STILL STED Forklift XOP1 Workshop Manual – PDF DOWNLOAD

Description

STILL STED Forklift XOP1 Workshop Manual – PDF DOWNLOAD

FILE DETAILS:

STILL STED Forklift XOP1 Workshop Manual – PDF DOWNLOAD

Language : English
Pages : 216
Downloadable : Yes
File Type : PDF

DESCRIPTION:

STILL STED Forklift XOP1 Workshop Manual – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

STILL STED Forklift XOP1 Workshop Manual – PDF DOWNLOAD

1 Vehicle data
2 Travel motor
3 Drive wheel
4 Gear
5 Brake
6 Idling wheels
7 Hydraulic
8 Cylinder
9 Line break protection
10 Hydraulic pump
11 Aisle recognition
12 Steering
13 Vehicle control system (FZS)
14 Operating panel
15 End-of-aisle safety system (EASS)
16 Speed sensor
17 Braking monitor (ABÜ)
18 Travel control
19 Travel switch
20 BDI/HM
21 Travel control software
22 Steering software
23 Hand-held programming unit
99 Maintenance
Section Contents Sheet
Foreword 2
Updating of workshop manuals 2
Exchanging faulty sheets 3
Insertion of supplementary sheets 3
Remarks, imprint 4
Sections 5
1 Vehicle data
Definition of vehicle model names 1-01
Signs on the vehicle 1-02
Travel speed 1-03
Outside the aisle 1-03
Inside the aisle 1-03
2 Travel motor
General 2-01
Temperature monitor 2-01
Technical data 2-02
Terminals 2-02
Removing the travel motor 2-03
Installation 2-04
Maintenance 2-05
General 2-05
Cleaning 2-05
Visual inspection, replacing damaged parts 2-06
Checking the brush mechanism 2-08
Commutator 2-09
Bearings 2-09
3 Drive wheel
General 3-01
Removing the drive wheel 3-01
Installing the drive wheel 3-01
4 Gear
Remove 4-01
Installing the gear 4-02
Changing oil 4-03
Oil change method 4-04
Checking the oil level 4-05
Lubricating the bogie bearing 4-05
Table of Contents
Issue: 08/03 Workshop-
Replaces issue : M a n u a l XOP1 Sheet no
Copy g p o e ed o p o
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Table of Contents
Section Contents Sheet
5 Brake
Electromagnetic spring brake 5-01
General 5-01
Function 5-02
Removal 5-03
Checking the rotor 5-03
Adjusting the brake clearance 5-04
General 5-04
Adjustment process 5-04
Adjusting the braking force 5-05
Maintenance 5-06
Measuring the brake deceleration 5-07
General 5-07
Preparations for measurement 5-07
Evaluating the measurement 5-08
6 Idling wheels
General 6-01
Removal 6-01
7 Hydraulic
Montagevorschrift 7-01
Hydraulic circuit plan 7-01
Block diagram for NO/HO 7-02
Block diagram for NM/HM 7-03
Pump unit 7-04
General 7-04
Components: 7-04
Electrically releasable non-return valve 7-05
Replacing the carbon brushes (NO, NM) 7-06
Replacing the carbon brushes (HO, HM) 7-07
Removal 7-08
Removing the pump motor (NO, NM) 7-09
Removing the pump motor (HO, HM) 7-10
Adjustment Pressure release valve 7-11
Changing the hydraulic oil 7-12
Bleeding the lift cylinders and the hydraulic system 7-13
Procedure 7-13
Distributor block 7-14
Bubble reservoir 7-15
Hydraulic hoses 7-16
Issue: 08/03 Workshop-
Replaces issue : M a n u a l XOP1 Sheet no
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Table of Contents
Section Contents Sheet
8 Cylinders
Cylinder support 8-01
Main lift cylinder on NO/NM 8-02
Removal 8-02
Dismantling 8-03
Main lift cylinder on HO/HM 8-04
Removal 8-04
Dismantling 8-05
Additional lift cylinder on NM/HM 8-06
Removal 8-06
Dismantling 8-07
9 Line break protection
General 9-01
10 Hydraulic pump
General 10-01
Removing 10-02
Dismantling 10-03
11 Aisle recognition
General 11-01
12 Steering
Block diagram of the steering system 12-01
Pin assignment 12-02
Setpoint potentiometer, steering wheel 12-04
Replacing 12-04
Setpoint potentiometer, steering knob 12-05
Replacing 12-05
Actual value potentiometer 12-06
Replacing 12-06
Quick start 12-07
Travel on curves function 12-08
Steering lock 12-09
13 Vehicle control system (FZS)
General 13-01
Location 13-01
Identification 13-01
Technical data 13-01
Guide to versions 13-02
Pin assignment 13-03
Input/output assignment 13-06
Issue: 08/03 Workshop-
Replaces issue : M a n u a l XOP1 Sheet no
Copy g p o e ed o p o
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Table of Contents
Section Contents Sheet
13 Vehicle control system
Error diagnosis 13-07
Flashing code, FZS2 13-07
Table of functions, FZS2 13-08
Application 13-08
Pedestrian operating mode 13-09
Switch-over, 2nd operating console 13-10
Power outputs 13-11
Travel enable 13-12
14 Operating console
Position of the operating elements 14-01
Removal 14-01
Installing 14-01
Wheel position display 14-02
Adjustment 14-02
Teaching in the FZS2 14-02
2nd operating console 14-03
Pedestrian operating mode 14-04
15 End-of-aisle safety system (EASS)
End-of-aisle safety system (EASS) 15-01
General 15-01
EASS Universal 15-02
Error codes 15-03
EASS Inductive 15-04
Function 15-04
Guide to the system 15-06
Monitoring 15-07
Mounting the proximity switches 15-08
Testing the proximity switches 15-08
Displays and pin assignment 15-09
EASS Magnetic (bistable) 15-10
Function 15-10
Guide to the system 15-12
Monitoring 15-13
Magnetic switch 15-14
Description 15-14
Bistable action 15-14
Switching magnet 15-15
Description 15-15
Handling instructions 15-15
Displays and pin assignment 15-16
8
Issue: 08/03 Workshop-
Replaces issue : M a n u a l XOP1 Sheet no
Copy g p o e ed o p o
this manual may be reproduced in any form
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Table of Contents
9
Section Contents Sheet
16 Speed sensor
General 16-01
Terminals block connector X2 16-01
Signal sequence 16-01
Testing the speed sensor 16-02
17 ABÜ – Braking monitor
Block diagram 17-01
Pin assignment 17-02
General 17-04
Functions 17-05
Travel on curves 17-05
Signal adaptation 17-05
Flashing error codes 17-06
18 Travel control
Block diagram for “Travel” 18-01
General 18-02
Main current section – terminals 18-03
Pin assignment 18-04
Description of functions 18-07
Braking modes 18-07
Table of operating modes 18-07
Hour meter 18-08
Service hour meter 18-08
Battery discharge indicator 18-08
Monitoring function 18-09
Error display 18-10
Test procedure 18-10
19 Direction sender
General 19-01
Replacing 19-01
20 BDI/HM
General 20-01
Pin assignment 20-02
Function 20-03
Error display 20-03
Battery discharge indicator 20-03
Hour meter 20-04
Issue: 08/03 Workshop-
Replaces issue : M a n u a l XOP1 Sheet no
Copy g p o e ed o p o
this manual may be reproduced in any form
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Section Contents Sheet
21 Travel control software
General 21-01
Making a connection 21-01
Setting parameters 21-02
Test 21-03
Diagnosis 21-03
“File” menu 21-03
Summary of the most important parameters 21-05
Battery discharge curves 21-06
List of parameters 21-07
Description of parameters 21-12
Errors displayed with flashing code 21-17
List of error codes 21-18
Tester Table 21-19
22 Steering software
General 22-01
Making a connection 22-02
Errors 22-03
Current errors 22-03
Stored errors 22-03
Teaching in 22-04
General 22-04
Procedure 22-04
Setpoint potentiometer 22-05
Actual value potentiometer 22-06
Tester 22-09
Speed measurement 22-09
Amplifier data 22-10
Digital inputs and outputs 22-11
Travel on curves active 22-11
Deadman 22-11
Steering wheel/ -knob 22-11
Steering OK 22-11
Steering motor contactor 22-12
Safety relay 22-12
Potentiometer voltages 22-13
Supply voltage of actual and setpoint values 22-13
Setpoint voltage at the steering wheel 22-13
Actual value voltages at the drive wheel 22-13
Table of errors 22-14
10
Table of Contents
Issue: 08/03 Workshop-
Replaces issue : M a n u a l XOP1 Sheet no
Copy g p o e ed o p o
this manual may be reproduced in any form
Copyright reserved
Section Contents Sheet
23 Hand-held programming unit
General 23-01
Operating elements 23-01
Switching on 23-02
Switching off 23-02
Language selection 23-03
Setting parameters 23-04
PROGRAM menu 23-04
Function 23-05
Special program menu 23-06
Resetting to initial settings 23-07
Loading settings from the control system
into the programming unit 23-08
Loading settings from the programming unit
into the control system 23-09
Deleting the diagnosis data 23-10
Adjusting the display contrast 23-11
Language selection 23-12
Displaying information about the programming unit 23-12
Displaying information about the control 23-12
Test menu 23-13
Displaying current errors 23-14
Error history 23-14
11
Table of Contents
Issue: 08/03 Workshop-
Replaces issue : M a n u a l XOP1 Sheet no
Copy g p o e ed o p o
this manual may be reproduced in any form
Copyright reserved
Section Contents Sheet
99 Maintenance
General 99-01
Safety instructions 99-02
Handling fuels and lubricants 99-02
Brake 99-03
Functional check of the deadman brake 99-03
Functional check of the neutral brake 99-03
Functional check of the reversing brake 99-03
Maximum wear on the brake lining 99-03
Brake clearance 99-03
Battery 99-04
Checking the electrolyte level 99-04
Checking the electrolyte density 99-04
Cleaning the battery 99-04
Battery lock 99-05
Battery charger 99-05
Operating elements 99-06
Ease of movement 99-06
Function test 99-06
Steering 99-07
Ease of movement 99-07
Reversed steering 99-07
Steering angle 99-07
Switching-off in the event of error 99-07
Toothed gear ring 99-07
Lifting chains 99-08
General 99-08
Checking the lifting chains for damage 99-09
Checking the chain elongation 99-13
Main lift 99-13
Checking the chain elongation 99-14
Additional lift 99-14
Replacing the lifting chains 99-15
Repairing the lifting chains 99-15
Lubricating the lifting chains 99-16
Cleaning the chains 99-17
Hydraulic tank 99-18
Volume 99-18
Seals 99-18
12
Table of Contents
Issue: 08/03 Workshop-
Replaces issue : M a n u a l XOP1 Sheet no
Copy g p o e ed o p o
this manual may be reproduced in any form
Copyright reserved
Section Contents Sheet
99 Maintenance
Wheels 99-19
Wear 99-19
Wheel bearings 99-19
Castor wheels 99-19
Motor 99-20
Carbon brushes 99-20
Checking the brush springs 99-20
Other maintenance work 99-20
Gear 99-21
Changing the gear oil 99-21
Noises 99-21
Leaks 99-21
Mast 99-22
Mast rollers 99-22
Guide rollers 99-22
Windscreen 99-22
Lifting cylinder 99-22
Guides, surfaces 99-22
Forks 99-22
Chain adjustment 99-22
Pump assembly 99-23
Carbon brushes 99-23
Oil level 99-23
Noises 99-23
Soiling 99-23
Lubrication 99-24
Lubricants 99-24
Disposal 99-24
Lubrication plan 99-25

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