PDF Workshop Manual Still Wagner EFU 3001 - 1 MB
The workshop manual for the Still Wagner EFU 3001 contains all the technical information needed for service and major repairs.
It details procedures for the electrical system, hydraulics, and mechanical components.
Technicians will find this guide essential for complex diagnostics and overhauls.
Keep your equipment in top condition with factory-approved repair methods.
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--- Page 1 ---
Workshop Manual EFU 3001
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
reserved.
1/0360
First issued: 04/01 Workshop EFU 3001
Last update: Manual with Highpulse Id. No. W8 054 232
--- Page 3 ---
Chapter 1 Vehicle data
Signs on the vehicle
1 Factory nameplate (next to the driver's seat) 1 5
2 UVV test plaque
3 Maximum pressure for hydraulics
4 Towing points
5 Vehicle no. on chassis (behind the
driver's seat and on drive motor support)
Vehicle data 1/0360
• Load bearing capacity 3000kg 4
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
• Drive motor 5.2kW
• Maximum speed 12km/h
• Dimensions L/W/H 3700/990/1930
• Unloaded weight 2340kg 1 2
reserved.
• Battery type PzS
Volts/amps 48/560
Weight min/max 886 - 933kg
1/0309
3
Issue: 04/01 Workshop EFU 3001 Sheet no.
Replaces issue: Manual with Highpulse 1-01
--- Page 4 ---
Chapter 2 Travel drive
Drive motor maintenance
Visual inspection, replacing damaged
parts
• Straighten or replace dented sealing tapes.
• Check fan impellers for damage. Damaged fans
(imbalance, reduced output) must be replaced.
• Clean the gear ventilation channels (1). To do so,
remove the drive motor and clean the channels
with a vacuum cleaner (do not blow them out with
compressed air). Soiling impairs the air
circulation, which leads to increased
temperatures in the motor and possibly to
irreparable damage. 1
• Check field and armature coils for signs of over-
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
loading (overheating): dark coloration, brittle or
burned insulation, unsoldered commutators.
Motors with this kind of damage must be
replaced without delay.
• If you discover oil or grease in the motor (usually
a paste made up of oil, oil vapour mixed with dust 5/0039
and carbon abrasions), investigate the cause
reserved.
immediately and remedy it.
The motor must be cleaned extremely
thoroughly.
Remark: Rapid carbon brush or commutator wear
is generally due to the effect of oil.
The oil/grease burns in the brush sparks,
leaving behind a sharp-edged oil ash
which has an abrasive effect.
This can lead to inadmissibly high levels
of carbon brush wear before the
scheduled maintenance date is reached.
Issue: 04/01 Workshop EFU 3001 Sheet no.
Replaces issue: Manual with Highpulse 2-10
--- Page 5 ---
Chapter 3 Steering
Steering controller WLR 48/30
Id. no. W8 409 943
General
The steering controller is used in combination
with a split field motor in electrically assisted
steering systems.
The setpoint request made with the steering
wheel is measured by differential magneto-
resistive sensors and evaluated, as a result of
which the integrated MOSFET power amplifier
is driven.
In combination with the non-linear current/
torque characteristic curve, this gives a 1/0297
steering performance that guarantees both
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
high stability during fast travel and easy
steering at a standstill.
Internal monitoring functions guarantee a safe
function.
reserved.
Issue: 04/01 Workshop EFU 3001 Sheet no.
Replaces issue: Manual with Highpulse 3-08
--- Page 6 ---
Chapter 4 Brake
Installing/removing the drive motor
brake
Note: Once the brake has been removed, the
vehicle is no longer braked. For this
reason:
• Pull out the battery plug.
• Jack up the vehicle and secure it to
prevent it from rolling away.
Removal:
• Remove the brake hose (1) from the brake
cylinder, making sure that no oil runs out over
the brake and motor.
• Remove the brake housing (2) by releasing the 4
hexagon socket screws (3).
• The brake can now be removed from the drive
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
motor. 1
• For easy removal of the cable pull, relieve the
tension on it at the adjusting device of the hand-
brake lever.
• Separate the baseplate (4) from the housing by
releasing the 7 hexagon socket screws (4) M8 x
16.
reserved.
Installation:
• Attach the baseplate to the housing.
• Secure the cable pull for the handbrake.
• Set the brake on the motor and screw the
housing to the motor flange.
• Attach the brake hose.
• Bleed the brake and reset the handbrake.
• Check that the brake functions correctly.
• Brake pedal function check
• Handbrake function check.
1/0291
4 5 3 2
Issue: 04/01 Workshop EFU 3001 Sheet no.
Replaces issue: Manual with Highpulse 4-03
--- Page 8 ---
Chapter 5 Travel control
Highpulse 2400-5
Protective devices
• Reverse voltage protection
The wiring must be exactly as shown in the circuit
diagram, so that the power section is not damaged.
The main contactor protects the power section from
reverse voltage.
The logic itself is protected internally against reverse
voltage.
• Wiring errors
All the inputs are protected against wiring errors.
All the outputs for selecting the contactors may only
be loaded with a maximum of 3A, although they are
protected against overloading and short-circuiting.
• Overheating
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
If the housing temperature (heat sink temperature)
rises above 80 C, the maximum current is reduced in
proportion to the rise in temperature.
The temperature must not rise above 85 C. If it does,
the system switches off.
• Battery flat
If the battery is flat (remaining capacity <10%), the
reserved.
maximum current is reduced to 50%. This function
can be switched on and off with the notebook. In this
vehicle, the function is switched off.
• External influences
The control unit is built into a closed housing and is
therefore protected against dust and splashing water
(IP 54).
• Uncontrolled driving away
In order to put the vehicle into gear, a certain
switching-on sequence must be followed. If this is not
carried out correctly, the vehicle does not start up.
Switching sequence:
Key switch ON, door switch actuated, then travel
direction signal.
Issue: 04/01 Workshop EFU 3001 Sheet no.
Replaces issue: Manual with Highpulse 5-02
--- Page 9 ---
Chapter 5 Travel control
Highpulse 2400-5
Configuration
Remark: Values in <bold print> apply for this
vehicle .
BYPASS CONTACTOR (not used)
BATTERY CHECK
• OFF (0) = The charging level of the bat-
tery is not monitored;
• ON (1) = The charging level of the bat-
tery is monitored. If the remai-
ning capacity is less than 10%,
the maximum
current is reduced by half and
the error LED flashes continu-
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
ously.
ANTIROLLBACK (ARB)
• Free (0) = No "Anti-rollback"
• Check (1) = "Anti-rollback" is active, i.e. if
the vehicle rolls backwards on
starting up, the logic reacts.
The motor is controlled with a
reserved.
steeper current curve to pre-
vent rollback as far as possible.
RELEASE BRAKING
• Free (0) = No generator braking when the
travel transducer is moved to
zero position (travel transducer
switch opens).
• Braking (1) = Generator braking when the
travel transducer is moved to
zero
position. The braking current
can also be increased with the
brake pedal (optional brake pe-
dal switch).
Issue: 04/01 Workshop EFU 3001 Sheet no.
Replaces issue: Manual with Highpulse 5-12
--- Page 10 ---
Chapter 5 Travel control
Highpulse 2400-5
Error diagnosis
Flashing code on the diagnosis LED
The number of flashing impulses represents the error number. There is a pause of 2
seconds between each code. Only the last error to have occurred is displayed.
Error
1 Error in the electronics (EEPROM DATA KO, EEPROM PAR. KO, EEPROM
OFF LINE, CHOPPER NO CONF, WATCH-DOG)
2 When the system is switched on, a travel direction is selected or the start se-
quence is not maintained (INCORRECT START)
3 VMN not in order (VMN, NO FULL COND)
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
4 Error in potentiometer signal (VACC NOT OK / VACC >1V)
5 Current flow in main current circuit is not in order (STBY I HIGH,
I = 0 EVER)
6 Error at the contactor drivers (DRIVER SHORTED, COIL SHORTED)
reserved.
7 Temperature > 80 C (TH PROTECTION)
8 The contactors do not close or VMN high is idle position
(BRAKE CONT. OPEN, DIR. CONT. OPEN, VMN HIGH)
9 Contactors do not open
(BRAKE CONT.CLOSED, DIR.CONT.CLOSED)
Continuous flashing light Battery discharged; remaining capacity < 10%.
Continuous light Both travel directions selected at the same time.
Issue: 04/01 Workshop EFU 3001 Sheet no.
Replaces issue: Manual with Highpulse 5-22
--- Page 11 ---
Chapter 6 Servicesoftware
WinPulsE
Opening a file
(File Open )
Option 2: 1 2
Alternatively, the file can be opened from the
"Parameter Change" window (1).
• Select the Open button (2). The "Open" window (3)
appears.
• In the "Search in" input field (4), select the directory in
which a vehicle file has been stored, e.g. the customer
directory. All the saved files are listed in the selection
window (5).
Remark: The standard setting is the WinPulsE
directory.
1/0150
• Select the file you want (6). This should appear in the
"File name" window (7). 6 4 3 5
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
• The file can be read in with the Open button (8). The
"Parameter change" window (9) opens and the
parameters are displayed.
• There is a User_Comment (10) under the selection
window that was entered when the file was saved.
Remark: A file that is opened in this way can be
modified and then saved under the same
name or a different name! 1/0156
reserved.
Before the data can be sent to the control 7 8
unit, the connection must be made. 9
• The current window can be quit by selecting the
Close button (11).
Close
1/0152
10 11
Issue: 04/01 Workshop EFU 3001 Sheet no.
Replaces issue: Manual with Highpulse 6-05
--- Page 12 ---
Chapter 6 Servicesoftware
WinPulsE
Test function
(Tester)
1
Remark: Display function for various control unit
signals.
No settings can be made in this function.
• In the menu bar, click on "Function" and then "Tester"
(1).
• The - Tester - window (2) opens.
The data for the tester is read automatically out of the
1/0149
control unit.
• In the selection window (3), use the scroll bar (4) to 3 4 2
find the function you require and click on it with the
mouse. The function is automatically displayed in the
"Test name" display window (5) with the corres-
ponding "Test value" (6).
Copyright protected. No part of this manual
Remark: A maximum of 4 functions can be displayed
may be reproduced in any form. Copyright
at one time. If you wish to display different
functions, one or all the functions must first
be deleted.
• Click on the function you want to delete with the
mouse. The background to the function turns blue,
e.g. "Brake switch" (7). 1/0162
Signal button (8) to delete the selected
• Use the Clear signal
function. 5 7 6
reserved.
Clear all
• The Clear all button (9) deletes all the selected test
points from the display window (10).
• Use the Close button (3) to quit the active window.
1/0163
10 9 8 11
Issue: 04/01 Workshop EFU 3001 Sheet no.
Replaces issue: Manual with Highpulse 6-15
--- Page 13 ---
Chapter 8 Hydraulic system
Pump assembly
General 1
The pump assembly is made up of the
following components:
Item.Component
8 7
1 Pump motor
(compound) 4
2 Hydraulic pump 9
3 Hydraulic suction filter
4 Lowering valve (pilot controlled non-
return valve 6
3
5 Tank (1.5 litres)
Copyright protected. No part of this manual
10
may be reproduced in any form. Copyright
6 Air filter
7 Carbon brushes
8 Pressure relief valve
9 Lowering brake valve
10 Non-return valve (load holding valve)
reserved.
8/0064
2
5
Issue: 04/01 Workshop EFU 3001 Sheet no.
Replaces issue: Manual with Highpulse 8-02