Workshop-Manual Comfort package

Ident-Nr. 164602 - en

STILL GmbH Stand: 11/2003 ( Ersatz fr Stand: 02/02 )

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Comfort package
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Contents Comfort package General Retrofitting requirements Software Hardware Safe parking Seat switch monitor Seat belt monitor Lift height dependent operation Steer angle dependent operation CSC Parameterisation

STILL GmbH Position as per: 11/2003 (Replaces version:

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Comfort package General
Lift height dependent operation - Safe driving through limitation of driving speed and acceleration with lifted load. - The lift height monitor reduces the risk of accident when driving with lifted load. - Above the lift height h1, the driving speed is limited to a reduced maximum value. - A drive program with reduced limiting values for acceleration can also be selected. - Lift height detection via sensor on mast (permanently set height). Steer angle dependent operation CSC - Steer angle dependent limitation of the maximum speed minimises the risk of tipping in curves. - Limiting function via truck-specific characteristics. - Evaluation of steer angle change and sequence. - No straight ahead restriction

Why - Arguments for - Higher safety and protection for persons - Higher safety level in comparable sectors, e.g. passenger vehicles - Changed statutory requirements, tighter regulations - Minimisation of risks for companies and persons - Exemplary function by STILL Scope of functions The comfort package is made up of the following modules: - Safe parking - Seat belt monitor - Lift height dependent operation - Steer angle dependent operation CSC The individual modules can be retrofitted by conversion and/or parameterisation in future to all STILL series trucks (see chapter Retrofitting requirements). Safe parking - Safe truck parking by applying the parking brake and lowering the fork. - Monitoring of the parking brake and lift height on leaving the truck. - The indications APPLY BRAKE and LOWER FORK, audibly or visually, ensure that the truck is always parked safely and accidents are virtually impossible. - Different reactions can be parameterised in the event of malfunction: - E.g. audible warning (beeper), visual warning (lamp), driver information in display. - Entry in FleetManager. Seat belt monitor - Safe driving by wearing seat belt. - A buckle switch detects whether the belt is used. - The buckle monitor only allows normal operation when the seat belt is worn. - If the seat belt is not worn, this initiates a reaction, e.g. the maximum speed is reduced. - Further reactions can be parameterised operation and customer-specific. - Prevention of manipulation via plausibility check. - Commissioning is possible without wearing seat belt at reduced speed.

STILL GmbH Stand: 11/2003 ( Ersatz fr Stand:

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Retrofitting requirements

Software versions The specified software versions are minimum requirements. The comfort package is contained in all higher versions.
Operating softw are V 0.32 V 0.22 V 0.55 B asic softw are V 1.01 V 1.04 V0.06

Truck 5051 - 55 2008-14, 2017-24, 2037-44 2015i , 2045i - 48i 6022-32, 6042-52 6022-29 6033-35, 6053-55

C ontrol C ontrol computer P ump controller C ontroller C entral computer B attery computer C ontroller R60S 20, S20E T C ontroller R60S 60 C entral computer B attery computer C entral computer B attery computer

R emark C ontrol computer V0.32 sonly runs wi th pump controller V0.22 (or higher )

V 0.03 V 0.62 -V 1.17 V 1.06

V0.02 V0.06 -V0.04 V0.05 C onversion to controller R60S 20E T C entral computer V1.17 per download, replace battery computer

6036-39

STILL GmbH Position as per: 11/2003 (Replaces version:

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Retrofitting requirements
Steer angle dependent operation CSC Standard or retrofittable by parameterisation to the following trucks: Currently available only in speed-controlled variant!

Seat belt monitor All drivers seats should generally be fitted with buckle switches as standard to enable retrofitting of the seat belt monitor. The following drivers seats are currently fitted with buckle switches: Driver's seat ISRI 2400 ISRI 6000 Grammer MSG 20 B uckle switch moisture class IP40, only i ndoor use IP40, only i ndoor use IP40, only i ndoor use

Truck 5051 - 55 2008-14, 2017-24, 2037-44 2015i , 2045i - 48i 6022-32, 6042-52 6022-29 6033-35, 6053-55 6036-39

C SC Series - always acti ve Variant Component Comfort package

NOT IMPLEMENT ED! not contai ned i n Comfort package

Lift height dependent operation The lift height sensor can generally be retrofitted to all standard masts. This function is currently released for the following trucks: Mast Tru ck 5 051 - 55 2 037 - 45 6030 - 35 / 605 0 - 55 6026 - 29 / 604 6 - 49 6036 - 39 / 6042 - 45 50 51 - 55 20 37 - 45 6030 - 35 / 6050 - 55 6026 - 27 / 6046 - 49 6036 - 39 / 6042 - 45 50 51 - 5 5 20 37 - 45 6 030 - 35 / 6050 - 55 6026 - 27 / 6046 - 49 6036 - 39 / 6042 - 45
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Te le

N iho

Trip le

STILL GmbH Position as per: 11/2003 (Replaces version:

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Safe parking

Truck requirements - Lift height detection (lift height sensor) - Signal transmitter (beeper, lamp) Function On leaving the truck, the fork must be lowered and the parking brake applied. The safe parking function ensures that an incorrectly parked truck generates messages in the display as well as audible or visual signals as necessary. NOTE - When the battery connector is disconnected, the function is inactive. - When the emergency stop switch is actuated, the function is active. Truck behaviour - When the seat contact is relieved, the control checks whether the parking brake was applied and the fork lowered below the lift height sensor. - When the parking brake is released, the message APPLY BRAKE appears in the display!. - When the fork is lifted, the message LOWER FORK appears in the display! - When the parking brake is applied, the control additionally checks whether the truck is stationary. The parking brake switch status ensures an insufficient braking torque. - The control stores the driving speed at the time of applying the parking brake and calculates from this the necessary braking time. - If the control detects truck movement after lapse of the calculated braking time, the message APPLY BRAKE appears in the display.! - Additional reactions to malfunctions are parameterisable.

STILL GmbH Stand: 11/2003 ( Ersatz fr Stand:

5a

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Seat switch monitor
Truck behaviour with seat switch unactuated: - With an unactuated seat switch, cancellation of the hydraulic restriction can be parameterised. - When the hydraulic sensor is activated, the message SEAT SWITCH! appears in the display. - This does not affect the steering function. - Lowering is always possible due to the provision of separate valve. - The truck cannot be driven. - Depending on the settings and basic conditions, the message SEAT SWITCH! appears in the display when the travel sender is activated. NOTE The message SEAT SWITCH! is also generated by the seat switch monitoring function.

Function For the safe parking and seat belt monitor functions, an extended three-stage seat switch monitor is necessary. 1. The seat switch must open once within a shift period - Shift period in hours - Maximum time without breaks adjustable depending on customer use. - If the seat switch remains actuated for longer than one shift period, an error is detected and the message SEAT SWITCH! appears in the display. 2. Within an operating period, he truck must be used with released parking brake and closed seat switch. - Operating period adjustable in minutes. - Monitoring of drive, steering and hydraulics. - If the truck remains inactive for longer than one operating period, an error is detected. NOTE: - Every action with the truck resets the clock. - Applying the hand brake stops the clock. Each of the monitors 1) and 2) can be activated individually and in combination. 3.Seat switch monitoring after turning off keyswitch - After switching off the truck (keyswitch OFF), the drive control continues to operate. - Subsequent operating time can be set in minutes. - The seat switch must open (seat relieved) within the subsequent operating time. - If the seat switch remains closed (seat actuated) within the subsequent operating time, an error is detected and stored. - When the control is switched on again, the message SEAT SWITCH! appears in the display and the maximum truck speed is reduced. - Other restrictions (hydraulic restriction) can be parameterised - All measures are cancelled when the seat switch is open once and reactuated (acknowledgement). NOTE: - Disconnecting the batter connector or switching off the system does not reset the error. - When the truck is next used, the seat switch must open once.

STILL GmbH Position as per: 11/2003 (Replaces version:

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Seat belt monitor
Fault states - Switch faulty: Switch always open. The safe state is assumed, i.e. the truck only moves slowly and hydraulic function restricted if necessary. - Switch faulty: Switch always closed. The buckle is always actuated. The fault is detected via a plausibility check. - Cable open-circuit: Corresponds to Case 1. - Short circuit of control input against truck chassis: Corresponds to Case 2. - Further faults, e.g. faulty control input can be attributed to Case 1 or 2.

Function Via the buckle switch, use of the seat belt is detected and monitored by the control. The control checks the possible combinations of switch signals from the buckle switch and seat contact switch as well as the sequence of switch signal variations. If the control detects an implausible state, a message appears in the display and a restriction measure is activated. Example: Belt is closed before seat loaded Truck behaviour - operation - If the buckle switch is open, the truck drives at reduced speed. - The reduced speed is parameterisable. - If the belt is opened while the truck is moving, the truck is braked to reduce the speed and the message SAFETY BELT appears in the display. - The speed reduction takes place as set in the drive program. - Hydraulic restrictions are also parameterisable. Truck behaviour starting Unrestricted operation is only given if the switching sequence of the seat contact switch and buckle switch was maintained: - Activate seat contact switch (operator seated) - Activate buckle switch (belt worn) - If the belt is not worn, the message SAFETY BELT! appears in the display when a sender or sensor is activated (travel sender, hydraulic sensor, steering).

STILL GmbH Position as per: 11/2003 (Replaces version:

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Lift height dependent operation
Reference lift - The message REFERENCE LIFT appears in the display if the control does not receive any plausible values from the sensors. - The driving speed is reduced and normal speed is initially resumed when plausible values are received from the sensors. - The control must be recalibrated via a reference lift - Calibration takes place by lifting the fork once above the sensor and lowering it again. - The control stores the sensor switching points and releases the maximum speed.

Lift height dependent operation To optimise safety when driving with lifted load, the truck can be provided with a lift height monitor. This device ensures that the driving speed is reduced above a maximum lift height. Normal speed is resumed when the lift height is below the maximum lift height. NOTE: Optimal safety is only ensured when the speed reduction occurs at a low lift height with minimal delay. Truck behaviour operation - The maximum lift height h1 (about 500mm) and the direction (lifting or lowering) is monitored by two sensors and stored. - If the fork is lifted above the maximum lift height h1, the message LIFT HEIGHT! appears in the display and the maximum speed is reduced. - The truck is decelerated until the reduced speed is reached. - Deceleration takes place as set in the currently selected program. - Alternatively, a drive program with special acceleration values can be selected. - When the fork is lowered and the maximum lift height h1 is not reached, normal speed is resumed again. - If a truck is parked with lifted fork above the maximum lift height h1, the message LOWER FORK! appears in the display. - Additional reactions to malfunctions are parameterisable. Truck behaviour starting - when the control is switched off the last stored information is retained. - If the truck is parked with lifted fork and the fork lowers when the control is switched off, a so-called reference lift must be carried out when the truck is started. - The message REFERENCE LIFT appears in the display. - The driving speed is reduced until the reference lift or calibration has been successfully completed.

STILL GmbH Position as per: 11/2003 (Replaces version:

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Lift height sensor

Installation on a triple or Niho mast The diagram shows the installation of the lift height sensor on a triple mast with a load capacity of 1.6 2.0t. - Install sensor according to installation drawing (included in package group) on outer mast. - Clamp sensor cable to lifting cylinder and route parallel with hydraulic line. - Weld blocks to fork carriage according to drawing. - Route cabling parallel with truck cable harness to the rear in counterweight.

Installation on Tele mast The drawing shows the installation on a Tele mast with a load capacity of 2.2 - 3.0t. - Install sensor according to installation drawing (included with package group) to outer mast cross member. - Clamp sensor cable to cross member and route parallel with hydraulic line into truck. - Weld blocks to inner mast cross member according to drawing. No additional blocks are required for Tele masts with a load capacity of 1.6 - 2.0t. - Route cabling parallel with truck cable harness to the rear in counterweight.

STILL GmbH Position as per: 11/2003 (Replaces version:

8b

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Lift height sensor

Lift height sensor 7B43 The lift height sensor is an inductive double sensor with two active switches S1 and S2. S1 NO contact S2 NC contact Pin assignments Connector Pin 1 Pin 2 Pin 3 Pin 4 Assignment +10V Switch S1 GND Switch S2 Colour BN (brown) WH (white) BU (blue) BK (black)

Technical data Operating voltage Operating di stance in mm Safety di stance in mm Current rating Short-ci rcui t-proof Ambi ent temperature Class of protecti on 9.5 ... 30V 10 ( with flush surface) 20 ( 2x operati ng distance) 15mA rated current No -40 ... +60C IP68
5 051- 55 S ensor +1 0V S1 S2 GND 2 037- 44 S ensor +1 0V S1 S2 GND 204 5 S ensor +1 0V S1 S2 GND 6 042- 45 6 030- 32 S ensor +1 0V S1 2 GND 6 036- 39 6 053- 55 S ensor +1 0V S1 S2 GND C able harne ss 7B 43 1 2 4 3 C able harne ss 7B 43 1 2 4 3 C able harne ss 7B 43 1 2 4 3 E2 9 1 9 2 3

E lec trica l termina ls Distributor boa rd front X 38 0 1 2 2 3 Fuse board X 26 3 X6 0 11 11 41 14 4 9/10 Fuse board X 50 1 9 2 3 Fuse board X 29 1 9 2 3 4 1 9/10 Fuse board X 29 1 9 2 3 X 154 5 4 1 6 30 24 25 7 X 20 X 60 11 11 41 14 7/8 X4 9 5 4 1 6 30 24 25 7 7/8 X 381 X 370 1 2 3 6 5 4 3 11 C ontrol c omputer X 45
+10V_sensor Res_1 Res_2 GND _sensor

C ontroller X 11
10V _E X T_1 GEB RES 1 GEB RES 2 GND _S

Ce ntral compute r X44

10V E X T_OUT GEB RES 1 GEB RES 2 GND B us

C able harne ss 7B 43 1 2 4 3 E2 9 1 9 2 3

C ontroller X 11
10V _E X T_1 GEB RES 1 GEB RES 2 GND _S

C able harne ss 7B 43 1 2 4 3 E2 9 1 9 2 3

Ce ntral compute r X 44
10V E X T_OUT GEB RES 1 GEB RES 2 GND _BUS

STILL GmbH Position as per: 11/2003 (Replaces version:

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Lift height sensor

Calibration/Test function To test whether the lift height sensor is functioning correctly, the control must know the exact position of the lifting lever at which lifting or lowering starts. For value verification and adjustment, calibration with test function is necessary. The test function is activated with the parking brake applied via the address special cell for sensor calibration. The test function deactivates itself automatically after about 2 minutes or when the parking brake is released. The lifting movements are indicated via the direction indicator lights on the console or control computer. Forward indicator light flashes - Lifting active Reverse indicator light flashes - Lowering active Both indicator lights flash - Neutral Function - Apply parking brake - Activate test function via special cell for sensor calibration: R20, R60 Addr. 151 Value 06 Rx50 Addr. A0F2 Value 04 - Both direction indicator lights flash, the lifting lever is unactuated - Slowly pull lever until lifting movement starts - The indication changes at the same time - only forward indicator light flashes - Bring lever in into neutral position again - Lifting movement stops and the indication changes - both indicator lights flash - Slowly push lifting lever until lowering movement starts - The indication changes at the same time - only reverse indicator light flashes Optimal adjustment: Once the ideal values have been set, mast movements start with simultaneous switching of the direction indicator lights. Correction: If these two actions are carried out at different times, the values must be adjusted appropriately. Provided for this purpose are addresses in the parameterisation that are set with default values. Correction lifting active R20 Addr. 1C4 Value 48 R60 Addr. 1C4 Value 38 Rx50 Addr. A0AA Value 38 Correction lowering active R20 Addr. 1C5 Value 15 R60 Addr. 1C5 Value 35 Rx50 Addr. A0AB Value 35 Correction lifting: - Lifting movement distinctly before change of indication Reduce parameter value. Step width 5dec - Lifting movement distinctly after change of indication Increase parameter value. Step width 5dec Correction lowering: - Lowering movement distinctly before change of indication Reduce parameter value. Step width 5dec - Lowering movement distinctly after change of indication Increase parameter value. Step width 5dec NOTE Each change of values must be followed by a reset. The test function must subsequently be activated in order to verify the new settings. As the behaviour changes slightly depending on the load lifted, this time-consuming calibration procedure should be carried out in the case of significant deviation. A simplified procedure via diagnostic notebook is currently unavailable.

STILL GmbH Position as per 11/2003 ( Replaces version:

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