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Still RX20-14 RX20-16 RX20-18 RX20-20 Electric Truck Workshop Literature Manual – PDF DOWNLOAD
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Description
Still RX20-14 RX20-16 RX20-18 RX20-20 Electric Truck Workshop Literature Manual – PDF DOWNLOAD
FILE DETAILS:
Still RX20-14 RX20-16 RX20-18 RX20-20 Electric Truck Workshop Literature Manual – PDF DOWNLOAD
Language : English
Pages : 306
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Still RX20-14 RX20-16 RX20-18 RX20-20 Electric Truck Workshop Literature Manual – PDF DOWNLOAD
Information about the documentation:
- This workshop manual contains all the informa- tion required to assist a competent person with all
work, repairs and maintenance on this truck. For the purposes of clarity and completeness, some
components have been deliberately ex- cluded from this workshop manual and described in their own
speciο¬c documentation. Changes may be made at short notice and at any time, and are communicated
via service information docu- ments. - The documentation comprises operating instruc- tions, additional workshop manuals, special doc-
umentation and circuit diagrams.
Operating instructions
β’ Original operating instructions of the truck
β’ Display-operating unit III
β’ FleetManagerβ’
TABLE OF CONTENTS:
Still RX20-14 RX20-16 RX20-18 RX20-20 Electric Truck Workshop Literature Manual – PDF DOWNLOAD
56368010001.......................................................................................... 1 History of changes............................................................................... 3 Header........................................................................................... 5 Information about the documentation.......................................................... 5 Specialist................................................................................... 5 Symbols Used................................................................................. 6 Changes and retrofitting..................................................................... 6 Working with spare parts..................................................................... 7 Table of contents................................................................................ 9 00 Product information....................................................................... 17 Foreword................................................................................. 17 Product overview: RX20Β 14-20......................................................... 17 Safety information....................................................................... 19 Parking the truck so it is secured for service work.................................. 19 Working on the electrical system..................................................... 20 Jacking up the truck, front.......................................................... 21 Jacking up the truck, rear........................................................... 22 Securing the fork carriage........................................................... 24 Restrictions and obligations............................................................. 26 Speed limitation with a Tensor battery............................................... 26 Penalties............................................................................ 26 01 Service................................................................................... 27 Maintenance.............................................................................. 27 Maintenance instructions............................................................. 27 Maintenance - 1000Β hours/annually.................................................... 28 Maintenance - 3000Β hours/every two years............................................. 31 Tools.................................................................................... 32 Measuring instruments and testing equipment.......................................... 32 Repair and cleaning.................................................................. 33 Special tools........................................................................ 33 Harnesses and hoists, 1.0 t - 3.5 t.................................................. 34 Standardised tightening torques for standard-pitch threads and fine-pitch threads.... 35 Standardised tightening torques for hose fittings.................................... 36 02 Diagnostics............................................................................... 37 Introduction to DiaMon................................................................... 37 STEDS-Navigator...................................................................... 37 Diagnostics service box.............................................................. 38 Diagnostic set-up.................................................................... 39 Starting DiaMon...................................................................... 40 Working with DiaMon...................................................................... 41 Reading out and clearing the error list.............................................. 41 Reading out access codes............................................................. 42 Working using the ABE.................................................................... 43 Error lists via ABEΒ 3................................................................ 43 Parameters via ABEΒ 3................................................................. 44 Calibration via ABE.................................................................. 44 03 Parameterising............................................................................ 45 Hydraulics............................................................................... 45 Axle assignment of the operating devices............................................. 45 Input characteristic curves for the operating devices................................ 48 Speed and dynamics of the operating devices.......................................... 49 11 Electric motor............................................................................ 51 Traction motor........................................................................... 51 General technical data............................................................... 51 Electrical connections............................................................... 51 Drive unit........................................................................... 52 Pump motor............................................................................... 53 General technical data............................................................... 53 Electrical connections............................................................... 53 Pump motor........................................................................... 54 Sensors.................................................................................. 55 Speed sensor......................................................................... 55 Temperature sensor................................................................... 58 22 Mechanical drive axle..................................................................... 61 Drive axle AE18-11....................................................................... 61 General technical data............................................................... 61 Drive axle AE18-11................................................................... 62 Removing the drive wheel unit........................................................ 63 Changing the shaft seal on the drive wheel unit...................................... 64 Refitting the drive wheel unit....................................................... 67 Traction motor - Removing the rotor.................................................. 68 Traction motor - Replacing the bearing and shaft seal................................ 69 Traction motor - Installing the rotor................................................ 71 Service brake AE18-11................................................................ 73 Dismantling the brake................................................................ 74 Assembling the brake................................................................. 75 Brake clearance...................................................................... 76 Checking the oil level, changing the oil............................................. 77 30 Chassis, bodywork and fittings............................................................ 81 Chassis.................................................................................. 81 Battery door......................................................................... 81 Battery door sensor 1S27............................................................. 82 Overhead guard bearings.............................................................. 82 Counterweight............................................................................ 84 Counterweight........................................................................ 84 Hoods and panelling...................................................................... 85 Panels on the driver's compartment................................................... 85 Overhead guard........................................................................... 88 Repairing the roof panels............................................................ 88 42 Steering system........................................................................... 91 Hydraulic steering....................................................................... 91 General technical data............................................................... 91 Steering system...................................................................... 92 Steering angle sensor 3B1............................................................ 95 Steering turntable....................................................................... 96 General technical data............................................................... 96 Functional description............................................................... 97 Steering angle sensor 3B2............................................................ 98 Removing/installing the steering axle................................................ 99 Combined axle............................................................................102 General technical data...............................................................102 Functional description...............................................................103 Removing/installing the steering axle................................................105 Adjusting the steering angle.........................................................107 Wheel hub - Replacing the bearings and sealing ring..................................109 Disassembling the steering cylinder and track rod....................................111 Replacing the axle stub, bearings and wiper..........................................113 Steering cylinder, changing the seals................................................115 Steering angle sensor 3B2............................................................117 50 Operating devices.........................................................................119 Accelerator pedal........................................................................119 Accelerator pedal, generation 2......................................................119 Dual pedal, generationΒ 2.............................................................121 Brake actuation..........................................................................124 Brake actuation......................................................................124 Brake sensor 1B2.....................................................................126 Handbrake switch 1S3.................................................................126 Adjusting the service brake..........................................................127 Adjusting the handbrake..............................................................129 Electric parking brake...................................................................131 Function and layout..................................................................131 Removing/installing the ELFΒ 2........................................................132 Changing and adjusting the brake cable...............................................133 Zero position switch 1S3.............................................................137 ELFΒ 2 - Calibration..................................................................138 Hydraulic actuation......................................................................139 Hand lever...........................................................................139 JoystickΒ 4Plus.......................................................................141 Mini-lever 2.........................................................................143 Fingertip switch.....................................................................146 56 Display elements..........................................................................149 Operating console........................................................................149 Drive direction selector and indicator module, generation 3..........................149 Display..................................................................................151 Display and operating unit ABEΒ 3.....................................................151 60 Electrics/electronics.....................................................................153 General..................................................................................153 General technical data...............................................................153 Overview of the controllers..........................................................154 Overview of electrical components....................................................155 Software compatibility...............................................................156 Parameter management.................................................................157 Electrical checks........................................................................159 Intermediate circuit.................................................................159 Insulation testing for electric trucks...............................................162 Insulation testing on the drive battery..............................................164 Insulation testing the lithium-ion battery...........................................165 Component insulation testing.........................................................166 Wiring...................................................................................168 CAN bus system.......................................................................168 CAN bus connections..................................................................170 Diagnostic connector X50.............................................................171 Earth wires in the truck.............................................................172 Maintenance guidelines for power cables..............................................172 Repairs: power cables of the electric motor..........................................173 Electrical system........................................................................174 Power distributor PDU (A5)...........................................................174 Current sensor Mini-SU (A43).........................................................177 Contactor 1K1........................................................................178 Fuse box A21.........................................................................179 Fuses................................................................................181 Sensor system............................................................................183 Sensor overview......................................................................183 Lift height switch 7B41..............................................................185 Lifting stage sensor 7B43............................................................187 Tilt angle sensor 7B46...............................................................189 LED lift height sensor 6B32..........................................................191 Additional electrical installations......................................................193 CAN distributor......................................................................193 Standard CPP.........................................................................195 CPPΒ 3 (seat).........................................................................197 Option board (A8)....................................................................199 Cooling system...........................................................................200 Cooling system.......................................................................200 Fan..................................................................................201 64 Electronic controls.......................................................................203 Traction controller......................................................................203 Truck control unit MCUΒ 3.............................................................203 Removing/installing the MCUΒ 3........................................................204 Converter................................................................................206 Converter............................................................................206 Converter SACΒ 1.1....................................................................207 SAC-TP converter.....................................................................208 69 Batteries and accessories.................................................................209 Lead-acid battery........................................................................209 General technical data...............................................................209 Battery..............................................................................210 Battery male connector...............................................................211 Battery male connector - sensor system...............................................213 Maintenance guidelines for appliance plugs...........................................214 Repair - Battery male connector contacts.............................................216 Working with reducer sleeves.........................................................217 Lithium-ion technology...................................................................219 Working on lithium-ion batteries.....................................................219 General technical data...............................................................220 Battery management system (BMS)......................................................221 Diagnostics..........................................................................222 Battery display......................................................................223 Battery discharge....................................................................224 Course of action for a deeply discharged battery.....................................226 Battery male connector...............................................................226 Checking that the battery male connector is de-energised.............................228 Removing/installing the battery cable................................................229 70 Hydraulics................................................................................231 General..................................................................................231 General technical data...............................................................231 Releasing the pressure from the hydraulics...........................................232 Operating speeds for lowering........................................................234 Operating speeds for lifting.........................................................234 Operating speeds for tilting.........................................................235 Safety check.............................................................................236 Forward tilt safety test.............................................................236 Lowering safety test.................................................................236 Safety checks of hose assembly.......................................................237 Basic hydraulics.........................................................................238 Basic hydraulics: Hand lever.........................................................238 Basic hydraulics: Servo hydraulics...................................................239 Oil temperature sensor 2R17..........................................................240 Changing the hydraulic oil...........................................................242 71 Working hydraulics........................................................................243 Pump-motor unit..........................................................................243 General technical data...............................................................243 Hydraulic pump.......................................................................243 Auxiliary hydraulics.....................................................................245 Operating lock for attachments in accordance with ISO 3691...........................245 76 Valves....................................................................................247 Hand lever...............................................................................247 General technical data...............................................................247 Servo hydraulics.........................................................................248 General technical data...............................................................248 80 Load lift system..........................................................................249 Mast bearings............................................................................249 Mast bearings, 1.4 t - 2.0 t.........................................................249 81 Lift mast.................................................................................251 Lift mast................................................................................251 General technical data...............................................................251 Line break safety valve..............................................................252 Support rollers (108)................................................................254 Support rollers (117)................................................................256 Load chains - Checking and cleaning..................................................257 Run-out stop.........................................................................260 Working on lift masts................................................................261 Telescopic lift mast.....................................................................262 Telescopic lift mast NeMaS...........................................................262 Adjusting the load chains (108/117-NeMaS)............................................264 Removing/installing outer cylinders..................................................264 Changing the support rollers in the lift mast........................................267 Outer load chains and chain rollers..................................................269 NiHo lift mast...........................................................................271 NiHo lift mast NeMaS.................................................................271 Adjusting the load chains (108/117-NeMaS)............................................273 Triplex lift mast........................................................................274 Triplex lift mast NeMaS..............................................................274 Adjusting the outer load chains (108/117-NeMaS)......................................276 Adjusting the middle load chain (108/117-NeMaS)......................................277 Removing/installing the middle cylinder..............................................278 Removing/installing outer cylinders..................................................279 Changing the support rollers in the lift mast........................................283 Outer load chains and chain rollers..................................................286 Middle load chain and chain roller...................................................289 Mono lift mast...........................................................................292 [MODULE].............................................................................292 Lift cylinders...........................................................................293 Lift jack............................................................................293 Working on lift cylinders............................................................294 Bleeding the hydraulic cylinders.....................................................295 Disassembling/assembling the outer cylinder..........................................295 Disassembling/assembling the middle cylinder.........................................297 End position damping, type B (bottom)................................................299 End position damping, type A (top)...................................................300 84 Load support..............................................................................301 Fork carriage............................................................................301 Removing/installing the fork carriage................................................301 Fork wear protection.................................................................304
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