Still Wagner FM-I Type 451 Forklift Service Repair Manual.pdf

Workshop
Manual Id. Nr. 8 054 259
First issue: 02/02
Last revision: 05/05
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FM-I Type 451
1/0035
Workshop Manual, FM-I Type 451

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 doumentation, the
manual must be updated using the method
described overleaf.
Foreword
Issue: 02/02 Workshop Sheet no.
Replaces issue: Manual
FM-I Type 451
I
5/0002
5/0003
5/0004
1/0035
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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
information at the left-hand side of the page
footer (1). The date of issue is updated here
in the Issue line (2). The date of issue of the
sheet which needs replacing is specified in
the Replaces issue line (3). The sheet no.
remains the same (4).
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 workshp manual
edition is immediately obvious.
2. Inserting new sheets
If new, altered or additional components are
introduced to the series, it may be necessary
to insert one or more additional sheets.
An additional sheet can be identified by the
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footer (5 + 6).
At the left, in the Issue line, is the current
date of issue (7). At the right, the additional
sheet is marked with the sheet no. with a
consecutive index (8).
The list of contents for the assembly in
question must also be replaced.
We send new sheets, whether they are
replacement or additional sheets, and new
lists of contents, to all the vehicle owners we
know of by mail.
Foreword
Issue: 02/02
Replaces issue:
Workshop
Manual
Sheet no.3-04
Issue: 10/02
Replaces issue: 02/02
Workshop
Manual
Sheet no.3-04
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1 4
2
3
Issue: 02/02
Replaces issue:
Workshop
Manual
Sheet no.
FM-I Typ 451 3-04
Issue: 10/02
Replaces issue:
Workshop
Manual
Sheet no.
3-04.1
FM-I Typ 451
Page footer of an existing sheet
Page footer of an additional sheet
6
5
7
8
Replaces issue: 02/02 Manual
FM-I Type 451
II
First issued: 02/02
Last updated:
Workshop
Manual
Id. no. 8 054 258
Page footer of a cover sheet
9
FM-I Typ 451
FM-I Typ 451
FM-I Typ 451
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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
Foreword
FM-I Type 451
III
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Guide to chapters
Issue: Workshop Sheet no.
FM-I Type 451 IV
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02/02
Chapter 1: Vehicle data
Chapter 2: Drive motor
Chapter 3: Drive wheel
Chapter 4: Gear
Chapter 5: Electro-magnetic parking brake
Chapter 6: Generator service brake
Chapter 7: Hydraulic/mechanical service brake
Chapter 8: Brake deceleration
Chapter 9: Steering
Chapter 10: Guide to the electrical components
Chapter 11: Travel and pump controller (FPS) A10
Chapter 12: Load handling controls module (LAS) 8U61
Chapter 13: Converters 1U6/2U3
Chapter 14: Display 8A5
Chapter 15: CAN bus
Chapter 16: Supply and emergency-stop circuit
Chapter 17: Joystick 2A20
Chapter 18: Single-lever potentiometers 2R9-2R13
Chapter 19: Inductive proximity switches
Chapter 20: Travel transducer 1U20

Guide to chapters
FM-I Type 451 V
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05/05
06/03
Chapter 21: DC/DC converter U30
Chapter 22: Height measuring system 8B21
Chapter 23: Seat adjustment
Chapter 24: Hydraulic functions
Chapter 25: Chassis valve block
Chapter 26: Reach carriage valve block
Chapter 27: Additional hydraulics valve block
Chapter 28: Line break protection
Chapter 29: Lowering brake valve
Chapter 30: Load holding valve
Chapter 31: Pump unit
Chapter 32: Pump motor
Chapter 33: Hydraulic pump
Chapter 34: Tank indicator
Chapter 35: Tank
Chapter 36: Runback filter
Chapter 37: Lubrication plan
Chapter 38: Service software
Chapter 39: Error codes
Chapter 40: Winflash
Chapter 41: Height preselection

Guide to components
FM-I Type 451 VI
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10/02
• Drive wheel..............................................................................................Sheet 3-01
• Brake pedal .............................................................................................Sheet 7-05
• DC / DC converter .................................................................................Sheet 21-01 ff
• Display ...............................................................................................Sheet 14-01 ff
• Speed sensor of drive/hydraulic motors...........................................Sheet 13-09
• Speed sensor of drive motor ..............................................................Sheet 02-05
• Speed sensor of hydraulic motor ......................................................Sheet 32-05
• Pressure relief valve .............................................................................Sheet 25-04
• Single-lever potentiometer ..................................................................Sheet 18-01
• Electro-magnetic parking brake .........................................................Sheet 5-01 ff
• Travel and pump controller..................................................................Sheet 11-01 ff
• Travel transducer...................................................................................Sheet 20-01 ff
• Drive motor..............................................................................................Sheet 2-01 ff
• Gear ...............................................................................................Sheet 4-01 ff
• Main brake cylinder ...............................................................................Sheet 7-10
• Height measuring system ....................................................................Sheet 22-01 ff
• Hydraulic motor ......................................................................................Sheet 32-01 ff
• Hydraulic pump ......................................................................................Sheet 33-01
• Hydraulic/mechanical brake................................................................Sheet 7-01 ff
• Inductive proximity switch....................................................................Sheet 19-01
• Actual value potentiometer..................................................................Sheet 9-15 ff
• Joystick ...............................................................................................Sheet 17-01 ff
• LAS module.............................................................................................Sheet 12-01 ff
• Load holding valve ................................................................................Sheet 30-01
• Line break protection ............................................................................Sheet 28-01
• Steering unit............................................................................................Sheet 9-01 ff
• Steering wheel........................................................................................Sheet 9-14
• Emergency release valve ....................................................................Sheet 25-06
• Proportional valve for lowering...........................................................Sheet 25-05
• Pump unit ...............................................................................................Sheet 31-01
• Runback filter..........................................................................................Sheet 36-01
• Lowering brake valve............................................................................Sheet 29-01
• Seat adjustment .....................................................................................Sheet 23-01
• Setpoint potentiometer .........................................................................Sheet 9-10 ff
• Tank ...............................................................................................Sheet 35-01
• Tank indicator..........................................................................................Sheet 34-01
• Travel converter .....................................................................................Sheet 13-01 ff
• Hydraulic converter ...............................................................................Sheet 13-01 ff
• Chassis valve block...............................................................................Sheet 25-01 ff
• Reach carriage valve block .................................................................Sheet 26-01 ff
• Additional hydraulics valve block .......................................................Sheet 27-01
02/02

Contents
FM-I Type 451 VII
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05/05
• Chapter 1: Vehicle data
-Guide to signs and vehicle number ............................................Sheet 1-01
-Production number and consecutive identification numbers ......Sheet 1-02
-Technical data.............................................................................Sheet 1-03
-Definition of the directions of movement.....................................Sheet 1-04
• Chapter 2: Drive motor
-General.......................................................................................Sheet 2-01
-Technical data.............................................................................Sheet 2-02
-Connections................................................................................Sheet 2-02
-Temperature monitoring..............................................................Sheet 2-03
-Speed sensor..............................................................................Sheet 2-05
-Removal......................................................................................Sheet 2-06
-Installation...................................................................................Sheet 2-09
-Dismantling.................................................................................Sheet 2-10
-Maintenance ...............................................................................Sheet 2-12
-Mast hitch ...................................................................................Sheet 2-13
-Half mast hitch............................................................................Sheet 2-14
• Chapter 3: Drive wheel
-Changing the drive wheel ...........................................................Sheet 3-01
• Chapter 4: Gear
-Commissioning ...........................................................................Sheet 4-01
-Changing the oil..........................................................................Sheet 4-02
-Removal / installation..................................................................Sheet 4-03
• Chapter 5: Electro-magnetic parking brake
-General.......................................................................................Sheet 5-01
-Function......................................................................................Sheet 5-01
-Removal......................................................................................Sheet 5-02
-Changing the brake disk.............................................................Sheet 5-03
-Adjusting the brake clearance ....................................................Sheet 5-04
-Adjusting the braking moment ....................................................Sheet 5-05
-Releasing the brake mechanically..............................................Sheet 5-05
-Checking the brake coil ..............................................................Sheet 5-06
-New magnetic brake from 04/2005.............................................Sheet 5-07
• Chapter 6: Generator service brake
-General.......................................................................................Sheet 6-01
-Function......................................................................................Sheet 6-01
10/02

Contents
FM-I Type 451 VIII
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02/02
• Chapter 7: Hydraulic/mechanical service brake
-Function......................................................................................Sheet 7-01
-Plan of the braking system .........................................................Sheet 7-02
-Removal......................................................................................Sheet 7-03
-Adjusting the brake clearance ....................................................Sheet 7-04
-Adjusting the brake pedal ...........................................................Sheet 7-05
-Bleeding/filling the brake system
• Filling ........................................................................Sheet 7-07
• Bleeding....................................................................Sheet 7-08
-Main brake cylinder
• General.....................................................................Sheet 7-10
• Special base valve....................................................Sheet 7-11
• Removal/installation .................................................Sheet 7-12
• Chapter 8: Brake deceleration
-General.......................................................................................Sheet 8-01
-Preparations for measurement ...................................................Sheet 8-01
-Evaluating the measurement
• Testing the service brake..........................................Sheet 8-02
• Testing the parking brake .........................................Sheet 8-02
• Chapter 9: Steering
-General.......................................................................................Sheet 9-01
-Technical data for the steering unit.............................................Sheet 9-01
-Function......................................................................................Sheet 9-02
-Block diagram.............................................................................Sheet 9-04
-Steering unit
• General.....................................................................Sheet 9-05
• Connections..............................................................Sheet 9-05
• Removal ...................................................................Sheet 9-07
• Installation ................................................................Sheet 9-08
-Removing the drive unit..............................................................Sheet 9-09
-Setpoint potentiometer
• General.....................................................................Sheet 9-10
• Connections/signals..................................................Sheet 9-11
• Testing ......................................................................Sheet 9-12
• Removal ...................................................................Sheet 9-12
-Adjusting the turning force of the steering wheel........................Sheet 9-14
-Actual value potentiometer
• General.....................................................................Sheet 9-15
• Connections/signals .................................................Sheet 9-16
• Testing ......................................................................Sheet 9-17
• Removal ...................................................................Sheet 9-17
-Adjusting the entire steering system...........................................Sheet 9-19

Contents
Replaces issue: 06/03 Manual FM-I Type 451
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• Chapter 9: Steering
-360° Steering
• General.................................................................................Sheet 9-20
-Recognisable features......................................................Sheet 9-21
• Setpoint potentiometer
-General.............................................................................Sheet 9-22
-Connections/signals .........................................................Sheet 9-23
• Actual value potentiometer
-General.............................................................................Sheet 9-24
-Connections/signals .........................................................Sheet 9-25
• Steering unit..........................................................................Sheet 9-26
• Drive unit...............................................................................Sheet 9-27
-Software versions .......................................................................Sheet 9-28
• Chapter 10:Guide to the electrical components
-To 04/2005
• Basic equipment .................................................................Sheet 10-01
• Options................................................................................Sheet 10-02
• Block diagram .....................................................................Sheet 10-03
-From 05/2005
• Basic equipment .................................................................Sheet 10-04
• Options................................................................................Sheet 10-05
• Block diagram .....................................................................Sheet 10-06
VIII.I

Contents
FM-I Type 451 IX
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05/05
06/03
• Chapter 11:Travel and pump controller (FPS) A10
-General ..................................................................................Sheet 11-01
-Differences between FPS 1 & FPS 2.....................................Sheet 11-01.1
-Differences between FPS 2 & FPS 3.....................................Sheet 11-01.3
-Regulating principle of the drive motor .....................................Sheet 11-02
-Regulating principle of the hydraulic motor...............................Sheet 11-04
-Pin assignment/signals for FPS 1/2......................................... Sheet 11-05
-Pin assignment/signals for FPS 3......................................... Sheet 11-06.1
-FPS 1/2
• "Control OK" signal (SOK)......................................Sheet 11-07
• Charging the capacitor unit.....................................Sheet 11-09
• Control of the main contactor .................................Sheet 11-10
• Converter enable....................................................Sheet 11-12
• Phase monitoring....................................................Sheet 11-13
-FPS 3
• "Control OK" signal (SOK)......................................Sheet 11-14
• Charging the capacitor unit.....................................Sheet 11-16
• Control of the main contactor .................................Sheet 11-17
• Converter enable....................................................Sheet 11-19
• Phase monitoring....................................................Sheet 11-20
-Travel control signals
• Vmax ........................................................................Sheet 11-21 •
• V=2.5 km/h..............................................................Sheet 11-22
-Hydraulics control signals .........................................................Sheet 11-23
-Determining the battery capacity (FPS 1/2)..............................Sheet 11-24
-Determining the battery capacity (FPS 3).................................Sheet 11-25
-Hour meter................................................................................Sheet 11-26
-Anti-roll monitor.........................................................................Sheet 11-27
-Software versions .....................................................................Sheet 11-28

Contents
FM-I Type 451 XI
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• Chapter 12:Load handling controls module (LAS module) 8U61
-General.....................................................................................Sheet 12-01
-Control of the hydraulics
• General...................................................................Sheet 12-02
• Block diagram.........................................................Sheet 12-03
• Control signals for lifting the main lift......................Sheet 12-04
• Control signals for lowering the main lift.................Sheet 12-05
• Control signals for DS reaching..............................Sheet 12-06
• Control signals for LS reaching ..............................Sheet 12-07
• Control signals for DS tilting ...................................Sheet 12-08
• Control signals for LS tilting....................................Sheet 12-09
• Control signals for transv. reach right, joystick .......Sheet 12-10
• Control signals for transv. reach left, joystick..........Sheet 12-11
• Control signals for transv. reach right, 4-lever........Sheet 12-12
• Control signals for transv. reach left, 4-lever ..........Sheet 12-13
• Simultaneous movements ......................................Sheet 12-14
• Zero point monitoring..............................................Sheet 12-15
• Reach dampening ..................................................Sheet 12-16
• Hydraulic options....................................................Sheet 12-17
• Guide to input/output signals for hydr. functions.....Sheet 12-19
-Electro-magnetic brake control
• General...................................................................Sheet 12-20
• Parking and emergency braking function ...............Sheet 12-20
• Monitoring...............................................................Sheet 12-21
-Joystick / 4-lever system operation coding...............................Sheet 12-22
-General vehicle options ............................................................Sheet 12-23
-Safety monitoring
• General...................................................................Sheet 12-24
• Switching-on sequence ..........................................Sheet 12-26
• Block diagram.........................................................Sheet 12-27
-Pin assignment X10..................................................................Sheet 12-28
-Pin assignment X11 ..................................................................Sheet 12-30
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X

Contents
FM-I Type 451 XI
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• Chapter 13:Converters 1U6/2U3
-General ..................................................................................Sheet 13-01
-General (Converter to 04/2005)................................................Sheet 13-02
-Technical data (Converter to 04/2005)......................................Sheet 13-02
-General (Converter from 05/2005).........................................Sheet 13-02.1
-Technical data (Converter from 05/2005) ..............................Sheet 13-02.1
-Diagram of functional principle .................................................Sheet 13-03
-The principle of speed/torque regulation ..................................Sheet 13-04
-Status LED (to 04/2005) ...........................................................Sheet 13-05
Supply and enabling (from 05/2005).......................................Sheet 13-05.1
-To 04/2005:
• Connections
- Control signals ...................................................Sheet 13-06
- Power signals.....................................................Sheet 13-07
• Charging the capacitor unit .....................................Sheet 13-08
• Speed sensor..........................................................Sheet 13-09
• Temperature monitoring ..........................................Sheet 13-10
• Converter coding.....................................................Sheet 13-11
-From 05/2005:
• Connections
- Control signals ...................................................Sheet 13-12
- Power signals.....................................................Sheet 13-13
• Charging the capacitor unit .....................................Sheet 13-14
• Speed sensor..........................................................Sheet 13-15
• Temperature monitoring ..........................................Sheet 13-16
• Converter coding.....................................................Sheet 13-17
• Chapter 14:Display 8A5
-General.....................................................................................Sheet 14-01
-Displays ....................................................................................Sheet 14-02
-Onboard diagnosis....................................................................Sheet 14-03
• Travel program selection ........................................Sheet 14-04
• Battery type setting.................................................Sheet 14-05
• Display of the digital inputs.....................................Sheet 14-06
• Display of the analogue inputs ...............................Sheet 14-08
• Display of the vehicle type......................................Sheet 14-12
• Software version query...........................................Sheet 14-13
-Error codes ...............................................................................Sheet 14-14

Contents
FM-I Type 451 XII
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• Chapter 15:CAN bus
-General.....................................................................................Sheet 15-01
-CAN 1 bus structure (vehicle bus)............................................Sheet 15-02
-CAN 2 bus structure (converter bus) ........................................Sheet 15-03
-Signal levels..............................................................................Sheet 15-04
-Data telegrams
• CAN 1 (vehicle bus)................................................Sheet 15-05
• CAN 2 (converter bus)............................................Sheet 15-07
-Error codes / bus test................................................................Sheet 15-08
• Chapter 16:Supply and emergency-stop circuit
-Block diagram (to 04/2005).......................................................Sheet 16-01
-Block diagram (from 05/2005) ..................................................Sheet 16-02
• Chapter 17:Joystick 2A20
-General.....................................................................................Sheet 17-01
-Potentiometer structure ............................................................Sheet 17-02
-Resistance measurement.........................................................Sheet 17-02
• Chapter 18:Single-lever potentiometer 2R9-2R13
-General.....................................................................................Sheet 18-01
• Chapter 19:Inductive proximity switches
-General.....................................................................................Sheet 19-01
• Chapter 20:Travel transducer 1U20
-General.....................................................................................Sheet 20-01
-Measured values ......................................................................Sheet 20-01
-Adjustment................................................................................Sheet 20-02
• Chapter 21:DC/DC converter U30
-General.....................................................................................Sheet 21-01
-Technical data ..........................................................................Sheet 21-01
-Connections..............................................................................Sheet 21-01
• Chapter 22:Height measuring system 8B21
-General.....................................................................................Sheet 22-01
-Function ...................................................................................Sheet 22-01
-Removing/installing the measuring system ..............................Sheet 22-03
-Removing the sensor bearing...................................................Sheet 22-04
-Installing the sensor bearing.....................................................Sheet 22-05

Contents
FM-I Type 451 XIII
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• Chapter 23:Seat adjustment
-General.....................................................................................Sheet 23-01
• Chapter 24:Hydraulic functions
-Lifting the main lift.....................................................................Sheet 24-01
-Lowering the main lift................................................................Sheet 24-02
-Reaching ..................................................................................Sheet 24-03
-Tilting/transverse reach/additional hydraulics...........................Sheet 24-04
-Block diagram...........................................................................Sheet 24-05
• Chapter 25:Chassis valve block
-Guide to the valve block ...........................................................Sheet 25-01
-Functional elements..................................................................Sheet 25-02
-Adjusting work
• Pressure relief valve...............................................Sheet 25-04
• Max. lowering speed...............................................Sheet 25-05
-Emergency release valve .........................................................Sheet 25-06
-Electrical data ............................................................................Sheet25-07
• Chapter 26:Reach carriage valve block
-Functional elements..................................................................Sheet 26-02
-Adjusting work ..........................................................................Sheet 26-04
-Electrical data ...........................................................................Sheet 26-04
• Chapter 27:Additional hydraulics valve block
• Chapter 28:Line break protection
-General.....................................................................................Sheet 28-01
-Types used ...............................................................................Sheet 28-02
• Chapter 29:Lowering brake valve
-General.....................................................................................Sheet 29-01
-Function ...................................................................................Sheet 29-01
• Chapter 30:Load holding valve
-General.....................................................................................Sheet 30-01

Contents
FM-I Type 451 XIV
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• Chapter 33:Hydraulic pump
-General.....................................................................................Sheet 33-01
-Types used ...............................................................................Sheet 33-01
• Chapter 34:Tank indicator
-Tank indicator............................................................................Sheet 34-01
• Chapter 35:Tank
-Tank ..........................................................................................Sheet 35-01
• Chapter 36:Runback filter
-General.....................................................................................Sheet 36-01
-Replacing the filter....................................................................Sheet 36-01
• Chapter 37:Lubrication plan
-Lubrication plan ........................................................................Sheet 37-01
-Lubricants .................................................................................Sheet 37-02
-Taking out of service / disposal ................................................Sheet 37-03
• Chapter 38:Service software
-General.....................................................................................Sheet 38-01
-Making a connection.................................................................Sheet 38-02
-FM-I Servicemaster
• Menu guide.............................................................Sheet 38-03
• Commissioning the steering ...................................Sheet 38-05
-Commissioning check..........................................Sheet 38-09
-Correcting the straight-on position.......................Sheet 38-09
-Adjusting the flutter...............................................Sheet 38-11
-A/D converter calibration......................................Sheet 38-17
-Correcting the steering speed..............................Sheet 38-19
-Reverse steering..................................................Sheet 38-20

Contents
FM-I Type 451 XV
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05/05
06/03
• Chapter 38:Service software
-FM-I Servicemaster
• Commissioning the hydraulics................................Sheet 38-21
-Commissioning with standard parameter set.......Sheet 38-23
-Recommended values for initial commissioning ..Sheet 38-31
-Commissioning with vehicle-specific file ..............Sheet 38-34
-Commissioning with LAS module data ................Sheet 38-35
• Loading parameters................................................Sheet 38-36
• Diagnosis................................................................Sheet 38-37
-Error memory .......................................................Sheet 38-38
-List of errors .........................................................Sheet 38-40
-Analogue values for hydraulics ............................Sheet 38-43
-Analogue values for steering ...............................Sheet 38-44
-Input switching signals LAS / FPS .......................Sheet 38-45
-Travel transducer .................................................Sheet 38-47
-Travel drive ..........................................................Sheet 38-48
-Hydraulic drive .....................................................Sheet 38-49
• LAS module software update .................................Sheet 38-50
• Setting the parameters in the FPS .........................Sheet 38-54
-Travel parameters................................................Sheet 38-55
-Hour meter...........................................................Sheet 38-57
-Battery type..........................................................Sheet 38-58
-Hydraulics curve ..................................................Sheet 38-59
-Software updates
• FM-I Servicemaster V1.08
-General ................................................................Sheet 38-60
-Teaching-in the joystick / 4-lever system .............Sheet 38-61
-New parameters for "hydraulic outputs"...............Sheet 38-62
-Diagnosis of analogue values for steering ...........Sheet 38-63
-Teaching-in the 360° steering ..............................Sheet 38-64
•Starting teaching-in.........................................Sheet 38-66
•Setting the steering wheel turns .....................Sheet 38-69
•A/D converter calibration.................................Sheet 38-70
•Flutter..............................................................Sheet 38-71
•Setting the gear transmission ratio .................Sheet 38-74
-Teaching-in the 180° steering
•Setting the gear transmission ratio .................Sheet 38-75
-Error messages for teaching-in 180° and 360°....Sheet 38-76
• FM-I Servicemaster V1.09
-General ................................................................Sheet 38-84
• Chapter 39:Error codes
-Description of errors .................................................................Sheet 39-01

FM-I Type 451
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XVI
Contents
05/05
• Chapter 40:Winflash
-General.....................................................................................Sheet 40-01
-Block diagram...........................................................................Sheet 40-02
-Version V1.06
• Description ..................................................................Sheet 40-03
• Setting up a connection with the vehicle .....................Sheet 40-07
• Downloading the FPS software...................................Sheet 40-08
• Downloading the steering software .............................Sheet 40-09
• Downloading the LAS module software ......................Sheet 40-10
• Updating programs......................................................Sheet 40-12
-Version V1.11 and higher
• Description ..................................................................Sheet 40-13
• "Select control system" window...................................Sheet 40-15
• "Select file" window .....................................................Sheet 40-16
• Principle of the download process...............................Sheet 40-16
• "Check connection" button ..........................................Sheet 40-17
• "Start programming" button.........................................Sheet 40-17
• Chapter 41:Height preselection
-Height preselection functions
• General.......................................................................Sheet 41-01
-Insertion, Removal, Assistant, Pallet free-lift..........Sheet 41-02
-Reference cycle, Reference height........................Sheet 41-03
• Function......................................................................Sheet 41-04
-Incremental encoder, Reference switch.................Sheet 41-05
-Inductive proximity switch, Fork free-lift switch ......Sheet 41-06
• Block diagram.............................................................Sheet 41-07
• Operation
-Insertion/removal....................................................Sheet 41-08
-Insertion .................................................................Sheet 41-10
-Removal .................................................................Sheet 41-11
-Target correction ...................................................Sheet 41-12
-Teaching-in the levels ............................................Sheet 41-13
-Display functions
• General.......................................................................Sheet 41-15
• Displays and key assignment .....................................Sheet 41-16
• Operation
-On-board diagnosis................................................Sheet 41-18
-Adjusting the proportional valve for lowering .........Sheet 41-25

Kapitel 1
FM-I Type 451 1-01
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02/02
FM-I Type 451
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Copyright
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Copyright
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FM-I Type 451 1-01
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Copyright
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02/02
Chapter 1 ehicle data
Guide to signs on the vehicle and vehicle number
1/0035
1/0221
1/0218
1/0219
1/0220
Vehicle no. on reach carriage
Load diagram
UVV test plaque
Factory nameplate

61 1856 0 58300
Production number and consecutive identification numbers
Our industrial trucks are allocated a production number for identification purposes.
This production number can be found on the factory nameplate of the vehicle.
The production number contains a code for the vehicle type and a consecutive
identification number. Vehicle changes are always introduced from a certain
identification number onwards.
However, please always specify the entire production number when making enquiries.
This workshop manual is labelled by our usual system, as follows: all the vehicles in
this FM Group are described in this manual. The type/model number is used and
specified in the footer of each sheet, e.g.
The following vehicles are described in this workshop manual: Type 451 with load
carrying capacities of 1.2 t (FM12), 1.4 t (FM14), 1.7 t (FM17) and 2.0 t (FM20).
Guide to production numbers
Kapitel 1
FM-I Typ 451
FM-I Typ 451 3-04
Production number
FM12 I
Consecutive identification number
61 1878 0 00001
FM14 I
61 1879 0 00001
61 1880 0 00001
FM17 I
61 1881 0 00001
FM20 I
Fahrzeugdaten
Kapitel 1
FM-I Type 451 1-02
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Fahrzeugdaten
02/02
FM-I Type 451
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ist
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Copyright
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FM-I Type 451
FM-I Type 451 1-02
02/02
Chapter 1 vehicle data

FM-I Type 451
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FM-I Type 451 1-03
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Copyright
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Technical data
The data listed here applies for a standard vehicle (mast h1= 2250 mm). The values for
"Current consumption" and "Operating pressures" are average values taken from several
different vehicles. These values are influenced, among other things, by the mast (mast
height h1), the max. load-bearing capacity and the battery used.
Vehicle type FM12 I
Rated load-bearing capacity 1
Battery voltage
kg
V
1200
48
Battery capacity
Power consumption in acc. with VDI cycle
Battery weight ± 5% (acc. to manufacturer)
Empty weight incl. battery 2
Ah
KWh/h
420
4.6
kg
kg
750
2780
FM14 I FM17 I
1400
48
1700
48
FM20 I
2000
48
420/560/700
4.6
420/560/700
5.3
750/940/1120
3035/3235/3425
750/940/1120
3065/3265/3455
560/700
5,90
940/1120
3296/3496
Drive motor output
Hydraulic motor output
Steering motor output
max. travel speed with/without load 3
KW
KW
6
11.5
KW
km/h
0,50
12
Acceleration over 10m with/without load
Climbing ability with/without load
Drive motor curr. at V=2.5km/h, w/o load 4
Drive motor curr. at V=12km/h, w/o load 4
s
%
4.8/4.5
10/15
A
A
ca. 60-80
ca. 80-100
6
11.5
6
11.5
0.5
12
0.5
12
6
11.5
0,5
12
5.0/4.6
10/15
5.2/4.6
10/15
ca. 70-90
ca. 100-120
ca. 70-100
ca. 100-130
5.5/4.7
9.5/15
ca. 70-100
ca. 100-130
Drive motor current on acceleration to
12 km/h, without load 4
Lifting speed with/without load
Operating pressure, lifting with load
Current consumption, lifting with load
A
m/s
ca. 230-260
ca. 0.38/0.6
bar
A
ca. 140-170
ca. 260-290
Lowering with load (main lift)
Lowering with load (free lift)
Reaching speed with load 5
Operating pressure, reaching with load
m/s
m/s
ca. 0.52
ca. 0.49
cm/s
bar
9.5-11.5
ca. 40-70
ca. 260-280
ca. 0.36/0.6
ca. 260-290
ca. 0.32/0.6
ca. 130-190
ca. 250-280
ca. 200-230
ca. 270-290
ca. 260-310
ca. 0.28/0.48
ca. 160-180
ca. 270-290
ca. 0,52
ca. 0,49
ca. 0.54
ca. 0.49
9,5-11.5
ca. 40-70
9.5-11.5
ca. 40-70
ca. 0.50
ca. 0.48
9.5-11.5
ca. 40-70
Current consumption, reaching with load
Tilting time out of vertical
Operating pressure for tilting with load
Current consumption for tilting with load
A
s
ca.100-140
ca. 3.0
bar
A
ca. 40-80
ca. 100-150
Transverse reach with load 6
Oper. pressure, trans. reach with load 6
Current cons., trans. reach with load 6
Adjustment of pressure limiting valve 7
cm/s
bar
ca. 4.4
ca. 40-60
A
bar
ca. 80-130
ca. 150-190
ca.100-140
ca. 3.0
ca.100-140
ca. 3.0
ca. 40-80
ca. 100-150
ca. 40-80
ca. 100-150
ca.100-140
ca. 3.0
ca. 40-80
ca. 100-150
ca. 4.4
ca. 40-60
ca. 4.4
ca. 40-60
ca. 80-130
ca. 150-220
ca. 80-130
ca. 210-245
ca. 4.4
ca. 40-60
ca. 80-130
ca. 180-200
1 = As the lifting height increases, the load-bearing capacity decreases (see diagram of loads on the mast)
2 = The empty weight varies according to the different mast heights. These specifications apply for a mast
with a height of h1= 2250 mm
3 = The max. travel speed can be set separately in 5 different travel programs to between 1 and 12 km/h
4 = All values measured with the travel parameters set to the default factory settings (please see "Service
software, FM-I Servicemaster, Setting the parameters in the FPS, Travel parameters)
5 = The reaching speed can be set with parameters and is between 5 and 6 seconds from one stop to the
other, depending on the type of battery used (affects the reaching depth) and the vehicle type (mean
reaching speed 10.5 cm/sec.)
6 = Optional extra
7 = The valve is generally set to "Operating pressure for lifting with nominal load + 10%"

Definition of the directions of movement
Kapitel 1
0/0352
Lifting
mast
Lowering
mast
Travel direction
load side (LS)
Travel direction
drive side (DS)
Reach to
drive side
(DS)
Reach to
load side
(LS)
Tilting
Load side (LS) Drive side (DS)
The descriptions left and right assume that you are looking in the drive
side travel direction!
Replaces issue: Manual FM-I Typ 451
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Fahrzeugdaten
Kapitel 1
1-04
Fahrzeugdaten

Chapter 2
FM-I Type 451 2-
Copyright
protected.
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part
of
this
manual
may
be
reproduced
in
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form.
Copyright
reserved.
Drive motor
10/02
01
General
The drive motor is a 3-phase alternating current
motor (asynchronous motor with squirrel cage
rotor).
It is controlled by a converter which generates
sinusoidal 3-phase alternating voltage from the
battery voltage (please see "Converter, General").
The 3-phase stator rotary field generates voltage in
the squirrel cage rotor (1) by breaking magnetic
field lines (on the principle of voltage induction).
This induced voltage is short-circuited by the short-
circuit rings (2). The power generated in this way in
turn generates a rotor magnetic field. This rotor field
attempts to follow the stator rotary field, i.e. the
rotational speed of the stator field is higher than that
of the rotor field (asynchronous).This difference in
rotational speed is known as slippage.
This functional principle means that carbon brushes
are no longer needed in the motor, and
consequently that soiling in the inside of the motor
from carbon brush dust is no longer a problem.
In this way, by changing the rotational speed of the
stator field (frequency of the alternating voltage),
the speed can be changed, and by changing the
voltage the current can be changed indirectly, and
consequently the torque regulated (please see
"Converter, The principle of speed/torque
regulation").
The speed is detected by a speed sensor integrated
in the motor (sensor bearing (3)), which is
connected directly at the converter (please see
"Drive motor, Speed sensor").
Also integrated in the motor (in the stator coil (4)) is
a temprature sensor, which protects the motor from
overloading (please see "Drive motor, Temperature
monitoring"). This is also connected directly at the
converter.
2/0238
2/0239
Magnetic field of the
stator rotary field
Rotational direction
of stator rotary field
2/0240
1 2
3 4

Chapter 2
FM-I Type 451 2-
Copyright
protected.
No
part
of
this
manual
may
be
reproduced
in
any
form.
Copyright
reserved.
Drive motor
02
Technical data
Model: AF 124 - L3
Motor design: Alternating current
asynchronous motor with
squirrel cage rotor
Connection method: Delta
No. of pairs of poles: 2
Class of rating: S2 - 60
Voltage: 0 - 28 V AC
Rated current: 177 A AC
Rated frequency: 80 Hz
Frequency response: 0 - 130 Hz
Rated output: 6.0 KW
Rated speed: 2340 rpm
Protection class: IP 00
Insulation class: F
Motor bearing lifetime: 12,000 hrs
Remark: Some of this technical data can be found
on the motor nameplate (1).
Connections
2/0241
1
Designation on motor Meaning
Main current terminals
U
V
W
Phase U from converter
Phase V from converter
Phase W from converter
Sensor terminals
X2.1
Input, temperature sensor
Iconst = 2.56 mA1
/ 1,66 mA2
X2.2
X2.3
X1.1
n.c.
0V supply, temperature sensor
12V supply, speed sensor
X1.2
X1.3
X1.4
Channel B, 0V active switching
0V supply, speed sensor
Channel A, 0V active switching
2/0242
2/0243
2/0244
X2 X1
1 = Converter to 04/2005
2 = Converter from 05/2005

Chapter 2
FM-I Type 451 2-
Copyright
protected.
No
part
of
this
manual
may
be
reproduced
in
any
form.
Copyright
reserved.
Drive motor
03
Temperature monitoring
The motor temperature is sensed by a temperature
sensor integrated directly in the stator coil (1).
The temperature sensor works by the same
principle as a PTC resistor (increasing temperature
= increasing resistance value), however this special
version (silicon sensor) has an almost linear course
(see characteristic curve).
The temperature sensor is supplied by the conver-
ters (up to 04/2005) with a constant current I = 2.56
mA (cf. "Converters, terminals, control signals").
For converters from 05/2005, this current is appr.
1.6 mA.
In this way, the measured temperature is sent back
to the converter as a voltage value.
At 20°C, this represents a voltage of about 1.4V/
0,9V (145°C = 3.35V/2V, 150°C = 3.45V/2,15V).
The temperature measured in this way is sent to the
FPS via the CAN bus 2 (please see "CAN bus"). In
the event of excess temperature, the FPS then
issues an error code, which is sent via CAN bus 1
to the LAS module (entry in the error memory) and
to the display (to be displayed). The result is a
power reduction.
Error code (see "Error codes")
FE25: Temperature > 145°C, 50% power reduction
(for converters from 05/2005 Vred = 2.5 kph)
FE26: Temperature > 150°C, motor is switched off
FE27: Temperature sensor faulty or connector
pulled out (please see "Drive motor,
Connections");
The motor is switched off.
(for converters from 05/2005 Vred = 2.5 kph)
1
2/0245
2/0246

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Chapter 2
FM-I Type 451 2-
Copyright
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part
of
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manual
may
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in
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form.
Copyright
reserved.
Drive motor
10/02
04
Temperature monitoring
Test
To test the sensor, connector X2 at the motor must
be disconnected. A resistance measurement must
then be carried out on the sensor side of the
connector between X2.1 and X2.3. Finally, the
temperature at the motor housing must be
measured. The measured values should
correspond with those shown in the table to the
right ± 20 .
Important note on measuring the insulation
resistance at the motor:
The temperature sensor must be short-circuited
without fail for insulation measurement,
otherwise the sensor will be damaged by the
high test voltage!
T/°C R/Ohm T/°C R/Ohm
-40
-30
355
386
100
110
1000
1063
-20
-10
0
10
419
455
120
130
493
533
140
150
1129
1197
1268
1340
20
25
30
40
576
598
160
170
621
668
180
190
50
60
70
80
718
769
200
210
824
880
220
230
1415
1493
1572
1654
1739
1825
1914
2006
90 939 240 2099

Chapter 2
FM-I Type 451 2-
Copyright
protected.
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part
of
this
manual
may
be
reproduced
in
any
form.
Copyright
reserved.
Drive motor
05
2/0247
1
2/0248
2 3
5
4
Speed sensor
The speed sensor is designed as a "sensor bearing"
(ball bearing with speed sensor) and is located inside
the motor, pressed onto the rotor shaft (1).
Structure
- Connecting lead (2)
- Outer sensor ring (3)
- Inner pulse ring (4)
- Deep-groove ball bearing (5)
It is connected directly to the converter, which supplies it
with 12V power and evaluates it (please see "Converter,
Connections, Control signals").
The two sensor signals (signal A and signal B) are also
sent to the FPS.
Remark: Monitoring of the speed sensor signal by the
FPS is only possible with the so-called "FPS
2".
On vehicles with "FPS 1", the speed sensor
is not connected to the FPS (please see
"FPS").
The converter needs the sensor information in order to
regulate the speed of the drive motor.
If no signals arrive at the converter, the motor is only
controlled by a minimum.
Remark: The converter (to 04/2005) itself does not
generate an error code if the sensor is faulty!
The converter from 05/2005 generate an er-
ror code (see "error code").
The FPS (from FPS 2) compares the speed sensor
information that it has recorded itself, with the
information it receives from the converter via the CAN
bus 2.
If there is a difference between these two speed values,
the FPS generates an error code "FE 28" (please see
"Error codes"). However, this does not have an effect on
the way the motor behaves.
As a result, the speed sensor fails to detect a pulled plug
(with the converters used up to 04/2005 no error code,
only minimal motor actuation). For converters from 05/
2005 onwards, a pulled plug causes the truck to come to
a standstill with the error code "FE 28"!

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