Still STED forklift Power pallet truck EXU-16 EXU-18 EXU-20 Workshop manual

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4.493.516 [EN]

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4.493.516 [EN]

III

a

This workshop manual essentially consists of two parts: General product information, fault diagnosis and special tools: Assembly 0 Repair instructions: Assemblies 1 - 9 The two parts of this workshop manual consist of individual sheets arranged in a STILL folder according to their assembly number and page number.

installation of the truck and also the determination of the precise cause. The fault diagnosis is structured as follows: Use of a Notebook Parameterisation of the motor controller Menus Chapter 6 contains wiring diagrams in the DIN-A4 format and at the end of the manual also in the DIN-A3 format.

The manual is structured according to the same rules as the parts catalogue, which is divided into subgroups (assemblies or construction groups).

To simplify the marking of the treated assemblies, the number of the relevant assembly is located at the top right corner of each page.

This workshop manual contains the standard models of the corresponding types and some common variants.

Where required, tables are provided with the technical data for the after-sales service, which even an experienced service engineer should consult.

No warranty claims will result by working according to this manual. The STILL warranty conditions stay unaffected.

This manual contains a detailed description of the technical characteristics as well as the functional description of the individual components or assemblies.

Notes and instructions and explanatory illustrations are inserted in the description of the tasks in this manual.

STILL S.A.R.L. 4 avenue de la Libération 60761 MONTATAIRE CEDEX Still is always developing its products further. For this reason we reserve the right to make changes in the specifications and the design without prior notice.

The fault diagnosis allows a quick detection of the cause of a problem detected in the electrical

4.493.516 [EN]

-1

1 Tiller 2 Document holder 3 Battery plug 4 Cubby hole 5 Load wheels KUBOTA-Wortliste vom 11.03.04 Forks 7 Key switch 8 Composite instrument 9 Lift cylinder 10 Pump motor 11 Traction battery

12 13 14 15 16 17 18 19 20 21

Hydraulic oil tank Stabiliser Traction wheel Reduction gearbox Stabiliser Traction motor Inbuilt battery charger * Brake Control Fuse carrier

* Option

-2

4.493.516 [EN]

1 2 3 4

Handle Lower pushbutton Lift pushbutton Horn pushbutton

5 6 7

4.493.516 [EN]

Throttle Belly switch Throttle

-3

-4

4.493.516 [EN]

Manufacturer Designation of the manufacturer Platform Power source: Electric, Diesel, petrol, LPG, electric mains Operation: hand, pedestrian, stand-on, seat, picker

STILL

STILL

STILL

Battery

Battery

Battery

Pedestrian Pedestrian

Pedestrian 2000

Lifting capacity / load

Q (kg)

1600

1800

Load centre distance

c (mm)

600

600

600

Load distance

x (mm)

1028

1028

1028

Wheelbase

y (mm)

1426

1426

1468

kg

430

550

550

kg

724/1118

912/972

972/1586

kg

332/98

422/128

422/128

V

V

V

?230 x 75 1 x ?85 x 100 2 x ?125 x 40 1x -2/2

?230 x 75

?230 x 75

2 x ?85 x 80

2 x ?85 x 80

2 x ?125 x 40 1x -2/4

2 x ?125 x 40 1x -2/4

b 10 (mm) 469

469

469

b 11 (mm) 388

388

388

h 3 (mm)

Dead weight Axle loading with load Axle loading without load

with battery Driver s end/load end Driver s end/load end

Tyres: Superelastic (SE), air (L), Vulkollan (V) Wheel size

Driver s end

mm

Wheel size

Load end

mm

Stabiliser dimensions

Driver s end

mm

Wheels, number (x = drive wheels)

Driver s end/load end

Distance between centreline of tyres, front Distance between centreline of tyres, rear

130

130

h 7 (mm)

h 14 (mm) 740/1230

740/1230

740/1230

Fork height

h 13 (mm) 85

85

85

Total length

l 1 (mm)

1743

1743/1785

1785

Length of powerhead

l 2 (mm)

553

553/595

595

Total width

b 1 (mm)

720

720

720

Fork thickness

s (mm)

55

55

55

Fork width

e (mm)

172

172

172

Lift Height of driver s platform Height of tiller in driving position

min/max

4.493.516 [EN]

130

-5

Fork length

l (mm)

1190

1190

1190

Width across forks

b 5 (mm)

560

560

560

Ground clearance Working aisle width with 800 x 1200 pallets

m 2 (mm) Ast (mm)

30 1991

30 1991/2033

30 2033

Turning radius

Wa (mm)

1619

1619/1661

1661

6

6

Travel speed

With load

km/h

6

Travel speed

Without load

km/h

6

6

6

Lifting time

With load

s

3.0

3.0

3.0

Lifting time

Without load

s

2.2

2.2

2.2

Lowering time

With load

s

3.0

3.0

3.0

Lowering time

Without load

s

3.0

3.0

3.0

Gradient

With load

%

-

-

-

Gradient Acceleration time (0 - 10 m)

Without load

% s

-

-

-

With load

-

-

-

Acceleration time (0 - 10 m)

Without load

s

Electromagnetic

-

kW

1.2

kW

2.2 No

U (V)

24

Service brake

Traction motor, rating S2 = 60 min Lift motor, rating S3 = 15% Battery to DIN 43531/35/36 A, B, C, no Battery voltage Battery capacity Battery weight Power consumption to VDI cycle

Depending on supplier

1.2

1.2

2.2 No/ IEC 254 -2; B 24/24

2.2 IEC 254 -2;B 24

180/240 195/220

240 220

-

-

-

SCR

SCR

SCR

68

68

68

K 5 (Ah) 180 kg (+/-5%) 195 kWh/h

Type of drive control

Electromag- Electromagnetic netic

Noise level, driver s ear

dB (A)

-6

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4.493.516 [EN]

-7

Manufacturer Designation of the manufacturer

STILL

Platform Power source: Electric, Diesel, petrol, LPG, electric mains

Platform Battery

Operation: hand, pedestrian, stand-on, seat, picker

Stand-on / pedestrian

Lifting capacity / load

Q (kg)

2000

Load centre distance

c (mm)

600

Load distance

x (mm)

1028

Wheelbase

y (mm)

1468

kg

550

kg

972/1586

kg

422/128

Dead weight Axle loading with load Axle loading without load

with battery Driver s end/load end Driver s end/load end

Tyres: Superelastic (SE), air (L), Vulkollan (V)

V

Wheel size

Driver s end

mm

?230 x 75

Wheel size

Load end

mm

2 x ?85 x 80

Stabiliser dimensions Wheels, number (x = drive wheels)

Driver s end

mm

2 x ?125 x 40 1x -2/4

Distance between centreline of tyres, front

b 10 (mm)

469

Distance between centreline of tyres, rear

b 11 (mm)

388

h 3 (mm)

130

h 7 (mm) h 14 (mm)

675/1035

Height of forks

h 13 (mm)

85

Total length

l 1 (mm)

2313

Total length

l 1 (mm)

1922

Length of powerhead

l 2 (mm)

1077

Length of powerhead

l 2 (mm)

685

Total width

b 1 (mm)

720

Fork thickness

s (mm)

55

Fork width Fork length

e (mm)

172

l (mm)

1190

Driver s end/load end

Lift Height of driver s platform Height of tiller in driving position

-8

min/max

4.493.516 [EN]

Width across forks

b 5 (mm)

560

Ground clearance Working aisle width with 800 x 1200 pallets Working aisle width with 800 x 1200 pallets

m 2 (mm) Ast (mm)

30 2486

Ast (mm)

2110

Turning radius

Wa (mm)

2114

Turning radius

Wa (mm)

1738

Travel speed

With load

km/h

6

Travel speed

Without load

km/h

6

Lifting time

With load

s

3.0

Lifting time

Without load

s

2.2

Lowering time

With load

s

3.0

Lowering time

Without load

s

3.0

Gradient

With load

%

10

Gradient Acceleration time (0 - 10 m)

Without load

%

20

With load

s

-

Acceleration time (0 - 10 m)

Without load

s

electromagnetic

Service brake

Traction motor, rating S2 = 60 min

kW

1.2

Lift motor, rating S3 = 15%

kW

Battery to DIN 43531/35/36 A, B, C, no Battery voltage

2.2 -

U (V)

24

K 5 (Ah) kg (+/-5%)

240 220

kWh/h

-

Battery capacity Battery weight

Depending on supplier

Power consumption to VDI cycle

Type of drive control

SCR dB (A)

Noise level, driver s ear

4.493.516 [EN]

68

-9

TRAY 95

180

195

690

145

660

TRAY 112

240

212

627

212

624

TRAY 113

360

288

627

284

624

-10

4.493.516 [EN]

71 0140 0 00001

Complete serial no.

71: Montataire (France)

0140: EXU 16 0141: EXU 18 0142: EXU 20

0: Standard truck 1: Truck with hinged driver s platform (option with EXU 20) 2: Truck with built-in battery charger 4: Cold store model

00001: Consecutive number from start of manufacture

4.493.516 [EN]

-11

DIN 912 / ISO 4762 DIN 931 / EN ISO 4014 DIN 933 / EN ISO 4017 8.8

10.9

12.9

8.8

10.9

12.9

M3 x 0.5

1.3

1.9

2.3

-

-

-

M4 x 0.7

3

4.5

5

-

-

-

X 0.8

6

8.5

10

-

-

-

M6 x 1

10

15

17.5

9

13

15.5

M8 x 1.25

25

36

42

22

32

37

M10 x 1.5

48

71

83

42

63

73

M12 x 1.75

84

123

144

74

108

126

M14 x 2

133

195

229

116

171

201

M16 X 2

206

302

354

181

264

309

8.8

10.9

12.9

8.8

10.9

12.9

M3 x 0.5

1

1.35

1.6

-

-

-

M4 x 0.7

2.1

3

3.5

-

-

-

M5 x 0.8

4.2

6

7

-

-

-

M6 x 1

7

10

12.5

6

8.8

11

M8 x 1.25

17.5

24.5

30

15.5

22

27

M10 x 1.5

34.5

49

59

30

43

52

M12 x 1.75

60

84

101

53

74

89

M14 x 2

95

137

161

-

-

-

M16 X 2

147

210

252

129

185

222

DIN 7984 DIN 6912

-12

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Vervus-Ripp Cl.100 -

10.9

-

-

10.9

-

M6 x 1

-

15

-

-

13.6

-

M8 x 1.25

-

37

-

-

33

-

M10 x 1.5

-

73

-

-

65

-

M12 x 1.75

-

-

-

-

111 -

-

-

127 -

-

M14 x 2 M16 X 2

-

311

-

-

272

-

-

For tightening of screws in aluminium parts the torque must be multiplied with the following factor:

DIN 7991 Ic 110.91 -

10.9

-

-

10.9

-

M6 x 1

-

11

-

-

9.5

-

M8 x 1.25

-

28

-

-

25

-

M10 x 1.5

-

56

-

-

50

-

M12 x 1.75

-

96

-

-

85

-

M14 x 2

-

156

-

-

137

-

M16 X 2

-

240

-

-

211

-

4.493.516 [EN]

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ULS / ISO 7380 ULF -

10.9

-

-

10.9

-

M6 x 1

-

11

-

-

10

-

M8 x 1.25

-

27

-

-

25

-

M10 x 1.5

-

52

-

-

48

-

M12 x 1.75

-

100

-

-

90

-

DIN 7500

Useable as retaining screws 10.9

M6 x 1

10

M8 x 1.25

24

M10 x 1.5

48

M12 x 1.75

83

M14 x 2

-

-14

These torques are guide values and can be varied depending on the required security.

The torque to be used must therefore be determined beforehand with tests.

4.493.516 [EN]

eg: ECO SYN

Useable as retaining screws

D 2.5

0.8

D3

1.4

D 3.5

2

D4

3

D5

5.5

These torques are guide values and can be varied depending on the required security. The torque to be used must therefore be determined beforehand with tests.

D6 9 If a torque wrench is used: max 600 rpm

DIN 74361-2 (Form G)

DIN 74361-2 (Form A)

8.8

10.9

-

8.8

10.9

-

M12 x 1.5

83

125

-

83

125

-

M14 x 1.5

135

210

-

135

210

-

M6 x 1

M8 x 1.25

M12 x 1.75

M14 x 2

M16 X 2

5

10

45

63

90

45 H

4.493.516 [EN]

M10 x 1.25 20

-15

This table applies only for joining two metal parts.

If washers are used, the torque must be multiplied with the factor stated in the table.

When installing in aluminium parts it must be observed that the torque must be multiplied with the factor stated in the table.

If this information is not applicable for a certain application, please request further information.

Tightening safety-related parts Wheel fasteners, motors, reduction gearboxes and hydraulic cylinders, mast-to-frame fasteners, mast rollers, steering stop, brake fasteners, support roller fasteners, pump unit, turntable: ±10% Other parts (bonnet, accessories, etc...): ±20%

-16

4.493.516 [EN]

The cables shown to the right are the 2 interface cables between the PC and controller. Below are the 2 order numbers for the related cables: Adapter cable for PC / controller, number: 4498916 (1) Connecting cable for controller, number: 5456433 (2)

Display of the desired acceleration (in %) Display of the exciting current (in amperes) Display of the armature current (in amperes) Display of the cyclical ratio of the field winding voltage (in %) Display of the cyclical ratio of the armature voltage (in %) Battery voltage (in volts) Temperature at the controller base State of the forward travel input State of the reverse travel input State of mode 1 input State of mode 2 input 4.493.516 [EN]

-17

State of the interlock switch input State of the belly button input State of the main line contactor output State of the auxiliary output

Certain information is not accessible for all controllers.

Proper operation Slow starting speed Short in the area of the main line contactor or the field winding Temperature sensor defective Wiring problem at the belly button Exciter circuit open High pedal disable activated Hardware problem detected Battery voltage too low M- in contact with BMain contactor is sticking Contactor failure Battery overvoltage SRO triggered with direction of travel Performance cutback by the control unit due to unusually high temperature Fault at the wiper contact of the traction control (throttle) Fault at the lower point of the traction control (throttle)

-18

4.493.516 [EN]

To gain access to the protocol port parameters, click on the icon "Select Protocol Port(1)".

Click on "Auto Detect"(2) for the port to be used.

In our example the port COM1(3) must be used.

To do so, click "OK"(4).

Click "Connect "(1) in the "Protocol selection" window.

Click the "Connect "(2) icon.

Press the "F2" key on the keyboard.

Open the menu "Device/System" and click "Connect".

If the Notebook is connected to the control unit, the lower bar of the software window (1314 PC Programming Station) must display "Mode: CONNECTED "(A).

4.493.516 [EN]

-19

If the Notebook is correctly connected via the controller software interface, it is possible to use it 5 functionalities by clicking "1243-4209 "(1).

The following 5 icons (2) are available: Device Information(3) Device Parameters (4) Monitor Device Test Data (5) Service Function (6) Diagnosis (7)

Click the icon"Monitor Device Test Data "(1).

In order to have all functionalities shown in a single table, click on "Monitor "(2).

However, it is possible to access each functionality individually (3).

Click on the icon "Device Parameters "(1) to display and modify the device parameters.

Select the parameter to be modified (in our case: "M2 BRAKE C/L "(2)) The selected parameter is changed by sliding the cursor(3) with the two arrows on the right and left (5) or by directly entering the desired value (6).

The new parameter value only becomes valid after clicking "OK "(4).

-20

4.493.516 [EN]

If you click the icon "Device Parameters "(1), the vertical function bar (A) will appear.

Now it is possible to select the following 7 choices: Print open window. (2) Print all parameters. (3) Export parameter in the form of an EXCEL table (format.XLS). (4) Read controller parameters. (5) Retrieve parameters from PC (hard disk or diskette). (6) Saving the parameters to the control unit. (7) Saving the parameters to the PC (hard disk or diskettes). (8)

After each change of the device parameters, the window shown at the right must appear in the display.

4.493.516 [EN]

-21

To open the error list, click on the fault diagnosis icon, then on"Fault History"(1).

The error list will then appear on the screen (2).

To clear the error list, click the icon "Clear entries" or click directly on the list to be cleared, then click on "Clear"(3).

-22

4.493.516 [EN]

1,1

CURRENT SHUNT FAULT

1,2

HW SAFE

1,3

M-SHORTED

1,4

SRO

2,1

THROTTLE FAULT 1

2,2

EMR REV WIRING CHECK

Tiller safety circuit failure

2,3

HPD

- Incorrect chronological sequence of key switch/brake/change in the direction of travel.

High pedal - Incorrect configuration of the throttle used disable activated with the programming unit.

- Potentiometer set incorrectly (lower position).

2,4

THROTTLE FAULT 2

- Electric circuit open at lower position of potentiometer.

- Short at lower position of potentiometer.

- Incorrect configuration of the throttle used.

3,1

CONT COIL/FIELD SHORT

Short or interruption at lower position of potentiometer Overcurrent in the contactor coil or the field winding

3,2

DIR CONT WELDED

- Direction contactors stick or shorted (power circuit).

3,4

MISSING CONTACTOR

4,1

LOW BATTERY VOLTAGE

Direction contactors stick Shunt winding or contactor missing Low battery voltage

4,2

OVERVOLTAGE

Current sensor fault Hardware problem

- Controller defective - Controller defective - Wiring problem

Short to terminal - Connect terminal M- to earth.

M- Internal short in the motor.

SRO fault - Incorrect chronological sequence of key switch/brake/change in the direction of travel.

- Incorrect SRO configuration.

- Brake circuit or direction of travel selection circuit open.

- Intervals between actuations are too short.

Wiper contact in - Connection between throttles /controller potentiometer interrupted. faulty - Cables of the throttle shorted to earth or B+.

- Potentiometer defective.

- Incorrect configuration of the potentiometer with the programming unit.

Battery overvoltage

4.493.516 [EN]

- Tiller safety circuit open.

- Check circuit for tiller safety open.

- Direction contactor coils shorted.

- Shunt winding shorted.

- Electric circuit of direction contactor coil open.

- Contactor missing.

- Interruption in contactor wiring.

- Battery voltage 1< 16 Volt.

- Battery leads corroded.

- Drop in voltage at the battery clamps or the controller.

- Battery voltage > 45 Volt.

- Battery charger connected to truck.

-23

4,3

THERMAL CUTBACK

Temperature too - Temperature > 85°C or < 25°C. high/low.

- Truck overloaded.

- Controller installed incorrectly.

- Operation in an extreme environment.

4,4

ANTI-TIEDOWN

Mode 2 or mode 4 chosen at key-on.

- Mode contacts shorted to B+ or set permanently.

The last detected fault is always shown. The LED code for normal operation is 1,0.

-24

4.493.516 [EN]

VOLTAGE

Position for regular voltage

2

M1 DRIVE C/L

Mode 1 current limit (in amps)

200

M2 DRIVE C/L

Mode 2 current limit (in amps)

M3 DRIVE C/L

Mode 3 current limit (in amps)

M4 DRIVE C/L

Mode 4 current limit (in amps)

M1 BRAKE C/L

Mode 1 brake current limit (in amps)

M2 BRAKE C/L

Mode 2 brake current limit (in amps)

M3 BRAKE C/L

Mode 3 brake current limit (in amps)

M4 BRAKE C/L

Mode 4 brake current limit (in amps)

M1 ACCEL RATE

Mode 1 acceleration rate (in seconds)

2.5

M2 ACCEL RATE

Mode 2 acceleration rate (in seconds)

1

M3 ACCEL RATE

Mode 3 acceleration rate (in seconds)

M4 ACCEL RATE

Mode 4 acceleration rate (in seconds)

M1 DECEL RATE

Mode 1 deceleration rate (in seconds)

M2 DECEL RATE

Mode 2 deceleration rate (in seconds)

M3 DECEL RATE

Mode 3 deceleration rate (in seconds)

M4 DECEL RATE

Mode 4 deceleration rate (in seconds)

THROTTLE DECEL

Delay time after information (in seconds)

0.5

M1 BRAKING RATE

Mode 1 braking from neutral position (in seconds)

3

M2 BRAKING RATE

Mode 2 braking from neutral position (in seconds)

1

M3 BRAKING RATE

Mode 3 braking from neutral position (in seconds)

M4 BRAKING RATE

Mode 4 braking from neutral position (in seconds)

QUICK START TAPER RATE

Quick-start throttle factor (seconds) Regeneration current rate when changing the direction of travel

0 10

M1 MAX SPEED

Mode 1 max speed (cyclical ratio of the output signal in %)

67

M2 MAX SPEED

Mode 2 max speed (cyclical ratio of the output signal in %)

100

M3 MAX SPEED

Mode 3 max speed (cyclical ratio of the output signal in %)

M4 MAX SPEED

Mode 4 max speed (cyclical ratio of the output signal in %)

CREEP SPEED

Starting threshold (in seconds)

0

THROTTLE TYPE

Throttle type used

1

THROTTLE DEADBAND Dead range of throttle (in % of 5 kOhm) Max acceleration rate (in % of 5 kOhm) THROTTLE MAX

200

5

7 100

THROTTLE MAP

Form of the acceleration ramp (in %)

20

FIELD MIN

Min exciting current (in amps)

8

FIELD MAX

Max exciting current (in amps)

25

FIELD MAP START

Start of exciting current modification (in amps)

75

FIELD MAP

Modified form of exciting current (in %)

50

CURRENT RATIO

Current ratio Braking ramp (in A)

4

RESTRAINT LOAD COMPEN

Charge compensation (in %)

3

HPD

High pedal disable activated

2

SRO

Static return to off Sequencing delay (in seconds)

0

SEQUENCING DLY

4.493.516 [EN]

10

1

-25

Main contactor Delay time of main contactor (in seconds)

ON

MAIN OPEN DLY CONT DIAG

Contactor diagnosis

ON

AUX TYPE

Auxiliary output

1

EMR REV C/L

Emergency reverse current limit for emergency isolator button (in amps)

200

AUX DLY

Opening delay of main contactor

0.2

EMR REV CHECK

Monitor of belly button

ON

EMR DIR INTR

Interlock cycle behind belly button

ON

VARIABLE BRAKE

Proportional braking in acceleration position

ON

ANTI-TIEDOWN

Starting at low speed

OFF

POT LOW FAULT

Low potentiometer point fault

ON

FAULT CODE

Output fault 1 and 2

ON

MAIN CONT INTER

Only modes 1 and 2 are used on the EXU 16-1820.

DECEL RATE: total range (0.1 to 10)

Below you will find the parameters which can be changed by the after-sales service along with their adjustment range

MAX SPEED: total range

BRAKING RATE: from 0.1 to 3

BRAKE C/L: from 130 to 200 ACCEL RATE: from 0.5 to 3

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10

a

The truck is equipped with separately excited traction motor.

The direction of motor rotation is reversed by changing the polarity of the terminals of the armature windings.

The travel speed depends on the cyclical ratio of the controller pulses.

This traction motor no longer has a terminal strip.

The tiller pivot is an integral part of the traction motor body.

If the cable loom of the traction motor is damaged, cut it off a few centimetres from the motor.

Then crimp on a new cable loom with transition sleeves.

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-1

Designation

JULI 1001250

Motor type

GF 084-G5

Operating voltage (V)

24V

Amperage (A)

61 A

Separate excitation Rated speed (rpm)

8.5V - 11 A 2850 rpm

Power (kW)

1.2 kW

Short duty

S2 = 60 min*

Protection class

IP20

Insulation Brush dimensions (mm)

F 25 x 26 (length) x 10 (thickness)

Min length of brushes (mm)

14 mm

Number of brushes

4 Rated 55 mm, min 50 mm

Diameter of collector * S2 = 60 min: Motor in operation for 1 hour under full load, followed by 1 hour off duty

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When the traction motor is removed, the truck can no longer be braked. To prevent the truck from rolling, it must therefore be secured on squared timbers.

Block up the truck on squared timbers.

Disconnect the battery connector.

Remove the covers.

Disconnect the cable loom for the motor, tiller and electric brake.

Removal of the tiller the tiller", P. 4-10

Chapter "Removal of

Remove the socket head screw M6 (1) on the electric brake.

Install an eyebolt in its place.

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-3

Remove the steering stop (2).

Attach a lifting sling to the traction motor.

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Remove the three socket head screws (3).

Remove the traction motor upwards.

Installation is the reverse of removal.

The following conditions, however, must first be fulfilled: Clean the hole in the gearbox and the ventilation slots.

Do not contaminate the gearbox oil.

Set the traction wheel to straight ahead.

Check the oil level. The max oil level corresponds to the centre of the pinion (1). The min oil level is 2 mm below the lower edge of the pinion (2).

Place the traction motor in correctly on the gearbox, paying attention to the seal (4).

During its installation, the motor must be guided on to the gearbox to prevent damage to the teeth of the shaft (otherwise a risk of loud operating noise).

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-5

The following services are required between the regular maintenance intervals: Cleaning General visual inspection Replace defective components Check the carbon brushes and commutator Replace the carbon brushes if needed Check the condition of the brush springs The following services must be carried out every 500 hours or every 3 months.

To prevent shorts or personal injuries, disconnect the battery connector before any services on the motor.

Remove the brush cover (1) at the motor and take out the brushes (2).

Clean the traction motor with compressed air (do not inhale carbon dust, wear a protective mask).

Do not bend the brush springs more than required and do not bend them to the side.

Check the gearbox ventilation slots for accumulation of dirt. Dirt reduces the air circulation and causes the motor to overheat, which can lead to its destruction.

Check the field winding and armature for traces of overheating: dark colouration, broken or scorched insulation, soldered commutators.

Motors showing such characteristics must be replaced immediately.

If there is oil or grease inside the motor (most often a slush composed of oil, oil vapours mixed with dirt and coal dust), its cause must be determined immediately. Clean the motor thoroughly and check the condition of the seal.

A rapid wear of the brushes and the armature is most often due to the penetration of oil. The oil and grease burn in the flame of the brushes, leading to rubbing deposits. This can lead to a premature wear of the brushes.

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After cleaning the fastener, the brush should move freely in the holder when the spring is raised. Do not work on the brushes with emery paper or any other abrasive when they are seated in the holder. Replace the brushes as a set to avoid overheating. The brushes must not be broken or excessively worn at the rubbing surface.

Always replace brushes in a complete set. The length of the shortest brush is decisive in this case.

Only install genuine brushes (please refer to the parts list).

Do not allow the springs to fall down during the installation of the brushes.

Replace brushes even if the minimum length has not been reached, for the remaining service life could be shorter than the time to the next service interval.

A general reworking of the motor is necessary after the brushes have been replaced 3 times.

After each replacement, the brushes must be run in at decreased speed.

The contact surface of the commutator (1) must be completely smooth and have a black-grey colour. The commutator must not be worn, scored or eccentric. The commutator must be reworked if one of these characteristics is evident.

Never work on the commutator with a file, emery paper or a similar tool.

Do not grease the ball bearings (2). The amount of grease is sufficient for the time between two general overhauls.

The bearings must be checked at each general overhaul.

The bearings must be renewed at least every 5 years or every 2000 service hours.

Only install the bearings specified in the parts list.

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-7

Notes on overload risk with a discharged battery: Stop work immediately and check the state of battery charge if the motor speed decreases noticeably.

Never drive with the truck if a supply voltage is too low!

Remove the protective screen at the commutator.

Remove the brushes.

Remove the two circlips on the motor shaft (3).

Remove the large circlip (it will be refitted) from the stator cage (4).

Pull the rotor out to the rear.

Remove the rotor fully.

Remove the bearing (2).

If necessary, rework the commutator.

Remove the 8 socket head screws in pairs with a 5mm Allen key (5).

-8

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Remove the 4 windings (6).

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-9

The brushes must be replaced when they have a residual length of approx. 50%. If the brushes approach the wear limit of 50%, they must be renewed immediately and not at the next service interval in a few months.

New brushes

Replace at:

26 mm

14 mm

The brushes must always be renewed as complete set of 4 items.

Park the truck and remove the front cover.

Disconnect the battery connector.

Open the strap (1) (brush cover) on the traction motor.

Lift the brush springs (2) and hold them.

Pull the brushes (2) off via the lead.

Relax the brush springs slowly.

Disconnect the lead by loosening screw (3).

Clean the area around the commutator.

Install new brushes.

Do not inhale carbon dust, wear a protective mask.

After the renewal of the motor brushes, do not run the motor immediately with a full load. The brushes will run in relatively fast with a reduced load.

Brush springs, whose tension (force < 5 N, measured with a spring scales) is too low, lead to the

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destruction of the commutator. It is also important to make sure the brushes move easily in the holders.

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-11

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a

Attention: The gearbox is delivered without oil.

Capacity (L)

1

Max load (N)

10000

Max static torque (Nm)

900

Max dynamic torque (Nm)

600

Max permanent torque (Nm)

150

Gear reduction ratio

21.7

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-1

The reduction gearbox is now maintenance-free.

This drive unit does not have either a grease nipple or an oil drain plug.

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Put the truck on a level surface.

Disconnect the battery connector.

Secure the truck against rolling with squared timbers.

Remove the covers.

Removal of the traction motor tion motor", P. 1- 3 .

Chapter "Trac-

Check the oil level. The max oil level corresponds to the centre of the pinion (1). The min oil level is 2 mm below the lower edge of the pinion (2).

If needed, add gear oil with a viscosity index of µ=108.

When the traction motor is removed, the truck can no longer be braked. Block up the truck on squared timbers to prevent it from rolling.

Disconnect the battery connector.

Loosen the five nuts at the traction wheel.

Put the truck on squared timbers, about 250 mm against a wall.

Remove the traction wheel.

Remove the covers, then the traction motor Chapter "Traction motor", P. 1- 3 .

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-3

Loosen the four gearbox fastening bolts (5)The two other screws (6) were removed previously to lift out the stop and the traction motor.

Screw three M8 x 120 eyebolts into the holes of the motor fastening bolts. Now the gearbox can be attached to slings.

Seal the hole (4) with a clean cloth to prevent oil from running out on to the floor when removing the gearbox.

Attach the hoist so that the gearbox can be pulled out over the frame.

Tauten the hoist chain and lifting sling (7) so that the last four bolts (5) can be removed.

Lower the gearbox to the ground.

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Remove the lifting slings from the eyebolts.

The gearbox is now accessible.

Installation is the reverse of removal. To install, place the traction wheel axle before the opening in the frame. When securing the gearbox on the motor chassis, observe the table of torques Chapter "Table of torques in Nm", P. 0-12.

Before installation of the reduction gear make sure that the opening and the ventilation slots are clean.

Observe the torques when installing the gearbox Chapter "Table of torques in Nm", P. 0-12.

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-5

Remove the metal cap (1) to gain access to the centre nut on the wheel hub.

Remove the screw (2).

Remove the washer and seal (3) with a flat screwdriver.

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Remove the press-in gasket (4) with a flat screwdriver.

Position a very fine flat screwdriver so that the ribs (5) can be removed from the groove in the gearbox.

Carefully remove the complete gasket from the groove.

It is not necessary to dismantle the gearbox for the removal of this gasket (5).

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-7

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a

The frame consists of automatically welded sections. The type of steel used is S235 or S355, depending on the component.

The fork tips are made of cast steel with an integrated entry piece.

The covers are made of ABS plastic (new)

4.493.516 [EN]

-1

To gain access to the electrical installation in the motor compartment proceed as follows: Disconnect the battery connector.

Turn the tiller to the right and remove the two socket head screws on the brake cover (1).

Take out the parts of the brake cover.

Remove the socket head screw (3) in the main cover (2).

Tilt the tiller and then pull firmly on the cover, in particular at the document holder (5).

Then loosen the right part of the frame cover and remove it altogether (4).

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Installation is the reverse of removal.

Tilt the tiller.

First place the cover in the cut-outs at the bottom in the frame (6).

Press the top part of the cover into the clips with a short, solid blow in the area of the document holder (7).

Put the right part of the cover into the frame again and fasten it with the socket head screw (8).

Insert the right part of the brake cover in the cable holder. Turn the tiller to the right to fasten the left part of the brake cover with two socket head screws (9).

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-3

For the removal of the right part of the cover including the instrument and key switch, proceed as follows: Remove the three socket head screws (10), (11) and (12).

Mark the cable of the key switch.

Disconnect the instrument and key switch.

If necessary, disconnect the plug of the built-in battery charger (option).

Remove the cover.

Installation is the reverse of removal.

Remove the two opposite screws (13) of the battery compartment.

Remove the battery cover.

Installation is the reverse of removal.

-4

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a

The standard tiller head consists of a formed double handle (1) containing a p. c. board (2), 3 pushbuttons (lifting, lowering and horn), 2 butterfly switches (throttles) for traction, a safety microswitch with belly button (12) and 3 covers (4, 5 and 6).

In the event of a failure of the tiller head, the whole p. c. board assembly must be replaced.

When the throttles are operated, they are connected with a potentiometer, which changes the desired value according to of the rotation angle of the throttles (butterflies). The 3 pushbuttons are "on/off" switches.

The communication between the tiller head and the controller is by "wire".

Safety microswitch (7) PC board assy (2) Throttles for directions of travel (8) Horn push (9) Lift button (10) Lowering button (11) Belly button (12)

From now on, all tiller heads have a label with the week and the year of the manufacture affixed.

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-1

"Cold store" trucks have p. c. boards (1) with special resistors for the cold store duty. These resistors are supplied with power via connector (2).

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Disconnect the battery connector.

Separate the two shells (1) and (2) by putting a flat screwdriver in between the recess between the two shells as shown in the opposite photo.

Several recesses between the two shells facilitate the removal.

The photo to the right shows the fastening system of the two shells.

Remove the upper shell (1).

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-3

Remove the two socket head screws (3).

Raise the shell (4).

Simply pull the cover of the belly button (7) up to remove the button. This belly button is pressed on.

Remove the socket head screw (5) below the block.

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Disconnect the connector (6) below the tiller p. c. board.

Then remove the p. c. board.

Remove the two socket head screws (8).

The tiller head is now dismantled.

To remove the bottom cover, remove the 7 screws (12) with a Phillips screwdriver.

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-5

Pull both throttles (9) to the side with force.

The throttles may only be removed after the p. c. board block has been removed from the enclosure.

Installation is the reverse of removal.

To refit the two throttles, push them on their locating and fastening clips.

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The gas-filled spring inside the tiller is under high pressure. For its removal, set the tiller to the home position.

Separate the two shells (1) and (2) by placing a flat screwdriver in the slot between the two shells (see removal of the tiller head for procedure Chapter "Removal of the tiller head ", P. 4- 3 ).

Remove the cover (1).

Remove the screw (3).

Also remove the two other screws (4) at the base of the tiller.

Remove the tiller cover (5).

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-7

Remove the two pivot locks (6) and (7).

Use a flat screwdriver to take the two locks off.

Remove the top part of the cylinder with a flat screwdriver.

Also remove the bottom part of the cylinder.

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The installation is carried out in the reverse order of removal: First insert the lower part of the cylinder and lock it.

Insert the upper part of the cylinder and lock it.

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-9

The tiller cable must always be removed first.

The tiller head must be removed so that the cable loom can be disconnected from the p. c. board in the tiller Chapter "Removal of the tiller head ", P. 4- 3 .

Open the tiller and take the top part of the gasfilled strut out of its mounting Chapter "Gasfilled spring", P. 4- 7 .

Drive the two pins (1) out of the tiller base.

Withdraw the pin (2) in the tiller base.

Remove the tiller.

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1 2

Stabilisers Traction wheel

3

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Load wheels (single or tandem)

-11

Dimensions of new wheels: 230 x 75 mm The traction wheel must be replaced if: the running surface has cracks, is softened or very untrue, the diameter of the wheel has reduced by 10 % (admissible minimum diameter: 207 mm).

Vulkollan (standard) Vulkollan with profile (variant) Rubber (variant) Natural rubber "non-colouring" (variant) Natural rubber with profile "non-colouring" (variant) Vulkollan with profile (variant)

For the safe removal of the traction wheel an opening (1) is provided in the frame of the powerhead, which allows the most difficult services to be carried out, for example, loosening and tightening of the traction wheel without having to go underneath the truck.

Move the truck until a nut (2) appears in the opening (1), then turn the key switch to "OFF" and disconnect the battery connector.

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Using a load suspension means (car jack, hoist ), place the truck on both sides on squared timbers about 230 mm high. Using a ratchet with a 19 mm nut and an extension of about 110 mm, loosen and remove the wheel nuts through the hole in the frame.

Reconnect the battery connector and set the key switch to "ON" to turn the traction wheel secured by the squared timbers until another nut is visible in the opening. Repeat this until all five wheel nuts are loosened and removed.

Removal of the traction wheel

Always replace wheel nuts and wheel lugs showing signs of a damaged thread.

Clean the bearing area of the wheel at the hub.

Mount the wheel on the gearbox and fasten it with the five nuts until the wheel is seated on the gearbox.

Roll the truck on squared timbers and align a nut with the opening, then turn the key switch to " OFF", disconnect the battery connector and then torque the nut to 83 Nm. Reconnect the battery connector and then set the key switch to "ON". Repeat this procedure until all 5 wheel nuts have been torqued to 83 Nm.

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-13

Raise the truck with a load suspension means (car jack, hoist ...) to remove the timbers, then lower the truck on to the ground.

After the replacement of the traction wheel, it is recommended to check the adjustment of the stabilisers.Link error: Target with XID = "Stuetzraeder" not found!

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Stop the pallet truck and put the traction wheel on a support 1 mm thick.

Remove the screw (4) and cotter pin (5) at the stabiliser.

Using a spider (11), , turn the sleeve (6) in or out until the wheel touches the ground.

Secure the cotter pin (5) and screw (4).

The wear of the traction wheel can be compensated in part with the adjustment of the stabilisers.

Perform the adjustment on both stabilisers. After installation, check the stabiliser for proper operation. In the event of a change in the direction of travel, the stabiliser must turn 180° after a short distance.

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-15

Dimensions of new wheels: 125 x 40 mm Remove the screw (4) and cotter pin (5) at the stabiliser.

Turn the bush ( 6) out fully to be able to remove the stabiliser from below.

Remove the circlips (7).

Using a hub drift, separate the pins (8) and bearings (9). The circlips (10) hold the 2 bearings (9) firmly in the hole of the bush (6).

Remove the circlips (10).

Lift the bearing (9) out of the hole of the bush (6).

Pull the bearing (12) from the shaft (13).

Installation is the reverse of removal.

When installing the stabiliser, coat the thread with "Loctite 8102" adhesive grease.

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On the pre-series trucks (about 300 trucks) the axle pivot pin in the stabilisers is not systematically mounted on bearings, but on sliprings.

4.493.516 [EN]

-17

The EXU can be equipped with two different types of load wheels, depending on the requirements of the customer: Single load wheels Tandem load wheels The load wheels must be replaced if: their running surface is worn their diameter is only 76.5 mm their bearings are damaged

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To replace the load wheels, proceed as follows: Raise the forks to the maximum height.

Position the tiller so that the traction wheel is set to straight ahead.

Squat in front of the forks and raise the truck 90°, using your legs and not your back.

When refitting the load wheels, observe the table of torques in .

4.493.516 [EN]

-19

New wheel dimensions: 85 x 100 mm Raise the forks to relieve the bearing of the load wheel so that the axle (1) can be removed.

Block up the side of the truck on which the wheel is to be replaced with squared timbers at about 100mm.

Drive out the pin (2), then remove the axle (1).

Remove the load wheel (3) and maintenancefree sleeves (4).

Take care not to lose the 2 washers (5).

New wheel dimensions: 85 x 80 mm Block up the side of the truck on which the wheel is to be replaced with squared timbers at about 100mm.

Then remove both fastening screws (4).

Take out the wheels (5), see-saw (6) and maintenance-free sleeves (7).

Do not grease the see-saw (6) and stirrup (1), which are mounted with maintenance-free sleeves.

After reinstallation, always check the see-saw (6) for ease of movement.

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Type

BFK 457-08-Basic

Manufacturer Braking torque

LENZE

Power consumption of field winding at 20°C

25 W

Voltage Weight

20 V 1.9 kg

Min gap

0.2 mm

16 Nm

Max gap

0.5 mm 7 mm min.

Thickness of brake disc

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-21

The following drawing shows the brake inoperative, ie in the braking position.

The compression springs (1) press the brake plate (2) axially against the brake lining (3) and this in turn presses against the flange mounted on the motor.

If the tiller is moved from the home position to the driving position, the microswitch in the tiller base is operated by a cam.

The microswitch sends a signal to the controller, which then excites the winding of the electromagnetic brake (5).

1 2 3

Compression spring Brake plate Brake lining

-22

As soon as the field winding of the electromagnetic brake is excited with DC current, the magnetic circuit between the brake plate (2) and the magnetised part (5) closes.

The brake plate (2) moves axially on the permanently fixed magnetised part, whereby the air gap "a" is reduced to "zero", thus releasing the brake lining (3).

The air gap of this brake is adjustable. Link error: Target with XID = "Bremsspiel_einstellen_und_pruefen" not found!.

4 5 6

Adjustment screw Coil Threaded part

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The truck can only be driven with the tiller in position (2). In the lower range (1) and in the top range (3) the electromagnetic brake is turned off and the traction drive cut off.

The brake system is designed to function like a traction interlock.

The gas-filled spring returns the tiller to the vertical position (3), which cuts off the electromagnetic brake. The electromagnetic brake is also cut off when the tiller is set to the horizontal position (1).

This brake is used as parking brake and as service brake.

Lower the platform (4) and stand on it with both feet.

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-23

The correct setting of the electromagnetic brake must ensure a minimum air gap to release the brake lining on the one hand and to hold the wear of the brake linings as low as possible on the other hand.

The dimension "a"(1) indicates the gap ("stroke of the brake"), which should be 0.2 mm upon a new adjustment or readjustment.

Release the brake disc by actuating the tiller.

Check the air gap with a set of shims. The brake air gap "a" must be between 0.2 and 0.5 mm.

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EXU 16: 1.6 tons EXU 18: 1.8 tons EXU 20: 2 tons

Keep the stopping distance clear and keep a sufficient safe distance.

Turn the switch key (4) to the "hare"(6) position Accelerate the truck to 6 km/h.

Apply the brake and measure the braking distance: If the braking distance is longer, have the brake disc replaced by your after-sales service.

Never drive the truck with a defective brake.

If the coil no longer ensures an air gap of < 0.5 mm, check the battery voltage. The electric brake can not operate properly if the battery voltage is incorrect.

4.493.516 [EN]

-25

Adjust dimension "a" to 0.2 mm with the adjustment screws (2) and the threaded piece (6).

Using a feeler gauge, measure dimension "a" at 3 points in the vicinity of the screws (2).

Each time the brake lining is replaced, it must be checked for easy movement at the hub. Replace the brake disc if its residual thickness is only 7 mm.

Park the truck on a level floor.

In the event of a malfunction, it may be necessary to release the truck brake manually.

To do so, proceed as follows: Disconnect the battery connector.

Remove both brake covers.

Release the brake with two M5 x 35 screws.

The truck can now be moved manually.

The truck can no longer be braked. Move the truck on level floors only! The brake is released by screwing out the two M 5 screws.

The pre-series trucks (about 350) do not have any holes allowing the manual release of the brake.

On these trucks the brake must be disengaged from the motor pinion to be able move the truck manually.

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Disconnect the battery connector.

Secure the truck against rolling with squared timbers.

Remove the covers.

Disconnect the leads of the electromagnetic brake (1).

Cut the cable ties (2).

Loosen the cable guard (3).

Detach the electric cables.

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-27

Remove the 2 pins of the microswitch (4) at the base of the tiller.

Remove the 3 cheese head screws (5).

Withdraw the electromagnetic brake upwards.

Remove the brake lining (6).

-28

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a

The safety microswitch (1) is triggered by the belly button (7). It is a safety element which must function according to the accident prevention regulations.

Its proper operation must therefore always be checked whenever the truck is serviced.

When the safety microswitch is actuated, the direction of travel is reversed. As soon as the safety microswitch (belly button) is released, the truck stops.

The truck can only be returned to service in 2 ways: Put the throttles in neutral and then reoperate them Set the key switch to off, then return it to driving and move the tiller to the braking position.

The illustration to the right shows the method of control of the belly button (safety reversing switch) and the directions of travel of the EXU: Forward (2) and Reverse (3)

4.493.516 [EN]

-1

Potentiometer" P1"(A) Wiper contact (variable output) red (10) Position for "full power" (0V input) green (11) Off position (5V input) yellow (12) Direction of travel contact "1S1"(B) Controller input (0V) blue (13) Forward travel output (5V in off position and 0V when active) white(14) Reversing output (5V off position and 0V when activated) black (15)

The first segment of 5° (1) corresponds to the neutral zone. When this segment is passed, a direction of travel (2) is chosen. From 7.5° to 43° the potentiometer is active (3). Finally, from 43° to 47° the constant value of "full power "(4).

The illustration to the right shows the cross section without the wiper contact.

External view of the potentiometer

-2

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The battery discharge indicator functions according to the principle of permanent comparison of the battery voltage with a series of internally defined reference voltages.

The reference voltage divided into 36 levels corresponds to the curve of the controlled battery discharge.

If the average battery voltage less than the related reference voltage for 46 seconds, the battery discharge indicator (BDI) automatically makes a comparison with the next lower reference voltage level. This procedure is repeated with each voltage level.

As the voltage levels drop, the LED indicator (1) goes from the right to the left. When the cut-off threshold is reached (voltage at the discharge state), the two red LEDs on the left blink.

At the back of the device it is possible to adjust the discharge characteristic to the existing conditions of use(see page 09-04).

The storage of the discharge state of the battery is buffered by a lithium battery (10 years), whereas the levels of the battery discharge indicator are stored in an EEPROM.

The battery discharge indicator runs as soon as the battery connector is connected. The monitoring of the discharge process protects the battery from deep discharges. When a residual capacity of 20% is reached, the lifting function is cut out.

If the battery is fully charged, only the extreme right diode of the 10 LEDs (1) is illuminated. As the battery capacity decreases, the indicator moves to the left. When the battery discharge is 70%, the next to last red diode blinks to indicate that the battery must be charged. When the discharge is 80%, the next to last and last red LEDs flash alternately. The lifting function is cut out and which battery must be charged.

The hour meter (2) counts to 99,999.9 hours.

As soon as the tiller is in work position, the hour meter begins to run.

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-3

Pin 7 = B+ (24V) Pin 5 = BPin 3/4: Cut-off when the discharge voltage is reached, ie 20% of the residual capacity of the battery.

The cut-off is carried out with a thyristor. For this reason it is necessary to pay attention to the correct polarity (logic positive (A) / negative (B), Fig. 3). Incorrect polarity can destroy the indicator or the line contactor.

Pin 2: LED indicator supply voltage Start depending upon use from B+ to(6) or from B- to (1)

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The discharge voltage (Volt/cell) can be adjusted with the potentiometer (1).

The recommendations of the battery manufacturer in respect to the setting must be observed (see the table to the right).

The voltage at the begin of the gas discharge is 2.35V/cell for at least 6 minutes connection of a battery with a quiescent voltage of at least 2.09V/cell.

Open lead battery

1.73

Maintenance-free gel battery

1.93

In some cases of a heavy load (high power demand for a short time) it may be necessary that the operation starts too early. In this case must the correct setting must be found by the trial and error method.

4.493.516 [EN]

-5

Please also refer to the type plate (1) for the specifications.

10 LEDs: 5 green, 3 yellow, 2 red.

Rechargeable lithium battery.

Reset to zero if the voltage is 2.35V/cell at the beginning of gas discharge or the quiescent voltage has reached 2.09V/cell.

Stop by a locking break contact.

Technical prerequisites for the discharge are adjustable.

Warning with optical indicator when residual capacity drops to 25%.

Commutation current 3 amperes.

Indication with 6-digit LCD. Resolution 0.1 hour.

Flashing display of the symbols.

Due to EEPROM, memory is independent of power supply.

Operating voltage 24V and 48V. Tolerance +/- 25% of the rated voltage.

Operating temperature -40°C to +85°C. Accuracy (max deviation 2%).

Protection class (IP 65 at the front).

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4.493.516 [EN]

a

The units listed below are not necessarily assembled on all trucks.

Name A1 A11 A111 A112 A2

Row of electroluminescent diodes Plug holder

A3 2A3

Hydraulic module

C1

Capacitor

F1 F2

Traction or line fuse Pump fuse

F3

Control fuse

F4 F5

Control fuse Steering fuse

F6

Option fuse

F7

Option fuse

F8

Option fuse

F9

Option fuse

G1

Traction potentiometer

P2

Hydraulic potentiometer

P3

Steering setting potentiometer

P4

Steering recopy potentiometer

P5

Tiller inclination potentiometer Battery discharge and/or hour meter potentiometer

6P20

Traction controller Battery charger

Control box Steering controller

P1

RC

Generic names Key or Digicode S1 S2

Emergency stop

S3

Presence sensor (dead man s handle) 1

S4 S5

Battery

4H1

Warning horn;

H2

Indicator or rotating light

K1 K2

Traction or line contactor Pump contactor

K3

Heating resistance

Tiller sensor Height of low lift sensor

S6

Presence sensor (dead man s handle) 2

S7

Loading frame height sensor

S8

Anti-foot compression sensor

S9

Push-button unlocking

S10

Speed reduction sensor

S11

Emergency stop

S12

Emergency stop

S13

Fold-up platform sensor

S14

Fold-up railing sensor 1

S15

Fold-up railing sensor 2

S16

Emergency stop

S17

Push-button, forward travel, right

S18

Push-button, forward travel, left Push-button, driving platform lifting

S19 S20

Push-button, driving platform lowering

Braking relay

S21

Driving platform raising sensor

K4

Option relay

S22

Lift button, right-hand backrest

K5

Option relay

S23

K6

Steering relay

S24

Lift button, left-hand backrest Lower button, right-hand backrest

M1

S31

M2

Traction motor Pump motor

M3

Steering motor

S33

Push-button, reverse travel, left Button, computer confirmation

M4

Fan motor

S34

Button, computer confirmation

S25 S32

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Lower button, left-hand backrest Push-button, reverse travel, right

-1

S82

Push button, slow travel

X8

Positive terminal

S83

Push button, slow travel

X9

Various connectors

X10

Tiller bundle connector

X11

Various connectors

X12

Various connectors

X13

X15

Various connectors Connector, brake/tiller on-off switch Various connectors

X16

Various connectors

Traction names Forward travel or forward/reverse 1S1 travel throttle valves 1S2 Reverse travel throttle valve 1S30

Anti-collision micro-contact shield

Hydraulic names

X14

2S1

Lowering push-button

X17

Various connectors

2S2

Lifting push-button

X18

Various connectors

2S80

Push-button, low lift, "lifting"

X19

2S81

Push-button, low lift, "lowering"

X20

Various connectors Connector,tiller case 1

X21

Connector, tiller case 2

Y1

Lowering solenoid valve

Y2

Brake Loading frame solenoid valve

Signalling names 4S1 X1

Horn push-button

X2

Controller connector Display connector

X3

Battery connector

X4

Various connectors

X5

Various connectors

X6

Various connectors Negative terminal

X7

-2

Y3 Y4 Y5 Y6

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Low lift solenoid valve Driving platform raising solenoid valve Solenoid valve, disconnection of hydraulic accumulator

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The most favourable operating temperature is between 25 °C and 40 °C. To avoid lasting damage to the battery, the maximum acceptable temperature of the electrolyte, 55 °C, must never be exceeded.

If there is great stress and use in winter temperatures, the battery should be charged every day even if less than 80% of the rated capacity has been used up.

It is essential to take off or open the chassis lid or the battery covering before charging or during interim charging.

During battery charging, a rise in temperature of 10 to 12°C should be expected. For batteries under great stress, this can lead to a rise in the temperature of the electrolyte to over 50 °C. If necessary, stop the battery charging and allow it to cool. Unsuitable lifting gear damages the battery (deformation of the case and damage to the insulation).

During charging, the stoppers of the cells may remain in place.

Close the chassis lid or the battery covering 1/2 an hour before the end of charging at the earliest.

Always connect the charger with the correct polarity to avoid destroying the battery and the charger (+ to +).

Checking electrolyte level. If necessary: fill up the distilled water towards the end of charging.

This filling must be carried out when the level of the electrolyte reaches the height of the deflector, at the latest.

Towards the end of charging, check if effervescence at rest in all the cells is regular. When charging is finished, measure the acid density and the temperature, and record the difference compared with the recommended values.

When charging is finished, measure the temperature of the electrolyte in all the cells. If a cell shows a large difference in comparison with neighbouring cells, it must be checked separately. The insulation resistance of the battery must be measured in accordance with the VDE, external current circuit cut. The lower limit value is 50 Ohms per volt, rated voltage. However, you must not go below 1000 Ohms. If the insulation resistance is less, the cells and the container must be cleaned.

Check the operation of the charger, and particularly the level of charging current and the start of intense effervescence (2.4 V/cell). Check that the operation of the plugs and plugging devices is correct.

Only charge using direct current.

To avoid leakage currents, the batteries must always be kept clean and dry (Neutralo spray).

The terminals and connections must be cleaned with a terminal spray, to avoid any oxidation and formation of sulphates.

Unsuitable lifting gear damages the battery (deformation of the case and damage to the insulation).

Apart from these basic recommendations, those of the battery manufacturer should generally be observed.

Protect the battery from impurities, metallic dust and ammonia vapours, for example.

If the mixture is correct, the density of the acid gives an indication of the battery charge status.

But it only increases strongly enough towards the end of charging. This is due to effervescence which starts at around 2.4 V/ cell.

If in doubt, contact the after-sales service of the battery supplier.

The density of the acid is measured with a hydrometer (siphoning density).

Acid density in the battery completely: Charged 1.27 kg/l Discharged: 1.13 kg/l

Battery charging

-4

During measurement, the floater must not touch laterally or above. The correct value for the acid 4.493.516 [EN]

density is obtained about 1/2 hour after charging finishes.

If the correct value is to be ensured, avoid measuring immediately after topping up with water, because the water and the acid must be mixed.

The battery temperature must not differ much from 30 °C during measurement.

When handling batteries, you are exposed to a high risk of accident. For this reason it is essential the following points are observed.

Measures to be taken: Good ventilation, avoid electrical sparks, no naked flames in battery compartments, no smoking.

Measures to be taken: Wear protective clothing against acids, rubber gloves and safety glasses, keep neutralisation products close at hand. Have water ready for rinsing eyes (if there is any injury to the eyes call a doctor immediately).

Measures to be taken: Do not touch current conducting elements, inform the personnel. Respect VDE 0100 and VDE 0105.

Measures to be taken: Only use appropriate, safe lifting gear. When transporting, provide appropriate protection to prevent the batteries from tipping over or slipping off the load platform of the means of transport.

After removing the closing stoppers, all the cells must be filled regularly with sulphuric acid, density 1.25 kg/l, up to the lower acid level marker, (using a cell filling system or a plastic hopper).

The filling acid must have a temperature greater than or equal to 15 °C. After a rest period of 5 to 6 hours, possibly add a little acid.

The rise in temperature must be measured using a thermometer dipped into the electrolyte of a cell in the middle of the battery. If the rise in temperature is less than 10 °C, the battery can be connected to the charger for recharging.

The charging time is from 6 to 12 hours, until automatic stoppage by the charger control switch.

The temperature must be monitored during charging. It must not exceed 55 °C. if it does the charging process must be stopped so that the battery can cool down.

At the end of the charging process, the acid density must be 1.27 kg/l plus or minus 0.01 kg/l. If it is not, charging must be continued until a uniform acid density of 1.27 kg/l is reached.

The battery is then ready to operate. If necessary, bring the electrolyte up to the nominal level, using distilled water. If the acid density is too high, remove some acid and add distilled water.

Measures to be taken: Do not eat or drink where batteries are charged, always wash your hands after working on batteries.

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The battery change may only be carried out by specially trained personnel according to the instructions of the manufacturers of the battery, battery charger and truck. Please follow the maintenance instructions for the battery.

Smoking and naked flames are not allowed when servicing the battery. No inflammable substance and no sparking tool is allowed within 2m of the truck, the battery charger or the battery to be charged. The room must be well ventilated. Fire extinguishers must be held ready and at hand.

When the battery is being serviced, the truck must be parked securely. The truck may only be taken back into operation if all covers are in place and the connectors are properly connected.

Park the truck with the tiller (1) set to the vertical position. Remove the switch key(4).

Disconnect the battery connector (3).

Open the battery cover (2) to the back.

Screw out the knob (6) and remove the latch (5).

For the change, the battery can be lifted out with a hoist.

To prevent shorts, it is recommended to protect batteries with unprotected terminal clamps or connections with a rubber mat.

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Disconnect the battery connector.

Open the battery compartment.

Unlock the battery.

Attach the hoist (1) as specified to the battery (2) and then lift it out of the truck.

The hoist must exercise a vertical pull to prevent damage to the tray. The hooks must be installed so that they can not fall on the battery cells when the lifting gear becomes slack.

Carefully lift the battery out of the truck.

The weight and dimensions of the battery affect truck stability. The installed battery must have the same weight. Do not remove any added weights or change their location.

Please observe the "Battery specifications" in the chapter "Description".

The information required for charging the battery can be found in the maintenance instructions in the chapter "Servicing the battery".

The installation a charged battery is carried out in the reverse order of removal. Be sure to refit all covers correctly.

Do not damage the cables when changing the battery.

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Make sure that there are no objects between the battery cover and the edge of the frame when closing the cover. Danger of crushing!

Reconnect the battery connector (3).

Reinsert the latch (5).

Screw in the knob (6).

Close the cover (1).

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The battery charger, if fitted, is mounted on the left-hand side of the frame of the drive unit as shown in the opposite illustration.

2 versions: one for lead batteries, one for gel batteries.

461552 (for : 1521, version for lead batteries).

468970 (for : 2459, version for gel batteries).

Illustrations of a battery charger (1) and its location in an EXU pallet truck (optional with this model).

The label is affixed on the top of the battery charger and has the dimensions 51 x 32 mm.

It contains the following information: Name of the manufacturer: I.E.S. (Intelligent Electronic Systems) Type of battery charger: "CHARIS HF 24 V 30 A STD" Manufacturing index number: 9 Electrical specifications: 230 V, 8.5 A, 50 Hz Battery capacity: 160 Ah - 300 Ah Protection class: IP20 (protection against solid objects in excess of 12 mm) Product number: (serial number) Serial number: (after the type number)

This data sheet applies for built-in battery charger developed by IES.

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-9

The charging curve, which is fully controlled by a microprocessor, adjusts automatically to batteries with a capacity from 160 to 300 Ah, even for intensive rapid charges.

300 Ah max for No. 461552 (for : 1551, version for lead batteries).

240 Ah max for No. 468970 (for : 2459, version for gel batteries).

The charging period depends on the capacity of the battery to be charged: 15 hours for batteries with a capacity of 300 Ah 12 hours for batteries with a capacity of 240 Ah 8 hours for batteries with a capacity of 160 Ah

The first charging procedure after the connection of the battery charger to the battery results in an overvoltage time of at least one hour. This property allows new batteries, which may have been stored several months, to "desulphurise".

The energy conversion follows a separation pattern functioning at 80 kHz.

Built-in battery charger connected permanently to the traction battery.

-10

Storage temperature

- 10 to + 50 °C

Operating temperature

0 to + 40 °C

Relative humidity Weight

90% 2.2 kg

Filling capacity

1.6 L

Rated input voltage

Mains power 230 V +10/-15%

Mains frequency Transient current (with mains connection)

50 Hz +/-1% limited by CNT

Max output power

720 W +/-3%

Max output current

30 A +/-2%

Rated battery voltage

24 V

Voltage tolerance of U-shaped end plate

1%

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Air inlet for fan at top of battery charger, protected by a screen Air outlet at the back Secured with the baseplate and three 6mm studs Cable with a 2.5mm gauge at the front

The charging procedure is started by connecting the battery charger to mains power.

Insert the mains plug (4) of the battery charger into a 230V, 50/60 Hz mains outlet protected by a 16A circuit breaker.

The primary circuit of the battery charger is protected by a 250V, 10A slow blow fuse and two 25A fuses built in as false-polarity protection.

A green LED (3) will come on as soon as the charger is connected to the mains power supply.

A yellow LED (2) comes on and flashes during the charging procedure.

If at all possible, do not interrupt the charging procedure prematurely; a prolonged connection of the battery charger (eg over the weekend) is advantageous.

The start of charging is not ensured if the battery voltage at the poles is less than 9V. Charging proceeds in different phases according to the programming of the microcontroller in the battery charger. If the battery charger stays connected to the mains, new charging cycle will be started every 48 hours after conclusion of charging to equalise any self-discharging.

The battery charger will stop automatically: 4.493.516 [EN]

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in case of overlong charging time. The green LED (3) flashes (= error).

Battery charger no. 461552 (for :1521): 12 hours max in phases I1+P und 5 hours max in phase U. Battery charger no. 468970 (for :2459): 12 hours max total charging time, 8 hours max in phases I1+P. In these cases check if: a) A battery cell has failed. b) The battery charger is fully suited for the capacity and battery type. c) The temperature inside the truck exceeds 40°C (the battery charger will then automatically reduce the charge, thus delaying the charging procedure). If the temperature exceeds 40°C, determine if the air inlets and outlets of the battery charger are free.

In case of a false temperature measurement inside the battery charger.

After conclusion of the charging procedure the yellow LED (2) will extinguish.

Disconnect the plug (4) from mains socket and place it in its holder.

Take the truck back into operation.

Pull the plug out of the mains socket.

Disconnect the battery and then reconnect it.

Reinsert the plug of the battery charger into the mains socket.

It is possible that the battery charger has stored a fault in its memory. In this case follow the instructions in the section entitled "Procedure in case of a microcontroller reset".

-12

Connected

Running

ON

ON

Connected

Running

ON

Connected

Running

ON

Flashes fast Flashes slowly

4.493.516 [EN]

Connected

Not running

ON

Short flash, long pause

Connected

Running

ON

Short flash, long pause

Connected

Not running

ON

Connected

Running

ON

Connected

No effect Not running

Flashes

No effect

OFF

OFF

Disconnected

I V Ph Tps

Current Voltage Phase Time

A E M

OFF Depending on phase

Stop Equalising charge Trickle charge

Connected

Running

ON

ON

Connected

Running

ON

Connected

Running

ON

Flashes fast Flashes slowly

Connected

Running

ON

Flashes slowly

Connected

Not running

ON

Connected

Running

ON

OFF Depending on phase

Connected

No effect Not running

Flashes

No effect

OFF

OFF

Disconnected

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I V Ph

-14

Current Voltage Phase

Tps A M

Time Stop Trickle charge

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Phase cycle the right:

according to schematic to

The first phase with a constant current (maximum current) continues until the battery voltage is under 24V. The following phase is a phase in which the output of the battery charger is held constant.

The current drops slightly while the battery voltage rises. The value of the power is equivalent to the rated power of the battery charger. This phase ends when the battery voltage reaches the voltage value of the following phase.

In phase the battery voltage remains constant and the current taken up by the battery in this phase drops continuously. The voltage threshold value at the charger output is 29V.

1 2 3 4 5 6 7 8

Current Voltage Phase l1 Phase P Phase U Phase l2 Time Stop

1 2

l2 with stop Ah in phases l+P

The final phase is a constant current phase with the purpose of creating an overvoltage required for the proper agitation of the electrolyte. At the end of the charging procedure the voltage is limited to 34V (2.83V/cell).

The current amplitude of this phase is determined by the charge injected in the initial phases and . The diagram at the right shows the law providing the current according to the charge: The duration of the end phase is established so that the quantitative charge of this phase is 17% of the charge injected in the previous phases , which guarantees an overcharging coefficient 1.15.

In the event of a rapid charge, the charging procedure is stopped by the user before the end of the charging procedure. In this case, the Ah injected during phases are stored in memory. They are added to the Ah of phases of the next charge to determine the overvoltage time. The cumulation will continue until a charging procedure is terminated by a complete overvoltage. The overvoltage current is determined by the law mentioned above and starts with the cumulation of the number of ampere hours.

If the battery charger stays connected to the mains, a new charging cycle will be started every 48 hours after conclusion of the charging.

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The adjusts automatically to the discharge state of the battery, thus allowing all kinds of partial charging (rapid charging).

The calculation of the overcharge takes the partial charges into account. The agitation is always sufficient and does not cause any unnecessary water consumption, thus avoiding premature wear of the battery (often due to overlong overvoltage periods) and reducing maintenance.

This form of charging automatically begins 15 minutes after the end of each complete charging procedure. It is effected with a current equal to half of the overvoltage current. The equalising charge ceases when the battery voltage has stabilised (fluctuations of less than 60 mV / hour).

This type of charging eliminates the phenomenon of sulphation and allows the 12 two-volt cells of which a 24V battery consists to equalise.

The charging procedure is stopped when the charging period exceeds 12 hours. This fault occurs when a battery cell is defective (shortcircuit).

In the event of a mains power failure, all charging parameters are stored in memory for 13 minutes.

As soon as the mains power is back again, the charging procedure resumes at point (I, U) at the moment of the power failure and stores the injected number of ampere hours (Ah) in memory.

If the power failure lasts longer than 13 minutes (the pallet truck might have been used in the meantime), a full charging cycle is initiated.

The installed battery charger is cooled by a fan.

Therefore do not allow the air inlets and outlets to become clogged.

The cooling fan begins to run as soon as the mains power is connected. The cooling fan stops when the charging procedure is terminated or when the mains power is disconnected.

As a form of protection, the battery charger output is reduced when the ambient temperature exceeds the operating temperature range.

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The battery charger also cuts out when the microcontroller has detected a fault in the temperature sensing.

Galvanic isolation: 1500 Vrms (effective mean value) False-polarity protection of battery: Two 25A automotive fuses in the output.

The green LED (3) indicates mains power is applied.

The yellow LED (2) indicates the current state of charging: It is illuminated in phases In phase

and .

it flashes fast.

It flashes slowly during the final overvoltage phase.

It flashes with the on periods much shorter than the off periods starting from the end of the overvoltage until the end of the equalising charge phase.

It goes off when charging is completed.

The green LED flashes if a charging time fault occurs (abnormal duration of phases ).

The battery charger does not need any special maintenance. Depending on the duty conditions, however, it is recommended to inspect the mechanical and electric fasteners regularly for security to achieve a high availability and durability of the charger.

Although the battery charger is suited for rapid charges, it is nevertheless recommended to charge the battery completely at least once a week.

In order to determine if the battery charger is defective, carry out the following checks:

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-17

Check the security of the cable connections between battery charger and battery.

Check the connections between the battery cells.

Check if the battery is connected properly (positive pole of battery = red lead; negative pole of battery = black lead).

Check if the battery voltage is over 9V. Check that the mains voltage is 230V +10%/15% and that the battery charger is connected properly via the power supply cable.

After conclusion of these checks connect the battery charger to the mains power supply and check the LED for proper operation.

If the green LED flashes, the battery charger is defective and a new start is only possible after a reset (see below). If the fault reoccurs after the reset when it is reconnected to the battery and the mains power supply, send back the battery charger.

If neither of the LEDs illuminates, send back the battery charger.

Check if the operation of all the LEDs and the cooling fan corresponds to the information in the tables below. Also measure the current output of the charger with a clip-on ammeter. If no current is emitted during phases I1, P1, U1, I2 or U2, send back the battery charger.

Disconnect the battery charger from the mains power outlet.

Disconnect the battery charger from the battery and then short the battery terminals on the charger or, even better, wait 10 minutes before reconnection.

Reconnect the charger to the battery.

Reconnect the charger to the mains power outlet.

Check the all LEDs and the cooling fan for proper operation (see "Tables and charging curves"). If this is not the case, send back the battery charger.

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4.493.516 [EN]

1 2 3

Mains fuse Line fuse (2 X 25 A) Fan

These fuses respond to sparking when connecting or disconnecting the battery connector during the charging procedure. We therefore recommend to inspect the wear state of the truck s battery connector exactly during all inspections or servicing of the battery charger. A badly worn battery connector, both the male and female connectors, can cause the power fuses of the battery charger to blow. If the truck is to be cleaned with water, the battery charger must always be removed.

If the battery fuses (automotive-type fuses) of a defective battery charger are located in an open circuit, make sure the charger is disconnected.

Remove the screws joining the two mechanical parts of the battery charger. Remove the varnish on the battery fuses and the fuse holders with 4.493.516 [EN]

-19

a brush soaked in acetone. Remove the fuses and fuse holders and also clean them carefully with acetone. Install two new fuses (25A rating) and close the battery charger again. Reconnect the charger to the battery, paying attention to the polarity (positive pole of battery = red lead; negative pole of battery = black lead). Connect to the mains power supply and check all LEDs and of the fan for proper operation. Also measure the current output of the charger with a clip-on ammeter.

Type: Automotive fuses 25A, 2 items Disconnect the battery charger from the mains outlet.

Wait 2 to 3 minutes (for the quenching of the input capacitors).

Disconnect the battery and remove the battery charger.

Remove the 6 cover fastening screws at the base of the battery charger.

Remove the two 25A fuses with flat nose pliers.

Install new fuses (push firmly into the clips).

Refit the 6 cover fastening screws in the base.

Reinstall the battery charger in the pallet truck and reconnect the cables and battery.

Reconnect the battery charger to the mains and check the state of charge (charging voltage about 28V).

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Disconnect the battery connector.

Remove the brake cover.

Disconnect the two connectors (1) for the power supply of the microswitch after marking them.

Remove both screws (2) on the microswitch.

The microswitch is not adjustable.

4.493.516 [EN]

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Disconnect the 2 pins of the limit switch (1).

Remove the 2 screws (2) and the limit switch.

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4.493.516 [EN]

Specifications - traction controller Voltage range

24V - 36 V

Lower voltage limit

16.8 V

Upper voltage limit

45 V

Electric insulation of the enclosure Max. armature output current

200 A for 2 min

Max. field winding output current

25 A for 2 min

500V 30 A for 1 He 10 A for 1 He

Commutating frequency

15 kHz

Ambient temperature range

- 40°C to +50°C

Weight

1.45 kg

Dimensions (mm)

168×114×68 (L× W× H)

The controller (1) is a control element driven by a "MOSFET" microprocessor. The microprocessor exercises a direct control over the input signal of the throttle over the total range of signal processing, including the integration of the current limit.

The RPM and the rated output of the traction motor is governed between 0 and 100% by the cycle rate of the transistor excitation.

The controller has an internal and external safety monitor, which stops the truck when a malfunction occurs.

Due to an LED (2) installed in the control unit, the fault diagnosis is easy to perform.

The adjustments are carried out with a programming unit or a Notebook.

To gain access to the controller and the other electric components, first remove the covers.

4.493.516 [EN]

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1 2 3 4 5

Terminal B+ Terminal BTerminal MTerminal S1 Terminal S2

6 7 8 9 10

Main contactor Fuse 125 A Battery Traction motor winding Armature

is connected to the positive pole of the battery and the armature terminal (A1) via the main contactor. is connected to the negative pole of the battery.

Internally it is connected to the source of the power MOSFET and the capacitors. is connected to the armature (A2). Internally it is connected to the drain of the power MOSFET. is connected to the induction winding. is connected to the other end of the induction winding.

The polarity of S1 and S2 affects the sense of rotation of the motor as soon as a forward/reverse or belly button control command is applied.

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The input and output signals are arranged on the 16-pin connector X1 fitted directly in the control unit of the controller (1).

PIN 16: Supply voltage +24V via the key switch. This initialises the controller and activates an internal monitoring circuit. When turning on the controller, the power-on sequence must be observed: Key switch / direction of travel microswitch.

PIN 15: Tiller microswitch input +24V. PIN 14: MODE selection input.

PIN 13: Tiller belly button input +24V. As soon as this input carries power, the controller reduces the traction motor current to 60% of the rated output and changes the direction of travel.

PIN 12: Direction of travel input + 24V (forward travel).

PIN 11: Direction of travel input + 24V (reverse travel).

The inputs 12 and 11 activate the power stage of the controller.

1-16

Connector 16-pin X1 control unit

Voltage test between terminals 6(+) and 7(-): Throttle in neutral: about 3.5V. Full throttle: about 0V (between 0 and 0.1 V).

PIN 6: Desired acceleration values (from 5 k to 0 k ) PIN 7: Power supply (lower point) for traction potentiometer (acceleration).

PIN 8: Control of electric brake (0V).

PIN 5: Power supply (top point) for potentiometer (option). Not used.

PIN 10: Control output of belly button on tiller head.

PIN 9: MODE selection input (not used).

PIN 4: Controlled negative for main contactor.

PIN 3: FAULT 1 output (not used).

PIN 2: FAULT 2 output (not used).

PIN 1: Not used.

4.493.516 [EN]

-25

Only the modes 1 and 2 affect the parameters: Acceleration (mode 1 = 2.5 s, mode 2 = 1 s) Plugging (mode 1 = 3 s, mode 2 = 1 s) Max. speed (mode 1 = 4 km/h, mode 2 = 6 km/h These are factory settings to make two parameters available for selection, depending on the use of the truck. This makes it unnecessary to connect the truck to the programming unit or the computer. These modes may be activated by selecting the "tortoise" mode (1)(mode 1) or the "hare" mode (2) (mode 2) with the key switch (3).

1 2 3 4 5

0V

0V

+24V

0V

Programming unit Curtis 1307 Tiller belly button (microswitch) Forward travel input Reverse input Select mode -26

6 7 8 9 10

Select mode 2 Brake switch Switch key Main contactor coil False-polarity protection diode

4.493.516 [EN]

11 12 13

Control fuse 7.5 A Throttle Optional test of tiller belly button

If a fault is detected, a status LED (1) indicates the error with a flash code. The LED is located on the face of the controller (2).

The code blinks until the controller is reset (switching the controller off and on; sometimes the brake switch is enough), provided that the fault has been eliminated.

The following fault diagnosis information is generated by the controller. The fault diagnosis LED in the controller enclosure indicates the diagnostic code by "flashing".

The figure shows an example: One flash - short pause (3) - two flashes - long pause (4), etc. The code of this example is: 1,2 Please refer to the table in with the description of the flash codes.

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3 4

Short pause Long pause

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1 2 3 4 5 6 7 8 9 10

Hydraulic control unit Solenoid valve Pump motor Solenoid valve Driver Hydraulic pump Suction line Filter Return line Hydraulic oil tank

11 12 13 14 15 16 17 18 19 20

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Spool Fastening screw O-ring Fastening clamp O-ring Filler neck Cover Nut Lowering pressure relief valve Lifting pressure relief valve

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1 2 3 4 5

Lift cylinder Hydraulic unit Lowering solenoid valve Lowering restrictor Hydraulic oil tank

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6 7 8 9 10

Pump motor Filter Pump Lifting pressure relief valve Non-return valve

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The hydraulic control unit is set to 160 bar at the factory. It is up to you to set the pressure for your model: EXU 16: 111 bar EXU 18: 122 bar EXU 20: 130 bar

When the pressure at port ?C? rises, the pressure at the pressure relief valve (9) also rises and the pressure relief valve opens and the oil flows back to the hydraulic oil tank.

To lower the load, the lowering solenoid valve (3) must be energized with the lowering button.

When the pump motor (6) is turned on, it drives the gear pump (8) which immediately pumps oil from the hydraulic oil tank (5) to port ?C? via the suction strainer (7) and the non-return valve (10).

The solenoid valve then changes its control position.

A hose is connected to port ?C?, which is connected to the lift cylinder (1).

This valve controls the oil flow for a certain time, thus controlling the lowering speed.

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To prevent the load from descending too fast, a lowering restrictor(4) is installed downstream of the solenoid valve.

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Output

3.6 cm3/ rev

Sense of rotation Torque

Anti-clockwise as seen from the motor shaft 22 Nm ±1

Working pressure (static) in bar

Ports

3/8 BSPP

Flow control valve

15 litres/min

Setting depending on model (load capacity) in bar

Volume Oil type

EXU16

100

EXU18

110

EXU20

117

EXU16

111

EXU18

122

EXU20

130

0.8 L used, 1.25 L maximum DS46 for standard and HVLP32 for cold store models

Suction strainer

250 µm

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Designation Motor type

AMJ5239 Compound-wound motor

Operating voltage (V)

24V

Amperage (A)

155 A at 130 bar

Power (kW)

2.2 kW

Duty period

S3 8% at rated load * and S3 5% at 2.2 kW

Protection class

IP54

Insulation Brush dimensions (mm)

Class F 16 x 16 (length) x 9 (thickness)

Min length of brushes (mm)

11 mm

Number of brushes

4

Diameter of collector

42 mm

* Operation of the motor at rated load during 8% of the time and at full load during 5% of the time

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Lower the forks.

Disconnect the battery connector.

Block up the truck on squared timbers.

Remove the covers.

Disconnect the pump motor (1) and of the solenoid valve(2) leads.

Disconnect the hydraulic hose (3).

Unlock the battery (4) and remove it with a hoist.

Place squared timbers under the pump unit so that it does not drop after the 2 fastening bolts are screwed out.

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Screw out the 2 pump unit fastening bolts (5) over the battery compartment.

Lift out the pump unit.

The installation is carried out in the reverse order of removal. Do not forget to replenish oil to the correct level.

Oil can run out.

Lower the forks.

Disconnect the battery connector.

Block up the truck on squared timbers.

Remove the covers.

Disconnect the pump motor leads (1).

Remove the 4 socket head screws M5 (2).

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Loosen the flat tightening strap (3).

Remove the hydraulic oil tank.

Remove the strainer (?22 flat).

Screw out the two M6 socket head screws (4).

Remove the pump.

Remove the pump unit.

Remove the two M10 screws (5).

Remove the commutator cover (6).

Remove the whole unit.

Drive the rotor out through the opening for the pump shaft (7).

Withdraw the 2 bearings from the rotor.

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The brushes must be replaced when they have a residual length of approx. 50%. If the brushes approach the wear limit of 50%, they must be renewed immediately and not at the next service interval in a few months.

New brushes

Replace at:

16 mm

11 mm

The brushes must always be renewed as complete set of 4 items.

Park the truck and remove the front cover.

Disconnect the battery connector.

Remove the two M10 screws at the top of the motor.

Pull the brush cover (1) up to make the 4 brushes (2) accessible.

Take care not to lose the washer (3).

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Loosen the 4 brushes leads.

Press down on the brush holder to remove the brushes indicated by arrows 1 and 2.

The procedure applies for the removal of all 4 brushes.

Clean the area around the commutator.

Install new brushes.

Do not inhale carbon dust, wear a protective mask.

After the motor brush renewal, do not run the motor immediately with a full load. The brushes will be run in relatively fast with a reduced load.

Brush springs, whose tension (force < 5 N, measured with a spring scales) is too low, lead to the destruction of the commutator. It is also important to make sure the brushes in the move easily in the holders.

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The lowering solenoid valve Y1 (1)allows the oil to flow to the hydraulic oil tank flow as soon as the lowering button at the tiller head is actuated.

The coil resistance of the solenoid valve is 40 Ohm, measured between terminals 1 and 2.

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Remove the covers.

Remove the battery.

Seal the oil filler plug of the pump unit.

Tilt the truck 90°. To do this, squat down and place the weight on the legs, not on the back.

The back must stay straight.

Drive the two pins (1) from the lever shaft.

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Set the truck back onto the floor.

Remove the 4 fastening screws (2) of the battery connector via the battery tray.

The spacer (3) between plug and frame must be maintained.

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Place the battery connector into the motor compartment.

Remove the screw (5) to remove the sensor (4).

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Attach lifting slings to the two holes(6) in the battery compartment.

Raise the truck at the battery compartment, until 3 squared timbers can be put in position as shown in the illustration at the right.

Remove the circlips (7) at the cylinder head.

Drive the 2 pins (8) out, taking care not to lose the 2 washers (9).

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Separate the powerhead from the forks by raising of the battery compartment.

Set the forks on their head with a block and tackle.

Drive both pins (10) out of the lifting shaft.

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Remove the 2 pins (11).

Drive the two straight pins (12) out of the fork joining piece.

Remove the 2 pins (13), taking care not to lose the 2 pairs of washers (14).

Remove the two pull rods (15).

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Drive out the two straight pins (16) at the end of the pull rod.

Drive out the pin (17).

Take care not to lose the white spacers.

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Drive out the 2 straight pins (18).

Remove the 2 pins (19) .

Remove the lifting shaft.

Hook the battery compartment into lifting slings.

Tip over the powerhead.

Assemble the two parts as shown in the illustration at the right.

Refit the 2 pins (20). Do not forget to install the 2 spacers (21).

Secure the two 2 lifting shaft pins with straight pins.

The rest of the assembly is carried out in the reverse order of removal.

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Lower the forks.

Disconnect and remove the battery.

Remove the hydraulic fitting (1) at the lift cylinder and install a plug to prevent the oil from flowing out on to the floor.

Attention, oil under pressure, risk of oil spurts.

Remove the circlips at the cylinder head.

Remove the four screws (2).

Raise the fork carriage in the direction the two battery compartment holes.

Remove the cylinder.

Take care not to lose the sleeve (3).

Installation is the reverse of removal. Do not forget to install the sleeve (3).

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Clamp the piston rod in a vice.

1 2 3 4 5 6

Wiper ring Guide bush Lip seal Guide bush Piston rod Cylinder barrel

Press off the cylinder barrel (6)with a wooden wedge.

The piston rod is not held by anything in the barrel. Do not stand behind the piston rod if compressed air is used to drive it out.

Separate the piston rod from the cylinder barrel (6).

Successively remove the wiper ring (1), first guide bush (2) and lip seal (3).

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The second guide bush (4) is located slightly recessed in the barrel.

a

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12

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Still GmbH Berzeliusstrasse 10 D-22113 Hamburg Ident no. 4.493.516 EN

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Ident no. 4.493.516 EN

Still GmbH Berzeliusstrasse 10 D-22113 Hamburg