STILL STED forklift EXU-S 22 EXU-S 24 EXU-SF 20 EXD Electrical and hydraulic Schematic Manual

EXU-S 22 EXU-S 24 EXU-SF 20 EXD 20 EXD-S 20 EXD-SF 20

The tables are valid from serial numbers: F20177C00001 F20178C00001 F20282C00001.

The tables replace "Ver. 00" due to updates to the fan connection and the

electrical steering and replacement of the steering potentiometer.

The tables replace the previous versions due to the introduction of the lithiumion batteries and the setup for Fleet Manager called "Mobile EasyKey (UPA/CO)".

EXD, EXD-SF, EXU-SF electrical schematic views updated and integrated. EXD, EXD-S, EXD-SF, EXU-S, EXU-SF. hydraulic schematic views updated and integrated.

50018026020 [EN]

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- 1

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- 3

a

50018026020 [EN]

V

50018026020 [EN]

-1

.

05-08

White

Blue Orange

Brown

Green Violet

Red

Yellow Grey

WH

BU

OG

BN

GN VT

RD

YE

-2

GY

Black

BK

S2

Electrical steering motor 02 Emergency stop button 05

M3

06

Lift motor

07

Traction motor

M2

02-04 400-A general power fuse 05 7.5-A auxiliary protection 08 fuse 20-A electrical steering 02 fuse Lead/gel battery 01 Main contactor 05 Electrical steering relay 02-03

Electronic traction and lifting control Electrical steering

M1

K6

G1 K1

F5

F4

F1

A3

A1

50018026020 [EN]

50018026020 [EN]

-3

.

White

Blue Orange

Brown

Green Violet

Red

Yellow Grey

BU

OG

BN

GN VT

RD

YE

-4

GY

Black

WH

Electronic traction and lifting control (16-19) Electrical steering (13-15) Lithium-ion battery electronic control (09-12) 400A (16) fuse 7,5A (18) fuse 25A (13) fuse

BK

A1 A3 A4 F1 F4 F5

F8 G1 K1 K6 K7 M1

7,5A (19) fuse Lithium-ion battery (12) Main contactor (16) Electrical steering relay (13-15) Power supply relay for auxiliary circuits (19) Traction motor (18)

M2 M3 Rt S2 S8 S11

Lifting motor (17) Electrical steering motor (13) CANBUS 120 Ohm 1W (12) resistor Emergency stop button (16) Micro CAN side socket (10) Lithium-ion battery starter button (11)

Micro +24V side socket (10) Battery socket (12) Deutsch 4-way connector (12) Charger connector (09)

50018026020 [EN]

7S13 X1 X33 X100

50018026020 [EN]

-5

.

40

31-34 36

25-30

20-50

Main contactor

Fan motor Emergency stop button

Platform sensor Fork sensor Speed reduction sensor Electromagnetic brake

Speed sensor Heat probe

6-way Saab connector

42-way Saab connector Male 7-way circular diagnostic connector 10-way Saab connector

M4

S3 S5

1B2 1B4

D

1X1

White Blue Orange

Brown

Green

Violet Red

Yellow Grey

BN

GN

VT RD

YE

-6

GY

OG

Black

WH BU

10-way Saab connector

X17

BK

4-way Saab connector

7X6 X13

6X7

Y2

S7

S2

41-47

31-40 48-50

45-48

49-50

23

20 41-44

38

21

20

K1

F3

25-30

Dashboard 7.5-A controller protection fuse

A2

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-7

.

7.5-A lights fuse

F6 F8

69-76 59-68

56-73

Horn

Solenoid valve

Initial lift solenoid valve

Brake solenoid valve 25-way Amp JPT connector 4-way Saab connector

2-way Saab connector 4-way Saab connector

10-way Saab connector

10-way Saab connector

42-pin Saab connector

4H1

Y1

Y3

Y4

G

X10 X15

1X1

White Blue Orange

Brown

Green

Violet Red

Yellow Grey

WH BU

BN

GN

VT RD

YE

-8

GY

OG

Black

BK

L

E

C

3B2

87-90

77-78

84-86

79-92

72

70

56

58

87-90

84-86

3B1

F9

53

52 51

77-92

55-73

3-A auxiliary fuse Potentiometer for electrical steering, tiller position Hall sensor for electric steering, wheel position

3-A hydraulic fuse

Electronic control Electrical steering

A3

A1

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50018026020 [EN]

-9

.

Green

Violet

Red

Yellow Grey

VT

RD

YE GY

-10

Brown

Blue Orange

GN

White

BU

OG BN

Black

WH

6-way Saab connector

D

BK

Dashboard

Dashboard

A2

(1*)

93-98 / 116-121 93-98 / 116-121

(2*)

Electronic key

(3*)

Antenna

(4*)

50018026020 [EN]

Electronic controller

50018026020 [EN]

-11

.

Crash detector

Antenna

GSM module Black 6-pin Saab connector (female) Black 6-pin Saab connector (male) Woodhead Molex connector Woodhead Molex connector Woodhead Molex connector Antenna connector 14-way Micro Timer 2 connector Woodhead Molex connector Woodhead Molex connector

6B1

W1

W2

Green

Violet

Red Yellow Grey

VT

RD YE

-12

GY

Brown

Blue Orange

BU

GN

White

WH

OG BN

Black

BK

6X18

6X17

6X16

6X15

6X14

6X13

6X12

DA

D

TDU

S100

144

137

126-136

148 / 154

144

137 / 144 / 150 137 / 144 / 150

137-142

126-132

144 / 150

149 / 155

137 / 150

126-136

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50018026020 [EN]

-13

.

162

165-166

164

Dead man's pedal 1800-mm magnetic sensor Black 4-pin Saab connector (female) Black 4-pin Saab connector (male) Black 2-pin Saab connector

Micro Timer socket pin

Green

Violet

Red

Yellow Grey

VT

RD

YE GY

-14

Brown

Blue Orange

GN

White

BU

OG BN

Black

WH

2-pole Deutsch connector 177-178/ (female) 181-183 6-pin Saab connector 179-180 Resistor with CAN 182-183 120 Ohm 1 W

171-174

167-170

164

158

Dead man's pedal

UPA EXU-S dual pedal UPA EXD-S 1800-mm lift block

BK

Rt

D

X34

1x1:38

X30

X13

X13

S10

S3 S3/1

(1*) (2*)

(3*)

Adaptor for Retro t from lead/gel battery to lithium battery

(4*)

Adaptor for Retro t from lithium battery to lead/gel battery

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-15

187

189

192 - 193

185

189 - 190

187 - 188 185 - 189

12-V relay

24-V relay

24-V relay Eyelet terminal, 8-mm diameter

10-pin Saab connector

10-pin Saab connector

K50

K51

K52

X17

X17A X50

.

193 - 194

185

2-A fuse

F50

Green

Violet

Red Yellow Grey

VT

RD YE

-16

GY

Brown

Blue Orange

BU

GN

White

WH

OG BN

Black

BK

1x1:38

X8

16-pin Saab connector Micro Timer female terminal

191 - 192

6-way Saab connector

DA

195

186

Eyelet terminal, 8-mm diameter 6-way Saab connector

B-

D

"Mobile EasyKey" (not supplied).

(1*)

50018026020 [EN]

50018026020 [EN]

-17

a

Blue Orange

BU

-18

Brown

White

WH

OG BN

Black

Fuel cell battery (196 207) 2-pin Deutsch connector (201 203)

BK

G2 X40

X41 1X1

6-pin Deutsch connector (200 205) 42-pin SAAB connector (206)

GND

.

Red Yellow Grey

RD YE GY

Green Violet

GN VT

8-mm eyelet terminal (205)

50018026020 [EN]

50018026020 [EN]

-1

.

-2

YE

Yellow Grey

GY

GN

VT RD

Violet Red

OG BN

Green

Brown

BK

WH BU

White Blue Orange

Electronic control (04 06) Electrical steering control (02 03) 400A (04) fuse

Black

A1 A3 F1

F4 F5 G1

7,5A (06) auxiliary circuit fuse 25A (02) electrical steering fuse Lead/gel battery (01)

K1 K6 M1

Main contactor (04) Electrical steering relay (03) Traction motor (06)

M2 M3 S2

50018026020 [EN]

Lifting motor (05) Electrical steering motor (02) Emergency stop button (04)

50018026020 [EN]

-3

.

RD

YE

Red

Yellow Grey

-4

GN VT

Green Violet

GY

OG

BN

Brown

BU

Blue Orange

BK WH

Electronic control (13 15) Electrical steering control (11 12) Lithium-ion battery electronic control (07 10) 400A (13) fuse 7,5A (15) auxiliary circuit fuse 25A (11) electrical steering fuse

Black White

A1 A3 A4 F1 F4 F5

F8 G1 K1 K6 K7 M1

7,5A (16) auxiliary circuit fuse Lithium-ion battery (10) Main contactor (13) Electrical steering relay (12) Auxiliary circuit relay (16) Traction motor (15)

M2 M3 Rt S2 S8 S11

Lifting motor (14) Electrical steering motor (11) CANBUS 120 Ohm 1W (10) resistor Emergency stop button (13) Micro CAN side socket (08) Lithium-ion battery starter button (09)

Micro +24V side socket (08) Battery socket (10) 4-pin Deutsch connector (10) Charger connector (07)

50018026020 [EN]

7S13 X1 X33 X100

50018026020 [EN]

-5

.

RD

YE

Red

Yellow Grey

-6

GN VT

Green Violet

GY

OG

BN

Brown

BU

Blue Orange

BK

WH

White

Speed sensor (22) Thermal sensor (23) 7,5A fuse () Main contactor (18)

Black

1B2 1B4 F3 K1

M4 S1 S2 S5

Fan motor (24) Key (17) Emergency stop button (17) Fork sensor (21)

S7 X11 X13 1X1

(h3>300 mm) mast sensor (27) 10-pin Saab platform connector () 4-pin Saab connector (27) 42-pin Saab connector (17 27)

6X2 6X7 7X6 Y2

50018026020 [EN]

4-pin Mini Universal MATE-N-LOK connector (19) 7-pin circular diagnostic connector (20 21) 10-pin Saab connector (22) Electromagnetic brake (25)

50018026020 [EN]

-7

26-47

30

31

Cold store resistor

Micro tiller Anti-crush switch Lowering button

Lift button

RC

S4

45

44

46

Brake solenoid valve AMP JPT 25-way connector Saab 4-way connector

Saab 2-way connector

Saab 4-way connector

Tiller PCB connectors Saab 10-way connector

Y4

G

L

J1-J11

BK WH

BU

OG

BN

Blue Orange

Brown

-8

25-34

45

44

42 Saab 10-way connector 36 Micro Mate N Lok 18-way 25 connector Saab 42-pin connector 29 Saab 16-way connector 29

Black White

1X3

1X1

X20

X10 X15

E

C

Initial lift solenoid valve

Y3

43

29

41

Solenoid valve

4S1 Y1

27 29

26

35 32

25

46

45

Horn Horn push button

2S81 4H1

2S80

2S1 2S2

1S30

P4

P3

Initial lift button Initial lowering button

33

Drive potentiometer Hydraulic potentiometer Electrical steering potentiometer Electrical steering potentiometer

P1

28

39

Reversing lights

H6

P2

37 40

Brake lights

38

H4 H5

Work lights

24

3-A auxiliary fuse Lights

F9

H3

22

3-A hydraulic fuse

F8

44-47 23

25-34

7.5-A lights fuse

Tiller PCB Electrical steering

A2

A3 F6

Electronic control

A1

.

Red Yellow Grey

Violet

Green

GN

GY

RD YE

VT

50018026020 [EN]

50018026020 [EN]

-9

.

55/61

52/53

48/49 55/59

51

Combi tiller microswitch Saab 10-way connector (female) Saab 4-way connector (male) Saab 2-way connector

Saab 2-way connector Saab 6-way connector

Saab 4-way connector

S43

X30A X31

XS7

Blue Orange

Red Yellow Grey

-10

RD YE

Violet

GY

GN

VT

Green

OG BN

BU

White

Brown

BK

WH

Black

X30

X13

X11

50

54/60

56

49/53

51

55/61

58/62

Side panel microswitch

S14

S10

S7

S15

S6

57/61

Platform sensor Mast sensor (h3 > 300 mm) Mast sensor (h3 > =1800 mm) Side panel microswitch

Platform sensor

COMBI OPTION + fork sensor h3 > =1800

S3

(1*)

(2*)

1X3:16 from main harness

(3*)

EXD-SF speed reduction with forks h3 > =1800

50018026020 [EN]

50018026020 [EN]

-11

.

YE

Yellow Grey

-12

RD

Red

GY

GN VT

Green Violet

OG BN

BU

Blue Orange

Brown

BK

WH

White

Faston terminals Eyelet terminal, 8-mm diameter Saab 2-way connector Amp Superseal 2-way connector

Black

SL2

SL1

B-

6X5A

6X5

6X2A

6X2

1X3A

1X3

X12

X8

63

63

64

70

63

70 Selector Eyelet terminal, 8-mm 63 diameter Saab 10-way connector 68-71 (female) Saab 16-way connector 65-66 (female) Saab 16-way connector 65-66 (male) Mini Univ. MATE-N-LOK 67 4-way connector Mini Univ. MATE-N-LOK 67 4-way connector Mini Univ. MATE-N-LOK 68 4-way connector

64

S42

K7

Buzzer Spot Light e Buzzer auxiliary relay

1-A fuse for Spot Light e 63 Buzzer Blue Spot Light light 63

4H7

H7

F7

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.

GSM module

Saab 10-way connector Mini Univ. MATE-N-LOK 72/77 4-way connector (male) Mini Univ. MATE-N-LOK 72/91 4-way connector (female) Woodhead Molex 91/98/105 connector Woodhead Molex 91/98/105 connector Woodhead Molex 98 connector Antenna connector 102/110 Micro Timer 2 14-way 75-89 connector Woodhead Molex 91 connector Woodhead Molex 99 connector

W2

X12

RD

YE

Red

Yellow Grey

-14

GN VT

Green Violet

GY

OG

BN

Brown

BU

White

Blue Orange

BK

WH

Black

6X18

6X17

6X16

6X15

6X14

6X13

6X12

6X2A

6X2

Antenna

W1

75-89 90-96/104111 103/111 97-102/10 4-110 73

Crash detector

6B1

74

Selector Fleet Manager TDU

S100

S42

50018026020 [EN]

50018026020 [EN]

-15

.

YE

Yellow Grey

-16

RD

Red

GY

GN VT

Green Violet

OG BN

BU

Blue Orange

Brown

BK

WH

White

Adaptor for retro t from lead/gel battery to lithium-ion battery

Black

(1*)

(2*)

Adaptor for retro t from lithium-ion battery to lead/gel battery

Rt X34

CANBUS 120 hm 1W (119 120) resistor 4-pin Deutsch connector (114 115/118 119)

4-pin Mini Fit MATE-N-LOK connector (116 117) 4-pin Mini Fit MATE-N-LOK connector (116 117)

50018026020 [EN]

6X2 6X2A

a

(1) (2) (3)

Lift cylinder Hydraulic unit Solenoid valve Y1

(4) (5) (6)

50018026020 [EN]

Flow restrictor Tank Pump motor

-1

(7) (8) (9) (10) (11)

-2

Oil lter Lift pump Pressure relief valve Non-return valve Manual emergency lowering

50018026020 [EN]

a

50018026020 [EN]

-1

1 2 3 4 5 7 8 9 10

Base lift cylinder (Z1) Safety stop Main lift cylinder (Z2) Main lift cylinder (Z2) Safety stop Hydraulic block Main lift solenoid valve (Y4) Base lift solenoid valve (Y3) Hydraulic unit

11 12 13 14 15 16 17 18

Fork lowering solenoid valve (Y1) Flow restrictor Pressure relief valve Tank Oil lter Pump motor Lift pump Non-return valve

X

X

X

X X X

.

-2

50018026020 [EN]

X X

50018026020 [EN]

-3

1 2 3 4 5 6 7 8 9

Base lift cylinder (Z1) Main lift cylinder (Z2) Main lift cylinder (Z2) Base lift solenoid valve (Y3) Main lift solenoid valve (Y4) Hydraulic block Manual emergency lowering Fork lowering solenoid valve (Y1) Oil lter

10 11 12 13 14 15 16 17

Flow restrictor Non-return valve Pressure relief valve Lift pump Pump motor Oil lter Tank Hydraulic unit

X

X

X

X X X

.

-4

50018026020 [EN]

X X

STILL GmbH 50018026020 EN 11/2017