Still STED forklift TSR30 CSR12 5 16 20 Workshop Manual – PDF DOWNLOAD

Still STED forklift TSR30 CSR12 5 16 20 Workshop Manual – PDF DOWNLOAD

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Still STED forklift TSR30 CSR12 5 16 20 Workshop Manual – PDF DOWNLOAD

Language : English
Pages : 40
Downloadable : Yes
File Type : PDF
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Still STED forklift TSR30 CSR12 5 16 20 Workshop Manual – PDF DOWNLOAD

Foreword

This workshop manual provides specifications and describes functional characteristics of the standard truck. This provides you with a comprehensive documentation to ensure better understanding of the vehicle technology and so permit correct maintenance and repair work to be carried out. The workshop manual is always updated by supplementary sheetsUpdating of workshop manualsThe industrial truck range is subject to continuous further development. This means that certain components or assemblies are exchanged or modified. To ensure that the holder of this manual always has the most up to date version of the documentation, it is important to abide by the following updating system.

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TABLE OF CONTENTS:

Still STED forklift TSR30 CSR12 5 16 20 Workshop Manual – PDF DOWNLOAD

1 Vehicle data
2 Travel motor
3 Drive wheel
4 Gear
5 Brake
6 Steering
7 BDI/HM
8 Circuit board
9 Travel control
10 Accelerator pedal
11 Hydraulic TSR
12 Hydraulic CSR
13 Lifting device
14 Mast CSR
99 Maintenance
Section Contents Sheet
Foreword 1
Updating of workshop manuals 1
Exchanging faulty sheets 2
Insertion of supplementary sheets 2
Remarks, imprint 3
Sections 4
Contents 5
1 Vehicle data
Identification 1-01
Signs on the vehicle 1-02
2 Travel motor
General 2-01
Technical Data 2-02
Terminals 2-02
Removing the drive motor 2-03
Replacing the carbon brushes 2-04
Maintenance 2-05
General 2-05
Cleaning 2-05
Visual inspection, replacing damaged parts 2-06
Checking the brush unit,
replacing the carbon brushes 2-07
Commutator 2-08
Bearings 2-08
3 Drive wheel
Replacing 3-01
Removal 3-01
4 Gear
Removing 4-01
Lubricating the bogie bearing 4-02
Changing the gear oil 4-02
Oil change 4-03
Oil change procedure 4-03
Table of Contents
Copyright protected No part of
this manual may be reproduced in any form
Copyright reserved Issue: 08/03 Workshop-
Replaces issue: Manual TSR/CSR Sheet no 6
Table of Contents
Section Contents Sheet
5 Brake
Function 5-01
Service brake (brake pedal) 5-01
Parking brake (handbrake) 5-01
Guide to components 5-02
Installing/removing the drive motor brake 5-03
Removal 5-03
Installation 5-03
Adjusting the brake clearance 5-04
Checking the brake lining thickness 5-04
Adjusting the brakes 5-04
Adjusting the handbrake 5-05
Checking the setting 5-05
Adjusting the brake pedal 5-06
Measuring the brake deceleration 5-07
General 5-07
Preparations for measurement 5-07
Measuring the brake deceleration 5-08
Evaluating the measurement 5-08
Main brake cylinder 5-09
Bleeding / filling the brake system 5-10
Filling the brake system 5-10
Bleeding the brake system 5-10
6 Steering
General 6-01
Structure of the steering system 6-02
Steering sensor 6-03
General 6-03
Slipring system 6-04
Adjusting the steering sensor 6-05
General 6-05
Adjustment when installed 6-05
Adjustment when not installed 6-07
Servo unit 6-08
General 6-08
Terminal markings on terminal board 6-08
Exchanging the carbon brushes 6-09
Specifications 6-09
Steering controler 6-10
General 6-10
Function 6-10
Safety monitoring 6-11
Adjusting the current limitation 6-12
Copyright protected No part of
this manual may be reproduced in any form
Copyright reserved Issue: 08/03 Workshop-
Replaces issue: Manual TSR/CSR Sheet no
Table of Contents
7
Section Contents Sheet
7 BDI/HM
Curtis Combi-Controller 803 7-01
General 7-01
Pin assignment 7-02
Setting the final discharge voltage 7-03
Technical data 7-04
Accumeter EL-AC5 (up to 6/93) 7-05
Battery discharge indicator 7-05
Hour meter 7-06
Accumeter EL-AC5 (from 7/93) 7-07
General 7-07
Installation 7-07
Electrical connection 7-08
Specifications 7-09
Adjusting accumeter EL-AC 7-10
8 Circuit board
Circuit board A1with adapter card A8 8-01
Components 8-01
Fuses 8-02
Testing the fuses 8-03
Components 8-04
Rating plate 8-04
Contactor clearance 8-04
Contact pressure 8-04
9 Travel control
General 9-01
Functional characteristics 9-01
Cycle ratio and current profile 9-01
Setpoint value current, frequency characteristic 9-02
Primary current circuit 9-03
Ignition process 9-03
Thyristors 9-04
Function 9-04
Thyristors 9-05
Installation 9-05
Installation instructions 9-05
Thyristor power block 9-06
General 9-06
Diodes 9-07
Functional characteristics 9-07
Layout, installation 9-07
Copyright protected No part of
this manual may be reproduced in any form
Copyright reserved Issue: 08/03 Workshop-
Replaces issue: Manual TSR/CSR Sheet no
Table of Contents
8
Section Contents Sheet
9 Travel control
Diodes 9-08
Testing the diodes 9-08
Diode power block 9-09
General 9-09
Testing 9-09
Terminal 9-09
Functional Characteristics 9-10
Testing the primary current 9-11
Test procedure 9-12
Current actual value sensor n35 9-13
Functional characteristics 9-13
Control circuit board u200 9-14
Functional characteristics 9-14
Checking the safety circuit 9-14
Removing 9-15
Settings 9-15
Speed restriction GB (from 12/90) 9-15
Ramp-up time HZ 9-15
Reversing current RS 9-16
Drive current FS 9-16
Drive reduction 2,5kph 9-17
Adjustment of drive current 9-18
Current setting 9-18
Adapter card A8 9-20
General 9-20
Settings 9-21
Default factory settings 9-21
LED display 9-22
Measured signals 9-23
Block circuit diagram 9-24
Wiring diagram 9-25
Circuit board A1 with adapter card A8 9-25
10 Accelerator pedal
General 10-01
Functional characteristics of the magnetoresistor 10-01
Copyright protected No part of
this manual may be reproduced in any form
Copyright reserved Issue: 08/03 Workshop-
Replaces issue: Manual TSR/CSR Sheet no
Table of Contents
9
Section Contents Sheet
11 Hydraulics
Block diagram 11-01
Hydraulic circuit diagram 11-01
Pump assembly 11-02
General 11-02
Function LIFTING 11-03
Function LOWERING 11-04
Electrically pilot controlled non-return valve 11-05
Replacing the carbon brushes 11-06
Removal / Installation 11-06
Removal 11-07
Installation 11-07
Removing the pump motor 11-08
Hydraulic pump 11-09
General 11-09
Removing the hydraulic pump 11-10
Setting the maximum pressure 11-12
Recommended values for pressure adjustment: 11-12
Hydraulic oil change 11-13
Bleeding the lifting cylinder and hydraulic system of air 11-14
Procedure 11-14
12 Hydraulic system
Diagram of the hydraulic system 12-01
Pump unit 12-02
Removal 12-02
Carbon brushes 12-02
Directional slide valve block 12-02
Adjusting the maximum pressure valve 12-03
13 Lifting device
Function of the angled lever 13-01
Adjustment 13-01
Drawbar adjuster 13-01
End stops at bottom 13-01
End stops at top 13-02
Lift stop 13-02
Angled lever – pressure rods 13-03
Lifting cylinder, low lift 13-04
Guide to parts 13-04
Adjusting the tension springs 13-04
Copyright protected No part of
this manual may be reproduced in any form
Copyright reserved Issue: 08/03 Workshop-
Replaces issue: Manual TSR/CSR Sheet no
Section Contents Sheet
14 Mast
Basic lift 14-01
General 14-01
Setting the height when lowered 14-01
General 14-02
Load carriage, concealed cylinder version 14-02
Load carriage, exposed cylinder version 14-02
Function 14-03
Removing the telscopic load carriage 14-04
Mounting 14-04
Removing the lift cylinder 14-05
Support rollers – outer mast 14-06
Lift bracket 14-07
General 14-07
Removing 14-07
Lift bracket 14-08
Setting the adjusting screws 14-08
Chains 14-09
General 14-09
Setting the control chains 14-10
Setting the clearance lift chain 14-11
Chain setting at the triplex load carriage 14-12
Testing with/without rated load 14-12
99 Maintenance
General 99-01
Safety instructions 99-02
Handling fuels and lubricants 99-02
Brake 99-03
Testing the function of the service brake 99-03
Testing the function of the parking brake 99-03
Testing the function of the reversing brake 99-03
Wear limit for the brake lining 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
Steering 99-07
Ease of movement 99-07
Cut-out in the event of error 99-07
Steering chain 99-07
Reverse steering 99-07
Table of Contents
10
Copyright protected No part of
this manual may be reproduced in any form
Copyright reserved Issue: 08/03 Workshop-
Replaces issue: Manual TSR/CSR Sheet no
Section Contents Sheet
99 Maintenance
Lifting chains 99-08
General 99-08
Checking the lifting chains for damage 99-09
Checking the lifting chains for damage 99-12
Checking the chain elongation 99-13
Replacing the lifting chains 99-14
Lubricating the lifting chains 99-15
Cleaning the chains 99-16
Hydraulic tank 99-17
Volume 99-17
Seals 99-17
Soiled oil 99-17
Wheels 99-18
Wear 99-18
Wheel bearings 99-18
Load wheels 99-18
Motor 99-19
Carbon brushes 99-19
Checking the brush springs 99-19
Other maintenance work 99-19
Gear 99-20
Changing the gear oil 99-20
Noises 99-20
Leaks 99-20
Mast 99-21
Mast rollers 99-21
Guide rollers of the fork holder 99-21
Windscreen 99-21
Lifting cylinder 99-21
Guides, surfaces 99-21
Forks 99-21
Chain adjustment 99-21
Pump assembly 99-22
Carbon brushes 99-22
Oil level 99-22
Noises 99-22
Soiling 99-22
Lubrication plan 99-23
Lubricants 99-23
Disposal 99-23
Lubrication plan 99-24