2. Foreword
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Foreword
This workshop manual (WM) is a collection of
technical data and functional descriptions for the
standard vehicle.
It is intended as a guide which should be kept at
hand at all times, to help explain the technical
features of the vehicle and consequently ensure that
maintenance and repair are carried out correctly.
The workshop manual is updated on a regular basis
with additional sheets.
Updating workshop manuals
Our range of equipment is subject to continuous
development and improvement. A consequence of
this is that components or assemblies are
sometimes replaced or their function changed.
In order to guarantee that the owner of a workshop
manual is always in possession of up-to-date and
relevant documentation, the manual must be
updated using the method described overleaf.
5/0003
5/0004
5/0002new
1/0096
3. Foreword
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Updating workshop manuals
1. Replacing incorrect sheets
If a sheet contains an error, e.g. if
adjustment values have been altered, the
sheet in question must be replaced.
The new sheet can be identified by the
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date of issue of the sheet which needs
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Every time a change is made, the cover
sheet is replaced. The date of first issue
and the date of the last update are shown
in field 9. This means that the workshop
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2. Inserting new sheets
If new, altered or additional components
are introduced to the series, it may be
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The list of contents for the assembly in
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SU/SD/SV
SU/SD/SV
SU/SD/SV
SU/SD/SV
4. Foreword
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Issue 09/03 Workshop
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Updating workshop manuals
We send new sheets, whether they are replacement
or additional sheets, and new lists of contents, to all
the workshop manual owners we know of by mail.
Notes, Imprint
We can accept no liability for warranty claims relating
to work carried out in accordance with the
instructions in this workshop manual.
The warranty terms remain unaffected.
STILL WAGNER works continuously on the
development of its industrial trucks. We would ask for
your understanding that we reserve the right to make
alterations and that errors cannot be excluded, and
that no warranty claims may be based on the
information, illustrations or descriptions contained in
this workshop manual.
Published by
STILL WAGNER GMBH & CO KG
Trainingszentrum (Training Centre)
Ernst-Wagner-Weg 1-5
72766 Reutlingen-Mittelstadt
Germany
5. Guide to chapters
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Chapter 1:
Chapter
Chapter
2:
3:
Chapter
Chapter
Chapter
Chapter
4:
5:
6:
7:
Chapter
Chapter
Chapter
Chapter
8:
9:
10:
11:
Chapter
Chapter
Chapter
Chapter
12:
13:
14:
15:
Chapter
Chapter
Chapter
Chapter
16:
17:
18:
19:
Chapter
Chapter
20:
99:
Drive wheel
Gear
Drive motor
Speed sensor
Steering
Brake
Mast
Vehicle control
Component panel
ABÜ - braking monitor
Curtis display unit
Battery
Valve driver
Block diagram of hydraulics
Pump assembly
Pressure sensor
Valve block
Steering software
Travel control software
Summary of errormessages
Maint
6. List of contents
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Chapter 1: Drive wheel
• Changing the drive wheel .....................................................................1-01
- Removal .............................................................................................1-01
- Installation ..........................................................................................1-01
• Information table: ID numbers of drive wheel .......................................1-02
Chapter 2: Gear
• Removing the gear ...............................................................................2-01
• Commissioning the travel drive (after replacement) .............................2-02
- Lubricating the bogie bearing .............................................................2-02
• Oil change.............................................................................................2-03
Chapter 3: Drive motor
• Removing the gear ...............................................................................3-01
• Carbon brushes ....................................................................................3-02
- Replacing the carbon brushes............................................................3-02
• Technical data ......................................................................................3-03
• Maintenance .........................................................................................3-04
- General...............................................................................................3-04
- Cleaning .............................................................................................3-04
- Visual inspection, replacing damaged parts.......................................3-05
- Checking the brush unit, replacing the carbon brushes .....................3-06
- Commutator........................................................................................3-07
- Bearings .............................................................................................3-08
Chapter 4: Speed sensor
• General.................................................................................................4-01
• Testing the speed sensor .....................................................................4-02
Chapter 5: Steering
• Block diagram of steering SU ...............................................................5-01
• Block diagram of steering SD/SV .........................................................5-02
• Pin assignment .....................................................................................5-03
• Setpoint potentiometer..........................................................................5-05
• Actual value potentiometer ...................................................................5-06
• Quick start adjusting the steering .........................................................5-07
• Travel on curves function......................................................................5-08
Chapter 6: Brake
• Electromagnetic spring brake ...............................................................6-01
- Function..............................................................................................6-01
- Removal .............................................................................................6-02
- Replacing the brake lining ..................................................................6-04
- Adjusting the brake clearance ............................................................6-05
- Adjusting the braking force.................................................................6-06
- Measuring the brake deceleration ......................................................6-07
Sheet no.
7. List of contents
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SU/SD/SV Sheet no. V
- Checking the brake deceleration........................................................6-10
- Maintenance.......................................................................................6-12
Chapter 7: Mast
• Removing the mast...............................................................................7-01
• Removing the lift carriage.....................................................................7-03
• Exchange Guiderollers .........................................................................7-04
• Sideplay................................................................................................7-04
Chapter 8: Travel control
• Block diagram for "Travel" ....................................................................8-01
• Pin assignment .....................................................................................8-03
• General.................................................................................................8-06
• Braking modes......................................................................................8-07
• Table of operating modes.....................................................................8-07
• Travel on curves ...................................................................................8-08
• Hour meter............................................................................................8-09
• Service hour meter ...............................................................................8-09
• Battery discharge indicator ...................................................................8-09
• Self test.................................................................................................8-10
• Error display..........................................................................................8-11
• Test procedure......................................................................................8-11
Chapter 9: Component panel
• Arrangement of the components on comonent panel for SU................9-01
• Arrangement of the components on comonent panel for SD................9-02
Chapter 10: ABÜ - Braking monitor
• Block diagram of braking monitor ABÜ (U50).....................................10-01
• Pin assignment ...................................................................................10-02
• General...............................................................................................10-04
• Functions ............................................................................................10-05
-Wheel position display (optional).....................................................10-05
-Adjust the display ............................................................................10-05
-Driving while curve ..........................................................................10-06
-Flashing error codes........................................................................10-07
Chapter 11: Curtis display unit
• General...............................................................................................11-01
• Pin assignment ...................................................................................11-02
• Function..............................................................................................11-03
• Error display........................................................................................11-03
• Battery discharge indicator .................................................................11-03
• Hour meter..........................................................................................11-04
Sheet no.
8. List of contents
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Chapter 12: Battery
• General
12-01
• Durability and lifetime .........................................................................12-01
• Handling and maintenance.................................................................12-02
• Maintenance intervals.........................................................................12-03
• Acid density test..................................................................................12-04
• Prevention of damage and accidents .................................................12-05
• Commissioning unfilled battery with charged plates...........................12-06
• Changing the battery ..........................................................................12-07
- Lifting and removing the battery .......................................................12-07
- Installing the battery .........................................................................12-08
Chapter 13: Valve driver
• Block diagram.....................................................................................13-01
• Pin assignment ...................................................................................13-02
• General...............................................................................................13-03
• Removal..............................................................................................13-05
• Flashing error codes...........................................................................13-06
• Table of functions ...............................................................................13-07
Chapter 14: Hydraulics
• Block diagram of hydraulics................................................................14-01
• Filter....................................................................................................14-02
- Maintainens....................................................................................14-02
• Lowering brake valve..........................................................................14-03
- General...........................................................................................14-03
- Exchange........................................................................................1403
Chapter 15: Pump assembly
• Individual components........................................................................15-01
• LIFTING function ................................................................................15-02
• LOWERING function...........................................................................15-03
• Electrically pilot controlled non-return valve (2/2-way valve)..............15-04
• Replacing carbon brushes on the SU.................................................15-05
• Replacing carbon brushes on the SD.................................................15-06
• Removing the pump motor .................................................................15-07
• Hydraulic pump...................................................................................15-08
- General.............................................................................................15-08
- Removing the hydraulic pump..........................................................15-09
• Adjusting the pressure relief valve on the SU.....................................15-10
• Adjusting the pressure relief valve on the SD/SV...............................15-11
- Proportional valve.............................................................................15-11
• Changing the hydraulic oil ..................................................................15-12
• Pumpassembly SV tecnical datas ......................................................15-13
- Removal .........................................................................................15-13
- Exchange of Carbonbrush..............................................................15-13
• Pumpcontaktor 2Y1 ............................................................................15-14
• Tankvolume ........................................................................................15-14
Sheet no.
9. List of contents
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SU/SD/SV Sheet no. VII
Chapter 16: Pressure sensor
• Pressure sensor..................................................................................16-01
Chapter 17: Valve block
• General SD.........................................................................................17-01
• Hydraulic connections SD...................................................................17-01
• Electrical values..................................................................................17-01
• General SV .........................................................................................17-02
• Hydraulic connections SD...................................................................17-02
• Electrical values SD............................................................................17-02
• Other Valves SD.................................................................................17-02
Chapter 18: Steering software
• General...............................................................................................18-01
• Making a connection...........................................................................18-02
• Errors..................................................................................................18-03
• Teaching in .........................................................................................18-04
- Setpoint potentiometer .....................................................................18-04
- Actual value potentiometer...............................................................18-06
• Tester..................................................................................................18-07
- Speed measurement ........................................................................18-10
- Amplifier data....................................................................................18-11
- Digital inputs and ouputs ..................................................................18-12
- Potentiometer voltages.....................................................................18-14
• Settings...............................................................................................18-15
- Wheel distance.................................................................................18-15
Chapter 19: Travel control software
• General...............................................................................................19-01
• Setting parameters .............................................................................19-02
• Test.....................................................................................................19-03
• Diagnosis............................................................................................19-03
• "File" menu .........................................................................................19-03
• Setting parameters with the hand-held programming unit..................19-05
• Summary of the parameters that have to be set.................................19-19
• Battery discharge curves ....................................................................19-20
• List of parameters 1............................................................................19-21
• List of parameters 2............................................................................19-22
• List of parameters 3............................................................................19-23
• List of parameters 4............................................................................19-24
• List of parameters 5............................................................................19-25
• Description of parameters...................................................................19-26
• Errors displayed with flashing code ....................................................19-32
• List of flashing error codes..................................................................19-33
• Tester table.........................................................................................19-34
Sheet no.
10. List of contents
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SU/SD/SV Sheet no.
Chapter 20: Summary of errormessages
• Errormessages of the Travel control...................................................20-01
• Errormessages of the ABÜ-Braking monitor......................................20-01
• Errormessages of the Steering controler...........................................20-01
• Errormessages of the Valve driver ....................................................20-01
Sheet no.
VIII
11. Chapter 1 Drive wheel
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SU/SD/SV Sheet no. 1 – 01
Changing the drive wheel
Dimensions of new wheel: ř 250 x 80 mm
Change at residual diameter: ř 225 mm
The drive wheel must be replaced when:
• the running surface is very pitted,
• the running surface is out of round,
• the running surface is cracked,
• the diameter of the tyre has decreased
by 10%.
Removal
1. Pull out the battery plug.
2. Jack up the vehicle safely on both sides and
secure it to prevent it rolling away.
3. Remove the covers.
4. Move the drive wheel into the straight-on
position.
5. Loosen the 5 drive wheel nuts (1) and unscrew
them.
6. Pull off the drive wheel, taking care not to
damage the threaded bolts.
Installation
1. Before installing the drive wheel, clean the area
where the wheel is seated on the axis and ensure
that it is in perfect condition.
2. Push on the drive wheel and tighten the 5 wheel
nuts by hand.
3. To secure the new drive wheel, tighten the wheel
nuts diagonally in several passes with a torque
wrench.
Tightening torque for the wheel bolts: 140 Nm
6/0168
1
12. Chapter 1 Drive wheel
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SU/SD/SV Sheet no. 1 – 02
Information table
ID numbers of drive wheels
Design
Id. no.
ř 250/100
Solid rubber tyre, press-fit
Solid rubber tyre, tread press-fit
8 305059
8 305060
Solid rubber tyre, natural rubber
Solid rubber tyre, with tread
8 329012
8 329013
Solid rubber tyre, electrically conductive
Vulkollan tyre, vulcanized in place
8 340792
Vulkollan tyre, press-fit
Vulkollan tyre, profile press-fit
8 305063
8 305064
13. Chapter 2 Gear
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SU/SD/SV Sheet no. 2 – 01
Removing the gear
1. Jack up the vehicle and secure it to prevent it
rolling away (distance of approx. 10cm between
drive wheel and floor).
2. Turn the drive wheel to one side so that the gear
is visible.
It is more practical not to remove the
drive wheel to start with when you
want to take out the gear.
3. Pull out the battery plug.
4. Position a fork-lift truck or a low-lift truck under
the drive wheel so that the weight of the gear is
supported (clear distance between forks approx.
220 mm).
5. Support the gear safely from below.
6. Raise the fork-lift truck or low-lift truck until there
is a slight pressure applied to the drive wheel.
7. Remove the 6 gear screws M10x40 (2).
8. Raise the motor with a rope (special tool, cable
pull, see the section entitled "Removing the drive
motor") and underlay it in at least 2 places with
flat steel bars approx 20 mm thick (3).
9. Slowly lower the fork-lift truck and remove the
gear at the front.
Cover the gear opening to prevent dirt
entering. Support the gear with a taut
rope or chock it up from below with
wood to prevent it tilting over to the rear
or side.
2
8-0518
6/0167
3
3
min. 10cm
Floor
14. Chapter 2 Gear
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SU/SD/SV Sheet no. 2 –
Commissioning the travel drive
(after replacement)
The following types of gear oil are used:
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 -30°C
Id. no. W8 036 929
For vehicle use in special conditions, please contact
the manufacturer for further information.
Oil volume: approx. 1.5 l
Transmission: i = 15.18
The given amount of oil is a guideline only.
The correct amount of oil is that required
for the level to reach the lower edge of the
filling hole (1). This means that the spur
gear is submerged in oil by about 1/3 of its
height (1).
Overfilling must be avoided, otherwise oil can escape
at the gear bleeder screw, the seals may be
damaged and it is possible that the operating
temperature may not be maintained.
Check that the gear bleeder screw is clean.
Lubricating the bogie bearing
The bogie bearing should be lubricated once a year
through the two lubricating nipples at opposite sides
(2 and 3). This is particularly important every time the
gear has been cleaned (e.g. with steam jets).
The bearing play at the bogie bearing must be
checked whenever maintenance is carried out.
Grease type: All-purpose grease
6/2016
oil level
1
6/2014
2 3
02
15. Chapter 2 Gear
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SU/SD/SV Sheet no. 2 –
Oil change
The first oil change must be carried out after approx.
1000 operating hours.
All subsequent oil changes should be carried out
after approx. 2000 operating hours or at least once
a year.
Between the oil change intervals, the oil level should
be checked once a quarter and topped up if
necessary.
The gear oil must be drained off when
the vehicle is warm.
The maximum permissible operating
temperature is 80°C.
Changing the oil
Remove the filler screw (1). Check the oil level with
a dipstick through the threaded hole of the filler
screw. The gear oil level should be at the lower
edge of the filler hole. Top up if necessary (Fig. 1).
or:
• Jack up the vehicle and secure it to prevent it
rolling away.
• Move the gear into the drainage position.
• Set an oil catchment vessel under the oil drain-
age screw (3) (should have a vol. of approx. 1.5l).
• Remove the oil filler screw (1).
• Remove the oil drainage screw (1) and allow the
oil to run out.
Risk of scalding!
The oil temperature may be as high as 80°C!
• Clean the magnet on the oil drainage screw (3)
• Screw the oil drainage screw back in place, using
a new sealing ring (2).
• Fill with new gear oil up to the lower edge of the
threaded hole for oil filler screw (approx.1.5l).
• Screw the oil filler screw back in place, using a
new sealing ring (4).
Sealing rings: Id. no. W8 006 172
Tightening torque for the oil filler (1)
and drainage screw (3) MA= 22Nm.
6/2012
6/2013
6/2016
Oil level
4
Fig. 1
1
2
3
4
1
03
16. Chapter 3 Drive motor
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SU/SD/SV Sheet no. 3 – 01
Removal
Once the drive motor has been removed,
the vehicle is no longer braked. Secure
the vehicle to prevent it rolling away!
• Pull out the battery plug.
• Mark and disconnect the field coil connections.
• Mark and disconnect the armature coils.
• Mark and disconnect the speed sensor and brake
connector.
• Unscrew the supports for the component panel (1).
• Unscrew the 8 M6 screws (2).
• Screw a screw-fit eyebolt (3) into the motor shaft
and hitch to the rope and lifting bar.
• Lay the lifting bar on the arm console and lever the
motor out of its guide by lifting.
20408
20408
20408
1
2
3
17. Chapter 3 Drive motor
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SU/SD/SV Sheet no. 3 – 02
Carbon brushes
Replacing the carbon brushes
The carbon brushes must be replaced when they
have reached a residual length of 16 mm.
• Pull out the battery plug.
• Remove the drive motor (please see Drive motor,
Removal).
• Lever out the black plastic cap (1).
• Shape a loop out of a piece of wire and use it to
pull off the carbon brush spring (2).
• Pull carbon brush out of the guide shaft.
• Unscrew the carbon brush connecting screw (3)
and, if necessary, replace the carbon brushes.
Always replace the full set of carbon
brushes (4 brushes).
20411
1
20412
2
3
18. Chapter 3 Drive motor
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Technical data
Model...................................GF 114-F4
Excitation type.....................Shunt motor
Voltage ................................24 V
Rated current ......................104 A
Rated output........................2000 W
Rated speed........................2700 rpm
Direction of rotation .............right / left
Protection class...................IP 00/20
Insulation class....................F
Switching-on time................S 2 = 60 min
Drive motor terminals
Designation Meaning
at the motor
A 1 rotor coil; B+
A 2 rotor coil; B -
F1 shunt field coil,
F2 shunt field coil,
Direct current motor with
separately excited field coil
(without commutation poles)
Clockwise
Anti-clockwise
+ - + -
A1 A2 F2 F1
M
+ - - +
A1 A2 F2 F1
M
6110003
19. Chapter 3 Drive motor
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SU/SD/SV Sheet no. 3 –
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.
Before carrying out any work on the
motor, always first pull out the battery
plug to avoid short circuits or injury.
Cleaning
• Remove the cover and take out the brushes.
• Clean the motor thoroughly using compressed
air, taking care not to breathe in any dust (wear a
protective mask).
• Clean soiled commutators and brush unit using a
clean cloth (not cleaning wool) moistened with
benzine and dry well.
Do not lift the brush springs more than
is necessary and do not bend them to
the side.
04
20. Thank you very much
for your reading. Please
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21. Chapter 3 Drive motor
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SU/SD/SV Sheet no. 3 –
Maintenance
Visual inspection, replacing damaged
parts
• Check that the gear ventilation channels (1) are
clean. Soiling impairs the air circulation, which
leads to increased temperatures in the motor and
possibly irreparable damage to the motor.
• Clean the gear bleeder screw.
• Check the field and armature coils for signs of
overloading (e.g. 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.
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 next
scheduled maintenance date is reached.
6/2008
1
05
22. Chapter 3 Drive motor
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SU/SD/SV Sheet no. 3 – 06
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 with the spring raised.
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
thermally overloaded.
It is also important that the carbon brushes are not
broken or chipped at the running edges.
• Always replace the entire brush set, basing your
assessment on the shortest brush.
• Only use original replacement 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 specialist
workshop).
