at the stub axle. 1 Axle body 2 Retaining plates 3 Hexagon bolt 4 Lock washer 5 Buffer elements Removing the steering axle

Stand: August 1999 ( Ersatz für Stand: )

CAUTION: Only remove the steering axle with the mast fitted! Danger of tilting! - Engage the handbrake. - Prevent truck from rolling by securing front wheels with wooden chocks. - Loosen nuts of steering axle wheels. - Jack up truck properly. (See Group 01) - Remove wheels. Unscrew hydraulic connections from steering cylinder. CAUTION: When unscrewing the hydraulic connections, hydraulic oil discharges. Collect hydraulic oil and dispose of properly. - Place a hand pallet truck or similar with wooden blocks under the steering axle. - Unscrew four cheese-head screws for fixing the steering axle.

Urheberrechtlich geschützt. Jede Form der Vervielfältigung untersagt Copyright reserved.

Fitting the steering axle - Fitting takes place in reverse order to removal. - Tightening torque of the 4 cheese-head screws: MA = 195 Nm CAUTION: Do not interchange left and right hydraulic connections!

3

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

4

5 10 6

1

7 2 11 12

9 8

Position as per August 1999 (Replaces version: )

-Loosen nuts (11) and remove wheel. - Remove dust cap (7). - Loosen hexagon nut (8). - Remove washer (9) with pin (6). -Remove wheel hub. -Remove taper roller bearings (4) and (10) from the wheell hub; for this purpose, the radial seal (3) must be removed. - Remove outer ring of taper roller bearings (4) and (10) if necessary. Fitting the wheel hub - Thoroughly grease the sealing lips of the radial seal. - Fill taper roller bearings with grease F between the inner ring and cage. - Fill bearing spaces with grease F at the marked points (x). - Fitting takes place in reverse order to removal. -Tighten hexagon nut (8) constantly turning the wheel hub. Tightening torque: MA = 145 Nm

3

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

4

02

Workshop manual 6030 - 35

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

Adjusting the steer angle

- 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

1

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per August 1999 (Replaces version: )

The steer angle is limited by one stop bolt (1) on each side respectively.

5

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

2

16

3

15 4

14 13

5

12 11 10

6 7

9 8

Position as per August 1999 (Replaces version: )

- 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.

1

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

6

02

Workshop manual 6030 - 35

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

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per August 1999 (Replaces version: )

- Fit spacer (9) in the stub axle.

1 2 3 12

13

14

11 10

9

5

8

7

6

4

- Fit both taper roller bearings (8+10). Thoroughly grease both bearing with grease FL! - Thoroughly grease sealing lips of scraper rings (7+11) with grease FL. - Fit scraper rings (7+11), both spacers (13, 6 ) and O-ring (12). - Fit stub axle in the axle. - Insert king pin (3) from below, lightly oil the bolt for this purpose. - Fit washer (2). - Fit a new hexagon nut (1) and tighten with a tightening torque of: MA = 290 Nm - Press in bolt (16) of tie rod and secure with pins. - Fit the wheel. - Grease steering axle with grease FL. Greasing the steering axle - While greasing the steering axle, the steering should be operated. - Grease the 8 nipples of the steering axle with grease FL until fresh grease discharges from the bearing points (see diagram on page 8)

7

02

Workshop manual

6030 - 35

Steering axle Removing the tie rods

4

3

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

- Remove pins (4) - Press out bolts (5) Fitting the tie rods - Fitting takes place in reverse order to removal

Press-in force of bolts on stub axle side: max. 26 kN

Position as per August 1999 (Replaces version: )

Press-in force of bolts on cylinder side: max. 21 kN

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

8

02

Workshop manual 6030 - 35

Steering axle Removing the steering cylinder – Remove tie rods. – Unscrew hydraulic connections and mark. ATTENTION:

Hydraulic oil discharges

– Loosen four fixing bolts (1) Fitting the steering cylinder – Tighten fixing bolts (1). Tightening torque: MA= 210 Nm – Screw hydraulic connections in place. ATTENTION: Do not interchange hydraulic lines.

Position as per August 1999 (Replaces version: )

– Fit tie rods. NOTE: Removal and fitting of the steering cylinder is described under Group 06. Greasing the steering axle – Relieve steering axle during lubrication and operate steering. – Grease 8 nipples (2) of the steering axle with grease FL, starting from the top nipples, until fresh grease discharges from the bearing points.

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

NOTE: When greasing the top bearing, it is unnecessary for grease to discharge from the top seal. It can also deviate downwards.

2

2

2

2

9

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

 STILL GmbH Position as per: 2/2000 (Replaces version:

) (1 )

03

Workshop manual 6030 - 35

Technical service data Oil control screwsGroup 03 Axle designation

A D 20

Axle on chassis

Cheese-head screw M20 x 40 8.8 Tightening torque 385 Nm

Right wheel drive

Cheese-head screw DIN 912 M10 x 35 10.9 Tightening torque 64 Nm

Left wheel drive

Cheese-head screw DIN 912 M10 x 35 10.9 Tightening torque 64 Nm

Gear oil

Oil quantity: Left wheel drive: 0,4 l Right wheel drive: 1,4 l Oil quality: SAE 90, API-GL 4 SAE 85-90, API-Gl 4 SAE 85 W 90, API-GL 4

Slotted nut

DIN 981 KM 12 Tightening torque 650 +20 Nm

Oil filler screw

Socket screw plug M18x1,5 A3C

Oil drain screw

Socket screw plug DIN 908 M 10x1

Seal for oil drain plug

A 10 x 13,5 - CU (DIN 7603)

Oil control plugs ( 2 )

Socket screw plug DIN 908 M 10 x 1 5.8

Seal for oil control plugs

A 10x 13.5 CU (DIN 7603)

 STILL GmbH Position as per: 2/2000 (Replaces version:

) ( 2)

5.8

03

Workshop manual 6030 - 35

Wheel drive

Description of the drive axle The drive axle consists of the axle body (2) as well as the left (1) and right (3) wheel drive. Located in the axle body is the electric drive motor as well as the brake. The axle body is bolted to the chassis on each side of the vehicle with 6 hexagon bolts M 20 x 40 8.8 and washers respectively according to DIN 6796. The tightening torque is 385 Nm. The wheel drives are bolted to the axle body with 16 cheese-head screws M 10 x 35 - 10.9 respectively. The tightening torque is 64 Nm.

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.

 STILL GmbH Position as per: 2/2000 (Replaces version:

) (3 )

03

Workshop manual 6030 - 35

Wheel drive Oil level check in wheel gear 1

Note: The oil level check must be carried out with the vehicle standing horizontal. - To check the oil level, the wheel must be turned so that the one control screw (2) is in 000 position and the second control screw (3) is either in 300 (as illustrated) or 900 position. - Unscrew both control screws. - In this whel position, the oil level must be up to the lower edge of the lateral control opening (3). Otherwise oil must be filled into the filler plug (1) until it discharges from the control opening (3). Oil capacity:

3

Left wheel drive: 0.4 l

2

Right wheel drive: 1.4 l Oil qualities: SAE 90, API - GL 4 or SAE 85 - 90, API - GL 4, multigrade oil or SAE 80 W 90, API - GL 4, multigrade oil.

ã STILL GmbH Position as per: 2/2000 (Replaces version:

) (4)

03

Workshop manual 6030 - 35

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

fit with Loctite No. 270 * optional

 STILL GmbH Position as per: 2/2000 (Replaces version:

17 18 19 20 21 22 23 24 25

) (5 )

Remark

Slotted nut DIN 981 KM12 fit with Loctite No. 243 Lock ring DIN 472 140x4 Carrier Washer Washer Washer Cheese-head screw DIN 912 M8x25-8.8-A2C Circlip DIN 7993 B30 Sun gear Ring gear Planetary carrier Planetary gear Roller bearing 18x30,86x13 Circlip DIN 471 18x1.2 Shaft seal DASW45x62x8/6-V80 Cheese-head screw DIN 912 M10x35 - 10.9

03

Workshop manual 6030 - 35

Wheel drive Components of wheel drive 2 (right)

Item

D esignation

R emark

Item

D esignation

7

Transmi ssi on case

7

Transmi ssi on case

8

Hexagon screw plug M18 x 1.5 - A3C

8

Hexagon screw plug M18 x 1.5 - A3C

9

O-ri ng 192x4 V80

9

O-ri ng 192x4 V80

10

Slotted nut D IN 981KM 12

11

locked wi th Locti te 243

10

Slotted nut D IN 981KM 12

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

 STILL GmbH Position as per: 2/2000 (Replaces version:

) (6)

R emark

locked wi th Locti te 243

03

Workshop manual 6030 - 35

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 o’clock position) from drive motor casing. Attention: -

Residual oil discharges.

Remove complete wheel drive.

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. -

Recheck oil level as specified. Fit wheel and tighten fixing bolts with MA 210 Nm Connect battery cable. Lower the vehicle.

 STILL GmbH Position as per: 2/2000 (Replaces version:

) (7)

03

Workshop manual 6030 - 35

Wheel drive

Replacing shaft seal on left wheel drive - Remove left wheel drive. - Renew shaft seal (24).

-

Attention: The lips of the seal must point towards the outside of the axle. -

-

-

Unscrew bolt (16) and washers (13…15). Remove planetary carrier (20) with planetary gear train (11, 12, 17…19, 21…23) from transmission case (7). Unscrew slotted nut (10) with slotted nut wrench from shaft of wheel hub (1). With a rubber hammer, carefully knock against the face of the wheel hub in order to separate the bearing halves of the taper roller bearing (4). Remove roller cage of inner bearing from the shaft. Withdraw wheel hub from the transmission case. Renew shaft seal (5).

Attention: The lips of the seal must point towards the outside of the axle. -

After fitting, check for correct seating of spring in the seal and lightly oil the seal. Check wheel bearing. If the bearings are worn, the complete wheel drive must be renewed. Lightly oil both roller cages.

 STILL GmbH Position as per: 2/2000 (Replaces version:

) (8)

Fit wheel hub in transmission case. Fit roller cage of inner bearing on the shaft. Secure slotted nut (10) with Loctite No. 243 and bolt to the shaft. Tightening torque: MA = 650 +20 Nm

Note: While screwing on the slotted nut, turn the hub so that the bearing halves fit evenly. -

-

Fit new O-ring (9) in transmission case. Fit planetary carrier (20) with planetary gear train (11, 12, 17…19, 21…23) in transmission case (7). Screw in bolt (16) with washers (13…15), noting correct washer sequence. Refit wheel drive.

03

Workshop manual 6030 - 35

Wheel drive

Replacing shaft seal on right wheel drive - Remove right wheel drive. - Unscrew bolt (17) and remove washer (16). - Remove planetary carrier (12) with planetary gear train (11, 13…15) from transmission case (7). - Unscrew slotted nut (10) with slotted nut wrench from shaft of wheel hub (1). - With a rubber hammer, carefully knock against the face of the wheel hub in order to separate the bearing halves of the taper roller bearing (4). - Remove roller cage of inner bearing from the shaft. - Withdraw wheel hub from the transmission case. - Remove old shaft seal (5). - Fit new shaft seal. Attention: The lips of the seal must point towards the outside of the axle. -

After fitting, check for correct seating of spring in the seal and lightly oil the seal. Check wheel bearing. If the bearings are worn, the complete wheel drive must be renewed. Lightly oil both roller cages. Fit wheel hub in transmission case. Fit roller cage of inner bearing on the shaft. Secure slotted nut (10) with Loctite No. 243 and bolt to the shaft with a slotted nut wrench.

 STILL GmbH Position as per: 2/2000 (Replaces version:

) (9)

Tightening torque: MA = 650 +20 Nm Note: While screwing on the slotted nut, turn the hub so that the bearing halves fit evenly. -

Fit new O-ring (9) in transmission case. Fit planetary carrier (12) with planetary geara train (11, 13…15) in transmission case (7). Screw in bolt (17) with washer (16). Refit wheel drive.

Workshop manual

04

6030 - 35

Technical service data Scre w t i ght e ni ng t orque Siz e

PR

Air pressure

Disc wheel

Side ring

Collar

Manufacturer´s 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

Scre w t i ght e ni ng t orque 195 Nm Solid rubber tyres Größe

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

Ti ght e ni ng t orque for s pl i t ri m M10x30 8.8 46 Nm Scre w t i ght e ni ng t orque 195 Nm Super - Elastic - T yres Siz e

Scheibenrad Manufacturer´s 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

Scre w t i ght e ni ng t orque 195 Nm

ã STILL GmbH Position as per: 2/2000 (Replaces version:

) (2)

06

Workshop manual 6030 - 35

Table of contents

Page

Technical data

2

Mode of operation

3

Functional description

3

Steering column

4

Steering unit

4

Priority valve

6

Steering cylinder

7

ã STILL GmbH Position as per: 8/1999 (Replaces version:

) (1)

06

Workshop manual 6030 - 35 Technical service data Lenkeinheit

Fabri kat

D anfoss

Typ

OSPC 40 LS 150 – 8143

Förderlei stung

40 cm3 /Umdrehung

Überdruckventi l

90 +5/0 bar

Schockventi l

140 +20/0 bar

Fabri kat

D anfoss

Typ

OLS 40 152 B 8015

Vorspanndruck

7 bar

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per: August 1999 (Replaces version: )

Prioritätsv entil

2

06

Workshop manual 6030 - 35

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

steering appropriate to the respective steering speed, independent of the load in the steering system and hydraulics. For steering purposes, a smaller oil quantity is required than for initiation of individual hydraulic functions. For this reason, the pump unit is kept at a low speed during steering with the hydraulics inactive. In the event of failure of the oil flow, the steering unit automatically functions as a hand pump to enable manual steering of the vehicle (emergency steering).

<---------P

R 7

4

EF

P

8 6

CF

Rechts

LS

L inks

2 P

LS 3

L R

T

1 – Pump 2 – Steering column tank 3 – Steering unit

5 – Slider bank 6 – Hydraulic

4 3– Prority valve

8 – Suction filter

7 – Steering cylinder

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

1

Position as per: August 1999 (Replaces version:)

5

Fahrtricht ung

06

Workshop manual 6030 - 35

Steering column/steering unit Steering column tilt adjustment The steering column can be tilted about 10° after loosening the grip screw (2) (turn anticlockwise). After being adjusted to the required position, the steering column must be locked in position again by tightening the grip screw.

2

Position as per: August 1999 (Replaces version: )

Steering unit

1

The steering unit (1) is is fixed to the steering column bearing with four cheese-head screws. The steering unit incorporates the following valves, which are set to a fixed value by the manufacturer: Relief valve: 90 + 5/0 bar Shock valve: 140 +20/0 bar ATTENTION: The valve settings must not be altered. LS

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Removing the steering unit – Remove floor plate. – Unscrew left inside covering. – Unscrew rear steering column cover. – Unscrew hydraulic connections T (tank), P (pumps) and mark L (left connection), R (right connection), LS (control connection).

L

R

T

P

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.

4

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

7

1

9

2

Remove rear steering column cover. MA = 50Nm MA = 100 Nm

8

9

4

5

4 3

Installed in steering unit

10

6

Repairing the steering unit – If the steering unit is damaged it must be replaced. – Exception: Oil leak Available for this repair is a seal kit Ident. No:144694, consisting of 1 x Lip seal (14) 1 x Dust seal ring (15) 7 x Washer (16) 3 x O-ring (17) 1 x Fitting instructions NOTE: For the replacement of the lip seal and dust seal ring, special tools available from Messrs Danfoss are necessary.

12

12 Copyrighted. Reproduction in any form forbidden. Copyright reserved.

– For stemming union leaks at the connections of the steering unit, seals are available from the STILL spare parts service. However, the pipe connection tightening torques must be checked.

11

14 15

17

16

5

Position as per: August 1999 (Replaces version: )

ATTENTION: The previously marked hydraulic lines must be screwed back in the same position again to avoid the risk of accident.

13

06

Workshop manual 6030 - 35

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

Position as per: August 1999 (Replaces version: )

Dismantling the priority valve Proper functioning of the priority valve may be disturbed due to impurities in the hydraulic oil. Free movement of the gate (3) in the housing is hindered by dirt particles. This is noticeable by sluggish/ jerky movement of the steering. 1 Screw plug 2 O-ring 3 Gate 4 Biasing spring 5 LS plug 6 Housing - Unscrew screw plug (1) and LS plug (5) - Remove gate (3) - Clean all parts and blow out

P

LS

Copyrighted. Reproduction in any form forbidden Copyright reserved.

Assembling the priority valve

EF

CF

Assembly takes place in reverse order to dismantling. Observe tightenting torque of 50 Nm for parts (1) and (5) ATTENTION: After completing work on the steering unit, the system must be bled via the bleeder at the LS connection.

12

3 6

4

2

5

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

8

7 9

10

11

Position as per: August 1999 (Replaces version:)

Remove steering cylinder. See group 02. Remove circlip (10). Remove bushing (9). Remove piston rod (11). Remove circlip and bushing on the other side.

1

Assembling the steering cylinder -

Use a new seal kit. Fit new seal (8). Fit piston rod (11). Fit bushing (9) with new seal kit (4-7). Fit circlips for retaining bushing. Fit steering cylinder. See group 02. Bleed steering system.

-

7

10

4

7

5

6

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

9

07

Workshop manual 6030 - 35

Table of contents

Page

Technical service data

1

Brake view

2/3

Parking brake

4

Pedal adjustment

4

ã STILL GmbH Position as per: 2/2000 (Replaces version:

) (1)

07

Workshop manual 6030 - 35

Technical service data Brake fluid HGS oil Aral Fluid HGS according to STILL specification

ã STILL GmbH Position as per: 2/2000 (Replaces version:

) (2)

07

Workshop manual 6030 - 35

Brake view

5

7

5 1 4 2

ã STILL GmbH Position as per: 2/2000 (Replaces version:

) (3)

07

Workshop manual 6030 - 35

Brake view

2

4

1

5

9

3 2 8

1

7

6

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 ã 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

Workshop manual 6030 - 35

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

- Fix clevis with lock nut (3). Attention! The liquid in the tank (4) is mineral oil according to STILL specification.

ã STILL GmbH Position as per: 2/2000 (Replaces version:

1

1mm

) (5)

08

Workshop Manual 6030 - 32

Table of contents

Page

Technical Data for Maintenance Service Electrical installation Controller block diagram Insulation test

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

Electronic control unit Replacing the electronic control unit Replacing the control card Field regulator

30 31 32 33

Console Replacing the console Cold store version FleetManager

34 34 34 35

Proportional system - Joystick

37

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

(1)

08

Workshop Manual 6030 - 32

Technical Data for Maintenance Service Controller Drive motor speed control Pump motor speed control

Digital control R60 via a transistorized power circuit for four quadrants via a transistorized power circuit for one quadrant

Accelerator pedal Brake pedal transmitter for el. braking Transmitters, hydraulic

Potentiometer 4 kOhm Potentiometer 4 kOhm Electric pressure pick-ups

Rated voltage

80 Volt

Current limitation per traction motor Drive motor armature/field Hydraulic motor

400 A / 40 A reduction after 40 seconds 320 A

Speed Speed reduction

Adjustable via drive program, max. 16 km/h Adjustable via drive program

STILL contactor 1K 1 — C oi l — Contact tips / contact tip material

2 pins, with arc blow-out magnets 24 Volt ( wired in series with a resistor and a diode ) Replaceable, silver alloy

Relays

24 Volt (coil 255 Ohm)

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

1000 Ohm / Volt 1000 Ohm / Volt 1000 Ohm

Electrical protection — Electrical installation — Electrical machines

IP 23 FM IP 22 HM IP 20 IP 23

— Controller

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

(2)

— —

approx. 80 kOhm approx. 80 kOhm

08

Workshop Manual 6030 - 32

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

2

item 1 item 2 item 3 item 4 item 5

1

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

Under floor plate • Signal horn (centre)

4H1

Drive motors / hydraulic motor • Motor brush monitor • Temperature sensors • RPM sensor • Fan Battery compartment cover • Parking brake switch • Seat contact switch

1S4 7S1

In the counterweight • Controller • Main contactor • Power circuit fuse (300A) • Fuse carrier • Power supply (optional) • Relay board, rear (optional)

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

A9 1K1 1F1 A7 U1

)

(3)

3/4

08

Workshop manual 6030 - 32

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

7

8

F2

A2

5 1

6

2

3

X17

A9

14 A1

24

A1

13

23

14

24

13

23

3

G1

40 0A

1K1 A2

2

N

P

7 K2 A2

1

2

Polarity in „forward“travel direction

X2 6

 STILL GmbH Position as per: 2/2000 (Replaces version:

4 X 17

1

1F2

F1

)(4)

4

08

Workshop Manual 6030 - 32

Controller block diagram

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

(5)

08

Workshop Manual 6030 - 32

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.

Measuring insulation resistance (earthing) The resistance of the insulation material used on electrical components must amount to at least 80,000 ohms or 80 kilohms. Testing the insulation resistance against chassis: Leads to electrical machines Motive power battery G1 Electrical machines (see F.G. 11) Measuring instrument: e.g.

Isolavi 8 METRISO 500D Metra Hit 16i

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

(6)

08

Workshop Manual 6030 - 32

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)

When converting the direction indicator switch or reconverting the forward-reverse switch to the touch sensitive function, the levers must be turned anticlockwise. ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

(7)

08

Workshop Manual 6030 - 32

Console

DISPLAY 1 (5)

DISPLAY 2 (6)

PRG

DISPLAY 3 (7)

DISPLAY 4 (8)

PRG

F2 F1 1

2

3

Operating the keypads

5

6

The value that can be edited (modified) by the keypads identified by an arrow starts flashing.

Panel keypads for selecting the displays directly

– Adoption of the new value by pressing PRG – Abandoning the modification by pressing O PRG

keypad calls display 3 or 7 keypad calls display 1 or 5 keypad calls display 2 or 6 keypad calls display 4 or 8

Abandon / NO / Escape keypad

PRG

Acknowledge/ YES/ Enter keypad

Pressing O PRG and PRG

scrolling/counting up scrolling/counting down

)

O PRG

Starting and terminating the programming mode:

Function keypads identified by an arrow for selecting menu items and for changing parameters (numeral/text)

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

4

(8)

simultaneously.

08

Workshop Manual 6030 - 32

Console Display The indications are via an LCD display in the dash panel.

PRO G 1

Standard display of display level 1: • Drive program (top left) • Time (top right) • Battery charge indicated by bar (bottom)

BA T T

PRG

F1

S E R VI CE

The display remains on for approx. 50 sec after the truck is switched off.

I N

00000 , 0h

Fault indication in case of malfunctions via messages on level 1: • Service requierd • Batt. discharged • Overheating • Service brake • Motor brushes • Seat switch • Parking brake

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

Standard display of display level 2: (Changeover with keypad 13) • Time remaining to next service • Total service hours • Hydraulic oil pressure for auxiliary hydraulics (standard display when option is installed)

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

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

1

(9)

7 2 8 3 9 4 10 5 11 6 12

14 13

08

Workshop Manual 6030 - 32

Console

DISPLAY 1 (5)

DISPLAY 2 (6)

PRG

DISPLAY 3 (7)

DISPLAY 4 (8)

PRG

F2 F1 1

2

3

4

5

6

Parameterization via the console

Programming level 0 (without password)

Displays 1 to 4: 1 to 4 and PRG

Calling the programming level: Press keypads PRG and O PRG simultaneously:

are selected by pressing keypads

Keypads 5 and 6: are used for scrolling and changing the entries. PRG

:

serves for confirming the entry.

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

Display level 2 is called with PRG . It indicates the remaining hours until the next service and die service hours: SERVICE IN 00999,9h

999h

)

ENGLISH

by scrolling with keypad 5, the following flashing displays will appear in succession: TIME 14:37 DATE 23:01:98 DAY-KM 15.4km/D DAY-HR 3.6h/D PASSWORD LEVEL 1 COD 0000 Scrolling down is by means of keypad 6. Adjusting / Programming Adjusting the time, line TIME

14:37

The upper right-hand panel is selected by keypad3. The minutes will start flashing; the minutes are adjusted with keypads 5 and 6 and confirmed by pressing keypad PRG The hours are flashing; adjust with keypads 5 and 6 and confirm by pressing keypad PRG Line TIME

You can return to display level 1 by pressing PRG .

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

LANG.

14:37 flashes, adjustment is terminated.

Setting of DATE and LANGUAGE and resetting of DAY-KM and DAY-HR is done similarly.

( 10 )

08

Workshop Manual 6030 - 32

Console – Password Level Password level 1 (Fleet manager) Password level 1 can be called from programming level 0. PASSWORD LEVEL 1 CODE 0000 The upper line flashes. Press key 4, the last digit below on the right-handside will start flashing. Set the desired digit with keys 5 and 6 confirm by pressing key PRG ; the last-but-one digit will start flashing etc. If the wrong CODE is entered, CODE 0000 will appear again after confirmation of the last digit. If the correct CODE is entered, the display BATTERY TYPE LEAD will appear. The upper line will flash. By scrolling up with key 5, the following displays will appear in succession (key 6 for scrolling down): DISPLAY 1 PROG 5 MAXPROGRAMS PROG VMAX,FW DRIVE MODE HYDRAULICS LIFTING VERSION RESET

3 $ 6 6: 25 ' / ( 9 ( / 

35*



35*

&2' (

) )

1

2

3

4

5

6

Password level 2 (Service) Password level 2 can be called from programming level 1. PASSWORD LEVEL 2 CODE 0000 If the correct CODE is entered, the display SERVICE IN 999h F-ID 6030001234 will appear. The upper line will flash. By scrolling up with key 5, the following displays will appear in succession (key 6 for scrolling down). These display appear in addition to the displays of password levels 0 and 1: ERROR LIST RESET NO

5

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

The upper line will flash in each case.

The top line flashes in each case.

The fields can be selected and changed from these displays.

The fields can be selected and changed from these displays.

Via the SERVICEADR. 000 display field, parameter values which influence the driving performance can be edited via the console.

In the bottom line of display fields further displays can be scrolled up.

Parameterisation via the console should only take place in emergencies. Parameterisation via Notebook is generally preferred for security reasons.

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 11 )

08

Workshop Manual 6030 - 32

Console – plain text parameters Batterie BATTERY TYPE LEAD The battery type can be changed. Possible selections are: LEAD – CSM – GEL – SPE GEL – SPEC.1 – SPEC.2 Display DISPLAY 1 PROG 1 The indication on the display occurs on two levels. Panels 1 to 4 are displayed on level 1 and panels 5 to 8 on level 2. Different information can be assigned to these panels. The display panel is selected by scrolling, the following indication will appear: PROG 1 drive program BATT: battery charge bar BATT: 80 % battery charge in % 00023.4 h hours totalized by the counter 09:42 time 10.03.00 date 0.0 km/h speed 8398 km kilometres totalized by the odometer 0.0 km/D trip mileage odometer 12.3 h/D daily hours counter SERVICE IN 999h - hours left before next service becomes due 0 bar pressure regulator unit EMPTY no display Number of drive programs MAX PROGRAMS 5 The driver can choose between five different drive programs to suit the requirement. If 3 has been selected, the driver can use only drive programs 1, 2 and 3. Adjustment of drive programs PROG 1 VMAX,FW 16.0 km/h There are 5 drive programs that are individually adjustable. The drive program is selected by scrolling, the following indication appears in the lower line: VMAX,FW 16.0 km/h VMAX,RV 16.0 km/h ACCEL,FWD 80 % ACCEL,REV 80 % DECEL,FWD 80 % DECEL,REV 80 % MODE 0 REVERSE, F 80 % REVERSE, B 80 % BRAKE DELAY 80 %

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 12 )

DISPLAY 1

DISPLAY 2

PRG

DISPLAY 3

DISPLAY 4

PRG

F2 F1

1

2

3

4

5

6

The values for speed, acceleration, delay and reversing for forward and reverse, as well as braking delay (electric braking assistance) can be set. The mode (driving mode) can also be set. Driving mode MODE 0 Distinction is made between a speed-controlled and torque-controlled driving mode: speed-controlled 0 torque-controlled 1

Standard setting of drive programs Drive program

1

2

3

4

5

Travel speed km/h

16

16

16

16

16

Acceleration position

80

90

100 110 120

Deceleration position

80

90

100 110 120

Reverse forward / backward

80

90

100 110 120

Brake delay position

60

70

80

90

100

08

Workshop Manual 6030 - 32

Console – Plain text parameters Switching to driving mode DRIVE MODE 1 By changing the mode, driving can be changed from single to two pedal operation and the driving direction changed via the joystick. Selection: Mode 0 Two pedal Mode 1 Single pedal with CAN Mode 2 Single pedal without CAN Mode 3 Driving direction per console (CAN) and joystick (from console SW 0.17) Mode 4 Driving direction per joystick

PRG

DISPLAY 4

PRG

F1

1

2

3

4

5

6

VERSION – Software Version All the versions of the control unit software are indicated by scrolling the top line: VERSION 1 (Operating-software) V0.30 VERSION 2 (Basic-software) V0.06 VERSION 3 (L-controller EEprom) V0.04 VERSION 4 (Hardware control card) V2.11

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).

New password for password level 1 and 2 PASSWORD LEVEL 1 NEW CODE XXXX The upper line flashes. Press keypad 4, the lower right digit in display 4 starts flashing. Select the desired digit with keypads 5 and 6 and confirm with keypad PRG The last-but-one digit starts flashing. Repeat the procedure until the desired setting has been achieved for all 4 digits. Attention: The previous codes have been changed!

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

Change of travel sender characteristics By scrolling up with keypad, the following indication will appear in the lower line: DRIVE ACCEL. X 30 % DRIVE ACCEL. Y 10 % This function has not yet been released.

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

DISPLAY 1

( 13 )

08

Workshop Manual 6030 - 32

Console – plain text parameters Service interval SERVICE IN 999h F-ID 6030002345 In the upper line, the service interval can be set. Hourly intervals from 000 to 990 can be defined. After lapse of a service interval, the message SERVICE REQUIRED appears in the display. Truck serial number SERVICE IN 999h F-ID 6030002345 Shown in the lower line is the vehicle serial number. The serial number can only be changed via the Notebook. The following appear in succession when paging with the 5 key: S-ID 0160041 ID-No. of controller VERSION 1.17 Software version of console Error list ERROR LIST RESET NO Setting the bottom reset line to YES will clear the fault list. Hour meter COUNTER MODE 2 The mode of the hour meter can be selected with this function. 1 Meter runs when keyswitch S1 is turned on; SERV.-ADDR 0C4, VALUE 01 2 Meter runs when traction motor or hydraulic motor runs; SERV.-ADDR 0C4, VALUE 02 4 Meter runs when driver seats SERV.-ADDR 0C4, VALUE 04 Reading parameters over service address SERVICE ADDR. 000 VALUE 00 With the service address it is possible to change the truck and lighting parameters. A detailed description is included in Functional Group 09.

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 14 )

DISPLAY 1

DISPLAY 2

PRG

DISPLAY 3

DISPLAY 4

PRG

F2 F1

1

2

3

4

5

6

08

Workshop Manual 6030 - 32

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

(turned clockwise 90°) Electrical connections From battery G1 to keyswitch S1: G1 (+) – X40 – F9 – X53/1,2 – X47/1 – S1 From keyswitch S1: S1 – X47/2 – X53/3,4 – controller A9 and fuses.

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 15 )

08

Workshop Manual 6030 - 32

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

Battery connector half X2 is mounted at the righthand side of the bulkhead. Electrical connections Batt.(+) – 1F2 – 1K1

– terminal 2/A9

Batt.(–)

– terminal 1/A9

Coding system of battery connectors for wet and dry batteries with LB 160 AL Both connector halves are each fitted with a keying plug between contacts to prevent accidental voltage mismatching. When mounting the connector, the keying plugs are adjusted to the relevant battery voltage (visible through a window in the connector housing). Connector halves can be mated only provided they are both set to the correct voltage.

Coding of socket half - battery gray marked with „T“ for dry battery gray marked with „N“ for wet battery Coding of pin half - charging station gray, short for dry battery white for wet battery Coding of pin half - truck yellow

Coding for 80V battery connector

Dry battery (T)

Charging station (T) ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

Wet battery (N)

Truck ( 16 )

Charging station (N)

08

Workshop Manual 6030 - 32

Accelerator pedal – single pedal Single pedal control Linked to the accelerator, the accelerator pedal transmitter 1B1 is a transmitting device controlling travel speed. Depression of the foot pedal closes safety switch 1S16 and controls potentiometer 1B1. Two studs secure the accelerator pedal transmitter (transmitter) to the underside of the floor plate. Only the pedal passes through the floor plate. Made from fibre-glass-reinforced plastics, the pedal is articulated on a greased-for-life, sealed shaft mounted in a housing. It is maintained in the rest position by a return spring located on the lower end of the pedal. Voltage checks: Transmitter voltage – pedal un-operated yellow X16/4 (–) against red X16/3 (+) = 4,7 Volt – 5,3 Volt The voltage can be corrected to obtain correct setting by slackening screws (1) and adjusting potentiometer.

1S16

1B1

Transmitter voltage – pedal operated yellow X16/4 (–) against red X16/3 (+) = 8,5 Volt – 9,5 Volt The voltage can be corrected to obtain correct setting by slackening screws (2) and adjusting position of support. Voltage supply yellow X16/4 (–)

X16

against green X16/8 (+) = approx.10 Volt

Safety switch un-operated black X16/2 – blue X16/1 – continuity Safety switch operated black X16/2 – green X16/5 – continuity

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

1

2 ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 17 )

08

Workshop manual 6030 - 32

Travel sender, two-pedal Two-pedal control The driving direction is determined by two directiondependent pedals. The pedals are mechanically interconnected and move in opposite directions. Below the left pedal are two potentiometers (senders 1B3 and 1B4). These are moved by the action of the pedal and are located in the centre resting position. When a pedal is depressed, the sender is moved, while the other sender follows the movement due to its spring force. Electrical connections Sender 1B3: +10Volt – 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 ã STILL GmbH Position as per: 2/2000 (Replaces version:

) (18)

Adjustment of reverse pedal The procedure is the same as for the forward pedal, however, in reverse Retrofitting When retrofitting a two-pedal control, the parameter address must be adjusted: Address 08A to value 00

08

Workshop Manual 6030 - 32

Signal horn / horn button Horn button 4S1 The horn switch is installed in the floor plate at the front left side. Electrical connections X16/7 – X48/2 – 4H1– X54/2 X16/6 – X48/1 – X54/1 For removal, the horn button can be levered out of the floor plate with a screwdriver. Then the lead to the horn button can be disconnected or connected.

Optional: Horn button located in centre of the steering wheel. The horn button is pressed into the centre of the steering wheel and connected to the signal horn via two slip rings in the steering column. The contacts leading to the signal horn are located on the side of the steering column in the dash panel cover.

4S1

Signal horn 4H1 The signal horn is an audible warning device giving warning to other persons of a dangerous situation. The signal horn is therefore part of the safety equipment and it must always be in good working order. The signal horn is mounted in the front part of the frame in the centre under the front plate. An integrated circuit prevents interference with the electronic control when the signal horn button is pressed.

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 19 )

08

Workshop manual 6030 - 32

Brake sender – Brake fluid switch Brake sender 1B2 The brake sender 1B2 is fixed to the right bearing bracket of the brake pedal shaft on the front cover plate. The sender is a potentiometer that is operated via pedal actuation. Electrical connections +10 Volt – X50/2 Set value – X11/36 GND – X50/5

– 1B2/3 green – 1B2/2 red – 1B2/1 yellow

Checking the brake sender • Plug Mark II plus measuring adapter into the connector 1B2. • Connect digital multimeter to the measuring adapter: 1B2/2 (+) – 1B2/1 (–) • Brake pedal unactuated: The digital multimeter must give a reading of 0.65 – 0.80 Volt. • Brake pedal actuated: When the brake pedal is actuated, a sender voltage between 2.5 – 5.0 Volt must be indicated. • At a sender voltage higher than 9.4 Volt, a fault is set, the controller detects an interruption GND. • An excessive sender voltage can also be caused by misadjusted hammer head screws or worn brake linings. Adjustment of brake sender Slightly bias potentiometer 1B2 when fitting the bearing block so that the given neutral position is reached.

1B2

Brake fluid switch 6S4 The brake fluid switch is fixed to the left bearing block of the brake pedal shaft on the front cover plate. The switch 6S3 is a NO contact, which generates an alarm with an insufficient level. Electrical connections GND

– X11/42 – X50/5

– 6S4/1 – 6S4/2

6S4

 STILL GmbH Position as per: 2/2000 (Replaces version:

) (20)

08

Workshop Manual 6030 - 32

Parking brake switch Parking brake microswitch 1S3 Raising the engine hood will expose brake microswitch 1S3, which is located below the parking brake lever. Brake switch 1S3 is closed when the parking brake is released. As soon as the parking brake is engaged, brake switch will open, cutting out power to the traction circuit.

Brake operated – switch open

1S3

Brake switch adjustment is carried out by slackening screws item 1 and moving support item 2. Electrical connections Brake switch 1S3 is directly connected to controller A9. 1S3/1 – X27/1 1S3/2 – X27/2

– 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

If the parking brake is engaged only slightly on an incline, the truck is no longer braked electrically and will therefore roll back.

2

1

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 21 )

08

Workshop Manual 6030 - 32

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.

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 22 )

08

Workshop Manual 6030 - 32

Transmitters (senders) for hydraulic functions Transmitters for hydraulic functions 2B1 – 4 The transmitters transmit the rpm set-point values for pump motor for lift, tilt and auxiliary operations. The following transmitters are installed: • 2B1 transmitter for hoisting • 2B2 transmitter for tilting • 2B3 transmitter for aux. hydraulic functio1 • 2B4 transmitter for aux. hydraulic functio2 The transmitters involved are valve spool travel sensors whose output voltage variation is proportional to spool travel. Electrical connections are made via 3-pin Timer connectors: Pin 3: +10 volts Pin 2: rpm set-point value Pin 1: GND

2B2 2B3

The transmitters are connected via connector X11 to controller A9. Checking the transmitters • Plug Mark II plus adapter into connector of corresponding control valve section. • Turn the keyswitch ON. • Connect a digital multimeter to the measuring adapter as per the table below and take voltage reading. CAUTION: Watch mast movement !

Test points

Transmitter

Voltage in volts

P o s.

Neg.

2B1 hoisting

2

1

2B2 tilting

2

1

2B3 a. h. f. 1

2

1

2B4 a. h. f. 2

2

1

Lever pulled b a ck

Lever moved forward

7.5

2.5

Operation / Adjustment / Replacement For a detailed description refer to Functional Group10.

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 23 )

2B1

08

Workshop manual 6030 - 32

Drive motor speed sensor Sensor bearing The speed sensor is a sensor bearing that is integrated into the plastic bearing retainer plate or brush yoke ring. In the sensor bearing are two staggered Hall effect sensors, which scan the internal magnetic ring. The sensor generates 80 pulses per revolution. The phase shift is 90° ± 45°. Drive motor 1M2 Sender (br) – X12/1 Sender (ge) – X12/4 Sender (gn) – X12/2 Sender (ws) – X12/3

– – – –

X11/11 X11/12 X11/25 X11/7,8

– – – –

+10 Volt Signal Signal GND

Checking the sensor bearing • Remove floor plate • Plug Mark II measuring adapter with connected digital multimeter (with integrated pulse duty factor measurement, e.g. Metra Hit 15S) into the connector X12 on the axle. • Connect digital multimeter to: Positive – Adapter, Pin 4 Negative – Adapter, Pin 3 Positive

– Adapter, Pin 2

Negative – Adapter, Pin 3 • Set lock switch to ON • Pulse duty factor measuring range – AC % • At full throttle, the digital multimeter must give a pulse duty factor reading of 40% – 60% (ideal 50%)

Fitting and removal The sensor bearing must be renewed only complete with bearing retainer plate. A detailled description is provided under Group 11. Change to IFM sensor This option is available for axle drives, where the sender wheel is also provided. The IFM sensor must be screwed to the plastic bearing retainer plate with two screws. A detailled description is provided in Schnell Info No. 01/00.

 STILL GmbH Position as per: 2/2000 (Replaces version:

) (24)

08

Workshop manual 6030 - 32

Hydraulic motor speed sensor Pulse generator at 2M1 The speed of the hydraulic motor is measured by a pulse generator, which is located at the top in way of the bearing retainer plate, protected by a plastic cover and fixed in place with two screws. This is an inductive proximity switch. The switch responds to the proximity of iron, in this case to the 12 cams of the sender wheel. When the sender wheel rotates, the pulse generator delivers with each cam a positive voltage. The controller A9 calculates from this the motor speed.

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

In a fitted condition, a simple test of the proximity switch is possible. • At controller A9, disconnect one of the armature cables (terminal 7 or 8). • Connect a multimeter between X14/3 (–) – X14/2 (+) • Turn the sender wheel of the hydraulic motor manually. • Multimeter shows a distinct voltage jump about 8 Volt

Mark II - Adapter

Attention The motor must be voltageless, disconnect armature cable!

Fitting and removal A detailed description is provided under Group 11.

 STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

(25)

08

Workshop Manual 6030 - 32

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.

Battery capacity dependent on temperature A fully charged battery reaches its full capacity at 27°C. A drop in temperature of 1°C represents a reduction in capacity of 1 %. This means that at 0°C there is a reduction in capacity of 27 %. In other words, only 73 % remain of the 100% battery capacity originally available.

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 26 )

08

Workshop Manual 6030 - 32

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°

The armature assembly is the movable part of the contactor, which is mounted between the contactor frame and the coil assembly. The contact screws/tips of the contactor frame and armature assembly are identical. Torque loading of contact screws should be 10+1 Nm, i.e.: The contact screws must be screwed fully home (i.e. up to the thread root) and further tightened with 60° angle of rotation.

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 27 )

1K1 24 Volt

08

Workshop Manual 6030 - 32

STILL contactor Contact pressure Contact pressure of contactor in the fully operated state: Required value ³ 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.

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 28 )

08

Workshop Manual 6030 - 32

Fuse carrier – fuses — relays Fuse carrier A7 All the control circuit fuses required for the electrical installation and the optional relays are installed on the fuse board.

D es.

Value

Connection

F1

5A

Signal horn 7H1

F2

5A

emergency stop contactor

F3

5A

Brush wear

F4

20 A

heater, Mobab (optional)

F5

5A

Controller power supply

F6

15 A

24 Volt auxiliary loads

F7

5A

Hydraulic controller

F8

5A

F an

F9

10 A

Main line fuse ahead of S1

K1

24 V 255Ohm

auxiliary loads, equipment A

K2

24 V 255Ohm

auxiliary loads, equipment A

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 29 )

08

Workshop Manual 6030 - 32

Controller SAAB-connector, 42 pins &DQ%XV ;

;

A9, left

A9, right

CAN-bus female connector





 

 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.

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

2B1 – 2B5

)





Main connections Connector X17 X17/1 – not used X17/2 – not used X17/3 – F1 / motor field (–) for 1M1 X17/4 – F2 / motor field (+) for 1M1 X17/5 – 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

CAN bus female connector 1 – Bus signal approx. 2-3-Volt 2 – Bus signal approx. 2-3-Volt 3 – 24 Volt 4 – GND

( 30 )

08

Workshop Manual 6030 - 32

Replacing the Controller Replacing the controller If the controller needs to be replaced because it is beyond repair, certain aspects must be considered before removing the faulty controller from the truck.

PRG

The replacement controller normally does not contain any data or parameters. The data and parameters are, as a rule, stored in the control unit and the console by continuous automatic data save. For data security reasons, however, a text file of the truck parameters should always be created.

NO

PRG

YES

The operating hours of replacement controllers are set to “0000”. Currently, these can not yet be set to the previous meter count. Procedure • Safely park the truck on level ground. • Disconnect the batteries. • Disconnect all leads from the controller, including the earth lead. • Thoroughly coat the controller mating surface with heat conducting paste. • Tighten the M10 screws to 46 Nm. Caution: The torque loading of the screws must be checked at the next inspection in order to ensure the optimum heat exchange. • Connect the new controller; reconnect the earth lead to the controller! • Reconnect the batteries. • Turn keyswitch S1 to ON. D – EEPROM VALID ? >>are the parameters stored in the console valid?<< will be displayed on the LCD panel. • As the controller was replaced and the parameters from the console are required, press YES (PRG ) as confirmation. On the display appears the question: ARE YOU SURE? Press YES (PRG ) as confirmation. The information data stored in the controller is now transmitted to the console and the display indicates: PLEASE WAIT • Then an automatic reset is performed. • By calling up the truck number in the display, it is possible to check whether the correct drive parameters have been downloaded.

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

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 31 )

08

Workshop Manual 6030 - 32

Replacing the control card Control card

CAN-Bus

X11 Ribbon cable (64 pins)

Controller A9

Replacing the control card

• As the control card was replaced and the parameters from the console are required, press YES (PRG ) as confirmation. On the display appears the question: ARE YOU SURE? Press YES (PRG ) as confirmation.The information stored in the console is now transmitted to the controller and the display indicates: PLEASE WAIT • After a successful data transfer an automatic reset is performed. • By calling up the truck number in the display, it is possible to check whether the correct drive parameters have been downloaded.

In some cases only the control card of the controller has to be renewed. The modular design of the control card allows a simple removal and installation. The replacement controller normally does not contain any data or parameters.The data and parameters are, as a rule, stored in the control unit and the console by continuous automatic data saves. For data security reasons, however, a text file of the truck parameters should always be created. The operating hours of replacement controllers are set to “0000”. Currently, these can not yet be set to the previous meter count. Procedure • Safely park the truck on level ground. • Disconnect the battery plug. • Disconnect connector X11 and the CAN bus and remove both screws on the controller. • Disconnect the ribbon cable connector (64 pins) from the control card. • Renew the control card and reassemble the controller in the reverse order of disassembly. • Reconnect the battery plug. • Set keyswitch S1 to ON. D – EEPROM VALID ? >>are the parameters stored in the console valid?<< will be displayed on the console-mounted LCD panel. ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

Note If a control card with truck-specific parameters is installed, the query D–EEPROM VALID ? must be acknowledged with NO, otherwise the console will overwrite the control card parameters.

( 32 )

08

Workshop Manual 6030 - 32

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 • • • • • • • • • •

Switch off vehicle Disconnect battery connector Remove control board The field regulator is located below the printed circuit board Loosen the fixing and terminal screws and ribbon cable of the field regulator Renew field regulator Before fitting the new field regulator, coat the heatsink with heat transfer compound To ensure good heat transfer, firmly tighten the screws (10 Nm) Reassemble the controller in reverse order Subsequent parameterisation is unnecessary

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 33 )

08

Workshop Manual 6030 - 32

Replacing the console Replacing the console If the console must be replaced due to an unrepairable fault, the instructions relating to the replacement of the controller must first be read. After any changes made to truck parameters it will be advisable to produce a new text file in the form of a backup diskette. Normally an empty console is used as a replacement part.

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.

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 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

Workshop Manual 6030 - 32

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

As long as the vehicle is not yet integrated into the fleet via the configuration card (Mastercard) of the fleet manager, the vehicle can be moved without card.

With FleetManager deactivated, the card reader is switched off; no reactions are initiated when test cards are inserted.

The card reader is active in the background and registers when a card is inserted into the card holder. Depending on the inserted card type, various test messages and reactions, which are not described here further, appear on the display (see operating instructions).

Attention: FleetManager must be reactivated following service or diagnostic routines in any event!

Activate access control To activate the access control function and record vehicle operating data, the vehicle must be integrated into the fleet with the Mastercard. This normally takes place at customers by the fleet manager and is not described here further (see operating instructions).

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 35 )

08

Workshop Manual 6030 - 32

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.

The card holder can be renewed individually as a spare part. It is bonded to the console with a special adhesive foil. Adhesive residues of the old card holder must be removed from the console. The surfaces must be clean (free from dust and grease and dry). If possible, the card holder should not be touched for several hours to ensure optimal bonding. Note Suitable adhesive foils and cleaning agents have not yet been determined. Retrofitting FleetManagers

Card loss during operation If the card or complete card holder should be mislaid during operation or accidently removed, the vehicle switches to a parameterisable emergency mode. There are two behaviour patterns: - In the event of card loss, the vehicle slows down. When a valid card is inserted, the slow operating mode is cancelled. If a card without access authorisation is inserted, the drive is stopped (main contactor is opened). - In the event of card loss, the vehicle control is deactivated the vehicle is braked electrically and the main contactor opens. The available combinations and fine adjustments take place in paramerisation per Notebook.

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

Card holder renewal

)

( 36 )

In principle, any vehicle can be retrofitted by simply exchanging the console. A requirement is the vehicle software version 0.24, 0.30 or higher. Note: The FleetManager console is always also available in a type suitable for cold store use. The heater cables may only be connected for cold store use; connection for other purposes will cause the console to overheat.

08

Workshop Manual 6030 - 32

Table of contents

Page

Proportional system components, Emergency Stop

38

Proportional system components, control

39

Horn control

40

Hydraulic controller

41

Communication – Safety function

42

Parameterisation

43

Controller renewal

44

Control valve block

45

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 37 )

08

Workshop Manual 6030 - 32

Proportional system components, Emergency Stop Design of the proportional system The proportional system (Joystick system) consists of the following electronic components: • • • • •

Multifunction lever (Joystick) Hydraulic controller 2A7 CAN bus power supply Horn control 4A1 Safety relay K1 Since October 1999, replaced by integrated safety functions in the hydraulic controller 2A7

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

On activation of the Emergency Stop switch, an appropriate message appears on the console display when the pedal is pressed with the direction selected.

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 38 )

08

Workshop Manual 6030 - 32

Proportional system components, control Controller 2A7 • Installation on the right on the lateral part chassis under floor plate. includes: • Control electronics • Power electronics for lifting magnets • Heater connections for Joystick

2A7

CAN bus 24V power supply • Via T connection to CAN bus cable of the vehicle controller A9 in the steering column.

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.

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 39 )

08

Workshop Manual 6030 - 32

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

The horn is then only actuated via the horn button in the floor plate.

X48

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 40 )

08

Workshop Manual 6030 - 32

Hydraulic controller

2A7 2X1

2X2

2X3

Hydraulic controller 2A7 The hydraulic controller 2A7 features a microprocessor control (16Bit) and processes the signals of the multifunction lever. The multifunction lever is connected to the controller 2A7 via a CAN bus cable via socket 2X2. The 24V power supply of the hydraulic controller 2A7 takes place via the CAN bus socket 2X3. This CAN bus cable is connected to the CAN bus main cable (vehicle controller A9) via a tee unit. The hydraulic controller 2A7 includes: Power electronics for controlling the lifting magnets Control electronics The following signals are received and output: Joystick Zoom Lifting magnets 2Y1-10 Hydraulic motor speed Driving direction Horn button control 4A1 Joystick heater 9S3 Emergency Stop 7S2 SAAB connector 2X1 Control cables, 42-pole

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 41 )

CAN bus socket 2X2 1 – Bus signal about 2-3V 2 – Bus signal about 2-3 V 3 – 24V 4 – GND CAN bus socket 2X3 24V power supply 1– 2– 3 – 24V 4 – GND

4

3

1

2

08

Workshop Manual 6030 - 32

Communication – safety function CAN bus connections

Safety function

The hydraulic controller 2A7 communicates with the joystick exclusively via the CAN bus cable 2X2. A CAN bus connection to the vehicle controller A9 does not exist. Both controllers operate independent of the other and may not be interconnected via the CAN bus.

The “hydraulics shutdown with non-actuated seat switch“ safety function is available in two variants. Distinction is made between the variants “External safety relay K1“ and “Integrated 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

External safety relay K1 The relay K1, depending on the switching status of the seat switch 7S1, is controlled by the vehicle controller A9 and is connected in series with the Emergency Stop switch 7S2. With a non-actuated seat switch, the Emergency Stop circuit of the hydraulic controller 2A7 is interrupted and the hydraulics are shutdown. - Emergency Stop circuit K1 2A7 2X1/4 – 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.

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 42 )

08

Workshop Manual 6030 - 32

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

This means that all hydraulic speeds are only transferred via the “additional hydraulics1“ connection. The speed value for the additional hydraulics1 set in vehicle parameterisation defines the maximum permissible speed for all hydraulic functions. Standard value: max 2550 rpm

Address 128 Value 40

Hydraulic configuration Hydraulic speed via hydraulic controller

Address 12A Value FF

Max. pump speed max. 2550 rpm

Transfer of direction information:

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

For direction preselection via joystick, the direction switches on the console must be replaced with covers.

Note: To ensure reliable operation, the standard value for the additional hydraulics1 should be set in vehicle parameterisation to the maximum permissible speed.

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

Address 08A Value 00 01 03 04

( 43 )

08

Workshop Manual 6030 - 32

Controller renewal Replacement of hydraulic controller 2A7

Differences between hydraulic controllers

To avoid malfunctions, it is important to note the system used on the respective vehicle.

By unscrewing the housing cover, a check can be made to see which controller hardware is provided if the controller is not clearly identified by a number.

Distinction is made between the variants “External safety relay K1“ (old) and “Integrated safety function“ (series since October 1999). When installing a hydraulic controller variant “Integrated safety function” in a vehicle variant “External safety relay K1”, two retrofitting solutions are generally possible:

Hydraulic controller variant “External safety relay K1“

Continue to use variant “External safety relay K1“: - Check/change parameterisation - Joystick parameterisation, page Note/Extras safety function seat switch: Value 12 (Hydraulic controller with external relay) - Vehicle parameterisation, page Reserve Block 5 Input channel: Driver seated Output channel: Relay K1 Conversion from variant “External safety relay K1” to variant “Integrated safety function” - Establish cable connection from A9,X11/32 to 2A7,2X1/6. - deactive external relay K1 - Check/change parameterisation - Joystick parameterisation, page Notes/Extras Safety function seat switch: Value 0 (Hydraulic controller with internal relay) - Vehicle parameterisation, page Reserve Block 5 Deactive input and output channel

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 44 )

Hydraulic controller variant “Integrated safety function“ (series since October 1999)

08

Workshop Manual 6030 - 32

Control valve block Hydraulic lifting magnets 2Y1 – 2Y10 The actuating mechanism of the hydraulic valves consists of single and two-way acting lifting magnets. The following lifting magnets are available: • • • • • • • • • •

2Y1 2Y2 2Y3 2Y4 2Y5 2Y6 2Y7 2Y8 2Y9 2Y10

Lifting magnet, lifting Lifting magnet, lowering Lifting magnet, tilt back Lifting magnet, tilt foward Lifting magnet, additional hydraulics 1 Lifting magnet, additional hydraulics 1 Lifting magnet, additional hydraulics 2 Lifting magnet, additional hydraulics 2 Lifting magnet, release Lifting magnet, additional function

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 2–pole 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.

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

( 45 )

2Y5 2Y6 2Y7 2Y8

08

Workshop manual 6033 - 35

Table of contents

Page

Technical service data

2

Introduction Basic principles Induction of movement Generation of the magnetic field Generation of three-phase voltage

3 4 5 6

Electrical installation

7

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

 STILL GmbH Position as per: 2/2000 (Replaces version:

) (1)

08

Workshop manual 6033 - 35

Technical service data Controller Drive motor speed control Pump motor speed control

Digital control R60 via a transistorized power circuit for four quadrants via a transistorized power circuit for one quadrant

Accelerator pedal Brake pedal transmitter for el. braking Transmitters, hydraulic

Potentiometer 4 kOhm Potentiometer 4 kOhm Electric pressure pick-ups

Rated voltage

80 Volt

Current limitation per traction motor Drive motor armature/field (FM1, FM2) Hydraulic motor

320 A

Speed Speed reduction

Adjustable via drive program, max. 19 km/h Adjustable via drive program

STILL contactor 1K 1 — C oi l — Contact tips / contact tip material

2 pins, with arc blow-out magnets 24 Volt ( wired in series with a resistor and a diode ) Replaceable, silver alloy

Relays

24 Volt (coil 255 Ohm)

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

1000 Ohm / Volt 1000 Ohm / Volt 1000 Ohm

Electrical protection — Electrical installation — Electrical machines — Battery / Central Computer — Converter

IP 23 FM IP 64, HM IP 64 IP 23 IP 23

ã STILL GmbH Position as per: 2/2000 (Replaces version:

(5A)

)(2)

— —

approx. 80 kOhm approx. 80 kOhm

08

Workshop manual 6033 - 35

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

The illustrated magnetic lines move from the north to the south pole. (Based on the spatial arrangement, this is a two-pole machine)

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.

When three-phase current is applied to three 120° staggered pole pairs, a rotating magnetic field is produced. Three-phase current is three alternating currents by 120° out of phase. Generation of the rotating field is described in the following.

 STILL GmbH Position as per: 2/2000 (Replaces version: (3 )

)

Figure 3

08

Workshop manual 6033 - 35

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.

The speed of the rotating field (synchronous speed of the machine) depends only on the frequency and number of poles. As magnetic poles always occur in pairs, calculation is made with the number of pole pairs per phase.

Rotating field speed (rpm) = Frequency(Hz) x 60sec Number of pole pairs At a frequency of 50 Hz and 2 poles, the following calculation is given: 50Hz x 60sec 1

= 3000 rpm

 STILL GmbH Position as per: 2/2000 (Replaces version: (4)

)

Figure 2

Magnetic lines of force moving in the same direction Magnetic lines of force moving in the same direction

Figure 3

08

Workshop manual 6033 - 35

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 αρε √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° .

 STILL GmbH Position as per: 2/2000 (Replaces version: (5)

)

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

Workshop manual 6033 - 35

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.

+

The converter uses pulse width modulation; the pulse frequency is 13kHz. The converter takes over pulse width modulation automatically as programmed in the central computer.

B-

U

Figure 3

 STILL GmbH Position as per: 2/2000 (Replaces version:

) (6)

V

W

08

Workshop manual 6033 - 35

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

Workshop manual 6033 - 35

Converter Converter LED

The converter has the following power terminals: B– : – Pole of battery + : + Pole of battery B+ : Terminal for optional fuse (nv) U : Field terminal asynchronous maschine V : Field terminal asynchronous machine W : Field terminal asynchronous machine

X150/151

LEDs indicate the converter status as follows: Steady light:

The converter is ok.

No indication:

1. No supply from battery computer. 2. The converter is without function.

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

7

13

6

12

5

11

Power output reduction on overtemperature: By means of an installed tmperature sensor, the converter monitors its temperature household. Within a temperature range of 80° - 120°, the converter continuously reduces its power output.

4

Also monitored are the temperatures of the connected three-phase machines. Continuous power output reduction also takes place here within a temperature range of 145° - 160°.

Working with the battery computer is described on the following page. To be noted is that the battery computer monitors the phases U and V and precharges the d.c. link of the converter before the isolating relay (contactor 1K1) closes and applies the battery voltage to the d.c. link.

2

9

1

8

Pin assignments of connector X150/151: Pin1: Pin2: Pin3: Pin4: Pin5: Pin6: Pin7: Pin9:

Pin10: Pin11: Pin12: Pin13:

(8)

10

Figure 2

Battery computer

ã STILL GmbH Position as per: 2/2000 (Replaces version:

3

)

Input lock switch Contactor control (optional) Speed sensor supply (12V/50mA) GND for speed sensor Input speed sensor Phase 1 Input speed sensor Phase 2 Input motor temperature sensor Converter identification. GND – Hydraulic converter Open – Drive motor converter CAN-High Terminal CAN-Low Terminal CAN-15V CAN-GND

08

Workshop manual 6033 - 35

Block diagram converter/battery computer Battery computer

Converter

CAN communication

CAN-Bus Monitoring of U and V

d.c. link 80V supply

Power supply

Motor temperature sensor

Measuring circuit Bearing sensor

d.c. link precharging Converter isolating relay

Contactor control

Battery current measurement

Shunt

Technical data of converter: - Own power supply from terminal supply and feeding external sensors with 12V - CAN-Bus with 250 KB - 2 input channels for motor speed, possible sensor type from 32 - 160 pulses per revolution. - 1 measuring channel for motor temperature sensor - Own speed controller (P controller) - Current sensors for the phases U and V, phase W is calculated. - Current controller unit - Converter section as pulse width modulator with a pulse frequency of 13 Khz - Alternating current frequency range: 0 - 150 Hz - 4-quadrant controller with regenerative brake - Supply voltage range: 56 - 104V  STILL GmbH Position as per: 2/2000 (Replaces version: (9)

)

- Max. phase current: 340A - Installed temperature sensor with linear regulating characteristic from 80 - 120°C - Temperature range: -35 - +55°C

08

Workshop manual 6033 - 35

Fitting and removing converter Removing the converter Before removing a converter, a check must be made to ensure that the internal backup capacitors are discharged. Procedure: - A suitable multimeter must be connected to the positive and negative bar (see Figure 1). - When the vehicle is switched off, only a small current (< 1V) should be measured. - If a voltage equal to the battery voltage (80V) is measured, the internal discharge circuit of the converter must be activated. - Switch on the lock switch, the measuring instrument indicates the battery voltage. - Switch off the lock switch, the internal discharge circuit automatically discharges the backup capacitors. This takes about 1 minute. - After switching off the display, the voltage should have reduced below 5V. - If the voltage has not reduced, the procedure below should be followed. - Switch on the lock switch and disconnect the battery connector. The voltage will reduce and the backup capacitors will discharge. Note: If the discharge circuit is without function, the capacitor circuit can be discharged with a suitable discharge resistor or an 80V incandescent lamp. The same connecting points should be used as for the measuring instrument shown in Figure 1. - Connectors X150/151 must subsequently be disconnected - The power terminals and connecting bars can subsequently be removed and the 4 fixing screws in the floor plate loosened and the converter removed. Fitting the converter - Before fitting the converter, a check should be made to ensure that the floor plate of the converter is located flush on the cooling surface. The old heat transfer compound must be removed and the cooling surface coated with new compound.

 STILL GmbH Position as per: 2/2000 (Replaces version: (10)

)

Figure 1

08

Workshop manual 6033 - 35

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

- Receipt of Master-Reset from the central computer after switching off the lock switch or in the event of a fault, as a reaction to the switching of the safety contactor 1K1. - Battery fine voltage measurement for the discharge indicator - Battery current mesurement via the shunt for the discharge indicator - Converter frequency monitoring - Precharging of converter backup capacitors (about 8A in 2 sec) - Control of safety contactor 1K1

(11)

- The internal power supply provides the CAN-Bus with 24V. - The installed Watchdog serves for time and program monitoring as well as for process data monitoring. Also monitored is the pulse frequency of both converters.

The battery computer takes over in the vehicle control the following functions:

 STILL GmbH Position as per: 2/2000 (Replaces version:

Further components of the battery computer and their functions:

)

08

Workshop manual 6033-35

Central computer

Central computer

Stroke limiter

Lift Tilt Additional 1 Additional 2 Additional 3 Master-Reset Dead man’s switch (Res4) Travel sender Brake fluid switch Travel sender switch Steering transmitter Brake sender

The central computer is located at the front in the centre below the floor plate and has the following inputs and outputs: Travel sender Brake sender Hydraulic sender Console switches via CAN-Bus Drive process data via CAN-Bus (actual motor speed) Process data monitoring to battery computer Network watchdog to battery computer Master-Reset to battery computer Relay box control via CAN-Bus 3 digital outputs for fuse board control In addition to a watchdog, time and program monitoring

 STILL GmbH Position as per: 2/2000 (Replaces version: (12)

)

and process data monitoring, the central computer contains a real-time clock, process and parameter data storage, error code evaluation, drive, control regulation and monitoring. The power supply, which also supplies an external sender, is supplied from from the 24V-CAN-Bus voltage.

08

Workshop manual 6033 - 35

Removing central computer Preconditions for removal: The converters must be discharged and the battery connector disconnected. The central computer is located below the floor plate behind the front splash shield (see Figure 1).

In order to loosen the fixing nuts, the cover, which is located on the front splash shield, must be removed (see Figure 2). Figure 1 Behind the cover are three nuts, which are screwed to the studs of the central computer (see Figure 3).

The nuts must be removed with a suitable tool (e.g. socket wrench with size 7 socket). The central computer can subsequently be removed from the interior. The CAN-Bus cable and Saab connector can subsequently be easily removed. Before fitting another central computer, the studs must be repositioned.

Figure 2

Figure 3

 STILL GmbH Position as per: 2/2000 (Replaces version: (13)

)

08

Workshop manual 6033 - 35

Speed sensor Drive and hydraulic motor speed sensor

Checking the sensor bearing

The speed sensor consists of a ball bearing with two staggered Hall effect sensors, which scan the inner magnetic ring. The phase shift is 90° ± 45° and defined as follows:

• Plug Mark II measuring adapter with connected digital multimeter (with integrated pulse duty factor measurement, e.g. Metra Hit 15S) into the connector X12 or X14. • Connect digital multimeter to:

When the inner ring rotates clockwise viewed on the sensor side, the rising edge of signal B is located before the rising edge of signal A. All signals are measured to GND (see Figure).

Drive motor 1M2 Sender (rt) – X12/1 Sender (we) – X12/4 Sender (bl) – X12/2 Sender (sw) – X12/3

– – – –

X151/3 X151/5 X151/6 X151/4

– – – –

Positive – Adapter, Pin 4 Negative – Adapter, Pin 3 Positive – Adapter, Pin 2 Negative – Adapter, Pin 3 • Set lock key to ON • Pulse duty factor measuring range – AC % • At full throttle, the digital multimeter must give a pulse duty factor reading of 40% – 60% (ideal 50%)

+10 Volt Signal Signal GND

The drive motor sensor generates 80 pulses per revolution, the bearing internal diameter is 45mm. Hydraulic motor 2M1 Sender (rt) – X14/1 – Sender (we) – X14/4 – Sender (bl) – X14/2 – Sender (sw) – X14/3 –

X150/3 X150/5 X150/6 X150/4

– – – –

+10 Volt Signal Signal GND

Removing and fitting A detailed description is provided under Group 11.

The hydraulic motor sensor generates 64 pulses per revolution, the bearing internal diameter is 30mm.

 STILL GmbH Position as per: 2/2000 (Replaces version: (14)

)

08

Workshop manual 6033 - 35

Fuse panel, rear Fuse panel, rear The rear fuse panel carries the optional relays K2 and K1, which are controlled by the central computer A4 via connectors X50/1 and X50/2. The relay contacts receive from the voltage transformer 24V supply voltage via connectors X22/5 and X22/7. The switched voltage can be tapped off via connectors X32/3 and X34/1(K1) and X36/3 (K2). The fuses are supplied with 80V via the post terminals X40 and X41 and protect the following circuits: F3 - 5A:

Supply battery computer via X60/4

F6 - 15A: Supply voltage transformer via X22/1 and X22/3. F8 - 5A:

Supply battery computer via X60/3.

F9 - 10A: Lock switch via X53/1 and X53/2 F11- 30A: Leads to post terminal X42.

 STILL GmbH Position as per: 2/2000 (Replaces version:

) (15)

08

Workshop manual 6033 - 35

Fuse panel, front Fuse panel, front The front fuse panel is connected to the central computer via connector X154. The signals from the dead man’s switch and stroke limiter sensor are looped through to the central computer via connector X29. The fuse panel also contains the horn relay, which is controlled by the hydraulic control unit. Connected in parallel to the horn relay contact are the contacts of the horn button in the floor plate and steering column. The 80V supply is applied to the terminal posts X152 and X153. The board also contains the following fuses: F1 - 5A:

80V supply horn

F4 - 20A:

80V supply Mobab heater

F5 - 5A:

80V supply fan rmotor

F7 - 5A:

80V supply hydraulic control

F10 - 5A:

80V spare terminal

 STILL GmbH Position as per: 2/2000 (Replaces version:

) (16)

09

Workshop Manual 6030 - 35

Table of contents

Page

Lighting system design Variants Status A: Controller, distributor panel Status B: Controller, relay box, distributor panel Status C: Controller, 2 x relay boxes

2 2 2

Transformer Relay box Distributor card/panel CAN-Bus connections R6030 - 32 CAN-Bus connections R6033 - 35

3 4 5 6 7

Parameterisation via console Lighting/additional electrics

8

ã STILL GmbH Position as per: 2/2000 (Replaces version:

) (1)

2

09

Workshop Manual 6030 - 35

Configuration of the optional electrical equipment

Variants

Configuration of the optional electrical equipment

There are three different equipment variants for the lighting or optional electrical equipment.

On truck models in this range, electrical loads such as working lights, windscreen wipers, heater, lighting, etc. are supplied by • • • •

Variant A 80 Volt version: Controller A9, fuse carrier A7 with relays K1 and K2 and/or distributing circuit board (front scuttle)

relays K1 and K2 on fuse carrier A7 distributing circuit board control relay board and distributing circuit board 2 control relay boards

24 Volt version: Controller A9, fuse carrier A7 with relays K1 and K2, voltage converter U1 and/or distributing circuit board (front scuttle).

Electrical consumers with an operating voltage of 24Volt (48 Volt) can be connected. The electrical consumers are operated by pressing keypads integrated into the console and/or by switches/ transmitters of the electrical system.

Variant C Controller A9, fuse carrier A7, voltage converter U1, control relay boards (counterweight and front scuttle).

The control relay board / control relay boards are driven by controller A9 via the CAN bus. The wiring harness for the distributing circuit boards and control relay boards is pre-installed in the truck. For retrofits, only the electrical connection between the consumer and the corresponding distributing circuit / relay board is required.

 STILL GmbH Stand: 7/2001 ( Ersatz für Stand: 2/00

)

2

09

Workshop Manual 6030 - 35

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

Input voltage range

35V....120V

Output voltage

24V regulated

Output current 100% cont. duty

16.7A

Output power 100% cont. duty

400 W

Overload capabi li ty

Short-resi stant

Resi dual ri pple

20 mVRMS

Overload behavi our

C urrent li mi tati on at approx. 23 A

Overvoltage behavi our

C ut-off at approx. 140 V

Undervoltage behavi our

C ut-off at approx. 33 V

Overvoltage resi stance

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. 80°C

False polari ty protecti on

yes

Radi o i nterference suppress.

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.

ã STILL GmbH Position as per: 2/2000 (Replaces version:

) (3)

09

Workshop Manual 6030 - 35

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: • Relay box, front SERVICE-ADR. OA6 - VALUE 41 • Relay box, rear SERVICE-ADR. OA5 - VALUE 40

Relay box inputs The consumer connector markings are identical in both relay boxes. front: 0A6

rear: 0A5

0B

01

X71 / 1 , 3

0C

02

X70 / 1 , 3

0D

03

X69/ 3

0E

04

X69/ 1

0F

X

05

X67 / 4 , X68 / 4

10

X

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

Important information for R6033-35 The following must be noted when replacing a relay box: In this CAN-Bus system, only relay boxes with 250kB data transfer rate function. Other relay boxes do not function here! High-speed relay boxes with 250kB can be set to 50kB, slower relay boxes cannot be changed to 250kB. Meaning of dip switches below: Switch 1 set to on: Relay box front Switch 1 set to off: Relay box rear Switch 4 set to on: CAN baudrate 250kB Switch 4 set to off: CAN baudrate 50kB

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 ã STILL GmbH Position as per 2/2000 (Replaces version:

) (4)

09

Workshop Manual 6030 - 32

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.

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

(5)

09

Workshop Manual 6030 - 32

CAN bus connections R6030 - 32 The vehicle controller A9 is connected to the console directly via the CAN bus, or depending on the vehicle status, via the relay boxes. For vehicles with joystick, a second separate CAN bus circuit exists. The hydraulic controller 2A7 is connected directly to the joystick via the CAN bus. The hydraulic controller 2A7 receives the 24V supply from the vehicle controller A9 via a tee unit connection under the battery hood. The signal cables are not looped-through. It is not possible to establish with the CAN bus connection of the console a connection to the hydraulic controller 2A7.

For diagnostic purposes, the CAN bus connection is established via the console in the case of vehicles without joystick. In the case of vehicles with joystick, a tee unit must be inserted into the CAN bus connection below the battery hood for diagnostic purposes. Possible CAN bus configurations are shown below.

Diagnose

Diagnose

A9

A9

2A7

2A7

Joystick

Joystick

* T-Stück für Diagnose, 24V-Busversorgung

A9

ã STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

A9

)

(6)

09

Workshop Manual 6033 - 35

CAN Bus connection R6033 - 35 The console is connected to the relay boxes, central computer, battery computer and both converters via a high-speed CAN-Bus (250kBaud). For safety reasons two isolated CAN-Bus circuits exist. The connecting point of both circuits is the battery computer, which is solely connected to the converters via the second CAN-Bus. Note: Only consoles may be used that can process a CANBus with a data rate of 250KB. The hydraulic controller with joystick receives from the battery computer via the CAN-Bus a 24V supply

ã STILL GmbH Position as per: 2/2000 (Replaces version:

)(7)

via a tee coupling below the steering covering. A data circuit does not exist as the signal lines are not looped-through. For hydraulic controller diagnosis purposes, a tee unit (isolating point is located under the covering for the handbrake switch) is also necessary. The converters are illustrated once again as an example, but are not identical in all other configurations.

09

Workshop Manual 6030 - 35

Parametrization of electrical options via console If a truck is to be retrofitted with spotlights, headlights or stop lights, the parametrization does not have to be performed with diagnostic case. The parameters of simple circuits can also be set via the console.

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.

The condition for this is that the engineer is familiar with the handling of the console and has read the previous pages about parametrization. Furthermore, for a better understanding some notes on the processing of the switching commands in the controller are necessary.

Note The VALUE will only be stored in memory when both characters are confirmed with PRG and the entire line is flashing.

The controller has a SERVICE ADDRESS for each input and output of a functional block.

Then further consumers can be registered or the inputs can be saved with a RESET. For a better overview, the SERVICE ADDR. and VALUE of frequently used function blocks, keypads, switches and transmitter are shown on the following double pages.

SE RV I CE ADDR 0 0 0

FF

V AL UE

The selection of the relay and/or the input channel in the control relay board is done using the circuit diagrams for the lighting and optional electrical equipment in the appendix.

So that the controller can recognize all keypads, switches, transmitters, relays and control relay boards, they have been assigned a VALUE.

Relays K1 and K2 are only available with variant A.

Control relay board, front (2) has the SERVICE ADR 0A6 and the VALUE 41. Control relay board, rear (1) has the SERVICE ADR 0A5 and the VALUE 40.

PRG PRG

F2 F1  STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

(8)

Workshop Manual 6030 - 35

 STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

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

9

0

0

0

0

0

0

0

0

A

0

1

0

1

1

1

1

1

1

0

0

1

0

0

1

1

1

1

0

1

1

1

1

1

0

0

1

0

0

0

0

0

0

1

1

1

1

1

0

0

1

0

1

1

0

0

0

0

1

1

1

1

1

1

0

0

Lighting, stop light, flashing beacon

09

1B

RELAY BOX, front

Lighting / Optional electrical equipement

1F

0B 0C

Workshop Manual 6030 - 35

 STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

RELAY BOX, rear S1

41 42

0D8

IN

OUT

in = out

0 D9

stop light 3C 3F

N )

3D

R

3E

(10)

rev. and driver seated

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

6

X65

7

X62

0E3

0 1 1 1

flashing beacon fuse buard 1B

45

1C

7S1

46 47 57

lift cut off

58

= VALUE, when actuated = VALUE, when NOT actuated

K2

09

dead man function

K1

Lighting / Optional electrical equipement

V

01

Workshop Manual 6030 - 35

 STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

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

Spotlight, reversing light, reserve

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

9

X65

A

X62

RELAY BOX, front

09

1B

X71 / 1 , 3 X70 / 1 , 3

Lighting / Optional electrical equipement

1F

0B 0C

41 42

0E4

IN

in = out

OUT

0E5

Reserve 1 0E6

IN 1

0E7

IN 2

3C 3F

N )

3D

R

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

6

X65

7

X62

fuse buard 1B

= VALUE, when actuated = VALUE, when NOT actuated

K1 K2

09

lift cut off

03

1C

47 57

X71 / 1 , 3 X70 / 1 , 3

Reserve 3

46

dead man function

01 02

out2 1 0 0 1

Reserve 4 7S1

RELAY BOX, rear

Lighting / Optional electrical equipement

V

in1 0 0 1 1

OUT 1 0 E 8 OUT 2 0 E 9

Workshop Manual 6030 - 35

 STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

S1

Workshop Manual 6030 - 35

 STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

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

9

X65

A

X62

0F1 0F2

out2 0 0 1

Heater

Flasher, heater, wiper/washer

09

1B

RELAY BOX, front

Lighting / Optional electrical equipement

1F

0B 0C

41 42

3C 3F

N )

3D

R

3E

(14)

rev. and driver seated

RELAY BOX, rear

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

6

X65

7

X62

fuse buard

45 1B

7S1

46

1C

47 57

lift cut off

58

= VALUE, when actuated = VALUE, when NOT actuated

K2

09

dead man function

K1

Lighting / Optional electrical equipement

V

Workshop Manual 6030 - 35

 STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

S1

09

Workshop Manual 6030 - 35

Parameterising via the console Interconnection of functional blocks

Relay and relay box

On the double page which follows here you will find a simplified representation of the interconnection of additional functions within the optional electrical equipment. Knowledge of the application of logic gates and truth tables is assumed when performing this type of parameterization.

The choice of the relay or the input channel in the relay control board is made using the circuit diagrams for lighting and optional electrical equipment in the appendix. Relays K1 and K2 are only available in variant A.

The combination of different functions is effected by the simultaneous use of AND gates, OR gates and the functional blocks already dealt with, however with a VALUE on the output side. The complete range of switches, senders, relays and relay boxes will in that case retain the VALUE assigned to each of them. Procedure To begin with, the 3 digit SERVICE ADDR. for the input of a functional block and the VALUE of the switch desired are entered. Then are entered the 3digit SERVICE ADDR. for the output of that functional block and the VALUE of the input channel on the AND gate, OR gate, relay box, relay or of a different functional block. A further number of logging-in operations can then be carried out, or the entries can be stored in the memory unit by carrying out a RESET.

 STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

(15)

09

Workshop Manual 6030 - 35

Parameterizing via the console Example of parametrization The spotlight, front and spotlight, rear are to be installed in equipment variant A. Switching is done with relays K1 and K2 on fuse carrier A7. The spotlight, front is to be turned on and off with keypad 10. The spotlight, rear is to be turned on and off with keypad 4 in conjunction with the selection of “reverse” travel.

Spotlight, front Input signal for button/switch

Function block

1F

0DF

Output signal for consumers

0E0

in

1C

SPOTL IGHT, front

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

SPOTL IGHT, rear

1C

K1 K2

Exclusiv e OR, inv ertedv alue

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

 STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

)

00 (16)

0 DE 1B

09

Workshop Manual 6030 - 35

Lighing / optional electrical equipment

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

SPOTL IGHT, front

Rev Flasher

3E in 1 in 2

2A

SPOTL IGHT, rear

1B2

4A

1B1

48

1S4

44

Exclusiv e OR, inv ertedv alue

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

 STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

in 1

46 47 57

HEATER

58

)

(17)

09

Workshop Manual 6030 - 35

Lighing / optional electrical equipment SER V I CE ADDR 00 0

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

RELAIS BOX, rear

Exclusiv e OR, inv ertedv alue

out 1 out 2

0EC 0ED

RESERVE 3 08 09

Exclusiv e OR, invertedv alue

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

= VALUE, when actuated = VALUE, when NOT actuated

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

Exclusiv e OR, inv ertedv alue

 STILL GmbH Stand: 2/2000 ( Ersatz für Stand:

X70 / 1 , 3

Fuse board

SPOTL IGHT, front 117

X71 / 1 , 3

02

STOP LIGHT

in1 in 2 out

Exclusive

out

01

K1 K2

10

Workshop manual 6030 - 35

Table of contents

Page

Technical service data Functional description of lift and tilt hydraulics

2 3

Control valve block Control Design Installation instructions Circuit diagram - function Circuit diagram - function

4 5 6 7 8

Control valve Lifting/lowering Lifting/lowering Tilting Tilting Additional hydraulics Additional hydraulics

9 10 11 12 13 14

Control valve block Relief valve block seal Sender function and replacement Pump motor speeds Tilt cross-section reducer

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

ã STILL GmbH Stand: 10/1999 ( Ersatz für Stand:

)

(1)

10

Workshop manual 6030 - 35

Technical service data H ydraulic pump D eli very capaci ty

14cm³ / Revoluti on

D i recti on of rotati on

counter-clockwi se (arrow on pump)

Fi xi ng screw ti ghteni ng torque

50 + 10 Nm

Pump motor speeds (basi c setti ng) Steeri ng

500 1/ mi n

Li fti ng

wi thout load about 3000 rpm/ wi th load about 2550 rpm

Addi ti onal hydrauli cs (followi ng attachment)

500 / 700 / 800 and 2550 1rpm

Ti lti ng

up to rated stroke 3500 = 1100 rpm up to rated stroke 5000 = 650 rpm above rated stroke 5000 = 500 rpm

C ontrol valve block Reli ef valve

Setti ng value = 250 bar Setti ng range = 100 - 260 bar

Block screw ti ghteni ng torque

25 + 8 Nm

Threaded connecti on

P + A1 = G 1/2 , R = G 3/4 , A + A2 + B = G 3/8

Ti lt cross-secti on reducer

from rated stroke 5000 mm = 0.9 mm

Permi ssi ble automati c ti lti ng

to UVV = max. 0.5 degrees per second

Permi ssi ble automati c loweri ng

to UVV = max. 100 mm i n 10 mi nutes

Pressurising valve - pressuri si ng pressure

Forward ti lt = 125 bar

Air filter Fi lter fi neness

20 µ ( absolute )

Operati ng pressure - bypass valve

0.25 ± 0.05 bar

H ydraulic tank C apaci ty

dependi ng on mast type = 21 to 23 li tres

Hydrauli c oi l ( OZ )

Quali ty to D IN 51524 /part 2 or ISO VG 46 HM

S p eed s Tele / N iho Triple

Li fti ng at rated load

6030/31/33/34 6032/35 0.53 m/sec 0.45 m/sec 0.50 m/sec 0.43 m/sec Tolerance ± 12 %

Ti lti ng at rated load (pre-ti lt)

up to rated stroke 3500 mm mi n. 0.12 / max. 0.20 sec per degree up to rated stroke 5000 mm mi n. 0.20 /max. 0.37 sec. per degree above rated stroke 5000 mm mi n. 0.37 / max. 0.56 sec per degree

Loweri ng at rated load

0.45 - 60 m / sec.

ã STILL GmbH Stand: 10/1999 ( Ersatz für Stand:

)

(2)

10

Workshop manual 6030 - 35

Hydraulic system Functional description of lift and tilt hydraulics

A pressurising valve installed in the tilt valve (connection A ) prevents automatic forward tilting of the mast.

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.

A lowering brake (8) limits the load lowering speed. For functional description of lowering brakes and check valves installed in the masts, see Group 20. For functional description of steering hydraulics, see Group 06.

Attention Before carrying out any work on the hydraulic system, fully lower the fork carriage and disconnect the battery connector.

The following functional components are contained in the control valve block (2) : - A stop valve prevents excessive automatic lowering of the load. - A relief valve protects the hydraulic system against overloads.

 STILL GmbH Position as per: 10/1999 (Replaces version:

)

(3)

10

Workshop manual 6030 - 35

Control valve block

1. Valve carrier fixing bolts 2. Pin 3. Balancer 4. Control symbols 5. Megibuffer 6. Axle 7. Control valve block 8. Control lever 9. Hood 10. Lever 11. Control valve block fixing bolts 12. Rubber pad 13. Bolt 14. Valve carrier Function: When actuating a control lever (8), the slider of the control block valve (7) is pushed in or pulled out. The pump motor is controlled via the sender flanged to the control valve block (7). Design The valve carrier (14) is flexibly fixed in rubber pads (12) to the chassis partition. On the upper side of the control lever (8), various control symbols (4) are provided corresponding to the respective functions.

 STILL GmbH Position as per: 10/1999 (Replaces version:

)

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

Workshop manual 6030 - 35

Control valve block - design

 STILL GmbH Position as per: 10/1999 (Replaces version:

)

(5)

10

Workshop manual 6030 - 35

Control valve block Design

Sender/Sensor (9 a-d) :

I. Control valve block - lift/lower II. Control valve - Additional hydraulics 1 III. Control valve - Additional hydraulics 2

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

Sender 9a = Bosch No. 0 538 009 188 Sender 9b = Bosch No. 0 538 009 189 Sender 9c = Bosch No. 0 538 009 188 Sender 9d = Bosch No. 0 538 009 183 The Bosch numbers are on the sender housings.

Relief valve setting Setting value

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.

 STILL GmbH Position as per: 10/1999 (Replaces version:

) ( 6)

: 250 bar

Setting range : 100 - 260 bar Tightening torques Pos 2 Pos 3 Pos 11 Pos 12 Pos 13

= = = = =

46 29 5.5 3.5 25

+ + + + +

15 10 1.8 1.2 8

Nm Nm Nm Nm Nm

10

Workshop manual 6030 - 35

Control valve block - Function diagram

 STILL GmbH Position as per: 10/1999 (replaces version:

)

(7)

10

Workshop manual 6030 - 35

Control valve block Function diagram I II III

= Control valve block - lift/lower = Control valve - additional hydraulics 1 = Control valve - additional hydraulics 2

A1 A2 B A+B

= Connection - lift/lower = Connection - backward tilt = Connection - forward tilt = Connections - additional hydraulics

P R

= Connection - pump line = Connection - tank return

Stop valve - lift/lower (4) The stop valve in connection “A1“ to the lifting cylinders prevents automatic lowering of the load in a neutral position of the valve. Sender (5a - d) The senders (5a-d) connected to the valves (3) set the pump motor speeds according to the valve deflection. NOTE The pump motor speeds provided for the individual hydraulic functions as a basic setting as well as replacement and adjustment of the sender are shown in the chapter “Sender - pump motor speeds“ in Groups 10 and 13.

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

Control valve (6) The control valve installed between the pump channel “P“ and tilt valve limits the oil flow for tilting to maximum 26 l/min. Pressurising valve - tilting (8) The pressurising valve prevents automatic forward tilting of the mast or load.

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.

Set pressurising pressure = 125 bar

Check valves (2) The check valve installed between the pump channel “P“ and valves (3) prevent the oil flowing back into the pump channel.

 STILL GmbH Position as per: 10/1999 (Replaces version:

)

(8)

10

Workshop manual 6030 - 35

Control valve - Lifting/Lowering

1 26

2

25

3 4

24 R

23 A1

P

22 21

R

5 20

R

19 18

10 11

17

12 13

16

14 15

 STILL GmbH Position as per: 10/1999 (Replaces version:

)

(9 )

6 7 8 9

10

Workshop manual 6030 - 35

Control valve Lifting/lowering

The spring chamber is accordingly pressure relieved and the valve cone (21) is forced upwards against the spring (23) by the load pressure. The oil can discharge from the lifting cylinders into the return.

A1 = Connection lifting cylinder P = Pump channel R = Return channel

Stop valve (Item 21- 26) In the event of excessive automatic lowering of the load, the stop valve must be checked for fouling or damage.

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

- Remove screw plug (24) - Remove spring and valve cone - Check bore (22) for clear passage NOTE According to UVV, the maximum permissible automatic lowering of the load can be maximum 100 mm in 10 minutes. Test : - Lift the rated load about 0.5 m - After 2 minutes waiting time, mark fork carriage and outer mast - After 10 minutes, measure lowering path Check valve (Item 5- 9) If the load initially lowers a certain amount within the fine control range before being lifted, the ball seat (5) may be fouled or the spring (6) faulty. In this case, the control valve block must be renewed. Valve position (1) The valve (1) must not be rotated more than 55° to the left or right, otherwise malfunctions can occur at the stop valve

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.

- The fault carriage cannot be lowered.- The load lowers automatically too quickly. Renew valve seal (Items 2, 4, 19, 20)

After lifting the load and a neutral position of the valve (1) (see Fig.), the ball (5) of the check valve is forced into its seat by the spring (6).

See chapter “Control valve, additional hydraulics“. Sender (Items 12, 13, 14, 15) Replacement and adjustment, see chapter“ P u m p motor speed sender“

The valve cone (21) is also forced downwards into its seat by the spring (23) and the pressure which is active in the spring chamber via the bore (22). This prevents automatic lowering of the load.

Tightening torque: Item 16 = 3.5 + 1.2 Nm Item 24 = 29 + 10 Nm

On upward actuation of the valve (lowering), the spring chamber is connected to the return channel “R“ via the bore (26).

 STILL GmbH Position as per: 10/1999 (Replaces version:

)

(10 )

10

Workshop manual 6030 - 35

Control valve - Tilting

 STILL GmbH Position as per: 10/1999 (Replaces version:

)

(11 )

10

Workshop manual 6030 - 35

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.

A2 = Connection - backward tilt B = Connection - forward tilt P = Pump channel R = Return channel 1. Slider 2. Wiper 3. Cover plate 4. O-ring 5. Cross-section reducer 6. Spring 7. Piston 8. Pin 9. Bores Check and 10. Housing control valve 11. Spring 12. O-ring + retaining ring 13. Circlip 14. Screw plug 15. O-ring + retaining ring 16. Thrust washer 17. Return spring 18. Spacer 19. Sleeve 20. Sleeve 21. Sender (inductive sensor) 22. Sender fixing screw 23. Spring washer 24. Washer (stroke limiter) 25. Valve cone 26. Valve disk Pressuring valve 27. Spring 28. O-ring 29. Spring 30. Pressurising valve screw plug

After tilting and a neutral position of the slider (1) (see Fig.), the housing (10) of the control and check valve is forced back into its seat by the force of the spring (11). Check and control valve (Item 5 - 14) An oil volume of maximum 26 litres/minute flows from the control valve via a cross-section reducer (5) and via the bores (9) for the tilt function. For function of check valve, see chapter “Lift/lower control valve“ Pressurising valve (25 - 27) Set pressurising pressure = 125 bar NOTE In the event of excessive automatic forward tilting of the load (see UVV test), the complete pressurising valve must be replaced. NOTE With the single-lever control variant for the lift/tilt functions, the pressurising valve is omitted in the control valve. For this, a pressurising valve is installed in the feed line to the tilt cylinder (see chapter Pressurising valve).

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“.

Sender (Item 18, 19, 20, 21) : See chapter “Pump motor speed sender“

Renew slider seal (Item 2, 4, 15): See chapter “Control valve additional hydraulics“

Tightening torque: Item 22 = 3,5 On upward actuation of the slider (1) (forward tilt), the oil flows from the pump channel “P“ via the control and check valve to connection “B“ to the rear tilt cylinder chambers.

ã STILL GmbH Position as per: 10/1999 (Replaces version:

)

( 12)

+ 1,2

Nm

10

Workshop manual 6030 - 35

Control valve Additional hydraulics

1

R

P R

R

 STILL GmbH Position as per: 10/1999 (Replaces version:

)

(13 )

10

Workshop manual 6030 - 35

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

– Mark position of lift/tilt valve (valve must not be reinstalled rotated). – Remove valve (1) from below. – Fit new wiper (2) and O-ring (4) in block and fit shroud (3). – Fit new O-ring (20) and retaining ring (19) on valve up to retaining ring (10). ATTENTION Seals can be damaged by sharp valve edges. – Refit valve (1) in block. – Fit new spacers in sender housing (15). – Carefully slip sender (15) over sleeve holder and screw to valve block. Alternately tighten bolts (16) with the prescribed tightening torque.

Function There are two types of control valve for the additional hydraulics.

Tightening torque: Item 16 = 3,5 + 1,2 Nm Sender (Items 12, 13, 14, 15) See chapter “Pump motor speed sender“.

– as an end block with integrated plate – as a centre block (e.g. third control valve with double additional hydraulics)

Check valve (Items 5 - 9) See chapter “Lift/lower control valve“.

The function is basically identical. On upward or downward actuation of the valve (1), the oil flows from the pump channel “P“ via the check valve ball (5) forced out of its seat to the connections “A“ and “B“ to the attachment. Renew valve seals (Items 2, 4, 19, 20) When sealing the valves (1), particular care must be taken, as these are adjusted to the senders (15). – Remove control valve block – Remove shroud (3) – Loosen bolts (16) – Carefully remove sender (15) from sleeve holder (13) – Take care not to lose any spacers (12)

 STILL GmbH Position as per: 10/1999 (Replaces version:

)

(14 )

10

Workshop manual 6030 - 35

Control valve block Relief valve 1. Cap 2. Lock nut 3. Washer 4. Adjusting screw 5. O-ring 6. Spring 7. Valve housing 8. O-ring 9. Valve disk (valve seat) 10. Valve cone

1 2 3 4 5 6 7 8

The relief valve in the “lifting/tilting“ control valve block protects the hydraulic system against overloads. If, e.g. a load is fully lifted and the final pressure set at the valve is exceeded, the valve cone (10) is forced out of its seat (9) against the spring (6). The pressurised oil at “P“ can flow into the return “R“ to the hydraulic tank. After loosening the lock nut (2), the pressure can be increased or reduced by tightening or loosening the adjusting screw (4).

R

9 10

P 1

Set final pressure : 250 bar (Setting ranger: 100 - 260 bar )

R

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.

 STILL GmbH Position as per: 10/1999 (Replaces version:

)

P P

1 2

R

1 R

(15 )

10

Workshop manual 6030 - 35

Control valve block Sender function and replacement

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 ( - )

- Refit cover (7). The sender consists of the sleeve holder (4) permanently screwed to the valve and the sensor (6) with plug connector.The sender is adjusted to the valve stroke by means of spacers (3). The output voltage of the sender can be adjusted with a movable sleeve (5) on the sleeve holder (4). The output voltage changes with displacement of the valve (1) proportional to the valve stroke. For replacement of the sender (replacement delivery consists of Items 4, 5, 6 and 7), the following must be observed :

Item 4 = 0.5 + 0.17 Nm Item 8 = 3.5 + 1.2 Nm

Tightenting torques:

1

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

7

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.

A

B

Pump motor speeds (without load): Lifting

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

Additional hydraulics 1 and 2

 STILL GmbH Position as per: 10/1999 (Replaces version:

)

C

(16 )

See group 13

Workshop manual

10

6030 - 35

Control valve block Tilt cross-section reducer

2 1,2 mm

1. Union with cross-section reducer bore 2. Cross-section reducer marking (recess) In the event of possible malfunction of the pump motor control (excessive pump motor speed), to counteract rapid inclination of the mast, in the case of the masts

1

from a rated stroke of 5000 mm a threaded pipe (1) with a cross-section reducer bore of 1.2 mm diameter is installed in connection “B“ of the tilt control valve. Union tightening torque: 66 Nm NOTE The installation of a cross-section reducer union (1) is recognisable by the outer recess (2) on the hexagon. ATTENTION For replacement of the mast, a check must be made to ascertain whether or not these cross-section reducer unions need to be used depending on the mast type.

 STILL GmbH Position as per: 2/00 (Replaces version:

)

17

10

Workshop manual 6030 - 35

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

Set pressurising pressure = 125 bar (Setting range = 0-130 bar)

R Design 1. Housing 2. Valve screw

7 8

3. Freewheel balls 4. Seal 5. Cone with damping

6

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

Workshop manual 6030 - 35

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).

1

- Set keyswitch to 0 position and check that tilt slider of control valve is in a neutral position. Note: According to UVV, the mast must now no longer move forward by more than 0.5 degrees per minute. In the event of too rapid forward tilting, it is possible that the cone seat (5) is fouled. Remove pressurising valve and check for fouling.

2 Dismantling

R

- Remove pressurising valve. - Note dimension “X“. - Unscerw adjusting screw (7) with circlip plier.

7

- Remove spring (6) and valve cone (5).

8

- Check valve seat for fouling and damage. - Fit Items (5) and (6) and screw adjusting screw (7) back into the old position (dimension X).

6 Note After dismantling twice, the action of the plug (8) is no longer ensured.

5 4 3 2 9 1 P

 STILL GmbH Position as per: 10/1999 (Replaces version:

)

(19 )

10

Workshop manual 6030 - 35

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.

8

Lowering (direction of flow B ---> F) The action of the oil flowing back from the lift cylinders causes the restrictor (1) to be pushed into the control piston (4). The oil has to flow via an annular gap. As a result of the occurring flow resistance, the control piston (4) is pushed further into the housing (3) against spring force. Depending on the size of the load, flow bores in the control piston (4) are closed and the oil flow is throttled.

B

F

The lowering brakes are adjusted to the vehicles and masts, i.e. independent of the operating pressure, to a specific operating flow. The following lowering brakes are installed: 6030/31/33/34

=

SS 3 36 / 170

6032/35

=

SS 3 42 / 170

1

Type designation, operating flow and operating pressure are shown on the hexagon housing (2) and on the front of the lowering brake valve housing (3).

1

Example : Type = SS3 Operating flow = 36 Liter Operating pressure = 170 bar

ATTENTION The maximum permissible lowering speed is 0.6 m/sec.

 STILL GmbH Position as per: 10/1999 (Replaces version:

B )

(20 )

10

Workshop manual 6030 - 35

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)

- For the installation of a new pump, the seals (5 + 9) must be renewed. - Fit catch (2) on pump shaft journal. - Grease O- ring (3) on pump neck. - Place pump in pump motor (1), so that the motor shaft journal engages in the catch (2). - Fix pump with two bolts (8) to the motor. - Fix intake duct (10) of air intake to the pump. - Fix oil supply line flange (7) to the pump. - Connect air intake hose (11) to air filter cover.

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.

Tightening torques: Item 8 = 50 + 10 Nm Removal - Fully lower fork carriage and tilt mast fully forward. - Disconnect battery connection and remove plate. - Jack up left vehicle side (see Group 01). - Remove left front wheel. - Disconnect air intake hose (11) from air filter cover.

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).

- Remove intake duct (10) from the pump (four bolts Item 12) and remove air intake hose from above. - Disconnect oil supply line (7) from the pump (four bolts Item 6) - Unscrew two fixing bolts (8), see Fig. 2 and remove pump (4) from the motor.

 STILL GmbH Position as per: 10/1999 (Replaces version:

)

(21 )

10

Workshop manual 6030 - 35

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.

 STILL GmbH Position as per: 10/1999 (Replaces version:

)

(22 )

10

Workshop manual 6030 - 35

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. -

Place vehicle horizontal. Fully tilt back mast. Gabelträger vollständig absenken Disconnect battery connector. Remove plate. Unscrew breather filter (8). Unscrew drain screw (5) and discharge oil into a collecting container. - Screw in drain screw and tighten. - Fill new hydraulic oil via breather opening (8). - Check oil level. Hydraulic oil ( OZ ) Quality according to DIN 51524, part 2/HLP ISO VG 46 HM Level check - Place vehicle horizontal. - Fully tilt back mast and fully lower fork carriage. - Remove breather filter (8) - Check that oil level reaches I or II mark on dipstick. - Refill hydraulic oil if necessary. - Re-insert breather filter. Mast Overall height (mm)

Filling capacity (Litres) 6030/31/33/34

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

I

Breather filter The breather filter (8) with a filter fineness of 25µ prevents dust and dirt entering the hydraulic tank. The breather filter must be renewed every 3000 operating hours.

The specified filling capacities correspond to the total filling capacity of the hydraulic system. ã STILL GmbH Position as per: 10/1999 (Replaces version:

)

(23 )

10

Workshop manual 6030 - 35

Air filter Function and maintenance Type : Air filter with paper filter cartridge withg bypass valve and strainer. Paper filter cartridge (3) : Filter fineness = 15 µ (nominal) Bypass valve(1) : Operating pressure: 0.25 ± 0,05 bar Strainer (2) : 200 µ 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.

ã STILL GmbH Position as per: 10/1999 (Replaces version:

)

(24 )

10

Workshop manual 6030 - 35

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.

Cone unions with O-ring (DKO) The union nuts of these unions must be finally tightened after tightening (noticeable resistance) with maximum half a turn (180 °). Any further tightening can result in deformation and leaks.

180 o

ã STILL GmbH Position as per: 10/1999 (Replaces version:

)

(25 )

10

Workshop manual 6030 - 35

Hydraulic unions Pipe union with soft seal (EO2)

2

1

The previously used antifriction collar pipe unions have been replaced by a new, improved sealing union system with soft seal.

3

The new unions consist of:

4

1. Function nut (union nut) 2. Seal 3. Retaining ring (antifriction collar)

5

Pipes (4) and threaded pipes (5) correspond to the old antifriction collar pipe union. Installation Saw pipe at right angles Deburr pipe internally and externally ATTENTION: Any burr on the external diameter of the pipe can damage the seal (2).

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.

1

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.

1

ã STILL GmbH Position as per: 10/1999 (Replaces version:

)

(26 )

10

Workshop manual 6030 - 35

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

1

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.

ã STILL GmbH Position as per: 10/1999 (Replaces version:

)

(27 )

3

2

10

Workshop manual 6030 - 35

Speeds The vehicles are delivered with the following working speeds, measured with rated load: Lifting:

Tilt speeds w ith load (backw ard tilt)

( 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

min. about 0.09 max. about 0.17

5000

min. about 0.17 max. about 0.31 min. about 0.31 max. about 0.47

NOTE: For Niho and triple masts, the mean value from the measured speeds in stroke I and stroke II is decisive.

Tilt time = Tilt speed x Tilt angle Measurement must be made over the entire tilt range.

Lowering: Tele mast

=

0.45 - 0.60 m/sec.

Niho/triple mast

=

0.40 - 0.60 m/sec.

NOTE Special equipment on the vehicles may produce deviating values.

ATTENTION: 0.60 m/sec. must not be exceeded!

Tilting:

Tilt speeds w ith load (forw ard tilt) Rated stroke - h3 above to

3500 5000

-

Seconds per degree Tilt angle

3500

min. about 0.12 max. about 0.20

5000

min. about 0.20 max. about 0.37 min. about 0.37 max. about 0.56

ã STILL GmbH Position as per: 10/1999 (Replaces version:

)

(28 )

10

Workshop manual 6030 - 35

Hydraulic diagram

ã STILL GmbH Position as per: 10/1999 (Replaces version:

)

(29 )

10

Workshop manual 6030 - 35

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

ã STILL GmbH Position as per: 10/1999 (Replaces version:

)

(30 )

Tele

Niho

Triple

A

B

C

10

Workshop manual Joystick 6030 - 35

Table of contents

Page

Technical service data

32

Hydraulic system Functional description of lift and tilt hyraulics

33

Actuation Joystick/Function Joystick/Function, installation information Emergency lowering

34 35

Control valve block Installation Design Arrangement - installation information Diagram - function Diagram - function

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

Control valve block Relief valve, block seal Tilt cross-section reducer

47 48

Hydraulic diagram Diagram Legende

49 50

ã STILL GmbH Position as per: 10/1999 (Replaces version:

)

(31 )

10

Workshop manual Joystick 6030 - 35

Technical service data H ydraulic pumpe D eli very capaci ty

14cm³ / revoluti on

D i recti on of rotati on

counter-clockwi se (arrow on pump)

Fi xi ng bolt ti ghteni ng torque

50 + 10 Nm

Pump motor speeds (basi c setti ng) Steeri ng Li fti ng

500 rpm wi thout load about 3000 rpm/ wi th load about 2550 rpm

Addi ti onal hydrauli cs (followi ng attachment)

500 / 700 / 800 and 2550 rpm

Ti lti ng

up to rated stroke 3500 = 1100 rpm up to rated stroke 5000 = 650 rpm above rated stroke 5000 = 500 rpm

C ontrol valve block Reli ef valve

Setti ng value = 250 bar Setti ng range = 100 - 260 bar

Block bolt ti ghenti ng torque

13.5 + 4.5 and 25 + 8 Nm P + A1 = G 1/2 , R = G 3/4 , A + A2 + B = G 3/8

Threaded connecti on Ti lt cross-secti on reducer

from rated stroke 5000 mm = 0.9 mm

Permi ssi ble automati c foward ti lt

accordi ng to UVV = max. 0.5 Grad per second

Permi ssi ble automati c loweri ng

accordi ng to UVV = max. 100 mm i n 10 mi nutes Forward ti lt = 125 bar / Backward ti lt = 40 bar

Pressurising valve - pressuri si ng pressure Air filter Fi lterfei nhei t

20 µ ( absolute )

Bypass valve operati ng pressure

0.25 ± 0.05 bar

H ydraulic tank C apaci ty Hydrauli c oi l ( OZ )

dependi ng on mast type = 21 to 23 li tres Quali ty to D IN 51524 / part 2 or ISO VG 46 HM

S p eed s

Li fti ng wi th rated load

Ti lti ng wi th rated load (forward ti lt)

Tele / N iho Triple

up to rated stroke 3500 mm mi n. 0.12 / max. 0.20 sec. per degree up to rated stroke 5000 mm mi n. 0.20 / max. 0.37 sec. per degree above rated stroke 5000 mm mi n. 0.37 / max. 0,.6 sec per degree

Loweri ng wi th rated load

ã STILL GmbH Position as per: 10/1999 (Replaces version:

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

Workshop manual Joystick 6030 - 35

Hydraulic system Functional description of lift and tilt hydraulics

The control valve block (2) contains the following functional components:

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.

- A stop valve prevents excessive automatic lowering of the load. - A relief valve protects the hydraulic system against overloads. - Pressurising valves installed in the tilt valve (connections A and B ) prevent automatic tilting of the mast. A lowering brake (8) limits the load lowering speed. For functional description of the lowering brakes and hose failure safety devices installed in the masts, see Group 20. For functional description of steering hydraulics, see Group 06.

Attention Before carrying out any work on the hydraulic system, fully lower the the fork carriage and disconnect the battery connector.

ã STILL GmbH Position as per: 10/1999 (Replaces version:

)

(33 )

10

Workshop manual Joystick 6030 - 35

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).

3

2

1

CAUTION To prevent damage to the joystick, before opening the battery hood: - Move the seat right back - Fully lower the armrest

1. Joystick (Multifunction lever) 2. Armrest 3. Locking wheel 4. Horn button (red) 5. Forward indicator switch (yellow) 6. Fine control (dark grey) 7. Function button for attachments (light grey) 8. Reverse indicator switch (yellow) 9. Balance

4

6

7

8

Moving the joystick to the left or right in conjunction with the function button (7) activates various functions in the additional hydraulics, i.e. attachment movements. Fine control (6) Additionally actuating the fine control button halves the working speeds of all loads. NOTE The joystick is only active with switched seat contact.

1

Moving the joystick forward or back activates lifting or lowering of the load.

1

The mast can be tilted forward or back by moving the balance (9) up or down.

9

ã STILL GmbH Position as per: 10/1999 (Replaces version:

5

)

(34 )

10

Workshop manual Joystick 6030 - 35

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

Moving joystick forward or back: - Lower or lift load Moving joystick forward or back with F function button depressed: - Lower or lift bucket - Move fork forward or back NOTE Further settings can be parameterised.

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

1

To remove the joystick, all screws 1 and 2 must be loosened.

2 1 2

2 1 3

ã STILL GmbH Position as per: 10/1999 (Replaces version:

)

(35 )

10

Workshop manual Joystick 6030 - 35

Control valve block Installation

Removal of control valve block

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

-

Disconnect battery connector. Unscrew valve covering. Remove plate. Disconnect all electrical and hydraulic connections from control valve block. - Loosen fixing bolts (2) of valve carrier (4) and remove complete valve carrier with valve bonnet from chassis panel. - Separate control valve block (5) from valve carrier by loosening bolts (3).

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.

ã STILL GmbH Position as per: 10/1999 (Replaces version:

)

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

Workshop manual Joystick 6030 - 35

Control valve block arrangement

 STILL GmbH Position as per: 10/1999 (Replaces version:

)

(37 )

10

Werkstatt-Handbuch Joystick 6030 - 35

Control valve block Design

The control magnet (8) pushes the lifting valve downwards and opens the connection “A“ to the connection “P“. The control magnet (11) opens the lowering valve and opens the connection “A“ to the return “R“ (see also chapter Function diagram).

I = Control valve block - lifting/lowering II = Control valve - tilting III = Control valve - additional hydraulics 1 IV = Control valve - additional hydraulics 2 1.-3. Block bolts 4. Magnet coils (push slider) 5. Magnet coils (pull slider) 6. Union nuts 7. Solenoid valve 8. Control magnet - lifting 9. Emergency lowering - manual

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

The solenoid valve (7) can only be replaced as a complete unit (solenoid valve and valve cartridge). Loosen magnet coil fixing nut, remove magnet coil and unscrew valve cartridge. - The magnet coils (4 + 5) can be removed from the oil supply line after unscrewing the union nut (6) and renewed.

In the event of repairs to the slider bank, particular care must be taken as any soiling and damage of the sealing surfaces can result in malfunctions (valve slider can no longer be moved by the control magnet) and leaks.

- The tightening torques of the block bolts (1 to 3) must be observed. Tightening torques Item 1 = 13.5 + 4.5 Nm Items 2 and 3 = 25 + 8 Nm

The control valve blocks are delivered only complete as 3 and 4 blocks: 3 block = control valve I, II and IV 4 block = control valve I to IV The control valves II - IV (tilt and additional hydraulics) are basically identical in design. Additionally integrated in the control valve II (tilting) are two pressurising valves and one flow control valve. The control valve IV is designed as a plate. Sealing of the control valves with respect to each other takes place with O-rings and retaining rings on the flange surfaces.

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

Workshop manual Joystick 6030 - 35

Control valve block function diagram

B A

5

IV B A

5

III

3 B A

5 7 3

8 9 10

6

A

5 4

II

11 12

3

I

Y1 Y

13

2 1 R

P

 STILL GmbH Position as per: 2/00 (Replaces version:

)

39

10

Workshop manual Joystick 6030 - 35

Control valve block Function diagram

Shuttle valves (3) The shuttle valves ensure that the highest working pressure is applied to the pressure regulator via the control channels Y1 and Y on simultaneous actuation of several loads.

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

Stop valve in lower valve (4) The stop valve (4) installed in the lower valve prevents automatic lowering of the load in a neutral position of the valve (5). Check valves (5) The check valves present in all control valves prevent undesired load movements in the fine control range and with simultaneous actuation of several loads.

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

Solenoid valve (1) A safety valve that prevents undesired energisation of the control valve block via the electronics. In a non switched condition, the valve establishes a connection between the control line “Y“ and the return “R“. The pressure regulator (13) is opened and the oil flows from “P“ directly into the return. Only when the joystick is actuated does the solenoid valve close and interrupt the connection between the control line “Y“ and the return “R“, so that the pressure regulator (13) is closed and the oil flows to the loads.

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.

Control valve - tilting (7) Control valve - lowering (6) These valves set to a specific oil flow limit the maximum oil volume in order to protect the control elements. Pressurising valves (8 + 9) The pressurising valves prevent automatic lowering of the load Pressurising pressure: Item 8 = 125 bar Item 9 = 25 bar Check valve - lifting (11) This valve is closed during lowering and in a neutral position of the lift valve (12). During lowering, the oil flows to the lower valve (4). In a neutral position of the lift valve, automatic lowering of the load is prevented.

When load is applied, the pressure in the control channels increases and the relief valve (2) opens when the set final pressure is reached. As a result of the now higher pressure in the pump channel P, the pressure regulator is moved against spring force and the entire oil can flow via the open return into the tank.

 STILL GmbH Position as per: 2/00 (Replaces version:

)

In the event of excessive automatic lowering of the load, the valve must be checked for foreign bodies and damage.

40

10

Workshop manual Joystick 6030 - 35

Control valve connection block lifting/lowering

 STILL GmbH Position as per: 2/00 (Replaces version:

)

41

10

Workshop manual Joystick 6030 - 35

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

When the pressure reaches the final pressure set at the relief valve in the spring chamber via control channel “Y“, it opens and allows oil to flow into the return. The now higher pressure above the rod moves the same downwards and the entire oil flow can flow from “P“ to “R“ back into the tank. NOTE In the event of failure of the hydraulic system (e.g. no or minimal load movement), malfunctions of the pressure regulator can be due to foreign bodies. Check pressure regulator. Unscrew screw plug (23). Check rod for smooth movement (18) by depressing. Remove rod upwards and check for marks. Check spring (17). Blow out bore (19) with compressed air. ATTENTION When carrying our work on the pressure regulator, the existing distance spacers (20) must be refitted. Lift rod (8) During lifting, the rod (8) is pushed downwards proportional to joystick actuation by the control magnet (2) via the plunger (5) against the springs (10+11). The oil flows from “P“ to “A“ (lift cylinder). The setting of the screw (12), which determines the opening range of the rod, must not be altered. Lower valve (7) The valve is opened via the plunger (5) of the control magnet (3) and the oil can flow from “A“ into the return “R“. The valve prevents, like the check valve (28-31), automatic lowering of the load. The valve (7) is is locked against rotation by a screw (26). This valve cannot be repaired. Control magnets (2 + 3) After unscrewing the union nut (1), the magnet coil (2+3) can be removed from the pressure pipe. For fitting new O-rings (6), the flange (24) and the pressure pipe can be removed by loosening the screws (25). The control magnets (2+3) are identical in design.

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“.

Lower control valve (32 - 38) During lower, the oil flows via the cross-section reducer (33) through the bores in the sleeve (34) to the lower valve (7) and into the return.

On actuation of a valve, pressure builds up in the spring chamber (17) via the control channel (17). The rod (18) is pushed upwards and the oil flow from “P“ to “R“ is closed partly or completely.  STILL GmbH Position as per: 2/00 (Replaces version:

)

42

10

Workshop manual Joystick 6030 - 35

Tilt control valve

1

2

3 4 5 6 7 23 24 25

8

P

P 26

A 27 28 27

Y1 9 10 11 12 13 14 15 16

R

P

B

R

26 25 24 23

 STILL GmbH Position as per: 2/00 (Replaces version:

Y

17 18 19 20 21 22

)

43

10

Workshop manual Joystick 6030 - 35

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

The oil discharged from a tilt cylinder chamber flows via one of the load connections “A“ or “B“ to the pressurising valve (26 - 28). When the set pressurising pressure is reached, the valve cone (28) is lifted from its seat and the oil can flow via the bores in the valve disk (27) and via the slider opening into the return “R“. Control and check valve (9 - 16) An oil volume of maximum 26 litres/minute flows form this valve via a cross-section reducer (10) and via the bores (12) for the tilt function. This valve also has athe function of a check valve due to the valve cone (11). Pressurising valves (26 - 28) Set pressurising pressure: Connection A Connection B

In the event of excessive automatic tilting of the load (see UVV test), the complete pressurising valve must be replaced. ATTENTION The slider screw plug (22) and also the nut (21) 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 (18), as well as removal of the pressure pipe (4) and the slider (8) is therefore not possible.

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).

 STILL GmbH Position as per: 2/00 (Replaces version:

= 25 bar = 125 bar

)

44

10

Workshop manual Joystick 6030 - 35

Control valve additional hydraulics/end valve

1

2

3 4 5 6 7

8

P

P

A

B

R

Y1

P

9

R

10 11 12 13 14 15 16 17 18

19  STILL GmbH Position as per: 2/00 (Replaces version:

)

45

10

Workshop manual Joystick 6030 - 35

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.

 STILL GmbH Position as per: 2/00 (Replaces version:

)

46

10

Workshop manual Joystick 6030 - 35

Control valve block Relief valve Y = Control channel 6. Lock nut R = Return 7. Adjusting screw 1. Valve disk 8. Plain washer 2. Valve cone 9. Valve housing 3. Spring 10. O-ring 4. Gudgeon pin 11. Housing 5. O-ring Set value of relief valve: 250 bar (Setting range = 100 - 260 bar) When load is applied, the pressure in the control line Y increases. When the final pressure set at the relief valve is reached, the valve cone (2) opens and allows the oil to flow into the return. This causes the pressure regulator to open and allows the entire oil volume to flow into the return. The final pressure can be increased or reduced by unscrewing or tightening the adjusting screw (7). ATTENTION Do not remove any plain washers (8) and do not set the pressure higher than 250 bar. Lock adjusting screw (7) with lock nut (6). NOTE In the event of failure of the hydraulic system (e.g. no or only minimal lift or tilt), malfunctions of the relief valve can be caused by foreign bodies. Unscrew relieft valve cartridge (1-9). Unscrew valve disk (1) from valve housing (9) and check valve cone seat (2).

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.

)

R

5

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.

 STILL GmbH Position as per: 2/00 (Replaces version:

R

47

4

3

2 1

10

Workshop manual Joystick 6030 - 35

Control valve block Tilt cross-section reducer 1. Union with cross-section reducer bore 2. Cross-section marking (recess) In order to counteract rapid tilting movements of the mast in the event of failure of the pump motor control (excessive pump motor speed), the masts from a rated stroke of 5000 mm are provided in the connection “A“ of the tilt control valve with a threaded pipe (1) with a cross-section reducer bore of 0.9 mm in diameter. NOTE The installation of a cross-section reducer union (1) is recognisable by the outer recess (2) on the hexagon. Tightening torque Item 1 = 66 Nm ATTENTION When replacing the mast, a check must be made to ascertain whether this threaded pipe has to be used or not, depending on the mast type.

 STILL GmbH Position as per: 2/00 (Replaces version:

)

48

10

Workshop manual Joystick 6030 - 35

Hydraulic diagram

 STILL GmbH Position as per: 2/00 (Replaces version:

)

49

10

Workshop manual Joystick 6030 - 35

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

ã STILL GmbH Position as per: 2/00 (Replaces version:

)

50

Tele

Niho

Triple

A

B

C

Workshop manual

Table of contents

Page

Technical service data

2

Drive motor (AD20 axle) Drive motor type Circuit diagram Position of motor terminals Removing the drive motor Fitting the drive motor Removing the armature Fitting the armature Checking and replacing carbon brushes Speed sensor bearing Drive motor (exploded drawing) Drive motor (sectional view)

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

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per June 2000 (Replaces version: November 1999 )

11

6030 - 32

1

11

Workshop manual 6030 - 32

Technical service data

Type

GF 148 - P8

Manufacturer

JULI

Motor type

4-pole separately excited d.c. motor with commutating poles

Voltage (V)

80

Current (A)

165

Excitation

12 V/16 A

Rated speed rpm

2500

Maximum speed rpm

3800

Overspeed test speed rpm

6500

Power (kW)

11

Mode

S2 (60min)

Degree of protection

IP 23

Insulation class

F

Carbon brushes

EG34D-J

a) Dimensions

12.5 x 25 x 40

b) Wear limit

15 mm, replace by residual length 17 mm (on indication)

c) Quantity (units)

8

d) Carbon brush monitoring

yes (isolated)

Weight (kg)

146

Ventilation

Independent air cooling

2

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

6030 - 6032 (AD20)

Position as per: November 1999 (Replaces version: )

Group 11 Drive motor

Workshop manual

11

6030 - 32

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per: November 1999 (Replaces version: )

Technical service data Group 11 Pump motor

6030 - 6032 (AD20)

Type

GP 116 - Q2

Manufacturer

JULI

Motor type

4-pole d.c.motor

Voltage (V)

80

Current (A)

132

Rated speed rpm

3000

Maximum speed rpm

4000

Overspeed test speed rpm

5000

Power (kW)

12

Mode

S3 (20%)

Degree of protection

IP 23

Insulation class

F

Carbon brushes

A121

a) Dimensions

12.5 x 40 x 40

b) Wear limit

15 mm, replace by residual length 17 mm (on indication)

c) Quantity (unit)

4

d) Carbon brush monitoring

yes (isolated)

Weight (kg)

35

Ventilation

Independent air cooling

3

11

Workshop manual 6030 - 32

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

B1 / B2 = Commutating pole winding

M

A1/B2

A1/B2

F1 / F2 = Field winding Rechtslauf right rotation

A2 and B1 are the main current terminals of the rotor and commutating pole winding. These terminals are lead outside. Internally in the motor, the two terminals A1 and B2 are interconnected, i.e. the rotor and commutating poles are permanently interconnected. F1 and F2 (see drawing) are the terminals of the excitation winding and form the field (stator).

4

F1 F2

Linkslauf left rotation

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Terminals

F1

Position as per: November 1999 (Replaces version: )

(-) (+)

Workshop manual

6030 - 32

11 Drive motor

Removing axle with drive motor

The wheel gears can now be removed from the drive motor housing (previously drain gear oil). Fitting the drive motor Fitting the drive motor and mounted wheel gears takes place in reverse order, whereby the front axle fixing bolts must be tightened with a tightening torque of 385Nm.

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per: November 1999 (Replaces version: )

When removing the drive motor, the vehicle must initially be jacked up. - Remove wheels - Suppport mast and remove (see BG20) - Remove floor plate - Disconnect independent air cooling hose at motor housing - Disconnect main power cables (A2 and B1) and field terminals (F1 and F2) - Disconnect connectors x12 and x13 - Unhook parking brake cable (on lever of parking brake actuating mechanism) - Remove brake line at hydraulic brake housing - Place hand elevating truck below the axle and support - Unscrew 12 axle fixing bolts (6 bolts per side) - Remove axle from vehicle

5

11

Workshop manual 6030 - 32

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!

Fitting the armature

Fitting of the brush yoke ring with speed sensor bearing takes place with a threaded rod (600 long), wheel nut 18x1.5, two washers (ø 45mm e.g. washer on gear/chassis) and a sleevese (ø 54mm, 70-80 long). Push the threaded rod through the armature shaft and secure with washer and wheel nut. On the brush yoke ring side, only the sleeve is additionally placed between the washer and bearing. The brush yoke ring can now be pressed in place with this auxiliary construction. Under no circumstances strike the brush yoke ring with speed sensor bearing! 1 = Wheel nut 6 = Threaded rod 2 = Sleeve 7 = Armature shaft 3 = Washer 4 = Speed sensor bearing 1

3

3

4 7 5 2

6

6

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Fitting of the armature/rotor takes place in reverse order and the following should be noted: - Before fitting the aramature the washers must be fitted in the axle - The armature must be fitted against the pressure of the washers (tightening device). The screw holes in the brush yoke ring must be centered with a mandrel if necessary. - Note bolt tightening torques, e.g. wheel hub bolts 67 Nm - Gear oil must be filled from above into the filler screw, the check screw is on the front face of the wheel hub and must be located in 9 or 3 o’clock position.

Position as per: November 1999 (Replaces version: )

- Disconnect cable connections on the brush yoke ring - Remove carbon brushes (springs must subsequently be reseated in the shafts) - Separate plug connection on the brush yoke ring from the carbon brush monitor and temperature sensor and remove (do not crush!) - Disconnect connector of the speed sensor to the electrical installation. remove cover and place cable in the motor contour (towards wheel side - Unscrew brush yoke ring fixing screws (4 hexagon socket screws M6) - Remove armature (extraction device) - Note fitting position of washers on the axle housing (Bellville springs)

Workshop manual

11

6030 - 32

Drive motor Checking/replacing carbon brushes 1

Checking can take place through the openings on the left (4x on the circumference) in the drive motor. Only the plastic cover needs to be removed to gain access to the carbon brushes. The carbon brush spring must be lifted and locked in place. The carbon brush can now be removed from the brush shaft and measured with the aid of a vernier caliper. If the wear limit is reached (25mm), the brush should be replaced.

CARBON BRUSHES

The minimum remaining length of 15 mm is indicated via the carbon brush wear indicator on the console display (1).

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per: November 1999 (Replaces version: )

Carbon brush dimensions The dimension X (see Fig.) for the new carbon brush is 40 mm, the wear limit is 25 mm and the minimum remaining length is 15 mm. The carbon brush has the dimensions 12.5 x 25 x 40.

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

7

Position as per: November 1999 (Replaces version: )

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

8

Workshop manual 6030 - 32

11

Drive motor

Workshop manual

11

6030 - 32

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per: November 1999 (Replaces version: )

Drive motor

2

Detail view of bearing

3

1 = Ball bearing 2 = Bellville springs 3 = Shaft seal (secured with Loctite 243) 4 = Insulator (secured with Loctite 243)

1

4

9

11

Workshop manual 6030 - 32

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.

Pump motor type The drive motor is a four-pole series-wound motor. It includes a temperature monitor, carbon brush monitor and a speed sensor.

Motor terminals The motor terminals are laterally arranged. These are the terminals A1 and D2. Position as per: November 1999 (Replaces version: )

Connection of temperature and cabron brush monitors The temperature monitor and carbon brush monitor are connection to the electrical installation via connector x15 (four-pole).

Speed sensor The speed sensor is connected to the electrical installation via connector x14 (four-pole).

The shaft ends are supported in the bearing retainer plates via grooved ball bearings.

Circuit diagram

+ A1 X14

A1 and A2 = rotor (armature) D1 and D2 = series winding

D2

n

X15

M υ

Neutral zone The brush yoke ring is not adjustable. The neutral position is ensured due to the design.

10

(D1) ( A2)

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Armature support

11

Workshop manual 6030 - 32

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.

Stand: November 1999 ( Ersatz für Stand: )

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).

Checking/replacing carbon brushes

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Checking can take place by loosening the strap to gain the access to the carbon brushes. The carbon brush must initially be lifted and locked in place. The carbon brush can now be removed from the brush shaft and measured with the aid of a vernier caliper. If the wear limit is reached (25mm) the brush should be replaced.

1

The minimum remaining length of 15 mm is indicated via the carbon brush wear indicator on the console display (1). Carbon brush dimensions The dimension X (see Fig.) for the new carbon brush is 40 mm, for the wear limit 25 mm and for the minimum remaining length 15 mm. The carbon brush has the dimensions 12.5 x 40 x 40.

11

11

Workshop manual 6030 - 32

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

2,8±0,2

• Unscerw speed sensor from the bearing retainer plate by loosening the two screws. Fitting the speed sensor

Electrical connection of speed sensor The speed sensor is supplied with operating voltage via the controller. At its switching output, it delivers a square-wave signal. The frequency of this squarewave signal depends on the speed. +Ub x11/11 ->X50/3 ->X14/1 -> speed sensor Signal x11/40 <—X14/2 <— speed sensor - Ub x 11/7 ->X50/6 ->X14/3 -> speed sensor

• Turn pump motor until a tooth of the ring is located in front of the speed sensor. • Connect battery connector. • The digital multimeter must show a reading of about 4.8 Volt.

Position as per November 1999 (Replaces version: )

• The speed sensor is fixed to the bearing retainer plate with two screws. • The distance between the speed sensor and ring must be adjusted to 2.8±0,2 mm.

Testing the speed sensor • Disconnect battery connector

• Connect digital multimeter to the measuring adapter: Positive —> X14 Pin 2 Negative — > X14 Pin 3 • Turn pump motor until a gap of the ring is located in front of the speed sensor. • Connect battery connector. • The digital multimeter must show a reading of about 0.8 Volt. • Disconnect battery connector

12

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

• Plug SKT measuring adapter into connector X14 at the controller.

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.

When the fault has been cleared, the vehicle must remain switched on for about 10 minutes, so that the error message can be cancelled. If the vehicle is switched off before this time has elapsed, the error message is displayed despite no fault being present. Checking the carbon brush monitor • Disconnect battery connector. • Plug SKT measuring adapter into connector X 13 or X 15. • Connect battery connector. • Switch on lock key. • Measure the voltage with the digital multimeter: Between X 13/5 and X 13/2 for the drive motor, between X 15/3 and X 15/2 for the pump motor. • With sufficient brush length, the voltage must be about 80V.

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per November 1999 (Replaces version: )

Generation of the error message can also be due to incorrect parameterisation of the DRIVE MODE or HYDRAULIC MODE. Correct setting, see parameterisation BG08.

13

11

Workshop manual 6030 - 32

Temperature monitor Functional principle

X 11

As temperature sensors, silicon temperature sensors are installed in the brush yoke rings of the drive and pump motor. The temperature sensors are connected in series and are supplied from a power source with a permanently set current of 1.3 mA. The voltages across the temperature sensors vary depending on the temperature. The voltages are measured in the controller and the motor temperatures calculated. As the temperature sensors are connected in series, an interruption in one motor will result in failure of temperature measurement in both motors.

X 13 1 2 3 4 5 6 22 23 38

Ξ 15 1 2 3 4

1 2 3 4

ν

Φαηρµοτορ

1 2 3 4

ν

Πυµπενµοτορ

Testing the temperature sensors

Voltage across the temperature sensors: • Remove battery connector. • Plug SKT measuring adapter into connector X13 or X15. • Connect battery connector.

Position as per November 1999 (Replaces version: )

The power source and voltages across the sensors can be tested.

• Measure the voltage with the digital multimeter: Between 1 and 4 (X13) for the drive motor and between 1 and 4 (X15) for the pump motor.

14

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

• The voltage across the temperature sensor is about 0.7 V with the electric machine at room temperature.

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per November 1999 (Replaces version: )

Workshop manual 6030 - 32

11

Pump motor

15

Position as per November 1999 ( Replaces version: )

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

16

Workshop manual 6030 - 32

11

Pump motor

Workshop manual

6030 - 32

11 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.

Position as per: November 1999 (Replaces version: )

Insulation values of the electric machines should be minimum 80kW for the drive motor and pump motor. Testing connection of armature or field winding to frame (ground) Drive motor A2 or B1 to frame (ground) and F1 or F2 to frame (ground) Pump motor A1 or D2 to frame (ground)

Testing armature against field winding

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

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

Workshop manual 6030 - 32

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 Ø Pump motor 78 mm Ø Removal of commutator mica insulation

Sawing depth: About width of mica insulation. After skimming the commutator and sawing out or milling out the mica insulation, it may be necessary to remove the burr produced on the segement edges. For this purpose, the commutator must be honed with fine emery cloth (grit 320). Subsequently carefully blow-out rotor.

1=

Mica is correctly removed.

2 = Mica is not correctly removed, still present on segement flanks.

18

2

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Improperly removed segment insulation or even protruding mica residues, as well as copper burr on the segments will attack the carbon brush contact surface and cause high brush wear.

1

Position as per: November 1999 (Replaces version: )

The mica insulation between the individual segments must be carefully sawn out or milled out. IT must be ensured that the entire mica insulation width is removed completely, also on the segment flanks.

Werkstatt-Handbuch

Table of contents

Page

Technical service data

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

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per: Juni 2000 (Replaces version: November 1999 )

11

6033 - 35

19

11

Workshop manual

6033 - 35

Technical service data Group 11 Drive motor

6033/34/35

Type

A F 128 - K 1

Motor type Manufacturer

Squirrel-cage induction motor, star-connected/4-pole JULI

Voltage (V)

~ 45 V Y

Current (A)

200

Rated speed rpm

2400

Max. speed rpm

5000 (at 20 km/h)

Overspeed test speed rpm

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

Position as per June 2000 (Replaces version: )

Degree of protection

S2 - 60 min

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

20

11

Workshop manual 6033 - 35

Technical service data Group 11 Pump motor

6033/34/35

Type

A P 124 - K 1

Motor type Manufacturer

JULI

Voltage (V)

~ 45 V Y

Current (A)

200

Rated speed rpm

3000

Max. speed rpm

3100

Overspeed test speed rpm

3900

Rating (kW)

12.6

Mode Degree of protection

S 3 - 20% I P 64

Insulation class

F

Weight (kg)

50

Ventilation Speed sensor Temperature sensor

Surface cooling Sensor bearing 64 pulses/rev. Philips KTY 84-130

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per June 2000 ( Replaces version: )

Squirrel-cage induction motor, star-connected/4-pole

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.

Position as per June 2000 (Replaces version: ) Cyoprighted. Reproduction in any form forbidden. Copyright reserved.

22

11

Workshop manual 6033 - 35

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.

Position as per June 2000 (Replaces version: )

Removing the drive motor - Jack up the vehicle and remove the wheels - Support the mast and remove (see BG 20) - Remove the floor plate - Disconnect 3 main supply cables from the motor - Separate priority valve from the axle - Disconnect connectors x12 and x13 - Unhook parking brake cable (on lever of parking brake actuating mechanism) - Remove brake line on hydraulic brake housing - Place a hand elivating truck under the axle and support - Unscrew 12 axle fixing bolts (6 per side) - Remove axle from the vehicle contour

W V U

x13

x12

The wheel gears can now be removed from the axle body (previously drain gear oil). Fitting the drive motor

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Fitting of the drive motor and mounted wheel gears takes place in reverse order to removal, wherey, the front axle fixing bolts must be tightened with a tightening torque of 385 Nm.

23

11

Workshop manual

6033 - 35

Drive motor Replacing the sensor bearing

-

-

If a sensor bearing is ordered from the central spare parts service, the delivery will include - a sensor bearing - 2 shaft seals - 3 service bolts M8x50 with nuts - 5 corrugted tube retainers.

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

24

-

Posiiton as per June 2000 (Replaces version: )

- Disconnect connectors x12 and x13 (speed and temperature sensor) (1, 1a) - Remove contact plate bolts (2) (only loosen rear bolts) - Lift contact plate (3) and insert speed sensor connector x12 (1) into contact shaft (4) - Remove wheel rim (5) - Drain gear oil (6) on both sides - Remove wheel gear fixing bolts (7) - Remove wheel gear (8) - Remove gear (9), inner shaft (23) remains in the axle. - Remove two planetary carrier bolts (10) - Remove planetary carrier (11), including rotor (12) from the axle body (note sensor cable, remove temperature sensor cable from the corrugated tube). - Remove lock ring (13) of planetary gears (14) - Remove planetary gears (14) with puller - Remove thrust washer screws (15), mark position of cable exit of sensor bearing (18) on planetary carrier (11) and remove seal (22) - With the puller, remove planetary carrier (11) from rotor (12); support puller on tubular shaft with a size 28 socket or similar sleeve - Remove race (16). For this purpose, heat the race - Remove lock ring (17) - Remove sensor bearing (18) above outer ring of rotor (12), do not damage the sensor ring. Do not lose washer (21) - Drive out shaft seal (20) from planetary carrier (11) and clean seal seat - Place new sensor bearing (18) on bearing hole of planetary carrier (11). Note position of cable exits at sensor bearing (18). Previously fit Oring of old sensor bearing. - Place thrust washer (19) on sensor bearing (18) (note cable exit!) - Screw service bolts (M8x50mm with nut) through thrust washer holes in planetary carrier (11) to the root. - With nuts on service bolts, bring new sensor bearing (18) into position in planetary carrier (11) (fully) by evenly turning in ½ steps. Attention, do not use a hammer! - Remove service bolts! - Thrust washer (19) remains on sensor bearing (18), insert thrust washer bolts (15) with Loctite 243 and tighten with a torque of 25 Nm. - Fit washer (21) on shaft - Fit planetary carrier (11) with new fitted sensor bearing (18) above sensor bearing insulator on rotor (12). Attention, do not use a hammer!

The use of a threaded rod, which is inserted through the shaft, as well as a fitting bush is useful. Fit lock ring (17) Bond race (16) to degreased shaft end. The race must be coated with Loctite 243 on the joint side over the full inner circumference. The race (16) must now be pressed on to the rotor shaft (12) (fully) using the threaded rod. The race (16) must subsequently be thoroughly cleaned inside and out to remove adhesive residues. Fit new shaft seal (22). Note fitting direction and previously grease the sealing lip! Carefully insert rotor (12) into the axle housing (do not damage winding!). The cable of the sensor bearing must also be inserted through the contact shaft (4) to the outside. Attention, guide the cable so that the rotor can rotate freely! Fit planetary carrier (11) with planetary carrier bolts (10) in the axle housing and fit shaft seal (20). Fit planetary gears (14) on planetary carrier (11. Bearing inner ring can be driven in with a plastic hammer. Fit lock rings (13) Fit gear (9) on inner shaft (23). O-ring in gear on outer side! Carefully fit wheel gear (8) and fix with fixing bolts (7). Fill gear oil on both sides through filler screw (25) or (25a) Fit wheel Recheck sensor bearing cable in contact shaft (must not come into contact with rotating parts). Fix contact plate with contact screws (2). Plug sensor connector (1) into holder and check for tightness.

11

Workshop manual 6033 - 35

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

10 = Planetary carrier bolts 11 = Planetary carrier 12 = Rotor 13 = Lock ring 14 = Planetary gears 15 = Thrust washer bolts 16 = Race 17 = Lock ring

18 = Sensor bearing 19 = Thrust washer 20 = Shaft seal 21 = Washer 22 = Seal 23 = Inner shaft 24 = Ring gear 25a = Filler screw

Kontrollmaße zur Hülsen und Dichtringmontage (10,5 mm)

10,5

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per June 2000 (Replaces version: )

10,5

25

Position as per June 2000 (Replaces version: )

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

26

w v u

6033 - 35 Workshop manual

11

Drive motor

Ju li

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per June 2000 (Replaces version: )

Workshop manual 6033 - 35

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

floor plate on the right side. It is arranged horizontally on rubber bearings. The catch connects the drive to the gear pump. Pump motor type The drive motor is a 4-pole, star-connected squirrelcage induction motor. It includes a temperature monitor and a speed sensor bearing.

The pump unit is located under the

Position as per June 2000 (Replaces version: ) Copyrighted. Reproduction in any form forbidden. Copyright reserved.

28

11

Workshop manual 6033 - 35

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

Position as per June 2000 (Replaces version: )

- Disconnect main supply cable from pump motor housing - Disconnect connectors x14 and x15 - Disconnect pressure and suction flange (4 hexagon socket screws each) - Loosen three motor fixing bolts - Remove cover on the upper side and screw in an eyebolt - The pump motor can now be lifted out of the vehicle contour with lifting equipment

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Fitting the pump motor Fitting of the pump motor takes place in reverse order to removal.

bottom

top x15

x14

29

Position as per June 2000 (Replaces version: )

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

30

6033 - 35 Workshop manual

11

Pump motor

11

Workshop manual 6033 - 35

Speed sensor/Temperature sensor Drive and hydraulic motor speed sensor The speed sensor consists of a ball bearing with two staggered Hall effect sensors, which scan the inner magnet ring. The phase shift is 90 degrees +/- 45 degrees, and is defined as follows: If, when viewed on the sensor side, the inner ring rotates in clockwise direction, the indicating edge of signal B is located in front of the rising edge of signal A. All signals measured to GND. (See diagram opposite) The drive and hydraulic motor sensors differ as follows: The drive motor sensor generates 80 pulses per revolution, the bearing internal diameter is 45 mm.

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per June 2000 (Replaces version: )

The hydraulic motor sensor generates 64 pulses per revolution, the bearing internal diameter is 30 mm. The terminals are marked as follows: red: +Supply blue: Signal B white: Signal A black: GND Temperature sensor Incorporated in the machine are temperature sensors, which inform the control of the currently prevailing temperature. These are the sensors KTY 84 - 130. In order to check the sensor for proper functioning, the temperatures with corresponding ohmic values are shown in the table. The constant current for these values is 2 mA.

Temperature (°C)

Resistance (Ohm)

-40

355

-30

386

-20

419

-10

455

0

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).

Position as per June 2000 (Replaces version: )

Drive motor U, V and W to frame (ground)

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

32

13

Workshop manual 6030 - 35

Table of contents

Page

Technical service data

2

Pressure regulator I and II Function

3

Pressure regulator Relief valve, Pressure gauge

4

Control valve block Installation of cross-section reducer, speeds

5

Pressure relief for sideshift clamps

6

Joystick

7

ã STILL GmbH Stand: 2/00 ( Ersatz für Stand:

)

1

13

Workshop manual 6030 - 35

Technical service data Pressure regulator Relief valve Setting value

according to specifications of attachment manufacturer

Setting range

0 - 160 bar

Control valve block Fitting cross-section reducer Cross-section reducer 3.7mm Ø

--> (basic cross-section reducer) fitted on vehicle delivery without attachment and in replacement control valves --> fitted for sideshift functions B

Cross-section reducer 1.2 mm Ø

--> for clamp functions/ rotating heads/ buckets

No cross-section reducer Motor speed (additional hydraulics against excess pressure)

ã STILL GmbH Stand: 2/00 ( Ersatz für Stand:

Sideshift functions Other functions

)

= 500 rpm = up to 2550 rpm

2

13

Workshop manual 6030 - 35

Pressure regulator I and II

I = Additional hydraulics 1 II = Additional hydraulics 2

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.

1. Relief valve 2. Connections for attachment 3. Sender 4. Return to tank 5. Control valve block

The connection of a clamp function must always take place at the outer control valve in any event.

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.

 STILL GmbH Position as per: 2/00 (Replaces version:

)

(3)

13

Workshop manual 6030 - 35

Pressure regulator Relief valve - Setting range: 0 - 160 bar - Manually controllable

1

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

1

6

The oil flows from P —> R By tightening and opening the handle (1), the pressure setting can be increased or reduced. The setting range and maximum pressure are limited by distance spacers (3) to 160 bar.

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).

R

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.

 STILL GmbH Position as per: 2/00 (Replaces version:

)

Druck : 140 b ar

4

13

Workshop manual 6030 - 35

Control valve block Cross-section reducer for attachments with sideshift 1. Union with cross-section reducer bore 2. Cross-section reducer marking (recess) 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 are installed in the first threaded pipe (1) with a cross-section reducer bore of 1.2 mm diameter. NOTE Installation of the threaded pipe (1) with cross-section reducer bore is recognisable by the outer recess (2) on the hexagon. ATTENTION When retrofitting an attachment with sideshift, it must be ensured that threaded pipes with cross-section reducer bore are installed. Vehicles with additional hydraulics, which are delivered without attachment, are provided with cross-section reducer unions for safety reasons. Union tightening torque (1) : 66 Nm

1,2 mm

2

1

Pump motor speeds and cross-section reducers for attachments:

An b au g erätetyp

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 rä t D re hg e rä 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 la mme rg a b e l (o hne S e i te schub ) 1,5 T 401

K a up

2550

K la mme rg a b e l (mi t S e i te nschub ) 1,5 T 411

K a up

500

B a lle nkla mme r (o hne S e i te nschub )1,5 u. 2 T 403

K a up

2550

B a lle nkla mme r (mi t S e i te nschub ) 1,5 u. 2 T 413

K a up

500

2550

K a up

500

2550

K a up

500

800

S e i th

2550

Zi nke nve rste llg e rä t

u. 2 T 409

2 T 163

S cha ufe l 1000 / 1250 / 1500 B re i te Typ 10.20.033 , 10.20.05 u. 20.20.07

 STILL GmbH Stand: 2/00 ( Ersatz für Stand:

)

5

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 Ø 1. Zu satz h yd r.

ja ne i n 2550

ja ne i n ja ja ja ne i n

13

Workshop manual 6030 - 35

Pressure limitation for sideshift clamps Pressure limitation for clamps with integrated sideshift ATTENTION Vehicles of the 6030 - 35 series in contrast to older 60 series vehicle types will no longer be provided with additional hydraulics with pressure reduction for an integrated sideshift function. When using these clamp types, it must be ensured that the clamp itself is provided with pressure reduction for the sideshift. There is otherwise a danger of the clamp opening and the clamped goods falling out when the sideshift is moved fully to the left or right. In case of doubt, the attachment supplier must be consulted and the clamp retrofitted.

 STILL GmbH Position as per: 2/00 (Replaces version:

)

6

13

Workshop manual Joystick 6030 - 35

Table of contents

Page

Additional hydraulics Pressure regulator I and II Installation of attachments

8

Additional hydraulics Cross-section reducers and pump motor speeds for attachments

 STILL GmbH Position as per: 2/00 (Replaces version:

9

)

7

13

Workshop manual Joystick 6030 - 35

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.

Pressure regulator I and II I = Additional hydraulics 1 II = Additional hydraulics 2 1. Control valve block 2. Return hoses 3. Return to tank 4. Relief valve 5. Sender 6. Connection for attachment

5

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.

 STILL GmbH Position as per: 2/00 (Replaces version:

)

6

7

8

8

13

Workshop manual Joystick 6030 - 35

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.

Tightening torque Items 1 and 2 = 66 Nm

 STILL GmbH Stand: 2/00 ( Ersatz für Stand:

)

9

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

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per: November 1999 (Replaces version: )

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

1

Workshop manual

6030 - 35

20-25 Technical service data

Tightening torque = 275 Nm (M16x45 / M16x110 , 10.9)

Support roller bolts

Tightening torque = 20 Nm

Chains

max. elongation 3 % according to UVV

Lowerieng speed

max. permissible 0.6 m/sec

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per: November 1999 ( Replaces version: )

Mast bearing bolts

3

Workshop manual

20-25

6030 - 35

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per: November 1999 (Replaces version: )

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.

All mast types are clearview masts. The mast is a double T-section. The fork carriage and mast sections are guided by support rollers, which take up the side loads. Removing the mast - Secure the device, so that all mast dismantling work can be carried out. - Place the mast vertically and firmly secure at the top with a steel rope or chain. - Remove fork or attachment. - Disconnect lift cylinder hose line. - Remove tilt cylinder bolt from mast guide. - Unscrew fixing bolts for mast bearing. - Withdraw mast.

Fitting the mast Fitting of the mast takes place in reverse order to removal.

Note: In order to reduce wear, the roller tracks must be greased as required with : High-pressure adhesive lubricant STILL Part No. 147873

5

20-25

Workshop manual 6030 - 35

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.

The stop prevents the fork carriage falling out (see page 15 )

Position as per: November 1999 (Replaces version: )

A lowering brake installed in the pipe ensures a maximum lowering speed of 0.60 m/sec.

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

6

Workshop manual

20-25

6030 - 35

Telescopic mast

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per: November 1999 (Replaces version: )

Hydraulic oil flow in mast

1

The oil enters at the lowering brake, from where it flows via hose lines to the two cylinders. The hose failure safety devices installed at the bottom of the cylinders prevent the load falling too quickly in the event of a pipe fracture. 1 - hose failure safety device (520621) LB3 C 0,5 - 45

7

20-25

Workshop manual 6030 - 35

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.

1

When making the chain adjustment, it must be ensured that the minimum distance of 2mm to the stop is maintained (see adjustment, page 15).

Position as per: November 1999 (Replaces version: )

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

X

8

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

E

Workshop manual

20-25

6030 - 35

Niho mast Functional description

1

A lowering brake ensures a maximum lowering speed of 0.60 m/sec.

1 - Stop The stop prevents the fork carriage falling out (Adjustment, see page 15).

Copyrighted. Reproduciton in any form forbidden. Copyright reserved.

Position as per: November 1999 ( Replaces version: )

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 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 inner mast.

9

20-25

Workshop manual 6030 - 35

Niho mast

2

Position as per November 1999 (Replaces version: )

3 1

- Stroke 1 lifts the fork carriage. - Stroke 2 lifts the inner mast. The hose failure safety devices in the cylinders prevent the load being lowered too quickly in the event of pipe fracture.

10

Left lift cylinder One hose failure safety device (1) in the cylinder base (528030) and one hose failure safety device (2) at the top in the adapter (528030). Right lift cylinder One hose failure safety device in the cylinder base (525557). Centre lift cylinder One hose failure safety device (3) at the bottom (523514).

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

The oil enters via a lowering brake. From this point it flows to the outer cylinders via the hose line. The oil flows to the centre cylinder via the left outer cylinder. Owing to the varying piston areas, the centre cylinder piston is extended first.

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).

Position as per November 1999 (Replaces version: )

1 Attention: The chains must be inspected for wear, damage and elongation according to UVV.

Dimension “X“

X

6030/6031/6033/6034 X = 20 6032/6035 X = 15

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Insertion depth “E“ 6030/6033 6031/6034 6032/6035

E = 321 E = 371 E = 369

E

11

20-25

Workshop manual 6030 - 35

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).

Position as per November 1999 (Replaces version: )

A lowering brake ensures a maximum lowering speed of 0.60 m/sec.

1

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

12

20-25

Workshop manual 6030 - 35

Position as per November 1999 (Replaces version: )

Triple mast

2

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

1

The oil enters at the lowering brake, from where it flows via hose lines to the outer cylinders. The oil flows to the centre cylinder via the left outer cylinder (plunger case) and pipe. The centre cylinder pistons are extended first due to their varying piston areas. When the end stop is reached, the outer cylinder pistons are extended. - Stroke 1 lifts the fork carriage - Stroke 2 lifts the centre and inner mast. The hose failure safety devices in the cylinders prevent the load being lowered too quickly in the event of pipe fracture.

Left lift cylinder One hose failure safety device (1) in the cylinder base (525556) and one hose failure safety device (2) at the top in the adapter (525555). Right lift cylinder One hose failure safety device in the cylinder base (525557). Centre lift cylinder One hose failure safety device (2) at the bottom (523514).

13

20-25

Workshop manual 6030 - 35

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“.

1

Never compensate tyre wear by retensioning the chains. When making the chain adjustment, it must be ensured that the minimum distance of 2mm to the stop is maintained (see adjustment, page 15). Position as per November 1999 (Replaces version: )

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

2

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

X

E

14

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

E

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

1

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.

2

It must be ensured that a gap of not less than 2mm is present between stop (1) and stop (2).

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.

1

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per November 1999 (Replaces version: )

2

15

20-25

Workshop manual 6030 - 35

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)

Position as per November 1999 (Replaces version: )

Roller diameter 80.9 81.2 81.5 81.8

1 - Support roller 2 - Washer 3 - Countersunk screw Tightening torque = 60 Nm fork carriage Gabelträger

Min. 0.1 mm, max. 0.3 mm at the narrowest point, otherwise max. 1.1 mm.

The support rollers of 2.0t masts (Telescopic, Niho, Triple) are only push-fitted, see diagram opposite. A

16

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Permissible lateral clearance

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.

It is important, in order to reduce wear to a minimum, that the support roller tracks are sprayed with adhering lubricant 147873 as necessary. The support rollers must previously be cleaned thoroughly to remove dirt.

The diagrams on the right show how dimension “X“ of the fork carriage support rollers should be determined. - Lift fork carriage - Place wooden block below fork - Lower fork carriage The support rollers make contact with the side opposite to the track. - Dimension “X“ can now be determined.

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per November 1999 (Replaces version: )

After lapse of an operating time depending on the application, the dimension “X“ will hardly vary.

17

20-25

Workshop manual 6030 - 35

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

The cylinder head (3) is secured with Loctite 243 (519899), 3 beads on the circumference. 1 - Adapter (triple mast) 2 - O-Ring (fitted with grease) 3 - Cylinder head 4 - Check valve (525555) LB3 C 1,0 - 48 3x caulked on the circumference 5 - Circlip 6 - Guide ring

Position as per November 1999 (Replaces version: )

Note: The adapter (1) is secrued with Loctite 275 (524199).

1

5

18

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

6

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

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per November 1999 (Replaces version: )

1 Seal kit replacement

2 3

- Clamp cylinder in the vise. - Unscrew cylinder head with a hook-type wrench. If the cylinder head cannot be moved, heat with a flame.

4

The cylinder head is secured with Loctite 243 (519899), 3 beads on the circumference.

5

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

Workshop manual 6030 - 35

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

- Lift fork carriage, place wooden block under, lower, hang out chain at fork carriage. - Disconnect hydraulic connection at cylinder liner - Remove lift cylinder - Clamp cylinder barrlet firmly in vise at cylinder liner (so that cylinder barrel is not distorted) - Unscrew cylinder head with a hook-type wrench. If the cylinder head cannot be moved, heat with a flame. - Remove cylinder from cylinder barrel - Clamp piston in vise (protective jaws!) and unscrew bearing yoke. Bearing yoke is secured with Loctite 243. - Remove cylinder from piston.

7

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

B

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

The piston cover (8) is secured over the entire area and sealed with Loctite 275 (524199) Tightening torque = 350 Nm +50Nm

Position as per November 1999 (Replaces version: )

Removing the centre cylinder

20-25

Workshop manual 6030 - 35

Lowering brake valve Lowering brake valve The lowering brake valve ensures a constant lowering speed independent of the size of load.

B

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.

1

F

Position as per: November 1999 (Replaces version: )

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.

B

2

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

3 1 - Diaphragm in free flow direction 2 - Piston spring 3 - Control piston 4 - Guiding edges 5 - Diaphragm in normal position

5

4 F

21

20-25

Workshop manual 6030 - 35

Check valve Function : The check valve prevents a load being lowered too quickly and uncontrolled in the event of a pipe fracture.

B

The check valve is a plate valve, the valve disc of which is lifted from the valve seat by a spring in a non-operated state and maintains a flow crosssection of variable width.

4

F

3 1 - Piston cover 2 - Cylinder liner 3 - Check valve 4 - Valve disc The diagrams show the position of the check valve (LBS) :

Position as per: November 1999 (Replaces version: )

The force of the flow resistance and baffle effect at the valve disc in flow direction B--->F (operating direction) are subject to the counterforce of the spring in normal operation, the valve remains open. If the flow should increase in the event of a pipe fracture due to the driving load, the flow forces will exceed the spring force and the valve will close. The valve disc does not have any hole through which oil can flow from B to F depending on the size of the load, so that the load is slowly lowered to the ground.

- in adapter Niho mast (top) - in aapter triple mast (centre) - in cylinder liner of centre cylinder (bottom) 3

2 3

22

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

1

Workshop manual

20-25

6030 - 35

Lift cylinder

1

2

4

B A

B

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per: November 1999 (Replaces version: )

3

End position damping The end position damping ensures that the piston rod of the outer cylinder with end position damping is hydraulically retarded shortly before reaching its end position while lowering the mast in the transition from stroke 2 to stroke 1, in the case of the Niho and triple mast. Metallic impact is thus avoided.

5

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

1 - Bolt to limit fork downward travel 2 - Bolt to retain chain link

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per: November 1999 ( Replaces version: )

Support roller adjustment: See pages 16 /17

25

20-25

Workshop manual 6030 - 35

Roller retainer Replacement of support roller bearing A

The bearings (1) are welded all around to the roller retainer with a 5mm fillet weld. Before welding the bearings (1) to the roller retainer, the position of the notch in the bearings (1) must be noted.

K

1

Welding takes place with a lime-basic electrode (KB electrode).

K

The bearing (1) and roller retainer material is St 52 - 3.

C

1 - Bearing No. 327175 2 - Retainer No. 324167 (Niho/Triple) K - Notch in bearing (1) A

B

C

D

E

B

D Position as per: November 1999 (Replaces version: )

E

1.6t 60 300 450 55 93 1.8t 60 350 500 55 93 2.0t 65 350 ---

K

50 91

Note the following dimensions for telescopic mast 1.6t/2.0t: Tele 1.6t B = 350 C = 500 D = 80 E = 118 Tele 2.0t B = 400 D = 80 E = 121 37

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

3

Position as per: November 1999 (Replaces version: )

2

4

5

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

6

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

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

Position as per: November 1999 (Replaces version: )

When clamping the piston rod in the vice, use protective jaws.

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

8

7

11 10 9

Hub

L 6

4 5 3

2

1

29

20-25

Workshop manual 6030 - 35

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

Tightening torque = 130 Nm (+10 Nm). After assembling the pistson guide ring, seal and seal kit for the cylinder head, it must be ensured when inserting the cylinder head into the cylinder barrel that the recess in the cylinder head faces towards the threaded pipe hole.

X

For assembly note dimension “X“ = 805 +6/-10mm!

Dimension L and stroke, see table on page 31.

15 - Ring for Tele/Niho fitted externally for triple fitted internally

L Position as per: November 1999 (Replaces version: )

When fitting the tilt cylinder in the vehicle, it must be ensured that the connections face outwards. The holes for receiving the tilt cylinder bolts must be lubricated prior to fitting the tilt cylinder bolts! The ball sockets must be caulked on both sides to prevent lateral movement. Caulking of the ball sockets takes place at the points marked with arrows.

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

30

Workshop manual

20-25

6030 - 35

Tilt cylinder a

ß

h4

h3

Position as per: November 1999 (Replaces version: )

h

h5

h2

Copyrighted. Reproduction in any form forbidden. Copyright reserved.

When carrying out repairs to the tilt cylinders, it must be ensured that the mast tilt is not altered. Any change to the tilt angle can result in a change in stability.

h - Overall height h2 - Free lift, Tele 150mm h3 - Nominal lift h4 - Maximum height

a = Forward tilt ß = Backward tilt L

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

3

5

Triple

1860 to 3260

31