sw STitt WAGNER Workshop Manual, FM-I Type 451 3 fe is \ > Firstissue: 02/02 Workshop ) \ Last revision: 05105 Manuat FMI Type 451] 4, nr. 8.054259( Foreword Foreword This workshop manual (WM) is a collection of technical data and functional descriptions for the standard vehicle. itis intended as a guide which should be kept at hand at all times, to help explain the technical features of the vehicle and consequently ensure that maintenance and repair are carried out correctly. The workshop manual is updated on a regular basis with additional sheets. 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 doumentation, the manual must be updated using the method described overleaf. Issue: 02/02 Workshop | LReplaces issue Manual FMA Type 451 | sheet:art ofthis manual "err, Copyright protected, No ray reproduced nm reserved MY Gace (replaces issue: 02/02 Manual ( Foreword ) \ Updating workshop manuals 4. Replacing incorrect sheets Ifa 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 information at the left-hand side of the page footer (1). The date of issue is updated here = alam in the Issue line (2). The date of issue of the Reepaces issue: tou Prarie Shestro3.o4 } sheet which needs replacing is specified in \ I the Replaces issue line (3). The sheet no. Page footer of an existing sheet 4 remains the same (4) 2 age footer of a corrected sheet Every time a change is made, the cover igsue 2 iaiarap sheet is replaced. The date of firstissue | Replaces issue: 02/02 Manvel rural Snest nego and the date of the last update are shown in field 9. This means that the workshp manual edition is immediately obvious. 3 Page footer of a cover sheet (Firstissued: 02102 Workshop pyatypast 2. Inserting new sheets | ast update Mama TMIPASH| io. 00 If new, altered or additional components are 9 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 Page footer of an exi 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 1g sheet issue: 0202 Workshop ‘Sheet no, \ Replaces issue: Manual UDP 3-04 consecutive index (8). 5 r The list of contents for the assembly in Page footer ofan additional sheet question must also be replaced. (issue: 10102 Workshop, sheotn.g4)) jeplaces issue: nN Manual test a We send new sheets, whether they are 7 replacement or additional sheets, and new 8 lists of contents, to all the vehicle owners we know of by mail. Issue: 10/02 Workshop EMA Type 451 | Peet"(Foreword 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 industrial 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 Published by STILL WAGNER GMBH & CO KG Trainingszentrum (Training Centre) Ernst-Wagner-Weg 1-5 72766 Reutlingen-Mittelstadt may be reproduced in ay form, Copyrgnt reserved i STit_t WAGNER Germany (Issue: 02/02 Workshop ‘Sheet no. | LReplaces issue Manual FM-I Type 451 LJwt dz re us \ (Guide to chapters Chapter 1: Vehicle data Chapter 2: Drive motor Chapter 3: Drive wheel Chapter 4: Gear Chapter 5: Electro-magnetic parking brake Chapter 6: Generator service brake Chapter 7: Hydraulic/mechanical service brake Chapter 8: Brake deceleration Chapter 9: Steering Chapter 10: Guide to the electrical components Chapter 11: Travel and pump controller (FPS) A10 Chapter 12: Load handling controls module (LAS) 8U61 Chapter 13: Converters 1U6/2U3 Chapter 14: Display 8A5 Chapter 15: CAN bus Chapter 16: Supply and emergency-stop circuit Chapter 17: Joystick 2A20 Chapter 18: Single-lever potentiometers 2R9-2R13 Chapter 19: Inductive proximity switches Chapter 20: Travel transducer 1U20 (Issue: 02/02 (Replaces issue: wessr EM Type 451[™"™ — qY ) Manualwt dz re us \ {Guide to chapters Chapter 21: DC/DC converter U30 Chapter 22: Height measuring system 8B21 Chapter 23: Seat adjustment Chapter 24: Hydraulic functions Chapter 25: Chassis valve block Chapter 26: Reach carriage valve block Chapter 27: Additional hydraulics valve block Chapter 28: Line break protection Chapter 29: Lowering brake valve Chapter 30: Load holding valve Chapter 31: Pump unit Chapter 32: Pump motor Chapter 33: Hydraulic pump Chapter 34: Tank indicator Chapter 35: Tank Chapter 36: Runback filter Chapter 37: Lubrication plan Chapter 38: Service software Chapter 39: Error codes Chapter 40: Winflash Chapter 41: Height preselection issue: 05/05 Shoot no. Replaces issue: 06/03 Workshop EM. Type 451 Manual Vv)(Guide to components ) \ + Drive wheel...... Sheet 3-01 + Brake pedal... secieesesnaseeseea seceesssaneeeessneeete Sheet 7-05. +DC/DC converter Sheet 21-01 ff + Display Sheet 14-01 ff + Speed sensor of drive/hydraulic MOtOFS...........s00 see see Sheet 13-09 + Speed sensor of drive motor Sheet 02-05 + Speed sensor of hydraulic motor Sheet 32-05 + Pressure relief VAIVE .....ssessessessesenserenissesenane seranererrveee Sheet 25-04 + Single-lever potentiometer Sheet 18-01 + Electro-magnetic parking brake Sheet 5-01 ff + Travel and pump controller...... dietitian Sheet 11-01 ff + Travel transducer. Sheet 20-01 ff + Drive motor. Sheet 2-01 ff + Gear eens see sentaniataneesiesasteseesve SHO 4-01 ff + Main brake cylinder. Sheet 7-10 + Height measuring system Sheet 22-01 ff + Hydraulic motor... .. Sheet 32-01 ff + Hydraulic PUMP... estnsensaesasnentnesassevas nena Sheet 33-01 . Hydraulic/mechanical brake Sheet 7-01 ff + Inductive proximity switch......... sitters Sheet 19-01 + Actual value potentiometer. Sheet 9-15 ff + Joystick ... Sheet 17-01 ff + LAS module. . .. Sheet 12-01 ff + Load holding valve Sheet 30-01 + Line break protection . Sheet 28-01 + Steering unit. Sheet 9-01 ff + Steering wheel... sone Sheet 9-14 + Emergency release valve. . .. Sheet 25-06 + Proportional valve for lowering........ .. Sheet 25-05 + Pump unit Sheet 31-01 we + Runback filter......... . Sheet 36-01 3H - Lowering brake valve. . sateen Sheet 29-01 =z —_- Seat adjustment Sheet 23-01 ke — - Setpoint potentiometer..... Sheet 9-10 ff M3. Tank Sheet 35-01 + Tank indicator. Sheet 34-01 + Travel converter... .. Sheet 13-01 ff + Hydraulic converter . . soe . Sheet 13-01 ff + Chassis valve block. Sheet 25-01 ff + Reach carriage valve block Sheet 26-01 ff + Additional hydraulics valve block... Sheet 27-01 (ssw: 0702 eisor EM Type 451[™"™ VL ) (Replaces issue: 02/02 Manual(Contents ) + Chapter 1: + Chapter 2: + Chapter 3: 22 + Chapter 4: SEE. chapter 5: wt 22 ro ke iB q * Chapter 6: Vehicle data Guide to signs and vehicle number ......... -Production number and consecutive identification numbers “Technical data... Sheet 1-01 Definition of the directions of movement... Sheet 1-04 Drive motor -General... Sheet 2-01 -Technical dat Sheet 2-02 -Connections.. Sheet 2-02 “Temperature monitoring . . Sheet 2-03 -Speed sensor. Sheet 2-05 -Removal Sheet 2-06 -Installation. Sheet 2-09 -Dismantling Sheet 2-10 “Maintenance .eserrsnsnnetinenanininesnneeneniinananstesnN@Ct 212 -Mast hitch Sheet 2-13 -Half mast hitch... Sheet 2-14 Drive wheel -Changing the drive wheel..... Sheet 3-01 Gear -Commissioning.... Sheet 4-01 Sheet 4-02 ..Sheet 4-03 -Changing the Oil... -Removal / installation Electro-magnetic parking brake -General... -Function. -Removal “Changing the brake dis -Adjusting the brake clearance Sheet 5-01 Sheet 5-01 Sheet 5-02 Sheet 5-03 Sheet 5-04 Adjusting the braking moment... ectineneniniis inane SHOW 5-05 -Releasing the brake mechanically Sheet 5-05 -Checking the brake coil Sheet 5-06 -New magnetic brake from 04/2005. Sheet 5-07 Generator service brake -General Sheet 6-01 -Funetion Sheet 6-01 (Tssuo: 05705 escort Type 451[™"™ VIL ) (Replaces issue: 10/02 Manual(Contents ) + Chapter 7: Hydraulic/mechanical service brake AFUNCHION wa seserseerenre evesistrnntatininestsieetnatnsine Sheet 7-01 -Plan of the braking System ...jjs:ssnsnneneenteanannanststere SHECt 7-02 -Removal Sheet 7-03 -Adjusting the brake clearance....... sn Sheet 7-04 -Adjusting the brake pedal..... Sheet 7-05 -Bleedingffiling the brake system + FlliNg os senent er Sheet 7-07 + Bleeding. .. Sheet 7-08 -Main brake cylinder + General. + Special base valve + Removal/installation Sheet 7-12 + Chapter 8: Brake deceleration -General... eiaeesetaneanesneseesans -Preparations for measurement ..... oo -Evaluating the measurement * Testing the service brake.. + Testing the parking brake Sheet 8-01 ..Sheet 8-01 Sheet 8-02 Sheet 8-02 “Chapter 9: Steering -General Sheet 9-01 “Technical data for the steering unit Sheet 9-01 -Function Sheet 9-02 -Block diagram Sheet 9-04 -Steering unit + General Sheet 9-05 + Connections. Sheet 9-05 + Removal. + Installation ... -Removing the drive unit -Setpoint potentiometer Sheet 9-07 Sheet 9-08 ‘Sheet 9-09 + General...... Sheet 9-10 a + Connections/signals. . . sonrensSheet O11 a + Testing Sheet 9-12 Fo + Removal ‘Sheet 9-12 ¢ + Installation Sheet 9-13 is -Adjusting the turning force of the steering wheel. Sheet 9-14 -Actual value potentiometer + General. Sheet 9-15 + Connections/signals Sheet 9-16 + Testing so... Sheet 9-17 + Removal . Sheet 9-17 + Installation ... Sheet 9-18 Sheet 9-19 -Adjusting the entire steering system. (Tssuo: 0at02 wessr Emel Type 451|™"™ VIN ) (Replaces issue: Manual(Contents ) + Chapter 9: Steering -360" Steering * General sesrneeee -Recognisable features. + Setpoint potentiometer Sheet 9-20 Sheet 9-21 =GONEFAl....esceeeereseeee ses Sheet 9-22 -Connections/signals .... ..eSheet 9-23 * Actual value potentiometer -General. Sheet 9-24 -Connections/signals Sheet 9-25 + Steering unit. Sheet 9-26 + Drive unit. Sheet 9-27 -Software versions Sheet 9-28 + Chapter 10:Guide to the electrical components -To 04/2005 + Basic equipment. Sheet 10-01 + Options........... Sheet 10-02 + Block diagram .. Sheet 10-03 -From 05/2005, + Basic equipment Sheet 10-04 + Options Sheet 10-05 + Block diagram Sheet 10-06 wt zz £o ke i issuer 08708 Workshop Shooto Replaces issue: 06/03 Manuat FM-I Type 454 VIII )