Still wagner gx13 forklift service repair manual

Workshop
Manual Id. no. 8 054 131
First Issue: 4/96
Last Revision: 8/98
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GX13
5/
Workshop Manual GX13

Foreword
This workshop manual provides specifications
and describes functional characteristics of the
standard truck.
This provides you with a comprehensive
documentation to ensure better understanding
of the vehicle technology and so permit correct
maintenance and repair work to be carried out.
The workshop manual is always updated by
supplementary sheets.
Updating of workshop manuals
The industrial truck range is subject to
continuous further development. This means
that certain components or assemblies are
exchanged or modified.
To ensure that the holder of this manual always
has the most up to date version of the
documentation, it is important to abide by the
following updating system.
Foreword
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Issue: 2/97 Workshop Sheet no.
Replaces issue: 4/96 Manual GX13 I
5/
5/
5/
5/

Updating workshop manuals
(Contd.)
1. Exchanging faulty sheets
If a particular page contains mistakes, for
example due to altered setting values, the
respective sheet must be exchanged.
A newly inserted sheet can be recognized by the
altered left-hand baseline (1). Here, the date of
compilation is updated in the line entitled Issue
(2). In the line Replaces issue (3) is the
compilation date of the sheet to be replaced. The
sheet no. remains the same (4).
With every revision the first sheet will be repla-
ced. In (9) you see the first issue and the date of
the last revision. This tells you the revision state
of the whole book.
2. Insertion of supplementary
sheets
If new, modified or additional components are
included in the series truck, it may be necessary
to add one or more supplementary sheets.
The additional sheet is recognized by the left-
hand and right-hand page baseline (5+6).
In the Issue line on the left-hand side is the
compilation date (7). On the right, the
supplementary sheet is marked by the sheet no.
with continuous index (8).
In addition, the table of contents of the respective
assembly must also be exchanged.
Newly compiled sheets, whether replacements or
supplementary sheets, and the new tables of
contents are sent by post to all known holders of
workshop manuals.
Foreword
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Issue: 4/96
Replaces issue:
Workshop
Manual
sheet.no.
GX13 A 1
Issue: 2/97
Replaces issue: 4/96
Workshop
Manual
sheet-no.
GX13 A 1
Page baseline of the existing sheet
Page baseline of the corrected sheet
1 4
2
3
Issue: 4/96
Replaces issue:
Workshop
Manual
sheet-no.
GX13 A 1
Issue: 2/97
Replaces issue:
Workshop
Manual
sheet-no.
GX13 A 1.1
Page baseline of the existing sheet
Page baseline of the supplementary sheet
6
5
7
8
Replaces issue: 4/96 Manual GX13 II
First issue: 4/96
Last revision: 2/97
Workshop
Manual
SERVICE
TRAINING
GX13
Page baseline of the first sheet
9

Remarks, imprint
No guarantee claims arise as a result of
working in accordance with the instructions
contained in this manual.
This does not affect the guarantee stipula-
tions.
We are continuously involved in the further
development of our industrial trucks. Please
appreciate that this documentation is subject
to alteration and error, and that no claims
may be derived from information, illustrations
and descriptions contained in the workshop
manual .
Publisher
STILL WAGNER
GMBH & CO KG
Trainingszentrum
Ernst-Wagner-Weg 1-5
72766 Reutlingen-Mittelstadt
Foreword
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Replaces issue: 4/96 Manual GX13 III

Definition of movement directions
Foreword
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Replaces issue: Manual GX13 V
5/
Mainlift
Lift
Mainlift
Lower
Backwards
travel
Forwards
travel
Left and right are as seen when looking in the direction of forwards travel.
If the truck is equipped with shelf selector the definition of the movement
directions is different. See chapter WPG for details.

Assemblies:
A Travel drive
B Steering
C Brake
E Lifting device
F Cylinders
M Electrical system
N Hydraulic system
R Lubrication plan
T Swivel shift fork
U Installations, covers
V PLC
W WPG
Z Trouble shooting
Special tools
Assemblies
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Replaces issue: Manual GX13 0

Contents
Sheet
Motor, general ...........................................................................................A 2
Terminal markings at the motor.................................................................A 4
Removing the travel motor ........................................................................A 5
Removing the drive pinion.........................................................................A 5
Changing the drive wheel..........................................................................A 10
Exchanging the carbon brushes................................................................A 12
Carbon brush monitor (travel motor) .........................................................A 13
Temperature monitor, travel motor............................................................A 14
Travel motor, maintenance........................................................................A 15
Travel motor specifications........................................................................A 19
Commissioning the gearbox......................................................................A 20
Oil change, gearbox ..................................................................................A 21
Removing the gearbox ..............................................................................A 25
Assembly A Travel drive
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Replaces issue: Manual GX13 A 1

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Motor, general
Id. no. W8 405 949
The travel motor used is a force-ventilated 48 V
shunt motor (Fig. 1, no. 1).
The armature and field windings are controlled
separately by the travel pulse control. This gives a
higher torque when starting up and keeps the
rotational speed stable on load alternation (Fig. 2).
The rotational speed of the motor is controlled by
the clock ratio of the MOS-FET transistors in the
travel pulse control and is about16 KHz.
In the lower speed range (starting up), the field
excitation is at a maximum and when the armature
current is increased, the rotational speed is also
increased = high starting torque (Fig. 3).
In the upper speed range, the field excitation is
weakened and the armature current held stable
= increase of rotational speed to final speed
(Fig. 3).
When the load changes, a combination of both
these control methods is used = stable rotational
speed.
The motor is braked electrically by intensifying the
field strength. This has a generator effect, which
results in negative feed to the battery.
The sense of rotation of the motor depends on the
direction in which the current flows through the
field winding. A full-bridge field rheostat is used for
this purpose.
When transistor pair 1 is operating, the
current flow is E1 --> E2, or forwards travel
direction (Fig. 4).
When transistor pair 2 is operating, the
current flow is E2 --> E1, or backwards travel
direction.
The full-bridge field rheostat is integrated in the
travel pulse control system.
Load moment M
1
5/0153
Fig. 1
Fig. 2
Shunt motor only
Series wound motor only
Combination of both motors
Setpoint/rotational speed
Start-up Acceleration
I
I
Fig. 3
5/0007
o
o
.
.
1
2
1
2
E1
E2
Fig. 4 5/0008
5/0506

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Continued
Motor, general
There is a speed sensor on the top of the
travel motor for measuring the motor speed
(1).
(For instructions on testing the speed sensor,
see sheet M 60.)
The travel motor is fitted with a temperature
sensor and a carbon brush monitor to
improve its operational safety.
The carbon brush monitor works using signal
carbon.
The carbon connected to terminal A1 of the
motor is monitored.
The temperature sensor registers the
temperature of the carbon brush shaft fitted
with the signal carbon.
5/0153
5/0152
1
1

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Terminal markings at the motor
5/
Marking at the motor Meaning
A1 Start of the armature winding
A2 End of the armature winding
E1 Start of the shunt field winding
E2 End of the shunt field winding
X2.1 0 V signal, temperature sensor
X2.2 0 V supply, temperature sensor
X2.3 0 V signal, carbon brush monitor
X1.1 15 V supply, speed sensor
X1.2 Speed sensor signal channel A
X1.3 Speed sensor signal channel B
X1.4 0 V supply, speed sensor
Main current terminals
Sensor terminals
The 4-pin JPT connector with two blue wires is not used (extra
field winding temperature sensor).
1
2 1
2 1
2
4 3 4 3
Connector
(JPT)
X1 X2
5/0507
Motor terminal board
Free connector

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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. Move the driver's seat back electrically.
2. Pull out the battery plug.
3. Remove the electromagnetic spring-loaded
brake (1) (see sheet no. C 21) and the rotor
(2).
4. Remove the flange (3).
5. Unscrew the shaft journal (4) and remove the
disc.
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)
and disconnect and isolate them.
The travel motor connecting cables
must be isolated because the battery
will later be reconnected for further
stages of the process.
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.
Continued on sheet no. A6
1
6-0802
4
6-0805
5
6
8
7
2
3

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Continued
10. Screw an eyebolt (1) into the travel motor
armature shaft.
11. Construct a pulley on the protective roof frame,
using a rope loop and a snap hook. Ensure
that the snap hook hangs above the centre of
the travel motor (see sheet no. Z 33).
12. Lay the pulley rope over the load carriage and
tie it to the fork (see sheet no. Z33).
: Place protective tubing or other aid at
the point where the rope passes over
the mast and at the toothed rack
(see sheet no. Z33).
13. Guide the pulley rope through the snap hook
on the protective roof frame and attach the
pulley rope to the eyebolt with the other snap
hook (2).
1
6-0810
1
41,5
48
6/0114
M8x25
41,5
48
2

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Continued
14. Plug in the battery plug.
: Check the pulley and rope system
again (see sheet no. Z33) and ensure
that the rope does not run over any
sharp edges.
15. Carefully raise the fork or load carriage, which
will start the pulley rope moving. Ease the travel
motor out of its support by moving it gently to
and fro (see Fig. 1).
: The travel motor must be removed
vertically from above to prevent
damage.
16. Once the travel motor is release from its
support, continue raising the fork.
17. Pull the travel motor clear of the vehicle with the
pulley rope (1) and carefully lower the travel
motor by lowering the forks.
18. Cover the exposed gearbox opening.
To replace the travel motor, follow the instructions
above in reverse order, checking the following
points and ensuring the torques are correct:
- Tightening torque = 23 Nm (see sheet no. A5,
no. 8)
- Check that the brakes are adjusted correctly
(see sheet no. C22)
6-0819
1
Fig. 1
6-0820
Fig. 2

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Removing the drive pinion /
bearing bushing A
Id. no. for drive pinion W 8 416 721
Id. no. for bearing bushing A W 8 405 677
1. Remove the travel motor (see sheet no. A5).
2. Remove the self-locking groove nut (1).
(tightening torque: 65 Nm)
3. Pull the drive pinion off the rotor axle with a
"disc puller" (2) (Id. no. W1 099 989).
4. To remove bearing bushing A, the rotor must
be removed from the motor housing. This
prevents damage to the field windings. To do
so, remove the circlip (3) from the bearing B
side, lift the 4 carbon brushes (4) off the
commutator and fix with carbon brush springs
(5).
5. Knock out the rotor with a rubber mallet.
1
5-01 11
5-0212
2
5-0220
3
5-0217
4
5

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Removing the drive pinion /
bearing bushing A
Continued from sheet no. A8
6. Remove the inner circlip (1) from bearing
bushing A.
7. Pull off bearing bushing A with the "disc
puller" (2).
Mounting
To mount the bearing bushing, follow the
instructions above in reverse order.
On the back of bearing bushing A
there is a rotary shaft seal (3)
(Id. no. W8 417 452).
This seal must be replaced every
time the bearing bushing is removed
and replaced.
1
5-0208
2
5-0212
5/0028
3

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Changing the drive wheel
Id. no. W8 365 234
New dimensions: 343x136mm
It is necessary to change the drive wheel
when:
- the running surface is pitted or out of
round or the surface is cracked,
- the tyre diameter has reduced by 10%.
- The drive wheel must be replaced when it
has worn down to a diameter of 308 mm.
Removing the drive wheel
2. Jack up the vehicle safely on both sides
(1) (the drive wheel must be lifted clear of
the floor).
3. Secure vehicle against rolling away.
4. Remove the covers (2/3).
5. Turn the steering (90°) until the drive
wheel nuts are visible (4).
6. Release the 7 drive-wheel nuts (5) and
remove them.
7. Remove the drive wheel (6) through the
opening (8).
To replace the drive wheel, follow the
instructions above in reverse order.
Tightening torque (5): 140 Nm.
5/0504
3
5-1204
2
1
4 8
5
6

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Exchanging the carbon
brushes
Id. no. W8 405 673
Id. no. W8 405 674 (signal carbon brush)
The carbon brushes must be replaced when
they reach a minimum length of 15 mm,
which is equivalent to wear of about 50 %.
Length of a new carbon brush: 31 mm
Always replace the complete set of four
carbon brushes.
Removing the brushes
2. Remove the vehicle covers (see sheet
no. U9, covers (1)).
3. Remove the fan hose at tensioning belt.
4. Remove the travel motor tensioning belt
(1).
5. Lift off the brush spring (2) with a
hexagon socket screw key and pull out
the carbon at the connecting cable (3).
6. Disconnect the connecting cable (4).
7. Clean out the commutator compartment
with compressed air.
Never breathe in carbon
dust.
8. Mount the new carbon brushes.
After exchanging the brushes,
do not run the motor straight
away under full load. The
carbon brushes run in
relatively quickly under
minimal loads.
Checking the brush springs
Id. no. W8 402 244
Brush springs with insufficient pre-tension
lead to burning of the commutator.
Ensure that the carbon brushes run easily in
the shaft.
min. 15
mm
5/0034
5/0029
1
2
4
3
5-0334

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Carbon brush monitor
(travel motor)
Signal carbon Id. no. W8 405 674
When the brush has worn down to the
minimum length, the insulation of the signal
lead (2) is worn away, and the carbon
brushes with an integrated signal lead (1)
send a signal to the ABB travel and lift pulse
control system (3).
The travel and lift pulse control system then
sends this signal on to the vehicle display (4)
via an interface connection (RxD, TxD).
An error code is displayed (see sheet no.
M33 or M34)
5/0503
6/0010
5/0125
1
3
2
3

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Temperature monitor,
travel motor
The temperature of the travel motor is monitored.
If the temperature sensor responds, the travel and
lift pulse control system reduces the power supply
to the motor until the temperature drops below the
critical level again (see also sheet no. M97).
The temperature sensors are PTC resistors
(Positive Temperature Coefficient resistors), i.e. as
the temperature rises, the sensor's resistance also
increases.
At a specific temperature (depends on the type of
sensor), the resistance greatly increases.
This can be compared to the breaking function of a
switch.
Temperature sensor switching point
Travel motor: 130°C Id. no. W8 401 227
On both motors, the temperature sensors are
mounted at the side on a carbon brush shaft.
RA: Initial resistance at room temperature
RN: Nominal resistance = 2 • RA
RE: Final resistance = approx. 10 000 • RN
Resistance/temperature curve of a ceramic
PTC resistor
Travel motor temperature sensor
6/0056
6/0054

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Travel motor, maintenance
General
Maintenance work between major overhauls should
consist of the following:
- Cleaning
- General visual inspection
- Exchanging damaged parts
- Checking the brush unit and commutator
- Exchanging the carbon brushes (if necessary)
This work should be carried out at least every 500
operating hours or once a quarter.
We recommend having major motor overhauls
carried out by a specially equipped workshop, as
special tools and specialized knowledge are
required.
Before carrying out any work on the
motor, always first pull out the battery
plug to avoid short circuits or injury.
Cleaning
- Remove the sealing tape and take out the
brushes.
- Clean the motor thoroughly using compressed
air, taking care not to breath in any dust (wear a
protective mask).
- Clean oiled commutators and brush unit using a
clean cloth (not cotton wool) moistened with
benzene and dry well.
Do not lift the brush springs more than is
necessary and do not bend them to the
side.
5/0040
5/
5/0042

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(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
cleaner (do not clean them with
compressed air). Soiling reduces the air
circulation, leading to increased
temperatures in the motor and to possible
destruction.
- 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
(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.
5/0039
1

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(Contd.)
Checking the brush unit,
changing the carbon brushes:
After cleaning the brush unit, it should be
possible to move the brushes easily in their
guides when the spring is lifted.
If one or more of the brushes jam, they must
not be sanded down with emery paper or any
other abrasive.
In this case, the entire brush unit must be
exchanged, as it is possible that the brushes
have been thermally overloaded.
The brushes must also not be broken or bent
at the running edges.
- Always exchange the entire brush set,
basing your assessment on the shortest
brush.
- Only use original spare carbons (observe
spare parts list!).
- Do not allow the brushes to drop onto the
springs when mounting.
- If the minimum length has not quite been
reached, exchange anyway, as the
remaining running time is probably shorter
than the next maintenance interval.
- A maximum of 3 consecutive brush sets
should be exchanged before carrying out a
general overhaul of the motor (by a
specialized workshop).

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(Contd.)
Commutator:
The running surface of the commutator
should be even and smooth with a grey-black
appearance. The commutator must not be
worn, fluted or out of round.
Should one of the above phenomena occur,
the commutator must be reworked (major
overhaul).
Never attempt to achieve the necessary finish
using a file, emery paper or similar.
Using the size when new (approx. 82 mm) as
a comparison, the commutator must not be
worn down further on one side than the
amounts shown in the table to the right. In
these cases, the mica must be sawn back to
a depth of at least 0.5 mm.
Bearings:
The ball bearings are maintenance-free.
If the bearings are removed during repair
work, they must be replaced.
Whenever sealing elements are removed,
they must be replaced without fail!
The bearings must be renewed after approx.
25,000 operating hours.
Only use the bearings stipulated in the spare
parts lists.
If the motor speed drops noticeably, interrupt
work immediately and check the battery.
Recharge if necessary.
Never drive with insufficient voltage!
Carbon running surface Max. wear on
diameter (commutator) one side
33 mm 1.0 mm
36 - 64 mm 1.5 mm
67 - 100 mm 2.0 mm
107 mm 2.5 mm
126 mm 5.0 mm
(These values only apply for Schabmüller
motors)

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Travel motor specifications
Model: N220 / 4.5 FK
Motor type: Shunt motor
Voltage (V): 48
Current (A): 136
Output (KW): 4.5
Speed (rpm): 3305
Protection class: IP10
Operating mode: S2 60 min
Insulation class: F

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Commissioning the gearbox
(after exchanging)
Id. no. W8 414 977
Oils must be used with the following viscosities:
Standard oil: SAE 80
Ambient temperature: 0°C to 40°C
Id. no. W8 036 925
Low-temperature oil: SAE 75 W-90
partly synthetic
Ambient temperature: to -40°C
Id. no. W8 036 929
For special requirements, we recommend
contacting the manufacturer.
Oil quantity: approx. 3.6 l
The specified oil quantity is a guideline
value. The correct oil quantity is
ascertained by filling the tank up to the
lower edge of the filling hole (1).
At this level, about 1/3 of the the spur
wheel is submerged in oil (2).
It is important to avoid overfilling, as otherwise the
seals will be damaged and it is possible that the
operating temperature will not be maintained.
Lubrication of the bogie bearing:
The bogie bearing should be relubricated once
a year using the two lubricating nipples (3), in
particular after cleaning the gearbox (using a
steam jet).
Grease type: all-purpose grease
(see also lubrication plan R 2)
5-0123
1
2
5/0037
5/0038
3

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Oil change, gearbox
The first oil change should take place after
around 50-100 operating hours.
All subsequent oil changes should be carried
out at intervals of 2000 operating hours or
once a year.
Between oil changes, the oil level should be
checked once a quarter and topped up if
necessary.
The gear oil must be drained
when at service temperature.
The maximum permissible
service temperature is 80°C.
Changing the oil
1. Jack up the vehicle and secure it against
rolling away.
2. Set the gearbox to the oil drainage
position (see Fig. 1).
3. Place an oil catchment vessel under the
oil drainage screw (Fig. 1, (1)). It should
have a capacity of at least 4 l.
4. Unscrew the oil filler cap (Fig. 2, (2)).
5. Remove the oil drainage screw and drain
off the oil.
The oil temperature can be
as high as 80°C.
6. Replace the oil drainage screw, at the
same time replacing the sealing ring
(Id. no. W8 001 795).
7. Fill up with new gear oil to the lower edge
of the threaded hole for the oil filler cap.
8. Replace the oil filler cap with a sealing
ring.
5-0112
1
Fig. 1
5/0038
2
Fig. 2

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Still wagner gx13 forklift service repair manual