PDF Workshop Manual STILL Wagner STED GX13 Forklift - 2 MB
This complete workshop manual covers all service and repair procedures for the STILL Wagner STED GX13 Forklift.
It is a comprehensive resource for technicians, containing detailed instructions for maintenance, troubleshooting, and component overhauls.
Ensure your forklift operates safely and efficiently by using the manufacturer's specified procedures.
This guide is essential for keeping your material handling equipment in prime condition.
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--- Page 1 ---
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
reserved.
First Issue:
Last Revision: 8/98
4/96
Workshop Manual
Manual
Workshop
GX13
5/
Id. no. 8 054 131
GX13
--- Page 3 ---
Assembly A Travel drive
Removing the travel motor
After the travel motor has been
removed, the vehicle is no longer
braked. For this reason, the vehicle
must be secured against rolling away. 1
1. Move the driver's seat back electrically.
2. Pull out the battery plug.
7
3. Remove the electromagnetic spring-loaded
brake (1) (see sheet no. C 21) and the rotor
(2).
8
4. Remove the flange (3).
5. Unscrew the shaft journal (4) and remove the
disc.
6-0802
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
6. Disconnect the block plug (5) for the travel
motor fan.
7. Open the tensioning belt (6) and remove with
the travel motor fan.
8. Mark the travel motor connecting cables (7) 4
and disconnect and isolate them.
reserved.
The travel motor connecting cables
must be isolated because the battery 6
will later be reconnected for further 2
stages of the process.
3
9. Unscrew and remove the 6 hexagon socket
screws (8). A hexagon socket screw key bent
at a right angle should be used for this
purpose. 5
6-0805
Continued on sheet no. A6
Issue: 4/96 Workshop Sheet no.
Replaces issue: Manual GX13 A5
--- Page 4 ---
Assembly A Travel drive
Travel motor, maintenance
(contd.)
Visual inspection, exchanging
damaged parts:
- Straighten or exchange dented sealing
tapes (Id. no. W8 405 826).
- Check fan impellers for damage. Damaged
fans (imbalance, reduced output) must be
exchanged (Id. no. W8 415 994 (48 V)).
- Clean the ventilation channels at the gear
box (1). To do so, remove the travel motor
and clean the channels using a vacuum 1
cleaner (do not clean them with
compressed air). Soiling reduces the air
circulation, leading to increased
temperatures in the motor and to possible
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
destruction.
5/0039
- Check field and armature windings for
signs of overloading (overheating): dark
coloration, brittle or burned insulation,
unsoldered commutators.
Motors bearing this kind of damage must
be exchanged without delay.
- If you discover oil or grease in the motor
reserved.
(usually an oil paste, oil vapour mixed with
dust and carbon abrasions), investigate the
cause immediately and remedy. The motor
must be cleaned extremely thoroughly.
Rapid carbon brush or commutator wear is
generally due to the effect of oil.
The oil/grease burns in the brush sparks,
leaving a sharp-edged oil ash which has an
abrasive efect.
This can tend to lead to inadmissibly high
levels of carbon brush wear before the
scheduled maintenance dates.
Issue: 4/96 Workshop Sheet no.
Replaces issue: Manual GX13 A 16
--- Page 5 ---
Assembly B Steering
Principle of the manual steering
PLC Master
Digital setpoint generator
Input module
5/0508
Vehicle standstill
5/0120
5/0509
Steering controller
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
A 21 distribution board
5/0500
relay error, steering
EWL W95 Error steering control current (3K11)
Type 2
reserved.
Error, steering main current
+48V
6/0516
Actual value
potentiometer 6/0515
Servo unit
5/0131
Issue: 4/96 Workshop Sheet no.
Replaces issue: Manual GX13 B2
--- Page 6 ---
Assembly B Steering
Steering controller EWL W 95, type 2
Continued X1
2. Potentiometer (2) can be used for fine
adjustment during mechanical presetting of the
actual value potentiometer.
Procedure
- Turn the setpoint generator until input E10.3
channel 5 is illuminated in the PLC (actual value,
straight-on).
- Switch the rail switch (light scanner). This forces
the controller into straight-on mode.
X2
- Turn potentiometer (2) until the drive is straight.
3. Potentiometer (3) can be used for fine
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
adjustment when readjusting the 90° steering 3
angle (clockwise rotation to decrease the
steering angle). 2
Turn this potentiometer until a steering angle of
90° is achieved to the left and right.
1
Do not turn too far. The drive must not
knock against the mechanical stop.
4 12 F 0
E
D 4
3
C 5
4. If the steering angle is too small, potentiometer B
A9 8 6
reserved.
7
(1) must be turned (anti-clockwise).
5. Turn the service switch (4) back to its normal
position Ø. X3
Enable
Actual value
Setpoint
X4
5/0123
Issue: 4/96 Workshop Sheet no.
Replaces issue: Manual GX13 B 12
--- Page 7 ---
Assembly B Steering
LR80
Operating mode
Manual steering:
Once the self-test is completed, the indicator light
goes off (3).
The displays (4 and 5) flash alternately (speed limit
2.5 km/h, wire search). If the vehicle is to be driven
away from the induction loop, button (1) must be
pressed once. Display (4) lights up and the maximum
speed Vmax can be reached.
Steering with the inductive control system:
Travel with the inductive control system takes place
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
in three stages.
a) Wire search mode 5/0155
When the scan switch (1) is pressed, the "Wire 1
search" function is activated, and indicator lights
(5 and 6) flash alternately.
The closer an areial comes to the guide wire, the
shorter these intervals become. When an aerial is
positioned directly above the guide wire, the
interval changes to a continuous signal. 2
reserved.
b) Preparatory aisle-travel mode
Once the guide wire has been detected by an
aerial, the system switches automatically into
preparatory aisle travel, i.e. when the manual
steering is automatically disconnected, the control
unit continues steering at a reduced speed of
travel until the vehicle is correctly aligned, ready
to enter the aisle. This operating mode is 5/0156
indicated by a flashing indicator light (6). 3 4 5 6
Issue: 4/96 Workshop Sheet no.
Replaces issue: Manual GX13 B 22
--- Page 8 ---
Assembly B Steering
LR 80
Central processing unit
DC/DC converter Id. no. W8 007 390
The DC/DC converter (1) generates a voltage of
5 V and 12 V. Both voltages can be adjusted. 1
Before it can be adjusted, the converter must be
removed from the central processing unit. To do
so, unscrew the front panel and remove.
The trimming potentiometer for the 5 V voltage
(2) is on the converter motherboard.
Adjustments can be made with a 0.5 x 2.8 x 100
screwdriver, which is pushed into a hole with a
cover (ADJ 5 V) (2).
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
The trimming potentiometer for the 12 V voltage 1 3
(3) is on the right-hand side when viewed from
the pin side.
O
The following applies for both voltages:
OUTPUT 2
DC/DC-Converter S12V
Clockwise rotation: voltage increases
OUTPUT 1
Anti-clockwise rotation: voltage decreases Adj.
reserved.
Adj.
Voltage range: 5V min: 3.6 V INPUT
Power 10-30V
max: 5.8 V
12 V min: 9.6 V
max: 14.7 V 2
Issue: 4/96 Workshop Sheet no.
Replaces issue: Manual GX13 B 30
--- Page 9 ---
Assembly B Steering
LR 80
Commissioning
Adjusting the wheel of the potentiometer
- Test 03 - (Set mode switch to 3)
Beforehand the offset potentiometer
must be set to ± 00 (see B42).
Using the Manual potentiometer, set the guided
wheel exactly to "forward travel", set the Wheel
potentiometer so that the display indicates:
WHEEL = 800. Then fix
The position of the hand wheel (set-
point value) is of no significance for
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
the synchronization of the actual
value and drive mechanism.
Testing the controller (controller setting, dyna-
mics)
- Test 04 - Set operating mode switch to 4.
- Turn steering potentiometer to the centre
position.
reserved.
When the turning carriage meets a mechanical
stop, check the wheel potentiometer setting. If
in order, check the connections of the
proportional valve. If the steering movement is
too slow or too fast, set the optimum angle
speed using the angle control amplifier
potentiometer.
- Turn the steering potentiometer to the left and
right against the steering stop. If the maximum
angle stop on the right or left is not correct, the
stops can be adjusted using the potentiometer.
(See from B90)
Issue: 4/96 Workshop Sheet no.
Replaces issue: Manual GX13 B 46
--- Page 10 ---
Assembly B Steering
LR 80
Error signal:
* Service display unit data transmission fault *
Test of data transmission to the service display unit
In this test, the transmission of data to the service display unit is
performance tested.
(If undefined symbols appear in the service display unit, the unit or
the cable can be defective.)
What to do when this error signal appears:
If this fault occurs, the cable connection to the service display unit
must be checked.
- If defective, exchange the cable
- Using the test service display unit at X3 central unit, test whether it
functions with the test service display unlt. If so, exchange the
service display unit at the truck.
Error signal
* 12 V voltage too high *
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
* 12 V voltage too low *
Test of 12 V voltage (min. max. value testing)
In this test, the voltage is tested for a minimum and maximum value.
(The voltage value must lie within this range).
What to do when this error signal appears:
If this fault occurs, check the 12 volt output voltage of the DC/DC
converter. Exchange the power supply unit in the central unit.
reserved.
Error signal
* 5 V voltage too high *
* 5 V voltage too low *
Test of the 5 V voltage (min. max value testing)
In this test, the voltage is tested for a minimum and a maximum value.
(The voltage value must lie within this range).
What to do when this error signal appears:
If this fault occurs, check the 5 V output voltage of the power supply
unit.
Exchange the DC/DC converter in the central unit.
Issue: 4/96 Workshop Sheet no.
Replaces issue: Manual GX13 B 56
--- Page 11 ---
Assembly B Steering
LR 80
Changing the parameters (German software)
Configuration continued
Position the cusor on the S of SICH (= Save)
EXE
the display then reads
SICH A MODE
the display then reads
SICH C
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
enter your personal code, e.g.
L R EXE
The setup program is now stored and can be
called again at any time.
reserved.
Continued on sheet no. B 95
Issue: 4/96 Workshop Sheet no.
Replaces issue: Manual GX13 B 92
--- Page 12 ---
Assembly B Steering
LR 80
Continued
Setting the LR 80 with a PSION
Maximum steering angle limit to the right
Aim: To determine the maximum steering angle without the drive hitting against the
mechanical stop.
Example:
PSION entry
S shift
and D A A EXE
= maximum steering angle to the right
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
PSION reads: S DAA SEND
Display reads: SANZ DAA
When the EXE command is given, the drive rotates. Ensure that the service
switch is set to position "A" (see sheet no. B 10). The example value given above
(DAA) should not be selected too high, otherwise the drive wll hit the mechanical
stop. The value must be raised step by step, so that the drive stops approx. 20
mm before the mechanical stop.
reserved.
When the correct value has been determined, e.g. D A A (make a note of it), this
is later written in under an addresss (see sheet no. B110) as follows:
D A A
Entries at High, with an additional Entries at
Ø in front of the D low
PSION entry
S shift and 8 Ø Ø EXE = centre
PSION reads: S 8ØØ SEND
Display reads: SANZ 8ØØ
The drive turns back into the central position.
Continued on sheet no. B 103
Issue: 4/96 Workshop Sheet no.
Replaces issue: Manual GX13 B 102
--- Page 13 ---
Assembly B Steering
LR 80
Continued
Setting the LR 80 with a PSION
Optimising the parameters
Address Designation Value
Emergency-off parameters
XE 59 Max. error for lateral deviation 4 Ø (guide value) must be
Preparatory aisle steering determined
(1 aerial has identified induction loop)
XE 5A Max. error for lateral deviation 2 Ø (guide value) must be
Aisle steering (dimension "B") determined
Copyright protected. No part of this manual
may be reproduced in any form. Copyright
XE 5B Max. error for lateral deviation, 15 (guide value) must be
Aisle steering take-over determined