STILL STED Forklift Reach trucks FM-X, FM-X N, FM-X W, FM-X EW, FM-X SE, Li-ion FM-X-10 FM-X-12 FM-X-14 FM-X-17 FM X-20 FM-X-20 HD FM-X-25 Workshop Manual – PDF DOWNLOAD

This workshop manual contains all the information required to assist trained service engineers with all work, repairs and maintenance performed on this truck. In addition, some of the components have been deliberately excluded from this workshop manual and are explained elsewhere to ensure a clear and complete overview. Changes may be made at short notice and at any time, and are communicated via service information documents. The additional documentation comprises workshop manuals, special documentation and operating circuit diagrams.

? FleetManager? 4.x

? Error list
? Overview of consumables
? FEM 4.004 test log book

? See the circuit diagram overview

? All references made to the service software in this workshop manual refer to DIAMON version 3.6.3

00 Product information
Foreword
About FM-X FM-X N FM-X W FM-X EW FM-X SE
Safety information
Safety instructions Electrical system
Jacking up the tow tractor
Securing the fork carriage
Parking the truck so it is secured for service work
01 Service
Maintenance
Maintenance instructions
Maintenance – 1000 hours/year
Maintenance – 3000 hours/every two years
Additional maintenance guidelines for using the truck in a cold store – 500 hours or every
Measuring and testing equipment 01
Tools (general) 01
Harnesses and hoists 1 0 t- 3 5 t 01
Standardised tightening torques for standard-pitch threads and fine-pitch threads 01
Standardised tightening torques for hose fittings 01
02 Diagnostics
Introduction to DiaMon
STEDS-Navigator
CAN box diagnostics
Diagnostic set-up
Starting DiaMon
Working with DiaMon
Reading out and clearing the error list
Reading out access codes
Onboard truck configuration
General
Height pre-selection teach-in
Table of contents
11 Electric motor
Traction motor 11
General 11
Testing 11
Repair 11
Maintenance 11
Rev sensor 11
General 11
Temperature sensor 11
General 11
Testing 11
Repair 11
22 Mechanical drive axle
Front bevel gears 22
General 22
Testing 22
Repair 22
Corona electrode 22
Maintenance 22
31 Chassis
Driver’s compartment mounting 31
Driver’s compartment design – Repairs 31
Battery lock 31
Battery lock stabilisation 31
Side chassis supports 31
Adjusting the side chassis supports 31
Reach carriage 31
Adjusting the side guide rollers on the reach carriage 31
Adjusting the eccentric guide rollers on the reach carriage 31
Retrofitting optional guide rollers 31
Energy chain 31
Support mounting for the energy chain 31
Setpoint device – overview – 9
Checking the setpoint device – 11
Setpoint device – Repair – 13
Setpoint device – maintenance – 14
Actual-value transmitter – overview – 15
Checking the actual-value transmitter – 15
Actual-value transmitter – repair – 17
Actual-value transmitter – maintenance – 22
General – 1
Maintenance – 1
– 2
General – 2
Repair – 3
Maintenance – 3
General – 5
Maintenance – 5
General – 6
Repair – 7
Maintenance – 8
51908012001 EN – 08/2017 XI
Table of contents
34 Driver’s compartment
Electrical driver’s compartment adjustment mechanism 34
General 34
Repair 34
42 Steering system
Electric steering (ELK) 42
Electric steering – Overview 42
Steering unit – Overview 42
Checking the steering unit 42
Steering unit – Repair 42
Steering unit – maintenance 42
Emergency steering 42
Setpoint device 42
Actual-value device 42
46 Wheels and tyres
Wheels ( standard truck) 46
Drive wheel 46
Running wheel 46
Wheels (FM-X SE) 46
Drive wheel 46
Running wheel 46
General -18
Testing -20
Repair -22 -24
Truck equipment: Lifting / lowering / tilting / transition shift / Auxiliary hydraulics:
none -24
Truck equipment: Lifting / lowering / tilting / transition shift / Auxiliary hydraulics 1: fork
arm positioner / Auxiliary hydraulics 2: none -25
XII 51908012001 EN – 08/2017
Table of contents
49 Brake system
Brake system 49
General 49
Electric operating brake 49
General 49
Hydraulic operating brake 49
General 49
Testing 49
Repair 49
Maintenance 49
Parking brake 49
General 49
Testing 49
Repair 49
Maintenance 49
50 Operating devices
Single pedal – Accelerator with dual track potentiometer 50
Overview of the accelerator 50
Checking the accelerator 50
Repairing the accelerator 50
Foot switch 1 S25 50
Dual pedal 50
General 50
Function 50
Testing 50
Repair 50
Maintenance 50
Joystick 4Plus / fingertip switch 50
Signal converter of joystick 4Plus / fingertip switch 50
Configuration of joystick 4Plus / fingertip switch 50
Truck equipment: Lifting / lowering / tilting / transition shift / Auxiliary hydraulics 1: fork
arm positioner /Auxiliary hydraulics 2: turret -26
Truck equipment: Lifting / lowering / tilting / transition shift / Auxiliary hydraulics 1: turn
fork / Auxiliary hydraulics 2: none -27
Truck equipment: Lifting / lowering / tilting / transition shift / Auxiliary hydraulics 1: fork
arm positioner / Auxiliary hydraulics 2: turn fork -28
Truck equipment: Lifting / lowering / tilting / transition shift / Auxiliary hydraulics 1: turret /
Auxiliary hydraulics 2: none -29
Truck equipment: Lifting / lowering / tilting / transition shift / Auxiliary hydraulics 1: none /
Auxiliary hydraulics 2: clamp fork -30
Truck equipment: Lifting / lowering / tilting / transition shift / Auxiliary hydraulics 1: load
holder (vertical) / Auxiliary hydraulics 2: none -31
Truck equipment: Lifting / lowering / tilting / transition shift / Auxiliary hydraulics 1: fork
carriage with auxiliary lift / Auxiliary hydraulics 2: none -32

56 Display elements
Display
General
Testing
Repair
Maintenance
Operating console
General
Testing
Repair
Maintenance
60 Electrical enclosure
General
Error ring buffer
Intermediate circuit
Insulation testing for electric trucks
Insulation testing on the drive battery
Insulation testing of traction motor
Pump motor insulation testing
Parameter management
Parameter management when replacing RCUs and converters
Wiring
Power cables
Maintenance guidelines for power cables
Repair – Contact elements
DC/DC converter
General
Sensor system
Functions

Height sensor LED 8B65 – 25
Re?ector – 29
Lifting stage switch 8B66 – 30
Incremental transducer 8B21 – 34
“Fork in free lift” switch 8B27 – 35
Reference switch 8B20 – 35
Strain gauge 2B70 for active load stabilisation (ALS) – 35
Reach travel sensor 2B60 – 38
Load measurement sensor 2B31 – 41
Sensors on the reach/lower lock (reach travel sensor 2B65) – 46
Brake ?uid switch 6S4 – 48
Foot switch 1S25 – 48
Seat switch 9E12 – 49

CAN power port 60
CAN-Power-Port (CPP) 60
CPP lighting 60
Fuses 60
Fuse assignment 60
64 Electronic controls
Switch-on sequence 64
Switch-on sequence of the electronic components 64
Active load stabilisation (ALS) 64
General 64
Requirements for ensuring functionality 64
Suppression capacitor of the ALS at the converter 64
Reach truck control unit (RCU) 64
Reach truck control unit (RCU) 64
XNXB plug (RCU) – Changing the pin assignment 64
CAN bus 64
CAN bus 64
Converter 64
Converter – Overview 64
Converter – Supply and enabling 64
Converter – Charging the condenser 64
Converter – Rev sensor analysis 64
Converter – Temperature monitoring 64
Checking the converter 64
General – 7
Assembly -10
XVI 51908012001 EN – 08/2017
Converter- Repair
Converter- Maintenance
69 Battery and accessories
Traction battery
Battery
Discharge indicator
Lithium-ion technology
Working on lithium-ion batteries
General technical data
Battery management system (BMS)
Diagnostics
Battery display
Battery discharge indicator for a lithium-ion battery
Battery charge
Penalties
Battery connection assembly
Checking for zero voltage on the battery male connector
Testing the insulation of the lithium-ion battery
Removing/installing the battery cable
Checking the truck wiring
70 Hydraulics, general
Safety check
Lowering safety test
Safety checks of hose assembly
Basic hydraulics
Oil tank
Bleeding the hydraulic system
Releasing the pressure from the hydraulics
Compact hydraulic plug system STH-C – 4
General – 4
Testing – 5
Repair – 6
Parameterising – 7
Maintenance – 7
– 8
General – 8
Testing – 9
Repair – 9
Maintenance – 10 General – 10
Testing – 11
Repair – 12
General – 1
Testing – 1
Repair – 2
General – 4
51908012001 EN – 08/2017 XVII
Table of contents
71 Working hydraulics
Pump-motor unit 71
General 71
Repair 71
Hydraulic pump 71
Reach cylinder 71
Positioning the reach cylinders 71
Tilt cylinder 71
Screw-in depth of the tilt cylinder in the rod end bearing 71
76 Valves
Valve block 76
Reach carriage valve block 76
General -10
Testing -11
Repair -12 General -13
Testing -14
Repair -15
General -16
Testing -17
Repair -19 General -21
Testing -22
Repair -2 -24
General -24
Testing -25
Repair -26
XVIII 51908012001 EN – 08/2017
Table of contents
Electrical testing of the valves
Voltage measured values for proportional valves and control valves
Pressure relief valve
General
Testing
Adjusting
Proportional valve
Main lift lifting
Main lift lowering
Shifting
Directional control valve
Tilting
Transition shift
General – 1
De?nition – 2
Con?gurations – 3
Operation – 6
Levels teach-in – 8
51908012001 EN – 08/2017 XIX
Table of contents
Lowering brake valve with exhaust valve
General
Repair
Exhaust valve 2Y21 {ISO valve)
Testing the exhaust valve 2Y21 (ISO valve)
81 Lift masT
Lift mast 81
General technical data 81
Telescopic lift mast 81
Triplex lift mast 81
Lift mast – Changing the lift mast configuration 81
Pre-tension of the hydraulic hoses during installation (fork tilter I sideshift, auxiliary
hydraulics) 81
Pre-tension of the cable harness during installation (fork tilter / sideshift, auxiliary hydraulics)
Lift mast- Removal 81
Lift mast- Installation 81
Load chains 81
Load chains – Checking and cleaning 81
Adjusting the load chainsTelescopic lift mast 81
Outer load chain Triple mast 81
Middle load chainTriplex lift mast 81
End position damping 81
End position damping, type B (bottom) 81
End position damping, type A (top) 81
Line break safety valve 81
Line break safety valve 81
90 Special equipment/accessories
Optional equipment
Height preselection