Still Wagner MX15-3 Forklift Service Repair Manual.pdf

Workshop
Manual I d. N
First issued: 02/01
Last update: 
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MX15-3
Workshop Manual MX15-3
1/0105

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MX15-3 MX15-3 I
Vehicles with
shunt technology (MX15-3)
and
alternating current technology (MX15-3 I)
are described in this manual. The pages which are relevant
for alternating current only are marked as such in the List of
Contents and in the footers of each page.

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 techni-
cal features of the vehicle and consequently en-
sure that maintenance and repair are carried
out correctly.
The WM is updated on a regular basis.
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.
Foreword
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Issue:  Workshop Sheet no.
Replaces issue: 06/02 Manual MX15-3 1
5/0002
5/0003
5/0004

Updating workshop manuals
(Continued)
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 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 workshop
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
changes at the left and right of the page
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 component 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
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Issue: 07/03 Workshop Sheet no.
Issue: 02/01
Replaces issue:
Workshop
Manual
Sheet no.
MX15-3 1-02
Issue: 07/01
Replaces issue: 02/01
Workshop
Manual
Sheet no.
MX15-3 1-02
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1 4
2
3
Issue: 02/01
Replaces issue:
Workshop
Manual
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MX 15-3 1-02
Issue: 07/01
Replaces issue:
Workshop
Manual
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MX15-3 1-02.1
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6
5
7
8
First issued: 02/01
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Workshop
Manual
Id.No. ...
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9
MX15-3

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 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.
STILL WAGNER GmbH & Co. KG
Trainingcenter
Ernst-Wagner-Weg 1-5
72766 Reutlingen
Foreword
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Issue:  Workshop Sheet no.

List of contents
• List of chapters......................................................................................P. 19
• Guide to components ...........................................................................P. 22
• Chapter 1: Vehicle data
- Guide to information plates and vehicle number .............................P. 1-01
- Hydraulic settings ............................................................................P. 1-02
- Hydraulic settings ............................................................................P. 1-02.1 (MX13-3)
- Vehicle speed..................................................................................P. 1-03
• Outside aisle ..............................................................................P. 1-03
• Inside aisle .................................................................................P. 1-03
• Chapter 2: Drive motor
- General............................................................................................P. 2-01
- Technical data for the drive motor...................................................P. 2-01
- Drive mor terminals .........................................................................P. 2-01
- Temperature sensor integrated in the
carbon brush yoke ..........................................................................P. 2-02
- Carbon brush monitoring.................................................................P. 2-03
- Replacing the carbon brushes.........................................................P. 2-04
- Checking the brush springs.............................................................P. 2-04
- Removing the drive motor ...............................................................P. 2-05
- Installing the drive motor .................................................................P. 2-06
- Drive motor maintenance ................................................................P. 2-07
For Alternating Current only:
- General ...........................................................................................P. 2-11 (MX15-3 I)
- Terminals ........................................................................................P. 2-12 (MX15-3 I)
- Speed monitoring ............................................................................P. 2-13 (MX15-3 I)
- Removal .......................................................................................P. 2-14 (MX15-3 I)
- Technical data.................................................................................P. 2-15 (MX15-3 I)
- Temperature monitoring..................................................................P. 2-16 (MX15-3 I)
- Speed sensor ..................................................................................P. 2-17 (MX15-3 I)
• Removal.....................................................................................P. 2-17 (MX15-3 I)
• Installation..................................................................................P. 2-19 (MX15-3 I)
• Chapter 3: Drive wheel
- Replacing the drive wheel ...............................................................P. 3-01
- Removing the drive wheel ...............................................................P. 3-01
- Replacing the idling wheels.............................................................P. 3-02
- Removing the idling wheels ............................................................P. 3-02
- Installing the idling wheels ..............................................................P. 3-02
• Chapter 4: Gear
- Oil change .......................................................................................P. 4-01
- Removing the gear ..........................................................................P. 4-02
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List of contents

• Chapter 5: Brake
- Electromagnetic brake.....................................................................P. 5-01
• Function .....................................................................................P. 5-01
• Removal .....................................................................................P. 5-02
• Replacing the brake linings ........................................................P. 5-03
• Adjusting the brake clearance....................................................P. 5-04
• Mechanical brake release ..........................................................P. 5-05
• Testing the brake coils ...............................................................P. 5-05
• Continuous release of the second stage....................................P. 5-06
• Continuous release of the second stage....................................P. 5-06.1 (MX13-3)
• Measuring the braking deceleration...........................................P. 5-07
• Checking the braking deceleration.............................................P. 5-08
• Checking the braking deceleration.............................................P. 5-08.1 (MX13-3)
• Adjusting the braking deceleration.............................................P. 5-10
• Adjusting the braking deceleration.............................................P. 5-10.1 (MX13-3)
• Chapter 6: Steering
- Adjusting the steering......................................................................P. 6-01
• General ......................................................................................P. 6-01
• Adjusting sequence....................................................................P. 6-02
• Turning the potentiometer of the steering controller
to the centre position .................................................................P. 6-03
• Adjusting the rotary force at the handwheel...............................P. 6-04
• Adjusting the retaining force in the straight-on position .............P. 6-04
• Adjusting potentiometers R11/R12 ............................................P. 6-05
• Adjusting the setpoint potentiometers ........................................P. 6-06
• Adjusting the actual value potentiometer (to approx. 11/02)......P. 6-07
• Adjusting the actual value potentiometer (from approx. 11/02)..P. 6-07.1
• Adjusting the max. steering angle..............................................P. 6-08
• Correction of straight-on.............................................................P. 6-09
- Rail guidance.........................................................................P. 6-09
- Free travel..............................................................................P. 6-09
• Teaching-in the wheel position display ......................................P. 6-10
- Steering controller ...........................................................................P. 6-10.1
• Block diagram of steering...........................................................P. 6-10.1
• Block diagram of steering controller...........................................P. 6-10.2
• Description .................................................................................P. 6-11
• Guide to the potentiometer and LEDs........................................P. 6-12
• Service switch ............................................................................P. 6-12
• Pin assignment...........................................................................P. 6-13
• Main current terminals................................................................P. 6-14
• Maintenance...............................................................................P. 6-14.1
- Steering motor.................................................................................P. 6-15
• General ......................................................................................P. 6-15
• Terminal designations on terminal board...................................P. 6-15
• Replacing the carbon brushes ...................................................P. 6-15
• Emergency steering ...................................................................P. 6-15
• Maintenance...............................................................................P. 6-15
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• Chapter 7: Mast
- Removing the mast..........................................................................P. 7-01
- Installing the mast..............................................................................P. 7-05
- Mast table ..........................................................................................P. 7-06
• Chapter 8: Vehicle control system 8U60
- General..............................................................................................P. 8-01
- Description.........................................................................................P. 8-01
- Replacing the FZS.............................................................................P. 8-01.1
- Pin assignment ..................................................................................P. 8-02
• Chapter 9: Travel and pump controller A10
- General..............................................................................................P. 9-01
- Terminals...........................................................................................P. 9-01
- Pin assignment ..................................................................................P. 9-02
- Block diagram....................................................................................P. 9-04
- Signal processing ..............................................................................P. 9-05
- Response of the main contactors ......................................................P. 9-06
- Control OK.........................................................................................P. 9-07
- Temperature monitor fo the drive and pump motors .........................P. 9-08
• General ........................................................................................P. 9-08
• Description ...................................................................................P. 9-08
• Testing the temperature sensors .................................................P. 9-08
• Contact assignment MARKII........................................................P. 9-08.1
- Temperature monitor for the travel and pump controller ...................P 9-09
- Carbon brush monitor for the drive and pump motors.......................P. 9-10
- Incremental encoder monitor.............................................................P. 9-12
• General ........................................................................................P. 9-12
• Description ...................................................................................P. 9-13
• Testing the incremental encoder of the drive motor.....................P. 9-14
• Testing the incremental encoder of the pump motor....................P. 9-15
- Instructions for repair.........................................................................P. 9-16
• Power unit ....................................................................................P. 9-16
• Control card..................................................................................P. 9-16
• Field regulator ..............................................................................P. 9-16
- Table of errors ...................................................................................P. 9-17
- Removing the FPS ............................................................................P. 9-18
- Installing the FPS ..............................................................................P. 9-19
- Removing the control card ................................................................P. 9-20
- Installing the control card ..................................................................P. 9-21
- Removing the field regulator .............................................................P. 9-22
- Installing the field regulator ...............................................................P. 9-24
- General..............................................................................................P. 9-26 (MX15-3 I)
- Block diagram....................................................................................P. 9-27 (MX15-3 I)
- Switching on the main contactors......................................................P. 9-28 (MX15-3 I)
• Step-by-step procedure................................................................P. 9-28 (MX15-3 I)
• Activation of the convertors..........................................................P. 9-28 (MX15-3 I)
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- Phase monitoring ..............................................................................P. 9-29 (MX15-3 I)
- Pin assignment for X1 .......................................................................P. 9-30 (MX15-3 I)
• Chapter 10: Operating console 8U62
- Operating elements ...........................................................................P. 10-01
- Block diagram....................................................................................P. 10-02
- Operating console board ...................................................................P. 10-03
- Pin assignment ..................................................................................P. 10-04
- Keyboard boards 1, 2 and 3 ..............................................................P. 10-05
- Operating console display .................................................................P. 10-06
• General ........................................................................................P. 10-06
• Basic display ................................................................................P. 10-07
• Operating hours ...........................................................................P. 10-07
• Remaining battery capacity..........................................................P. 10-07
• Wheel position display .................................................................P. 10-07
• Display LED for manual steering..................................................P. 10-08
• Status and maintenance symbols ................................................P. 10-08
• "Deadman switch not actuated" display .......................................P. 10-08
• "Creep speed" display..................................................................P. 10-08
• "2-handed operation not actuated" display ..................................P. 10-09
• "Barrier open" display...................................................................P. 10-09
• "Maintenance" display..................................................................P. 10-09
• "LR80 error" display .....................................................................P. 10-09
• "Acknowledgement required" display...........................................P. 10-10
• "Reserve1" display.......................................................................P. 10-10
• "Reserve2" display.......................................................................P. 10-10
- Operating console display .................................................................P. 10-11
• Error display.................................................................................P. 10-11
• Information display.......................................................................P. 10-11.1
• Switching-on test..........................................................................P. 10-12
• Switching over the operating console display ..............................P. 10-12
• LR80 operating status display......................................................P. 10-12
- Replacing the setpoint potentiometer ................................................P. 10-13
• Removing the setpoint potentiometer ..........................................P. 10-13
• Installing the setpoint potentiometer ............................................P. 10-15
• Rough adjustment of the setpoint potentiometer .........................P. 10-17
• Fine adjustment of the setpoint potentiometer.............................P. 10-19
• Teaching-in the setpoint potentiometer........................................P. 10-20
• Operating console display menu..................................................P. 10-20.1
- LR80 board (option)...........................................................................P. 10-22
• Description ...................................................................................P. 10-22
• Pin assignment.............................................................................P. 10-23
• Chapter 11: Load handling control 8U61
- General..............................................................................................P. 11-01
- Description.........................................................................................P. 11-01
- Pin assignment ..................................................................................P. 11-02
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• Chapter 12: EMERGENCY-STOP and amplifier module 7A22
- General..............................................................................................P. 12-01
- Description.........................................................................................P. 12-01
- Pin assignment ..................................................................................P. 12-02
- Safety relays K33 and K34 ................................................................P. 12-04
- Safety relay K35 ................................................................................P. 12-05
- Key switch relay K36 .........................................................................P. 12-06
- Relay K37 (steering error) .................................................................P. 12-07
- "Enable hydraulics" signal .................................................................P. 12-08
- Chain monitoring................................................................................P. 12-09
- Adaptation of the steering setpoint ....................................................P. 12-12
- Control of the electromagnetic brake.................................................P. 12-13
- Evaluation of the potentiometer value for the
height measuring system of themain lift .........................................P. 12-14
- Adaptation of incremental encoder signals........................................P. 12-15
• Chapter 13: Distributor board A13
- General..............................................................................................P. 13-01
- Structure ............................................................................................P. 13-02
- Replacement for distributor board A13..............................................P. 13-03
• Chapter 14: Negative feeder module A14
- General..............................................................................................P. 14-01
- Description.........................................................................................P. 14-01
- Terminals...........................................................................................P. 14-02
- Pin assignment X1.............................................................................P. 14-02
• Chapter 15: Main contactors K1 and K2
- General..............................................................................................P. 15-01
- Coil holder suppression .....................................................................P. 15-01
- Spacing distance ...............................................................................P. 15-01
- Contact pressure ...............................................................................P. 15-01
• Chapter 16: DC/DC converter
- General..............................................................................................P. 16-01
- Description.........................................................................................P. 16-01
- Electrical connections........................................................................P. 16-01
- Technical data ...................................................................................P. 16-01
• Chapter 17: Distance sensor for the main lift
- General..............................................................................................P. 17-01
- Location .............................................................................................P. 17-01
- Identification.......................................................................................P. 17-01
- Technical data ...................................................................................P. 17-01
- Pin assignment ..................................................................................P. 17-01
- Monitor...............................................................................................P. 17-02
- Safety instructions .............................................................................P. 17-03
- Description of errors ..........................................................................P. 17-04
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- Removing and installing the distance sensor ....................................P. 17-05
- Repair instructions
• 1. Replacing the potentiometer ....................................................P. 17-06
• 2. Replacing the cable..................................................................P. 17-07
• 3. Replacing the incremental encoder..........................................P. 17-09
• 4. Replacing the belt ....................................................................P. 17-10
• 5. Replacing the spring ................................................................P. 17-11
• Chapter 18: Distance sensor the for additional lift
- General..............................................................................................P. 18-01
- Monitor...............................................................................................P. 18-02
• Chapter 19: Distance sensor for swivelling
- General..............................................................................................P. 19-01
- Monitoring..........................................................................................P. 19-01
• Chapter 20: Distance sensor for side shifting
- General..............................................................................................P. 20-01
- Monitor...............................................................................................P. 20-02
• Chapter 21: SERVICE mode
- Description.........................................................................................P. 21-01
- Activating SERVICE mode ................................................................P. 21-02
- Deactivating SERVICE mode ............................................................P. 21-02
• Chapter 22: Teaching-in process
- General..............................................................................................P. 22-01
- Commissioning ..................................................................................P. 22-02
- Deleting teaching-in values................................................................P. 22-03
- Preparation for teaching in.................................................................P. 22-04
- Teaching in the main lift distance sensor...........................................P. 22-04
- Teaching in the additional lift distance sensor...................................P. 22-05
- Teaching in the swivelling distance sensor........................................P. 22-06
- Teaching in the side shift distance sensor.........................................P. 22-07
• Chapter 23: Reference sequence
- General..............................................................................................P. 23-01
- Reference sequence for the main lift.................................................P. 23-01
- Reference sequence for the additional lift .........................................P. 23-01
• Chapter 24: Chassis valve block
- Mounting instructions.........................................................................P. 24-01
- Functional elements...........................................................................P. 24-01
- Setting the maximum pressure..........................................................P. 24-02
- Parameterising the main lift...............................................................P. 24-02
- Soiling indicator.................................................................................P. 24-03
- High presure filter ..............................................................................P. 24-04
• Changing the filter - removal........................................................P. 24-04
• Changing the filter - installation ...................................................P. 24-04
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- Removing the chassis valve block ....................................................P. 24-05
- Fine control of lowering main lift........................................................P. 24-06
• Chapter 25: Attachment valve block
- Functional elements...........................................................................P. 25-01
- Adjusting work ...................................................................................P. 25-02
- Parameterising the ancilliary movements..........................................P. 25-02
• Chapter 26: Pump motor
- General..............................................................................................P. 26-01
- Technical data for the pump motor....................................................P. 26-01
- Pump motor terminals .......................................................................P. 26-01
- Temperature sensor integrated in carbon brush yoke.......................P. 26-02
- Carbon brush monitoring...................................................................P. 26-03
- Replacing the carbon brushes...........................................................P. 26-04
- Checking the brush springs...............................................................P. 26-04
- Pump motor maintenance .................................................................P. 26-05
- General..............................................................................................P. 26-06 (MX15-3 I)
- Terminals...........................................................................................P. 26-07 (MX15-3 I)
- Speed monitoring ..............................................................................P. 26-08 (MX15-3 I)
- Technical data...................................................................................P. 26-09 (MX15-3 I)
- Temperature monitoring ....................................................................P. 26-10 (MX15-3 I)
• Chapter 27: Hydraulic motor
- Function.............................................................................................P. 27-01
- Commissioning..................................................................................P. 27-01
- Technical data...................................................................................P. 27-01
- Checking for leaks.............................................................................P. 27-02
- Removal.............................................................................................P. 27-03
• Chapter 28: Pump
- Removing the pump ..........................................................................P. 28-01
• Chapter 29: Oil level indicator
- -Oil level indicator..............................................................................P. 29-01
• Chapter 30: Ventilation filter
- Function.............................................................................................P. 30-01
- Removal ............................................................................................P. 30-01
- Maintenance......................................................................................P. 30-01
• Chapter 31: Trilateral head (TLH)
- Adjusting work on the TLH ................................................................P. 31-01
- Adjusting the tooth profile play ..........................................................P. 31-02
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- Adjusting the eccentric rollers for the overshift function ....................P. 31-06
- Adjusting the swivel shaft for the additional lift..................................P. 31-09
- Removing the lift carriage..................................................................P. 31-11
- Adjusting the radial play on the lift carriage.......................................P. 31-12
- Adjusting the axial play on the lift carriage........................................P. 31-12
- Adjusting the potentiometer for side shifting .....................................P. 31-14
- Adjusting the poentiometer for swivelling..........................................P. 31-16
- Adjusting the 90° swivelling range.....................................................P. 31-17
- Adjusting the switching lug for side shifting.......................................P. 31-18
- Adjusting the limit switches for swivelling..........................................P. 31-19
- Adjusting the magnetic sensors ........................................................P. 31-20
• Chapter 32: Lubrication plan
- Guide to iols and lubricants ...............................................................P. 32-01
- Lubrication plan .................................................................................P. 32-02
- Disposal of oils and lubricants ...........................................................P. 32-03
• Chapter 33: Chains
- Lifting chains......................................................................................P. 33-01
• General ........................................................................................P. 33-01
• Checking the lifting chains for damage ........................................P. 33-02
• Checking the chain elongation.....................................................P. 33-06
• Replacing the lifting chains ..........................................................P. 33-08
• Lubricating the lifting chains.........................................................P. 33-09
- Cleaning the chains ...........................................................................P. 33-10
- Roller chains......................................................................................P. 33-11
• General ........................................................................................P. 33-11
• Chapter 34: Inductive automatic steering
- General. .. .. .......................................................................................P. 34-01
- Description of the operating modes...................................................P. 34-02
• Self-test .......................................................................................P. 34-02
• Manual operation .........................................................................P. 34-02
• Automatic operation .....................................................................P. 34-03
- Wire search.............................................................................P. 34-03
- Preparatory aisle travel ...........................................................P. 34-04
- Aisle travel.. .......................................................................................P. 34-05
• Switching back to manual steering..........................................P. 34-06
- Version 10.X ......................................................................................P. 34-07
• Improved detection mode........................................................P. 34-07
• Recognition process in the drive wheel
side (DWS) travel direction......................................................P. 34-08
•Recognition process in the load side (LS) travel direction.......P. 34-09
•1.Very flat approach angle.......................................................P. 34-09
•2.Flat approach angle ..............................................................P. 34-09
•3.Steep approach angle to 40° ................................................P. 34-09
•Displays on operating console during detection
process on detection curves....................................................P. 34-10
- Block diagram ..............................................................................P. 34-11
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-Test operating unit (TBE)..............................................................P. 34-12
•Test mode positions ................................................................P. 34-12
- Guide to components in the automatic inductive steering ...........P. 34-13
- Adjusting chart .............................................................................P. 34-14
- Checking the mechanical elements .............................................P. 34-20
• Steering bearing .....................................................................P. 34-20
• Gearwheels.............................................................................P. 34-20
• Wheels....................................................................................P. 34-20
- Checking the LR80 display ..........................................................P. 34-21
- LR80 display and LED displays ...................................................P. 34-22
- Balancing the digital filter.............................................................P. 34-23
- Central processing unit - CPU board ...........................................P. 34-24
- Central proccessing unit - DC/DC-converter................................P. 34-25
- Central proccessing unit - baseplate...........................................P. 34-26
• Counting method for connectors and sockets ........................P. 34-27
- Central unit...................................................................................P. 34-28
• View from the front with front panel mounted .........................P. 34-28
• View from the front with front panel removed .........................P. 34-28
• View of the baseplate .............................................................P. 34-28
• Switching outputs....................................................................P. 34-29
• Meaning of the switching outputs ...........................................P. 34-29
• "Steering enable" switching output .........................................P. 34-29
• Switching outputs....................................................................P. 34-30
.- Testing the switching outputs with the
. operating mode switch...........................................................P. 34-30
- Testing the speed sensor.............................................................P. 34-31
- Incremental encoder ....................................................................P. 34-32
• General ...................................................................................P. 34-32
• Monitoring...............................................................................P. 34-32
- Loading standard parameter set..................................................P. 34-33
- Language selection......................................................................P. 34-34
- Steering output stage...................................................................P. 34-35
• Setting the service switch .......................................................P. 34-35
• Enable LED.............................................................................P. 34-35
• Input/output signals.................................................................P. 34-37
• Signals from the LR80 central processing unit .......................P. 34-37
- Maximum steering angle..............................................................P. 34-38
• Allocation of value...................................................................P. 34-40
• Storing ....................................................................................P. 34-40
- Adjusting the setpoint potentiometer............................................P. 34-41
• Adjusting the turning force of the handwheel..........................P. 34-41
• Adjusting the retaining force of the centre
detent mechanism..................................................................P. 34-41
• End stop..................................................................................P. 34-41
• Adjustment of straight-on travel with the setpoint
potentiometer in centre detent mechanism............................P. 34-41
- Setpoint potentiometer (to approx. 11/02) ...................................P. 34-42
• General ...................................................................................P. 34-42
- Setpoint potentiometer (from approx. 12/02) ...............................P. 34-42.1
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• General ...................................................................................P. 34-42.1
- Setting the offset potentiometer for "Straight-on in
DWS and LS direction" to "00" ....................................................P. 34-43
-Adjusting the actual value potentiometer (to approx. 11/02).........P. 34-44
-Adjusting the actual value potentiometer (from approx. 12/02).....P. 34-44.1
- Actual value potentiometer (to approx. 11/02) .............................P. 34-45
• General ...................................................................................P. 34-45
• Testing the potentiometer .......................................................P. 34-45
- Actual value potentiometer (from approx. 12/02).........................P. 34-45.1
• General ...................................................................................P. 34-45.1
• Testing the potentiometer .......................................................P. 34-45.1
- Guide frequency generator................................................................P. 34-46
• The frequency generator viewed from the front ......................P. 34-46
• Battery buffer...........................................................................P. 34-46
• Commissioning the guide frequency generator.......................P. 34-47
• Adapting the output filter to a wire loop...................................P. 34-48
• Connecting the wire loop.........................................................P. 34-49
- Mounting and adjusting the aerials ..............................................P. 34-50
• 1. Determining the centre marking for mounting the
DWS antennas .......................................................................P. 34-50
• 2. Adjusting the DWS antenna...............................................P. 34-51
• 3. Setting the offset potentiometer for Straight-on
in direction of the drive wheel side" travel .............................P. 34-52
• 4. Mounting and adjusting the LS antenna.............................P. 34-53
• Setting the offset potentiometer for "Straight-on in
direction of the load side" trave ..............................................P. 34-54
- Aerials ..........................................................................................P. 34-55
• General ...................................................................................P. 34-55
• Function ..................................................................................P. 34-55
• Pin assignment........................................................................P. 34-55
• Technical data.........................................................................P. 34-55
- Emergency-off parameters...........................................................P. 34-56
• General ...................................................................................P. 34-56
• XE59 .......................................................................................P. 34-57
• XE5B.......................................................................................P. 34-58
• XE5A.......................................................................................P. 34-59
• XE5D.......................................................................................P. 34-60
- Steering angle limiter ...................................................................P. 34-61
• Description of function / An introduction to the component.....P. 34-61
• Block diagram for vehicles with distributor board A13 ............P. 34-62
• Block diagram for vehicles without distributor board A13 .......P. 34-62.1
• Conditions required for the detent to lock ...............................P. 34-63
• Conditions required for the detent to release..........................P. 34-63
• Pin assignment for connector X1 ............................................P. 34-64
• Monitoring ...............................................................................P. 34-65
• Adjustment ..............................................................................P. 34-66
• Modification to the steering angle limiter.................................P. 34-68.1
- Modified trip cams ..............................................................P. 34-68.1
- Modified end stop...............................................................P. 34-68.2
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List of contents

- Aisle recognition...........................................................................P. 34-69
• Aisle recognition sensors ........................................................P. 34-69
• Mounting the reflectors - aisle with two open ends .................P. 34-70
• Mounting the reflectors - aisle with one open end...................P. 34-70
• Aisle recognition error .............................................................P. 34-71
• Aisle recognition signal at LR80..............................................P. 34-72
- Table of LR80 situations ..............................................................P. 34-73
- Notebook .....................................................................................P. 34-74
• Preparing for programming the LR80......................................P. 34-74
- Programming/changing parameters/test selection
for LR80 with TEWAK .................................................................P. 34-75
- Storing parameters.......................................................................P. 34-78
- Error messages............................................................................P. 34-79
- Test selection with operating mode and frequ. switch .................P. 34-82
- Test selection with a notebook.....................................................P. 34-83
- Table for convers. from hexadecimal to decimal values ..............P. 34-84
• Chapter 35: Error codes
- General..............................................................................................P. 35-01
- Error classification .............................................................................P. 35-01
- Errors in FPS and converters in alternating current vehicles.............P. 35-01
• General ........................................................................................P. 35-01
• Error classes ................................................................................P. 35-01.1
• Cancelling errors..........................................................................P. 35-01.1
- Travel errors ......................................................................................P. 35-02
- Steering errors...................................................................................P. 35-04
- Main lift errors....................................................................................P. 35-08
- Additional lift errors............................................................................P. 35-10
- Reaching errors .................................................................................P. 35-11
- Rotating errors...................................................................................P. 35-13
- Errors in synchronours rotating/reaching movement 90°/180°..........P. 35-14
- Error configuration and automatic braking at end of aisle (EASS) ....P. 35-15
- Can bus errors...................................................................................P. 35-17
- General errors....................................................................................P. 35-18
- Errors in automatic braking at end of aisle (EASS) ...........................P. 35-22
- Travel and pump controller (FPS) errors ...........................................P. 35-26
- Load handling controls (LAS) errors .................................................P. 35-45
- Operating console (BPS) errors.........................................................P. 35-49
• Chapter 36: Troubleshooting guide
- Power supply function........................................................................P. 36-01
• General ........................................................................................P. 36-01
• Battery voltage .............................................................................P. 36-02
• Battery voltage after key switch ...................................................P. 36-04
• 1+battery voltage after key switch................................................P. 36-05
• 1+24V...........................................................................................P. 36-06
• 1+battery voltage after 1+24V......................................................P. 36-07
• EMERGENCY-STOP chain .........................................................P. 36-08
• 2+battery voltage .........................................................................P. 36-10
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List of contents

• 2+24V...........................................................................................P. 36-12
• Chapter 37: WINFLASH
- General..............................................................................................P. 37-01
- Block diagram....................................................................................P. 37-02
- Description.........................................................................................P. 37-03
- Setting up a connection with the vehicle............................................P. 37-06
- Loading the vehicle program .............................................................P. 37-07
- Updating programs ............................................................................P. 37-09
• Chapter 38: ParaDig 133 / ParaDig 153
- General..............................................................................................P. 38-01
- Setting up a connection with the vehicle............................................P. 38-02
- Opening the software.........................................................................P. 38-03
- Starting parameterising and diagnosis ..............................................P. 38-05
- Errors when starting parameterising and diagnosis...........................P. 38-06
• Outdated vehicle software............................................................P. 38-06
• ParaDig does not match the vehicle model..................................P. 38-07
- Old software version of vehicle program ...........................................P. 38-09
- Working with ParaDig ........................................................................P. 38-10
• Page selection..............................................................................P. 38-10
• Parameterising.............................................................................P. 38-11
- General ...................................................................................P. 38-11
- Combination field ....................................................................P. 38-12
- Direct entry..............................................................................P. 38-13
- Parameter value outside the permissible range......................P. 38-13
- Default value ...........................................................................P. 38-14
• Saving changes............................................................................P. 38-15
- General ...................................................................................P. 38-15
- Saving for test purposes .........................................................P. 38-16
- Saving permanently ................................................................P. 38-17
• Loading parameters from the vehicle...........................................P. 38-18
• Saving vehicle settings in a file ....................................................P. 38-19
• Loading vehicle settings from a file..............................................P. 38-21
• Diagnosis .....................................................................................P. 38-22
- Starting diagnosis....................................................................P. 38-22
- Working with diagnosis ...........................................................P. 38-23
- Closing diagnosis....................................................................P. 38-23
• Working with ParaDig in offline mode ..........................................P. 38-24
• Closing parameterising and diagnosis .........................................P. 38-27
• Closing the ParaDig service software ..........................................P. 38-28
• Chapter 39: Telescopic fork
- Functional description........................................................................P. 39-01
- Component names ............................................................................P. 39-01
- Home position....................................................................................P. 39-03
- Measurement of the extension depth Distance sensor......................P. 39-04
- Adjusting the middle carriage ............................................................P. 39-05
- Adjusting the upper carriage..............................................................P. 39-06
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List of contents

- Adjusting the position switch for the home position...........................P. 39-07
- Adjusting the distance sensor for reaching........................................P. 39-08
- Teaching in the distance sensor for reaching....................................P. 39-09
• Set vehicle control system to SERVICE mode.............................P. 39-09
• Delete values that are already taught in.......................................P. 39-09
• Teach in the distance sensor for reaching again .........................P. 39-10
- Parameterising...................................................................................P. 39-11
- Definitions..........................................................................................P. 39-11
- Maximum mech. extension parameter...............................................P. 39-12
- Monitoring of the distance sensor for reaching..................................P. 39-13
- Load handling controls LAS...............................................................P. 39-14
- Attachment valve block......................................................................P. 39-15
- Additional lift distance sensor ............................................................P. 39-16
• Monitoring ....................................................................................P. 39-17
• Teaching in the additional lift distance sensor .............................P. 39-17
- Maintenance instructions for drive chains and
return chains ......................................................................................P. 39-18
- Reliable lubricants and mineral oils ...................................................P. 39-19
• Chapter 40: Filling aid
- Functional description / Component names ......................................P. 40-01
- Preparation ........................................................................................P. 40-02
- Draining hydraulic oil out of the tank..................................................P. 40-03
- Filling the tank with hydraulic oil ........................................................P. 40-04
• Chapter 41: Converter (for Alternating Current only)
- General..............................................................................................P. 41-01 (MX15-3 I)
- Testing the CAN bus..........................................................................P. 41-04 (MX15-3 I)
- Speed monitoring...............................................................................P. 41-06 (MX15-3 I)
- Speed sensor.....................................................................................P. 41-07 (MX15-3 I)
- Temperature monitoring ....................................................................P. 41-08 (MX15-3 I)
• Testing the temperature sensors .................................................P. 41-08 (MX15-3 I)
- Charging the bank of capacitors........................................................P. 41-09 (MX15-3 I)
- Discharging the bank of capacitors....................................................P. 41-10 (MX15-3 I)
- Function of the LED...........................................................................P. 41-11 (MX15-3 I)
- Main current terminals .......................................................................P. 41-12 (MX15-3 I)
- Power recovery..................................................................................P. 41-13 (MX15-3 I)
- Pin assignment ..................................................................................P. 41-14 (MX15-3 I)
• X1.................................................................................................P. 41-14 (MX15-3 I)
• Chapter 42: Panel
- Main current component panel (to approx. 11/02).............................P. 42-01
- Control current component panel (to approx. 11/02).........................P. 42-02
- Component panel (form approx. 12/02).............................................P. 42.02.1
- Main current component panel ..........................................................P. 42-03 (MX15-3 I)
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List of contents

• Chapter 43: EASS
- EASS inductive..................................................................................P. 43-01
• General.........................................................................................P. 43-01
• Setting the "EASS inductive" option.............................................P. 43-02
• Proximity switches........................................................................P. 43-03
• Calculating the length of the steel plates......................................P. 43-04
• Calculating the maximum braking distance..................................P. 43-04
• Mounting the steel plates .............................................................P. 43-05
- Without absolute stop..............................................................P. 43-05
- With absolute stop at closed aisle end only ............................P. 43-07
- Without absolute stop at the open and closed aisle end.........P. 43-09
• Division into zones / General........................................................P. 43-10
- General....................................................................................P. 43-10
- Zone 0 .....................................................................................P. 43-10
- Zone 1 .....................................................................................P. 43-11
- Zone 2 .....................................................................................P. 43-12
- Zone 3 .....................................................................................P. 43-13
- Zone 4 .....................................................................................P. 43-14
- Zone 5 .....................................................................................P. 43-15
- Guide to maximum speeds in the various zones.....................P. 43-15
• Suppression of metal elements that cause interference ..............P. 43-16
• Diagnosis .....................................................................................P. 43-17
- EASS magnetic..................................................................................P. 43-18
• General ........................................................................................P. 43-18
• Setting the "EASS magnetic" option.............................................P. 43-19
• Magnetic switches........................................................................P. 43-20
- General....................................................................................P. 43-20
- Mounting the switches.............................................................P. 43-21
• Switching magnets .......................................................................P. 43-22
- General....................................................................................P. 43-22
- Definitions................................................................................P. 43-23
• Mounting the switching magnets..................................................P. 43-24
- Without absolute stop..............................................................P. 43-24
- With absolute stop at closed aisle end only ............................P. 43-26
• Division into zones .......................................................................P. 43-28
- General....................................................................................P. 43-28
- Zone 0 .....................................................................................P. 43-29
- Zone 1 .....................................................................................P. 43-30
- Zone 3 .....................................................................................P. 43-31
- Zone 5 .....................................................................................P. 43-32
• Diagnosis......................................................................................P. 43-33
- EASS reflexli .....................................................................................P. 43-34
• General.........................................................................................P. 43-34
• Setting the "EASS reflexli" option.................................................P. 43-35
• Reflector types .............................................................................P. 43-36
- Reflector types A and B...........................................................P. 43-36
- Reflector type C - Check .........................................................P. 43-36
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List of contents

- Reflector type C - Stop............................................................P. 43-37
- Reflector type D4 - Absolute stop............................................P. 43-38
• Mounting heights for reflector installation
on the shelves - both sides..........................................................P. 43-39
• Mounting heights for reflector installation
on the shelves - one side.............................................................P. 43-40
• Reflective light barriers.................................................................P. 43-42
- Arrangement of the reflective light barriers
for automatic braking at the aisle end.....................................P. 43-42
- Arrangement of the reflective light barriers for automatic
braking at he aisle end, stop and absolut stop and check......P. 43-42
- Arrangement of the reflective light barriers for reflector
installation on one side of the aisle with automatic
braking at the aisle end ..........................................................P. 43-43
- Arrangement of the reflective light barriers for reflector
installation on one side of the aisle with automatic
braking at the aisle end, stop and absolute stop and check...P. 43-44
- Definitions ...............................................................................P. 43-45
• Mounting the reflectors.................................................................P. 43-46
- Arrangement of the reflectors for automatic end of
aisle braking ...........................................................................P. 43-46
aisle braking and speed monitoring........................................P. 43-47
aisle braking and stop ............................................................P. 43-48
aisle braking and absolute stop..............................................P. 43-49
• Division into zones .......................................................................P. 43-50
- General ...................................................................................P. 43-50
- Zone 1.....................................................................................P. 43-51
- Zone 0.....................................................................................P. 43-52
- Zone 2.....................................................................................P. 43-53
• Important rules .............................................................................P. 43-54
• Diagnosis .....................................................................................P. 43-56
• Chapter 44: Individual driving settings
- General..............................................................................................P. 44-01
- Setting the "Individual driver settings" option ....................................P. 44-02
- Changing the speed settings for the hydraulic functions...................P. 44-03
- Changing the speed settings for travel..............................................P. 44-04
Changing the Optispeed adaptation ..................................................P. 44-05
- Saving the changed speed settings ..................................................P. 44-06
- Setting ranges ...................................................................................P. 44-07
- Diagnosis...........................................................................................P. 44-08
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List of contents

List of chapters
Chapter 1: Vehicle data
Chapter 2: Drive motor
Chapter 3: Drive wheel
Chapter 4: Gear
Chapter 5: Brake
Chapter 6: Steering
Chapter 7: Mast
Chapter 8: Vehicle control system (FZS)
Chapter 9: Travel and pump controller (FPS)
Chapter 10: Operating console
Chapter 11: Load handling control (LHC)
Chapter 12: EM.-STOP and amplifier module (NAV)
Chapter 13: Distributor board
Chapter 14: Negative feeder module
Chapter 15: Main contactors
Chapter 16: DC/DC converter
Chapter 17: Distance sensor for main lift
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List of chapters

List of chapters
Chapter 18: Distance sensor for additional lift
Chapter 19: Distance sensor for swivelling
Chapter 20: Distance sensor for side shifting
Chapter 21: SERVICE mode
Chapter 22: Teaching-in process
Chapter 23: Reference sequence
Chapter 24: Chassis valve block
Chapter 25: Attachment valve block
Chapter 26: Pump motor
Chapter 27: Hydraulic motor
Chapter 28: Pump
Chapter 29: Oil level indicator
Chapter 30: Ventilation filter
Chapter 31: Trilateral head TLH
Chapter 32: Lubrication plan
Chapter 33: Chains
Chapter 34: Inductive automatic steering
Chapter 35: Error codes
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List of chapters

List of chapters
Chapter 36: Troubleshooting guide
Chapter 37: WINFLASH
Chapter 38: ParaDig 133 / ParaDig 153
Chapter 39: Telescopic fork
Chapter 40: Filling aid
Chapter 41: Converter (AC only)
Chapter 42: Panel
Chapter 43: EASS
Chapter 44: Individual driving settings
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Replaces issue: Manual MX15-3 21
List of chapters

Guide to components
• Drive wheel ................................................................................P. 3-01
• Operating console 8U62 ............................................................P. 10-01 ff
• DC/DC converter U30 ................................................................P. 16-01
• Electromagnetic brake 1Y44......................................................P. 5-01 ff
• Drive motor 1M3.........................................................................P. 2-01 ff
• Travel and pump controller A10 .................................................P. 9-01 ff
• Vehicle control system 8U60......................................................P. 8-01 ff
• Fine control of lowering main lift.................................................P. 24-06
• Gear ...........................................................................................P. 4-01 ff
• Main contactors K1 and K2........................................................P. 15-01
• Distance sensor for the main lift.................................................P. 17-01 ff
• Distance sensor for the additional lift .........................................P. 18-01 ff
• Hydraulic motor..........................................................................P. 27-01 ff
• Load handling control 8U61 .......................................................P. 11-01 ff
• Steering motor 3M1....................................................................P. 6-15
• Steering controller 3A20.............................................................P. 6-11 ff
• Oil level indicator........................................................................P. 29-01
• Pump motor 2M1........................................................................P. 26-01 ff
• Negative feeder module A14......................................................P. 14-01
• Trilateral head ............................................................................P. 31-01 ff
• Attachment valve block ..............................................................P. 25-01 ff
• Chassis valve block....................................................................P. 24-01 ff
• Distributor board A13 .................................................................P. 13-01 ff
• Distance sensor for shifting........................................................P. 20-01 ff
• Distance sensor for swivelling....................................................P. 19-01
• EMERGENCY-STOP and amplifier module 7A22 .....................P. 12-01 ff
• Telescopic fork ...........................................................................P. 39-01 ff
• Panel..........................................................................................P. 42-01 ff
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Replaces issue: Manual MX15-3 22
Guide to components

Chapter 1 Vehicle data
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Guide to information plates and vehicle number
Vehicle no. on
turret head
Vehicle no. attachment
Vehicle no. on mast
Carrying load diagram
Factory nameplate
UVV check
0/0416
0/0414
0/0415
0/0412
0/0410
0/0413
30256

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Hydraulic settings
 The prerequisite for the following settings is a pre-set system pressure of
275bar, see also sheet no. 24-02.
Without load
Hydraulic function Speed Tolerance Pressure Tolerance
Lifting main lift appr. 370-420mm/s ±30mm/s Tele: appr. 110bar ±40bar
(h1-related) Triplex: appr.130bar ±40bar
(h1-related)
Lowering main lift 420mm/s ±20mm/s - -
Lifting additional lift 310mm/s ±30mm/s 50bar +50bar
Lowering additional lift 200mm/s +30mm/s - -
Side shift left/right 250mm/s +50mm/s 90bar +30bar
Swivelling left/right 30°/s. ±5°/s 120bar +80bar
End position swivelling 0m/s - 190bar +50bar
SSSB 90°/180° 30°/s ±5°/s 200bar ±30bar
Fork adjustment 1 cyl. Not currently used Not used 100bar +20bar
With load of 1500kg
(h1-related)
Lowering main lift 420mm/s +30mm/s - -
Lifting additional lift 250mm/s +50mm/s 200bar +50bar
Lowering additional lift 350mm/s ±30mm/s - -
Swivelling left/right 30°/s ±5°/s 120bar +80bar
SSSB 90°/180° 30°/s ±5°/s 200bar ±30bar
Fork adjustment 1 cyl. Not currently used Not used. 100bar +20bar

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Hydraulic settings
 The prerequisite for the following settings is a pre-set system pressure of
275bar, see also sheet no. 24-02.
Without load
(h1-related)
Lowering main lift 420mm/s ±30mm/s - -
Lifting additional lift 310mm/s ±50mm/s 50bar +50bar
Lowering additional lift 200mm/s +50mm/s - -
Swivelling left/right 30°/s. ±5°/s 120bar +80bar
SSSB 90°/180° 30°/s ±5°/s 200bar ±30bar
With load of 1300kg
Lifting main lift appr. 330-410mm/s ±30mm/s Tele: up to 175bar ±30bar
(h1-related) Triplex: up to 190bar±30bar
(h1-related)
Lowering main lift 420mm/s +30mm/s - -
Lifting additional lift 260mm/s +50mm/s 170bar ±50bar
Lowering additional lift 330mm/s ±30mm/s - -
Swivelling left/right 30°/s ±5°/s 120bar +80bar
SSSB 90°/180° 30°/s ±5°/s 200bar ±30bar
Fork adjustment 1 cyl. Not currently used Not used. 100bar +20bar

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Vehicle speed
Outside aisle
• Standing height of driver <1.2m and add. lift <1.2m: vmax = 9km/h
• Standing height of driver >1.2m or add. lift >1.2m: vmax = 2.5km/h
 When the cab is lowered as far as possible, the
standing height of the driver is 43cm.
• Fork outside the vehicle contour: vmax = 2.5km/h
Inside aisle (Type 15-3)
 When the vehicle is in an aisle, the max. speed depends on the height to
which the cab and the additional lift are raised. The current lift height is
calculated from 100% main lift + 50% additional lift, see sheet no. 5-06.
• Fork outside the vehicle contour: vmax = 2.5km/h
• Setpoint deviation, steering >5°: vmax = 2.5km/h
 The current lift height of the vehicle also affects the ramp function for side
shifting and swivelling. The higher the lift height, the sooner the ramp function
is initiated by the Optispeed for side shifting and swivelling.
Lift
height/m
1
2
3
4
5
6
7
8
9
1 2 3 4 5 6 7 8 9 10 11
V/km/h
DWS
LS
1
0
LS = Travel direction Loadside
DWS = Travel direction Drivewheelside

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