STILL STED forklift EGV-S workshop Manual - PDF DOWNLOAD

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Workshop Manual

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545 6446

EGV-S

Workshop Manual

EGV-S

SERVICE-TRAINING

Survey of Assemblies

Survey of Assemblies :

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A Travel drive B Steering C Brake E Lifting device F Cylinders K Swivel rollers M Electrical system N Hydraulic system R Lubrification chart U Covers Z Troubleshooting - Special tools

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Sheet no.

0

Foreword Foreword

This workshop manual provides specifications and describes functional characteristics of the standard truck.

This manual provides you with a document for a better understanding of the vehicle’s technology and for the proper performance of maintenance and repair work.

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The workshop manual is always updated by supplementary sheets.

Updating of workshop manuals The range of industrial trucks is subject to continuous further development. This means that certain components or assemblies will be replaced or modified.

To ensure that the owner of this manual always has an up-to-date and meaningful version of the documentation, it is important to abide by the following updating system.

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Sheet no.

I

Foreword Updating of workshop manuals (Contd.)

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1. Exchanging faulty sheets If a particular page contains mistakes, for example due to altered settings, the sheet in question must be exchanged.

A newly inserted sheet can be recognized by the altered left-hand baseline (1).

Here, the date of compilation is updated in the line entitled Issue (2). The line Replaces issue (3) contains the compilation date of the sheet to be replaced. The sheet no. remains the same (4).

The cover sheet must be replaced with every change. The first date of issue and the date of the last revision is given in field (9). This allows the reader to recognize the manual’s state of issue at a glance.

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Sheet no.

A1

1 2

4 Page baseline of corrected sheet

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02/96

Sheet no.

A1

3

2. Insertion of supplementary sheets If new, modified or additional components are installed in the series truck, it may be necessary to add one or more supplementary sheets.

The additional sheet is recognized by the left-hand and right-hand page baseline (5+6).

The compilation date (7) is in the issue line on the left-hand side. On the right, the supplementary sheet is marked by the sheet no. with the continuous index (8).

In addition, the table of contents of the assembly in question must also be exchanged.

Workshop EGV-S Manual

Page baseline of cover page Issue : 02/96 Replaces issue :

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SERVICETRAINING

9 Page baseline of existing sheet Issue : 02/96 Replaces issue :

5

Workshop EGV-S Manual

Sheet no.

A1

Page baseline of supplementary sheet

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Sheet no.

A 1.1

7

8

Newly compiled sheets, whether replacements or supplementary, and the new tables of contents are sent to all known owners of workshop manuals by mail.

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Sheet no.

6

II

Foreword Notes, imprint

No guarantee claims shall arise out of working in accordance with the instructions contained in this manual.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

This does not affect the guarantee stipulations.

We are continuously involved in the further development of our industrial trucks.

Please appreciate that this documentation is subject to alteration and error, and that no claims may be derived from information, illustrations and descriptions contained in the workshop manual.

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Sheet no.

III

Foreword

Definition of the directions of movement

Main lift Lifting

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Main lift Lowering

Reverse direction of travel

Forward direction of travel

The terns left and right mean as seen in the direction of travel !

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Sheet no.

IV

Assembly A

Travel drive

Contents

Sheet no.

Travel motor, general ............................................................................................. A 2 Terminal strip designations / travel motor .............................................................. A 3 Removing the travel motor..................................................................................... A 4 Installing the travel motor....................................................................................... A 7 Replacing the carbon brushes ............................................................................... A 10 Travel motor, maintenance ..................................................................................... A 11 Replacing the drive wheel...................................................................................... A 15 Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Removing the gears............................................................................................... A 16 Changing the gearbox oil ....................................................................................... A 18

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Sheet no.

A1

Assembly A

Travel drive

Travel motor Id. No. W8 405 700

General The travel drive installed is a split-field motor (series-wound motor).

Split-field motors consist of an armature winding (1) and two field windings (2 and 3).

The direction of travel is selected with the directionnal contactors (4 or 5) via the two field windings.

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The speed of the travel motor depends on the pulse control (6).

Note :

Split-field motors (series-wound motors) must never be operated without a load (e. g. gearbox).

There is a risk of the travel motor being destroyed.

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Sheet no.

A2

Assembly A

Travel drive

Terminal strip designations Travel motor Technical data - Field winding - Field winding

A1

- Armature winding

A2

- Armature winding

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1D1 2D2

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Sheet no.

A3

Assembly A

Travel drive

Removing the travel motor

Attention :

When the travel motor is removed, the truck is unbraked so that it must be secured against rolling.

1. Disconnect the battery plug.

2. Remove the cover (1, see U2).

3. Block up the truck securely on both sides (approx. 210 mm) (2).

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4. Remove the drive wheel (see A15).

5. Open the steering chain tensioner (3) (lefthand thread).

6. Remove the chain.

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Sheet no.

A4

Assembly A

Travel drive

Removing the travel motor

7. Fully open the steering motor chain tensioner (1).

8. Screw a 5 mm screw into the chain tensioner fixing pin (2).

Note :

Mark the position of the chain tensioner exactly.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

9. Position a mounting bar on the head of the 5 mm screw and pry the chain tensioner fixing pin out.

10. Remove the steering motor chain.

11. Drive out the two pins (3).

12. Remove the four screws (4).

13. Put the steering motor (5) to the side.

14. Remove the two screws (6).

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Sheet no.

A5

Assembly A

Travel drive

Removing the travel motor

15. Remove the three screws (1).

16. Put the end cover (2) aside.

17. Remove the electromagnetic spring-operated brake (refer to C4).

18. Mark the connecting cable on the travel motor terminal strip and diconnect it.

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19. Remove the three socket head screws (3) from below.

Note :

Pay attention to the length of the screws (3).

20. Take out the travel motor by lifting it up.

21. Cover the gearbox opening now left open.

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Sheet no.

A6

Assembly A

Travel drive

Installing the travel motor

Conditions : Battery plug disconnected, truck blocked up 1. Clean the gearbox opening.

2. Put the gearbox or drive wheel in the straight-ahead position.

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3. Place the travel motor (with O-ring) (1) into the gearbox.

Be sure that the terminal strip (2) is set to the 12 o’clock position (looking in the direction of the forks).

4. Install the three socket head screws (3) from below.

Torque : 23 Nm (Note the screw length !).

5. Install the drive wheel (refer to A15).

6. Install the electromagnetic spring-operated brake (refer to C4).

7. Place the end cover (4) in position.

8. Install the three screws (5).

9. Install the two screws (6).

10. Tighten screws (5) and (6).

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Sheet no.

A7

Assembly A

Travel drive

Installing the travel motor

11. Reconnect the connecting cable to the travel motor.

12. Screw the 5 mm screw (1) into the chain tensioner fixing pin (2).

13. Install the steering motor chain (3) on the travel drive.

14. Install the chain spanner (4) and drive in the fixing pin (2).

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Note :

Pay attention to the mounting position (see figure) ; the drive must face straight ahead.

15. Remove screw (1).

16. Insert two roll pins (5à in the drilled hole (6).

17. Slide the steering motor (7) and mounting over the roll pins (5).

18. Install four screws (8) with Loctite 242.

Torque : 20 Nm 19. Install the steering motor chain (3) on the steering motor sprocket (9) and connect the chain tensioner (4).

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Sheet no.

A8

Assembly A

Travel drive

Installing the travel motor

20. Tension the steering motor chain with screw (1).

21. Tighten the locknut (2).

22. Put the tiller and drive to the straight-ahead position.

23. Install the steering chain (3) on the two sprockets (4, 5).

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24. Connect the chain tensioners (6, 7).

Note :

The two chain tensioners (6, 7) must be situated between the two sprockets (4, 5).

25. Tension the steering chain.

26. Tighten the locknuts (8, 9).

27. Check for proper operation.

28. Check the adjustment of the brake (refer to C5, 6, 7).

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Sheet no.

A9

Assembly A

Travel drive

Replacing the carbon brushes Id. No. W8 402 140 The carbon brushes have to be replaced when a residual length of 50 % is reached.

Original brush length

Replace at

30 mm

15 mm

Replace only complete kit of (four) carbon brushes.

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Removal : 1. Disconnect the battery plug.

2. Lift off and hold the brushes spring (1).

3. Pull out the carbon brush at the connecting cable (2).

4. Disconnect the connecting cable (3).

5. Clean the commutator section (with an air jet).

Caution : Do not inhale the carbon dust.

6. Install new carbon brushes.

Note :

Do not run the motor directly with a full load after renewing the carbon brushes. The brushes are run in relatively quickly with a new load.

Checking the brush springs Id. No. W8 010 849 Brush springs with insufficient tension lead to a burning of the commutator.

Ensure that the motor brushes can run easily in the shaft.

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Sheet no.

A 10

Assembly A

Travel drive

Travel motor, maintenance

General The routine servicing between major overhauls consists of :

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- cleaning - routine visual inspection - replacement of any damaged parts - inspection of brush unit and commutator - replacement of the carbon brushes, if necessary (refer to sheet no. A10) It is recommended to have the major overhaul done by a specialist workshop as special tools and know-how are necessary.

Caution :

To prevent shorts or injuries, disconnect the battery plug before working on the motor.

Cleaning - Remove the cover band and take out the brushes (refer to sheet no. A10).

- Clean the motor well with an air jet (do not inhale the dust, use a respirator).

- Clean dirty commutators and brush unit with a clean cloth (not cleaning wool) moistened petrol, and dry them well.

Note :

Do not lift the brush springs any more than necessary and do not bend them to the side.

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Sheet no.

A 11

Assembly A

Travel drive

(Continued)

Travel motor, maintenance Visual inspection, replacing damaged parts :

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- Check the winding of the field and armature for signs of overloading (overheating) : dark coloured, broken or burned insulations, unsoldered armatures.

Replace motors with such overload damage immediately.

- If oil or grease is found in the motor (mostly a paste of oil, oil vapour with dust and carbon deposit), determine and eliminate the cause at once. Clean the motor very thoroughly.

Note :

Rapid wear of the carbon brushes or armature is caused in most cases by oil. The oil/grease burns in the brush fire and leaves a sharp-edged lug of oil with an abrasive effect.

This is why the brushes can be worn down below the limit before the routine maintenance interval.

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Sheet no.

A 12

Assembly A

Travel drive

(Continued)

Travel motor, maintenance Checking the brush unit, changing the motor brushes : After the brush unit is cleaned, the brushes should move easily in their guides.

If one or more brushes are sticking, they must not be worked on with emory paper or similar materials.

In this case, the entire brush unit must be replaced as the brushes were possibly overheated.

The brushes must also not be broken or chipped at the sliding edges.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Notes : - Always replace the entire set of brushes ; the shortest brush determines if a replacement is required (see sheet no. A10).

- Only use genuine replacement brushes (refer to the parts list !).

- Set the brush springs gently against the brushes during installation.

- If the minimum length is not quite reached yet, replace the brushes nevertheless because the remaining service period is possibly shorter than the next inspection interval.

- Only a maximum of 3 sets of brushes should be replaced in succession, as a major overhaul of the motor is then required (by a qualified workshop).

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Sheet no.

A 13

Assembly A

Travel drive

(Continued)

Travel motor, maintenance Commutator The running surface of the commutator should be evenly smooth and appear gray-black.

The commutator should not be run-in, scoured or untrue.

If the above-mentioned characteristics occur, the commutator must be reworked (general overhaul).

Do not rework it with a file, emory paper or similar objects.

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Bearings The ball bearings do not have to be lubricated. The grease packing is sufficient for the maintenance period between the general overhauls.

The bearings must be renewed during every major overhaul.

Only use the bearings specified in the parts lists.

Note on danger of overloading with discharged batteries : In the RPM of the motor drops noticeably, stop work immediately and check the battery without delay, charging it if necessary.

Do not drive with undervoltage !

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Sheet no.

A 14

Assembly A

Travel drive

Replacing the drive wheel Id. No. W8 305 061 Original dimension :

250 mm x 80 mm

The drive wheel must be replaced if - the running surface has spalled a lot or is out of round and shows signs of cracks.

- the tyre diameter is reduced by 10 % (minimum admissible tyre diameter : 225 mm).

Removal

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1. Disconnect the battery plug.

2. Securely jack up the truck (refer to A4, work step 3).

3. Rotate the drive until the wheel nuts (1) are facing the front.

(Refer to Figure 2 for definition of travel direction.)

Forward travel

Reverse travel

4. Loosen the wheel nuts (1).

5. Remove the wheel nuts (1).

6. Take out the drive wheel (2) downwards.

Assembly is in the reverse order of removal, but pay attention to the following points : 1. Before installing the drive wheel, clean the wheel seat and check for proper condition.

2. Install the drive wheel and tighten the 5 nuts by hand.

3. Tighten opposite nuts with a torque wrench.

Torque : 140 Nm.

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Sheet no.

A 15

Assembly A

Travel drive

Removing the gears Id. No. W8 413 216

1. Remove the travel motor (refer to A4) and drain the gear oil (refer to A18).

2. Raise the mast about 1000 mm.

3. Attach a perlon rope (diam. 8 mm) to the mast (1).

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4. Install an eyebolt (2) (special tool) on the gear removal tool (3) (self-manufactured).

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Sheet no.

A 16

Assembly A

Travel drive

Removing the gears To the mast

5. Attach the perlon rope (1) to the eyebolt (3) with a spring hook (2).

6. Position the gear removal tool (4) in the gearbox opening (5).

7. Raise the mast somewhat and tension the perlon rope (1) a little.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

8. Remove the 6 screws (6).

9. Slowly lower the mast, taking care not to let the washers (7) drop into the gearbox.

It is also necessary to note the quantity and location of the washers (7).

During installation, the washers must be installed in the same place.

10. Lower the mast, and thus the gears, and remove the gears downwards.

Installation is in the opposite sequence of removal.

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Sheet no.

A 17

Assembly A

Travel drive

Changing the gearbox oil Change interval : The first oil change should be after 50 to 150 service hours.

This filling is then for the entire service life (also refer to the lubrication chart, sheet no. R3).

Oil grade :

SAE 80 (coldstore : SAE 75W-90)

Oil capacity :

1.8 l

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Note :

The specified oil quantity is only an approximate value. The correct oil quantity will result by filling oil through the filler opening (2) up to the lower edge of the hole.

Avoid overfilling as this will destroy the seals and cause overheating of the oil.

Changing the oil 1. Disconnect the battery plug.

2. Support the truck securely on both sides (refer to A4, step A3).

3. Place an oil pan under the oil drain plug (1).

4. Remove the oil level/filler plug (2).

5. Remove the oil drain plug (1).

6. Drain the gear oil.

7. Install the oil drain plug (1) with a new sealing ring.

8. Fill transmission oil with a funnel (or similar means) through the filler hole (2).

9. Close the filler hole (2) with the filler plug and a new sealing ring.

10. Install plug with a new sealring in the filler opening (2).

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Sheet no.

A 18

Assembly B

Steering

Contents

Sheet No.

Tiller head, general ................................................................................................ B 2 Location of the tiller head components.................................................................. B 3 Belly switch ............................................................................................................ B 4 Tiller head components, travel switch.................................................................... B 5 Travel circuit board ................................................................................................. B 6 Initial lift lowering circuit board............................................................................... B 7 Tiller head disassembly ......................................................................................... B 8 Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Tiller hear assembly............................................................................................... B 9 Electric power steering, general ............................................................................ B 10 Operation of the magnetoresistor .......................................................................... B 11 Adjustment of the magnetoresistor ........................................................................ B 12 Steering control, general........................................................................................ B 13 Block diagram of steering control .......................................................................... B 14 Operation of steering control ................................................................................. B 15 Safety monitor ........................................................................................................ B 16 Safety monitor, continued ...................................................................................... B 17 Adjustment of the steering control ......................................................................... B 18 Initial operation....................................................................................................... B 19 Pin assignment ...................................................................................................... B 20 Servo unit, general................................................................................................. B 21 Changing the carbon brushes ............................................................................... B 22 Servo unit removal ................................................................................................. B 23

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Sheet no.

B1

Assembly B

Steering

Tiller head

General Id. No. : Id. No. : Id. No. : Id. No. :

W8 470 479 W8 367 833 W8 367 834 W8 370 480

without initial lift with initial lift coldstore w. initial lift coldstore w/o init. lift

Various functions can be selected and performed with the tiller head and its components.

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Without initial lift (1) Travel switch The travel is used for selecting the forward/reverse direction of travel and selecting the travel speed.

(2) Belly switch (for operation see sheet no. B4) (3) Horn With initial lift (4) Travel switch The travel switch is used for selecting the forward/reverse direction of travel and selecting the travel speed.

(5) Belly switch (for operation see sheet no. B4) (6) Initial lift lifting (7) Initial lift lowering (8) Horn

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Sheet no.

B2

Assembly B

Steering

Tiller head

Location of the tiller head components Without initial lift (1) Travel circuit board with belly switch and horn push (2) Travel switch (4) Key switch

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

With initial lift (1) Travel circuit board with belly switch and initial lift microswitch (2) Travel switch (3) Initial lift lowering citcuit board (4) Horn push

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Sheet no.

B3

Assembly B

Steering

Tiller head

Belly switch General

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

The belly switch is a safety device and it must operate as required by the accident prevention laws.

For this reason it must ne checked for correct operation when performing the maintenance services.

If the belly switch (1) is pressed, the direction of travel (3) is changed from forward to reverse and the truck stops after the belly switch is released.

Travel can be continued when the travel switch (2) is moved through the neutral position.

The belly switch function is realized in connection with the Highpuls Control (see assignment Pin 13 on sheet no. M5, and Pin 10 on sheet no.

M7).

Note 1 :

The belly switch functions only in the pedestrian mode of operation. If the belly switch is pressed during the stand-on mode, only the direction of travel will be cut out and the truck will coast to a stop.

Note 2 :

If the safety cut-out (see sheet no.

M8) of the Highpuls Control is activated, the belly switch function will have priority with some errors.

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Forward

EGV-S

Reverse

Sheet no.

B4

Assembly B

Steering

Tiller head components

Travel switch The installed travel switch needs 5 cams in order to control the direction of travel and speed via the travel circuit board (see sheet no. B9).

The following functions are selected with the cams :

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(1) Forward direction of travel and travel speed stage I (v/min) (2) Reverse direction of travel and travel speed stage I (v/min) (3) Travel speed stage II (v/max 1/2) (4) Travel speed III (v/max) (5) Cam for travel speed stage IV.

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Sheet no.

B5

Assembly B

Steering

Tiller head components

Travel circuit board (w/o initial lift) Id. No. W8 365 199 The travel circuit board is primarily composed of : (1) Belly switch (2) 2 microswitches for horn (3) 5 microswitches for direction of travel and travel speed

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

(4) Resistors for travel speed stages 5.6 k ; 2.7 k ; 4.7 k

Travel circuit board (with initial lifting) Id. No. W8 365 199 (1) Belly switch (2) 2 microswitches for initial lift lifting (3) 5 microswitches for direction of travel and speed (4) Resistors for travel speed stages 5.6 k ; 2.7 k ; 4.7 k

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Sheet no.

B6

Assembly B

Steering

Tiller head components

Travel circuit board (with initial lift lowering) Id. No. W8 365 198

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The circuit board for initial lift lowering primarily consists of the microswitches (1).

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Sheet no.

B7

Assembly B

Steering

Tiller head

Disassembly 1. Remove the 4 socket head screws (4).

2. Carefully pull the tiller head shells apart and take out the compression springs (3).

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Note : Note the location of the various components !

Mark the connecting plugs before disconnecting them.

3. Disconnect the plugs on the circuit boards (6 and 7).

4. Remove the travel switch (5).

5. Pull out the circuit boards.

Assembly is in the reverse order of removal.

For assembly, follow the instructions on sheet no. B9.

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Sheet no.

B8

Assembly B

Steering

Tiller head

Assembly When assembling the tiller head, pay attention to the following points : -

The cables must not be pinched between the tiller head shells or between the tiller head shells and the circuit boards.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

- The circuit boards must be installed correctly in the tiller head shell guides.

- The travel switch must be placed with the guide lugs (1) in the guides (2) on both sides of the lower tiller head shells.

- The travel switch spring (3) must be positionned correctly at the spring stop (4).

The ends of the spring (5) must contact the spring stop (4) at the top and bottom.

After the assembly, check all functions of the tiller head for proper operation !

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Sheet no.

B9

Assembly B

Steering

Electric power steering

General The electric power steering is a steering assist device.

In case of a failure of the electric power steering, emergency manual steering is still available !

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

The controller requires a voltage of 24 V. The current is limited to 14 A. (Refer to B12 and B18 for adjustment.)

The control electronics and the main current unit are mounted together in a closed unit (1).

The desired value sensor (2) is located on the travel motor and it is of the contactless magnetoresistor type.

Battery

The drive unit angle of lock is 95° to each side, where as the tiller angle of lock is only 65°.

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Sheet no.

B 10

Assembly B

Steering

Electric power steering

Operation of the magnetoresistor

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Id. No. W8 410 475 The magnetoresistor is a resistor controlled by a magnetic field. The magnetoresistors used in the sensor are of the differential type. These consist of two series-connected magnetoresistors (in a single housing) with centre tapping.

Depending on the position and influence of the magnetic field, the resistance ratio of the two magnetoresistors to each other changes and therefore also the potential of the centre tapping when voltage is applied (approx. 5 V) to the external terminals (1 and 3).

The change in potential of the centre tapping is transmitted to the control electronics as control signal.

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Sheet no.

B 11

Assembly B

Steering

Electric power steering

Adjustment of the magnetoresistor 1. Remove the cover (1) (refer to sheet no. U2).

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

2. Tilt the tiller to the operating position (pedestrian operation).

3. Connect a voltmeter to pin 4 (+) an pin 6 (-) at plug X1 (refer to sheet no. B20).

Voltage reading : 2.5 Volt.

If this value can be obtained, slacken screws (4). Move the magnetoresistor (5) until the value is obtained. If this mechanical adjustment is too inaccurate, turn the «symetry» trimmer (refer to sheet no. B18).

4. Move the tiller anticlockwise as far as the end stop.

(End stop is reached if the retainer (1) contact screw (2)).

Voltage reading : 2.5 V approx. -1.5 V. 5. Move the tiller clockwise as far as the end stop.

(End stop is reached if the retainer (1) contacts screw (3)).

Voltage reading : 2.5 V approx. +1.5 V. The angle of lock must be adjusted with screws (2 and 3) if the voltages specified under point 4 and 5 (± 1.5 V) are not nearly identical or exceed ± 1.5 V. Further possibilities of adjustment are located on the steering controller (refer to sheet no.

B18).

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Sheet no.

B 12

Assembly B

Steering

Electric power steering

Steering controller MLR Id. No. W8 405 942 General The 24 V steering controller is used in electric power assisted steering if a split-field motor is installed.

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The torque requirement via the tiller is sensed with a magnetoresistor, evaluated and controlled with the integrated MOSFET power stage.

In conjunction with the non-linear current-torque characteristic, this results in a steering behaviour characterized by high stability during fast travel and easy steering when standing still.

Numerous monitoring functions ensure safe operation : - overvoltage and undervoltage protection - short circuit-proof power stage due to «pulseby-pulse» current limitation - temperature monitoring of the power stage - false pole protection - external enable input - «steering error» signal output - steering motor brush monitoring with signal output (not used) - cable breakage monitor desired value sender The steering controller can be adapted to the truck with a potentiometer. The maximum motor current is limited to 14 A by means of fixed resistances.

The input fuse 30 A/125 V (1), Id. No. W8 405 541, protects the steering controller (also refer to block diagram on sheet no. B14).

The electric connections are with a 6-pin 6.3 mm «fast-on» combined connector for operating voltage and motor, and a 6-pin AMP connector for the sensors.

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Sheet no.

B 13

Assembly B

Steering

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Block diagram of steering controller MLR

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Sheet no.

B 14

Assembly B

Steering

Electric power steering

Steering controller MLR Operation

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The steering sensor is supplied with a stabilized 5 V voltage by the steering controller. The voltage is short circuit-proof. The load on this power source, however, must not exceed 25 mA during continous duty.

If the steering desired value deviates from the quiescent value of 2.5 V by a maximum of ± 1.5 V, the related power MOSFET of the power stage is driven and this signal controls the negative voltage over outputs «Field L» and «Field R».

Steering controller Enable

This means that the transistor turn-on ratio is directly proportional to the change in the desired value.

The steering works on demand.

not ready Brush

The power stage is only driven if 24 V is applied to the external enable input (X1.3) and the supply voltage is also 24 V (X2.2/X2.6).

Furthermore, the safety monitor must not have been triggered (refer to sheet no. B16).

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Sheet no.

B 15

Assembly B

Steering

Electric power steering

Steering controller MLR Safety monitor 1. Operating voltage The supply voltage is also buffered by the internal buffer capacitors.

If the voltage exceeds 40 V or drops below 12 V, the steering controller cuts out automatically.

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2. Short circuit-proof power stages In case of a short in the motor, the pulse-bypulse current limiter limits the maximum current to about 14 A to prevent a destruction of the transistors. If the system is endangered by short power peaks (over 60 A) or a fault in the current limiter, a short circuit monitor turns off the steering controller within 10 µs.

3. Overtemperature The power stage is protected against overheating.

When the power stage heat sink reaches a temperature of about 100°C, the steering controller is switched off.

4. False pole protection If the 24 V supply voltage is connected with the poles reversed, the internal safety relay (1) will not make.

Continued on sheet no. B17.

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Sheet no.

B 16

Assembly B

Steering

Electric power steering

Steering controller MLR Safety monitor Continued 5. External enable input The internal pulse with modulator, which enables the triggering of the transistors, is enabled only if 24 V is applied to the input.

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6. «Steering error» signal output Not used 7. Motor brush monitoring Not used.

8. Desired value sensor for cable breakage monitoring If there is a break in the power supply cables to the desired value sensor, the steering controller will be switched off and the «steering error» output sends a 0 V signal. If the desired value cable is broken, only the controller is turned off.

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Sheet no.

B 17

Assembly B

Steering

Electric power steering Steering controller MLR Adjustment The steering controller is preset and it does not require any additional adjustment at the three potentiometers (1). If the steering behaviour is not optimum or the steering motor is overheating, first check the steering sensor for proper adjustment (refer to sheet no. B20).

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«Symmetry» potentiometer P1 The symmetry needs only to be adjusted if the exact adjusment of the 2.5 V quiescent level is not possible with the adjustment of the steering sensor. the object of the adjustment is to achieve an identical setting-in of the power steering in both directions of rotation.

«Amplification» potentiometer P2 This potentiometer is used to vary the ratio of the steering desired value to the steering motor control. The maximum current limit of 14 A can not be influenced with this potentiometer as this limit is defined with fixed resistances.

This potentiometer can only be used to reduce the maximum current, but this also reduces the maximum torque.

«Dead range» potentiometer P3 The response of the steering to small steering movements (fast travel) can be varied with the adjustment of the dead range. Increasing the dead range increases the effort required for small steering movements.

If the dead range is too small, a current can flow already in the quiescent state. This must be avoided under all circumstances !

The power steering should be activated with a change ± 0.25 V in the desired value and this value is preset at the factory.

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Sheet no.

B 18

Assembly B

Steering

Electric power steering

Steering controller MLR Initial operation For the initial operation, the field circuit of the motor (terminals for field R and field L) is not connected.

After the operating voltage is turned on, check the wiring to the magnetoresistor. A voltage of 2.5 V must be applied to the centre tapping of the magnetoresistor. Turning the steering wheel to full lock should change the voltage by as much as approx. 1 V or 4 V, depending on the direction of rotation.

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Now apply the field circuit of the motor.

A reserved sense of control can be recognized by the steering controller reversing the direction of steering and by the increased steering effort required. The steering may also become unstable in some cases. To eliminate this problem, interchange the motor field connections.

If required, make a final adjustment of the steering controller as described on sheet B18.

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Sheet no.

B 19

Assembly B

Steering

Pin assignment Connector X2

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X2 Pin No. Designation

Explanation

1

Field R

Motor field terminal for CW rotation

2

+BAT (24 V)

Positive supply voltage terminal

3

Field L

Motor field terminal for CCW rotation

4

Brush_E (24 V) Input for detecting brush

5

Armature

Positive motor terminal

6

-BAT (0 V)

Negative supply voltage terminal

Connector X1 X1 Pin No. Designation

Explanation

1

VRef+ (5 V)

Positive reference voltage for magnetoresistor

2

N_ready

Fault output (if fault is low)

3

FG

Enable input (24 V= steer motor active)

4

Sensor (2.5 V)

Centre output voltage of magnetoresistor

5

Armature

Brush output (if detecting brush is low)

6

VRef- (0 V)

Negative reference voltage

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Sheet no.

B 20

Assembly B

Steering

Electric power steering

Servo unit Id. No. W8 416 142

Temperature monitor

Detecting brush

General

Detecting brush

The ball bearings are maintenance-free.

If the ball bearings have to be removed for repairs, they must be replaced. They must also be replaced after approx. 25,000 service hours.

The gears are greased for life und they are therefore maintenance-free.

The motor is equipped with a temperature monitor and a carbon brush for detecting motor brush wear.

The temperature monitor and the detecting brush, however, are not evaluated.

Temp. monitor

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The servo unit consists of an electric motor (48 V) and a flanged-on Cyclo gear (2).

The motor has two discrete series-connected field windings (split field motor), so that a clockwise and anticlockwise rotation is possible without reversing the polarity.

Terminal strip pin assignment A1 Dr/D1 Dl/D2

= = =

armature field 1 for CW rotation field 1 for CCW rotation

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Sheet no.

B 21

Assembly B

Steering

Electric power steering

Changing the carbon brushes Id. No. W8 013 531 Id. No. detecting brush W8 013 531 For detailed information on the brushes refer to the description of the travel motor (see sheet no.

A10).

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Original length : Minimum length : Brush kit : Note :

22 mm 11 mm 2 items

The detecting brush can be recognized by the black vein.

Steering motor maintenance The maintenance services are similar as for the travel motor (refer to sheet no. A11 to A14).

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Sheet no.

B 22

Assembly B

Steering

Electric power steering

Servo unit Removal 1. Perform steps 1, 2 on sheet no. A4.

2. Perform steps 7, 8, 9, 10 on sheet no. A5.

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3. Mark the connecting cables (1) at the steering motor and disconnect them.

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Sheet no.

B 23

Assembly C

Brake

Contents

Sheet No.

General .................................................................................................................. C 2 Method of operation ............................................................................................... C 3 Removal - installation............................................................................................. C 4 Adjustment of the air gap....................................................................................... C 5 Adjustment of the braking force ............................................................................. C 6 Adjustment of the brake release monitoring switch ............................................... C 7 Maintenance .......................................................................................................... C 8 Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Measurement of brake deceleration, general ........................................................ C 9 Measurement of brake deceleration, evaluation .................................................... C 10

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Sheet no.

C1

Assembly C

Brake

Electromagnetic spring-operated brake Id. No. Brake assembly Id. No. Rotor

W8 416 461 W8 410 216

General The brake installed in this truck is of the deadman type.

When the tiller is released, it is moved to the top braking position (1) by a gas-filled spring.

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This activates the brake, stopping the truck. The brake is both service and parking brake.

A microswitch (2) is used to detect if the brake is fully released. The air gap and braking force of this brake can be adjusted.

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Sheet no.

C2

Assembly C

Brake

Electromagnetic spring-operated brake Method of operation In the illustration to the right, the brake is shown in a powerless state, i.e. in the braking position (b).

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The compression springs (2) press the armature disc (3) axially against the rotor (4) and it, in turn, against the motor end cover (4).

When the tiller is moved from the braking position (b) to the travel position (a), the brake switch (1) is operated via a cam (6). The coil in the electromagnetic brake is excited with direct current and the magnetic circuit between the armature disc (3) and the magnet part (7) is closed.

The rotor (3) can move against the fixed magnet ; as a result, air gap “a” is reduced to “zero” and the rotor (4) is free to move.

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Sheet no.

C3

Assembly C

Brake

Electrimagnetic spring-operated brake Removal Note :

After the removal of the brake the truck is unbraked so that it must be secured against rolling.

1. Disconnect the battery plug.

2. Perfom step 2 on sheet no. A4.

3. Perfom step 14 on sheet no. A5.

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4. Perform steps 15, 16 on sheet no. A6.

5. Disconnect the cable (1) to the brake.

6. Disconnect the cable (2) to the brake release monitoring switch.

7. Remove the three socket head screws (3).

8. Remove the rotor (4).

Installation Installation is in the reverse order of removal.

During installation, pay attention to the following points : - The rotor must be replaced if the residual thickness is 6 mm.

- The armature disc (5) and rotor must be clean and free of grease.

- The rotor must move easily over the pinion (6).

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Sheet no.

C4

Assembly C

Brake

Electromagnetic spring-operated brake Adjustment of the air gap General

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The correct adjustment of the spring-operated brake should, on the one hand, ensure the proper running of the rotor when the brake is released and, on the other hand, allow the greatest wear limit for the rotor (1).

Dimension “a” indicates the air gap that must be set when a new adjustment or re-adjustment to 0.3 mm is required (brake air gap).

Adjustment 1. Move the adjusting sleeves (2) up into the magnet part.

2. Set dimension “a” to 0.3 mm with the three setscrews (3).

3. Check dimension “a” with a feeler gauge at least 3 places (near the screw, item 3).

4. Tighten the adjusting sleeves (2) downward and check dimension “a”.

If necessary, repeat steps 2 to 4.

Note :

The rotor (1) must be checked for ease of movement on the hub (4) after every replacement on the brake lining.

Original thickness of brake lining : Replace if worn down to :

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12 mm 6 mm

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EGV-S

Sheet no.

C5

Assembly C

Brake

Electromagnetic spring-operated brake Adjustment of the braking force As the setting of the braking force influences the braking distance, it must be adjusted in the course of routine maintenance or after the brake is replaced.

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The braking force can be determined with a dynometer (see table below).

Turning the adjusting ring (1) with the aid of a hook spanner changes the pressure on the pressure piece (2), the compression springs (3) and the armature disc (4).

During braking, the rotor (5) is pressed against the end cover of the travel motor with greater or lesser force.

Turning the adjusting ring anticlockwise less braking force (braking distance longer) Turning the adjusting ring clockwise : greater braking force (braking distance shorter) Note :

Minimal braking.

8.5 % with a load (this measurement is performed with a dynometer (refer to C10)).

Table for braking distance

Truck speed with a load 5.0 km/h

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1.05 m

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EGV-S

Sheet no.

C6

Assembly C

Brake

Electromagnetic spring-operated brake Adjustment of the brake release monitoring switch Id. No. W8 402 944 General

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The microswitch monitors the correct release of the spring-operated brake. If the brake is not correctly released, no +24 V signal is sent to the pulse control so that travel is inhibited.

Therefore the correct adjustment of the microswitch must be checked during servicing or repairs.

Adjustment 1. Carry out steps 2 and 3 on sheet no. A4.

2. Connect a voltmeter to pin 15(+) at the pulse control and to central negative at connector X1.

3. Loosen the locknut (1).

4. Tilt the tiller to the operating position (pull the tiller down).

5. Turn the screw (2) towards the locknut (1) until the screws head contacts the microswitch (3) properly.

6. Turn the screw (2) towards the microswitch (3) until a voltage signal of +24 V is indicated on the voltmeter.

7. Again turn the screw (2) 60° towards the microswitch (3).

8. Tighten the locknut.

9. Check for proper operation.

Note :

If a microswitch is replaced, secure the fastening screw (4) with Loctite 648.

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Sheet no.

C7

Assembly C

Brake

Electromagnetic spring-operated brake Maintenance When servicing the truck, the following procedures must be carried out or paid attention to : - Adjustment of the brake clearance (see sheet no. C5).

- Adjustment of the braking force (see sheet no.

C6).

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- Adjustment of the brake release monitoring switch (see sheet no. C7).

- Replace a spalled, unevenly worn or worn rotor (1).

- The rotor (1) should be able to move easily on the pinion (2). (Use Curil K2 as lubricant).

- Clean the brake of any oil with an air jet.

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Sheet no.

C8

Assembly C

Brake

Measurement of brake deceleration General The brake deceleration value is measured with a dynometer (Fig. 1), Id. No. W8 050 605.

The method of operation is based on the principle of the pendulum, which senses uneven movements exactly.

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When the speed is uniform, the pendulum is always vertical and the reading indicated on the scale (Fig. 2) is zero. When accelerating, the dial moves clockwise and when decelerating it moves anticlockwise.

Preparations for measurement Moisten the underside of the rubber base of the measuring instrument (preferably with glycerine) and then mount the dynometer with the lever (Fig. 1) (1)) on a horizontal support.

The sight glass must face the driver’s position and it must be mounted exactly in the direction of travel.

Before each measurement of braking deceleration, the measuring capsule (Fig. 1 (2)) must be tilted so the dial is pointing to zero. By tilting the measuring capsule, the correct “zero” position is achieved if the dial can make nearly a full anticlockwise rotation and half a clockwise rotation.

The maximum indicator (Fig. 2 (3)) must be turned clockwise with the knurled knob (Fig. 2 (4)) by hand until approximately the zero position is reached.

During the braking procedure, the maximum indicator moves along with the dial (Fig. 2 (5)) as far as the maximum value and then stays there (Fig. 3).

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Sheet no.

C9

Assembly C

Brake

Measurement of brake deceleration Continued

Evaluation 1. Determine the maximum truck speed (V = distance/time)

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2. Accelerate the truck in the direction of the forks (reverse) to vmax.

3. Brake the truck with maximum force and read the brake deceleration value “F” in per cent on the dynometer (maximum indicator reading).

4. The following values are required : Example v = 10 km/h With Rated Load

Without Rated Load

F = 1.86 x v

F = 1.86 x 1.6 x v

F = 1.86 x 10 km/h

F = 1.86 x 1.6 x 10 km/h

F = 18 %

F = 29.76 %

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Sheet no.

C 10

Assembly E

Lifting device

Contents

Sheet no.

Initial lift, general, and adjustment of lowered height ............................................ E2 Removal of the initial lift cylinder ........................................................................... E 3 Mast, general ......................................................................................................... E 4 Mast, general/continued......................................................................................... E 5 Removal of the telescopic mast............................................................................. E 6 Removal of the telescopic mast lift cylinder........................................................... E 7 Support rollers - outer upright................................................................................ E 8 Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Fork carriage, general............................................................................................ E 9 Chains, general...................................................................................................... E 10 Adjustment of the control chains ........................................................................... E 11 Adjustment of the supplementary free lift chains................................................... E 12 Chain inspection and servicing.............................................................................. E 13 Hydraulic hoses, general ....................................................................................... E 14

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Sheet no.

E1

Assembly E

Lifting device

Initial lift

General The wheel legs can be raised with the initial lift feature so that poor or uneven floors and ramp joints can be negotiated.

The lifting movement is carried out with the initial lift cylinder - bell crank - pressure rod - load wheel clevises.

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Adjustment of lowered height 1. Raise the initial lift cylinder (1).

2. Slacken the locknut (2) and screw the two socket head screws (3) upward.

3. Lower the initial lift.

4. Measure the lowered height (fork top to floor, 85 mm).

5. Adjust the two socket head screws (3) until the lowered height is reached.

6. Tighten the locknut (2).

Note :

After the adjustment, the forks must have the same height (check with a water level).

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Sheet no.

E2

Assembly E

Lifting device

Removal of the initial lift cylinder

1. Drive out the roll pin (1).

2. Operate the initial lift and extend fully.

3. Remove the cover (2).

4. Remove the hydraulic fitting (3).

5. Pull out the initial lift cylinder (4) upward.

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Installation is in the reverse order of removal.

After installation, raise the initial lift cylinder fully and bleed it of any air.

To bleed the cylinder, operate the pump and open the bleed screw (5) until hydraulic oil free of air bubbles emerges.

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Sheet no.

E3

Assembly E

Lifting device

Mast

General

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There are various types of masts, which are differentiated as follows : The mast types listed below are so-called freeview masts.

Fig. 1 :

Telescopic mast without supplementary free lift with 2 external lift cylinders.

Fig. 2 :

Duplex mast with supplementary free lift, 2 external lift cylinders and 1 internal supplementary free left cylinder.

The triplex mast (not shown) is similar to the mast version in Fig. 2, but it has 3 uprights.

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Sheet no.

E4

Assembly E

Lifting device

Continued

Mast, general

Telescopic mast without supplementary free lift

Operation of telescopic and triplex mast with supplementary free lift The telescopic mast consists of two mast sections : the outer and inner upright.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

The telescopic cylinder (6) is supported on the outer upright (1) and it lifts the inner upright (2).

This causes the lift chain (8) to pull the fork carriage up at twice the speed.

If, due to conditions of the building, a smaller truck height is required but nevertheless with a large lift height, the triplex mast with supplementary free lift is recommended.

Triplex mast without supplementary free lift

The triplex mast has 3 mast sections + telescopic cylinders. The cylinders (6) are located between the outer upright (1) and the intermediate upright (2).

If pressure is applied to cylinder (6), the intermediate mast (2) is lifted. The pulley of the control chain (5) is mounted on the intermediate mast. The end of the control chain is attached to the inner upright (3). The end of the lift chain (4) is fastened to the lower end of the intermediate upright (2).

Triplex mast with supplementary free lift

The triplex mast without supplementary free lift (7) carries out two independent movements.

First the lift chain and supplementary free lift cylinder lift the fork carriage as far as the end of the intermediate upright and then the mast is extended.

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Sheet no.

E5

Assembly E

Lifting device

Removal of the telescopic mast (with fork carriage)

Id. No. depends on truck version 1. Disconnect the battery plug.

2. Secure the truck against rolling.

3. Disconnect the hydraulic fittings.

4. Attach the inner upright (1) to a suitable hoist with the approved lifting means (A).

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5. Lift the inner mast approx. 1000 mm with the hoist.

6. Secure the inner mast against inadvertent lowering with blocks (see example with wooden supports (2)).

7. Remove the hexagonal screws (3), noting how many washers (4) are fitted on each side.

8. Lower the inner mast.

9. Now attach the lifting sling to both mast sections (inner upright (B) and outer upright (5)) and lift lightly until the slings are taut.

10. Also attach the fork carriage (fork tips) to the hoist in order to prevent the mast from tipping forward due to the shift in weight.

11. Slowly lift the mast out of the chassis with the hoist.

Installation Installation is in the reverse order of removal.

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Sheet no.

E6

Assembly E

Lifting device

Removal of the mast (telescopic mast) 1. Secure the truck against rolling.

2. Raise the mast approx. 100 mm.

3. Disconnect the battery plug.

4. Secure the inner mast against inadvertent lowering with a wooden block (see example (4)).

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5. Remove the circlip and washer (1).

6. Using a suitable tool, slide the piston rod back into the cylinder through the top end while operating the directionnal control valve block (lowering).

7. Loosen the fitting at the bottom of the cylinder (2).

Note :

On high masts the cylinder must be secured against tipping over with a hoist.

8. Remove the cylinder clamp (3).

9. Now the cylinder can be lifted up and removed.

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Sheet no.

E7

Assembly E

Lifting device

Outer mas support rollers Id. No. depends on the dimensions (seeparts list) The support rollers (1) and (2) guide the mast vertically.

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Except for a thin film of grease on the mast surface (corrosion protection), the support rollers do not require any servicing.

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Sheet no.

E8

Assembly E

Lifting device

Fork carriage

General The fork carriage runs in the inner mast.

Either 4 guide rollers or 6 guide rollers are installed, depending on the truck type.

The guide rollers can not be adjusted and they should be covered with a light film of grease (corrosion protection).

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

The following fork carriages are available : Fig. 1 :

Fork carriage with 4 guide rollers (1) is installed in Te/Do/Tr/EGV-S 13.

Fig. 2 :

Fork carriage with 6 guide rollers (2) is installed in Te/Do/Tr/EGV-S 16.

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Sheet no.

E9

Assembly E

Lifting device

Chains, general Id. No. refer to table in parts list Chains stretch in the course of time. If the lift chain stretches beyond a specified amount, it should be renewed. In order to keep the wear to a minimum, perform the following services every 3 months : 1. Regular cleaning with compressed air (in special cases with a steam cleaner without detergent additive) and subsequently spray the chain with chain spray.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

2. Check the chains for correct adjustment (tension).

3. Avoid a one-sided load on the chain due to incorrect chain tension or faulty mechanics.

The control chains are tensioned with the two chain tensioners (1).

For chain adjustment refer to E16.

The chain tensioner (2) for the supplementary free lift is located directly behind the supplementary free lift cylinder.

For the adjustment refer to E17.

Two types of chains are available : - 3/4” chains (19.05 mm) - control chains - 1” chains (25.4 mm) - supplementary free lift chains

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Sheet no.

E 10

Assembly E

Lifting device

Adjustment of the control chains (telescopic mast - free view version) Note :

If the truck is euipped with initial lift, it must be adjusted first (refer to E3).

1. Tighten the chains slightly with the chain tensioner (1).

2. Slowly raise the mast to the maximum lifting height.

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3. Retension the chains until screw (2) is at least 2 mm from the end stop (3).

4. If the gap of 2 mm is ensured, the rollers (4) must not project more than 40 % of their diameter (Ø ca. 76 mm) over the inner mast (3) when the fork carriage is raised. If necessary, modify the adjustment of the chain.

5. Check the lowered height (max. 86 mm).

The lowered height of the fork is measured from the ground to the top edge of the fork.

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Sheet no.

E 11

Assembly E

Lifting device

Adjustment of the supplementary free lift chain (Do. 1250 kg, 1600 kg) Adjust the chain tensioner (1) until a clearance of 85 mm is ensured.

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If the chain adjustment is correct, the distance from the top of the forks to the ground must be 85 mm (2).

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Sheet no.

E 12

Assembly E

Lifting device

Chain inspection and servicing

Inspection of the Flyer chains

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Ckeck the load and control chains when installed with at least 10 % the rated load.

The chain stretch should not be over 3 % (3 % equal approximately a single link with a measuring length of 33 chain links and 34 chain pins).

The measurement in made in the working area of the chain.

The admissible wear of 3 % equals half a double link with a chain length of 17 double links.

3/4” Chain new : If chain length = 648 mm (34 chain links) Chain worn : If chain length = 648 mm, only

35 chain pins can be fitted 34 chain pins can be fitted

1”

35 chain pins can be fitted 34 chain pins can be fitted

Chain new : If chain length = 864 mm (34 chain links) Chain worn : If chain length = 864 mm, only

Chain servicing Check all chain locks, chain anchors and chain tensioning screws for tightness.

In order to ensure the correct operation of the chains, they must be lubricated regularly with chain spray.

Note :

Before lubricating the chain with chain spray, first clean it with a spray cleaner or a similar cleaner.

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Sheet no.

E 13

Assembly E

Lifting device

Hydraulic hoses

General Hoses and hose lines are subject to natural aging even if they are stored properly and not overstressed. This limits their storage time and period of use (refer to accident prevention regulation ZH1/74).

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

In order to prevent a premature deterioration of the quality during storage, pay attention to the following points : - Store hoses tension-free and lying down.

- Store at a temperature of +15°C to +25°C. - Relative humidity 65 %.

- Storage in a low dust environment.

- Avoid direct exposure to sun or UV radiation.

- Do not expose to heat.

When in use, the hoses must be checked at least once a year for aging, cracks and damage and replaced, if necessary.

When replacing faulty hoses, pay attention to the following points : - Do not hinder their natural position and movement.

- During operation they must not exposed to stresses caused by pull, torsion or compression due to external influences.

- Do not paint hoses.

- Do not select a small bending radius.

Do not re-install used hoses.

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Sheet no.

E 14

Assembly F

Cylinders

Contents

Sheet no.

Removal of initial lift cylinder ................................................................................. F 2 Removal of lift cylinder........................................................................................... F 3 Hose safety valve................................................................................................... F 4

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Hose safety valve/continued .................................................................................. F 5

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Sheet no.

F1

Assembly F

Cylinders

Removal of initial lift cylinder

Note :

Removal of initial lift cylinder (refer to E3).

1. Pull the piston rod out until the retaining ring (1) is at the same level as the fitting (2).

2. Lever the retaining ring through the fitting into the groove (3).

3. Pull out the piston rod.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Note :

During assembly, the retaining ring must be seated tightly in the groove (3).

If this point is not observed, the retaining ring (1) will snap into the groove of the sealing ring (4) so that the piston rod can be neither installed nor removed.

Bend the retaining ring, if necessary, so that it makes close contact.

Id. No. W8 415 508 : sealing ring (4) Id. No. W8 415 509 : rod packing (5)

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Sheet no.

F2

Assembly F

Cylinders

Removal on lift cylinder

Removal 1. Remove the union groove (1) with hook wrench.

2. Pull out the piston rod (2).

3. In case of leaks, replace the entire seal kit.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Note :

a) There is a safety valve installed at the bottom of the lift cylinder. Refer to sheet no. F11 for more details. b) After the installation of the cylinder, open the bleeder screw (3) at the first slow extension of the mast so that the air can be eliminated.

Tighten the screw again as soon as hydraulic oil free of air bubbles emerges.

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Sheet no.

F3

Assembly F

Cylinders

Safety valve Type LB-3C...

Id. No. 8 410 942 (EGV Te 1250/1600 kg)

General The safety valve prevents an uncontrolled, accelerated movement of a hydraulic load (fall) when the hydraulic counterpressure is removed in the event of the hoses or pipes carrying the pressure breaking.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

It is screwed directly to or into the port of the hydraulic load to be protected.

Type LB is a plate valve whose valve screw is lifted from the valve seat by a spring when unoperated and which keeps a variable cross section of flow open.

Flow resistance and braking pressure at the valve screw in direction of flow B > F (operating or triggering direction) are normally less than the force of the spring and the valve remains open.

If, in the case of a breakage, the flow rate increases due to the driving load, the flow pressure exceeds the force of the spring and the valve closes at once.

The load is slowly lowered to ground height through the restrictor opening (1), which is 1 mm on the standard truck with Te 1250/1600 kg.

Symbol simplified

detailled

After the lift cylinder is lowered, the pressure on the B side of the safety valve decreases and the valve opens due to the force of the spring.

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Sheet no.

F4

Assembly F

Cylinders

Continued

Safety valve Type LB-3C...

Note :

The size of gap S determines the response point of the valve.

The gap is preset by the manufacturer and it must not be changed under any circumstances.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

The size of the gap is only specified for the purpose of verifying that the proper safety valve is installed.

The size of the gap for the standard mast EGV TE 1250/1600 kg is 1.55 mm.

The safety valves are installed in both lift cylinders at the bottom of the cylinders.

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Sheet no.

F5

Assembly K

Swivel rollers

Contents

Sheet No.

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Replacement of stabiliser wheel ............................................................................ K 2

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Sheet no.

K1

Assembly K

Swivel rollers

Stabiliser Id. No. 8 097 144 assembly Id. No. W8 097 158 stabiliser assembly

Replacement of stabiliser wheel Original dimensions : 150 x 175 Replacing the stabiliser wheels becomes necessary if : - the running surface is baldy spalled or uneven,

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

- the tyre diameter is reduced by 10 % (minimum tyre diameter : 135 mm).

Procedure 1. Disconnect the battery plug.

2. Perform work step 3 on sheet no. A4.

3. Remove the nut (1) and spring washer (2).

4. Drive out the axle (3) in the arrowed direction (4).

5. Take out the stabiliser wheel (5) downwards.

Installation is in the reverse order of removal.

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Sheet no.

K2

Assembly M

Electrical system

Contents

Sheet No.

Highpuls Control, general ...................................................................................... M 2 Overview of travel control assembly ...................................................................... M 3 Primary current circuit - terminals.......................................................................... M 4 Input and output signals......................................................................................... M 5 Travel stage logic ................................................................................................... M 6 Output signals ........................................................................................................ M 7 Safety monitor ........................................................................................................ M 8 Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Error display ........................................................................................................... M 9 Error flash code ..................................................................................................... M 10 Adjustment of Highpuls Control ............................................................................. M 11 General specifications............................................................................................ M 12 Combined controller, general ................................................................................. M 13 Pin assignment ...................................................................................................... M 14 Adjustment of the discharge end voltage .............................................................. M 15 Technical data ........................................................................................................ M 16 Battery handling and maintenance ........................................................................ M 17 Maintenance intervals/daily/weekly services ......................................................... M 18 Acid density measurement .................................................................................... M 19 Damage and accident prevention .......................................................................... M 20 Commissioning unfilled with charged plates.......................................................... M 21 Battery changeover................................................................................................ M 22 Measuring the insulation resistance of the truck and battery ................................ M 23 Truck measuring procedure ................................................................................... M 24 Wiring diagram....................................................................................................... M 30

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Sheet no.

M1

Assembly M

Electrical system

Highpuls Control

General The pulse control “Highpuls” (1) is a tested microprocessor-based control using power MOSFET technology.

The microprocessor has direct control over the travel switch input signal for all signal processing through to the current limiting integrator.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

To permit adjustment of the speed and output of the travel motor from 0 to 100 % triggering of the transistors is altered in a cyclical ratio.

Travel direction contactors are controlled completely by driver outputs in order to ensure sparkless switching.

The Highpuls Control is fitted with an internal and external safety monitor which brings the system to a standstill if an error occurs (see sheet no. M8).

Error diagnosis is easy with an LED mounted in the control section (see sheet no. M10).

Adjustments (see sheet no. M11) on the Highpuls Control can be carried out using the 5 potentiometers (depending on the software) for - maximum current of travel motor (Main) - reversing current (Plug) - ramp-up time (Accel) - creep speed (1 st travel stage) (Creep) - slow speed (speed reduction) (Low)

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Sheet no.

M2

Assembly M

Electrical system

Highpuls Control Overview of travel control assembly Item

Designation

Id. No.

1

Control section

W8 367 401

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Note :

If a control section (1) is removed and re-installed, use a heat transfer compound (Id. No. W8 405 113) between the heat sink and the circuit board.

2

2 Reversing contactors forward/reverse

W8 400 604

3

Pump contactor

W8 402 864

4

Travel fuse 100 A

W8 401 064

5

Lift main current fuse 200 A W8 401 066

6

Control current fuse 7.5 A W8 401 894

7

Control current fuse 15 A

W8 401 896

8

Steering controller

W8 405 341

9

Steering relay

W8 020 466

10

Safety guard relay

W8 014 372

11

Discharge indicator diode

W8 009 597

12

False protection diode for Highpuls Control

W8 009 597

13

Free wheel diode for safety guard relay

W8 355 359

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Sheet no.

M3

Assembly M

Electrical system

Highpuls Control

Primary current circuit - terminals The B+ terminal (1) is connected to the battery plus pole and the positive terminal of the field.

Internally, it is connected to the cathodes of the freewheel diodes and the capacitors.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

The B- terminal (2) is connected to the battery minus pole.

Internally, it is connected to the source of the power MOSFET and the capacitors.

The A2 terminal (3) is joined to the connection between armature and motor field.

Internally, it is connected to the cathodes of the armature diodes.

The M- terminal (4) is connected to the armature.

Internally it is connected to the drain of the power MOSFET, the anodes of the armature diodes and the anodes of the freewheel diodes.

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Sheet no.

M4

Assembly M

Electrical system

Highpuls Control Input and output signals The input and output signals are transferred over a 16-pin plug X30 plugged directly into the housing of the control section (1).

Inputs Pin 16 : Voltage supply of +24V via key switch causing control initialization and start of an internal monitoring circuit. When the control is switched on, the switch-on sequence must be observed : key switch --> travel switch.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Pin 15 : Brake switch input +24V. Pin 14 : Slow/fast travel stage +24V, software change required +24 V at Pin 14 = Fast travel stage 0 V at Pin 14 = Slow travel stage In the EGV-S, this pin is not assigned, therefore the parameter for the slow travel stage is set to 100 % (= Vmax) Pin 13 : Belly switch input +24V As long as this input is active, the control of the travel drive current is reduced to 60 % output and the travel direction is changed.

Pin 12 : Travel direction input (forward) Pin 11 : Travel direction input +24V (reverse) The power stage of the control is enabled through inputs 12 and 11.

Pin 8 :

Inputs of travel switch Neutral Travel stage 1 Travel stage 2 Travel stage 3 Travel stage 4

Pin 7 :

Voltage supply minus for travel switch.

Pin 6 :

Setpoint input for potentiometers (option).

Pin 5 :

Voltage supply plus for potentiometer (option).

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Measured against Pin 16 20 V 20 V 21.7 V 22.6 V 24.0 V

Workshop Manual

Measured against Pin 7 4.5 V (5.6 K ) see 4.5 V (5.6 K ) travel 2.8 V (2.5 K ) logic on 1.6 V (1.3 K ) sheet no.

0 V (0 K ) M6

EGV-S

Sheet no.

M5

Assembly M

Electrical system

Highpuls control

Travel stage logic

Tiller head board circuit

Travel stage 1 Via resistor R17 (5.6 K ).

Rtotal = approx. 5.6 K Travel stage 2

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Resistor R17 (5.6 K ) is connected in parallel to resistor R15 (4.2 K ).

Rtotal = approx. 2.5 K Travel stage 3 Resistors R15 (4.2 K ) and R17 (5.6 K ) are connected in parallel to resistor R16 (2.7 K ).

Rtotal = approx. 1.3 K Travel stage 4 The resistors are jumped.

Rtotal = approx. 0 K

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Sheet no.

M6

Assembly M

Electrical system

Highpuls control

Outputs Pin 10 : Monitoring output for belly switch.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

If this option is selected, a pulse is generated after switching on the control, which is received by the belly switch input Pin 13. A check is carried out for cable broken between the belly switch and the control.

Pin 9 :

Not assigned.

Pin 4 :

Switched minus for main contactor (option).

Pin 3 :

Switched minus for forward travel direction contactor.

Pin 2 :

Switched minus for reverse travel direction contactor.

Pin 1 :

Switched minus for the shunt field when the travel switch is actuated.

Note :

For the reduction of induction voltage at the travel direction contactor coils, there are two free wheel diodes integrated into the control section.

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Sheet no.

M7

Assembly M

Electrical system

Highpuls Control

Safety monitor The Highpuls Control is fitted with an internal monitoring circuit and a safety monitor for external components.

Note :

When the safety cut-out is triggered, the belly switch has priority with some errors.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

The monitoring includes : - Monitoring of potentiometers for broken cables or short circuits and inadmissible values.

- Switch-on sequence check (see M5 / Pin 16).

- Short-circuit monitoring and overvoltage recognition at switching outputs (travel direction contactor).

- Monitoring for fused contactor tips (travel direction contactor only).

- Monitoring for failed switching outputs (travel direction contactor only).

- Monitoring for broken travel direction contactor cables - Overtemperature monitoring • Current reduction from lmax at 85°C to l0 at 95°C - Undertemperature monitoring • Current reduction to 50% below -25°C. - Undervoltage (16 V) • Reduction of travel current until no further drop below undervoltage limit (control switches off below 16 V).

- Monitoring for broken belly switch cables.

- Short-circuit monitoring B- to M- (MOSFET) - Overvoltage (45 V) (control switches off) - Short-circuit monitoring of travel motor Any existing errors are displayed by a flashing code (see M10).

All errors are stored in an EEPROM. Errors can generally be removed with the key switch once the error situation no longer exists.

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Sheet no.

M8

Assembly M

Electrical system

Highpuls Control

Error display If an error is detected, an LED (1) indicates the type of error with a flashing code. The LED is located under a cover (2) which can be moved forward away from the control section housing.

It locks in the end position.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

The code is displayed by the flashing LED until the error is removed by switching the control off and on again (in some cases the brake switch is sufficient), provided the error is eliminated.

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Sheet no.

M9

Assembly M

Electrical system

Highpuls Control Example of flashing code :

Error flashing code The following diagnostic information is generated by the control. The diagnostic LED in the control section housing indicates the diagnostic code by flashing.

Evaluate the flashing code with the following table.

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DEL Continuous ON or OFF 1.0 1.2 1.3

1.4

Short pause

Explanation

Long pause

Possible causes

Faulty control Control ready Hardware error M-output short circuit MOSFET short circuit

1. Faulty control 1. M-short circuit to ground 2. Tr. direction contactor not connected 3. Tr. direction contactor not responded fast enough 4. Short circuit travel motor 1. Direction switch cable broken

2.1

Direction switch Input wiring error 5 K - 0 travel sensor error

2.2

**Belly switch error

2.3

3.1

*Switch-on sequence error Key switch travel switch Drive sensor minus - cable broken at Pin 7 or pin 8 (see wiring diagram) Contactor driver overcurrent

3.2

Travel direction cont. error

3.4 4.1

Travel direction cont. error Shunt field error Battery voltage too low

4.2

Overvoltage

1. Minus cable - cable broken 2. Minus cable - short circuit after B+ or B1. Travel dir. contactor coil - short circuit 2. Motor shunt field - short circuit 1. Travel direction contactor - tips are fused or loose 1. Travel direction contactor not made 2. Shunt field driver output open 1. Battery voltage under 16 V 2. Corroded battery terminals 3. Battery terminals loose 1. Battery voltage over 45 V

4.3

Over- / undertemperature

1. Temperature > +85°C or < -25°C

2.4

1. Travel sensor - cable broken 2. Travel sensor short circuit to B+ 1. Belly switch - cable broken 2. Monit. output - cable broken 1. Wrong switch-on sequence

Note : The last recognized error is deplayed in each case. In the belly switch function, the LED is always off. * Startup protection (switch-on sequence see sheet no. M5/Pin 16). ** In case of a belly switch error, the truck drives at reduced speed in both directions.

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Sheet no.

M 10

Assembly M

Electrical system

Highpuls Control

Adjustment of the Highpuls Control 1207 - 1103 The Highpuls Control is supplied with permanently programmed settings. For this reason, the 5 installed potentiometers (1) are in the “off” position = i.e. not operational. It is still possible to influence settings with some of the potentiometers.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Non-adjustable potentiometers (obligatory “OFF” position) : Main = Max. current, drive motor (set to 200 A by parameters) Plug

= Reversing current (set to 140 A by parameters)

Adjustable potentiometers (Position “0” - “4” possible). If these potentiometers are set to the range 0 to 4 instead of “OFF”, the value set with the potentiometers is used instead of the parameter value.

Accel = Ramp-up time 100 ms to 3 s Creep = Creep speed (for first travel stage only) 0 % to 25 % Low

= Slow travel 40 % to 100 % This potentiometer allows the maximum speed to be reduced.

Note :

As in EGV-S trucks the wiring is such that the “slow travel” function is always selected, the potentiometer must be in the “OFF” position, otherwise the maximum travel speed will be reduced.

Current limit

Speed limit

Turning the potentiometers back to the “OFF” position restores the stored parameter values.

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Sheet no.

M 11

Assembly M

Electrical system

Highpuls Control General specification

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Electrical specifications Voltage range :

24 V - 36 V

Undervoltage limit :

16 V

Overvoltage limit :

45 V

Electrical insulation of the housing :

500 V

Output current :

250 A 200 A 150 A 100 A

Switching frequency :

15 KHz

Switching outputs :

Maximum coil current 2 A

Ambient temperature :

-25°C to +50°C

for 1 mn for 2 mn for 5 mn for 1 hr

Mechanical specifications Dimensions :

165 x 122 x 60 (l x w x h) in mm

Weight :

1.1 kg

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Sheet no.

M 12

Assembly M

Electrical system

Curtis Combi-Controller Id. No. 8 402 709

General The Curtis Combi-Controller 803 operates according to the principle of a continuous comparison of the battery voltage with an internally determined series of reference voltages.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

This 36-step reference voltage corresponds to the progression of the selected discharge voltage.

If the mean value of the battery voltage drops below the selected reference value within a period of 46 seconds, the Combi-Controller 803 automatically compares it with the next lowest reference voltage.

This process is repeated from one voltage step to the next.

As number of voltage steps diminishes, the LED display (1) jumps from right to left. When it reaches the cut-out threshold (final discharge voltage), the two left-hand LEDs flash (red).

On the back of the device, it is possible to set the discharge characteristic line to the existing application (see sheet no. M42).

The battery discharge status is stored with a lithium battery (service life 10 years). The counter reading is stored in an EEPROM.

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Sheet no.

M 13

Assembly M

Electrical system

Curtis Combi-Controller 803

Pin assignment Operating voltage Pin 7 = B+ (24 V) Pin 8 = BCut-out function Pin 3/4 Cut-out on reaching the final discharge voltage, at 20 % residual battery capacity.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Battery voltage B+

Note :

Lower battery voltage in case of double voltage Key switch

The cut-out is made with a thyristor.

Cut-out

Therefore pay particular attention to correct polarity when connecting the controller! (For positive/negative logic, see the diagram on the right).

Positive start input Hour meter Negative start input Battery voltage B-

If the polarity is incorrect, the Curtis CombiController 803 and the switching contact Connection for positive Connection for negative can be destroyed. logic : logic : Key switch Pin 2

Switches on the LED display

Hour meter Pin 6 Pin 1

Start by applying from B+ to (6) or from B- to (1)

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Sheet no.

M 14

Assembly M

Electrical system

Curtis Combi-Controller 803

Setting the final discharge voltage The final discharge voltage (volts/cell) can be set at the potentiometer (1).

Use the setting recommended by the battery manufacturer (see table below).

Reset to “full”

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Gassing voltage from 2.35 V/C for at least 6 minutes

K L M N O P Q R S T U

or Connection of a battery with an idle voltage of at least 2.09 V/C.

(“S” set here)

1.57 1.63 1.68 1.73 1.78 1.82 1.84 1.86 1.89 1.91 1.93

Manufacturer’s recommended setting for standard loads Setting of final discharge in V/C

Battery type and manufacturer voltage Lead-acid wet batteries PzS

1.73

Lead-acid wet batteries, enhanced capacity CMS

1.78

Hagen PWF, CWF, PzV

1.82

Sonnenschein dryfit

1.93

Varta Carat (Gel) battery

1.93

Deta Dryflex

1.91

Gel batteries, general

1.93

Note :

In special cases involving high loads (high current consumption within a short period), the cut-out can occur too early. In these cases, ask the battery manufacturer.

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Sheet no.

M 15

Assembly M

Electrical system

Curtis Combi-Controller 803

Specifications Battery discharge display :

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

- 10 LEDs ; 5 green, 3 yellow, 2 red - Lithium storage battery - Reset on reaching gassing voltage of 2.35 V/C or idle voltage of 2.09 V/C - Cut-out by self-holding NC contact - Adjustable discharge characteristic - Optical warning display at 25 % residual capacity - Switching current 3 A

Type plate

Hour meter : - LC display, 6 digits - Resolution 0.1 h - Flashing symbol display - Memory independent of power supply through EEPROM Basic specifications : - Operating voltage 24 V and 48 V - Tolerance ± 25 % of rated voltage - Operating temperature -40°C to +85°C - Compact plug with locking function - Precision (max. discrepancy 2 %) - Protection class (IP65 front)

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Sheet no.

M 16

Assembly M

Electrical system

Battery

PzS Battery (standard lead battery) Handling and maintenance - The most favourable operating temperature is from 25°C to 40°C. To avoid permanent damage to the battery, the maximum permissible electrolyte temperature of 55°C should never be exceeded.

- For heavy duty and when used at winter temperatures, the battery should be charged daily ; even if less than 80°C of the standard capacity has been used.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

- Always remove or open the tray lid or battery cover before charging and for intermediate charging.

- When charging the battery, a temperature increase of 10°-12° may be expected. With heavily used batteries, the electrolyte temperature may increase to over 55°C. If this occurs, leave the battery to cool and interrupt the charging process.

- The cell plugs may remain in place during charging.

- Do not close the tray lid or battery cover until 1/2 hour after charging is completed.

- Always connect the charger correctly poled, otherwise destruction of the battery and the charger may result (+ to +).

- Only charge with direct current.

- To avoid creep currents, always keep batteries dry and clean (Neutralospray).

- Poles and connectors should always be sprayed with pole spray in order to avoid oxidization and sulphate formation.

- Unsuitable lifting gear may damage the battery (twisting of the tray and damage to the insulation).

- Protect the battery from contamination, e.g. metal dust, ammonia vapours.

- In case of doubt, call the after-sales service of the battery supplier.

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Sheet no.

M 17

Assembly M

Electrical system

PzS Battery Maintenance intervals Daily maintenance : Charging the battery.

Weekly maintenance : Check the electrolyte level. If necessary : top up distilled water towards the end of the charging process.

It should always be topped up when the electrolyte level has fallen to the level on the baffle.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Monthly maintenance : Check all cells towards the end of the charging process for even gassing. Measure acid density and temperature after completion of charging and register any deviations from the desired values.

Quarterly maintenance : After termination of charging, measure the electrolyte temperature of all the cells. If one of the cells registers a substantial difference to its neighbours, check it separately.

Measure the insulation resistance (see sheet no. M70) of the battery with a separate external circuit in accordance with VDE. 100 Ohm per V of rated voltage is the lowest limit ; however, 1000 Ohm should not be exceeded. If the insulation resistance is lower, clean the cells and containers.

Half-yearly maintenance work : Check the function of the charger, particularly the level of the charging current at the beginning of strong gassing (2.4 V/cell).

Check the plugs and connectors for proper function.

Note :

Beyond these basic instructions, always observe the instructions of the battery manufacturer.

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Sheet no.

M 18

Assembly M

Electrical system

PzS Battery Acid density measurement The acid density is an indication of the charge condition of a battery, provided the acid is well mixed. However, the acid density only increases towards the end of the charging process.This is due to the gassing, which starts at approx. 2.4 V/cell.

The acid density is measured with an hydrometer (acid syphon) (1).

Acid syphon

1 Hydrometer

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

During measurement, the float switch must not touch the side or top. The correct value for acid density is obtained by measuring around 1/2 hour before the end of charging.

To ensure a correct reading, avoid measuring immediately after topping up with water, as the water and acid must be mixed.

The temperature of the battery should not deviate much from 30°C. Adic density with fully charged battery = 1.27 kg/l Acid density with discharged battery = 1.13 kg/l

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Sheet no.

M 19

Assembly M

Electrical system

PzS Battery Avoiding damage and accidents Working with batteries is not without its dangers.

However, these can be avoided by following the procedures below :

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

a) Hazard : Charging gases can bring about deflagration or explosions.

Avoidance : Ensure good ventilation, avoid electric sparks or naked flames in battery rooms, no smoking. b) Hazard : Acid can cause injuries and corrosive damage to parts.

Avoidance : Wear protective acid-proof clothing and rubber gloves as well as protective goggles, keep neutralization agent at close hand.

Keep water for rinsing eyes ready (in case of accident, call a doctor immediately). c) Hazard : Voltages above 40 V can be dangerous to health.

Avoidance : Do not touch any live parts, instruct the staff accordingly. Observe VDE 0100 and VDE 0105. d) Hazard : Lead and lead compounds are dangerous to health if absorbed by the human body.

Avoidance : Eating and drinking is not permitted in the battery charging station, always wash your hands after handling batteries. e) Hazard : Batteries can cause damage if tipped over or when falling out of the lifting gear.

Avoidance : Only use suitable, safe lifting equipment.

During transportation, provide the necessary safeguards against tipping over or slipping off the loading surface of the transport vehicle.

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Sheet no.

M 20

Assembly M

Electrical system

PzS Battery Commissioning unfilled with charged plates After removing the stopper plugs, fill all cells evenly with sulphuric acid at a density of 1.25 kg/l up to the lowest acid level marking (use a cell filler or plastic funnel).

The filled acid must have a temperature of hours, top up with more acid, if necessary.

+15°C. After a standing period of 5 to 6

The temperature rise must be measured with a thermometer dipped into the electrolyte in one of the cells in the middles of the battery. If the temperature rise is lower than 10°C, the battery can be connected to the charger for recharging.

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Recharging until automatic cut-out by the control switch of the charger takes between 6 and 12 hours. For l-h charging (without automatic cut-out), a longer charging time (up to 20 hours) is required.

The temperature must be monitored during charging. It must not exceed 55°C, otherwise charging must be interrupted to permit the battery to cool down.

When the charging is completed, the acid density should be 1.27 kg/l ± 0.01 kg/l. If this is not the case, continue charging until the density of 1.27 kg/l is reached.

The battery is now ready for operation. If required, top up electrolyte with distilled water to the specified level. If the acid density is too high, draw off acid and replace with distilled water.

Note :

If the electrolyte temperature rises by more than 10°C after filling, or if the density of the filled acid has dropped by more than 0.03 kg/l, the plate material has lost some of its charge as a result of previous storage. In this case, a longer commissioning period is necessary. Beyond these instructions, also observe the instructions of the battery manufacturer!

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Sheet no.

M 21

Assembly M

Electrical system

Battery change

Removal The battery can be removed and installed in two different ways.

The battery can be lifted out with a crane (1) and a suitable lifting sling. Or it can be removed laterally with the optional battery trolley (2). The battery can be pulled out easily as it is rollermounted.

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Note :

When lifting out the battery, be sure that the hoist (crane) and the lifting sling have the specified lifting capacity and that they do not get hooked in the mast.

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Sheet no.

M 22

Assembly M

Electrical system

Measuring the insulation resistance of the truck and battery The insulation resistance of industrial trucks must be at least 1 k per volt of battery voltage.

For 24 V trucks, this means : 24 K

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The insulation resistance of industrial truck batteries must be at least 1 k . The measurement voltage must be greater than the battery voltage and less than 500 V. The battery remains in the truck during the measurement. However, the truck and the battery must be measured separately.

The following tools are required for the measurement : - Wagner Component Tester (WCT) - Multimeter

Measuring procedure for battery 1. Pull out the battery socket.

2. Connect the WCT meter output socket to the voltage terminals of the multimeter.

Set the multimeter to the 200 V range.

3. Connect the anode or cathode socket of the WCT to a blank part of the chassis, and the other to the plus pole of the battery socket (Fig. 1).

4. Set the WCT to “Insulation Test”.

5. Press key 2 for 200 V high voltage, 1 mA. The voltage indicated on the meter must not be lower than 10 V. 6. Repeat points 3 and 4, but now with the minus pole of the battery socket (Fig. 2).

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Sheet no.

M 23

Assembly M

Electrical system

Measuring procedure for the truck 1. Pull out the battery socket.

2. Mechanically activate travel contactor and pump contactor.

direction

3. Release connecting cable M- (3) from the Highpuls Control and connect it to terminal B- on the Wagner Highpuls Control.

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4. Disconnect plug X1 from the pulse control and bridge pin 1 to terminal B- at the Highpuls Control.

5. Connect the meter output of the WCT to the voltage terminals of the multimeter. Set the multimeter to the 200 V range.

6. Connect the anode or cathode socket of the CT to a blank part of the chassis, and the other to the plus pole of the battery appliance socket (Fig. 1).

7. Press key 2 for 200 V high voltage, 1 mA (Fig. 2). The voltage indicated at the meter (UL) must not be lower than 100 V for 24 V trucks.

9. Repeat ponts 3 and 4, but now with the minus pole of the battery socket (Fig. 2).

If the specified voltages are not obtained, the required insulation resistance is too low, i.e. a short has occurred.

This must be localized and eliminated with the appropriate remedial measures.

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Sheet no.

M 24

Wiring diagram EGV-S

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Assembly M

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Sheet no.

M 30

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1M1 1S13 1S14 1S3 1S9 1V6 1V14 1V15 1V16 1Y4 1Z4 2A10 2F1 2K1 2M1 2S1 2Y7 2Y8 2Z1 2Z7 2Z8 3A1 3B1 3F1 3M1 4H1 4S1 4Z2 6F20 6P20 6V1 6V2 6V3 9R3 9R4 9S4

1K12

CODE F2 G1 K13 K14 K15 S1 V10 V11 V12 X2 X8 1A10 1A11 1F1 1K11

DESIGNATION Fusible de commande, 7,5 A Batterie Relais, servodirection (bobine/contact) Relais, porte gauche (bobine/contact) Relais, porte droite (bobine/contact) Contact à clé Diode Diode Diode Borne Borne Circuit imprimé, variateur électronique Circuit imprimé, timon Fusible, moteur de traction, 100 A Contacteur, sens de marche arrière (bobine/contact) Contacteur, sens de marche avant (bobine/contact) Moteur de traction Micro-contact, porte droite Micro-contact, porte gauche Micro-contact du frein Micro-contact de frein, plateforme Diode Diode Diode Diode Electro-frein (bobine/contact) Résistance V.D.R. Circuit imprimé, descente Fusible, moteur de pompe 200 A Contacteur, moteur de pompe (bobine/contact) Moteur de pompe Micro-contact d’élévation Electrovanne d’élévation Electrovanne de descente Diode Diode Diode Circuit imprimé, direction Capteur de direction Fusible de commande direction 15 A Moteur de direction Klaxon Bouton-poussoir, klaxon Diode Fusible, contrôleur de batterie 7,5 A Contrôleur de batterie Diode Diode Diode Résistance de chauffage Résistance de chauffage Chauffage H1 D8 D8 C12 D5 / G8 G4 I8 I9 I12 F12 / D5 F11 B13 A1 I7 / B1 C1 C12 I13 I13 I7 I13 I14 H8 / 11 F10 A3 F10 I14 B14 I14 A3 C3 D2 D2 D2 F8 F8 C / D7

H5 / G2

POSITION A2 B / C1 I12 / G9 I8 / C9 I8 / C8 B2 B2 B1 C12 I2 A1 H1/7 A5/7 A1 H4 / G1

BENENNUNG Sicherung, Steuerstrom 7,5 A Batterie Relais, Lenkung (Spule/Kontakt) Relais, Schwenktüre links (Spule/Kontakt) Relais, Schwenktüre rechts (Spule/Kontakt) Schlüsselschalter Diode Diode Diode Klemme Klemme Leiterplatte, Impulssteuerung Leiterplatte, Deichsel Sicherung, Fahrmotor 100 A Schütz, Fahrtrichtung - Rückwärts (Spule/Kontakt) Schütz, Fahrtrichtung - Vorwärts (Spule/Kontakt) Fahrmotor Schalter, Schwenktüre rechts Schalter, Schwenktüre links Bremsschalter Totmann-Schalter, Plattform Diode Diode Diode Diode Magnetbremse (Spule/Kontakt) Widerstand variabel Leiterplatte, Senken Sicherung, Pumpenmotor 200 A Schütz, Pumpenmotor (Spule/Kontakt) Pumpenmotor Schalter, Heben Magnetventil, Heben Magnetventil, Senken Diode Diode Diode Leiterplatte, Lenksteuerung Lenkgeber Sicherung, Steuerstrom 15 A Lenkmotor Hupe Drucktaster, Hupe Diode Sicherung, Batteriekontrollgerät 7,5 A Batteriekontrollgerät Diode Diode Diode Heizwiderstand Heizwiderstand Heizung

LEGEND TO WIRING DIAGRAM EGV-S

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DESIGNATION Fuse, control current 7.5 A Battery Relais, steering (coil/contact) Relais, L.H. door (coil/contact) Relais, R.H. door (coil/contact) Key switch Diode Diode Diode Terminal Terminal IC-board, pulse control IC-board, tiller Fuse, drive motor, 100 A Contactor, travel direction backwards (coil/contact) Contactor, travel direction forwards (coil/contact) Drive Motor Doorswitch R.H. Doorswitch L.H. Brakeswitch Dead man’s switch, platform Diode Diode Diode Diode Electromagnetic brake (coil/contact) Resisitor variable IC-board lowering Fuse, pump motor 200 A Contactor, pump motor (coil/contact) Pump motor Switch, lifting Lifting solenoid valve Lowering solenoid valve Diode Diode Diode IC-board steering control Steer sensor Fuse, control current 15 A Steer motor Horn Push button, horn Diode Fuse, battery control unit 7.5 A Battery control unit Diode Diode Diode Heater resistor Heater resistor Heater

Assembly M Electrical system

Workshop Manual

EGV-S

Sheet no.

M 31

Assembly N

Hydraulic system

Contents

Sheet No.

Pump unit............................................................................................................... N 2 Block diagram ........................................................................................................ N 3 Replacing the motor brushes................................................................................. N 4 DLS directional control slide valve block ............................................................... N 5 DLS directional control slide valve block, position switch ...................................... N 6 DLS directional control slide valve block, directional control slide valve ............... N 7 DLS directional control slide valve block, adjustment of pressure relief valve ...... N 8 Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Slow lowering valve................................................................................................ N 9 Check the hydraulic oil level .................................................................................. N 10 Pipe union/hose union, general ............................................................................. N 11 Pipe union/hose union assembly ........................................................................... N 12 Pipe union/hose union assembly/continued .......................................................... N 13 Pipe union/hose union reassembly........................................................................ N 14

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Sheet no.

N1

Assembly N

Hydraulic system

Pump unit

The pump unit includes the following components : 1. Directional control slide valve block 2. Hydraulik tank 3. Pump motor 4. Hydraulic pump

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5. Suction filter 6. Air filter / oil dipstick 7. Limit switch

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Sheet no.

N2

Assembly N

Hydraulic system

Block diagram

Main lift cylinder Supplementary lift cylinder

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DLS directional control slide valve block

Initial lift cylinder Hydraulic oil tank

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Workshop Manual

EGV-S

Sheet no.

N3

Assembly N

Hydraulic system

Pump unit

Replacing the motor brushes The motor brushes must be replaced if the residual length is 13 mm. This equals a wear of about 50 %.

Original length of carbon brush : 26 mm The brushes should only be replaced as a complete kit (4 items).

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Removal 1. Disconnect the battery plug.

2. Pull out the 4 covers (1).

3. Lift and hold the brush spring (2).

4. Pull the brush at the connecting lead (3).

5. Release the brush slowly.

6. Disconnect the lead (4).

7. Clean the armature chamber (blow out with air jet).

Attention : Do not inhale carbon dust.

Note :

For further servicing refer to “Travel motor, maintenance”, A11-A14.

The motor brushes must be replaced as a kit.

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Sheet no.

N4

Assembly N

Hydraulic system

DLS directional control slide valve block General

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The DLS directional control slide valve block consists of a connecting block (1), which can be expanded on trucks with initial lift. This expansion block (2) consists of 2 switching valves which are controlled with the pushbuttons in the tiller head.

A pressure relief valve (3) is integrated in the connecting block.

A slow lowering valve (4) is screwed into the main port of the directional control slide valve block.

The operating speeds can be controlled infinitely with the control lever on the directional control slide valve block.

Operating the control lever (5) actuates the position switch (6), which starts the hydraulic pump.

When the control levers are released, they are returned to the home position by a spring (7).

This is also the centre position of the slide valve spools.

When the function initial lift is selected at the tiller head, the valves (2) in the expansion block are actuated and the hydraulic pump starts running (lifting).

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Sheet no.

N5

Assembly N

Hydraulic system

DLS directional control slide valve block Valve switch Id. No. 8 012 417 The position switch is used to start the pump unit via the pump contactor even with minimal movement of the valve control lever.

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With this position switch, the jumpers 11-12 and 23-24 can be used in the switching positions a or b, depending on wether it is required as a break or make switch.

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Sheet no.

N6

Assembly N

Hydraulic system

DLS directional control slide valve block Directional control slide valves The directional control slide valves are designated according to the number of hydraulic ports

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P R H B

= = = =

pressure return line working line working line

and the control position (a, 0, b).

The directional control valve shown in Fig. 1 is called a 4/3-port directional control valve.

4 ports, 3 directions (control positions) = 4/3port directional control valve.

The function of the directional control slide valves is shown schematically with a symbol.

Adjacent square boxes represent different control positions.

Arrows in the square boxes show the connections between the ports.

Broken lines represent blocked ports (1).

Fig. 2 shows the directional control slide valves installed in EGV trucks with initial lift.

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Sheet no.

N7

Assembly N

Hydraulic system

DLS directional control slide valve block Adjustment of maximum pressure valve The setting of the maximum pressure limit is the total operating pressure when lifting the rated load plus 10 %.

1. Pick up the rated load (observe the load capacity plate).

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

2. Connect a pressure gauge to boost pressure port (1).

3. Start the hydraulic system and determine the operating pressure.

Example :

150 bar operating pressure + 10 % (15 bar) 165 bar maximum pressure

(For setting of maximum pressure refer to N24).

4. Loosen the locknut (2, seal-lock) amply so that the vulcanized seal in the thread is not damaged.

5. Lift the load (forks) as far as the end stop.

Attention : Observe the load capacity diagram !

6. Adjust the setting of 165 bar with the setscrew (3) (refer to example).

Turning CW = increases pressure Turning CCW = reduces pressure 7. Tighten the locknut.

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Sheet no.

N8

Assembly N

Hydraulic system

Slow lowering valve Id. No. W8 415 562 Slow lowering valves are 2-port flow control valves for lowering single-acting cylinders with a constant lowering speed largely independent of the size of the load.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Method of operation When the load is lowered, a moving restrictor (1) is brought to the control position by the oil flow and forms an annular restriction in the control plunger (2). The flow resistance of this restriction in connection with the bias of the plunger spring (3) determines the size of the oil flow.

Lifting, flow direction F > B Free, unhindered oil flow with a low resistance, due to the restrictor moving out of the control position (restriction removed).

Lowering, flow direction B > F The oil flow is mostly constant as a result of the self-adjusting balance between the inner pressure difference and the force of the control piston spring.

Note :

The slow lowering valve is screwed onto the DLS directional control slide valve block.

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Sheet no.

N9

Assembly N

Hydraulic system

Check the hydraulic oil level

The hydraulic oil tank is provided with an oil dipstick (1).

The oil level can be determined by screwing the dipstick out.

Two marks (2) the minimum an maximum oil level.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

The oil can be replenished or extracted with pump (Id. No. W8 412 061) through hole (3).

Refer to R for the type of oil and change intervals.

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Sheet no.

N 10

Assembly N

Hydraulic system

Pipe union / hose union

General In order to obtain a sure, constant and leakproof hydraulic connection it is important to follow the following assembly instructions.

Function of the cutting ring union

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

The basic function of the EO cutting ring is the limited penetration of the cutting ring into the pipe, which is achieved by a precisely determined geometry.

Before tightening the union nut

The front cutter (A) has already started to penetrate the pipe before the second cutter (B) begins to cut. When the functionally predetermined cut out both cutters is achieved, any further progress into the pipe is stopped through the stop edge (C).

Due to the contour of the two cutters and due to the stop edge, any stress forces occuring are distributed favourably over the entire length of the cone.

This distribution of the forces and the specially formed inner contour at the end of the ring collar (D) ensure increased safety during flexuraltype stress.

Vibrations are therefore already dampened during entry into the ring.

After tightening the union nut

During assembly, the stop edge causes an increase in the tightening forces up to a clearly felt fixed point (assembly fixed point).

After completion of the assembly, the visible collar bead (E) must completely fill the space before the first cutter.

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Sheet no.

N 11

Assembly N

Hydraulic system

Pipe union / hose union

Assembly of the cutting ring union (pipe union) - Preparation of the pipe :

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

If necessary, remove any rust on the pipe and clean it. They saw it off squarely and deburr it lightly on the inside and outside (do not bevel the pipe).

Note : If a pipe cutter is used (not recommended), the burrs on the inside and outside of the pipe must be removed and file it also plane at the front so that the front end of the pipe fully contacts the pipe stop on the cone groove in the union is ensured.

a) Pipe cut off with a pipe cutter : heavy buring/angular cut

b) Sawed off pipe : hardly any burrs

- Preparation of individuel union parts : Oil the thread (1) and cone (2) of the union as well as the cutting ring (3) and thread (4) of the union cut.

Slide the union nut and cutting ring over the end of the pipe. Do not install the cutting ring incorrectly - incorrect assembly will result !

Right

Wrong

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Sheet no.

N 12

Assembly N

Hydraulic system

Pipe union / hose union

Assembly of the cutting ring union (continued) - Initial assembly in union neck

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Screw on the union nut by hand until noticeable contact is made. Press the pipe as far as the stop in the inner cone.

The mark facilitates observing the specified number of turns.

Tighten the union nut approximately 1 1/2 turns (pipe must not turn). The stop edge limits tightening by an increase in the torque.

- Check of the assembly : Loosen the union nut ; Check if the collar fills the space in front of the 1st cutter.

Note : It is not important if the ring can be turned on the end of the pipe.

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Sheet no.

N 13

Assembly N

Hydraulic system

Pipe union / hose union

Assembly of the cutting ring union (continued) - Reassembly

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After each loosening, the union nut must be tightened without using greater force.

The neck must helf fast.

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Sheet no.

N 14

Assembly R

Lubrication chart

Contents

Sheet no.

Lubrication chart .................................................................................................... R 2 Lubricants .............................................................................................................. R 3

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Oil tag .................................................................................................................... R 4

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Sheet no.

R1

Assembly R

Lubrication chart

Lubrication chart

1. Lubricate all lubricating nipples with general purpose grease : every 3 months 2. Lubricate the turntable bearing with general purpose grease : every 3 months 3. Lubricate all moving parts with oil : every 3 months Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

4. Change the hydraulic oil : every 12 months 5. Change the gear oil.

After 50 to 150 service hours, thereafter lubrication for life.

6. Chain spray : every 12 months 7. Grease swivel and wheel bearing : every 12 months 8. Keep mast channel surfaces free of rust with channel spray : every 3 months Note :

For designation of lubricants and viscosity refer to sheet no. R3.

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Sheet no.

R2

Assembly R

Lubrication chart

Lubricants Note :

The lubricants used in the truck are specified on the oil tag on the truck (refer to sheet no. R4).

Hydraulic oil Hydraulic oil (coldstore)

HLP 46 or HVLP 32 HVI 32

DIN 51524/T2

Id. No. W8 036 912

DIN 51524/T3

Id. No. W8 036 216

Capacity : approx. 25 l

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Gear oil

SAE 80

Id. No. W8 036 925

Gear oil (coldstore) SAE 75 - 90 (partially synth.)

Id. No. W8 036 929

Capacity : approx. 3.6 l Chain lubricant

Stabylan 2001

Id. No. W8 010 100

Chain lubricant (coldstore)

Syntesco

Id. No. W8 036 220

Lubricants for friction bearings and other lubrication points Beacon 2

Id. No. W8 010 107

Acedo X 2 (coldstore)

Id. No. W8 050 076

Channel spray for lifting device, sliding surfaces, spur gears Ceplattyn 1612 (also for coldstore)

Id. No. W8 052 125

ATE SL DOT 4 / DOT 3

Id. No. W8 034 957

Brake fluid Further special lubricants For all moving parts For fittings, union nuts

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For coldstore : Kompranol spray N74

Id. No. W8 050 077

Rivolta anti-seizing compound

Id. No. W8 050 078

Workshop Manual

EGV-S

Sheet no.

R3

Assembly R

Lubrication chart

Lubricants

Oil tag Id. No. W8 150 545 (VE = 100 items)

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

The lubricants used in the truck are specified on a tag on the truck. This card is attached near the oil tank filler opening.

The hydraulic oil filler opening is marked with symbol (1).

After filling the oil, check the type of oil used (2) and enter the date of the next oil change as specified by the lubrication chart (3) and the date for the next change of the brake fluid (4).

Taking out of operation, disposal If the truck described here must be taken out of operation, make sure that all components are discarded as required by the applicable regulations.

Above all, recycle or dispose of lubricants as required.

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Sheet no.

R4

Assembly S

Stand-on platform

Contents

Sheet no.

Removal of right guard .......................................................................................... S 2 Removal of left guard............................................................................................. S 3

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Removal of platform............................................................................................... S 4

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Sheet no.

S1

Assembly S

Stand-on platform

Removal of right guard (1)

1. Disconnect the battery plug.

2. Remove the cover (2).

3. Open the compartment door (3).

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

4. Open the guard (3), thus tensioning the gas-filled spring (4).

5. Place the special tool (10, self-manufactured) over the tensioned gas-filled spring (4). Open the guard further, thus transferring the tension pressure onto the special tool.

Note :

The special tool (10) is selfmanufactured.

6. Remove the 2 haxagonal nuts (5) and the gas-filled spring (4).

7. Mark the location of the cam (6) with the guard open.

8. Remove the grub screw (7).

9. Drive out the roller pin (8). approx. 15 mm

10. Pull out the guard (1) upwards.

approx. 15 mm

Special tool

Installation is in the reverse order of removal.

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Sheet no.

S2

Assembly S

Stand-on platform

Removal of left guard

Prerequisite : Block up the truck on both side, approx. 210 mm 1. Disconnect the battery plug.

2. Remove the cover (1).

3. Open the traction compartment door (2).

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

4. Open the guard (3), thus tensioning the gas-filled spring (4).

5. Place the special tool (12) over the tensioned gas-filled spring (4).

Open the guard further, thus transferring the tensioning pressure to the special tool.

6. Remove the 2 hexagonal nuts (5) and take off the gas-filled spring (4).

7. Mark the location of the cam (6).

8. Remove the grub screw (7).

9. Drive out the roller pin (8).

10. Push the guard (3) down.

11. Mark the position of the cam (9).

12. Remove the grub screw (10).

13. Remove the cam (9) downwards.

14. Remove the guard (3) upwards.

Installation is in the reverse order of removal. Pay attention to the following points : - Install the cam (9) with the guard open and pushed down.

- Close the guard and pull it up, then install the ring (11).

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Sheet no.

S3

Assembly S

Stand-on platform

Removal of platform

1. Disconnect the battery plug.

2. Block up the truck on both sides securely, 210 mm.

3. Raise the platform (1).

4. Remove the gas-filled spring (2).

5. Lower the platform.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

6. Block up the platform securely.

7. Drive out the 2 straight pins (3).

8. Drive out the shaft (4).

9. Remove the platform.

Note :

Note the number of washers (5) and their location.

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Sheet no.

S4

Assembly U

Cover

Contents

Sheet no.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Covers.................................................................................................................... U 2

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Sheet no.

U1

Assembly U

Covers

Covers

1. Cover (traction compartment).

2. Door (traction compartment).

3. Battery lid.

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

4. Door (battery compartment).

Issue : 01/97 Replaces issue :

Workshop Manual

EGV-S

Sheet no.

U2

Assembly Z

Appendix

Contents

Sheet no.

Special tool for JPT connector............................................................................... Z 2

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Special tool for Molex connector............................................................................ Z 3

Issue : 01/97 Replaces issue :

Workshop Manual

EGV-S

Sheet no.

Z1

Assembly Z

Special tool

Special tool for JPT connector (JPT = Junior Power Time) The following special tools are required for the JPT connector (1) and socket housing (2) :

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

Note :

In order to be able to press out the pins or sockets, open the flaps (7).

1. Socket housing, 14 pins

Id. No. 8 403 734

2. Single contact

Id. No. 8 403 726 Id. No. 8 403 729

0.5 - 1.0 mm2 : 1.5 - 2.5 mm 2 :

3. Press-out tool

Id. No. 8 052 115

4. Connector housing, 14 pins

Id. No. 8 403 739

5. Single contact

Id. No. 8 403 863 Id. No. 8 403 864

6. Press-out tool

Issue : 01/97 Replaces issue :

0.5 - 1.0 mm2 : 1.5 - 2.5 mm 2 :

Id. No. 8 052 116

Workshop Manual

EGV-S

Sheet no.

Z2

Assembly Z

Special tool

Special tool for Molex connector The following press-out tool is used for the Molex connectors on the “Curtis Combi-Controller 803” (option) and the Highpuls Control : (1) Connector housing, 8 pins Connector housing, 16 pins

Id. No. 8 403 826 Id. No. 8 403 828

(2) Single contact

Id. No. 8 403 829 Id. No. 8 403 830

Id. No. 8 052 117

Copyright protected. No part of this manual may be reproduced in any form, copyright reserved.

(3) Press-out tool

0.2 - 0.75 mm2 : 0.75 - 1.5 mm2 :

Issue : 01/97 Replaces issue :

Workshop Manual

EGV-S

Sheet no.

Z3