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Issue: 08/03 Workshop-
Manual
Replaces issue: EFU/EFV Sheet no. 1
Foreword
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.
00255
50002
50003
50004
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Updating workshop manuals
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 re-
placed. In (9) you see the first issue and the
date of the last revision. This tells you the
revision state of the whole book.
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 exchan-
ged.
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.
Issue: 5/03
Replaces issue:
Workshop
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sheet.no. 4-01
Issue: 11/03
Replaces issue: 5/03
Workshop
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sheet-no.4-01
Page baseline of the existing sheet
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1 4
2
3
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sheet-no.4-01
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sheet-no.
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6
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First issue: 5/03
Last revision: 11/03
Workshop
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N° id. -------
Page baseline of the first sheet
9
Foreword
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Vorwort
3
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 stipulations.
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.
STILL WAGNER
GMBH & CO KG
Trainingszentrum
Ernst-Wagner-Weg 1-5
72766 Reutlingen-Mittelstadt
Foreword
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Issue: 08/03 Workshop-
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Replaces issue: EFU/EFV Sheet no. 5
Section Contents Sheet
Foreword........................................................................................1
Updating of workshop manuals.............................................1
Exchanging faulty sheets ......................................................2
Insertion of supplementary sheets ........................................2
Remarks, imprint............................................................................3
Sections .........................................................................................4
Contents.........................................................................................5
1 Vehicle data
Identification..............................................................................1-01
Signs on the vehicle..................................................................1-02
2 Travel motor
General.....................................................................................2-01
Technical Data ..........................................................................2-02
Terminals ..................................................................................2-02
Removing the drive motor.........................................................2-03
Replacing the carbon brushes..................................................2-04
Maintenance .............................................................................2-05
General ............................................................................2-05
Cleaning...........................................................................2-05
Visual inspection, replacing damaged parts.....................2-06
Checking the brush unit,
replacing the carbon brushes...........................................2-07
Commutator .....................................................................2-08
Bearings...........................................................................2-08
3 Drive wheel
Replacing..................................................................................3-01
Removal....................................................................................3-01
4 Gear
Removing..................................................................................4-01
Lubricating the bogie bearing ...................................................4-02
Changing the gear oil................................................................4-02
Oil change.................................................................................4-03
Oil change procedure.......................................................4-03
Table of Contents
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Issue: 08/03 Workshop-
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Replaces issue: EFU/EFV Sheet no. 6
Table of Contents
Section Contents Sheet
5 Brake
Function....................................................................................5-01
Service brake (brake pedal)......................................................5-01
Parking brake (handbrake) .......................................................5-01
Guide to components................................................................5-02
Installing/removing the drive motor brake.................................5-03
Removal...........................................................................5-03
Installation........................................................................5-03
Adjusting the brake clearance ..................................................5-04
Checking the brake lining thickness.................................5-04
Adjusting the brakes.........................................................5-04
Adjusting the handbrake...........................................................5-05
Checking the setting.........................................................5-05
Adjusting the brake pedal .........................................................5-06
Measuring the brake deceleration ............................................5-07
General ............................................................................5-07
Preparations for measurement.........................................5-07
Measuring the brake deceleration ............................................5-08
Evaluating the measurement ...........................................5-08
Main brake cylinder...................................................................5-09
Bleeding / filling the brake system ............................................5-10
Filling the brake system ...................................................5-10
Bleeding the brake system...............................................5-10
6 Steering
General.....................................................................................6-01
Structure of the steering system...............................................6-02
Steering sensor.........................................................................6-03
General ............................................................................6-03
Slipring system.................................................................6-04
Adjusting the steering sensor ...................................................6-05
General ............................................................................6-05
Adjustment when installed ...............................................6-05
Adjustment when not installed .........................................6-07
Servo unit..................................................................................6-08
General ............................................................................6-08
Terminal markings on terminal board...............................6-08
Exchanging the carbon brushes.......................................6-09
Specifications...................................................................6-09
Steering controler .....................................................................6-10
General ............................................................................6-10
Function ...........................................................................6-10
Safety monitoring .............................................................6-11
Adjusting the current limitation.........................................6-12
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Table of Contents
7
Section Contents Sheet
7 BDI/HM
Curtis Combi-Controller 803 .....................................................7-01
General ............................................................................7-01
Pin assignment.................................................................7-02
Setting the final discharge voltage ...................................7-03
Technical data ..................................................................7-04
Accumeter EL-AC5 (up to 6/93)...............................................7-05
Battery discharge indicator...............................................7-05
Hour meter .......................................................................7-06
Accumeter EL-AC5 (from 7/93) ................................................7-07
General ............................................................................7-07
Installation........................................................................7-07
Electrical connection ........................................................7-08
Specifications...................................................................7-09
Adjusting accumeter EL-AC......................................................7-10
8 Circuit board
Circuit board A1with adapter card A8 .......................................8-01
Components.....................................................................8-01
Fuses........................................................................................8-02
Testing the fuses ..............................................................8-03
Components .............................................................................8-04
Rating plate......................................................................8-04
Contactor clearance.........................................................8-04
Contact pressure..............................................................8-04
9 Travel control
General.....................................................................................9-01
Functional characteristics.................................................9-01
Cycle ratio and current profile ..........................................9-01
Setpoint value current, frequency characteristic.......................9-02
Primary current circuit...............................................................9-03
Ignition process................................................................9-03
Thyristors..................................................................................9-04
Function ...........................................................................9-04
Thyristors..................................................................................9-05
Installation........................................................................9-05
Installation instructions.....................................................9-05
Thyristor power block................................................................9-06
General ............................................................................9-06
Diodes.......................................................................................9-07
Functional characteristics.................................................9-07
Layout, installation ...........................................................9-07
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Issue: 08/03 Workshop-
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Replaces issue: EFU/EFV Sheet no.
Table of Contents
8
Section Contents Sheet
9 Travel control
Diodes.......................................................................................9-08
Testing the diodes ............................................................9-08
Diode power block ....................................................................9-09
General ............................................................................9-09
Testing..............................................................................9-09
Terminal............................................................................9-09
Functional Characteristics................................................9-10
Testing the primary current ......................................................9-11
Test procedure .................................................................9-12
Current actual value sensor n35...............................................9-13
Functional characteristics.................................................9-13
Control circuit board u200.........................................................9-14
Functional characteristics.................................................9-14
Checking the safety circuit ...............................................9-14
Removing.........................................................................9-15
Settings ............................................................................9-15
Speed restriction GB (from 12/90)...........................9-15
Ramp-up time HZ ....................................................9-15
Reversing current RS ..............................................9-16
Drive current FS.......................................................9-16
Drive reduction 2,5kph .....................................................9-17
Adjustment of drive current ..............................................9-18
Current setting .........................................................9-18
Adapter card A8........................................................................9-20
General ............................................................................9-20
Settings ............................................................................9-21
Default factory settings.....................................................9-21
LED display......................................................................9-22
Measured signals.............................................................9-23
Block circuit diagram........................................................9-24
Wiring diagram .........................................................................9-25
Circuit board A1 with adapter card A8..............................9-25
10 Accelerator pedal
General...................................................................................10-01
Functional characteristics of the magnetoresistor..........10-01
11. Copyright
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Replaces issue: EFU/EFV Sheet no.
Table of Contents
9
Section Contents Sheet
11 Hydraulics
Block diagram .........................................................................11-01
Hydraulic circuit diagram.........................................................11-01
Pump assembly ......................................................................11-02
General...........................................................................11-02
Function LIFTING...........................................................11-03
Function LOWERING .....................................................11-04
Electrically pilot controlled non-return valve ...................11-05
Replacing the carbon brushes........................................11-06
Removal / Installation .....................................................11-06
Removal .........................................................................11-07
Installation ......................................................................11-07
Removing the pump motor .............................................11-08
Hydraulic pump ..............................................................11-09
General ..................................................................11-09
Removing the hydraulic pump........................................11-10
Setting the maximum pressure.......................................11-12
Recommended values for pressure adjustment: ...11-12
Hydraulic oil change .......................................................11-13
Bleeding the lifting cylinder and hydraulic system of air .........11-14
Procedure.......................................................................11-14
12 Hydraulic system
Diagram of the hydraulic system ............................................12-01
Pump unit................................................................................12-02
Removal.........................................................................12-02
Carbon brushes..............................................................12-02
Directional slide valve block....................................................12-02
Adjusting the maximum pressure valve .........................12-03
13 Lifting device
Function of the angled lever ...................................................13-01
Adjustment..............................................................................13-01
Drawbar adjuster............................................................13-01
End stops at bottom .......................................................13-01
End stops at top .............................................................13-02
Lift stop...........................................................................13-02
Angled lever - pressure rods..........................................13-03
Lifting cylinder, low lift.............................................................13-04
Guide to parts.................................................................13-04
Adjusting the tension springs .........................................13-04
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Section Contents Sheet
14 Mast
Basic lift ..................................................................................14-01
General ..........................................................................14-01
Setting the height when lowered....................................14-01
General...................................................................................14-02
Load carriage, concealed cylinder version.....................14-02
Load carriage, exposed cylinder version........................14-02
Function..................................................................................14-03
Removing the telscopic load carriage.....................................14-04
Mounting ........................................................................14-04
Removing the lift cylinder .......................................................14-05
Support rollers - outer mast ....................................................14-06
Lift bracket ..............................................................................14-07
General ..........................................................................14-07
Removing ......................................................................14-07
Lift bracket ..............................................................................14-08
Setting the adjusting screws .........................................14-08
Chains.....................................................................................14-09
General ..........................................................................14-09
Setting the control chains .......................................................14-10
Setting the clearance lift chain................................................14-11
Chain setting at the triplex load carriage ................................14-12
Testing with/without rated load.......................................14-12
99 Maintenance
General...................................................................................99-01
Safety instructions ..................................................................99-02
Handling fuels and lubricants.........................................99-02
Brake ......................................................................................99-03
Testing the function of the service brake........................99-03
Testing the function of the parking brake .......................99-03
Testing the function of the reversing brake ....................99-03
Wear limit for the brake lining.........................................99-03
Battery ....................................................................................99-04
Checking the electrolyte level ........................................99-04
Checking the electrolyte density ....................................99-04
Cleaning the battery.......................................................99-04
Battery lock ....................................................................99-05
Battery charger...............................................................99-05
Operating elements ................................................................99-06
Ease of movement .........................................................99-06
Steering ..................................................................................99-07
Ease of movement .........................................................99-07
Cut-out in the event of error ...........................................99-07
Steering chain ................................................................99-07
Reverse steering............................................................99-07
Table of Contents
10
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Replaces issue: EFU/EFV Sheet no.
Section Contents Sheet
99 Maintenance
Lifting chains...........................................................................99-08
General ..........................................................................99-08
Checking the lifting chains for damage ..........................99-09
Checking the lifting chains for damage ..........................99-12
Checking the chain elongation.......................................99-13
Replacing the lifting chains ............................................99-14
Lubricating the lifting chains ...................................................99-15
Cleaning the chains ................................................................99-16
Hydraulic tank.........................................................................99-17
Volume ...........................................................................99-17
Seals ..............................................................................99-17
Soiled oil.........................................................................99-17
Wheels....................................................................................99-18
Wear...............................................................................99-18
Wheel bearings ..............................................................99-18
Load wheels...................................................................99-18
Motor.......................................................................................99-19
Carbon brushes..............................................................99-19
Checking the brush springs............................................99-19
Other maintenance work................................................99-19
Gear........................................................................................99-20
Changing the gear oil.....................................................99-20
Noises ............................................................................99-20
Leaks..............................................................................99-20
Mast........................................................................................99-21
Mast rollers.....................................................................99-21
Guide rollers of the fork holder.......................................99-21
Windscreen ....................................................................99-21
Lifting cylinder ................................................................99-21
Guides, surfaces ............................................................99-21
Forks ..............................................................................99-21
Chain adjustment ...........................................................99-21
Pump assembly ......................................................................99-22
Carbon brushes..............................................................99-22
Oil level ..........................................................................99-22
Noises ............................................................................99-22
Soiling ............................................................................99-22
Lubrication plan ......................................................................99-23
Lubricants.......................................................................99-23
Disposal .........................................................................99-23
Lubrication plan..............................................................99-24
Table of Contents
11
14. 07/01 01
Chapter 1 Vehicle data
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Identification
01
EFU 2000/ 3000 EFV 125/ 160/ 200
• Load bearing capacity 2000/ 3000kg 1250/ 1600/ 2000kg
• Tavel motor 2,8/ 4,2kW 2,8kW
• Maximum speed 12km/h 8km/h
• Dimensions L/W/H ca. 2330-4700/ 980/ 1550mm 2230/ 980/ 2350mm
• Weight with battery 1450-2100kg 1700-2200kg
• Battery voltage 24/ 48V 24V
30000 30001
15. Chapter 1 Vehicle data
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Replaces issue: EFU/EFV Sheet no. 1 –
Signs on the vehicle
1 Nameplate (beside driver seat)
2 UVV check
3 Maximum pressure hydraulic
4 Towing points
5 Vehicle no. on chassis
6 Carrying load diagram
10309
1
2
3
4
02
30000
6
30002
5
16. 07/01 01
Chapter 2 Travel motor
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Issue: 08/03 Workshop-
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Replaces issue: EFU/EFV Sheet no. 2 –
General
Series-wound motors are used in the travel drive
unit.
The armature and field winding are connected in se-
ries, so ensuring greater torque particularly in the lo-
wer speed ranges.
Remark: Series-wound motors must never be
operated for long periods without load,
i.e. without being in gear. Otherwise,
they automatically increase their speed
to the point of self-destruction .
The motor speed is controlled by the stroke ratio of
the main thyristor, which is timed by the control circuit
board of the pulse control system.
The sense of rotation of the motor is controlled by the
flow direction of the current through the field winding.
The direction of flow is determined by the travel
direction contactors.
In 24V appliances, the motor is self-ventilating.
Ventilation is effected by a fan impeller wheel
mounted on the armature shaft.
48 V motors are additionally separately ventilated by
an external radial fan in the area of the commutator.
01
30003
17. Chapter 2 Travel motor
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Technical Data
Manufacturer JULI JULI
Model GF 116-14/1.9/2.8
Motor version Series-wound
Voltage (V) 24 48
Current (A) 145 108
Output (kW) 2,8 4,2
Speed (min -1
) 1700 2000
Protection class IP 21 IP21
Insulation class B B/F
Terminals
Designation new old
Armature coil A1/A2 A/B
Field coil D1/D2 E/F
The rotary direction of the motor (1) depends on the
direction in which the current (2) flows through the
field coil.
The current direction is determined by the travel
direction contactors.
1 2
A2
• • • • • • • •
A1 D2 D1 A2 A1 D2 D1
1 2
10279
18. Chapter 2 Travel motor
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Issue: 08/03 Workshop-
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Replaces issue: EFU/EFV Sheet no. 2 – 03
Removing the drive motor
Note: Because the brake (1) is flange-
mounted on the drive motor, the vehicle
is no longer braked once the motor has
been removed.
The vehicle must be secured before work
commences, to prevent it rolling away.
Removal
• Pull out the battery plug.
• Jack up the vehicle and secure it to prevent it from
roling away.
• Mark the motor connecting cable and disconnect it.
• Release the 4 hexagon socket screws M8x30 (4)
and remove them completely.
• Lift the drum brake up and out and set it down to
one side.
• Remove the 6 hexagon socket screws M8x30 (5).
• Lift and remove the motor (2) together with the
flange (6).
• The pinion stays on the shaft end of the motor.
• Cover the gear opening to protect the inside from
dirt.
Remark: When you install the motor again, you
must ensure that the bearing bridge is in
the correct position when the wheel is in
the straight-on position. When it is in the
right position, an optimal cooling
effect is achieved.
6
4
2
5
Bearing bridge
End shield
Ventilation
shafts
Wheel in
straight-on
position
10280
10281
30003
1
2
19. Chapter 2 Travel motor
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Replaces issue: EFU/EFV Sheet no. 2 – 04
Replacing the carbon brushes
The carbon brushes must be replaced when they re-
ach a residual length of 16mm resp. 20mm. At this
length, they are worn down by 50 %.
Length of a new carbon brush: 32mm (24V)
40mm (48V)
The entire set of brushes must always be replaced (4
brushes).
Removal:
• Pull out the battery plug.
• Remove the tensioning belt of the drive motor.
• Raise the brush spring (1).
• Pull out the carbon at the connecting cable (2).
• Disconnect the connecting cable.
• Clean out the commutator compartment (blow it
out).
Caution: Never inhale carbon dust!
• Mount the new carbon brushes.
Remark: After replacing the carbon brushes, do
not run the motor straight away at full
power. The carbon brushes run in
relatively quickly under low loads (see
drive motor maintenance).
Checking the brush springs
Brush springs with insufficient pre-tension cause the
commutator to burn.
Ensure that the carbon brushes move easily in the
shaft.
60163
10282
1
2
20. Chapter 2 Travel motor
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Maintenance
General
Maintenance work between major overhauls should
consist of the following:
• Cleaning
• General visual inspection
• Replacing damaged parts
• Checking the brush unit and commutator
• Replacing 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 specialist knowledge are required.
Note: Before carrying out any work on the mo-
tor, 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 breathe in any dust (wear a pro-
tective mask).
• Clean soiled commutators and brush unit using a
clean cloth (not cleaning wool) moistened with
benzine and dry well.
Remark: Do not lift the brush springs more than is
necessary and do not bend them to the
side.
10288
21. Chapter 2 Travel motor
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Replaces issue: EFU/EFV Sheet no. 2 –
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 com-
pressed air). Soiling impairs the air circulation,
which leads to increased temperatures in the motor
and possibly to irreparable damage.
• Check field and armature coils for signs of over-loa-
ding (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
and carbon abrasions), investigate the cause
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.
50039
1
06
22. Chapter 2 Travel motor
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Replaces issue: EFU/EFV Sheet no. 2 –
Maintenance
Checking the brush unit,
replacing the carbon brushes
After the carbon brush unit has been cleaned, it
should be possible to move the carbon brushes
easily in their guide.
If one or more of the carbon brushes jam, they must
not be sanded down with emery paper or any other
abrasive.
In this case, the entire carbon brush unit must be
replaced, as it is possible that the brushes were ther-
mally overloaded.
It is also important that the carbon brushes are not
broken or chipped at the running edges.
Remarks:
• Always replace the entire brush set, basing your
assessment on the shortest brush.
• Only use original spare carbon brushes (see
spare parts list!)
• Do not allow the carbon brush springs to knock
against the carbon brushes when you are
inserting the brushes.
• If the minimum length has not quite been
reached, replace the brushes anyway, as the
remaining running time may be shorter than the
next maintenance interval.
• A maximum of 3 carbon brush sets should be
replaced in succession before a general overhaul of
the motor is carried out (by a specialised works-
hop).
07
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24. Chapter 2 Travel motor
Copyright
protected.
No
part
of
this
manual
may
be
reproduced
in
any
form.
Copyright
reserved.
Issue: 08/03 Workshop-
Manual
Replaces issue: EFU/EFV Sheet no. 2 –
Maintenance
Commutator
The running surface of the commutator should be
even and smooth with a grey-black appearance. The
commutator must not be worn, scored or out of
round.
Should one of the above conditions occur, the
commutator must be reworked (major overhaul).
Never attempt to achieve the neccesary finish using
a file, emergy paper or similar.
Bearings
The ball bearings do not need to be re-lubricated.
The volume of grease in the bearings is sufficient for
the maintenance period between major overhauls.
The bearings must be replaced:
• without fail during every major overhaul,
• after they have been in use for 2000 operating
hours, at the latest
• if the vehicle is only used with short operating
times, then after 5 years at the latest.
Only use the bearings specified in the spare parts
list.
Note on risk of overloading when batteries are
run down:
If the speed of the motors drops noticeably, work
must be stopped immediately. Check the battery
without delay, then recharge it if necessary.
Never drive the vehicle if the voltage is too low!
08
25. 07/01 01
Chapter 3 Drive wheel
Copyright
protected.
No
part
of
this
manual
may
be
reproduced
in
any
form.
Copyright
reserved.
Issue: 08/03 Workshop-
Manual
Replaces issue: EFU/EFV Sheet no. 3 –
Replacing
Dimensions of new wheel: 300 x 130mm
The drive wheel must be replaced when:
• The running surface is badly cracked or out of
round, or its diameter is very different from that of
the other drive wheel.
• The tyre diameter has reduced by 10 %,
e.g. 300mm - 10 % = 270mm.
Removal
• Pull out the battery plug.
• Apply the handbrake.
• Jack up the vehicle securely and secure it to pre-
vent it from rolling away.
• Turn the drive wheel (1) until the wheel nuts (2) are
accessible.
• Release the wheel nuts.
• Remove the drive wheel.
• When mounting the new drive wheel, tighten the
wheel nuts diagonally in several passes.
Tightening torque: 140Nm.
01
10285
2 1
