BT Vector GB

SERVICEMANUAL
BT VECTOR GB
Model: C 12.5
Order number: 200422-040
Table of Contents
Table of Contents
Chapt. Theme
1. Comissioning
3. Technical Description
4. Mechanics
5. Hydraulics
6. Electrial Equipment
7. Sensors
8. System Messages
9. Equipment Check
10. Inputs, Outputs, flags
11. Service Parameters
12. Operating Diagrams
14. Hydraulic Diagrams
15. Driving-/ Lifting-/ Steering Control
19. Abbrevations
© BT Industries AB 200422-040
1
Table of Contents
2
1 Commissioning
1 Commissioning
Removal / installation of components other than those listed in
the spare parts catalogue is not permitted.
Required measuring instruments and test equipment

- Torque wrench
Chapt. Theme Page

1.1 General 3
1.2 Loose parts 3
1.3 Basic truck 3
1.4 Hoist frame 4
1.5 Load-lifting device (LAM) 4
1.6 Battery equipment 5
1.7 Hydraulics 5
1.7.1 Main pump unit 5
1.7.2 Hydraulic system 5
1.8 Supplied documentation 6
Indicates notes regarding safety that must be heeded to pre-

vent danger to personnel.
Indicates notes that must be heeded to prevent danger to

materials.
+ Indicates explanations.
1
1 Commissioning
2
1 Commissioning
1.1 General
The truck must be commissioned according to these instruc-
tions. In addition, the Operator’s Manual, especially chapter
Transporting and storing the truck, must be heeded. Assembly
on location, commissioning and operator training must be car-
ried out by personnel trained by the manufacturer.
Before commissioning, check the truck and the equipment for
completeness and a problem-free state. The operator must carry
out a danger analysis before commissioning. For this purpose,
the truck and its areas of use must be examined to prevent dan-
ger to the operator or other personnel.
1.2 Loose parts

All parts that are not yet attached to the truck when it is delivered
(so-called loose parts) are listed on the delivery note.
The following is supplied:
- 1 collision guard (attached to the cabin railing)
- various connection screws (supplied in box)
- covers (supplied in boxes)
- 1 air filter for the oil reservoir
- emergency lowering device (supplied in a box)
- components for special equipment
- APE-diagnostic set for service purposes (supplied in box)
1.3 Basic truck
+ Unloading and setting up of the truck and the lifting points for
the crane equipment are described in the Operator’s Manual,
chapter Transporting and storing the truck.
On WG-trucks, which are delivered lying, the WG-sensor below

the cabin is dismounted. In order to move the truck, the sensor
must be electrically connected to the plug after setting up the
truck.
Sensors of WG trucks are susceptible to danger due to their
closeness to the floor, especially when driving on ramps.
After setting up the truck,
- remove the plastic bands and the square timbers securing
the cabin
- set the switch for aisle recognition and end-of-aisle protec-
tion on the load side of the chassis to the correct height
and distance to the floor magnets (distance to floor: 40
mm)
- remove the collision guard from the cabin railing and
attach it to the load-bearing wheel housings
1. remove the oil reservoir lid and attach the air filter (see,
Operator’s Manual, chapter Transporting and storing the
truck)
3
1 Commissioning
- remove the rubber seal under the lid of the brake fluid res-
ervoir (see Operator’s Manual, chapter Transporting and
storing the truck)
- open the hydraulic cocks in the drive compartment as well
as under the battery lever parallel to the pipeline (see
Operator’s Manual, chapter Transporting and storing the
truck)
- check the oil level in the drive transmission (see Opera-
tor’s Manual, chapter Maintenance)
- check the entire truck for leaks
- check that the emergency lowering device is properly
stored under the driver’s seat
1.4 Hoist frame
+ If several trucks are delivered at the samt time, pay attention

that the serial numbers of the chassis, the hoist frame and the
load-lifting device agree.
If the hoist frame is not installed upon delivery:
- place the support washers on the hoist frame support onto
the chassis (do not mix the washers!!)
- pick the hoist frame up with a crane at the lifting eyes on
top of the mast (use a fork lift truck to set the hoist frame
upright)
- tighten the mast screws with the prescribed torque
(-> see section 4)
- check that the hoist frame is correctly tilted
(-> see section 4)
- connect the hydraulic lines to the lifting cylinder
- lay the electric cable harness in the chassis and in the
cable channel of the drive compartment.
1.5 Load-lifting device (LAM)
+ If several trucks are delivered simultaneously, pay attention

that the serial numbers of the chassis, the hoist frame and the
load-lifting device agree.
If the load-lifting device (swivel/traverse fork or telescopic fork) is
supplied separately,
- set the LAM on wood blocks
- set the LAM on suspension supports on the front of the
cabin and screw in and dowel the M 16 screws. If neces-
sary, use the existing washers (do not mix them!).
- check that the auxiliary mast is upright along the long axis
of the truck using a bubble level
+ The upright position results from the alignment of the pinion

shaft and the toothed rackings and cannot be changed.
- tighten the four M 16 fastening screws using a torque of
4
1 Commissioning
170 Nm
- remove the plugs of the hydraulic hoses in the attachment
and the cabin
- connect the hoses according to the markings
- connect the cables of the cabin and the LAM
1.6 Battery equipment

Working with acid batteries is described in the Operator’s Man-
ual, chapter Battery.
The weight of the battery and any provided additional weights
determine the stability of the truck.
If additional battery weights are provided, they must be properly
installed and secured by screws before operating the truck.
The required battery weight is shown on the truck identification
plate (see Operator’s Manual, chapter Presentation of the truck).
Other battery weights are not permitted.
- install additional weights
- insert the battery
- connect the battery cables to the battery poles
- connect the battery to the truck
- check the charging state and water level of the battery
(-> operating instructions of the battery manufacturer)
- insert the lateral battery covers
+ Moving the truck without battery power is described in the

Operator’s Manual, chapter Transporting and storing the truck.
1.7 Hydraulics
1.7.1 Main pump unit
To prevent destroying the pump, commissioning must be car-
ried out carefully.
To start:
- switch on the truck
- activate the main hoist frame for a few seconds; listen for
pump noises
In case of insufficient oil volume supply or untypical noise
coming from the pump (cavitation noise), switch pump motor
off immediately and investigate fault cause.
- switch off the truck
1.7.2 Hydraulic system

After commissioning the pump
- check all hydaulic connections for leaks, especially the
cabin / LAM connection
5
1 Commissioning
- ventilate the main and auxiliary lifting cylinders (see sec-

tion 5)
- check that the slack chain switch is working correctly (see
the Operator’s Manual, chapter Driving)
- check that the lifting sensors and toothed belt are working
properly
- check the operating states and safety cut-outs in the aisle
and the apron
The truck is now ready for operation.
1.8 Supplied documentation

The documentation pertaining to the product is compiled accord-
ing to the order, it is supplied with the truck as follows:
- Commissioning instructions
- EC approval
- 1 Operating instructions
- 1 Test protocol (factory settings)
- 1 Wiring diagrams
- 1 Hydraulic diagrams
- 2 Spare parts catalogues
- 1 Chain certificate
- 1 Fork certificate
6
3 Technical Description

the spare parts catalogue is not permitted
Chapt. Theme Page

3.1 Assembly arrangement 3
3.2 Components of the electrical
system 3
3.3 Components in the drive
compartment (rear view) 5
3.4 Components in the drive
compartment (right view 6
3.5 Technical data 7
3.5.1 Adjusting and testing data 7
3.5.2 Type structure 9
3.5.3 Fuses 10


materials.
1
2
3.1 Assembly arrangement
+ A survey of the mechanical assembly groups see the Operator’s Manual, chapter Pres-
entation of the truck.
3.2 Components of the electrical system
3
Pos Description
1 Sensor unit main lift (10-turn potentiometer and incremental trans-
mitter)
2 Sensor equipment of aux. lifting system (dual-gang 10-turn poten-
tiometer)
3 Sensor equipment for lateral traversing (dual-gang 10-turn poten-
tiometer)
4 Sensor equipment for swivelling (dual-gang 3-turn potentiometer)
5 Control panel with control system (UDR, UDL)
6 Control system cabin (VZK) below driver’s seat
7 Control system drive compartment (VZA)
4
3.3 Components in the drive compartment (rear view)

Pos Description
1 Lifting module block
2 Spring pressure brake
3 AC-Steering controller
4 AC-Pump controller
5 AC-Drive controller
6 Steering motor
7 Drive motor
8 Return flow filter
9 Oil service hose
10 Emergency lowering key
11 Oil reservoir
12 Refill- and ventilation filter
5
3.4 Components in the drive compartment (right

view)

Pos Description
1 Safety module
2 Fuse board control fuses
3 Controller board for load wheel brake
4 DC/DC converter (not visible in illustration)
5 EMC-hood, containing controller board, VZA-board, I/O-board, bus board
6 Motherboard VZA
6
3.5 Technical data

3.5.1 Adjusting and testing data
Description Unit Value
Truck
Dead weight (without load) ca. kg 5800 - 7800
Travelling speed with load km/h inductive guidance: 8,0-9,0
rail guidance: 10,0
Lifting (main lift) with/without load m/s 0,37 / 0,40
Lowering (main lift) with/without load m/s 0,40 / 0,40
Lifting (auxiliary lift) with/without load m/s 0,30 / 0,40
Lowering (auxiliary lift) with/without load m/s 0,40 / 0,30
Lateral traversing with/without load m/s 0,30 / 0,30
Swivelling by 180° with load s 7,5
Synchr. swivelling/traversing 180° / limit s 10,0-12,0
position
B Drive system
Transmission i 19,9
- Transmission oil charge l 3,7
- Drive plate M16 / M12 Nm 185
Drive motor
- Output (KB 60 min) KW 7,5
D Brake
Spring pressure brake drive motor
Thickness of brake disk (nominal) mm 13,0
Thickness of brake disk (minimum) mm 8,5
Brake release clearance mm 0,3 - 0,6
Max. stopping distance with/without load m 2,8
Load brake
Thickness of friction plate package (nomi- mm 3 mm
nal)
7
Description Unit Value
Minimum brake release play mm 2,25 mm

Max. stopping distance with/without load m 2,8 / 2,6
E Wheels / axles
Tyre diameter max. mm 300 / 406
Wheel nuts Nm 140
G Hoist frame
Screw connection to chassis M20 / 10.9 Nm 520
I Hydraulic system
Basic version
Hydraulic fluid H-LP 46 DIN 51.524
Oil charge: reservoir / hydr. system l / min 90 / 160
max
Max. overpressure bar 210
Pump unit cm³ 21,5
Pump motor KW 23
Return filter µma 10,0
Attachment
Oil charge, attachment l/ 4,0
max
Overpressure bar 210
Steering system
Steering motor KW 1,25 (AC)
Lenkgetriebe i 46
J Electrical equipment
Battery voltage V 2x40 = 80
Control voltage V 24
Truck mains system Two circuit system
Fuses see operating instructions
8
3.5.2 Type structure
Description Value
Capacity (kg) 1250 kg

Load centre (mm) B 600 mm (Pallette size1200 x 1200)
Chassis (y, z, H, m, W) rail guided 1950, 230, 60, 1200 mm
Chassis (y, z, H, m, W) wire guided 1950, 260, 60, 1200 mm
L2 / XD dim. (1200 x 1200) rail guided Wa = 2290 / 3228 / 1072 mm
L2 / XD dim. (1200 x 1200) wire guided Wa = 2290 / 3260 / 1072 mm
Load bearing wheels (Ø x W) 2 x diameter 300 x 157 mm
Drive 7,5 KW standing, AC-technology
Transmission i = 180, Pmax = 25000 N
Drive wheel (Ø x W) diameter 406 x 178 mm
Drive control system / end of aisle safety AC-controller 80 V, Control system VZA,
device end of aisle safety integrated into software
Double mast (ZT) hoist frame 2 Cylinders
Triple mast (DT) hoist frame 2 Cylinders
Lifting height h3 / h9 8250 / 1800 mm
Lifting height h tot htot = 9750 mm
Lifting cylinder, piston / cyl. Ø Double mast: 2 x diameter 55 / 60 / 70 mm
Load lift. dev. - SSG / SSG-BF 12 hs = 40 mm
AST (1200 x 1200) AST - rail guided 1605 SA 75 AST 3 = 3850 mm
AST (1200 x 1200) AST - wire guided 1705 SA 125 AST 3 = 3900 mm
Auxiliary lift h9 SSG 1500 up to max. 1800 mm
Auxiliary-lift cyl. SSG 55
Lift. control syst. - electr./hydr. AC / SECAN / Proportional valves
Hydraulic unit / motors 23 KW / 2600 rpm / 22,3 cm³
Electric control system 3 control systems: VZA, VZK, UDR with
CAN-Bus (CAN-open)
Steering syst., manual / autom. Electric steering with AC-controller, AC-
steering motor, wire guidance with 1 front
sensor, 1 rear sensor
Guidance systems Rail guidance: roller diameter: 95, 140, 180
x 50
Wire guidance
9
Description Value
Brake system drive wheel: Spring pressure brake/ load

wheels: hydr. brake system/
counter current brake/
end of aisle safety brake
Battery voltage 40 V; 2 trays
Battery size, capacity 560 Ah
Battery size, weight 760 kg
Battery trough, L 707 mm
Battery trough, W 520 mm
Battery trough, H with/without holders 864 / 784 mm
Circuit A
3.5.3 Fuses
+ Power- and Control fuses -> Operator’s Manual.
10
4 Mechanics
4 Mechanics

- Torque wrench
- Measuring tape, caliper gauge, feeler gauge
- Bubble level, lead plumb
4.1 Safety instructions 3

4.1.1 Working under lifted hoist frames 3
4.1.2 Working in dangerous heights 5
4.1.3 Gas pressure springs 5
4.2 Torque values for screwed
connections 5
4.3 Hoist frame and cabin 5
4.3.1 Screwed connection mast 5
4.3.2 Backward tilting of the mast 6
4.3.3 Guide rollers mast / cabin auxiliary
lift / fork carrier 6
4.4 Chassis 8
4.4.1 Lateral guidance (rail guided trucks) 8
4.5 Load-bearing axles 9

4.5.1 Load-bearing axle of trucks without load
wheel brake 9
4.5.2 Load-bearing axle of trucks with load
wheel brake 9
4.6 Load wheel brake 11

4.6.1 Dismounting of the brake 11
4.6.2 Checking the release play and the lining
thickness 11
4.6.3 Exchanging the brake plates 12
4.6.4 Visual testing of the load wheel brake 12
1
4 Mechanics
4.7 Mechanically released spring pressure

brake 13
4.7.1 Components of the magnetic brake 13
4.7.2 Adjustment of the airgap 13
4.7.3 Minimum brake lining thickness 14
4.7.4 Adjusting the braking effect 14
4.8 Drive unit 15

4.8.1 Removal/installation of the drive unit 15
4.9 Swivelling forks 16

4.9.1 Adjusting the side shift tooth flank
clearance 16
4.9.2 Adjusting the swivel chains 16


materials.
2
4 Mechanics
4.1 Safety instructions

4.1.1 Working under lifted hoist frames
When work is to be performed under lifted hoist frames, the
inner hoist frame and the cabin must be securely protected
against lowering. Therefore secure the hoist frame using the
hoist frame locking device.
Hydraulic functions (closing of main cock) is not a surfficient

safety measure!
Hoist frame locking device
The hoist frame locking device (2) is attached to the right-hand

outer frame (1). The securing screw (3) prevents undesired
engaging of the hoist frame locking device during operation of
the truck.
Pos Item
1 Outer frame, right side
2 Hoist frame locking device
3 Securing screw
Carefully check the hoist frame locking device for damages

and proper connection before using it.The hoist frame locking
device does not directly act upon the cabin but supports the
inner frame. When work is performed on the cabin lifting sys-
tem or if the system is damaged (e. g. lifting chains), the cabin
must first be completely lowered.
3
4 Mechanics
Activating the hoist frame locking device

To activate the hoist frame locking device
- lift the cabin until the lower edge of the inner hoist frame is
above the hoist frame locking device
- use an open-ended wrench to unscrew and remove the

securing screw. Keep the screw.
- Tilt up the hoist frame locking device until it stops
- Carefully lower the cabin until the inner hoist frame rests
on the hoist frame locking device
Deactivating the locking device

- Lift the cabin
- Tilt back the hoist frame locking device
- Insert and tighten the securing screw
Do not start the truck when the securing screw has been
removed.
4
4 Mechanics
4.1.2 Working in dangerous heights

For all works in dangerous heights reliably measures against
violent downfall must be taken, for example:
- Usage of safe ladders
- Protect ladders against falling and slipping away
- Protecting the worker against violent downfall (safety belt
and safety rope)
- Leave the lifted cabin via emergency abseiling device in
emergency situations (see the Operator’s Manual, chapter
Controls and Instruments)
Persons, staying below the worker, have to protect themselves

against downfalling parts by wearing a protective helmet.
4.1.3 Gas pressure springs

Gas pressure springs are mounted in the cabin barriers and the
top battery cover.
Never open gas pressure springs, danger of life! Defective gas

pressure springs must be exchanged completely.
4.2 Torque values for screwed

connections
- -> Operator’s Manual, chapter Maintenance
5
4 Mechanics
4.3 Hoist frame and cabin

4.3.1 Screwed connection mast
Pos. Item
1 Pull rod
2 Flattened part for engaging an open-ended wrench
3 Ball head joint of the pull rod
4 Rear screw connection of the pull rod
5 Screwed connection for connecting the hoist frame
6 Washer plates
The mast is connected to the chassis by screws.

Torque value: 580 Nm
Screws must be lubricated with oil or MoS2 grease before

tightening.
The correct sideward tilting of the mast is assured by the use of
plain washer plates.
The height of the plain washer plates (in mm) provided by the
factory is stamped onto the chassis at the spots marked "xx". It
must not be changed.
6
4 Mechanics
4.3.2 Backward tilting of the mast

The hoist frame is equipped with a backward tilting function at the factory.
+ After collisions or overload situations on the hoist frame the backward

tilting must be checked.
The values for backward tilting, which depend on the height of the hoist
frame, can be taken from the following table:
h1 (mm). backw. tilting X (mm)

2250 10
2500 11
2750 12
3000 13
3250 14
3500 15
3750 16
4000 17
4250 18
4500 20
4750 21
5000 22
5250 23
5500 24
5750 25
6000 26
According to the drawing, lateral tilting of the hoist frame may not exceed
+/- 5 mm. This value is the same for all hoist frame heights.
+ Adjustment of the lateral tilting -> chapter 4.3.1.
4.3.3 Guide rollers mast/cabin auxiliary lift / fork carrier

The inner hoist frame is supported by the outer hoist frame via 6 guide
rollers:
- 2 guide rollers at the top of the outer hoist frame
- 2 guide rollers at the rear of the outer hoist frame
- 2 guide rollers at the bottom of the inner hoist frame.
On triple mast trucks, the middle mast is supported in the same way.
7
4 Mechanics
The cabin is supported by the inner mast via 6 guide rollers:

- 2 lateral guide rollers at the top of the cabin
- 2 lateral guide rollers at the bottom of the cabin
- 1 rear guide roller at the top of the cabin
- 1 rear guide roller at the bottom of the cabin
The fork carrier is supported by the auxiliary lift hoist frame via 4
guide rollers:
- 2 lateral guide rollers at the top of the fork carrier
- 2 lateral guide rollers at the bottom of the fork carrier
Rear guide rollers
+ The guidance principal of inner

hoist frame / outer hoist frame,
cabin / inner hoist frame, fork
carrier / auxiliary hoist frame is
identically.
The rear rollers are adjusted and

fixed on factory site.
A re-adjustment on customer’s
site is not necessary.
Lateral guide rollers

The adjustment of the correct hoist frame clearance is effected
by inserting or removing the shims (3) below the hoist frame roll-
ers.
The shims are available in differ-
ent sizes.
Only use shims with a maxi-
mum size of 3,5 mm for the
hoist frame rollers.
+ Chippings in the area of the guide profiles indicate that the

clearance of 0,5 mm is too tight.
8
4 Mechanics
Slide pieces main and auxiliary lift

The slide pieces (5) at the lower hoist frame rollers prevent rat-
tling noises when the lifting gear is lowered.
To adjust the slide pieces:
- Loosen the counternut (6)
- Use the screw (7) to adjust the slide piece (5) until it butts
against the guide profile (4)
- Retighten counternut (6)
4.4 Chassis
4.4.1 Lateral guiance (rail guided trucks)

Adjusting the roller spacing
The appropriate roller spacing for the respective spacing
between the guide rails is set by removing or inserting plain
washer plates (9).
When adjusting the spacing, make sure that
- the load centre corresponds to the centre of the aisle; oth-
erwise, the stacking depth will vary depending on the
direction of lateral traversing; if necessary, remove plain
washer plates (2) on the side of the larger spacing and
insert the plates on the other side
- all 4 guide rollers sit evenly and without excess pressure
on the guide rails
- the truck moves straight ahead properly in the aisle; other-
wise, the Vulkollan tyres of the wheels will wear prema-
turely
+ Lubrication of the guide rollers via grease nipple (8) according

to the lubration schedule in the operating instructions.
9
4 Mechanics
4.5 Load axles and load wheels

4.5.1 Load axle
Pos.. Description
1 Load bearing wheel

2 Wheel brake
3 Cover
4 Distance ring
6 Roller bearing
7 Shaft nut
8 Locking washer
9 Seal
10 Allen screw
11 Allen screw
12 Allen screw
10
4 Mechanics
4.5.2 Load bearing wheel
Pos Description
21 Vulkollan tyre
22 Wear mark
23 Load wheel brake
24 Fixing screw of brake to chassis
25 Power supply of brake
26 Fixing screw toothed gear
27 Wheel support
28 Conical roller bearing
29 Wheel axle
30 Nilos-ring
31 Grease chamber
32 Distance bush
33 Sealing cover
11
4 Mechanics
The load-bearing wheels must be replaced

- if the Vulkollan tyre (21) is worn down to the wear mark
(22)
- if the Vulkollan tyres (21) are worn unevenly
- if the Vulkollan tyres (21) are damaged
4.6 Load wheel brake
+ Examination on the brakes, as well as exchanging of compo-

nents can only be performed on dismounted brake.
4.6.1 Dismantling of the brake

- Park the truck and render it safe
- Disconnect the brake electrically
- Jack up the truck, so that the load wheel comes free
- Remove the allen screws (32)
- Remove sealing cover (33)
- Pull off the load wheel from the axle (29)
- Remove fixing screw (24)
- Pull off the brake from the axle (29)
+ The fixing screws are secured with Loctite.

- lay down the brake onto a clean surface, otherwise dirt
gets into the magnetic part
4.6.2 Checking the release play and the lining

thickness
Check the release play (s) and the lining thickness (b) of the
plates as follows:
- Dismantle brake (see above)
- Connect the brake electrically to DC-supply (voltage acc.
to type plate of brake), brake will be activated.
Power supply can be taken from the fuse board in the drive
compartment of the truck.
- Check lining thickness
12
4 Mechanics
+ Minimum thickness: b = 3 mm in total or 0,6 mm per plate
If the plates are used below this wear allowance then they are
likely to distort.
- check release play (s) with a feeler gauge at two positions,
shifted by 180°
+ If the permissible release play of 2,25 mm is reached or

exceeded it can be re-adjusted to 1,0 - 1,25 mm by removing
the shims (2) and/or (3).
4.6.3 Exchanging the brake plates

- Dismantle brake (see above)
- Remove the 6 fixing screws (4) from the brake together
with the shims
- Place the screws together with the shims around the brake
(see illustration)
- Remove aluminium end plate (5)
- Remove tie plate (6)
- Remove friction plates (7) in order Outer friction plate -
Inner friction plate - Outer friction plate - Inner friction plate
- Outer friction plate
- Remove 6 distance bushes (8) with adjusting shims (2,3)
- Remove brass shim (9)
- Check magnet and coil housing for damages
- with paper towel, remove dust from magnet and coil hous-
ing
Assembly is carried out in reverse order.
New friction plates may only be changed as a complete set.

The exchange must be performed on both load wheels.
4.6.4 Visual testing of the load wheel brake

Every 1000 hours, dismount brakes and perform the following
work:
- check electrical connections for damage
- check gear of the hub for damages
- check for correct release play
- check for sufficient lining thickness
- perform visual check of the friction plate surfaces for dam-
ages
- check magnet and coil housing for damages
Never repair parts of the brake. Exchange with new genuine

parts.
13
4 Mechanics
4.7 Mechanically released spring

pressure brake
- All truck types are equipped with a magnetically released
spring pressure brake („magnetic brake“) on the drive sys-
tem.
- Releasing the brake mechanically
- The brake can be released mechanically if an electrical
release of the brake is no longer possible (e.g. after a volt-
age failure).
4.7.1 Components of the magnetic brake
Pos Description
36 Adjustment ring
37 Fastening screw
38 Magnet
39 Electrical connection
40 Spring
41 Brass shim
42 Anchor plate
43 Adjusting sleeve
44 Brake disk
45 Retaining ring
46 Hub
Releasing of the magnetic brake -> operating instructions
4.7.2 Adjustment of the airgap

The air gap (s) can be adjusted via three adjusting sleeves (48).
Stipulated value: s = 0.3 mm
Pos. Description
47 Adjustment ring
48 Adjusting sleeve
49 Brake shoes
b Lining thickness
50 Airgap
14
4 Mechanics
The air gap (s) may not be larger than 0.6 mm; otherwise, the
brake cannot be released reliably.
After the air gap has been adjusted, the braking force must be
readjusted.
4.7.3 Minimum brake lining thickness

Brake linings (49) are glued to the top and the bottom side of the
brake disk.
If the thickness (b) of the brake disk is below 8.5 mm, the brake
disk must be replaced. After exchange readjust braking force.
4.7.4 Adjusting the braking effect

The braking effect of the spring pressure brake can be adjusted
via the adjusting ring (47) by using a hook wrench:
Adjusting ring (47) is screwed out: -> braking effect is reduced
Adjusting ring (47) is screwed in: -> braking effect is increased
Dimension „y“ must not exceed 11.5 mm.

The correct values for braking the truck can be taken from the
acceptance protocol supplied with the truck.
+ In the case of trucks equipped with a load-bearing wheel brake,

the spring pressure brake is always adjusted and tested with
the load-bearing wheel brake activated.
15
4 Mechanics
4.8 Drive unit

4.8.1 Removal/installation of the drive unit
For removal of the drive unit
- Disconnect the electrical connection lines of the drive
motor (49) and steering motor (49a)
- Slightly lift the truck rear with hydraulic jack and secure it
properly
- Secure drive unit with a lifting device (see illustration)

- Unscrew the covering plate (50) of the drive.
- Loosen the screws (51) of the drive support plate.
- Loosen the outer screws (51) of the steering drive.
- Carefully lower down the rear of the truck
- Carefully pull out the complete drive unit towards the rear
and roll it aside on the drive wheel.
Installation is carried out in reverse order.
Torque of the screws (51): 186 Nm
+ Demounting of the drive unit -> spare parts manual.
+ Oil level of transmission gear box and mounting of the drive

wheel -> operating instructions.
16
4 Mechanics
4.9 Swivelling forks

4.9.1 Adjusting the side shift tooth flank clearance
The tooth flank clearance can be adjusted via excentric bushes
(52) on the upper and lower guide rollers.
Brass-distance bolts (53) prevent the sideshift from wiggling
when performing charge exchange movements
To adjust the flank clearance:
- Loosen brass distance bolts (53)
- Loosen the nuts of the guide roller bolts (52)
- by turning the excenter adjust tooth flank clearance until
the pinion shaft runs on the toothed rack without bracing
- Retighten brass-distances (53) again, until they touch the
slide surface slightly
- Retighten nuts of the guide roller bolts (52) again.
4.9.2 Adjusting the swivel chains

Proper adjustment of the swivelling chains prevents the cylin-
ders from acting as stops (instead of the swivelling stops) so that
they are not damaged.
To adjust the swivelling chains
- Connect the chain (55) with the chain support (56) at the
swivel bearing.
- Shift the piston rod to the dimension „s“ min. 14 mm.
- Manually swivel the fork against the respective stop.
- Adjust the screwed connection (54) at the piston rod in
such a manner that the hole pattern of the chain support
(56) matches the chain (55).
- Tighten the counternut of the screwed connection (54) on
the piston rod.
- Slightly pull out the piston rod.
- Connect the chain and the chain holder using the bolt and
the split pin.
- Adjust the piston rod of the other swivelling cylinder
accordingly.
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4 Mechanics
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5 Hydraulics
5 Hydraulics
Chapt. Theme Page

5.1 Torques for hydraulic conus
connections 3
5.2 Standard hydraulic diagrams 3
5.3 Safety instructions 4
5.4 Description of the hydraulic
installation 4
5.4.1 General features 4
5.4.2 Hydraulic aggregat 4
5.5 Hydraulic installation on the

chassis 6
5.6 Hydraulic installation in the
rear of the truck 7
5.6.1 Rear view 5 7
5.6.2 Top view 6 8
5.7 Tank 9
5.7.1 Oil filling 9
5.7.2 Draining the oil from the tank 9
5.7.3 Cleaning the tank 10
5.7.4 Refill the tank 10
5.7.5 Check hydraulic oil level 10
5.8 Fill- and ventilation filter 10

5.9 Return flow filter 11
5.10 Pump 12
5.10.1 Commissioning of the pump 12
5.10.2 Removing the pump aggregat 13
5.11 Lifting module block 13

5.11.1 Swivelling and side shift 13
5.11.2 Swivelling/side shift synchronous 13
5.11.3 Main lift / auxiliary lift 13
5.11.4 Pressure limiting valve 14
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5.12 Lift cylinders

(Main- and Auxiliary lift) 16
5.12.1 Design of the cylinders 16
5.12.2 Cylinder ventilation 17
5.12.3 Change of seals 17
5.12.4 Remove main lift cylinder 19
5.12.5 Mounting of the main lift cylinder 19
5.12.6 Exchange the lower piston rod guide 19
5.12.7 Line break safety device/Lowering
brake valve 20
5.12.8 Emptying the lift cylinders 20
5.13 Hydraulic installation

swivelling forks (SSG) 21
5.13.1 Side view 22
5.13.2 Front view 22
15.13.3 Adjusting the shock valves (side shift) 23
5.13.4 Adjusting the load holder valves
(swivelling) 21
5.13.5 Swivelling cylinders 24


materials.
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5.1Torques for hydraulic conus connections

Tighten screwed connections with the values of the table, if in the technical doc-
uments of the manufacturer no other torques are stipulated.
The results of the category of "steel" apply to the following surface protection:
- phosphated and oiled or
- galvanized and chromium plated.
Connection size Torque steel (Nm) Torque high-grade

steel1.4571 (Nm)
L = light
S = heavy
6-L 15 20
8-L 15 25
10 - L 25 30
12 - L 35 35
15 - L 45 50
18 - L 85 130
22 - L 110 160
28 - L 130 180
35 - L 215 275
42 - L 330 400
6-S 25 25
8-S 40 45
10 - S 50 65
12 - S 60 80
15 - S 75 100
18 - S 80 130
22 - S 120 180
28 - S 170 280
35 - S 250 375
38 - S 350 475
5.2 Standard hydraulic diagrams

Hydraulic diagrams C12.5 see chapter 14.
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5 Hydraulics
5.3Safety instructions
Also pay attention to the safety instructions in chapter 4
Mechanics!
While performing any work on the hydraulic installation

- pull battery plug
- lower main and auxiliary lift to the lower end limit
- close main ball valve below battery.
5.4Description of the hydraulic

installation
5.4.1 General features
- The speed of all movements can be controlled steadily by
the use of proportional valves
- The direction of the movements is controlled by way
valves
- Optimized efficiency by recuperation while lowering the
main lift
- Synchronous swivelling and sideshift in the apron as a
standard
- Synchronous lifting and lowering of the main lift and auxil-
iary lift
5.4.2 Hydraulic aggregat

The aggregat is installed lying below the battery. An AC-control-
ler supplies the AC-motor with energy and allows a steady con-
trol of the number of revolutions.
A careful commissioning of the pump is required
- after shipment / transportation of the truck
- after the exchange of the pump
- after interventions in the hydraulics system in the associ-
ated field of the pump
- if the pump produces abnormal noises (cavitation noises)
+ Commissioning of the pump see chapter 5.10.1.

Depending on the operating status, the hydraulic aggregate can
work as a motor or as a generator.
Motor operation
- lifting the main lift
- lifting the auxiliary lift
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5 Hydraulics
- side shift / swivel synchronous

Generator operation
- lowering of the main lift (slow speed to maximum speed)
In this case the pump works as turbine and drives the engine,
which returns energy through the AC-controller into the battery.
Small lowering speeds of the main lift (below the slow revolu-
tions per minute) are controlled by a hydraulic proportional valve
to guarantee a minimum number of revolutions per minute of the
unit.
Revolutions below 200 U/min damage the pump.
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5.5Hydraulic installation on the chassis
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Pos Description
3 Main lift cylinder
4 Pump unit (Pump H2 + Motor A2)
5 Main valve H6
6 Tank H1
7 Lift module block H3
8 Fill- and ventilation filter H26
9 Return line filter H18
5.6Hydraulic installation in the rear of the truck

5.6.1 Rear view
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5.6.2 Top view
Pos. Description
12 Lifting module block H3
13 Fill- and ventilation filter H26
14 Allen key for emergency lowering functions
15 Tank
16 Oil supply to pump unit
17 Manometer soiling display return flow filter H18
18 Return flow filter H18
19 Sealing screw of draining hose
20 Draining hose
21 Fixing clamp tank
22 Emergency lowering screw main lift
23 Emergency lowering screw auxiliary lift
24 Screwed connection (G1/2) for tank refilling by pump
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5.7 Tank
Oil reservoir, ventilation filter, return flow filter and lift module
block form a constructional unit.
+ Tank installation situation see chapter 5.6.1.
5.7.1 Oil filling

Oil amount (pressure liquid) in the tank: 90 liters
Complete amount of oil (tank+hydraulics system): to approx. 160
liters
Pressure liquid: according to ISO VG 46 (Shell Tellus oil T 46)
Wrong pressure liquids can lead to reduced performance or

damage of hydraulic components.
Never mix different kinds of oil.

Oil mixtures tend to produce foam and mud by fallout of addi-
tives. By reduced lubrication ability damages to pump and cylin-
der surfaces can appear.
5.7.2 Draining the oil from the tank
+ Always change oil in warm condition so that it runs out fast

and completely.
- lover main and auxiliary lift to the lower end
- switch off the truck, pull the battery plugs
- take off cap of fill- and ventilation filter
- hold the oil draining hose into a sufficiently big (min. 90 lit-
ers), flat bucket
- pull off and keep blanks of the oil draining hose
- let the oil flow off completely
- open ventilation screws of main and auxiliary lift cylinders
to empty them also
+ The tank can be emptied faster by using a pump. When using

this method also higher oil containers (cans, barrels) should
be used.
- close ventilation screws of main and auxiliary lift cylinders
again
- close and fasten the oil exchange hose at the tank
- dispose oil due to environmental regulations
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5.7.3 Cleaning the tank

Cleaning tank is necessary, if the oil in the tank is heavily soiled,
e.g. after a break of the return flow filter.
therefore
- empty the tank
- demount attached parts from the tank
- demount the tank
- wash the tank with hydraulic oil
5.7.4 Refill the tank
+ Screwed connection for filling the tank see figure chapter

5.6.2.
Always pump oil through the return flow filter into the tank for
cleaning
If the hydraulics installation also became newly refilled, ventilate
main and auxiliary lift cylinders and take pump in operation
according to chapter 5.10.
5.7.5 Check hydraulic oil level
+ see Operator’s Manual, chapter Maintenance.
5.8Fill- and ventilation filter

The fill- and ventilation filter (29) with 3 µma prevents the tank
from the entrance of dirt from the surrounding area.
Never operate the truck without fill- and ventilation fil-

ter.
+ Assembly see operating instructions.
Pos. Description
28 Screwed cap
29 Air filter
30 Sieve filter
31 Chain
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Oil level control

With lowered main and auxiliary lift the oil level in the sieve filter
(30) has to be between Min. and Max.
Checking the filter
A soiled fill- and ventilation filter produces a pressure below
atmospheric in the tank when raising the main or auxiliary lift.
This leads to increased noise and early wearing on the pump
units.
The filter must be replaced at the latest every time the hydrau-
lics oil is changed.
Examination:
- lift cabin with maximum speed
- remove screwing cap (28) of the filter when the pump is
working
+ If the noise level of the pump decreases significantly, the filter

is soiled and has to be exchanged.
5.9Return flow filter

The return flow filter cleans the oil running back into the tank
with 10 µma.
Examination of the filter
Unscrew and exchange the complete filter cartridge (33), if the
indicator of the manometer (32) is in the red area while main lift
is lowered with maximum speed.
Change filter right on time, otherwise a filter breakdown can

reslut in damages in the complete hydraulic system.
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5.10Pump
The pump aggregat is mounted beolw the battery.
When lowering the main lift, the pump is supplied with oil via pro-
portional valve 2Y31 and the valves 2Y35 and 2Y52. In this
operation the pump motor works as a generator and supplies
energy back into the battery via the lifting controller.
To avoid damages to the pump, in the lower range of pump rota-
tions, the speed is not controlled by the pump controller unit but
by the proportional valve 2 Y31.
+ Adjustment of the minimum number of revolutions of the

pump see chapter 11 service parameters, menu M13, parame-
ter D20.
5.10.1Commissioning of the pump

The pump has to be commissioned after
- installation of the truck at the customer
- exchange of the pump
- work in the hydraulics system
- oil changes
Immediately switch the pump off, if atypical pump noises (cav-

itation noises) occur, examin cause and remove it.
For the commissioning make sure that
- truck is ready for use
- ball valve below the battery is opened
- transport blank of the tank is removed and ventilation filter
is installed
- oil level in the tank is correct, refill if necessary
then
- switch on the pump for a short time and pay attention to
the working noise
- in case of doubt, attach manometer onto measurement
connection of the lifting module block and check correct
pressure build-up.
+ A bubble-free oil flow can be checked by separating the

manometer from the measurement hose and holding it into a
bucket.
Oil can squirt out at high pressure.
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5.10.2Removing the pump aggregat

- switch off the truck and pull battery plugs
- remove battery (see operating manual)
- close ball valve H6
- remove electrical connections from the pump motor
- unscrew hydraulic connections from the pump
- put blanks onto the leaking connection (DN 6)
- unscrew fastening screws of the pump unit
- remove the pump aggregat
The installation is carried out in reversed order
5.11Lifting module block

The lifting module block H3 on the tank has got the following
tasks:
- controlling all speeds of the attachment
- controlling the slow speed of lifting and lowering of the
main lift
- pressure limiting for all hydraulic movements
5.11.1Proportional priority flow control valve 2Y30
The three-port proportional solenoid priority control valve 2Y30

establishes the flow to the priority circuit and diverts the remain-
ing flow to the secondary circuit. The valve in normally closed,
that means without current supply, the priority circuit is closed
and the secondary circuit is open.
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5 Hydraulics
Supplied with full current (I max), the priority circuit is fully

opened and the secondary circuit is closed.
The regulated flow is independend of pressure at any of the

three ports. The 2Y30 valve controls the amount of oil, going
through the priority circuit. When the oil flow comes to a stop or
decreases, the valve opens the priority circuit on its own (hydro-
mechanically), according to a current of 600 mA (I max) and
closes the secondary circuit completely.
5.11.2Swivelling and side shift
+ Directional valves 2 Y40 ...43 see illustration in chapter 5.13

The priority flow control valve 2Y30 controls the speed of swivel
and side shift. Priority direction is swivelling, secondary direction
is side shift.
Swivelling movement:
For swivelling, 2Y36 and 2Y37 will be activated. According to the
swivelling direction, 2Y40 or 2Y41 will be activated. To control
the oil flow, 2Y30 is activated according to the selected swivel
speed (control range: I min to I max). The rest amount of oil is
returned to the tank via secondary line (side shift) of 2Y30.
Side shift movement:
For side shift, 2Y36 and 2Y37 will be activated. According to the
side shift direction, 2Y42 or 2Y43 will be activated. At the begin-
ning, 2Y30 is activated at maximum current I max. The total oil
flow goes via priority path (swivelling) of 2Y30 back to the tank.
Then the current is continuously reduced to I min. While the cur-
rent on 2Y30 is reduced, the secondary path of 2Y30 is supplied
with an increasing oil flow. The side shift movement is acceler-
ated to full speed.
+ For the exact adjustment of the movements the shock valves

and the load holder valves of the attachment must also be
adjusted (see chapter 6).
5.11.3Swivelling/side shift synchronous

The synchronous movement is controlled by the number of revo-
lutions of the pump for synchro-swivelling (service menu M07,
D12, D06) and the settings of I min and I max of the priority flow
control valve 2Y30 (service menu M07, I10, I11).
When the synchronous movement is selected:
- the pump starts to run at minimum number of revolutions
(according to sevice menu M07; D12)
- 2Y37 is opened.
- 2Y31 is supplied with constant current (acc. to service
menu M07; I10). This returns the rest oil to the pump, not
to the tank.
- Swivelling starts at minimum speed
- the current supply to 2Y30 is increased from I min to I max
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5 Hydraulics
- The number of rotations of the pump is increased to maxi-

mum (acc. to service menu M07, D06). This supplies the
secondary circuit with oil.
- 2Y36 is opened and the side shift movement starts. The
delay time (offset) for 2Y36 can be adjusted in service
menu M07, V21)
+ For the exact adjustment of the synchronous swivelling move-

ment see chapter 6.
5.11.4Main lift / auxiliary lift

Lifting the Main Lift:
The lifting speed of the main lift movement is controlled by the
number of rotations of the pump.
Lowering the main lift:
The lowering slow speed of the main lift movement is controlled
by the prop. valve 2Y31. When the main lift is lowered at full
speed, the speed should be controlled by the pump unit working
as a generator, else the energy regeneration is not working. The
speed at which the control is switched from the prop. valve 2Y31
to the pump unit, is regulated by service menu M04, V30.
Auxiliary lift movement:
Lifting the auxiliary lift:
The speed of the auxiliary lift movement is controlled by the pro-
portional valve 2Y30. 2Y32 is opened.
During startup of the movement, 2Y30 is supplied with an con-
tinuously increasing current and the pump is running at its mini-
mum number of rotations for lifting auxiliary lift. After startup to
full speed movement, 2Y30 is fully opened (current: I max) and
the number of rotations of the pump is continuously increased.
Lowering the auxiliary lift:
The lowering speed of the auxiliary lift is conrtolled by the pro-
portional valve 2Y49. 2Y33 is opened.
5.11.5Pressure limiting valve return flow

To adjust the pressure limiting valve (35)
- connect manometer to mini measurement connection (43)
- pull plug from 2Y32
- lift the auxiliary lift
The pressure has to be adjusted to the value mentioned in the
test protocol of the truck.
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Lifting module block H3
Pos. Description Pos. Description

33 Emergency lowering screw auxiliary 41 Way valve swivelling 2Y37
lift
34 Priority flow control valve 2Y30 and 42 Pressure limiting valve for 2Y30
Solenoid check valve 2Y52
35 Pressure limiting valve for return flow 43 Measuring connection
36 Way valve side shift 2Y36 44 Pressure converter H9 (2B10)
37 Solenoid proportional valve lowering 45 Pressure limiting valve for 2Y31
main lift 2Y31
38 Way valve lifting (2Y34) and lowering 46 Emergency lowering screw for main
(2Y35) the main lift lift
39 Way valve lifting (2Y32) and lowering 47 Pressure switch slack chain / chain
(2Y33) the auxiliary lift break
40 Solenoid proportional valve lowering 48 Way valve for pressure relief 2Y53
auxiliary lift 2Y49 (normally open!)
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5.12Lift cylinders (Main- and Auxiliary lift)

5.12.1Design of the cylinders
Main lift cylinder Auxiliary lift cylinder
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1 Line break safety device 9 Piston rod guide bands
2 Cylinder end 10 Ventilation screw
3 Lower piston rod guidance 11 Sealing for ventilation screw
4 Circlip (upper stop) 12 Grooved ring seal
5 Piston rod 13 Scrapper ring
6 Core tube 14 Locking ring
7 Cylinder head 15 Lowering brake valve
8 O-Ring 16 Hole for locking
5.12.2Cylinder ventilation
The ventilation of the lift cylinders has to be repeated until the
lifting movement works free of vibrations
Therefore
- lift the cabin (or auxiliary lift with load) app. 0,5 m
On all works in cylinder area see chapter 5.3 Safety instruc-
tions. Caution: Hoist frame can lower itself while ventilating!
- loosen ventilation screw (10) slightly
+ The screw has got a short thread, therefore do not loosen it too
much.
- ventilate, until oil comes out bubble-free
- re-tighten ventilation screw (46)
+ If the ventilation screw doesn’t close without leakage

exchange the copper shim (11) below the screw.
5.12.3Change of seals
+ Always change the complete set of sealings and guidance

pieces, as well as the ventilation screws (Pos. 8 - 13).
For change the seals
- lift up cabin until the hoist frame locking device can be acti-
vated (see chapter 4 Mechanics)
- remove the locking ring (14)
- lower the cabin down onto the hoist frame locking device
by using the emergency lowering valve
- slightly loosen the ventilation screw (10)
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5 Hydraulics
+ The screw has a short thread, therefore do not loosen it too

much.
- Lower down the cylinders completely by using the emer-
gency lowering valve for the main lift, close emergency
lowering valve
- By using a hook wrench, loosen the cylinder head (7)
Always make sure, that no dirt can fall into opened the cylinder.
- turn cylinde head (7) left and remove it upwards
- Change scrapper ring (13), Grooved ring seal (12), Piston
rod guidance bands (9) and O-Ring (8)
- Change and tighten ventilation screws (10) and seals (11)
Make sure, that the scrapper ring and the grooved ring seal are
mounted correctly (sealing lip downwards, according to the
illustration).
- Check phase at the beginning of the piston rod, make it
smooth, if necessary, so that the sealings and guidance
pieces of the cylinder head are not damaged while pulling
it over the rod.
+ Put oil on the scrapper ring, grooved ring seal, piston rod guid-
ance bands, o-ring and piston rod; this will facilitate assembly.
- Carefully pull the cylinder head onto the piston rod and
tighten it
+ While pulling the cylinder head onto the piston rod, the o-ring
(8) may not slide over the thread on the cylinder tube, other-
wise it will be damaged.
- Lift up main lift carefully, until cylinder touches the top
- Mount locking ring (14)
- Check visually the screws of the mast clamp; Secured with
Loctite!
- Lift up main lift for a short time
- ventilate cylinder via ventilation screw (11)
- Lift up the cabin from the hoist frame locking device
- Deactivate hoist frame locking device (see chapter 4
Mechanics)
- Lower down cabin completely
- Check main lift function, ventilate cylinder again
- Check cylinder for leakage
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5.12.4Remove main lift cylinder

- Lift up and support the cabin
- unscrew the screws (1) of the mast clamp (2), push
upward the clamp to the ventilation screws (11)
- fix the cylinder with a lifting device via belt on the cylinder
head below the mast clamp
Fix the cylinder properly, that it cannot fall down
while further actions. Fix the cylinder head with a
rope at the mast until it is lifted out.
- open lower fastening screw

- loosen and lower the adjusting piece (see change of seals)
- carefully lift out the cylinder with a lifting device and lay it
down
5.12.5Mounting of the main lift cylinder

The installation is carried out in reversed order.
+ When installing the cylinder pay attention that the ventilation

screws can be accessed easily.
At the installation of the mast clamp tighten the screwed con-

nection (1) after the cylinder is fixed on top and bottom in low-
ered status. It is assured that the cylinder is not mounted with
tension. Protect screwed connection (1) with Loctite 243.
A visual inspection of the screwed connection (1) has to be

performed regularly, at least once a year. Do not re-tighten the
screws, otherwise the Loctite protection is destroyed.
While the mast clamp is loose, there is danger of creaking the
main lift cylinder.
5.12.6Exchange the lower piston rod guide

When the upper piston rod guidance and the seals are wearing
too early after an exchange the lower piston rod guidance (3)
can be defective and has to be exchanged.
- remove cylinder
- take off cylinder head
- pull out the piston rod
- take off safety ring (14)
- exchange lower piston rod guidance (3)
- assembly in reverse order
- ventilate cylinder as described above
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5.12.7Line break safety device/Lowering brake valve

The activating of the line break safety device (1) on the main lift
cylinder and the lowering brake device (15) on the auxiliary lift
cylinder is an emergency function which is released by an
unpermissible high lowering speed. The appearing deceleration
values represent a situation of increased use for hydraulics and
mechanics of the truck.
The lowering limit screw on the lifting module block is so
adjusted that the line break safety device is only activated, when
really a hydraulic pipe between lifting module block and main lift
cylinders is broken, which means in a line break situation.
If the line break safety device is activated during normal oper-
ation or while adjustments on the lift and lowering control sys-
tem are performed without having a damage on the hydraulic
pipes, the adjustment of the lowering limit screw on the lifting
module block has to be checked and corrected, if necessary.
If a line break safety device has been activated, the following
work has to be performed before re-commissioning of the truck:
- find and remove the activating cause
- inspect all hydraulic and mechanic components of the
hoist frame carefully on damages
The line break safety devices / lowering brake devices may not
be adjusted or repaired. If the line break safety devices have to
be replaced, only the use of factory setted and tested genuine
parts provided with a test-stamp is permitted.
Never operate cylinders without line break safety device / low-

ering brake device. On new cylinders the existance of line
break safety devices must be checked.
5.12.8Emptying the lift cylinders

- lower main and auxiliary lift completely via emergency
lowering screw
- let the emergency lowering screw opened
- screw out the ventilation screw (10) completely, that the oil
can run out completely.
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5.13Hydraulic installation swivelling forks (SSG)

5.13.1Side view
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5.13.2Front view
Pos. Description
70 Auxiliary lift cylinder
71 Valve block side shift A3 with
shock valves
72 Hydromotor side shift A48
73 Pinion side shift
74 Sensor side shift
75 Valve block swivelling A7 with
load holder valves
76 Lowering brake valve auxiliary lift
cylinder A4
77 Swivel chain
78 Sensors swivelling
79 Pressure pipe to swivel cylinder
80 Swivel cylinder
81 Transparent leakage hose swivel
cylinder
82a Adjusting screw for shock valves
side shift, left shifting direction
82b Adjusting screw for shock valves
side shift, right shifting direction
83a Adjusting screws for load holder
valves swivelling, left direction
83b Adjusting screws for load holder
valves swivelling, right direction
84a Valve 2Y43:
side shift left direction
84b Valve 2Y42:
side shift right direction
85a Valve 2Y40:
swivelling right direction
85b Valve 2Y41:
swivelling left direction
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15.13.3Adjusting the shock valves (side shift)

The shock valves on valve block A3 (71) protect the hydromotor
A48 (72): If the pressure difference between supply flow the
return flow for side shift movement are exceeding 100 bar, the
shock valves open automatically and increase the pressure on
the return flow, so that the difference remains 100 bar at any
time. The hydromotor is designed to stand a pressure difference
of more than 100 bar (app. 130 bar).
+ The shock valves are adjusted to 100 bar limiting pressure dif-
ference from factory side.
If the side shift movement is correct, the shock valves needn’t be
adjusted.
To adjust the shock valves (e.g. after repair work):
+ Carry out adjustments in both side shift directions. The adjust-

ment has to be done with nominal load.
- connect manometer to the mini measurement connection

of the lifting module block
- tighten the adjusting screws (82a/b) completely
- turn forks into initial position
- activate side shift, and measure normal working pres-
sure (write down the value)
- move the fork end against a solid obstacle (e.g. against a
wall)
- open the adjusting screws (82a/b) completely (do not
remove them)
- tighten the adjusting screws (82/a/b) slightly; move forks
against obstacle again and measure the pressure.
- continue tightening the screws, until the pressure has
reached normal working pressure + 30 bar.
- pick up nominal load and make sure, that the side shift
movement works properly
- tighten the counter nuts on the adjusting screws
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5 Hydraulics
5.13.4Adjusting the load holder valves (swivelling)
The load holder valves on the valve block A7 (75) have the fol-
lowing functions:
- they lock the swivel cylinders (36) at any stop position
- they prevent the forks from swivelling faster and further as
it was provided by the SECAN-control
- they prevent the forks from swivelling during braking of the
truck in forward direction or accelerating of the truck in
backward direction
- they assure, that the forks can be rotated, in case of colli-
sion with obstacles.
+ If the forks are not sufficiently locked while normal operation,

the load holder valve has to be re-adjusted. As a spare part the
load holder valve is delivered with a correct setting.
+ Adjusting the load holder valves too tight results in shaky rota-
tion movement and a unsteady synchro-movement.
Each valve (left and right swivel direction) has to be adjusted
separately.
To adjust the load holder valves
- pull the forks to one side, to check, if they keep locked at
any stop position (at least 5 min.)
- swivel the forks by approx. 45 degrees from the initial posi-
tion towards the front; operate side shift against a solid
obstacle: the fork must swivel aside; if necessary, loosen
the adjusting screws (39a/b).
25
5 Hydraulics
- pick up a nominal load and secure with straps, move the

truck
- move the truck in drive direction and fully brake the truck
using the foot switch: the fork may not swivel; if necessary,
tighten and lock the adjusting screws (39a/b).
Do not perform the brake test into load direction, otherwise the
forks may abruptly turn to the front.
+ If the above-mentioned adjusting procedure for the load holder

valve cannot be carried out correctly, remove and clean the
load holder valve or replace it if necessary.
5.13.5 Swivelling cylinders

The seals must be replaced
- if oil escapes at the piston rod
- if oil flows via the transparent leakage hose through the
inlet tube into the compartment of the side shift arm.
+ Each time the truck is serviced, check whether oil has flown
into the drain hose.
26
5 Hydraulics

86 Bore hole for face spanner 94 Scrapper ring
87 Threaded ring 95 Seal
88 Piston rod guidance 96 O-ring
89 Pressure connection 97 Guide bands
90 Cylinder jacket 98 O-ring
91 Piston rod 99 Piston seal
92 Piston 100 Connection for leakage line
93 Bore hole for face spanner
If there is oil in the drain hose, the oil in the side shift arm should
also be drained:
- Remove the drain hose from the two swivelling cylinders
and actuate the swivelling function.
- Determine which swivelling cylinder leaks; replace the
seals.
27
5 Hydraulics
Exchange of seals:
- deinstall the cylinder.

- insert face spanner amf 764/40-80 into the bore holes (86)
and screw out the threaded ring (87).
- pull out the piston rod (91) along with the piston (92) and
the piston rod guide (88).
- insert face spanner amf 764/40-80 into the bore holes (93)
and unscrew the piston (92) from the piston rod (91).
- remove the o-ring (98), grease the new o-ring and insert it
- screw the piston back onto the piston rod.
- remove the set of seals and guides (94 - 97, 99).
- grease and install the new set of seals.
+ Installation position of the scrapper ring (94): sealing lip facing

outward.
Installation position of the seal (95): sealing lip facing inward.
Make sure that the edges and running surfaces of the cylinder
are not soiled or damaged; otherwise, the new seals will be
destroyed during assembly.
- Check the connecting nipple for the leakage hose.

- Reassemble the cylinder
+ Adjust the swivelling chains as described in chapter 4,

mechanics.
28
6 Electrical equipment
Chapt. Theme Page
6.0 Block Diagram of the

Control Concept 5
6.1 CAN-bus description 6
6.2 CAN-bus- features 6
6.3 Components of the control

systems 7
6.3.1 General information concerning the
components 7
6.3.2 Drive compartment processing
unit (VZA) 7
6.3.3 Design of the VZA 8
6.3.4 Cabin processing unit (VZK) 9
6.3.5 Control panel processing unit 11
6.4 Design of the Right Control

Panel(UDR) 12
6.5 Design of the Left Control

Panel (UDL) 15
6.6 Braking System 17

6.6.1 Safety circuit brakes 17
6.6.2 Description of the braking systems 18
6.6.3 Spring pressure brake 18
6.6.4 Load wheel braking system 19
6.6.5 Electrical braking system 22
6.6.6 General emergency stop 22
6.6.7 Functional emergency stop 22
6.7 Driving 23
6.7.1 Drive speeds 23
6.7.2 Adjustment of driving and electrical
brake 24
1
6.8 Steering 25
6.9 Triggering of the pump unit 27
6.10 Proportional controllers 28

6.10.1 Temperature compensation: 30
6.11 Functional relations 31

6.11.1 Driving 31
6.11.2 Manual steering 32
6.11.3 Lifting/Lowering of the main lift 32
6.11.4 Lifting / Lowering auxiliary lift 33
6.11.5 Side shift Right / Left 33
6.11.6 Swivelling Left / Right 34
6.11.7 Automatic synchronous
swivelling/sideshift Right/Left 34
6.12 Aisle recognition 35

6.12.1 Aisle recognition by Means of
Magnetic Switches 35
6.12.2 Aisle Recogniation via WG Wire
(Inductive Laying without Aisle
Recognition (IFoG)) 35
6.13 The service menu 36
6.14 Release of Options via Code

Numbers 36
6.15 End of aisle safety device

(Option) 37
6.16 Function Description 37

6.16.1 GESI with Manual Reset 37
6.16.2 GESI with Braking to Slow Speed
(Option) 37
6.16.3 GESI with Automatic Reset (Option) 38
6.17 Inductive guidance (WG) 38

6.17.1 Components 38
6.17.2 Tasks of the WG 39
6.17.3 Safety Supervision Functions of the WG 40
6.17.4 Starting and Setting of the WG 40
6.17.5 Safety concept 47
6.17.6 Monitoring the wire signal 49
2
6.17.7 Monitoring of the Steering Angle 49

6.17.8 Monitoring of the Actual Driving Speed 49
6.17.9 High speed release 49
6.17.10 Overview of Emergency Stop Criteria 49
6.17.11 Diagnosis 50
6.18 Interface for the Connection

of a Personnel Protection System
(PSA) 50
6.19 Automatic swivelling / side shift

synchronization 52
6.19.1 Geometric setting 52
6.19.2 Hydraulic Setting 55
6.20 Battery discharge monitor 56
6.21 Hour meters 57
6.22 Cut-outs 57
6.22.1 Lifting cut-outs and lowering cut-outs
(optional) 57
6.22.2 Side shift cut-out
(second stacking depth) 58
6.22.3 Drive cut-outs 58
6.23 Software administration 59


materials.
3
4
6.0 Block diagram of the control concept
5
6.1 CAN-bus description

6.2 CAN-bus- features
CAN = Controller Area Network (e.g. motor vehicles, machine
tools)
LAN = Local Area Network (e.g. stacker crane installations,
chemical industry)
WAN = Wide Area Network (e.g. telephone networks)
- serial bus system
- carrying media: twisted twin wiring
- important bus functions like data generating, synchronisa-
tion, error detection are implemented by means of the
hardware
- multi master capable, i.e. all VZ are equipped with equal
rights
- standard network distance: up to 40 m
- possible extention of the network up to approx. 1500 m at
reduced data transfer rates
- maximum data transfer rate: 1Mbit / s at a distance of 40 m
- high transfer safety
The CAN-bus has gained acceptance in many industrial uses in
between.
Especially motor vehicles, industrial vehicles, agricultural
machines, devices in medical technology, machines for the tex-
tile industry and smaller industrial systems are equipped with
CAN-bus-control systems.
All the involved control units are integrated into the bus system
in the same way ( physical coupling conform to ISO 11898):
Microcontroller
CAN Controller
TX0 TX1 RX1
5V
TxD RxD Ref V

CC
CAN Transceiver 100 nF
CAN_L Gnd
CAN_H
CAN_H
RT CAN bus network RT

CAN_L
termination resistance termination resistance
6
6.3 Components of the control

systems
6.3.1 General information concerning the
components
The entire control system consists of the four processing units
- VZA (drive compartment processing unit)
- VZK (cabin processing unit)
- UDR (right control panel processing unit)
- UDL (left control panel processing unit)
The design of the processing units and the individual compo-
nents is described on the following pages.
+ Layout and high sensitivity fuses of the boards of VZA and

VZK see chapter 9.
6.3.2 Drive compartment processing unit (VZA)

Tasks of the VZA
- connection and processing of all information arriving in the
drive compartment
- connection and control of all actuators located in the drive
compartment
- serial interchange of data with the computers in the cabin
via CAN bus
- connection of extension modules
- safety functions in accordance with the safety concept
7
6.3.3 Design of the VZA
Pos Description
1 Motherboard VZA collects and distributes the input and output signals
2 Computer plug-in card (SK-R); SMD-board contains the micro controller, the CAN-
bus connector modules and the EPROM-board
3 I/O-Plug-in card (SK_EA); SMD-board contains the processing unit for the analog or
digital inputs and the drivers for the analogous and digital outputs
4 Plug-in card VZA (SK-VZA); SMD-board contains the electronic system for the spe-
cial control processes in the drive compartment, e.g. steering system control, safety
circuit for driving, interface to the personnel protection system B.
5 Bus board VZA signal processing for the VZA-SMD-boards
6 Control circuit board for the load wheel brakes
7 Safety module (SIMO) contains the two safety relais SF 1 and SF 2 (see safety con-
cept)
8 Circuit board control fuses
9 DC - DC converter
8
+ The aluminium EMC-hood which covers the VZA-boards is

taken apart in the illustration.
Always substitute the complete EPROM-board, do not handle

EPROM separately.
+ Notes regarding assembly / disassembly of the VZA

- always pull out the battery plug before performing assem-
bly work on the VZA.
- always install plug-in boards in the correct position.
- the EMC hood must always be installed.
6.3.4 Cabin processing unit (VZK)

Tasks of the VZK
- Connection and processing of all information arriving in the
cabin
- Connection and control of all actuators located in the cabin
- Serial interchange of data with the computers in the VZA
and VZB via CAN bus
- Connection of extension modules
- Safety functions in accordance with the safety concept
9
Design of the VZK
Pos Description
10 VZK motherboard (blue colour); collects and distributes the incoming and outgoing
signals
11 Computer plug-in card (SK-R); SMD-board contains micro controllers and the
CAN-bus connector modules
12 I/O plug-in board (SK_EA); SMD-board includes the signal processing unit for the
analogous and digital inputs and the drivers for the analogous and digital outputs
13 VZK bus board: signal processing for the VZK-SMD-boards
14 EPROM-board includes the plugged in EPROM for the VZK
10
+ The aluminium EMC-hood which covers the VZK-boards is

taken apart in the illustration.
Always substitute the complete unit, do not handle the

EPROMs separately.
+ The electronic components are mounted on an aluminium

baseplate; the plug-in boards are protected by a aluminium
EMC-hood.
+ Notes regarding assembly / disassembly of the VZK

- always pull out the battery plug before performing assem-
bly work on the VZK.
- always install plug-in boards at the correct location.
- the EMC hood must always be installed.
6.3.5 Control panel processing unit
+ On each control panel (UDR, UDL), one processing unit is inte-

grated.
+ The functions of the control panels are described in the operat-

ing instructions.
Main board UDR
The main board is installed in the right side of the control panel.
Tasks of the main board UDR:
- evaluation of all UDR-control elements
- data storage: all truck parameters are kept in NV-RAM
- serial interchange of data with the computers in the cabin
and the drive compartment via CAN bus
- serial interchange of data with the service APE (optional)
via CAN bus.
- serial interchange of data with the left control panel (UDL)
via RS232
- communication to RS232-interface for external devices
Main board UDL
The main board UDL is istalled in the left side of the control
panel.
Tasks of the main board UDL:
- evaluation of all UDL-control elements
- serial interchange of data with the right control panel
(UDR) via RS232
11
6.4 Design of the Right Control Panel (UDR)
Pos Description Pos Description

19 Key for two-handed operation 27 Testspot Ground
20 Master switch 28 Connection to key for two-handed op.
21 2-keys board 29 Connection RS232
22 LED-Board 30 Connection Service-APE
23 Main board UDR 31 Connection UDL
24 Flash-PROM 32 Connection VZK
25 NV-RAM 33 Connection 2-keys board
26 Connector between main board 34 Connection master switch
UDR and LED board
12
Removal of the UDR
For removal, proceed as follows

- switch off truck
- disconnect cable connections from control panel
- unscrew 4 fixing screws of the control panel from the con-
trol panel support
- remove control panel and place onto clean surface as
shown in the figure.
- loosen 5 allen screws (1)
- loosen allen screw (2) at the master switch
- open bottom of the control panel to the left
Removal of the 2-keys board
- remove wire connector (3)

- turn plastic screws (4) by 90° and remove board
Removal of the UDR main board
The UDR main board is connected with the LED board below by
means of the plug connector (1).
- remove plug connector of the 2-keys board (2)
- remove plug connector VKZ (3)
- remove plug connector UDL (4)
- remove plug connector APE (5)
- remove plug connector RS232 (6)
- remove plug connector of key for two-handed operation (7)
- remove 6 lock screws with washers
- remove board
Do not handle EPROM separately!
13
Removal of the LED Board
- loosen lock pins and screws

- remove board
Design of the LED Board
The LED board is equipped with various control elements (key

switches) as well as LEDs (1) and a two line display (2).
All operating elements for the key switches can be removed.
The display is not designed for removal.
14
6.5 Design of the left control panel

(UDL)
Pos Description Pos Description

1 Key for two-handed operation 7 Ground connection test spot
2 Master switch 8 Connector steering channel B
3 2-keys board 9 Connector steering channel A
4 Main board UDL 10 Key switch horn
5 Connection RS232 11 EPROM
6 Test pads 12 Emergency switch
15
Bottom cover of UDL
Pos Description
13 Key for two-handed operation
14 Steering wheel unit
Removal of UDL
For removal, proceed as follows

- switch off truck
- disconnect wiring to control panel
- unscrew 4 locking screws of the control panel from the
panel support mechanism
- place the control panel onto a clean surface
- push out the steering wheel cap (15) with a screwdriver
- unscrew the steering wheel
- pull off the steering wheel
- turn the panel round and place it onto a clean surface

- remove 5 allen screws (1)
- open bottom cover of the control panel towards the right
side
Removal of the 2-keys board

- see removal of UDR
16
Removal of UDL main board
- remove plug connector of master switch (3)

- remove plug connector RS232 (3)
- remove plug connector of 2-keys board (4)
- remove plug connectors (5, 6) of steering unit
- remove wire connections key switch of horn (7)
- remove plug connector of key for two-handed operation (8)
- remove 4 screws with washers
- remove board
Do not handle EPROM separately!
17
6.6 Braking System

6.6.1 Safety circuit brakes
load wheel
brake
emergency
magnetic brake system
load wheel
brake
operating
system
emergency stop 1
emergency stop 2
return signal 1
return signal 2 emerg. 1
emerg. 2
release
end of aisle safety
emergency stop
contacts
safety relay
feedbacks
to VZA
optional
releases and
external
feedbacks components
not capable
of communication
emergency stop 1
emergency stop 2
return signal 1
return signal 2 Safety key pedal
feedback
to VZK
18
6.6.2 Description of the braking systems

Available braking systems:
- spring pressure brake system, actuated via safety circuit
- load wheel brake system A, actuated via truck control sys-
tem (general service)
- load wheel brake system B, actuated via hardware-safety
circuit (emergency stop service)
- counter current brake, actuated via truck control system
SECAN and the AC motor controller
- automatic counter current brake system (end of aisle brak-
ing system)
- coasting brake system, actuated via truck control system
SECAN and the AC motor controller
6.6.3 Spring pressure brake

The braking is carried out via a mechanical braking system, that
is activated via spring pressure and released electrically.
To release the brake, there is a safety circuit installed, that can
be intervened by hard- and software side (see illustration) On
the SIMO, there are two safety relais, whose contacts control the
coil of the magnetic brake.
There are two different mechanisms for triggering the spring
pressure brake:
- Components that are integrated into the trucks steering
system and thus into the communication system (e.g.: VZ)
do not act directly on the braking circuit by means of their
release contacts, but instead switch the SF safety relays.
Monitoring of the correct switching function is effected by
means of feedback contacts of the relays.
- Components that are not integrated into the communica-
tion system (deadman foot switch, personnel protection
systems) directly act on the braking circuit by means of
their release contacts. Also in this case, via signal return
line, it can be checked, if a braking has been actuated or
not.
The mechanical braking system serves as an emergency brak-
ing, as well as a stopping brake and is activated always, if one
component, that is integrated into the safety circuit, releases an
emergency stop.
19
6.6.4 Load wheel braking system

In addition to the spring pressure brake system, WG trucks are
equipped with an electrical load wheel braking system.
The system consists of the following components:
- multiple plate brake in both load wheels (description see
chapter 4)
- electrical control unit in the drive compartment, includes
control relay and the opwer relay for both loead wheel
brakes.
The load wheel brake is designed as an emergency brake. It is

not designed for permament use as an operating brake.
+ The load wheel brake is released when the truck is switched

off.
Actuation of the Load Wheel Brake
The brake is actuated via an actuation unit. In case of actuation

according to performance, both performance relays K1a (1) and
K1b (2) are actuated. The brake is connected with
U_Batt_Permanent vai the contacts of these relays.
The performance relays con be actuated in three different situa-
tions:
a) Actuation in General Service
In the case of actuation in general service, the software actuates
the actuation relay (k10) via an output. This relay actuates the
performance relays which apply the brakes. The braking proc-
ess lasts until the truck has come to a standstill. As soon as
standstill exists, the actuation process is finished.
Actuation in general service occurs in case of
- braking by means of the key switch pedal
- braking due to opening the barrier during driving
+ In this case, the stop functions of the truck are carried out
exclusively by means of the spring pressure brake on the drive
motor.
b) Emergency Stop Actuation
In the case of an emergency stop, it is possible that the actua-
tion of the braking process in general service is not guaranteed,
so that the bakre must be applied principally via a separate hard-
ware actuation path.(watchdolg circuit). The acutationg relays
K11 and K14 will then always change their switching status and
will thus actuate the performance relays K1a and K1b of the
actuation unit.
Emergency stop actuation will occur
- in the case of errors of the „emergency stop“ type (see
chapter „system messages“)
- errors in the SECAN control system
20
The braking action will last until the emergency stop case ends.
If the truck is left in the emergency stop status. the power supply
to the load wheel brake will continue which will cause an
increased power consumption and, during longer periods, a total
discharge of the battery.
For this reason, the following things must be done before leaving
the truck:
- remove key.
c) EMERGENCY SWITCH Actuation
If one of the EMERGENCY SWITCHES is actuated, all electrical
control devices are disconnected from the battery so that an
actuation of the brake of according to the aforesaid principle is
not longer possible.
In this case, a relay (K12) buffered by the capacitor C1 will actu-
ate the performance relays K1a, K1b for approximately five
seconds. The load wheel brake will thus be activated. This
guarantees braking also in EMERGENCY situations.
This kind of braking avoids the permanent actuation of the brake
via
U_Batt_Permanent when the truck is switched off.
Setting of the load wheel brake
The braking efficiency of the load wheel brake is set via the
bridge plugs X6j (1), X38j (2) and X39j (3) on the actuation unit
according to the individual truck.
The setting of the load wheel brake is generally done by the

manufacturer. The configuration of the bridge plugs on the
actuation unit must not be changed by the service personnel.
In case of replacement of the complete board, the bridge plugs
must again be configurated as stated in the approval records.
21
Test of Correct Actuation of the Load Wheel Brake

Evidence of the correct actuation of the load wheel brake is pos-
sible by measuring the voltage at the pug connector X40 (4) on
the actuation board between pin 1 and pin 3.
Actuation will occur when a voltage of 48V is applied.
a) test of actuation in general service
- drive truck slowly
- release key pedal
The load wheel brake system must be actuated.
b) test of the EMERGENCY actuation
- press key switch EMERGENCY STOP at the rear of the
truck
- watch relays K1a and K1b during this process.
The relays must be activated and then remain in this condition
for approx. 5 seconds.
- During this period, the voltage test can be carried out as
described above.
Testing of the Brake Action of the Load Wheel Brake System
- deactivate spring pressure braking system
- test load wheel braking system for correct function and
actuation (see above)
In the case of no or improper actuation of the load wheel brake
- visual inspection of the actuation unit, replacement if nec-
essary.
- inspection of the wire connections of the actuation unit
In case of proper actuation but no or improper function
- inspection of the wire connections from actuation unit to
load wheel brake
- inspection of the load wheel brake for wear or defects in
the magnetic component (see chapter 4 mechanical sys-
tem)
Maintenance
The actuation unit is maintenance-free. See chapter 4 „mechan-
ical system“ as well as the operating instructions for information
about the maintenance of the load wheel brake.
22
6.6.5 Electrical braking system

All the trucks are equipped with an electrical braking system
(regenerative), that can be adjusted in its braking efficiency via
service menu. The following braking states are differentiated:
- coasting brake, when the driver releases the master
switch; (adjustable)
- reduce brake, when the driver leads the master switch
slowly back, to get to a slower speed or when the truck is
automatically switched from normal speed to slow speed,
e.g. with optispeed (adjustable).
- manual counter current brake, when the driver moves the
master switch in reverse direction. The braking efficiency
is increased linear with the deflection. The limit values are
adjustable in the service menu.
- automatical counter current brake, effective while end of
aisle braking
+ For smooth transitions of the brake phases

- set coasting brake and reduce brake to the same value
- set also the min-value of the counter current brake to this
value
The regulations for the braking distance to be adjusted, always
refer to a maximum activated counter current brake.
6.6.6 General emergency stop

General emergency stop is a status, where the truck control sys-
tem switches all functions into a secure status. No truck-move-
ment is possible. The cause for this emergency stop can have
several reasons:
- a serious problem was detected by the control system;
Error message, that is assigned to the category emer-
gency stop (see error table).
In this case, the safety braking circuit is opened from hardware-
side
- chains are slack or broken (release of emergency stop by
truck control system)
- safety barriers are opend (release of emergency stop by
truck control system)
- external component has released emergency stop
- other cause (trucks with special components)
6.6.7 Functional emergency stop

This kind of emergency stop disables only the function con-
cerned; all the other functions can be used normal or in slow
speed. The cause for a funcional emergency stop is always a
function-related failure in the control system. (see error table).
The emergency stop is released by the truck control system.
23
6.7 Driving
The driving function is carried out via a speed-controlled asyn-
chronous motor and a voltage system converter control.
The release signal of the driving function is carried out as a zero-
switching signal from the SECAN-control and is switched, when:
- no emergency stop from the computer system active
- the foot switch is pressed
- no drive cut-out is active (e.g. lifting height related drive
cut-out).
The driving directions are released by the SECAN-control sys-
tem as a zero switching signal to the voltage system converter
control.
The set point from the SECAN is implemented as an analog sig-
nal 0...10V ausgeführt.
The revolution return of the drive motor to the voltage system
converter control is carried out by a sensor bearing with 64
pulses/R.
The incremental transmitter for the SECAN-control is directly
driven from the motor shaft.
An occuring failure in the voltage system converter control is
reported to the SECAN control via error reporting code interface.
From there, the error code can be called via a tag. Additionally,
directly on the voltage system converter control occuring failures
are displayed on a blinking LED.
6.7.1 Drive speeds

There are 4 drive speeds adjustable:
- slow speed 2,5 km/h with predefined control
- increased slow speed 4,0 km/h with predefined control
- maximum speed in the apron with adjustable control
- maximum speed in guided operation with adjustable con-
trol
The release signal of the speeds depends on the respective
truck states. see function table.
If the speed control is activated, the release signal of the drive
movement is reduced, until the permitted speed is below the
allowed speed.
24
6.7.2 Adjustment of driving and electrical brake

The adjustments can be done in the menu „Driving“
As the trucks are speed-controlled, it is only necessary to edit
the speed in km/h for the desired parameter. The truck itself con-
trols onto this speed, independend from load or temperature.
+ As all the speeds are controlled, it is recommended to set the

speed slightly below the control-speed. Otherwise „pump
movements“ can occur when the permitted speed is reached.
Examples:
slow speed: 2,5 km/h
control-speed: 2,5 km/h (fix)
adjustment of parameter: 2,4 km/h
maximum speed: 9,5 km/h

control-speed: 9,8 km/h (adjustable)
adjustment of parameter: 9,5 km/h
The starting acceleration can also be adjusted. This should be
done at the customer according to local conditions and the driv-
ers’ wishes.
The permitted values of the electrical brake are written down in
the test protocol.
For reasons of stability, the braking efficiency must not be

adjusted higher than permitted. The adjusted deceleracion has
to be proofed and documented by the use of a deceleration
gauge or the Datascope.
25
6.8 Steering
The steering system is a purely electrical system.
It consists of a steering controller with a speed controller for an
asynchronous motor.
steering truck control system 3~

wheel AC motor
(SECAN) controller motor
set value of
steering angle
incr. transmitter
IF
steering angle-detection
potentiometer
The steering controller can either operate on a manual set value

(turning the steering wheel) or a set value from a connected
guidance system (e.g. wire guidance)
As set value transmitter (steering wheel) two sensor bearings
with 64 upr is used.
The set value from the control panel is processed by the
SECAN-control system and is sent to the control system for the
asynchronous motor via CAN-Bus.
For the detection of the steering angle two different sensors are
used:
- high resolution incremental transmitter (channel A, B (90°
shift to A), that is evaluated by the motor control for the
rpm control as well as by the truck control system for the
steering angle control. This incremental transmitter is
located directly on the shaft of the steering motor.
- multi-gang potentiometer, that is used by the truck control
system only for calibration and redundancy purposes.
After switching on the truck an automatic initiation is carried out
by the steering system to determin the exact center position. As
a reference point for the center position the index pulse of the
incremental transmitter is used. As many index pulses are sent
in the permitted steering range, the potentiometer detects the
correct index pulse.
26
As it is hardly possible, to calibrate the index pulse (electrical

center position) exactly on the mechaincal center position, the
electrical center position can be adjusted in the service menu.
This is carried out in the unit „digit“, that means pulses from
channel A (see illustration).
Example:
- 3 digits
channel A
channel B
index
(el. center)
mech. center
corrected
el. center
In the example, the index and the exact mechanical center posi-
tion do not agree. in the menu item steering correction, the value
„-3 digit“ can be entered, to adjust the center position for the
truck control system.
Via service menu the steering wheel transmission is adjustable
to the requirements of the customer.
Adjustment of the steering
In the service menu, the control parameters for the different
steering states are adjustable.
The steering control parameters for the special operating states
(initiation, manual steering, WG-steering) far-reaching identically
on electrically rpm-controlled steering systems beim.
The standard control parameters, adjusted ex works, generally

must not be changed.
27
Interface for the Steering AC-controller

The release signal of the steering function is sent from the
SECAN control to the Steering AC-controller via CAN-Bus:
- no emergency stop from the control system
- driving release signal activated or truck is rolling
The set value from the SECAN is also sent to the Steering AC-
controller via CAN-Bus.
An occuring fault in the AC-controller is reported to the SECAN
control via an error code interface. From there, the error can be
called via a analog tag. In addition, errors that occur directly on
the AC-controller are indicated by LED (see also chapter 15).
6.9 Triggering of the pump unit

The pump unit is designed as a speed-controlled three-phase
current asynchronous motor, like the drive motor and steering
motor.
The advantage of the speed control is, that with a certain set
value, there is a exactly defined amount of oil is assured.
The number of revolution signal for the motor is generated in the
SECAN-control. There are functions, that are triggered by a con-
stant number of revolutions, where the speed of the function can
be controlled via proportional hydraulics by the driver. In addi-
tion, there are functions, that are used with variable number of
revolutions, that means, the driver controls the speed of the
functions via number of revolutions of the motor. Then the
according hydraulic circuits are opened completely.
Interface for the voltage system converter control
The release signal of the pump is sent from the SECAN control
to the Pump AC-controller via CAN-Bus when:
- no emergency stop from the control system:
- no cut-out active (e.g. main lift cut-out)
The set value from the SECAN control is also transmitted via
CAN bus.
The feedback for the number of revolutions of the pump unit to
the voltage system converter control is done by a sensor bearing
with 64 pulses per revolution.
An occuring fault in the Pump AC-controller is reported to the
SECAN via CAN-Bus. The error can be called via a analog tag
(see chapter 15). In addition, errors that occur directly on the
Pump AC-controller are indicated by a flashing LED.
While lowering the main lift the pump aggregate works as a gen-
erator and returns energy into the battery.
The power of the feedback current depends on the applied load
and the set descending speed.
28
6.10 Proportional controllers

All the hydraulic movements are triggered either via number of
revolutions of the pump or via proportional valves. The corre-
sponding valves are integrated into the hydraulic blocks.
Function principle:
A proportional valve creates a hydraulical output signal in pro-
portion to an electrical input signal. On the machine, flow valves
are used, that means, the hydraulic output signal is a variable
volume-flow.
A current, running through a magnet coil, creates a magnetic
force in the valve, that moves the internal slide proportionally to
the current and lets an according oil flow pass.
The control- and power electronic (amplifier) of the flow valves is
completely integrated into the SECAN-control system. The
required variable current for the proportional function is created
via pulse width modulation (PWM), that means by a flow of
pulses with different ON / OFF ratio at constant frequency (see
illustration).
high signal level low signal level
average
average
time time
The signal level can be determined via change of the scan ratio.
The frequency of the pulses, that is several kHz, is that high, that
the coil cannot follow each and every pulse and the magnet
forms an average value of the signal pulses. The width of the
ON-pulses in relation to the width of the OFF-pulses determines
the average value and thus the signal level.
The voltage pulses are converted into suitable signals for the
flow valves by the power electronics.
It is assured, that temperature changes of the coil, and thus
resistance changes, as well as fluctuations in the supply voltage
have no effect on the control current.
29
Also friction forces, that can cause hysteresis are avoided by a

socalled dithersignal, a AC signal that is superimposed onto
the control signal. The adjusted dither frequency is ca. 50 Hz,
the dither amplitude ca. 50% of the control signal.
General informations for the adjustment of the proportional
valves:
The normal, usable range of the proportional valves is ca.
between 150 mA and 550 mA, that means with a activating cur-
rent of 150 mA the valve begins to open, with a activating cur-
rent of 550 mA, it is fully opened. As all the different hydraulic
functions have different activating ranges, but are actuated by
the same valve or control lever, for each function a special cur-
rent range can be defined, within the activating takes place.
In this way for all functions the full angle ranges of the operation
lever is provided:
valve opening illustration actuation

in % in % of lever
in %
grey:
adjustable values
example see text
current I /mA
The activating range (Imin and Imax) can be adjusted in the

hydraulic menu for each single function separately. As a stand-
ard, suitable values are already pre-adjusted (see also table with
basic settings), that should only be changed in emergency
cases! The final adjustment of the speed (e.g. lowering speed)
is done in the hydraulic menu in % of the total range.
30
Example for lowering auxiliary lift:

minimum current value: 250 mA
maximum current value: 450 mA
To reach the desired lowering speed of 0,3 m/s for example, in
the menu item v_max_ lowering" the %-value of the scale can be
adjusted. If the value 75% is adjusted, this means: When the
operating lever is fully actuated, the proportional valve is actu-
ated with 75% of the provided range, that is in our example 400
mA!
With this kind of activating for each movement an optimum dos-
age can be reached.
6.10.1 Temperature compensation:

As the control electronics (PWM-analog outputs) has a tempera-
ture depending drift, a temperature compensation is carried out
by software.
Over the total actuation range there is a nearly linear increase of
the current with the temperature.
To compensate this effect, a linear compensation was intro-
duced. This is defined by a temperature zero, which is normally
the working temperature of the controlling electronics and a cor-
rection value (increase of current in percent). Both values are
adjusted in the service menu.
The predefined values generally may not be changed, as the
functionality of the hydraulic functions can be getting signifi-
cantly worse.
31
6.11 Functional relations

6.11.1 Driving
General constraints for function release:
- doors closed
- footswitch actuated
- chains not slack
- direction signal actuated
- set value present
- release of safety circuit of brake
Function Condition
driving apron full speed h3 + h9 < 0,5 m and steering angle
< ±10°
drivin apron 4,0 km/h 0,5 m ≤ h3 + h9 ≤ 3,0 m and steer-
ing angle < ±10°
driving apron 2,5 km/h 3,0 m < h3 + h9 ≤ hcrit (*) or h3 + h9
> hcrit* and steering angle < ±10°
guided driving full two-hand operation and h3 < h3crit
speed forward forward
guided driving full two-hand operation and h3 < h3crit
speed backward backward
guided driving 2,5 km/h two-hand operation and h3 > h3crit
forward forward
guided driving 2,5 km/h two-hand operation and h3 > h3crit
backward backward
(*) hcrit is the critical lifting height for the apron. It is pre-adjusted
truck-specific and is documented in the test protocol of the
truck.
h3crit forward / backward are the critical lifting heights for the
guided operation of the truck (depending on the driving direc-
tion).
32
6.11.2 Manual steering

constraints for function release:
- truck on the apron
- WG-mode selected, truck not engaged with the wire
- two-hand operation actuated
- speed ≠ 0
6.11.3 Lifting/Lowering of the main lift

general constraints for function release:
- doors closed
- chains not slack
- two-hand operation
- set value actuated
Function Condition
release lifting full h3 < end ahead top load lifting device in
speed startup position initiation of main lift com-
pleted
release lifting h3 > end ahead top or load lifting device
slow speed not in startup position fault in the lifting
system
release lowering h3 > end ahead bottom or load lifting
full speed device in startup position initiation not
finished or 0,3 m-switch not actuated
(although main lift above 0,3 m)
release lowering h3 < end ahead bottom or load lifting
slow speed device not in startup position
33
6.11.4 Lifting / Lowering auxiliary lift

- doors closed
- chains not slack
Function Condition
release lifting full h9 < end ahead top
speed load lifting device in startup position
release lifting slow h9 > end ahead top
speed load lifting device not in startup position
release lowering h3 > end ahead bottom or
full speed load lifting device in startup position
release lowering h3 < end ahead bottom
slow speed load lifting device not in startup position
6.11.5 Side shift Right / Left

- doors closed
- chains not slack
• Note: In the end position of the selected direction, the move-
ment is stopped.
Function Condition
release side shift The position of the side shift is not in the
full speed end ahead-range of selected direction.
release side shift The position of the side shift is in the
slow speed end ahead-range of selected direction.
34
6.11.6 Swivelling Left / Right

- doors closed
- chains not slack
• Note: In the end position of the selected direction, the move-
ment is stopped
.
Function Condition
release swivelling full The swivel position is not in the end
speed ahead-range of selected direction.
release swivelling The swivel position is in the end
slow speed ahead-range of selected direction.
6.11.7 Automatic synchronous swivelling/

sideshift Right/Left
- doors closed
- chains not slack
The synchronous movement is a controlled automatic proce-
dure. In case of a detected collision, the swivelling movement
stops and the pallet is returned into the truck contour by the side
shift movement.
35
6.12 Aisle recognition

6.12.1 Aisle recognition by Means of Magnetic
Switches
For the narrow aisle recognition, the truck can be equipped with
locking magnetic switches which are activated by magnets in the
aisle. A pair of magnetic switches is installed on both sides of
the truck at equal distances to the center of the aisle. For a cor-
rect actuation, both switches must be operated (two channel
actuation). With single channel actuation (defective switch or
improper passing of the magnet), an error message will be dis-
played.
Laying of the Ground Magnets see specification BT
6.12.2 Aisle Recogniation via WG Wire (Inductive

Laying without Aisle Recognition (IFoG))
With inductively guided trucks, the default aisle recognition proc-
ess is carried out by means of the proper threading on the WG
wire
The following points are to be observed:
- in case of release of code 22 (service menu options), the
IFoG is activated.
- for WG release, code 01 (service menu options) must be
released additionally.
+ If only code 01 has been released, the device is operated in

conventional way, i.e. with separate aisle recognition (WG with
aisle recognition, WGmG).
- After successful threading on the wire, the memory device
M212 is set onto „1“ (truck in aisle). All functions which are
only allowed in the aisle (e.g. diagonal drive) are again
released.
See operating instructions, chapter E, for additional safety

information about WG without aisle recognition.
36
6.13 The service menu

All setting of parameters, operating hours, options and a com-
prehensive error diagnosis with reference to function are only
possible by means of the service menu. Access to the service
menu is obtained via the display and programming unit after
entering a four-digit access code.
+ The Service menu is only available on the Display and Pro-

gramming Unit (APE). Use of the APE as well as access to the
service menu are described in chapter 9. See chapter 11 for the
structure of the service menu.
6.14 Release of Options via Code Num-

bers
In the truck, various options have already been integrated in the
software which can be activated by entering a truck-specific
code number in the service menu „M21 Options“ .
+ See chapter 11 for deposited options.

Release of the options is done according to the following proce-
dure:
- select the desired code in the service menu „M21
Options“.
- enter five-digit code number by menas of UP / DOWN
keys and confirm with ENTER:
If a wrong code number is entered, all functions are blocked.
The device must be switched off and then switched on again if
work is to be continued.
+ The code numbers for options activated by manufacturer are

quoted in the approval records.
For options which are to be included subsequently, the corre-
sponding code number must be requested from the manufac-
turer of the truck. This number must then be included into the
approval records after activation.
37
6.15 End of aisle safety device (GESI)

(Option)
The GESI system is largely integrated into the SECAN concept,
that is, no external control components need to be integrated. As
standard, the trigger system consists of 4 solenoid switches,
each with two active switches for each travel direction.
All further GESI-specific informations are taken from the sensor
system of the truck. In the standard version, the counter-current
brake is activated when the GESI system has been triggered.
The second braking circuit (magnetic brake) is automatically
switched on if defects have been detected in the counter-current
brake system. Simultaneously, a corresponding system mes-
sage appears. Triggering of the brake system and monitoring is
carried out via two channels.
The current state of the GESI system is indicated on the contol
panel display (see operating instructions).
6.16 Function Description

6.16.1 GESI with Manual Reset
The truck is automatically braked down to a standstill from the
current speed when it reaches the end of an aisle. Travel cannot
be continued until a manual reset has been activated. Standard
version.
After the braking procedure has ended, the operator must
acknowledge the GESI function before the normal driving func-
tion is released again. A button is provided for this purpose on
the control panel.
6.16.2 GESI with Auto-Reset
a) Braking to Slow Speed (Option)

Technical implementation as under standard except:
- braking not down to a standstill, but to slow speed
- fast driving cannot be continued until a reset has been
activated
- reset requirements:
1. leaving an aisle
2. driving in reverse direction over the GESI magnet towards
the aisle.
+ Further option: braking to stand still, then slow speed with

automatic reset.
38
b) GESI with Automatic Reset (Option)

The truck is automatically braked down to a standstill, then con-
tinues travelling at slow speed until GESI-reset is peformed.
Full speed is released, when the danger zone between GESI
magnet and aisle exit magnet (aisle recognition) has been left.
Between GESI magnet and aisle exit magnet, only slow speed is
allowed. In reverse direction full speed is released.
Reset conditions are:
- driving over the aisle exit magnet
- driving in reverse direction over the GESI magnet towards
the aisle.
+ On WG- trucks without aisle recognition and on trucks with

light optical aisle recognition only GESI with manual reset is
available.
The following GESI error states that occur are detected and dis-
played on the control panel display:
- failure of one or both triggering channels
- offset between the two triggering channels is too large
- braking is insufficient
- travelling speed is too high
- error in the control electronics or in the sensor equipment.
6.17 Inductive guidance (WG)

6.17.1 Components
Sensor System
- Front microsteering sensor (MSS): Mounted in front of the
load-bearing wheel axle, inductively determining the dis-
tance to the WG guide wire which is under an AC current.
The distance signal is transferred serially to the SECAN
control system.
- Rear microsteering sensor (MSS): Mounted behind the
drive wheel, inductively determining the distance to the
WG guide wire which is under an AC current. The distance
signal is transferred serially to the SECAN control system.
- Incremental transmitter for driving: Registers the travelling
speed and direction as well as the distance travelled by
the drive wheel. It is a standard part of the SECAN control
system.
- Actual value sensors for steering: These register the angle
of the steered wheel; they are a standard part of the
SECAN control system.
- Set value transmitter for manual steering (set value sen-
sors for steering): Registers the movement of the steering
wheel on the control panel for manual steering; it is a
39
standard part of the SECAN control system.

Actuators
- Steering system: Adjusts the steering angle of the drive
wheel; it is designed as an electrical steering system as
standard.
- Mechanical brake: Permits braking of the truck to a stand-
still. It is activated in case of an emergency stop; together
with the claw, it prevents a collision of the truck with the
shelf. The spring-loaded brake is constructed so that it is
activated if the power supply fails or the wire breaks. It is
controlled and monitored using two channels.
SECAN truck control system
- Drive compartment processing unit (VZA): The WG sen-
sors (except the set value sensors for steering) are ana-
lyzed here, as is the actuator activation. In addition, the
algorithms of the WG track control are calculated.
- Cabin processing unit (VZK): The menu functions for set-
ting parameters and configuring the WG-S are pro-
grammed here.
- control panel processing unit (UDR, UDL): The operating
and display elements for the WG-S are integrated here. In
addition, the set value transmitter for steering is analysed
here.
6.17.2 Tasks of the WG

The WG-S coordinates the steering in the WG device according
to the operating mode selected by the driver:
- in manual operation, the steering angle is always manually
preset by the driver
- in WG operation, the steering angle is automatically preset
in such a manner that the truck is at first guided onto the
WG guide wire and then drives so that the distance and
angle of the long axis of the truck compared to the WG
guide wire is as small as possible.
+ Manual operation is only possible in the apron (exception:

emergency operation in an aisle).
Release of Fast Driving in the Aisle:
In WG operation with aisle recognition (IFmG), fast driving in
an aisle is only possible if the truck was successfully guided onto
the guide wire in the apron, an aisle signal is present and the
claw is activated.
In WG operation without aisle recognition (IFoG), fast driving
is possible if the truck was
successfully guided onto the guide wire and the claw is acti-
vated.
+ More detailed information regarding WG with aisle recognition

and WG without aisle recognition see operating manuals.
40
6.17.3 Safety Supervision Functions of the WG

The WG-SECAN supervises the following functions:
- aisle signal may only be displayed when the truck is
engaged onto the WG wire (only trucks with aisle recogni-
tion via magnet switch).
- skewing of the truck to the WG wire
- distance of the truck center to the WG wire
- maximum value for distance in combination with skewing
must not be exceeded
- dynamic adaptation of the valid maximum values for dis-
tance and skewing to the current driving speed.
- measurement of the valid distance of the WG sensors
- maximum actual value of steering angle < 1°
- the MSS must always deliver a valid distance measure-
ment
If these requirements are not fulfilled, the truck is brought to an
immediate emergency stop.
Monitoring of the remaining components of the SECAN system
(i.e., the steering system, the driving sensor system and the
steering incrementer) is part of the SECAN safety concept, as in
the SF device.
6.17.4 Starting and Setting of the WG
+ The setting of all parameters is done in the service menu.

Before starting and setting up, the correct code number must
be entered to release the WG function (service menu „M21
Options“).
Setting procedure:
1. Step: Basic setting of the micro steering sensors

Call up menu item „M15 WG“.
Make the following settings
:
Menu item meaning normal setting*

P100 Frequency* wire frequency 1 (5,2 kHz)
P101 Height height of the sensor 45 mm
above the ground
P102 Current current rating through 35 mA
the wire
P103 Threshold current threshold 20 mA
P104 Hysteresis current threshold hys- 5 mA
teresis
P105 Algorithm calculation algorithm 2
41
menu item meaning default

P106 Frequency* wire frequency 1 (5,2 kHz)
P107 Height sensing height of the 45 mm
sensor above the
ground
P108 Current current rating through 35 mA
the wire
P109 Threshold current threshold 20 mA
P110 Hysteresis current threshold hys- 5 mA
teresis
P111 Algorithm calculation algorithm 2
(* ) pay attention to the following remarks on the:

Frequencies: The following set frequencies can be configured:
- Code 1: 5,20 kHz
- Code 2: 5,20 kHz
- Code 3: 5,20 kHz
- Code 4: 5,20 kHz
- Code 5: 5,70 kHz
- Code 6: 6,25 kHz
- Code 7: 7,00 kHz
- Code 8: 10,00 kHz
Current: Measure and enter the precise frequency generator
current rating.
Height: Enter the distance between the lower edge of the sen-
sor and the ground + 5 mm.
Threshold: The minimum current rating at which the signal is
detected; must be set to 70% if the generator current value.
Hysteresis: Current threshold hysteresis in the transition range
(standard 5 mA)
Algorithm: 1 = current-compensated; 2 = height-compensated
(standard)
42
Step 2: basic settings of the WG- track controller

The WG-track-controller consists of the parameters: Gkp- and
Bkp Search, Gkp- and Bkp Apron and Gkp- and Bkp
Aisle.anged.
Menu Item Meaning

P 112 Gkp Threading Correction factor for the skewing of
the truck during the threading process
P113 Bkp Threading* Correction factor for the distance of
the truck to the WG wire during the
threading process
P114 GKP Apron Correction factor for the skewing of
the truck when the truck is threaded
on the WG wire but there is no aisle
signal (only WG trucks with aisle rec-
ognition via magnetic switch)
P115 Bkp Apron Correction factor for the distance of
the truck to the WG wire when the
truck is threaded on the wire but there
is no aisle signal (only WG trucks with
aisle recognition via magnetic switch)
P116 Gkp Aisle Correction factor for the skewing of
the truck to the WG wire during travel
in the aisle
P117 Bkp Aisle Correction factor for the distance of
the truck to the WG wire during travel
in the aisle
The basic settings of the parameters must not be changed. Rea-

son: The speed-controlled drive is very sensitive to changes. In
case of problems, please contact the service staff of the manu-
facturer.
Step 3: Basic setting of the WG correction
In menu „M15 Inductive guidance“, set the parameters
P 121 --> Correction for MLS deviation to „0“
P 122 --> Correction for axis deviation to „0“.
Step 4: Basic setting of the WG steering parameters
The basic settings of the parameters must not be changed. Rea-
son: the speed-controlled steering unit reacts very sensitively to
changes.
Step 5: Basic setting of the straight-ahead correction for the
steering system
In menu „M12 Steering“, set „P24 StraightAheadCorr“ to „0“
43
Step 6: Calibrating the micro steering sensors
+ The basic setting (configuration) of the MSS (step 1) must be

carried out before the calibration.
Calibrating the front MLS:

- Move the front MLS next to the guide wire (min. 200 mm).
The truck angle to the guide wire should be ca. 5°. Set the
drive wheel to the straight-ahead position using manual
steering.
+ The distance is depending on the current in the wire. The truck

must be positioned, so that the WG-sensor cannot recognize
the wire (LEDs for WG sensors do not light).
- call menu item "M15 Inductive guidance" - "MSS front“ -

„TI90 Calibration". Confirm with ENTER; text "Calibration
... End = ENTER“ is displayed.
- Drive the front MSS slowly with constant speed over the
wire. Angle ca. 5°. Stop, when the MSS is 200 - 300 mm
away from the wire.
- End the calibration procedure with „ENTER“.
44
Calibration of the rear MLS:

- Drive the rear MLS next to the wire (min. 200 mm). Turn
the drive wheel to 90° by manual steering.
+ The distance is depending on the current through the wire. The

truck must be positioned so, that the WG-sensor cannot detect
the wire (APE-screen doesn’t show the squares for wire detec-
tion).
- Call menu item "M15 Inductive guidance" - "MSS rear“ -

„TI91 Calibration". Confirm with „ENTER“; text "Calibration
... End = ENTER" is displayed.
- Now slowly move the rear MSS with constant speed over
the wire at an angle of 90°. Stop when the microsteering
sensor is 200-300 mm from the guide wire.
- Press ENTER to terminate calibration.
45
Step 7: Basic test of the functions (apron)

Check the correct distance measure for both sensors:
- call configuration „K13 Inductive guidance“
- Drive the truck along the wire, so that MA144 and MA145
show 50 mm.
- Check real distance from the center of the sensor to the
wire. The permitted deviation between real geometric dis-
tance and display value is 3 mm.
- or
- drive the truck parallel to the wire, so that MA144 and
MA145 show 10 mm.
- Check real distance from the center of the sensor to the
wire. The permitted deviation between real geometric dis-
tance and display value is 1 mm.
If these tolerances are not met, the sensors have to be re-cali-
brated.
Now it can be attempted to engage the truck onto the wire and to
drive it:
- Press the WG button and drive onto the wire; the truck
must engage on the wire. If the sensors have recognized
the wire, the corresponding LEDs on the control panel
must light up.
- In menu „M24 Status display“, call up configuration „K13
Inductive guidance“.
- MA142: Status of front MLS: 3 = valid distance measure-
ment
- MA143: Status of rear MLS: 3 = valid distance measure-
ment
- MA144: Distance of front MLS to the wire (in mm)
- MA145: Distance of rear MLS to the wire (in mm)
Check whether the displayed distances of the two MSS units
agrees with the actual distance.
If so, continue with step 8. If not, repeat the calibration!
46
Step 8: Automatic correction of the MLS displacement

- In menu “M12 steering“-“steering WG aisle“-“P17 amplifi-
cation“ must be set to 400
- Switch off the truck and switch it on again.
- Trucks with aisle recognition by magnet switches: with the
key-operated WG emergency operation switch depressed.
- Let the truck engage on the wire.
- Select menu item „M15 Inductive guidance“ - „TI93 TI MSS
deviation“.
- Confirm using ENTER; the line-cursor is flashing.
- Now drive the truck forward and backward (min. 15 m
each way) until the line-cursor stops flashing.
The steering movements occurring during the Teach-In belong
to the self-learning correction procedure!
- Trucks with aisle recognition by magnet switches: Open
the WG emergency operation switch.
- The control system has now automatically written a value
in parameter P121 in menu „WG“ - „Corr. deviation MSS“.
Step 9: Automatic correction of the straight-ahead position of the
steering correction system
- In menu „M12 steering“ - „steering WG aisle“ - P17 amplifi-
cation must be set to 400.
- Switch off the truck and switch it on again.
- Trucks with aisle recognition by magnet switches: with the
key-operated WG emergency operation switch depressed.
- Let the truck engage on the wire.
- Select menu item „M15 Inductive guidance“ - „TI92 TI
steering straight“.
- Confirm using ENTER; the line-cursor starts flashing.
- Now drive the truck forward and backward (min. 15 m
each way) until the line-cursor stops flashing.
The steering movements occurring during the Teach-In belong
to the self-learning correction procedure!
- Trucks with aisle recognition by magnet switches: Open
the WG emergency operation switch.
The control system has now automatically written a value in
menu „M12 Steering“ - „P24 StraightAhead Corr“.
47
Step 10: Test drive in an aisle or with the claw activated

- Switch on the truck
- in menu „M12 steering“ - „steering WG aisle“ - P17 amplifi-
cation must be re-set to the value in the test protocol
- The WG is now completely set up and can be driven in the
aisle and apron. To check the driving behaviour, call up
configuration K13 „Inductive guidance“ in the menu „M24
Satus display“:
MA147: Angle of the truck to the guide wire (in 1/10°)
MA148: Distance of the truck center from the guide wire (in mm)
MA149: Set value for steering (1/10°)
MA150: Actual value for steering (1/10°)
At full speed with an activated claw, the following values must be
attained:
max. angle (MA147): ±0.3° (equals display ±3)
max. distance (MA148):±20 mm (equals display ±20)
max. actual value for steering (MA150):±1° (equals display ±10)
These limit values apply to both, forward and reverse driving.
Normally, these limit values are significantly above the values
attained by the WG-S.
+ Special attention must be paid that parameter MA150 oscillates

around 0 (i.e. thecentre) while driving. If the oscillation is
around a non-zero value, either the straight ahead correction
or the center setting of the steering sensors (incremental
transmitter and potentiometer) is incorrect and must be reset
either manually, as described in chapter 7 (Sensors) or auto-
matically, using the WG correction described in step 9.
6.17.5 Safety concept

Emergency stop diamond
In an aisle (at IFmG), the position of the truck in regard to the
WG wire is monitored using an emergency stop diamond. The
following parameters are included in the diamond calculation:
- truck geometry
- reaction and dead times
- braking delay
- travelling speed
- starting conditions
48
For the WG-S a new emergency stop diamond procedure is

used.
- Each truck has a truck-specific emergency stop diamond,
based on its maximum angle and maximum distance from
the wire. The diamond is permanently programmed in the
truck-specific EPROM. This emergency stop diamond is
designed for a maximum truck speed of 8.0 km/h in an
aisle as standard. Optionally, the emergency stop diamond
can also be designed for higher maximum speeds (see
test records!).
- The emergency stop diamond works dynamically to guar-
antee that the availability of the truck is as high as possi-
ble: In travel at low speed, higher discrepancies are
allowed than in travel with high speed.
- Since the area of the emergency stop diamond decreases
with increasing travelling speed, different triggering bound-
aries are programmed for different speed ranges:
An emergency stop is triggered when
- a combination of skewing (angle between truck and wire)
and distance (lateral displacement) is not within the pro-
jected diamond borders.
- the truck exceeds the maximum permissible speed v_max.
Diamond 1: v < 2.5 km/h

Diamond 2:2.5 km/h < v < 5.0 km/h
Diamond 3: 5 km/h < v < 7.0 km/h
Diamond 4: 7.0 km/h < v < v_max
49
6.17.6 Monitoring the wire signal

Apron: In the apron, the maximum permitted deviation from the
wire approximately equals the range of the MSS. If an MSS
loses the wire signal (e.g. also if the engaging angle is too
large), the truck is stopped (no error, thus no emergency stop!).
After braking to a standstill and pressing the WG button, the
driver can continue driving in manual operation and retry moving
the truck onto the wire.
Aisle: If an MSS loses the wire signal in the aisle, an emergency
stop is triggered (with error E183 or E184).
6.17.7 Monitoring of the Steering Angle

The maximum set value of the steering angle which is transmit-
ted from the SECAN control to the transverter control is limited
to +/- 1°.
The actual value of the steering angle which is transmitted to
the SECAN control by the incrementor must also be limited to
+/- 1°.
Additionally, the measured actual steering angel of the incre-
mentor is compared with the value of the absolute value emitter
(steering angle potentiometer).
If the maximum actual steering angle value is exceeded, or if a
specified tolerance between the incrementor and the potentiom-
eter of the steering system (actual value difference) is exceeded,
an emergency stop will occur, regardless of the current driving
speed.
6.17.8 Monitoring of the Actual Driving Speed

The actual drive speed is transmitted from the sensor support of
the drive motor to the SECAN control via a transverter control. If
the maximum permissible speed (which can be set) is exceeded,
an emergency stop is initiated.
6.17.9 High speed release

In WG operation, the following requirements for releasing high
speed must be fulfilled:
all regular conditions for high speed release (see chapter 6.11)
- aisle signal exists (only IFmG)
6.17.10 Overview of Emergency Stop Criteria

The following WG-specific conditions are considered as emer-
gency stop situations:
- communication problems with a steering microsensor
(SMS)
- internal error in a steering microsensor (SMS)
- violation of the emergency stop diamond
- exceeding of the maximum permissible steering angle at
WG drive (regardless of the actual driving speed)
50
- exceeding of the maximum speed

- internal errors in the steering sensor system (e.g. rupture
of wire)
- internal errors in the driving sensor system
- internal errors in the SECAN control
- internal errors in the drive motor control
- internal errors in the steering motor control
- emergency stop triggered by an external component, e.g.
personnel protection system
6.17.11 Diagnosis
The WG is fully integrated into the SECAN control system, i.e. all
SECAN diagnosis options are available. Using the status dis-
play, all relevant inputs/outputs/tags can be displayed ONLINE
on the display. Using the „Datascope“ diagnosis software, a
graphical analysis of the signals is possible.The driving behavior
of the WG can be documented very clearly with „Datascope“ and
should therefore be recorded with every truck.
6.18 Interface for the Connection of a

Personnel Protection System (PSA)
As a safety component, a personnel protection system must
have precisely defined interfaces to the trucks control system
and the electric system. Systems that are not sufficiently
planned, implemented or documented endanger the operator’s
safety and affect the operational safety and availability of the
truck.
The PSA interface is connected to a 25-pin Sub-Min-D plug con-

nector on the VZA motherboard (X143). See the wiring diagram
for details regarding the pin assignment. The function of the indi-
vidual current paths is shown in the circuit diagram. The inter-
face has been discussed and agreed upon with every single
PSA manufacturer. In service menu „options, codes, PSA“ -
„PSA“, two lifting height simulation switch signals can be freely
programmed (24 V outputs).
It is not permitted to use other interfaces for the integration of

personnel protection systems into the truck. The SECAN con-
trol system carries out extensive checks during run-up and
operation, triggering fault messages for any unauthorized
manipulation of the safety system!
Read the PSA documentation for the respective truck before

performing service work on a truck.
51
The following signals can be found on the interface:
Function / Signal Description Version
Release of emergency stop Interruption of the mechanical PSA: 2 potential-free contacts

brake circuit
Release for high speed by Full speed release signal PSA: 24 V / SECAN: OK (24 V,
PSA 10 mA)
Drive release, forward Locking of forward drive PSA: 24 V /
SECAN : OK (24 V, 10 mA)
Drive release backward Locking of backward drive PSA: 24 V /
SECAN : OK (24 V, 10 mA)
Drive speed Incremental transmitter, chan- SECAN : output voltage + 24 V
nel A
Drive speed Incremental transmitter, chan- SECAN : output voltage +24 V
nel B, 90° to A
Slow speed info For monitoring the travelling SECAN : output voltage + 24 V if
speed v < 2,5 km/h
Aisle signal 1 Signal directly from the aisle SECAN : 24 V in the aisle
switch
Aisle signal 2 Output signal from the control SECAN : output voltage + 24 V,
in the aisle
Lifting height 1 Freely programmable lifting SECAN : + 24 V, if lifting height
height signal reached
Lifting height 2 Freely programmable lifting SECAN : + 24 V, if lifting height
height signal reached
Supply 24 V For the PSA power supply fused with 3 A

Supply 0 V For the PSA power supply
52
6.19 Automatic swivelling / side shift

synchronization
The software for the Hi-Racker 100 already provides for auto-
matic swivelling/traversing synchronization in narrow aisles. This
option can only be activated after the correct truck-specific and
function-specific code has been entered (service menu, „M21
Options“).
This function allows pallets to be automatically swivelled in the
aisle in approx. 10 to 12 seconds by pressing the button „Syn-
chronous“ and simultaneously fully actuating the right-hand
master switch.
+ The function must be projected by the manufacturer of the

truck, that is, setting parameters and safety distances must be
calculated on the basis of the geometric data.
6.19.1 Geometric setting

Setting of the geometric data is carried out in the „M08 Geome-
trySynchr.Swivel“ menu.
In this menu, 6 geometric values that have been calculated by
the manufacturer of the truck must be set.
These values are written down in the appropriate project sheet
which is included with the acceptance records.
A projected parameter set is always truck-specific and is only
applicable for one pallet size. The use of other pallet sizes can
cause the truck to collide with the racks!
The geometric data can also be set by using a teach-in proce-
dure if the projected parameters are unknown or if the function is
to be adapted to pallet sizes other than the projected size. This
setting is also carried out in the menu „M08 GeometrySyn-
chr.Swivel“.
For this purpose, the attachment must be brought into three cali-
bration positions, which are then confirmed using the „ENTER“
key.
+ Application of the teach-in procedure must not be continued if

the projected geometric values are known and have been
entered via the menu. The values determined by the teach-in
procedure are less accurate than the calculated values.
53
Teach-In sequence:
The teach-in procedure must only be applied using the original

pallet.The synchronous function is only optimised for the teach-
in pallet size.
- Mark the forks center of motion at the left-hand stop for lat-
eral traversing on the floor.
Calibration point, position A:

- Align the rear fork carrier edge exactly above the marked
vertical point of the forks axis of rotation.
- In the menu M08 “Geometry Synchr Swivel“ menu, select
item TI10, position A and confirm with ENTER.
Calibration point, position B

- Align the rear pallet edge (point B) exactly above the
marked vertical point of the forks axis of rotation.
- In the meun M08 „Geometry Synchr Swivel“ select item
TI11, position B and confirm with ENTER.
54
4. Calibration point, position C

- Align the front pallet edge (point C) exactly above the
marked vertical point of the forks axis of rotation.
- If the front edge cannot be exactly aligned with the vertical
point for geometrical reasons, continue with calibration
position D!
- In the meun M08 „Geometry Synchr. Swivel“, select item
TI12, position C and confirm with ENTER.
5. Calibration point, position D

- Calibration point D may only be used if it was not possible
to set calibration point C.
- Align the front pallet edge (point D) with the transverse line
crossing the vertical point of the forks axis of rotation.
- In the menu M08 „Geometry Synchr. Swivel“, select item
TI13, position D and confirm with ENTER.
6. Aisle offset
- This menu item is used to set the contour (usable aisle
width) in which motion occurs. This value is calculated by
the manufacturer and written down in the project sheet
and the acceptance record. If an incorrect value is read in,
malfunctions (collision) cannot be excluded. Setting a
value that is too low causes the system to frequently
detect imminent collisions of one of the edges with the
usable aisle width. If the value is too high, it may happen
that the usable aisle width applied by the system is larger
than the actual aisle width so that the fork collides with the
rack.
55
6.19.2 Hydraulic Setting

Setting can be done in menu M07 „Hydraulic Synchr. Swivel“.
The process is designed in such a manner that the swivelling
function is carried out at constant speed and the traversing func-
tion is adjusted accordingly. If there is danger of collision, the
swivelling function is switched off until the traversing movement
has brought the pallet back into the aisle contour.
Process of Setting:
- drive the hydraulic system to normal operation tempera-
ture
- enter in or teach in the geometric values; set the startup
angle to 10°
- set the aisle offset to a high value (e.g. 500)
- set the control amplification to default value (do not
change!)
- set the number of revolutions to default value.
The following settings are only valid for the set number of rev-
olutions. If the number of revolutions is changed later, carry
out the whole setting process again.
- set the hydraulic parameters to default values
The synchronous movement reacts very sensitively to small-

est changes of parameters.
- Setting of the parameters I17 and I15: Set both parame-
ters to a high value (500 mA). Start the synchronous
movement from the startup position; there must not be any
movement. Now reduce I17 step by step (in steps of 10
mA, later 5 mA) and try repeatdely to start the movement
from the startup position. The value of I17, where the
movement starts slowly, can be taken over as setting
value of I15! As setting value of I17, the setting value I15
minus 20 mA is intended.
Example: The movement starts with a setting value I17of 425
mA
From this the following settings result:
I15: 425 mA
I17 = I15 - 20 mA = 405 mA
- set the swivel movement with the parameters V19 and
V20 so that the swivel movement is done within 10 to 12
seconds.
- set the aisle offset to a neccessary value; this is docu-
mented in the test records.
- If the max. side shift speed is too slow and the contour is
being left (swivelling stops), increase the parameters V22
and V23 slightly
56
- Test the movement with and without load and correct

slightly by setting the parameters V19, V20, V22 and V23.
Also set the startup angle of the side shift movement, if
necessary (not more than 15°).
+ With MA 229 and MA 230, the movement can be checked in the

status display. These tags display the calculated distance (in
mm) of the edges on the left and right side to the specified
contour. With a smooth process of the synchronous move-
ment, both tags must not display a value smaller than 20 mm. If
so, increase aisle offset slightly.
The setting of the two parameters I15 und I17 is very important
for the process:
I17 too low -> jerky start of the side shift movement
I17 too high -> swivelling starts too slowly
I15 too low -> side shift movement runs too fast against the end
position (jerk)
I15 too high -> side shift may not reach the end position
+ The speed of the movements can change with a changing oil

temperature.
When a pumping movement occurs while synchronous move-
ment under load occurses, the two set screws of the load holder
valves can be loosened slightly. Then the stability of the locking
of the swivel axis is reduced. Effect: swivelling while braking is
possible.
6.20 Battery discharge monitor

In the Hi-Racker 100, the discharge monitor is integrated into the
control system. The discharge monitor can be adapted to differ-
ent types of batteries:
- PzS-G
- PzS-H/L
- PzS maintenance-free
Adaptation can be carried out under „M01 Control panel“- „S31
Battery type“ in the service menu.
The default main lift cut-out occurs at a residual capacity of less
than 30%.
To avoid high motor current, the number of revolutions of the
main lift movement is reduced linearly, starting from a remaining
capacity of 60%. The reduction at 30% remaining capacity is
10% of the set number of revolutions for the main lift.
57
6.21 Hour meters

Several operating hour meters are integrated into the control
system:
BZ00: general movement time
BZ01: general switch-on time
BZ02: steering
BZ03: driving
BZ04: pump unit
The operating hours BZ00 are also indicated in the basic dis-
play. The operating hour meters can be called up in the configu-
ration „K1 Battery monitor“ in service menu „M24 Status
display“.
All operating hour meters, except BZ00, can also be reset or set
again in the menu „M22 Hour meters“!
After the reset function has been confirmed for all operating
hour meters, the data are lost and cannot be restored!
+
The data of the operating hour meters are stored in the attach-
able NV RAM of the control panel. Therefore, plug the old NV
RAM onto the new board when replacing the control panel
computer to adopt the stored data. Use a cable tie to secure
the NV RAM from getting loose!
Optionally, additional hour meters can be installed upon cus-
tomer’s request.
6.22 Cut-outs
The following cut-outs are available as an option and can be
activated in the service menu via input of the according code
number:
6.22.1 Lifting cut-outs and lowering cut-outs

(optional)
5 different lifting cut-outs and 3 different lowering cut-outs which
can be configured freely , are prepared in the software.
The lifting and lowering cut-outs can be configured in the service
menus „M17 Lift cut-out" and „M18 Lower cut-out“.
The following parameters can be adjusted separately for each
lifting cut-out:
- cut-out height; either via teach-in procedure or via numeri-
cal input
- override by a key switch: yes or no
- stock zone(s), in which the single cut-out should take
effect
- end ahead function, that is the distance to each cut-out in
mm, at which the lifting movement is changed to low
speed
58
If a lifting cut-out is active, the operator gets a message by a

flashing red STOP-LED on the panel and an explaining help text
„Lift cut-out“.
+ Lifting cut-outs can work correctly only if the sensor units of

the main lift have been calibrated carefully.
6.22.2 Side shift cut-out (second stacking depth)

A side shift cut-out with override is prepared in the software. The
setting of the option is done by means of entering a release code
in the menu „M21 Options“ as well as in the menu M19 „Side
Shift Cut-Out“. There, for both directions separately, a cut-out
distance in mm from the end position can be set. As the
mechanical and hydraulical conditions of the accessories are
almost never identically, it can happen, that to reach identical
cut-out distances on both sides, different values have to be
entered.
+ The actual cut-out distances must always be verified!

On retracting, the accessories travel up to the end stop. The
condition „Extend“ is detected for side shift to the left if the rota-
tion angle of the load lifting device is between 0° and 90° and for
traversing to the right if the rotation angle of the load lifting
device is between 90° and 180°.
The cut-out can be overridden by means of a key switch in the
control panel.
+ The side shift cut-out is not a fine positioning system. The

obtainable accuracy of the cut-out distance depends on the
smooth motion of the accessory, the set speeds and perhaps
on the applied load. In any case, an accuracy of +/-15mm is
obtained.
6.22.3 Drive cut-outs

After the release of a drive cut-out, the lifting height about which
or below which the driving function is to be locked, can be
quoted.
There are 3 programmable drive cut-outs available. Additionally,
a valid stock zone can be defined for each drvie cut-out. It can
also be defined whether the drive cut-out can be overridden or
not. The drive cut-out can be set in menu M16 „Drive cut-out“.
A further height-depending drive cut-out only for the apron is
available as a standard option.
As a standard option there is also a cut-out available for the
attachment not being in startup position.
59
6.23 Software administration

Each processing unit of the SECAN-control contains a specific
EPROM. For the administration of the versions, the following
must be observed:
- The version number is built up as follows:
V A.BC.XY
That is:
A: main software version
BC: Current release of the main version
XY: custom-made special version for the respective release; 00
always means standard version.
Example:
V 3.00.00 is the standard version (covers approx. 95% of all
trucks)
V 3.00.01 is a custom-made special version, that is recorded in
detail in the truck documents
- The EPROMs for UDR and UDL are for all main versions
not customer specific, that means there are no special ver-
sions.
- The EPROMs for VZA and VZK are programmed device-
specific and must always have the same version number.
These EPROMs have individual identification numbers
and are quoted in the truck parts lists. When ordering
spare parts, the ident numbers of the EPROMs or the
series number of the device must always be quoted.
It is not permissible to replace a defective special EPROM by a

standard EPROM. The EPROMS of UDL and UDR must not be
handled separately.
60
61
62
7 Sensors
7 Sensors

- multimeter
Chapt. Theme Page

7.1 Sensor units main lift 3
7.1.1 Potentiometer and incremental
transmitter 3
7.1.2 Reference switch 0,3 m 4
7.1.3 Startup and check of the main lift
sensor units 5
7.2 Sensor units actual value steering 6
7.3 Sensor unit driving 9
7.4 Sensor bearings drive and pump

motor 11
7.5 Temperature sensor drive and

pump motor 12
7.6 Sensor unit auxiliary lift 13
7.7 Sensor unit side shift 15
7.8 Sensor unit swivelling 16


materials.
1
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2
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7.1 Sensor units main lift

7.1.1 Potentiometer and incremental transmitter
The lift sensor unit consists of
- 10-turn dual gang-potentiometer (3), 2kOhm
- incremental transmitter (4), 1000 pulses/R (not visible in
illustration)
- magnet switch 0,3 m (Initiation point)
Pos Description
1 Tension device
2 Toothed belt
3 Potentiometer
4 Incremental transmitter
+ Assembly of the lift sensor unit see spare parts catalogue.
Assembly
- lower cabin to the bottom stop
- mount toothed belt (2) to the lower toothed belt clamp
- pull toothed belt over the pulleys and the pinion disk and
fix in the tension device (1)
- adjust toothed belt tight via tension device (see „checking
the tension of the toothed belt“)
- turn the potentiometer (3) anticlockwise against the
mechanical stop and turn back by 1/4 revolution
- connect the potentiometer via coupling with shaft of gear
- connect the plugs of the potentiometer
- mount incremental transmitter (4, not visible in illustration)
to the opposite shaft end of the gear
- connect the plugs of the incremental transmitter
Checking the adjustment of the potentiometer

- switch off the truck (cabin lowered completely)
- pull plug X104 from VZA board
- measure between Pin 2 and 3 with ohmmeter: correct
value: 1,7 - 1,9 kOhm
3
7 Sensors
Calibration (Teach- In):

- select service menu M04 "mainlift"
- select menu item TI06 and start teach-in by pressing
ENTER; the cursor bar starts flashing
- move cabin to the desired position and confirm with
ENTER
+ In this menu item, slow speed is predefined. With the correct

taking over of the value an acoustic signal is sounded.
- continue with menu item TI07 as described above
All further parameters in menu M04 can be adjusted via UP /
DOWN keys
+ It is not necessary to calibrate the incremental transmitter.
Checking the tension of the toothed belt

To check the thension of the toothed belt proceed as follows:
Tighten spring (2) until the height of the bush (3) is reached.
Attention
- Bolt (5) may not touch the mast bracket

- The end of the pitch of the screw thread (4) may not be
reached
- Ring (1) may not sit on top of the bush (bush must be mov-
ing with play)
7.1.2 Reference switch 0,3 m

For safety reasons, a magnet switch is installed, whitch switches
at a cabin height of 0,3 m ± 3 cm.
Pos. Description
6 Magnet switch
7 Plastic distance piece
8 Magnet
9 C-profile
Assembly
- mount the magnet switch (6) with plastic distance piece (7)
to the C- profile (9) centrically; cable output to the bottom;
strain relief cable
- mount the magnet (8) loosely to the C-profile (9), switching
distance ca. 10 mm; North pole (green) to the magnet
switch
- lift the cabin up to 300 mm
- adjust and tighten magnet centrically to the magnet switch
4
7 Sensors
7.1.3 Startup and check of the main lift sensor units
+ Parameters see service menu, chapter 11.

- mount the magnet for the 0,3m-switch so, that the switch
point is at 300 mm +/- 5 mm, when lifting
- type in the maximum main lift height h3 into parameter
G22
- type in the end ahead distance values into parameters
G20 and G21
- lower the main lift to the bottom stop and teach in the bot-
tom position into TI07
- lift the main lift up to the top end and teach into TI06
+ Always use the absolute end positions for the teach-ins. Other-
wise the scale is distorted. This leads to faults.
- lower the main lift to the bottom position, switch off and on
the truck again.
Checking the 0,3 m-switch
- call status of E143, MA164 and EA104 normalized
- lift main lift up to 500 mm
- lower the main lift, until MA164 shows exactly 300 mm.
The value of the potentiometer of EA104 has to show 300
± 15mm
- measure the heigt of the cabin floor from the ground floor
and write down (value Kh1)
- lower the cabin to the end position: MA164 has to show 0
± 5mm
- measure the height of the cabin floor from the ground floor
and write down (value Kh2)
+ The difference between Kh1-Kh2 has to be 300 +/- 5mm (opti-

mum: 300 ± 1mm).
Otherwise, re-adjust magnet for the 0,3m-switch:
Tolerance more than + 5mm: move magnet slightly down
Tolerance smaller than - 5mm: move magnet slightly up
- repeat procedure „Checking the 0,3 m-switch“.
- then lift the main lift from the lower to the upper end; there
may not be any error message.
- at the upper end, read value of the incremental transmitter
MA164 (write down)
- set main lift height in service menu M04; G22: G22 = noted
value - 5 mm.
example: MA164 top = 5500: G22 = 5495 mm.
+ The difference of 5mm is required for switching-off the motor

in the upper end position.
On the upper end limit, read potentiometer value EA104: The
value may only differ at maximum ± 30 mm from the value of
5
7 Sensors
the incremental transmitter MA164.
7.2 Sensor units actual value steering

Before switching on the truck, make sure, that no second per-
son is working on the steering system, as after each switching-
on a steering initiation is carried out automatically.
Sensor elements
- Incremental transmitter (9) on the steering motor (1000
Imp./U.);
- 5-turn potentiometer (10) (2kOhm);
Pos Description
9 Incremental transmitter
10 Potentiometer
11 Marking boreholes for straight ahead position
+ Assembly of the steering sensor unit see spare parts cata-

logue.
6
7 Sensors
Demounting the incremental transmitter (9)

- remove cap screw (9a)
- loosen screw (9b)
- pull off transmitter (9) from the motor shaft
Mounting the incremental transmitter (9)

- Fit transmitter (9) on motor shaft; pay attention, that safety
shim (9c) and shims of the tension element (9d) are
mounted correctly
- push pin (9e) into borehole on the motor plate
- tighten screw (9b) with torque of 1 Nm
Prevent the transmitter from axial or radial pressure. Adjust air

gap (L) to 0,5...0,7mm.
Assembly and mechanical adjustment of the

potentiometer (10)
- drive wheel ligned up centrically (marking bore holes (11)
have to be ligned up)
- set service menu M12, P24: "steering straight ahead" to
"0"
+ When mounting the complete unit, make sure that there is a

minimum tooth flanc clearance betwen motor gear rim and pin-
ion of the sensor unit. Fix pins after a corresponding test.
Before turning or exchanging the motor gear rim, remove sen-

sor unit.
+ Tighten the grub screws exactly onto the flat surfaces of the
potentiometer shaft. This guarantees a maximum protection
against twisting.
Checking the adjustment of the potentiometer

- manually set the steering wheel exactly into straigh ahead
position.
- potentiometer: measure with ohmmeter between pin 2 and
3 of the plug X108 pulled off. The measured value of the
potentiometer has to be between 0,95 kOhm and 1,05
kOhm (ideal: 1,0 kOhm).
Electrical setting
- set service menu M12, P24 to "0"
- switch on the truck, the steering initiates
- lign up the drive wheel absolutely straight by turning the
steering wheel (see marking bore holes (11)). Jack up the
truck if possible, that no tyre tension occurs.
7
7 Sensors
- measure with voltmeter between pin 2 and 3 of plug X108;

the measured value must be close to 6,0V ±0,2V.
- display EA 106 and EA# 107 in the service menu - status
display
- EA 106 has to show a value round ±20 (corresponds to
±2,0°);
- EA# 107 indicates the steering position which is detected
by the incremental transmitter (in 1/20°); this value has to
be noted down
- call parameter P 24 in the service menu "M12 Steering" -
"Straight ahead-correction" and enter the correction value:
correction value = - (value written down)

Example: value noted down = -5; correction value = +5 (unit is
´digit´, that means 1/20°)
- enter correction value
Checking the adjustment of the steering sensor unit

- switch on the truck (jack up, if possible); steering initiates
After the initiation, the drive wheel must be ligned up straight
ahead. (observe marking bore holes (11)).
Checking of the exact center position and fine-adjust-

ment
- call „status display“ in service menu and call up configura-
tion „K3 steering“
- drive the truck on a test track (min. 20 m) and set steering
manually to straight ahead driving; EA107 must show the
value "0" ±1
- drive ca. 10 m straight, do not touch the steering wheel;
the truck may not deviate from the straight driving line
+ If deviations can be recognized, the straight ahead position of

the steered wheel has to be re-defined. The actual straight
ahead position can deviate from the marked straight ahead
position in certain cases.
The fine-adjustment can be done in the service menu „M12
steering - straight ahead correction“. For the fine-adjustmen,
change the setting step by step by one or two digit and perform a
test drive again.
8
7 Sensors
Trucks with wire guidance

On trucks with integrated wire guidance there is the possibility of
a automatically centrical lign up of the steering (see chapter 6).
On WG-trucks a careful and clearance-free adjustment of the

measured value sensor unit of the steering is of decisive
meaning for the WG-behaviour of the truck.
+
The straight ahead positioning also on rail guided trucks has
to be carried out carefully, as the steering is ligned up straight
ahead automatically while driving into the aisle. Incorrect
adjustments lead to increased tyre wearing and possibly to
malfunctiuon when leaving the aisle. (truck drives out of the
aisle at a certain angle and doesn’t pass the aisle recognition
magnets properly).
The calibration also has to be carried out after exchanging a

VZA- control component.
Check WG-steering functions

- switch truck into WG-operation, engage truck onto the wire
and drive into the aisle
- call configuration „K3 steering“
- observe EA107 while slowly driving on WG-wire; The
value has to be close to ±0; if not, change the straight
ahead correction (P24) step by step until the target value
is reached.
9
7 Sensors
7.4 Sensor bearings drive and pump motor

The sensor bearings in the drive and pump motor give rotor
position, direction of rotation and speed to the control systems.
Exchanging a sensor bearing

- pull battery plug
- disconnect the motor electrically
- drive motor: remove magnet brake (15a) (see chapter 4)
- remove 4 nuts (15b) from the anchour (15d) of the end
shield (plate without schaft output)
- remove end shield (15c); devide from stator lamination
using a hammer
+ If the end shield cannot be removed, cut off the anchors (15d)
below the end shield to facilitate work (new anchors are
required when mounting).
- When taking off the end shield, push the wirings through
the opening
Do not damage the windings and the stator circuit.

- remove sensor bearing with a pullin-off device from the
shaft end
- mount new sensor bearing in correct position
Sensor ring must be in direction of the rotor. Press bearing

onto the shaft with a bush, that exactly fits onto the inner ring
of the bearing.
- press ball-bearing compensation washer with grease into
the borehole end shield
- re-mount end shield
Make sure, that the connection cables are pulled through the
opening of the plate correctly. Do not damage the windings
and the stator circuit when mounting.
- tighten 4 nuts (15b) with a torque of 23 Nm
- remount magnet brake (15a)
- connect motor electrically
10
7 Sensors
7.5 Temperature sensor drive and pump motor
Mounting of a new temperature sensor

The new temperature sensor can be stuck to the windings (16)
of the stator with 2-component balancing cement.
+ The 2-component balancing cement can be supplied by the

manufacturer.
- knead together the two components of the cement 1:1 yel-
low and blue
Work fast, the cement is hardening fastly

- press the cement onto the upper side of the temperature
sensor
- push the temperature sensor through the cable channel of
the motor
- stick the temperature sensor onto the copper wiring
11
7 Sensors
7.6 Sensor unit auxiliary lift
Sensor element
10-turn dual gang potentiometer (2k/2k)
Pos Description
1 Potentiometer
2 Support bracket for guide pulley
3 Guide pulley
4 Allen screw, bush
5 Chain bracket
6 Belt carrier
+ Assembly of the auxlift sensor unit see spare parts catalogue.
Assembly and mechanical adjustment

- lower forks to the bottom end
If the sensor unit has to be changed, remove the complete unit
first
- install toothed belt onto lower and upper guide pulley (3)
- install belt carrier (6)
- set the potentiometer (1) to the right-hand stop
- turn back potentiometer by 1/2 revolution
- install the potentiometer into its final position
Checking the potentiometer-adjustment

- measure resistance in on potentiometer on the pulled plug
between X512.2/Pin 2 and Pin 3 as well as between X512/
Pin5 and Pin 6 with ohmmeter.
+ The potentiometer is correctly adjusted, if on both measure-

ment points a value between 0,1 - 0,3 KOhm can be measured.
12
7 Sensors
Calibration (Teach- In)

- select service menu M05 „Auxiliary lift"
- perform the teach-in in bottom position and top position
Checking the settings

- select service menu, status display
- call K5 „Auxiliary lift"
- lift and lower the hoist frame once over the entire lifting
height and check whether the truck behaviour and the con-
figuration parameters are correct.
- repeat the adjustment in case of deviations
The calibration also has to be carried out after exchanging a

VZK-control component.
7.7 Sensor unit side shift
Sensor element
- 10- turn dual gang potentiometer (2kOhm / 2kOhm)
Pos Description
1 Potentiometer
2 Grub screws
3 Torsion protection

Requirements:
- move side shift unit in right-hand end position
+ The hydraulic motor must not be removed for installation and

removal purposes.
- set the potentiometer (1) to the left-hand stop
- turn back the potentiometer by 1/2 revolution
- tighten grub screws (2) (shifted by 180°)
+ For demounting the attachment, position it in such a manner,

that the grub screws of the coupling are accessible.
13
7 Sensors
Measure the potentiometer setting

- switch off the truck; side shift has to be placed at the left-
hand stop
- measure on potentiometer with pulled plug X512.1/Pin 2
and Pin 3 as well as between X512.1/Pin 5 and Pin 6 with
ohmmeter. Permissible value: 0,1 ... 0,4 kOhm

- select service menu M02 „Side shift"
- perform the teach-in on left hand end stop position and on
right hand end stop position

- select configuration K6 „Side shift" in the service menu
"Status display“
- actuate side shift left and right side once each check
behaviour of the truck for correctness
- on trucks with the option "second stacking depth", the cut-
out position right and left has to be entered separately.
Always measure the actual cut-out position, as the
adjusted value and the actual value do not correspond
exactly
- repeat adjustment if deviations occur
The calibration also has to be carried out, after a VZK control

component has been exchanged.
7.8 Sensor unit swivelling
Sensor element
- 3-turn dual gang potentiometer (2kOhm / 2kOhm)
Pos Description
1 Potentiometer
2 Pinion of the potentiometer
3 Bracket
+
Assembly of the swivelling sensor unit see spare parts cata-
logue.

- move the forks to the center position
14
7 Sensors

Always mount and demount sensor unit with potentiometer, pin-
ion and support
- set the potentiometer (1) to the center position (1,5 rota-
tions)
- measure on potentiometer Pin 2 and Pin 3 as well as
between Pin 5 and Pin 6 with ohmmeter. Permissible
value: 1,0 kOhm.
- install potentiometer and tighten screws of bracket (3)
- strain relief the cable connections; make sure that there
are no loops
Measuring of the potentiometer-setting

- measure on potentiometer on pulled plug X514.2 between
Pin 2 and Pin 3 as well as between Pin 5 and Pin 6 with
ohmmeter. Permissible value: 0,9...1,1 kOhm.

- select service menu M03 „Swivelling"
- perform teach-in on left hand end stop position as well as
on right hand end stop position

- select configuration „K7 Swivelling" in the service menu
"Status display"
- swivel left and right once each and check the truck behav-
iour and the configuration parameters for correctness
- repeat the adjustments, if deviations occur
The calibration also has to be carried out after a VZK-control

component has been changed.
15
7 Sensors
7.9 Sensor unit for load detection
Sensor element
- linear potentiometer (5kOhm)
Pos Description
1 Bush
2 Spring
3 Protection bracket
4 Chain anchor screw
5 Connector plug
6 Potentiometer

- prepare sensor unit completely for installation
- attach the connector plug (5) within the protection bracket
(3)
- loosely install the entire unit
- carefully push the entire unit upward until the spacer (7)
meets the chain anchor screw
- move the entire unit downward by 1 mm and tighten the
screws
- Important: The entire unit must be horizontal and aligned
with the centre
Disassembly of the spring (2)

- remove the sensor unit
- support the fork
- loosen the chain anchor screw (4) and remove the spring
with the bush (3)
Measuring the potentiometer setting

- switch the truck off; there must be no load on the forks
- in the VZK, measure the resistance on plug X214 between
pin 2 and pin 9 of the removed plug, using an ohmmeter.
- Permissible value: 4,5 ... 4,9 kOhms.
Calibration
- select service menu, M14 „Load sensor unit“
- enter all requested values
16
7 Sensors
Checking the setting

- select service menu, status display, M234, EA206, MA123
- pick up different loads and check whether the display is
correct
Calibration must also be carried out after a VZK control compo-
nent has been replaced.
Owing to friction and other influences, the load registration
works with a resolution of 50kg; the load registration system is
not a precision balance but gives the operator a rough estima-
tion with regard to the load that has been picked up!
17
7 Sensors
18
8 System messages
8 System messages

- multimeter
Chapt. Theme Page

8.1 Remarks for systematic error
diagnosis 3
8.1.1 Types of errors 3
8.1.2 Online-help 4
8.1.3 Startup errors 4
8.1.4 Operating errors 5
8.1.5 Status analysis 6
8.1.6 Flow chart: Systematic error diagnostics 8
8.2 Startup message 9

8.2.1 Startup messages VZA 9
8.2.2 Startup messages VZK 13
8.2.3 Startup messages VZB 15
8.3 Operation messages VZA 16

8.3.1 Operation messages VZA 16
8.3.2 Operation messages VZK 28
8.3.3 Operation messages VZB / LED error
codes of the control panel 36


materials.
1
8 System messages
2
8 System messages
8.1 Remarks for systematic error

diagnosis
8.1.1 Types of errors
The display and programming unit APE is the central tool for
error diagnosis. Here, all errors, detected from the SECAN-con-
trol system are displayed as an error code or a help text,
depending on kind and time of occurence of the error.
Message / type of error Kind of message

Error during the startup (after Startup-error; displayed as
switch on error code
H xxx
Important messages for the Online-help; Plaintext in
operator: respective language
Request of operator activity
Information about truck
states
Error during the operation Operation error; Display as
(after successful startup) error code
E xxx
Time of displaying different types of messages
+ In case of malfunction always use the APE first for elimitation

of errors.
3
8 System messages
A Startup-error message, operation error message or an online-

help message is only posible, if the SECAN control system rec-
ognizes one of the following situations.
Case of error Example

Mechanical error Slack chain switch activated
A release function is not car- Drive release signal transmit-
ried out ted, but not driving function
Inadmissible combination of Drive switch signal forward
input signals and backward at the same
time
Value over permitted limit Drive sensor recognizes that
drive speed is too high
Error in the SECAN-electron- VZK receives no answer from
ics or SECAN-communication VZA
Error in a sensor unit Breaking of the wire for
actual value potentiometer
steering
Some errors cannot be detected by the SECAN control.

Example: Failure of command key for auxiliary lift
+ If no error message is displayed although malfunction, the

cause can be determined by the status analysis, described in
chapter 8.
8.1.2 Online-help
+
APE notes see the Operator’s Manual, chapter Daily service
and function checks.
8.1.3 Startup errors

After the operating voltage is switched on, the processing units
in the drive compartment (VZA), in the cabin (VZK) and in the
control panel (UDR, UDL) carry out a self test of assemblies and
the peripherals. The first error recognized hereby is displayed as
startup error on the APE.
+ After a startup error (H xxx) has occurred, the SECAN-control

prevents the truck from going into operation. On error-free
startup an acoustic signal comes from the panel.
4
8 System messages
Depending on the concerned processing unit or its peripherics,

the “H“-messages are devided into three categories:.
Category of message Assembly concerned

H100...H199 VZA or its peripherals
H200...H299 VZK or its peripherals
+ The UDR-startup errors are not displayed as H-errors, but as E-

errors (E300...).
Startup errors are not „self-deleting“, which means, the error
message „H xxx“ disappears only, when the error has been
removed and the truck has been restarted.
8.1.4 Operating errors

After successful startup, the SECAN control checks the truck for
unpermitted states. Recognized errors are displayed as "E"-
errors on the control panel display.
Depending on the concerned processing unit or its peripherics
the „E“-messages are devided into three categories:
Category of message Assembly concerned

E100...E199 VZA or its peripherals
E200...E299 VZK or its peripherals
E300...E399 UDR or its peripherals
Operation-error messages are either „self-deleting“ or „not self-

deleting“, depending on the kind of error.
+ "Self-deleting" error messages disappear, when the error

cause is removed.
"Not self-deleting" error messages are still displayed after the
error cause has been removed. They only disappear after
switching off the power.
Not self-deleting errors are capable to make errors visible, that
occur only for a short time (memory function).
5
8 System messages
8.1.5 Status analysis

In certain cases, it can happen, that the control panel display
shows no error, although a malfunction has occurred.
Example:
The key for the auxiliary lift has failed. The SECAN-control can-
not recognize the intention of the operator, to lift the auxiliary lift.
The desired lift movement fails to appear, without a message.
In such cases, the error cause can be identified by the use of a
status analysis.
+ Via APE the „status tags“ can be requested. They describe the
current status of a device function.
Whether a certain status is reached, depends on certain condi-
tions. These conditions are predefined by the control software.
In chapter 10 all the states are described, that can be taken by
status tags.
+ The order of the listed states describes not necessarily the

functional flow on the truck.
If a desired device status is not reached, the error can be
detected via checking the relevant status tags.
Example:
The truck drives only in slow speed.
The status tag, relevant for this is MZ 100: Driving.
In addition to this it can be necessary to examin further status
tags.
e. g.: MZ 103: Aisle / Apron or MZ 108 end of aisle safety device
Before selecting any truck functions, always make sure, that

there are no persons in the danger area. In case of defective
trucks the danger of unexpected movements of the truck are
particularly high.
The single steps for the execution of a status analysis can be
taken from the flow chart „status analysis“.
6
8 System messages
Flow chart: Status analysis
Desired truck function fails
Error message? Yes Chapter 8
No
call testpage control panel (see chapter 9)

Operator action and check control panel elements
correctly executed for correct function
according to
operating instruction
SECAN
recognizes operator No
action?
Yes
Chapter 10
Check inputs of user action
Chapter 10

-> Chapter 11
choose relevant status tag Service configurations
(MZ xxx)

Choose other Check status of tag

relevant status tag (chapter 8)
j
Yes Status correct?
a
No
Repair:
Check conditions for
Check missing condition
desired status
7
8 System messages
8.1.6 Flow chart: Systematic error diagnostics
Malfunction
No No
Online-message? “H”-error? “E”-error?
No
Yes Yes Yes Chapter 8

Status tag analysis
Chapter 8 Chapter 8 Chapter 8
Cause found? No
ja
Yes All possibilities
checked?
Remove error No
ja
No
Define error by means

Test all functions
of circut diagramm;
Error description to
service department
Truck ok? No
ja
Yes
Submit truck to user
8
8 System messages
8.2 Startup messages

8.2.1 Startup messages VZA
Mesg. Description Possible measures

H100 Program memory (EPROM) defective - VZ-Check VZA
-Truck remains in startup-status, opera- - Visible check SK-R/SK-EPROM
tion not possible - cross exchange SK-R(VZA)/SK-R(VZK)
H101 Computer board SK-R defective - VZ-Check VZA
Truck remains in startup-status, opera- - Visual check SK-R
tion not possible - cross exchange SK-R(VZA)/SK-R(VZK)
H102 see H101 see H101
H105 - Computer-watchdog 1 -check other components (e.g. personnel
H109 -Truck remains in startup-status, opera- protection system)
tion not possible -check safety circuit braking
-visual check SK-R
-cross exchange SK-R(VZA) <-> SK-R
(VZK)
H110 - Computer-watchdog 2 -check other components (e.g. personnel
tion not possible -check safety circuit braking
-visual check SK-R
-cross exchange SK-R(VZA) <-> SK-R
(VZK)
H118 Installed UDR-software version is not suf- -insert correct UDR-software, ask manu-
ficient/correct facturer for update, if necessary
Truck remains in startup-status, opera- -VZ-check UDR
tion not possible
H119 Installed software of VZA and VZK do not -insert correct software of VZA and VZK,
fit, different versions ask manufacturer for update, if necessary
Truck remains in startup-status, opera- -VZ-check VZA and VZK
tion not possible
H120 CAN-bus controller defective -VZ-check VZA
Truck remains in startup-status, opera- -visual check of VZA
tion not possible -cross exchange SK-R of VZA <-> SK-R
of VZK
9
8 System messages

H123 CAN-bus communication with UDR -CAN-check
impossible -VZ-check VZK
Truck remainremains in startup-status, -cross exchange SK-CAN of SK-BPR <->
operation not possible SK-CAN of VZK
-cross exchange SK-CAN of VZA
<-> SK-CAN of UDR
-VZ-check VZA
-visual check SK-R of VZA
-cross exchange SK-R of VZA <-> SK-R
of VZK
H124 CAN-bus communication with VZK -CAN-check
impossible -VZ-check VZK
Truck remainremains in startup-status, -cross exchange SK-CAN of SK-BPR <->
operation not possible SK-CAN of VZK
-cross exchange SK-CAN of VZA
<-> SK-CAN of UDR
-VZ-check VZA
of VZK
H130 Control system intends to open path 1 -check cable connections of safety circuit
(SF1) of the safety circuit for braking, but for braking
feedback sends message „path 1 closed“ -VZ-Check VZA
Truck remains in startup-status, opera- -visual check SK-R of VZA
of VZK
H131 Control system intends to close path 1 -check other components (personnel pro-
(SF1) of the safety circuit for braking, but tection system.)
feedback sends message „path 1 open“ -check cabel connections of safety circuit
-Truck remains in startup-status, opera- for braking
tion not possible -VZ-Check VZA
cross exchange SK-R of VZA <-> SK-R
of VZK
H132 unpermitted coupling between path 1 and -check cabel connections of safety circuit
path 2 of "safety circuit of braking" when for braking
operating brake is activated -VZ-Check VZA
-Truck remains in startup-status, opera- -visual check SK-R of VZA
of VZK
10
8 System messages

H133 Control system intends to open path 2 -check cabel connections of safety circuit
(SF2) of the safety circuit for braking, but for braking
feedback sends message „path 2 closed“ -VZ-Check VZA
Truck remains in startup-status, opera- -visual check SK-R of VZA
of VZK
H134 Control system intends to close path 2 -check other components (personnel pro-
(SF2) of the safety circuit for braking, but tection system..)
feedback sends message „path 2 open“ -check cable connections of safety circuit
-Truck remains in startup-status, opera- for braking
tion not possible -VZ-Check VZA
-visual check SK-R of VZA-
of VZK
H135 End of aisle safety hardware defective -visual check SK-VZA, replace SK-VZA if
-Truck remains in startup-status, opera- necessary
tion not possible
H137 end of aisle switch forward, channel A, -cable connections end of aisle safety
cannot release magnet switches
-Truck remains in startup-status, opera- -visual check SK-VZA, replace SK-VZA if
tion not possible necessary
H138 end of aisle switch forward, channel B, -cable connections end of aisle safety
H139 end of aisle switch backward, channel A, -cable connections end of aisle safety
H140 end of aisle switch backward, channel B, -check cable connections end of aisle
cannot release safety magnet switches
-Truck remains in startup-status, opera- -visual check SK-VZA, ggf. SK-VZA
tion not possible ersetzen
H141 - end of aisle safety hardware defective -visual check SK-VZA, replace SK-VZA if
H152 -Truck remains in startup-status, opera- necessary
tion not possible
H153 Full speed release by control system not -check full speed release by WG
possible -check full speed release by PSA
-Truck remains in startup-status, opera- -check wiring for full speed
tion not possible -check SK-VZA, replace if necessary
11
8 System messages

H154 Full speed cannot be locked by control -check SK-VZA, replace if necessary
system -check wiring for full speed
-Truck remains in startup-status, opera-
tion not possible
H155 SK-R defective -VZ-Check VZA
-Truck remains in startup-status, opera- -visual check SK-R
of VZK
12
8 System messages
8.2.2 Startup messages VZK

H200 Program memory (EPROM) defective -VZ-Check VZK
-Truck remains in startup-status, opera- -visual check SK-R/SK-EPROM
tion not possible -cross exchange SK-R(VZK)/SK-R(VZA)
H201 - Computer board SK-R defective -VZ-Check VZK
H203 -Truck remains in startup-status, opera- -visual check SK-R/SK-EPROM
tion not possible -cross exchange SK-R(VZK)/SK-R (VZA)
H205 - Computer-watchdog 1 -check other components (e. g. personnel
tion not possible -check safety circuit for braking
-VZ-check VZK
-visual check SK-R/SK-EPROM
-cross exchange SK-R(VZK) <-> SK-R
(VZA)
H211 - Computer-watchdog 2 -check other components (personnel pro-
H215 -Truck remains in startup-status, opera- tection system..)
tion not possible -check cable connections of the safety
circuit for braking
-VZ-Check VZK
-visual check SK-R / SK-EPROM
-cross exchange SK-R of VZK <-> SK-R
of VZA
H220, CAN-bus controller defective -VZ-Check VZK
H221 -Truck remains in startup-status, opera- -visual check SK-CAN
tion not possible -cross exchange SK-CAN of VZK <->
SK-CAN of VZA
-visual check SK-R
cross exchange SK-R of VZK <-> SK-R
of VZA
H222 CAN-bus communication: no reception -CAN-check
from VZA and UDR -VZ-check VZK
-Truck remains in startup-status, opera- -visual check SK-CAN
tion not possible -cross exchange SK-CAN of VZK <->
SK-CAN of VZA
-visual check SK-R
of VZA
-VZ-Check SK-R of VZA and SK-BPR
13
8 System messages

H223 CAN-bus communication with UDR -CAN-check
impossible -VZ-check UDR
-Truck remains in startup-status, opera- -visual check SK-BPR
tion not possible -cross exchange SK-CAN of SK-BPR
<-> SK-CAN of VZA
-visual check VZK
-cross exchange SK-CAN of VZK <-> SK-
CAN of VZA
-VZ-check SK-R of VZA and SK-BPR
-VZ-check VZK
-visual check SK-R/SK-EPROM
of VZA
H224 CAN-bus communication with VZA -CAN-check
impossible -VZ-check VZA
-Truck remains in startup-status, opera- -visual check SK-BPR
tion not possible -cross exchange SK-CAN of VZA
<-> SK-CAN of UDR
-cross exchange SK-R of VZA<-> SK-R
of VZK
-VZ-check VZK
-cross exchange SK-CAN of VZK <-> SK-
CAN of UDR
-visual check SK-R / SK-EPROM
H230, 24V-release by outputs safety relais 1 -VZ-check VZK
H231 and 2 missing -visual check SK-R
-Truck remains in startup-status, opera- cross exchange SK-R of VZK <-> SK-R
tion not possible of VZA
H232 24V-release cannot be rejected by the -VZ-check VZK
output release SF1 -visual check SK-R
-Truck remains in startup-status, opera- -cross exchange SK-R of VZK <-> SK-R
H233 24V-release cannot be rejected by the -VZ-check VZK
output release SF2 -visual check SK-R
-Truck remains in startup-status, opera- -cross exchange SK-R of VZK <-> SK-R
8.2.3 Startup messages UDR
+ The UDR does not differ between startup and operation mes-
sages. All errors are displayed as E-messages (E300...).
14
8 System messages
8.3 Operation messages VZA
+
8.3.1 Operation messages VZA
(SL) = self-deleting message

E100 CAN-communication disturbed: reception -CAN-check
buffer channel 1 overflow -VZ-check VZA
-emergency stop: all movements locked,
braking
E101 CAN-communication disturbed: reception see E100
buffer channel 2 overflow
braking
E102 CAN-communication disturbed: send see E100
braking
braking
E104 CAN error see E100
(SL) -emergency stop: all movements locked,
braking
E105 CAN-error see E100
(SL) -emergency stop: all movements locked,
braking
E106 CAN error see E100
braking
timeout
braking
E108 CAN-communication disturbed: timeout see E100
reception from UDR
braking
E109 CAN-communication disturbed: timeout see E100
(SL) reception from VZK
braking
15
8 System messages

E110 analog/digital-converter SK-R, job not -VZ-check SK-R of VZA
(SL) done in time -visual check SK-R of VZA
-emergency stop: all movements locked, -cross exchange SK-R of VZA <-> SK-R
emergency braking of VZK
E111 Release 24V is missing (cut-out of 24V- -VZ-Check VZA
(SL) supply of the output drivers by watchdogs -visual check SK-R of VZA
-mechanical braking to slow speed -cross exchange SK-R of VZA <-> SK-R
-drive cut-out of VZK
E112 Release 24V end of aisle safety-channel -VZ-Check VZA
(SL) A missing (cut-out of 24V-supply spring -visual check SK-R of VZA
pressure brake) cross exchange SK-R of VZA <-> SK-R of
-mechanical braking to slow speed VZK
-drive cut-out slow -end of aisle safety device: via service
menu check end of aisle safety- code
number release
E113 Release 24V end of aisle safety-channel -VZ-Check VZA
B missing (cut-out of 24V-supply spring -visual check SK-R of VZA
pressure brake) cross exchange SK-R of VZA <-> SK-R of
-mechanical braking to slow speed VZK
-drive cut-out slow -end of aisle safety device: via service
menu check end of aisle safety- code
number release
E118 Measured value of sensor unit steering, -check setting sensor unit
(SL) potentiometer: out of max. range (+/- -status analysis
100°) -check coupling of the potentiometer
-steering deactivated
E119 Measured value of sensor unit steering, -check setting sensor unit
(SL) potentiometer: wiring break (A/D-vaule) -status analysis
-steering deactivated - display input analog via APE:
approx. 11...12V: Interruption of the 0V-
cable connection
approx. 0...1V: Interruption of the 12V-
connection or the measured value con-
nection
- measure 12V-supply potentiometer: cor-
rect value: approx. 11,5V
-check faulty connection, remove error
E120 Measured value of sensor unit steering, -check setting of sensor unit
(SL) potentiometer/incremental transmitter: -status analysis
deviation of the values too big - check coupling of potentiometer / incre-
-steering deactivated mental transmiter
-display input analog (potentiometer) and
(incremental transmitter) via APE
-replace defective transmitter
16
8 System messages

E121 Measured value sensor unit steering, -check setting of sensor unit
(SL) incremental transmitter: out of max. range -status analysis
(+/- 100°) -check coupling of incremental transmitter
-steering deactivated
E122 error in AC-steering control unit -observe the blink code of the control sys-
-general emergency stop tem(see chapter 15)
E125 measured value sensor unit main lift -check setting of sensor unit
(SL) potentiometer 1: wire break detection (A/ -status analysis
D-value) -display input/output via APE
-driving reduced to slow speed approx. 11...12V: interruption of the 0V-
-lifting and lowering the main lift reduced cable connection
to slow speed approx. 0...1V: interruption of the 12V-
nection
-measure 12V-supply of potentiometer:
correct value: approx. 11,5V
E127 measured value sensor unit main lift, -check setting of sensor unit
(SL) potentiometer 1:out of range (0, h3_max) -status analysis
-driving reduced to slow speed -display input/output via APE
-lifting and lowering the main lift reduced approx. 11...12V: interruption of the 0V-
to slow speed cable connection
approx. 0...1V: interruption of the 12V-
nection
-measure 12V-supply of potentiometer:
correct value: approx. 11,5V
-check coupling of potentiometer
E129 difference of measured value between -sensor unit diagnosis (configuration K4);
(SL) potentiometer and incremental transmitter newly teach in the potentiometer
main lift too big -check cable connections and plugs
-driving reduced to slow speed according to the wiring diagram
-lifting and lowering the main lift reduced -check level of voltage supply
to slow speed -check couplings for tight fixing, newly
teach in the potentiometer, if necessary
-If K4 recognizes faulty potentiometer- or
incremental transmitter signals:
check potentiometer and incremental
transmitter for damages, change if neces-
sary
17
8 System messages

E130 measured value sensor unit mainlift, -diagnosis of sensor unit (configuration
(SL) potentiometer 1, 0.3m-switch: deviation of K4); adjust switch exactly, if necessary
signal and value of channel 1 (see chapter 7)
-driving reduced to slow speed -check cable connections and plugs
-lifting and lowering the main lift reduced according to the wiring diagram
to slow speed -check level of voltage supply
-check coupling for proper fixage, newly
teach in the potentiometer
-check 0,3m-switch, replace if nec.
-If K4 recognizes faulty potentiometer- or
incremental transmitter signals:
check potentiometer and incremental
transmitter for damages, change if neces-
sary
E135 error in AC-pump motor controller -pay attention to the blink code of the con-
-general emergency stop trol systemd (see chapter 15)
E136 error in AC-drive controller -pay attention to the blink code of the con-
-general emergency stop trol systemd (see chapter 15)
E139 Resolution of the mechanical braking sys- -status analysis safety circuit braking
tem: VZA switches off channel 1, but still -check wiring
feedback from the SF-relay channel 1 -check safety module (SIMO), change if
-emergency stop: all movements locked, necessary
braking
E140 Resolution of the mechanical braking sys- see E139
tem: VZA switches off channel 2, but still
feedback from the SF-relay channel 2
braking
E 141 end of aisle safety: recognized only one -status analysis
channel release (forward switch, channel -WG-truck: check deviation from wire
A has released) -rail guided: check mounting of switches
-driving reduced to slow speed for lateral deviation
when end of aisle safety-activation via
light barrier: check alignment of sensor
and reflector
-check measures for mounting of switch
-heavy concussion of the truck: remove
cause
-check forward switch, channel A
-check forward switch, channel B
-check cable connections end of aisle
safety-switches
18
8 System messages

E 142 end of aisle safety: recognized only one see E 141
channel release (forward switch, channel
B has released)
-driving reduced to slow speed
channel release
(backward switch, channel A has
released)
channel release
(backward switch, channel B has
released)
E 145 end of aisle safety: forward switch, chan- -status analysis
nel A is released permanently -check forward switch, channel A
-driving reduced to slow speed -check cabling of the switch
- VZ-Check VZA
-visual check VZA, replace VZA, if neces-
sary
E 146 end of aisle safety: forward switch, chan- -status analysis
nel B is released permanently -check forward switch, channel B
- VZ-Check VZA
sary
E 147 end of aisle safety: backward switch, -status analysis
channel A is released permanently -check backward switch, channel A
- VZ-Check VZA
sary
E 148 end of aisle safety: backward switch, -status analysis
channel B is released permanently -check backward switch, channel B
- VZ-Check VZA
sary
19
8 System messages

E 149 end of aisle safety: unpermissible combi- -status analysis
nation of switches has released: -check measures for mounting of the
forward A, backward A switch
-driving reduced to slow speed -heavy concussion of the truck: eliminate
cause
-check end of aisle safety-switches
-check cables of end of aisle safety-
switches
E 150 end of aisle safety: unpermissible combi- see E 150
nation of switches has released:
forward A, backward B
forward B, backward A
forward B, backward B
E 155 end of aisle safety: end of aisle safety- see E 150
switch backward A cannot be testet,
because it is activated when switching on
the truck
E 156 end of aisle safety: end of aisle safety- see E 150
switch backward B cannot be testet,
because it is activated when switching on
the truck
E161 Maximum steering angle during WG- - observe MA149, MA150 during WG-
operation exceeded (> +-1,5°) travel (has to oscillate around!)
if not OK:
- check steering straight ahead correction
- check deviation of micro steering sen-
sors
E 164 end of aisle safety: unsufficient efficiency -check drive controller (see chapter 15)
of the counter current braking (control -check setting of braking efficiency via
curve) APE, correct if necessary
-emergency stop: all movements locked, -improve floor, if it is too smooth (clean,
braking improve roughness)
-reduce load
20
8 System messages

E 166 watchdog circuits cannot access the -VZ-check VZA
reset-channel of the control system -visual check SK-R of VZA, change if nec-
essary
-if software problems SK-R of VZA:
detailled error description and VZA-soft-
ware-ident number to Service-department
E 167 WG-SECAN: error 1 Missing-Pulse-Sig- -check sensor and cable
nal micro steering switch front -VZ-check VZA
-emergency stop: all movements locked, -visual check SK-VZA, change, if neces-
braking sary
E 168 WG-SECAN: error 2 Missing-Pulse-Sig- see E 167
nal micro steering sensor rear
braking
E 169 Motor temperature control via analog -let aggregat cool down, reduce load, if
(SL) input (Pull-Up) necessary
-check temperature sensors of the
motors:
contact closed when motor is cold
->switch is defective
-check switch cabling
-pump motor too hot: check pressure set-
tings and valve functions of the hydraulic
installation
-VZ-Check and visual check VZA
E 170 foot switch is not actuated, but brake -check foot switch for function and proper
(SL) doesn’t fall in working
-drive cut-out, mechanical brake actuated -check pressure switch load wheel brake,
change if necessary
-check safety circuit for braking
Problems in the brake system can cause
dangerous situations.Carry out test trav-
els always at reduced drive speed first.
E 172 difference between Set value and meas- -check steering control system, pay atten-
(SL) ured value of the steering too big tion to the blink code of the control system
-drive cut-out (see chapter 15)
-check steering mechanics for well proper
working
E174 steering initiation hasn’t been completed -deactivate recovery switch (if mounted
within a predefined time on the truck)
-steering deactivated -check steering for smooth working
-status analysis
-increase amplification factor in menu
steering/steering initiation
21
8 System messages

E 175 Supply voltage SK-EA: analog sensor -measure voltage supply 12V
(SL) channel 1 too low -investigate shorted cable connection by
-emergency stop: all movements locked, pulling the plugs for the analog sensors: If
braking the cable is disconnected and the supply
voltage is rising to approx. 11,5V, the
cable is defective, repair cable
-check the truck for mass circuit (Fault
current via transmitter cover); remove
mass circuit
E 176 Supply voltage SK-EA: analog sensor see E 175
(SL) channel 2 too low
braking
E 177 full speed released, but drive sensor -status analysis
(SL) doesn’t send pulses -check coupling sensor/motor shaft
-check cables
-check sensor by using respective config-
uration
-VZ-check SK-EA of VZA, visual check,
cross exchange mit SK-EA of VZK if nec-
essary
E 178 aisle recognition of track 1: unpermissible -status analysis
(SL) deviation between 1. and 2. recognition of -check magnet switches and cables track
the aisle recognition signal 1
-emergency stop: all movements locked, -check measures for mounting of the
braking switch
-remove the cause for the concussion
-VZ-check VZA
-visual check SK-EA of VZA
-cross exchange SK-E/A of VZA <-> SK-
E/A of VZK
E 179 aisle recognition of track 2: unpermissible -status analysis
braking switch
-VZ-Check VZA
E/A of VZK
22
8 System messages

E180 aisle recognition of track 3: unpermissible -status analysis
braking switch
-VZ-Check VZA
E/A of VZK
E 181 wire break at pressure sensor 1 (2B10) -check pressure sensor, supply and cable
(SL) prüfen
-VZ-Check VZA, check SK-E/A
E/A of VZK
E 182 WG: aisle signal too early -drive a wider bend for wire recognition
-emergency stop: all movements locked, -check position of the aisle magnets
braking
E 183 WG: lost wire signal -check WG-wire and signal generator,
-emergency stop: all movements locked, watch display in WG-signal generator
braking -measure deviation from the wire;
-check WG-steering behaviour and set-
ting of the steering lock
-VZ-check VZA
-visual check SK-VZA, change if neces-
sary
E184 WG: out of emergency stop diamond -measure deviation from wire and devia-
-emergency stop: all movements locked, tion frfom straight line
braking check WG-steering behaviour and set-
ting of the steering lock
-drive truck in WG-emergency operation
according to operating instructions newly
onto the IF-wire
-pay attention to further APE error mes-
sages (sensor or cable defective)
-VZ-check VZA
-visual check SK-VZA, replace if neces-
sary
-check maximum speed in the aisle,,
adjust to the emergency stop diamond,
see chapter 6 (when vmax-is exceeded:
E 193)
23
8 System messages

E 185 WG: error 1 Missing-Pulse-Signal micro -check micro steering sensor rear + cable
steering sensor rear -VZ-check VZA
-emergency stop: all movements locked, -visual check SK-VZA, change if neces-
braking sary
E 186 WG: error 2 Missing-Pulse-Signal micro see E185
steering sensor rear
braking
E 187 WG: communication with micro steering -check micro steering sensor front + cable
sensor front disturbed -VZ-check VZA
braking sary
E 188 WG: communication with micro steering -check micro steering sensor rear + cable
sensor rear disturbed -VZ-check VZA
braking sary
E189 WG: micro steering sensor front sends -check micro steering sensor front
internal error message
braking
E 190 WG: micro steering sensor rear sends -check micro steering sensor rear
internal error message
braking
E 191 WG: micro steering sensor front must be -re-calibrate micro steering sensor front
(SL) re-calibrated according to chapter 6
-full speed locked
E192 WG: micro steering sensor rear must be -re-calibrate micro steering sensor rear
(SL) re-calibrated according to chapter 6
-full speed locked
E 193 truck drives in WG-operation too fast; -check maximum speed inside the aisle,
emergency diamond not assured correct if necessary; controlled speed =
-general emergency stop adjust permitted WG-speed
E 194 brake not working, although electrically -check SK-VZA
(SL) activated -check wiring from VZA to brake control
-general emergency stop board
-check brake control board
-check wiring to brakes
-check brake coil for continuity
24
8 System messages

E 195 temperature drive motor too high -check motor temperature
(SL) if temperature >90°:
-check drive motor for mechanical friction
-check power wiring
-check spring pressure brake for correct
opening
else:
-check temperature sensor
E 196 Voltage supply for load wheel brake not -check brake wiring
OK -check power to brake control board
25
8 System messages
8.3.2 Operation messages VZK

E 200 CAN-communication disturbed: reception -CAN-check
buffer channel 1 overflow -VZ-check VZK
braking
E 201 CAN-communication disturbed: reception see E200
braking
E 202 CAN-communication disturbed: send see E200
braking
E 203 CAN-communication disturbed: send see E200
braking
E 204 CAN error see E 200
braking
E 205 CAN-error see E 200
braking
E 206 CAN error see E 200
braking
E 207 CAN-communication disturbed: send see E 200
timeout
braking
E 208 CAN-communication disturbed: timeout see E 200
reception from UDR
braking
E 209 CAN-communication disturbed: timeout see E 200
reception from VZA
braking
26
8 System messages

E 210 analog/digital-converter SK-R, operation -VZ-check SK-R of VZK
(SL) not finished in time -visual check SK-R of VZK
-emergency stop: all movements locked, -cross exchange SK-R of VZK <-> SK-R
braking of VZA
E211 Release 24V missing (Switch-off of the -VZ-check VZA
(SL) 24V-supply of the output drivers by -visual check SK-R of VZK
watchdogs) -- cross exchange SK-R of VZK
<-> SK-R of VZA
E 212 measured value-sensor unit auxiliary lift -check setting of sensor unit
(SL) potentiometer 1 wire break detection (A/ -status analysis
D-value) -display analog input of potentiometer on
-driving reduced to slow speed APE
-Lifting and lowering of the auxiliary lift high value: Interruption of the 0V-cable
reduced to slow speed connection
low value: Interruption of the 12V- or the
measured-value cable connection
-measure 12V-supply of the potentiome-
ter (correct value: approx. 11,5V)
E 213 measured value-sensor unit auxiliary lift see E 212
(SL) potentiometer 2: wire break detection (A/
D-value)
-Lifting and lowering of the auxiliary lift
reduced to slow speed
(SL) potentiometer 1: out of range (0, -status analysis
h9_max) -display analog input of potentiometer on
E 215 measured value-sensor unit auxiliary lift see E 214
(SL) potentiometer 2: out of range (0,
h9_max)
-Lifting and lowering of the auxiliary lift
reduced to slow speed
27
8 System messages

(SL) potentiometer 1 and 2: deviation of the -status analysis
values too high -display analog input of potentiometer on
-check potentiometer, change if neces-
sary
E 217 measured value-sensor unit side shift -check setting of sensor unit
-side shift reduced to slow speed high value: Interruption of the 0V-cable
connection
E 218 measured value-sensor unit side shift see E 217
D-value)
-side shift reduced to slow speed
(SL) potentiometer 1: out of range -status analysis
-driving reduced to slow speed display analog input of potentiometer on
-side shift reduced to slow speed APE
high value: Interruption of the 0V-cable
connection
-check coupling of the potentiometer
E 220 measured value-sensor unit side shift see E 219
potentiometer 2: out of range
-side shift reduced to slow speed
28
8 System messages

(SL) potentiometer 1, 2: deviation between -status analysis
the two values too high -display analog inputs of potentiometers
-driving reduced to slow speed on APE
-side shift reduced to slow speed high value: Interruption of the 0V-cable
connection
-check potentiometer-cable
-check coupling of the potentiometer
-check potentiometer, change if neces-
sary
E 222 measured value-sensor unit swivel -check setting of sensor unit
-swivelling reduced to slow speed high value: Interruption of the 0V-cable
connection
E223 measured value-sensor unit swivel see E222
D-value)
-swivelling reduced to slow speed
(SL) potentiometer 1: out of range -status analysis
-driving reduced to slow speed -display analog input of potentiometer on
-swivelling reduced to slow speed APE
high value: Interruption of the 0V-cable
connection
E 225 measured value-sensor unit swivel see E 224
(SL) potentiometer 2: out of range
-swivelling reduced to slow speed
29
8 System messages

(SL) potentiometer 1, 2: deviation of the -status analysis
measured values too high -display analog input of potentiometer on
-swivelling reduced to slow speed high value: Interruption of the 0V-cable
-swivelling reduced to slow speed connection
-check potentiometer cable
-check potentiometer, replace if neces-
sary
E 227 Sensor unit load measurement, wire Sensor unit misadjusted:
(SL) break or defective cable detected -check sensor unit (chapter 7)
-driving reduced to slow speed -Status analysis (MZ202)
Wire break or defective cable:
-check EA206: high value: 0V-cable def.
low value: 12V-cable def.
Potentiometer defective:
-check 12V supply of potentiometer (cor-
rect value: app. 11.5V)
E 228 Evaluation door switch: deviation -check input of door switch via APE
(SL) between 1. and 2. evaluation (electronic- -VZ-check VZK
internal) -visual check SK-E/A of VZK
-emergency stop: all movements locked, -cross exchange SK-E/A of VZA <->
braking replace SK-E/A of VZK; ggf. SK-E/A of
VZK
E 229 Evaluation slack chain switch: deviation --check input of door switch via APE-VZ-
(SL) between 1. and 2. evaluation (electronic- Check VZK
internal) -visual check SK-E/A of VZK
-emergency stop: all movements locked, -cross exchange SK-E/A of VZA <-> SK-
braking E/A of VZK; replace SK-E/A of VZK if
necessary
30
8 System messages

E 230 check sum in the parameter memory -wrong NV-RAM: insert original-NV-RAM
(NV-RAM) wrong with truck specific data
-emergency stop: all movements locked, -wrong contents: coordinate contents
braking and check sum of NV-RAM via Refresh-
function in the service menu. Only when
the contents and checksum of NV-RAM
agree, a parameter input is possible.
-NV-RAM defective: see above
Check all parameters and set newly, if
necessary.
By unintentional changes or defects of the parameter memory (NV-RAM) the behav-
iour of the truck can change in an unpredictable way. Therefore:
- change parameters only if absolutely required
- When replacing the control panel computer, leave the NV-RAM with the truck
settings on the truck, that means, the NV-RAM of the removed UDR-board
must be inserted into the new board
- In case of problems concerning the NV-RAM or interventions on the NV-RAM
check all truck-functions, at least safety relevant functions with slow speed.
Repeat tests with normal speed.
- Each and every occurance of E 230 must be reported to service!
E 231 watchdogs have no access to the reset -VZ-check VZK

connection of the computer -visual check SK-R of VZK, replace if
-emergency stop: all movements locked, necessary
braking -contact service:
exact error description and VZK-software
ident number (-> MA...)
E 232 voltage supply of analog sensors chan- -measure voltage supply 12V
(SL) nel 1 too low -detect shortened cable connection by
-emergency stop: all movements locked, pulling the plug for the analog sensors: If
braking the voltage sinks to approx. 11,5 V when
pulling the plug, then the plug is defective
-> repair
-VZ-check VZK
-visual check SK-E/A of VZK
-cross exchange SK-E/A of VZK <-> SK-
E/A of VZA
-replace SK-E/A of VZK if necessary
E233 voltage supply of analog sensors chan- see E 232
(SL) nel 2 too low
-mergency stop: all movements locked,
braking
31
8 System messages

E 234 input of wrong code number, display -input correct code number
stopped, no display available -ask for correct code number from cus-
-emergency stop: all movements locked, tomer service
braking -VZ-check UDR
-replace UDR-board if necessary
E235 master switch left side: set value availa- -status analysis
(SL) ble, but direction signal is missing -set sensors of master switch (teach-in)
-emergency stop: all movements locked, -check function of the micro switches
braking -check master switch via configuration K
18
-check master switch cable connection
-VZ-check UDR, replace if necessary
E 236 master switch left side: 2 direction sig- -status analysis
(SL) nals at the same time -check function of the micro switches
-emergency stop: all movements locked, -check master switch via configuration K
braking 18
E 237 master switch left side: direction signals -status analysis
(SL) available, but set value is missing -adjust sensors of master switch (teach-
-emergency stop: all movements locked, in)
braking -check function of the micro switches
-check master switch via configuration K
18
E 238 master switch right side: set value availa- -status analysis
(SL) ble, but directional signal is missing -adjust sensors of master switch (teach-
-test master switches via configuration K
17
E 239 master switch right side: 2 direction sig- -status analysis
(SL) nals at the same time -check function of the micro switches
-emergency stop: all movements locked, -test master switches via configuration K
braking 17
32
8 System messages

E 240 master switch right side: direction signal -status analysis
(SL) available, but set value is missing -adjust sensors of master switch (teach-
-test master switches via configuration K
17
E 241 Error Pump AC-controller -pay attention to the blink code of the
-emergency stop: all movements locked, control systemd (see chapter 15)
braking
E 242 Error in side shift center position control Potentiometer misadjusted or cable def.:
(SL) for telescopic forks -check potentiometer and cable
-movement of telescopit forks locked -re-calibrate potentiometer
Center position switch or cable:
-check center switch and cable
E243 pressure for side shift or auxiliary lift -check pressure sensors and cable con-
(SL) movements couldn’t be reduced below nections
an adjustable maximum during an adjust- -check settings according to the test pro-
able time tocol
(prevention of startup jumps) -check hydr. flow controller , replace if
-movement starts only if pressure has necessary (see chapter 5)
fallen below adjusted pressure
33
8 System messages
8.3.3 Operation messages UDR

To check the control panel functions in case of error messages
on UDR, use the Control Panel Test Page on the APE (see
chapter 9).
Note:
In case of critical errors on UDR, it can happen, that the APE-
Status display doesn’t show any actual value from the control
panels:
For safety reasons, in case of critical errors, the UDR is not
allowed to send any data to the cabin control unit (VZK). At that
moment, the acutal control panel data is not available on the
Status display on the APE.

E 301 Boot error of computer UDR -replace UDR-board (UDR or EPROM
-all functions locked defective)
-call service
E 302 CAN-Bus synchronisation error -if the error occurs in normal operation of
the truck: order UDR, UDL-update
-call service
E 303 steering unit returns different signals on -check cable connection between steer-
channel A and B ing unit and main board UDL
-all functions locked - turn steering wheel slowly and measure
switching of the phase signals by means
of a volt meter
- check voltage supply of both sensors
(corrosion, crimping, defective spots at
the cable or the plug, etc.)
E304 Unpermissible current consumption of -check cable connection betwee steering
(SL) steering wheel sensor channel A unit and main board UDL
- turn steering wheel slowly and measure
the phase signals by means of a volt
meter
E 305 NV-RAM error during boot-up -restart truck
-all functions locked -access service menu and follow the
instructions
E307 Unpermissible current consumption of -check cable connection betwee steering
(SL) steering wheel sensor channel B unit and main board UDL
- turn steering wheel slowly and measure
the phase signals by means of a volt
meter
34
8 System messages

E 308 no release from VZK after start of the -check CAN-connection (cable) to VZK
UDR: -check VZK (LED status)
after start-up, the control panel did not -replace UDR
receive the release signal for driving -check control panel for permanent or
operation from the VZK in time short-time interruption of voltage supply
E 309 Warm restart of computer during normal -restart truck
operation
-all functions locked
E 310 CAN-bus error -CAN-Check
-all functions locked
E314 Analog default settings do not corre- -cross exchange drive switch left/right
spond with the switching values (right -if the error does not diffuse:
side master switch) check the signals at the plug connection
to the board
replace main board
Attention:
Before starting the control panel: tighten
threaded fastener between UDL and
VZK, do not apply stress to cable con-
nection
E315 Analog default settings do not corre- -cross exchange drive switch left/right
spond with the switching values (left side -if the error does not diffuse:
master switch) check the signals at the plug connection
to the board
replace main board
Attention:
Before starting the control panel: tighten
threaded fastener between UDL and
VZK, do not apply stress to cable con-
nection
E 328 No RS232 connection between UDL and -Check cable connection between the
(SL) UDR right and the left part of the control panel.
- check voltage supply RS232
-RS232 check
also see description E329
E 329 Very short term communication error -Check cable connection RS232
occured between UDR and UDL -RS232 check
Note: This error can also be a result of -check of voltage supply UDL (at the
an E328. testing point control board UDL)
35
8 System messages

E 330 TxD and RxD on RS232-connection con- If error occurs without test plug:
nected -disconnect left control panel side
(Test plug with bridge has been installed if error disappears: exchange main board
or short circuit occured) UDL, else
-disconnect cable from UDR
if error disappears: check cable for short
circuit, else
exchange main board UDR
E 331 Interruption of the UDR supply voltage -check cable connection between VZK
recognized and VZA
-check cable connection between VZK
and UDR
-check for loose contacts
-check for short circuits
E 332 Interruption of the UDL supply voltage -check cable connection between UDR
recognized and UDL
-check for loose contacts
-check for short circuits
36
9 Equipment check
9 Equipment check

- multimeter
Chapt. Theme Page

9.1 Visual inspection of electronic
assemblies 3
9.1.1 Visual Inspection of Electronic
Assemblies 3
9.1.2 Cross Exchange of Electronic
Assemblies 4
9.1.3 Fuse Check 5
9.2 Interchanging electronic

assemblies 5
9.2.1 Connection of the APE to the Truck 5
9.2.2 Functions of the APE 6
9.2.3 Error Diagnosis on the Truck 10
9.2.4 Structure of the APE 12
9.3 CAN Check 14

9.3.1 General Information 14
9.3.2 Structure of the CAN bus 14
9.3.3 Flowchart CAN-Check 16
9.4 RS232-Check 18
9.4.1 General Information 18
9.4.2 Structure of the RS232 Connection 18
9.5 VZ-Check 21
9.5.1 Drive compartment processing unit
(VZA) 25
9.5.2 Cabin processing unit (VZK) 25
9.6 Check of Control Panel 28

9.6.1 Check Master Switch 28
9.6.2 Check of the Steering Wheel Sensor
Unit 29
9.6.3 Check of the Key Switches 29
1
9 Equipment check


materials.
2
9 Equipment check
9.1 General Information about System Diagnosis

9.1.1 Visual Inspection of Electronic Assemblies
Remove defective circuit board

Electrostatically sensitive componenets!
Straighten bent pins.

Plugs ok? In case of mechanical damages:
No
Replace board
Yes
Replace defective fuses;

Fuses ok? No if necessary,
rebend fuse holder
Yes
-Check whether the parts are

in right location (e.g. jumpers)
-Check the ID numbers of the
Plug-ins seated plug-in boards
correctly? No
(e.g. EPROM-module)
-Firmly plug the parts in,
check whether they have contact
Yes
Mechanical Do not repair!

Yes Replace board
damage visible?
No
Do not resolder!
Components loose? Yes Replace board
No
Bumtspots
visible?
yes
Yes Replace board
No
If possible, check by exchanging boards

Electronic defect (see chapter 9.2)
Replace defective assembly
3
9 Equipment check
9.1.2 Cross Exchange of Electronic Assemblies

If malfunctions occur in the area of the processing units, hard-
ware faults can be definitely recognized in certain cases by
cross exchange of boards.
During this procedure, electronic assemblies with identical hard-
ware are removed from the equipment, exchanged and installed
again.
A defective assembly is determined by the fact that the malfunc-
tion "follows" the assembly.
Such an exchange provides a solution if no spare parts are
available on site for tests. Ordering of the wrong spare parts can
thus be avoided.
Before exchanging assemblies, always check the equipment

interfaces of the apparently defective assemblies for inadmis-
sible voltage levels.
Damage to the assemblies to be interchanged can thus be

avoided
Changeable component Meaures before remounting

the component
Input/output board (SK-EA) No special measures required
(VZA <-> VZK) (identical hardware)
Computer board (SK-R) -Replace the EPROM; when
(VZA <-> VZK) doing so, check that the soft-
ware ID numbers for VZA and
VZK are correct
-Replace the jumpers on SK-
CAN:jumper for VZA, no
jumper for VZK
CAN bus board (SK-CAN) No special measures required
(VZA <-> VZK) (identical hardware)
Master switch control panel No special measures required
(UDL<->UDR) (identical hardware)
Double key board control No special measures required
panel (identical hardware)
(UDL<->UDR)
WG sensor -correct installation to the
(front<->rear) chassis
-WG setting (see chapter 6)
4
9 Equipment check
9.1.3 Fuse check

The electric circuits of the equipment are protected against dam-
age resulting from overload and short circuit by safety fuses.
+ Fuses see chapter Maintenance of the Operator’s Manual.
The computer boards of VZA and VZK are additionally protected

by microfuses on the board.
Only replace fuse units with the equipment switched off to pre-
vent injury to personnel and damage to material.
Pull out the battery plug before replacing main fuses. Otherwise,
short-circuits may be caused when loosening and tightening the
screwed connections.
To perform a continuity check with the multimeter, remove the
fuse links from the fuse holder.
If blade-type fuses on the fuse board are blown or not fitted, the
pertaining monitoring LED is not lit.
Before replacing fuse units
- check the current path for short circuits using the multime-
ter
- eliminate faults in the electric and electronic equipment
Observe the following when replacing strip fuse units:
- Do not forget the washers.
- Tighten screwed connections properly
9.2 Use of the Display and

Programming Unit (APE)
9.2.1 Connection of the APE to the Truck
An external display and programming unit for service operations
must be connected to the right side control panel (error diagno-
sis and parameter setting).
For this purpose, there is a CAN bus interface on the bottom sur-
face of the right control panel (marked with „APE“).
+ A service set, consisting of APE, connecting cable, support

and bag is available from BT.
The APE is connected as follows:

- Switch off the truck
The cable connection from UDR to APE must not be plugged in

or out when the truck is switched on. Electronic components
might be destroyed.
5
9 Equipment check
- Connect the cable to UDR and tighten the screws of the

plug.
- Fix the APE on the support at the cabin railing.
- Switch on the truck.
- As soon as the basic display appears, the service menu
can be called.
9.2.2 Functions of the APE

a) Basic Display
After connecting the APE to the
right control panel (UDR) and
switching on the truck, the basic
display appears.
6
9 Equipment check
:Shortcut functions from the basic display.
Keys Function Description

<F1+F3> Control panel Allows to check all panel
Test page keys and switches for cor-
rect function.
<F4> or Contrast brighter When the key is pressed
<F1+F4> and held, the display slowly
becomes brighter.
<F5> or Contrast darker When the key is pressed
<F1+F5> and held, the contrast of the
display changes quickly
(birght - dark cycle)
<F6> Password screen Enter password to access
service menu
b) Password screen
After adjusting the brightness of the APE and confirming with
ENTER, the Password screen appears.
At the first access to the service menu, the following password
must be entered:
Password: 1848
Never give the password to unauthorized personnel!
+ The password screen can be left by pressing <F1+F4> (ESC-

Function). Input of the password is done from right to left. By
pressing the keys <F2> or <F3> , the desired value can be set.
Use the keys <F4> as well as <F5> for selecting the desired
+
decimal digit.
After entering a wrong access code, a corresponding message

is transmitted. The truck must be restarted again before further
use.
After setting the correct code in this way, confirm by pressing the
key <F6>.
+ <F1 + F4> means:

- press F1 and hold
- press F6 briefly
7
9 Equipment check
c) Service Menu
The service menu appears on

the screen.
By pressing the keys <F2> or
<F3>, the line cursor can be
transferred into the respective
line. Access to the selected func-
tion menu (e.g. „M04 main lift-
ing“) is done by pressing the key
<F6>.
+
The structure of the function
menus M01 to M23 is
described in chapter 11.
Shortcut functions from the Service menu:

<F1+F3> Status display Allows to display all Inputs,
Outputs and Tags on the
screen for error diagnosis
<F1+F4> Escape Escape and return to the
previous display page.
d) Function Menus
Changing parameters in Function Menus
+ As an example, the function

menu „M04 Main Lift“ is dis-
played.
By pressing the keys <F2> or

<F3>, the line cursor can be
transferred into the respective
line. Activation of the selected
parameter is done by pressing
the key <F6>.
+ The character cursor appears.
8
9 Equipment check
Character Cursor
The character cursor marks only

one decimal digit of a setable
parameter. It blinks and marks an
active function (parameter value
can be changed).
+ For changing the value, press

the keys <F2> or <F3>. Holding
a key is equal to the repeated
pressing of the key.
With input fields with several dig-

its, e.g. in the editing of a
number, the cursor can be trans-
ferred to the digit to be edited by
pressing the keys <F4> und
<F5> verschieben.
During the input of a value, the permissible range for the input in
the lowest monitor line is displayed (Min/Max).
For the adoption of the new value, press the key <F6>.
Plausibility Check
On pressing <F6> (ENTER), only plausible values are adopted.
Wrong values are aborted. A corresponding status message is
displayed at the lower margin of the monitor.
Shortcut functions from the Function Menu:

<F1+F3> Status display Allows to display all Inputs,
Outputs and Tags on the
screen for error diagnosis
After finishing the service operations, switch off truck and

remove APE. Never hand over truck to operator with activated
service menu and connected APE. Before handing over the
truck to the operator, check all truck functions for flawless
function!
9.2.3 Error Diagnosis on the Truck

The menu „Status Display“, all operands available in the truck
control (inputs, outputs, tags) can be called and displayed during
the operation of the truck in real time. This allows for a very
quick recognition of the control status in case of malfunctions or
error messages, and the reason for the error can be determined.
9
9 Equipment check
The status display can be accessed as follows by pressing

<F1+F3> from the Service menu and all Function menus.
+ See chapter 10 „Inputs, Outputs and Tags“ for a list of oper-

ands.
Preparing the Status Display
Manual Call of Operands

- Press <F2> or <F3> to
select the line in which the
operand is to be displayed.
- Press <F6> (ENTER) to
activate the line; the char-
acter cursor appears. (see
Z00)
- Press <F2> or <F3> to
select the type of the oper-
and (E, EA, A, AA,...)
- Press <F6> (ENTER) to
adopt type; character cur-
sor jumps to the right (see
Z01)
- Enter counting number of
the operand; press <F4> or <F5> to select decimal digit,
press <F2> to reduce the value or <F3> to increase the
value.
- Press <F6> (ENTER) to adopt counting number; bar cur-
sor appears.
The current value of the operand is displayed in the line at the
right (see Z03).
+
As the Status display is an „online-screen“, in the right bottom
corner, there is a permanent counter. As long as the counter is
running, the system is still working.
Call Operand by Means of Configurations

For a faster display of several operands, so-called configura-
tions for all functions of the truck are pre-defined in the truck
software. If one configuration is called, all operands which are
assigned to this configuration are displayed automatically.
10
9 Equipment check
Call of a configuration in the status display:

- Place line cursor in the first line
- Press <F6>
- Press <F2> to edit the letter „K“ and confirm with <F6>
- Press the key <F2> to edit the desired counting number
and confirm with <F6>
All operands included in the configuration are shown on the dis-
play automatically.
+ Service display configurations see chapter 11.
Every status of the status tags (MZ) can be shown in the status
display as short text (see Z05) or as figures (see Z06). The
meaning of the figures or the short texts is explained in chapter
10 „Control Status“.
Shortcut functions from the Status display:

<F1+F3> Control panel Allows to check all panel
Test page keys and switches for cor-
rect function.
11
9 Equipment check
9.2.4 Control panel Test Page

To check all keys and switches on the control panel, there is a
Test Page for the control panel available.
The Test Page can be accessed by pressing <F1+F3> from the
- Basic Display and the
- Status Display.
Testing the keys on both panels:
Press desired key on the panel
and watch the respective row on
the Test Page. A black rectangle
must be shown between the
brackets.
Testing the Master switches:
Move the desired master switch
to one side. One row on the Test
Page shows the selected direc-
tion. A second row shows the
actual value in %.
To guarantee a maximum con-
+
trol, the value should start at 0
and proceed continuously to
100.
Testing the Steering wheel:

When turning the steering wheel, two rows show the actual
value of channel A and B from the steering wheel.
+ The values of channel A and B have to move parallel.
Shortcut functions from the Control panel Test page:

12
9 Equipment check
9.2.4 Structure of the APE

54 Cover sheet 58 Converter board
55 Top cover case 59 APE-motherboard
56 LC-display 60 O-ring
57 Flat cable 61 Bottom case
Always pull off the top cover (55) vertically, do not pry.
13
9 Equipment check
Structure of the APE Motherboard
14
9 Equipment check
9.3 CAN Check

9.3.1 General Information
The SECAN control system automatically detects faults occur-
ring in the CAN bus connection and indicates these faults by
appropriate error messages.
The CAN signals cannot be measured adequately using a multi-
meter since the pulse patterns change constantly according to
the transmitted data. Nevertheless, CAN faults can be examined
and eliminated by applying the methods described below.
CAN fault causes

CAN faults can be caused by
- defective or incorrectly installed CAN controller cards (SK-
CAN)
- jumpers on the CAN controller cards set incorrectly
- defective or corroded plug and socket connections
- interrupted or short-circuited lines
Shielding of the mast cable

Shielding of the CAN bus via the mast is necessary to comply
with EMC regulations.
The jumpers on the CAN controller cards are used to activate
terminators at the ends of the bus.
In case of missing or misplaced jumpers on the CAN controller
cards (SK-CAN), the data transfer can still be possible. It will
react more sensitively upon influences
15
9 Equipment check
9.3.2 Structure of the CAN bus
+ This diagram only shows the pins and leads of the link circuits
that are important for CAN data transmission..
16
9 Equipment check
9.3.3 Flowchart CAN-Check
CAN fault Remarks
Restart the truck
Sporadic fault.
Fault still present? No Truck is ready
for operation again
Yes
Switch off the truck
Check the plug

connections of the bus
-Correct slot?
Plug connections ok? No Remove fault -Plug engaged?
-Plug corroded or soiled?
-Shielding correctly connected?
-Lead properly in the pins?
-Isolation ok?
Yes
Assemblies -VZ-check (section 9)

No Remove fault -Visual inspection
plugged in correctly?
Yes
-Jumper pluggen on SK-CAN

Jumpers plugged
No Remove fault for VZA
in correctly?
-No Jumper for VZK
Yes
17
9 Equipment check
9.4 RS232-Check
9.4.1 General Information
The communication between the right control panel (UDR) and
the left control panel (UDL) is done via a serial connection
RS232. Additionally, there is serial interface for data transfer
with external computers (PC, Laptop) on the right control panel
(UDR).
+
9.4.2 Structure of the RS232 Connection
Only the connections required for data transfer are displayed.
Parallelly, there are two additionaly connections for voltage
supply.
The motherboards (VZ) of both UDL and UDR are equipped with
a RS232 communication component for the data interchange
between the right and the left control panel.
VZK sends a synchronisation message to UDR. This message is
transferred to the UDL via RS232 connection (1).
Within the specified period, these messages must be answered
by UDL. In this process, response messages are returned to
UDR via (2). If there is no response until the next SYNC signal is
+
sent, an RS232 communication error signal is transmitted.
RS232 errors see chapter 8 „System Messages“
9.4.3 RS232-Check
If a RS232 error message has appeared, the location of the error
on either the right or the left control panel can be determined by
performing the RS232-check.
Switch off truck before disconneting the plugs or inserting the

connection between the individual pins.
18
9 Equipment check
Remarks
2 x 120 Ohm in parallel

(VZA/UDR terminators)
Resistance test
X199 / pins 1-2
CAN bus
Approx. 60 Ohm? No fault This procedure only checks the lines
“CAN+” and “CAN-”, if necessary,
check all connectors with wiring
Yes diagram “CAN bus” with
Remove plug X299 disconnected plugs Ohm test
(lines “supply”, “ground”)
Resistance test:
X199 / Pin 1-2
in the base of the board
Approx. 120 Ohm? (VZA terminator)
Yes
No
Note:
Fault in the bus The CAN-bus can also be checked
VZK <-> UDR partly:
(in cabin)
possible; from X199 (VZA) to X199A
remove fault (driving AC-controller)
from X199A to X199B

(AC-controller -loop)
Resistance test:
X199 / Pin 1-2 from X199B to X200 (VZK)
in the mast cable plug (Driving AC-controller)
Yes Appox. 120 Ohm?
CAN bus ok?
Fault in the bus

VZK <-> VZA
Section 9 (over mast)
Interchange SK-CAN possible;
remove fault
Fault on VZ-assembly
Fault located? No
Yes
VZ-Check -VZ-check (see section 9)

Remove fault -Visual inspection (see section 9)
Visual inspection
19
9 Equipment check
Remarks
2 x 120 Ohm in parallel

(VZA/UDR terminators)
Resistance test
X199 / pins 1-2
CAN bus
Approx. 60 Ohm? No fault This procedure only checks the lines
“CAN+” and “CAN-”, if necessary,
check all connectors with wiring
Yes diagram “CAN bus” with
Remove plug X299 disconnected plugs Ohm test
(lines “supply”, “ground”)
Resistance test:
X199 / Pin 1-2
in the base of the board
Approx. 120 Ohm? (VZA terminator)
Yes
No
Note:
Fault in the bus The CAN-bus can also be checked
VZK <-> UDR partly:
(in cabin)
possible; from X199 (VZA) to X199A
remove fault (driving AC-controller)
from X199A to X199B

(AC-controller -loop)
Resistance test:
X199 / Pin 1-2 from X199B to X200 (VZK)
in the mast cable plug (Driving AC-controller)
Yes Appox. 120 Ohm?
CAN bus ok?
Fault in the bus

VZK <-> VZA
Section 9 (over mast)
Interchange SK-CAN possible;
remove fault
Fault on VZ-assembly
Fault located? No
Yes
VZ-Check -VZ-check (see section 9)

Remove fault -Visual inspection (see section 9)
Visual inspection
!VZ-Check
20
9 Equipment check
Check resting voltage RS232:

Plug X129 cabel: disconnect Pin 1, Pin 11
Measurment on cable between Pin 1 and Pin 3, as well as
Measurement on cable between Pin 11 and Pin 3
Check cable connection RS232

10V OK? No
Check plug X129 UDR externally
Replace computer board VZ-UDR, if necessary
Yes
Check operating voltage RS232 (Rxd UDL)

Testpoint RS232 UDL: Pin 2 and Pin 4
UDR sends no messages

approx. 8V OK?? No
Replace computer board VZ-UDR
Yes
Check operating voltage RS232 (Txd UDL)

Testpoint RS232 UDL: Pin 3 and Pin 4
approx. 7V OK?? UDL sends no messages

No
Replace computer board VZ-UDL
Yes
Inform central service
21
9 Equipment check
9.5 VZ-Check
The VZ-Check applies to the processing units in the drive com-
partment, (VZA), as well as in the cabin (VZK).
+ The EMV-Hoods of VZA and VZK must not be removed, except

for checks and test operation. In permanent operation, the
hoods must be mounted.
Before working at the electronic assemblies, precautions

against distruction by electrostatic discharge must be taken.
For this reason:
- Discharge body by touching metal, grounded items

- Touch board only by their edges
9.5.1 Drive compartment processing unit (VZA)
Nr Check Measure
.
1 Status Visual check of the electronic assemblies (see section 9.1.1)
2 Setup Check the interface board for correct assignment:- X153
free or used by special board
- X150 used by SK-E/A
- X152 used by SK-VZA
- X151 used by SK-R
- bus board correctly seated
- all boards plugged without pin offset, no bent or broken pins
3 Voltage supply Fuse check
4 Voltage supply Motherboard, battery voltage at X100 / pins 1, 2, 3, 4, 6, 8,
10 to pins 7, 9, 11, 12
Motherboard, 24V at X101 / pins 2, 4, 6, 7, 8, 10, 11, 12 to
pins 1, 3, 9
5 Voltage supply 24V between terminals 3 and 4 of DC converter 7A1
6 Voltage supply Remove fuse units F1, F2, F3 from the SK-R computer
board and check for continuity using an ohmmeter. When
inserting the units, check that the retaining springs provide
sufficient contact pressure, if necessary, rebend the retaining
springs
7 EPROM-mod- EPROM with the correct ID number according to the spare
ule parts catalogue must be plugged on computer card SK-R/
2X15; make sure it is seated correctly
8 SK-CAN plug- Controller card SK-CAN must be plugged on SK-R/2X14A
in board and 2X14B; make sure it is seated correctly.Jumper must be
plugged on SK-CAN
22
9 Equipment check
Design VZA
Free terminal SK-EA SK-VZA SK-R

(for options)
EMC hood
Bus board
Hexagon Stud
Interface
board
Alu base plate
Design computer plug-in board (SK-R) in the VZA
Plug-in Plug-in
board board
SK-CAN- SK-EPROM
-
Microfuses
1A MT
SK-R Jumper
Diagnostic plug connectors,
Status-LED, red processor bus (for manufacturer only)
Status-LED, green
23
9 Equipment check
Interface board VZA
This area is covered by the EMC hood
24
9 Equipment check
Blinking Codes of the Status LEDs VZA

Errors on the processing unit drive compartment (VZA) can be
determined by means of the status LEDs of the individual com-
puter plug-in boards.
For the check of the status LEDs, the EMV hood must be
removed.
LED Col- Meaning Measure

our
dark processing unit not in opera- Fuse Check
tion or no function Visual Check VZ
red Test of program memory Visual Check VZ
(EPROM) and RAM initiated, Cross exchange computer
but not completed success- board
fully
red + green Initialization and test of the CAN-Check
CAN-communication initi- Check other processing units
ated, but not completed suc-
cessfully
red +blink- CAN-Controller successfully CAN-Check
ing green tested, but Check of the not sending
- with VZA: no reception from processing unit
UDR
- with VZK: no reception from
UDR
blinking red CAN-Controller successfully CAN-Check
+green tested, but Check of the not sending
- with VZA: no reception from processing unit
VZK and UDR
VZA and UDR
blinking red CAN-Controller successfully CAN-Check
+ blinking tested, but Check other processing units
green - with VZA: no reception from
VZK and UDR
VZA and UDR
25
9 Equipment check
9.5.2 Cabin processing unit (VZK)
Nr. Check Measure

1 Status Visual check of the electronic assemblies
2 Setup Check the interface board for correct
assignment:
- X250 free or used by spe-
cial board
- X253 used by SK-E/A
- X251 used by SK-R
- bus board correctly seated
- all boards plugged without pin offset, no
bent or broken pins
3 Voltage supply Fuse check
4 Voltage supply Motherboard, battery voltage at X298A /
pins 1, 3, 4, 9 to pins 5, 6, 7
Motherboard, 24V at X298B / pins 1, 3, 4 to
pins 5, 6
5 Voltage supply Remove fuse units F1, F2, F3 from the SK-
R computer card and check for continuity
using an ohmmeter. When inserting the
units, check that the retaining springs pro-
vide sufficient contact pressure; if neces-
sary, rebend the retaining springs.
6 EPROM-module EPROM with the correct ID number accord-
ing to the spare parts catalogue must be
plugged on computer card SK-R/2X15;
make sure it is seated correctly
7 SK-CAN plug-in board SK-CAN must be plugged on computer card
SK-R/2X14A and 2X14B; make sure it is
seated correctly.
No jumper must be plugged on SK-CAN.
26
9 Equipment check
Design VZK
Free slot SK-R

SK-EA
(for options)
EMV hood
Bus board
Hexagon stud
Aluminium
Interface board base plate
Design computer plug-in board (SK-R) in the VZK

The SK-R boards of VZK and VZA are identical as far as the
hardware is concerned. They differ in the following:
- EPROM module; different software (check ID number)
- jumper on the CAN controller card SK-CAN (jumper for
VZA, no jumper for VZK)
+ See Figure „Design computer plug-in board (SK-R) in the VZA“

on page 21.
27
9 Equipment check
Interface board VZK
This area is covered by the EMV hood
Blinking Codes of the Status LEDs VZK

Errors on the processing unit cabin (VZK) can be determined by
means of the status LEDs of the individual computer plug-in
boards.
For the check of the status LEDs, the EMV hood must be
removed.
+ See „Blinking Codes of the status LEDs VZA“ on page 23.
28
9 Equipment check
9.6 Check of Control Panel

9.6.1 Check master switch
Cross exchange master switch (UDL <--> UDR)
Error follows? Yes Replace defective master switch
No
Check voltage: supply 24V:

Plug master switch: between Pin 2 and Pin 5
Check voltage supply 24V:

24V OK? No between master switch Pin 5 and
GND of main board
Yes
24V OK? No
Check analog signals:

Intial position: between Pin 8 and Pin 2: +5V
Direct signals: between Pin 6 and Pin 2: 0V or 5V Yes
between Pin 7 and Pin 2: 0V or 5V
Rated value: between Pin 4 and Pin 2: 0 -5V
No Check cable connection and plug

Signals OK?
Replace master switch, if necessary
Yes
Replace main board
Pins of the drive switch plug on the main board.

Pin 2: +0V (GND)
Pin 5: +24V (Supply)
Pin 4: Actual value (0V in initial position, approx. +10V at full
pegging)
Pin 8: Digital signal for initial position (+5V in initial position)
Pin 6, 7: Direction signals (+5V or 0V)
29
9 Equipment check
9.6.2 Check of the steering wheel sensor unit
Check plug connection again for loose contact
Cross exchange plug connectors channel A, channel B
Yes Error message

changes?
No
Check voltage supply on steering wheel channel A,B:

Plugs connected: between Pin 1 and Pin 4: 4,5V
Plugs disconnected: between Pin 1 and Pin 4: 5,0V
Voltage OK? No Replace main board UDL
Yes
Voltage measurement of the analog signals:

Channel A: betweem Pin 2 and Pin 3: 0V ; 4,8V
Channel B: between Pin 2 and Pin 3: 0V ; 4,8V
When steering wheel is turned slowly,

there must be a significant voltage alteration.
Signals OK?
9.6.3 Check of the Key Switches

All key switches on the panel can be checked by calling the Con-
trol Panel Test Page or the control panel configuration.
+
The configuration only shows correct values, if there is no crit-
ical control panel error. Design of the configuration for the
right and left control panel see chapter 11.
9.6.4 Check of the LEDs

The LEDs can be checked, when the truck is restarted. During
startup, all LEDs on the panel are lit for a short time. Special
30
9 Equipment check
attention should be paid to the LED „battery status“ (R5) and the
LED „driving and synchronous lifting/lowering (R1). They have to
be lit yellow.
Note: The above mentioned shortcuts in brackets refer to oper-
ating instructions.
31
9 Equipment check
32
10 Inputs, outputs, tags
10 Inputs, outputs,
tags
Removal / installation of components other than those listed in the spare parts catalogue is
not permitted.
Chapt. Theme Page

10.1 Assignment of the operands
to VZA and VZK 3
10.2 Inputs 5
10.2.1 Digital inputs VZA 5
10.2.2 Digital inputs VZK 7
10.2.3 Analog inputs VZA 8
10.2.4 Analog inputs VZK 9
10.3 Outputs 9
10.3.1 Digital outputs VZA 9
10.3.2 Digital outputs VZK 11
10.3.3 Analog outputs VZA 11
10.3.4 Analog outputs VZK 11
10.4 Tags 12
10.4.1 Digital tags VZA 12
10.4.2 Digital tags VZK 14
10.4.3 Digital tags VZK 16
10.4.4 Analog tags VZK 18
10.4.5 Status tags VZA 20
10.4.6 Status tags VZK 21
10.5 Control status VZK 22

10.5.1 MZ 100: Driving 22
10.5.2 MZ 101: Brake 24
10.5.3 MZ 102: Steering 25
10.5.4 MZ 103: Aisle/ Apron 25
10.5.5 MZ 104: Steering controller 26
10.5.6 MZ 105: Steering initiation 26
10.5.7 MZ 106: Drive AC control system 27
10.5.8 MZ 108: End of aisle safety device 28
10.5.9 MZ 110: Slack chains 28
1
10 Inputs, outputs, tags
10.5.10 MZ 111: master switch left 29

10.5.11 MZ 112: master switch right 29
10.5.12 MZ 113: WG 30
10.5.13 MZ 114: WG estimation value;
estimation gear angle/distance in apron 31
10.5.14 MZ 115: WG strategy 31
10.5.15 MZ 116, 117, 118, 119 31
10.6 Control system states of the VZK 32

10.6.1 MZ 200: Lifting the main lift 32
10.6.2 MZ 201: Lowering the main lift 33
10.6.3 MZ 202: Lifting auxiliary lift 34
10.6.4 MZ 203: Lowering the auxiliary lift 35
10.6.5 MZ 204: Swivelling 36
10.6.6 MZ 205: Side shift 37
10.6.7 MZ 206: Synchronous swivelling 38
10.6.8 MZ 208: Swivelling hydraulic contro 38
10.6.9 MZ 209: Side shift hydraulic control 39
10.6.10 MZ 210: Auxiliary lift hydraulic control 39
10.6.11 MZ 211: Synchronous swivelling
hydraulic control 40
10.6.12 MZ 212: Master switch left 40
10.6.13 MZ 213: Master switch right 41
10.6.14 Slack chains 41
10.6.15 MZ 215: Lift cut-out main lift 41
10.6.16 MZ 216:Pump motor controller 43
10.6.17 MZ 217: Hydraulic lift module block
function 43
10.6.18 MZ 218: Side shift cut-out 43
10.6.19 MZ 219: Main lift hydraulic controller 44
Indicates notes regarding safety that must be heeded to prevent danger to personnel.
Indicates notes that must be heeded to prevent danger to materials.
2
10 Inputs, Outputs, Tags
10.1Assignment of the operands to VZA and VZK

Inputs, Outputs and Tags are socalled „operands“. The operands are always assigned to the
respective assembly, from which they are operated. This does not necessarily have to be the same
assembly, to which the respective sensors and actors are attached to.
+ Only the "intelligent" processing units in the drive compartment (VZA) and cabin (VZK) process
operands. the processing unit control panel (UDR) is only applied for transmission of operating
actions on VZA and VZK and the displaying of informations.
Each operand consists of

- Short description: 1-3 capital letters (A, AA, E, EA, ERE, ERW, M, MA, MZ, P)
- 3-digit counter number
The 1. digit of the counter number identifies the processing assembly:

- "1xx": VZA
- "2xx": VZK
SD Operand Description
A Output digital Control signals, that can cover two states “0“ or „1“; e.g.
actuation of S/W-valves, blinker signals, etc.
AA Output analog Continuous output signals, e.g. set values for rheostats and
standardized AC-controllers, standardized into the respective physical
measurement unit.
AA# Output analog The continuous output signals digitalized (0 ... 1023), before
Hardware standardisation.
E Input digital signals from the truck electric system, that accept only the
status „0“ or „1“ (On or Off) , e.g. switches, keys, return infor-
mations from electronic components
EA Input analog stand- all external signals, that transmit continous values to the
ardized control system, e.g. potentiometers. Standardized means,
that the measured continuous value (EA#) is already con-
verted into a physical measurement unit e.g. lifting height in
m, load in kg, etc.
EA# Input analog Hard- The analog signals are converted via A/D-conversion into
ware digital information (0 ... 1023).
ERE Error detected Especially in the case of errors, that only occur for a very
short time, it is possible, to prove such an error in service
menu M24 „status display“ by editing ERE together with the
error number. („1“ if error detected, else „0“ )
3
SD Operand Description
ERW Error value Duration of the error signal
M Tag digital Value generated internally in the control system, that is gen-
erated from other values e.g. from the continuous signal of
the lift height measurement, a digital tag „end ahead top“ is
generated.
MA Tag analog Continuous value generated internally in the control system
MA# Tag analog Analog tag digitalized (0 ... 1023), without standardizing
Hardware
MZ Status Tag Indicates, in which status (processing step), a truck function
or component is at the moment
P Parameter The respectively adjusted truck parameters
4
10.2Inputs
10.2.1Digital Inputs VZA
SD Description
E100 key switch option
E101 Key End Of Aisle Safety Device Reset
E102 Key Lifting Movement Override
E103 Key Drive Override
E104 Key Slack Chain
E105 Key Fork Tine Adjustment
E106 Key Wg / Straight
E107 Key Shift Override
E108 Key Swivel Synchronous
E109 Key Main Lift And Auxiliary Lift Synchronous
E110 Key Shift
E111 Key Swivelling
E112 Key For Two-handed Operation Left Side
E113 Master Switch Left Outward
E114 Master Switch Left Inward
E115 Key Auxiliary Lift
E116 Key Main Lift/Auxiliary Lift Diagonal
E117 Key For Two-handed Operation Right Side
E118 Master switch right inside
E119 Master switch right outside
E120 E_BPK2_02
E121 E_BPK2_03
E122 E_BPK0_05
E123 E_BPK2_06
E124 E_BPK0_07
E125 switch aisle recognition 1, 1. recording
E126 switch aisle recognition 1 , 2.recording
5
SD Description
E129 switch End of aisle safety device forward channel A
E130 switch End of aisle safety device forward channel B
E131 switch End of aisle safety device backward channel A
E132 switch End of aisle safety device backward channel B
E133 return signal release signal brake 1
E134 return signal release signal brake 2
E135 personnel protection system release signal full speed
E136 personnel protection system drive release signal 1 forward
E137 personnel protection system drive release signal 2 backward
E138 return signal safety relais 1 opened to VZA
E139 return signal safety relais 2 opened to VZA
E140 Load wheel brake active
E142 sensor unit steering measured value 3B3 Index
E143 main lift below 0,3 m (initiation)
E145 supply voltage Load wheel brake OK
E146 E_Option:X170_5
E147 E_Option_X170_7
E148 E_Pressure_Slack Chain
E149 return signal 24V release signal End of aisle safety device channel A (internal)
E150 return signal 24V release signal End of aisle safety device channel B (internal)
E151 return signal 24V release signal watchdog
E152 switch aisle recognition 3 , 1.recording (forward)
E153 switch aisle recognition 3 , 2.recording (backward)
6
10.2.2Digital Inputs VZK
SD. Description
E200 key switch option
E201 key End of aisle safety device RESET
E202 key LIFTING OVERRIDE
E203 key DRIVE OVERRIDE
E204 key SLACK CHAIN
E205 key fork tine adjustment
E206 key WG/STRAIGHT
E207 key SHIFT OVERRIDE
E208 key SWIVEL SYNCHRONOUS
E209 key Main lift AND auxiliary lift SYNCHRONOUS
E210 key sideshift
E211 key swivel
E212 SAFETY SENSOR Left
E213 Master switch left outside
E214 Master switch left inside
E215 key auxiliary lift
E216 key main lift/auxiliary lift diagonal
E217 key for two-handed operation right side
E218 Master switch right inward
E219 Master switch right outward
E225 door switch (serial circuit S4, S5) 1. recording
E226 door switch (serial circuit S4, S5) 2. recording
E227 slack chain switch 1. recording
E228 slack chain switch 2. recording
E229 foot switch 1
E230 foot switch 2
E231 switch lifting stop driver protection hood
E232 key switch WG Emergency operation
7
SD. Description
E236 Option X295:7 (occupied by optional functions main lift-incremental transmitter)
E237 Option X295:5 (occupied by optional functions main lift-incremental transmitter)
E238 return signal safety relay 1 opened to VZK
E239 return signal safety relay 2 opened to VZK
E240 return signal 24V release signal watchdog
10.2.3Analog Inputs VZA
SD Description Unit
EA100 steering speed
EA101 steering acceleration
EA102 temperature sensor VZA (NTC) °C
EA103 pressure sensor 2B10 bar
EA104 main lift potentiometer 1 mm
EA105 temperature sensor lifting motor (B1) °C
EA106 steering measured value potentiometer 0,1°
EA107 steering measured value incremental transmitter 0,1°
EA108 EA_potentiometer_ 2_/2 (free)
EA111 supply voltage (12V) analog sensors channel 1 hardware
EA112 supply voltage (12V) analog sensors channel 2 hardware
EA113 measured input battery voltage 0,01V
EA114 current sensor A
8
10.2.4Analog Inputs VZK
SD Description Unit
EA200 auxlift measured value potentiometer 1 mm
EA201 auxlift measured value potentiometer 2 mm
EA202 side shift measured value potentiometer 1 mm
EA203 side shift measured value potentiometer 2 mm
EA204 swivelling measured value potentiometer 1 0,1°
EA205 swivelling measured value potentiometer 2 0,1°
EA206 load sensor potentiometer
EA207 supply voltage (12V) analog sensors channel 1 V
EA208 supply voltage (12V) analog sensors channel 2 V
EA209 temperature sensor PT100 /2 (B2) bar
EA210 measuring input battery voltage 0,01V
EA211 temperature sensor controller VZK °C
EA212 main lift incremental transmitter distance mm
+ 10.3 Outputs
10.3.1 Digital Outputs VZA
SD Description
A100 valve 2Y34 main lift lifting
A101 valve 2Y35 main lift lowering
A102 valve 2Y32 aux lift lifting
A103 valve 2Y33 aux lift lowering
A104 valve 2Y36 load carrying device
A105 valve 2Y52
A106 valve 2Y37 load carrying device swivel
A107 release signal controller main lift
A108 flash light 4H5
A109 Option X170:1
A110 Option X170:3
A111 release signal load wheel brake
9
SD Description
A112 release signal controller driving
A113 release signal controller steering
A114 release signal watchdog relay
A115 release signal full speed
A117 Aisle signal from SECAN to PSA
A118 Slow speed signal from SECAN to PSA
A119 Height signal 1 from SECAN to PSA
A121 release signal battery discharge control
A122 release signal safety circuit braking safety-relais1 (SIMO)
A123 release signal safety circuit braking safety-relais2 (SIMO)
10
10.3.2Digital Outputs VZK
SD Description
A200 valve 2Y40 swivelling right
A201 valve 2Y41 swivelling left
A202 valve 2Y42 side shift right
A203 valve 2Y43 side shift left
A204 WG-Signal
A205 valve 2Y53 pressure release
A206 valve 2Y46 (Reserve 3)
A210 release signal Watchdog-Relais
10.3.3Analog Outputs VZA
SD Description Unit
AA100 prop. valve 2Y30 LAM mA
AA101 prop. valve 2Y31 mA
AA102 voltage 10V V
AA103 set value steering 0,1°
10.3.4Analog Outputs VZK
SD Description Unit
AA200 prop. valve 2Y49 aux lift lowering mA
11
10.4Tags
10.4.1Digital Tags VZA
SD Description
M100 valve 2Y34 main lift lifting
M101 valve 2Y35 main lift lowering
M102 valve 2Y32 aux lift lifting
M103 valve 2Y33 aux lift lowering
M104 valve 2Y36 load carrying device
M105 valve 2Y52
M106 release signal controller lifting
M107 main lift initiation (1=OK)
M108 key switch WG emergency operation
M109 two hand operation
M111 hand operation left
M112 load carrying device in startup position
M113 main lift active
M114 load carrying device active
M115 foot switch
M116 barriers closed
M117 Teach-In
M118 APE LED Stop
M119 chain switch
M120 WG signal
M121 main lift below h3critical
M122 main lift and aux lift below 3000 mm
M123 main lift and aux lift below 500 mm
M124 drive speed below Vslow 2,5 km/h
M125 steering angle drive wheel below +/- 10 Grad
M126 drive wheel position straight
M127 End of aisle safety device-braking active
M128 safety-relais no access
M129 truck inside the aisle
12
SD Description
M130 battery switch off (discharged)
M131 LED Stop activated by VZA
M132 recovery
M133 Mech. braking system requested by driving
M134 WG-switch (0/1 = HAND/WG)
M135 WG-estimation (1 = valid geer angle)
M136 micro steering sensor front
M137 micro steering sensor rear
M138 truck in end of aisle zone
M139 WG-emergency operation
M140 WG Teach-In
M141 Options code 00
13
SD Description
M171 valve 2Y37 load carrying device swivel
10.4.2Digital Tags VZK
SD Description
M200 valve 2Y34 main lift lifting
M201 valve 2Y35 main lift lowering
M202 valve 2Y32 aux lift lifting
M203 valve 2Y33 aux lift lowering
M204 valve 2Y36 load carrying device
M205 valve 2Y52
M206 release signal lift controller
M208 main lift end ahead top
M209 main lift end ahead bottom
M210 main lift below h3critical
M211 drive speed below Vcreep 2,5km/h
M212 truck inside the aisle
M213 battery switched off (discharged)
M214 Teach-In
M215 WG signal
M216 key switch WG emergency operation
M217 300 mm switch below 300 mm
M218 slack chain switch
14
SD Description
M219 two hand operation
M220 hand operation left
M221 hand operation right
M222 load carrying device initial position
M223 load carrying device initial position right
M224 load carrying device initial position left
M225 aux lift end ahead top
M226 aux lift end ahead bottom
M227 swivelling end ahead left
M228 swivelling end ahead right
M230 main lift active
M231 aux lift active
M232 foot switch
M233 barriers closed
M234 overload
M235 LED STOP VZK
15
SD Description
M266 valve 2Y37 load carrying device swivel
M267 key main lift/auxiliary lift synchronous
10.4.3Analog Tags VZA
SD Description Unit
MA100.. hour meter BZ00 - BZ09 h
MA109
MA110 UBatt mean average value 0,1V
MA111 battery rest capacity
MA112 motor temperature °C
MA113 steering set value hardware
MA114 steering actual value hardware
MA115 steering control difference output hardware
MA116 steering number of rotations measured value hardware
MA117 status drive steering hardware
MA118 Set value master switch left hardware
MA119 Set value master switch right hardware
MA120 prop valve swivel 2Y30 mA
16
SD Description Unit
MA121 prop valve 2Y31 mA
MA122 Position aux lift mm
MA123 potentiometer load
MA124 steering angle
MA125 steering angle preset from control panel 0,1°
MA126 measured value main lift-potentiometer 1 mm
MA127 drive speed set value 0,01 km/h
MA128 drive speed measured value 0,01 km/h
MA129 drive speed limit value 0,01 km/h
MA130 driving direction (0=standstill; 85=forward; 86=backward) hardware
MA131 Stock zone hardware
MA132 Optipace height max mm
MA133 End of aisle safety device braking distance mm
MA134 pressure sensor 2B10 bar
MA135 End of aisle safety device braking curve limit mm
MA136 Difference between actual and valid speed 0,01km/h
MA137 Measured mean deceleration %
MA138 Speed in the brake-activating moment (starting speed) 0.01km/h
MA139 driving revolution rate hardware
MA140 driving distance Delta hardware
MA141 driving control status hardware
MA142 micro steering sensor status front 3 = OK
MA143 micro steering sensor status rear 3 = OK
MA144 micro steering sensor distance front mm
MA145 micro steering sensor distance rear mm
MA146 WG-estimation value display
MA147 WG-gear angle truck/wire 0,1°
MA148 WG-distance truck/wire mm
MA149 WG-steering angle set value 0,1°
MA150 WG-steering angle measured value 0,1°
MA151 WG-distance mm
MA152 End of aisle safety device direction hardware
17
SD Description Unit
MA153 End of aisle safety device switch point 1 hardware
MA154 End of aisle safety device distance mm
MA155 WG-speed 0,01 km/h
MA156 driving internal set value ramp hardware
MA157 AC steering controller error code hardware
MA158 AC driving controller error code hardware
MA159 aisle track 1 setoff hardware
MA162 distance measurement mm
MA163 set of parameters for steering hardware
MA164 main lift incremental transmitter distance mm
10.4.4Analog Tags VZK
SD Description Unit
MA200.. hour meter BZ 00 - BZ09 h
MA209
MA210 revolution rate limit value 1/min
MA211 Position main lift (potentiometer) mm
MA212 residual battery capacity %
MA213 stock zone
MA214 set value for number of revolutions of pump 2M1 1/min
MA215 driving direction (0=standstill; 85=forward; 86=backward) hardware
MA216 set value synchronous control hardware
MA217 control difference output for synchronous control hardware
MA218 pressure sensor 2B10 bar
MA219 type of main lift lifting hardware
MA220 master switch left set value hardware
MA221 master switch right set value hardware
MA222 prop valve swivelling 2Y30 mA
MA223 prop valve 2Y31 mA
MA224 revolution rate pump measured value hardware
18
SD Description Unit
MA225 pump status hardware
MA226 pump AC-controller error hardware
MA227 position aux. lift mm
MA228 synchro-swivelling output control difference hardware
MA229 safety distance left when swivelling mm
MA230 safety distance right when swivelling mm
MA231 distance main lift incremental transmitter mm
MA232 speed main lift incremental transmitter 0,01 km/h
MA233 pressure sensor for load
MA234 potentiometer for load detection
MA235 mean average value for load
MA236 mean average value for pressure
19
10.4.5Status Tags VZA
SD Description
MZ100 status driving
MZ101 status brake
MZ102 status steering
MZ103 status aisle / apron
MZ104 status steering AC-controller
MZ105 status steering initiation
MZ106 status of drive AC-controller
MZ107 status slow speed
MZ108 status end of aisle safety (GESI)
MZ109 ---
MZ110 status slack chains
MZ111 status master switch left
MZ112 status master switch right
MZ113 status WG
MZ114 status WG estimation value
MZ115 status WG strategy
MZ116 status error module steering control
MZ117 status error module drive control
20
10.4.6Status Tags VZK
SD Description
MZ200 status main lift lifting
MZ201 status main lift lowering
MZ202 status aux lift lifting
MZ203 status aux lift lowering
MZ204 status swivelling
MZ205 status side shift
MZ206 status synchronous
MZ207 status fork tine adjustment
MZ208 status swivelling hydraulic control
MZ209 status side shift hydraulic control
MZ210 status aux lift hydraulic control
MZ211 status synchronous hydraulic control
MZ212 status master switch left
MZ213 status master switch right
MZ214 status chains
MZ215 status main lift lifting cut-out
MZ216 status pump controller 2M1
MZ217 status function hydraulic lift module block
MZ218 status side shift cut-out
MZ219 status hydraulic control main lift
MZ220 status error module pump control
MZ221 status side shift while synchronous swivelling
MZ222 status swivelling while synchronous swivelling
MZ223 status main lift synchronous
MZ224 status auxiliary lift synchronous
MZ225 status main lift / auxiliary lift hydraulic control
21
10.5Status Tags VZA

10.5.1MZ 100: Driving
No. Tag Description Examine

001 STP: Notstop emergency stop error detected status with drive cut-
out and activated
braking
error message
EXXX
002 STP: Ketten chains not under tension MZ214
003 STP: Tür at least 1 barrier is opened E225 E226
offen
006 END: Zwei- two hand operation in aisle not OK M109
hand GA M111
010 STP: Code software emergency stop error message
z.B: during loading of default values EXXX
015 FA 2.5 PSA personnel protection system predefines configuration K15
creep speed
016 FA V STOP personnel protection sy tem locks driving configuration K15
PSA forward
017 FA R STOP personnel protection sy tem locks driving configuration K15
PSA backward
046 FA 2.5 GESI GESI with slowin down to creep speed MZ108
configuration K12
070 FA STOP GESI has taken control over truck MZ108
GESI configuration K12
087 Fahren GESI GESI counter current brake active MZ108 GESI
GSB configuration K12
088 FA GA Aus- speed too high when leaving the aisle MA128 speed.
fahrt truck is braked by control system
090 FA 2.5 LAM creep speed, when load carrying devide not M222 initial pos
in initial position M223 initial pos right
M224 initial pos left
091 FA VF 2.5 creep speed in apron at h3 > 3000mm EA212 main lift Incr.
or steering angle > 10 degrees EA200 aux lift Poti
EA106, EA107
092 FA GA 2.5 creep speed, because critical h3 in aisle EA212 main lift Incr.
h3krit EA200 aux lift Poti
MZ103
22
No. Tag Description Examine

094 FA VF 4.0 speed limited to 4 km/h at h3 > 500 mm and EA212 main lift Incr.
h3 < 3000 mm EA200 aux lift Poti
095 FA GA fast speed with WG in aisle released MZ103
Schnell
096 FA VF fast drive in apron released MZ103
Schnell
097 FA STOP Mech. brake is still activated MZ101
Bremse
098 FA STOP error in steering circuit detected MZ105 steer init.
Lenkung (e.g.: steering initiation not finished) MZ102 steering
099 FA VF STOP steering in apron not available MZ102
Lenk
100 FA VF STOP no diagonal drive in the apron MZ219 main lift hydr
Heben
101 FA STOP load wheel brake not working correctly E145: batt voltage
LRB E140: brake active
148 FA GA IF fast speed with WG in aisle released MZ113
Schnell MZ103
149 FA GA IF 2.5 WG-emergency creep speed in aisle MZ113
152 FA STOP Err driving error detected, driving locked error message
EXXX
153 FA Schl Err creep speed because of drive error error message
EXXX
167 FA VF STOP lift height depending drive cut-out EA212 main lift Inc.
H3 normally adjusted to 5M EA200 aux lift Poti
179 FA VF IF 2.5 creep speed, because WG in search opera- MZ113
tion apron
183 FA STOP drive cut-out active MZ100
ABS
184 FA Schl ABS creep speed after overriding of cut-out configuration K14
212 Fa STOP IF WG wire left configuration K13
Faed
237 FA SCHL HH creep speed predefined, main lift not M107
KEINE JUST adjusted, main lift initiation
23
10.5.2MZ 101: Brake
Nr. Tag Description Examine

001 STP: Not- emergency stop, error detected error message EXXX
stop
102 Bremse Brake OK and lifted configuration K14
gelüftet
103 Bremse foot switch activated E229
Fußtaster E230
104 Bremse brake requested by pers. prot. sys. safety circuit brake
PSA configuration K15
105 Bremse Bus component has released emergency safety circuit brake
BUS stop CAN-Check
106 Bremse Load wheel brake not working; E140 brake active,
LRB driving locked, braking to stand-still E145 power supply
107 Bremse driving locked, braking to stand-still error message EXXX
STOP Err
108 Bremse reduce speed to creep speed 2,5 km/h error message EXXX
Schl Err
137 Bremse brake active while movement load carrying M122, 123, 124: ini-
LAM dev. tial position
MZ204 swivel
MZ205 side shift
138 Bremse brake requested of module “GESI” MZ108
GESI
139 Bremse GESI has activated brake via hardware emer- MZ108
GESI Not gency stop configuration K14
140 Bremse brake requested of module “driving” MZ100
Fahren
24
10.5.3MZ 102: Steering

001 STP: Not- emergency stop error detected error message EXXX
stop
066 L GA steering switched on in the aisle MZ103
Abschaltun
g
067 L Gangein- Automatic straight ahead positioning for aisle only SF: MZ103
fahrt entrance
068 L VF Stand Steering cut-out in apron when truck is stand- configuration K3
ing
069 L VF Fahrt Steering in apron when truck is driving configuration K3
071 L Refer- initiation not completed yet MZ105 steering init.
ierung
145 Lenken steering locked because of error error message EXXX
STOP Err
146 Lenken IF steering in WG-operation while truck is driv- only WG: MZ113
Fahrt ing
147 Lenken IF steering in WG-operation while truck is stand- only WG: MZ113
Stand ing
10.5.4MZ 103: Aisle/ Apron

019 Gangaus- apron situation detected, but drive speed still aisle recognition
fahrt too high. configuration K11
020 Gangein- Aisle situation was detected, but wheel not aisle recognition
fahrt straight configuration K11
021 Gang Aisle situation was detected and wheel is in aisle recognition
straight ahead position. configuration K11
A: by aisle recognition switch
B: by WG-wire
022 Vorfeld apron situation detected and drive speed aisle recognition
adjusted configuration K11
25
10.5.5MZ 104: Steering Controller

074 Lenkung steering is cut-out MZ102
STOP
075 Lenkung steering activated MZ102
AKTIV
076 Lenkung steering is cut-out MZ102
ENDE
10.5.6MZ 105: Steering Initiation

073 Lenk. HOCH- turn steering wheel into startup position left
LAUF
077 LRef STOP potentiometer error (wire break ) error message
Er0 EXXX
078 LRef STOP error deviation potentiometer incremental error message
Er1 transmitter EXXX
079 LRef Initial. initialization phasis configuration K16
080 LRef Start Turn steering to the left side configuration K16
pos
081 LRef wait, until steering sensors are in stand-still configuration K16
Justierung then adjust incremental transmitter to poti
082 LRef Index from startup position (left) drive right until configuration K16
OK index detected
083 LRef finally set steering wheel into straight ahead configuration K16
Geradeaus position again
084 LRef beendet steering initiation finished successfully configuration K16
26
10.5.7MZ 106: Drive Control System

)
Nr. Tag Description Examine:

110 DACI inaktiv DACI has no release signal configuration K16
111 DACI V regenerative braking : configuration K16
Gegenst. truck drives backward although forward is
requested
112 DACI Vor- drive forward configuration K16
wärts
113 DACI V v- drive forward too fast , set value = 0 that configuration K16
Limit Vmax is not exceeded
114 DACI R regenerative braking: configuration K16
Gegenst. truck drives forward although backward is
requested
115 DACI Rück- drive backward configuration K16
wärts
116 DACI R v- drive backward too fast , set value = 0 that configuration K16
Limit Vmax is not exceeded
27
10.5.8MZ 108: End Of Aisle Safety Device

000 Ruhezustand GESI not activated (code not correct) Release Code GESI
119 GESI Frei- wait for release of end of aisle switch: when configuration K12
gabe switch detected -> activate GESI braking MZ100
120 GESI Brem- GESI-braking was released. E129
sung Depending on the GESI-Type braking until E130
creep speed or stop. E131
A: GESI with man. Reset key: E132
braking to stop and transition into MZ100
tag GESI STOP
B: GESI with AUTORESET standstill and
creep speed:
braking to stand still and transition to (tag
GESI creep speed
C: GESI with AUTORESET and then creep
speed:
braking to creep speed and transition into
tag GESI creep speed
213 GESI STOP only with GESI with Man. Resetkey. E101
wait, until GESI Reset key is activated
214 GESI Schl only with GESI with AUTORESET MA128
go on driving in creep speed, until Examine:
Autoreset Code0,Code8
249 GESI Init Tag is active, when truck is switched on
inside the aisle, but not in end of aisle zone.
10.5.9MZ 110: Slack Chains

011 Schlaffkette chains slack or slack chain switch not OK E227
E228
012 Ketten straff chains under tension E227
E228
28
10.5.10MZ 111: Control Panel Left Side

:

000 Ruhestellung no function chosen configuration K18
032 ZH Heben aux lift lifting chosen configuration K18
033 ZH Senken aux lift lowering chosen configuration K18
041 HH Heben main lift lifting chosen configuration K18
042 HH Senken main lift lowering chosen configuration K18
245 HH + ZH main lift and auxiliary lift synchronous lifting configuration K18
Synchron chosen
Heben
246 HH + ZH main lift and auxiliary lift synchronous lower- configuration K18
Synchron ing chosen
Senken
10.5.11MZ 112: Control Panel Right Side

030 Drehen swivel right chosen configuration K17
rechts
031 Drehen links swivel left chosen configuration K17
054 Schieben side shift right chosen configuration K17
rechts
055 Schieben side shift left chosen configuration K17
links
085 Fahren Vor- forward driving chosen configuration K17
wärts
086 Fahren Rück- backward driving chosen configuration K17
wärts
117 Synchron-S synchronous shift left chosen configuration K17
Links
118 Synchron-S synchronous shift right chosen configuration K17
Rechts
Mitte
29
10.5.12MZ 113: WG

185 IF Hand manual operation configuration K13
186 IF wire search requested configuration K13
Anforderung
187 IF Einfädeln wire search in operation configuration K13
188 IF Ausge- wire search not successful configuration K13
fädelt
189 IF Vorfeld WG-driving in apron configuration K13
190 IF Ga Ein- aisle entrance; wait for return signal from configuration K13
fahrt activated steering lock
191 IF Ga Schnell fast drive WG in aisle configuration K13
192 IF Ga Ausf leaving the aisle v>2,5 km/h configuration K13
Schn
193 IF Ga Ausf leaving the aisle v<2,5 km/h configuration K13
Schl
194 IF Notb Hand WG-emergency operation : manual opera- configuration K13
tion
195 IF Notb Anfor WG-emergency operation: wire search configuration K13
requested
196 IF Notb Fädel WG-emergency operation: wire search in configuration K13
operation
197 IF Notb Vor- WG-emergency operation: wire detected; configuration K13
feld conditions apron;
wait for switch emergency operation =off
198 IF NStop Ga WG-emergency stop: aisle signal configuration K13
Sig
199 IF NStop WG-emergency stop: wire signal lost ->error message
Draht
200 IF NStop WG-emergency stop: machine out of safety ->error message
Raute diamond
219 IF Einfahrt activated steering ; full speed locked; auto- configuration K13
matic steering
220 IF Schnell full speed released; automatic steering configuration K13
221 IF Ausfahrt leaving wire is selected, but speed is still > configuration K13
2.5 km/h; steering automatically
30
10.5.13MZ 114: WG Estimation Value; Estimation Gear Angle/distance In Apron

203 IF Schae Aus WG-estimation not active configuration K13
204 IF Schae WG-estimation requested; distance and configuration K13
Anford angle are calculated via drive- and steering
sensor unit
205 IF Schae valid WG-estimation for micro steering sen- configuration K13
Vorne sor front
Hinten sor rear
Beide sor front and rear
10.5.14MZ 115: WG Strategy

208 IF LNK manual steering configuration K13
Manuell
209 IF LNK Schw wire search; swivelling to wire; positive configuration K13
Pos steering angle
210 IF LNK Schw wire search; swivelling to wire; negative configuration K13
Neg steering angle
211 IF LNK Lin steering via linear controller configuration K13
Regl
10.6Control system states of the VZK

10.6.1MZ 200: Lifting The Main Lift

001 STP: Notstop emergency stop error detected error message
EXXX
002 STP: Ketten chainse not under tension MZ214
M119
003 STP: Tür at least 1 barrier is opened E225
offen E226
005 END: Zwei- Stop two hand operation violated M109
hand M111
31

008 END: Stillstd lift cut-out in apron, when truck is driving MA130
VF (diagonal drive lock)
009 END: Über- lift cut-out in case of overload error message
last EXXX
010 STP: Code Software emergency stop error message
z.B: during loading of default values EXXX
047 HH H Schl load carrying device not in initial position: M222
LAM lifting only in creep speed M223
M224
048 HH H SL end ahead top reached: lifting only in creep EA212
Vorende speed M120
049 HH H Schnell maximum lifting speed permitted configuration K4
050 HH H slack chain detected MZ214
Schlaffket. M119
slack chain override
051 HH H Low- lift cut-out: battery empty M130
batt
052 HH H lift cut-out has been activated MZ215
Abschaltung
053 HH H critical height reached, but drive speed still EA212
END:h3 krit above 2,5 km/h M124
132 HH H Schl end ahead lift cut-out: lifting only in creep MZ215
ABS speed
150 HH H STOP lift cut-out cabin roof E231
FSD
154 HH H STOP lifting error detected, lifting locked error message
Err EXXX
155 HH H Schl error detection reports: main lift lifting only in error message
Err creep speed EXXX
166 Ende Oben limit cut-out main lift top EA212

177 Schleich Teach-In in operation: only creep speed configuration K4
TEACHIN movements
10.6.2MZ 201: Main Lift Lowering

EXXX
32

M119
offen E226
hand M221
008 END: Stillstd lowering cut-out in apron, while truck is driv- MA130, MZ103
VF ing (diagonal drive lock) configuration K4
e.g. while loading of default values EXXX
044 HH S SL end ahead bottom reached: lowering only in EA212
Vorende creep speed M209
045 HH S Schnell maximum lowering speed permitted configuration K4
043 HH S Schl load carrying device not in initial position: M222
LAM lowering only in creep speed M223
M224
156 HH S STOP lowering error detected, lowering locked error message
Err EXXX
157 HH S Schl error detection reported: main lift lowering error message
Err only in creep speed EXXX
174 HH S Schl lowering cut-out: switching to creep speed configuration K4
ABS
175 HH S ABS lowering cut-out has been activated configuration K4
Stop
177 Schleich Teach-In-procedure running: movements configuration K4
TEACH IN only in creep speed
10.6.3MZ 202: Lifting Auxiliary Lift

EXXX
002 STP: Ketten chains are not under tension MZ214
M119
offen E226
hand M221
33

008 END: Stillstd Lift cut-out in apron, when truck is in move- MA128
VF ment (diagonal drive lock) configuration K5
009 END: Über- Stop overload error message
last EXXX
e.g. error while loading of default values EXXX
037 ZH H Schl load carrying device not in initial position: M222
LAM aux lift lifting only in creep speed M223
M224
configuration K5
038 ZH H SL end ahead top reached: creep speed EA200
Vorende M225
configuration K5
039 ZH H Schnell maximum lift speed permitted configuration K5
158 ZH H STOP lifting error detected, lifting locked error message
Err EXXX
159 ZH H Schl error detection reports: aux lift lifting only in error message
Err creep speed
166 Ende Oben End cut-out top EA200
configuration K5
TEACHIN only in creep speed
217 ZH HEBEN aux lift-cut-out has been activated configuration K5
ENDE ABS
218 ZH HEBEN end ahead of cut-out height reached: creep configuration K5
VORENDE speed
ABS
10.6.4MZ 203: Lowering the Auxiliary Lift

EXXX
002 STP: Ketten chains are not under tension MZ214
M119
offen E226
hand M221
34

008 END: Stillstd lowering cut-out in apron, when truck is in MA130
VF operation (diagonal drive lock)
034 ZH S Schl load carrying device not in initial position: M222
LAM aux lift lowering only in creep speed M223
M224
035 ZH S SL end ahead reached: creep speed EA200
Vorende M226
036 ZH S Schnell maximum lowering speed permitted configuration K5
040 ZH Senken cut-out: lower limit reached EA200
Ende configuration K5
160 ZH S STOP lowering error detected, lowering locked error message
Err EXXX
161 ZH S Schl error detection reports:: aux lift lowering error message
Err only in creep speed EXXX
TEACHIN
35
10.6.5MZ 204: Swivelling

EXXX
M119
offen E226
hand M111
007 END: Still- swivelling terminated MA130
stand
018 Druck safety cut-out at 140 bar at swivelling move- MA134
Drehen zu ments to be < 140 bar
hoch
025 DR VF STOP swivelling cut-out in apron above 4 m EA212
4m EA200
configuration K7
027 DR L SL end ahead left reached: creep speed EA204
Vorende M227
028 DR R SL end ahead right reached: creep speed EA204
Vorende M228
029 Drehen full speed permitted
schnell
162 DR STOP Err error message
EXXX
163 DR Schl Err error detection reports: swivelling only in error message
creep speed EXXX
configuration K7
36
10.6.6MZ 205: Side Shift

001 STP: Not- emergency stop error detected error message
stop EXXX
M119
offen E226
007 END: Still- truck has to stand still to side shift MA128 drive speed,
stand MA130 direction
056 Schieben full speed permitted configuration K6
schnell
057 SS STOP side shift cut-out has been activated MZ218
ABS configuration K6
058 SS Schl ABS end ahead of side shift cut-out reached: MZ218
creep speed configuration K6
164 SS STOP side shift stopped because of error error message
Err EXXX
165 SS Schl Err error detection reports: side shift only in configuration K6
creep speed
37
10.6.7MZ 206: Synchronous Swivelling

001 STP: Notstop emergency stop error detected error message EXXX
M119
offen E226
hand M111
007 END: Still- truck has to stand still MA128 drive speed
stand MA130 direction
010 STP: Code Software emergency stop error message EXXX
e.g. while loading of default values
133 SYN Kollision pallet collides with left racking: cut-out configuration K8
L
134 SYN Kollision pallet collides with right racking: cut-out configuration K8
R
135 SYN STOP pallet collides with right and left racking: cut- configuration K8
Koll. LR out
136 SYN Schnell full speed permitted configuration K8
162 DR STOP Err full speed permitted error message EXXX
164 SS STOP Err error message EXXX
215 STOP SYN swivel synchr.-cut-out has been activated configuration K8
ABS
10.6.8MZ 208: Swivelling Hydraulic Control

L

000 Ruhestellung Module without activation and function configuration K7,K9
ended
014 SLEEP Module without activation and function configuration K7,K9
030 Drehen Function swivel right configuration K7,K9
rechts
031 Drehen links Function swivel left configuration K7,K9
063 Druck Abbau pressure reduction after movement configuration K7,K9
10.6.9MZ 209: Side Shift Hydraulic Control
38

ended
054 Schieben function side shift right configuration K6,K9
rechts
055 Schieben function side shift left configuration K6,K9
links
223 SS START revolutions switched on and proportional configuration K6,K9
valve opened, but directional valve closed
(600ms)
10.6.10MZ 210: Auxiliary Lift Hydraulic Control

000 Ruhestellung Module without activation and function configuration K5
ended
014 SLEEP Module without activation and function configuration K5
032 ZH Heben function aux lift lifting configuration K5
033 ZH Senken Function aux lift lowering configuration K5
040 ZH Senken ending function. close directional valve first configuration K5
Ende and proportional valve fully opened (100ms)
063 Druck Abbau pressure reduction after movement configuration K5
216 ZH HEBEN Ending function. close directional valves configuration K5
ENDE first, prop-valve fully opened (100ms)
226 Druck vor pressure reduction before movement configuration K5
Beginn value 2B10 has to be smaller than P93
229 Druckloser drive pump to corect revolution in pressure- configuration K5
Umlauf less state
232 ZH SENKEN pressure reduction after movement configuration K5
DRUCKAB-
BAU
235 ZH SEN drive pump to corect revolution in pressure- configuration K5
UMLAUF less state
DRUCKL.
239 ZH Heben Termination of movement; direction valves configuration K5
LAM Ende are closed, prop. valve is opened
39
10.6.11MZ 211: Synchronous Swivelling Hydraulic Control

ended
117 Synchron-S L Synchro-swivelling left side configuration K8,K9
118 Synchron-S Synchro-swivelling right side configuration K8,K9
R
133 SYN Kollision Collision detected on left side (during syn- configuration K8,K9
L chro-swivelling)
134 SYN Kollision Collision detected on right side (during syn- configuration K8,K9
R chro-swivelling)
143 Synchron-S- Synchronous swivelling has reached the configuration K8,K9
Mitte center position
226 Druck vor pressure reduction before movement configuration K8,K9
Beginn value 2B10 must be smaller than P93
10.6.12MZ 212: Control Panel Left Side

032 ZH Heben aux lift lifting chosen configuration K18
033 ZH Senken aux lift lowering chosen configuration K18
041 HH Heben main lift lifting chosen configuration K18
042 HH Senken main lift lowering chosen configuration K18
Synchron chosen
Heben
Synchron ing chosen
Senken
40
10.6.13MZ 213: Control Panel Right Side

030 Drehen swivel right chosen configuration K17
rechts
031 Drehen links swivel left chosen configuration K17
054 Schieben side shift right chosen configuration K17
rechts
055 Schieben side shift left chosen configuration K17
links
085 Fahren Vor- forward driving chosen configuration K17
wärts
086 Fahren backward driving chosen configuration K17
Rückwärts
117 Synchron-S synchronous shift left chosen configuration K17
Links
Rechts
Mitte
10.6.14MZ 214 Slack Chains

011 Schlaffkette Chains slack or chain switch not OK M119, E227, E228
012 Ketten straff Chains tight M119, E227, E228
10.6.15MZ 215: Lift Cut-out Main Lift

124 HH ABS Frei- lift height cut-out not active; release signal configuration K4
gabe lifting is released
125 HH ABS lift height cut-out has detected end ahead configuration K4
Vorende before cut-out height: lifting reducet to creep
speed
126 HH ABS Tast wait for releasing the override-switch lift E102
height cut-out
127 HH ABS Stop cut-out at height A carried out configuration K4
A
41

128 HH ABS Stop cut-out at height B carried out configuration K4
B
129 HH ABS Stop cut-out at height C carried out configuration K4
C
130 HH ABS Stop cut-out at height D carried out configuration K4
D
131 HH ABS Stop cut-out at height E carried out configuration K4
E
42
10.6.16MZ 216: Pump Motor Controller

059 Pumpe: AN Pump unit activated MA214 set value
MA224 measured
value
060 Pumpe: AUS Pump unit off MA214, MA224
10.6.17MZ 218: Side Shift Cut-out

056 Schieben full speed allowed configuration K6
Schnell
168 SS ABS STP side shift cut-out, as 1. stacking depth configuration K6
1.EST reached and 2. stacking depth key not
pressed
169 SS ABS STP side shift cut-out, as 2. stacking depth configuration K6
2.EST reached override key not pressed
170 SS ABS END creep speed, as end ahead of 1. stacking configuration K6
1.EST depth reached
171 SS ABS END creep speed, as end ahead of 2. stacking configuration K6
2.EST depth reached
172 SS ABS End creep speed, as end ahead of center cut-out configuration K6
Mitte reached
173 SS ABS STP center cut-out reached configuration K6
Mitte
10.6.18MZ 219: Main Lift Hydraulic Controller

000 Ruhestellung Module without activation and function configuration K4
ended
041 HH Heben lifting is controlled by proportional valve with configuration K4
constant revolutions up to a predefined min-
imum speed
042 HH Senken main lift lowering configuration K4
063 Druck Abbau pressure reduction after lifting movement configuration K4
(100ms)
226 Druck vor pressure reduction before movement configuration K4
Beginn value 2B10 must be smaller than P93
43

227 HH Heben lifting is controlled with revolutions and con- configuration K4
Drehzahl stant opening of the proportional valve
228 HH Senken main lift lowering, controlled via pump revo- configuration K4
Drehzahl lutions
229 Druckloser drive pump to revolutions proportional lifting configuration K4
Umlauf D02
230 HH Senken main lift lowering break configuration K4
Pause
233 HH HEBEN at constant revolutions (proportional lifting configuration K4
ENDE D02) close proportional valve
234 HH SENKEN main lift lowering pressure reduction configuration K4
DRUCKAB-
BAU
44
10.6.19 MZ 225:Main lift and Auxiliary lift Synchronous Hydraulic control

000 Ruhestellung no function chosen
226 Druck vor Pressure reduction before movement (2B10 configuration K4
Beginn has to be less than P93 setting)
233 HH HEBEN at constant revolutions (proportional lifting configuration K4
ENDE D02) close proportional valve
245 HH + ZH main lift and auxiliary lift synchronous lifting configuration K18,
Synchron chosen K9
Heben
246 HH + ZH main lift and auxiliary lift synchronous lower- configuration K18,
Synchron ing chosen K9
Senken
10.6.20 MZ223: Main lift synchronous (hydraulic control)l

Synchron chosen
Heben
Synchron ing chosen
Senken
10.6.21 MZ224: Auxiliary lift synchronous (hydraulic control)l

Synchron chosen
Heben
Synchron ing chosen
Senken
45
46
11 Service parameters
Required measuring instruments and

test equipment
- multimeter
- stop watch
Chapt. Theme Page

11.1 Service display configurations 3
11.1.1 K1: Operating hour meters,
battery monitor 3
11.1.2 K2: Driving / brakes 4
11.1.3 K3: Steering 4
11.1.4 K4: Main lift 5
11.1.5 K5: Auxiliary lift 5
11.1.6 K6: Side shift 6
11.1.7 K7: Swivelling 6
11.1.8 K8: Synchronous swivelling 7
11.1.9 K9: Hydraulik components part 1
(motions) 7
11.1.10 K10: Hydraulik components part 2
(load wheel brake) 8
11.1.11 K11: Aisle recognition 8
11.1.12 K12: End of aisle braking 9
11.1.13 K13: Inductive guidance (IF) 9
11.1.14 K14: Safety circuit brakes 10
11.1.15 K15: Personnel protection system (PSA) 10
11.1.16 K16: AC-controls 11
11.1.17 K17: Right control panel 11
11.1.18 K18: Left control panel 12
11.2 Service menu / adjustment

parameters 13
11.2.1 Shortcuts for parameter types 13
11.2.2 Shortcuts in parameter 14
11.2.3 Minimum, maximum, default values 14
1
11.2.4 List of service menus. 15

11.2.5 M 01: Control panel 16
11.2.6 M 02: Sideshift 17
11.2.7 M 03: Swivelling 18
11.2.8 M 04: Main lift 19
11.2.9 M 05: Auxiliary lift 20
11.2.10 M 07: hydraulics synchr. swivel 21
11.2.11 M 08: geometry synchr. swivel 21
11.2.12 M 09: Fork tine adjust. (FTA) 23
11.2.13 M 10: Driving 23
11.2.14 M 11: Load wheel brake (LWB) 24
11.2.15 M 12: Steering 24
11.2.16 M 13: Pump 26
11.2.17 M 15: Inductive Guidance 26
11.2.18 M 16: Driving cut-out 27
11.2.19 M 17: Lift cut-out 27
11.2.20 M 18: Lowering cut-out 30
11.2.21 M 19: Side Shift Cut-Out 32
11.2.22 M 20: Optispeed 32
11.2.23 M 21: Options, Release Codes,
Personnel Protection System 32
11.2.24 M 22: Hour meters 34
11.2.25 M 23: Language 34
11.2.26 M24: Status display 34
11.2.27 M25: Datascope 35


materials.
2
11.3 Service display configuration

+ 11.1.1 K1: Operating hour meters, battery monitor
Operand Description Unit

MA100 Operating hour meters BZ 0 h
EA113 Measuring input battery voltage VZA V

MA110 Battery voltage filtered V
MA111 Calculated rest battery capacity %
M130 discharged battery (1=discharged)
11.1.2 K2: Driving / brakes
Oper- Description Unit

and
MZ100 Status driving
MZ101 Status brake
MZ106 Status AC Drive control
MA127 Set value drive control 0.01km/h
MA128 Driving velocity 0.01km/h
MA130 Driving direction (85=forward; 86=backward; 0=standing)
MA158 Error code drive AC-control
+ See also K14: Safety circuit brake
3
11.1.3 K3: Steering

and
MZ102 Status steering
MZ104 Status steering control
MZ105 Status steering initiation
MA125 Steering angle specified set value 0.1°
AA103 Steering set value V
EA106 Actual-value sensor steering potentiometer 0.1°
EA107 Actual-value sensor steering incremental transmitter 0.1°
M125 Steering angle drive wheel less than ±10°
M126 Steering angle drive wheel straight ahead
MA157 Error code steering AC-control
11.1.4 K4: Main lift

and
MZ200 Status main lift lifting
MZ201 Status main lift lowering
MZ219 Status main lift hydraulic
MZ216 Status pump control
MZ215 Status lift cut-out
MA214 Revolution rate pump set value min-1
MA224 Revolution rate pump measured value min-1
AA101 Set value prop. valve 2Y31 mA
MA232 Main lift velocity 0.1m/s
EA104 Main lift sensor potentiometer mm
EA212 Main lift sensor incremental transmitter mm
E143 Main lift sensor switch 0,3 m (0 = above 0,3m)
MA226 Pump AC-controller error
4
11.1.5 K5: Auxiliary lift

and
MZ202 Status aux. lift lifting
MZ203 Status aux. lift lowering
MZ210 Status aux. lift hydraulics
AA100 set value prop. valve 2Y30 mA
EA200 Aux. lift sensor potentiometer 1 mm
EA201 Aux. lift sensor potentiometer 2 mm
MA226 Pump AC-controller error
11.1.6 K6: Side shift

and
MZ205 Status side shift
MZ209 Status side shift hydraulics
MZ218 Status shift cut-out
AA100 set value prop. valve 2Y30 mA
EA202 Side shift sensor system potentiometer 1 mm
EA203 Side shift sensor system potentiometer 2 mm
M222 Attachment in startup position (1=OK)
11.1.7 K7: Swivelling

and
MZ204 Status swivelling
MZ208 Status swivelling hydraulics
5

and
MZ116 Status hydraulic block
EA204 Sensor system swivelling potentiometer 1 0,1°
EA103 Pressure sensor 2B10 bar
M222 Attachment in starting position (1=OK)
6
11.1.8 K8: Swivelling side shift synchronization

and
MZ206 Status synchronous swivelling
MZ211 Status synchronous swivelling hydraulic
EA202 Sensor system side shift potentiometer 1 mm
MA228 Synchro-swivelling output control difference mm
MA229 Distance reserve left mm
MA230 Distance reserve right mm
11.1.9 K9: Hydraulik components part 1 (motions)

ke

and
A100 Valve 2Y34
A101 Valve 2Y35
A102 Valve 2Y32
A103 Valve 2Y33
A104 Valve 2Y36
A105 Valve 2Y52
A200 Valve 2Y40
A201 Valve 2Y41
A202 Valve 2Y42
A203 Valve 2Y43
AA100 Prop. valve 2Y30 mA
MA224 Rotations pump measured value min-1
EA103 Pressure sensor 2B10 bar
7
11.1.10 K10: Load wheel brake

and
A112 Release load wheel brake
E140 Load wheel brake active
E145 Supply voltage OK
11.1.11 K11: Aisle recognition

and
MZ103 Status aisle / apron
E125 Aisle recognition track 1, switch A
E126 Aisle recognition track 1, switch B
MA159 Distance measuring offset aisle recognition track 1 mm
MA131 Stock zone
M129 Truck in the aisle
8
11.1.12 K12: End of aisle braking

and
MZ108 Status end of aisle braking
E129 End of aisle switch forward, channel A
E130 End of aisle switch forward, channel B
E131 End of aisle switch backward, channel A
E132 End of aisle switch backward, channel B
MA133 Braking distance counter-current braking mm
MA128 Drive speed measured value 0,01km/h
MA136 Difference between actual and valid speed 0,01km/h
MA137 Measured mean deceleration %
MA138 Speed in the brake-activating moment (starting speed) 0.01km/h
11.1.13 K13: Wire guidance (WG)

and
MZ113 Status WG
MZ114 Status WG estmation angle position / distance
MZ115 Status steering strategy
MA142 Status steering microsensor front 3 = OK
MA143 Status steering microsensor rear 3 = OK
MA144 Distance signal steering microsensor front mm
MA145 Distance signal steering microsensor rear mm
MA147 Angle position truck / wire 0.1°
MA148 Distance truck / wire mm
MA149 WG steering angle set value 0,1°
MA150 WG steering angle measured value 0.1°
MA128 Travelling speed 0.01km/h
E232 Key switch WG Emergency operation
A204 Acoustic signal WG
11.1.14 K14: Safety circuit brakes
9

and
MZ101 Status brake
E229 Feedback foot switch 1 (1 = pressed)
E230 Feedback foot switch 2 (1 = pressed)
A123 Safety relay 1 released by VZA (1 = released)
A124 Safety relay 2 released by VZA (1 = released)
E138 Feedback safety relay 1 to VZA (1 = closed)
E139 Feedback safety relay 2 to VZA (1 = closed)
E238 Feedback safety relay 1 to VZK (1 = open)
E239 Feedback safety relay 2 to VZK (1 = open)
11.1.15 K15: Personnel protection system (PSA)

and
E135 Release high travelling speed by PSA to SECAN
E136 Release travelling 1 by PSA to SECAN
E137 Release travelling 2 by PSA to SECAN
A118 Aisle signal from SECAN to PSA
A119 Slow speed signal from SECAN to PSA
10
11.1.16 K16: AC-control systems

and
A107 Release signal controller main lift
MZ106 Status drive control
A113 Release signal controller driving
MA127 Drive speed set value 0.01km/h
MA128 Drive speed measured value 0.01km/h
MZ104 Status controller steering
A114 Release signal controller steering
AA103 Set value steering 0.01°
EA107 Measured value steering angle position 0.1°
11.1.17 K17: Right side control panel

and
E101 Key end of aisle reset
E102 Key lifting cut-out override
E104 Key slack chain override
E107 Key 2. stacking depth
E109 Key main and auxiliary lift synchronously
E115 Key aux. lift
E117 Key two-handed operation right
E218 Direction switch of master switch right, inward
E219 Direction switch of master switch right, outward
MA221 Set value master switch
MZ213 Status master switch
11
11.1.18 K18: Left side control panel

and
E103 Key driving override
E105 Key fork tine adjustment device
E106 Key steering straight-on / IF-operation
E108 Key synchronous swivelling
E110 Key lateral traversing
E111 Key swivelling
E112 Key two-handed operation left side
E113 master switch left, outward
E114 master switch left, inward
MA220 set value master switch left digit
MZ212 Status master switch left
11.1.19 K19: Main/Auxiliary lift synchronous lifting/lowering

and
MZ223 Status Main lift synchronous
MZ224 Status Auxiliary lift synchronous
MZ225 Status Main/Auxiliary lift synchronous
AA100 Prop. valve 2Y30
12
11.2 Service menu / setting parameters

11.2.1 Shortcuts for parameter types
Short Meaning Remarks

cut
BZ Operation hour meter
C Codes Release codes for Options
D Number of revolutions
I Currents
G Geometry
P General Parameters
R Ramps Standard setting range 1...100
V Velocity Setting in % of maximum range
S System
T Times
TI Teach-In Value determined by means of teach-in proc-
ess
M Menu
E Command
13
11.2.2 Shortcuts in parameter
Short cut. Meaning

CO Cut-out
RR Revolution rate
I Current
ML Main lift
LWB Load wheel brake
MSS IF Steering Microsensors
TF Telescope Fork
TI Teach-In
V Velocity
AL Auxiliary lift
TAD Tine adjustment device
CCB Counter current brake
11.2.3 Minimum, maximum, default values
+ The minimum, maximum and default values for each parameter are showed on the APE. They
are therefore not listed in the following tables. Using default values, no satisfactory opera-
tion is possible.
For new parameter inputs consider the values of the truck´s acceptance certificate. Neces-
sary alterations have to be noted in the acceptance certificate, adding name and date.
Parameters with grey background in table should not be altered
14
11.2.4 List of service menus.
Menu Functional assembly

M01 Control panel
M02 Sideshift
M03 Swivelling
M04 Main lift (ML)
M05 Auxiliary lift (AL)
M07 Hydraulics Synchr. Swivel
M08 Geometry Synchr. Swivel
M09 Fork tine adjust. (FTA)
M10 Driving
M12 Steering
M13 Pump
M15 Inductive Guidance (IF)
M16 Driving cut-out
M17 Lift cut-out
M18 Lowering cut-out
M19 Sideshift cut-out
M20 Optipace
M21 Options
M22 Hour Meters
M23 Language
15
11.2.5 M 01: Control panel
PNr. APE text Meaning / measure Unit

“Time / Date” setting see operating instructions
S12 "Year"
S11 "Month"
S10 "Day"
S16 "Hours" “
S15 "Minutes" “
S14 "Seconds" “
“
“Battery monitoring” Enter battery type:
“PZS-G” Normal wet cell
“PZS-H/L” Empowered wet cell
“PZS maintenance- Maintenance-free lead-gel-battery
free”
S31 Select No:
16
11.2.6 M 02: Sideshift

TI01 "TI LPos left" Move to the left-hand end position and confirm
the position
TI02 "TI LPos right" Move to the right-hand end position and confirm
the position
G02 "Front part dim." Enter the correct dimension: b15 - 80 mm mm
G00 "End ahead" ahead end distance mm
G01 "End" Distance from end, at which the initial position is mm
recognized
G05 "TForks center" Enter center position of telescope: b15 / 2 mm
R00 "Braking ramp" Higher values mean a steeper ramp; setting

range: 1 - 100
R02 "Accel. ramp" “
V00 "Speed max left" Higher values mean a higher speed. Setting in %
% of the set control range of the flow controller.
V01 "Speed max right" “
V02 "Slowspeed left" “
V03 "Slowspeed right" “
I00 "Current min 2Y30" Flow controller offset, minimum control current mA
for the function.
I01 "Current max 2Y30" Maximum permissible control current value for mA
the function
D08 “RPM max" Number of revolutions required for maximum min-1

speed
17
11.2.7 M 03: Swivelling

TI04 "LPos. Left" Move to the left-hand end position and confirm
the position
TI05 "LPos. Right" Move to the right-hand end position and con-
firm the position
G10 "End ahead" ahead end distance °
G11 "End" Distance from end at which the initial position is °
recognized
R04 "Braking ramp" Higher values mean a steeper ramp

V04 "Speed max left" Higher values equal a higher speed. Setting in %
% of the set control range of the curent control-
ler.
V05 "Speed max right" “ %
V06 "Slowspeed left" “ %
V07 "Slowspeed right" “ %
I02 "Current min 2Y30" Flow controller offset, i.e. the set value is the mA
minimum control current for the function.
I03 "Current max 2Y30" Maximum permissible control current value for mA
the function
D07 "RPM max" Number of revolutions required for maximum min-1

speed
18
11.2.8 M 04: Main lift

TI06 "Teach-In top" Move to / confirm upper MHF end position
TI07 "Teach-In bottom" Move to / confirm lower MHF end position
G20 “End ahead top" Enter the ahead end distance to the top mm
G21 "End ahead bottom" Enter the ahead end distance to the bottom mm
G22 "Height"
R08 "Braking ramp lift" Higher values mean a steeper ramp.

R09 "Braking ramp lower" “
R10 "Accel. ramp lift" “
R11 "Accel. ramp lower" “
V08 "Speed max lift" Higher values of flow controller mean a higher %
speed
V09 "Speed max lower" “ %
V10 "Slowspeed lift" “ %
V11 "Slowspeed lower" “ %
I04 "Current min lift” Flow regulator offset, i.e. the set value (in mA) mA
is the minimum control current for the function
"Lifting main lift"
I05 "Current max lift" Maximum permissible control current value for mA
the function "Lifting main lift"
I06 "Current min lower” Minimum control current value for the function mA
"Lowering main lift“
I07 "Current max lower" mA
D18 “RPM slowspeed lift” Number of revolutions min-1

D00 "RPM max lift" “ min-1
D01 "RPM lower" “ min-1
D02 "RPM Prop. lift" “ min-1
D03 "RPM Prop. lower” “ min-1
V30 "SwitchSpeedRPM- “ min-1
Prop"
19
11.2.9 M 05: Auxiliary lift

TI08 "TI limit btottom" Move to / confirm bottom aux. lift end position
TI09 "TI limit top" Move to / confirm top aux. lift end position
G30 "End ahead top" Enter the ahead end distance to the top mm
G31 "End ahead bottom" Enter the ahead end distance to the bottom mm
G32 "Height" Measure h9 mm
R12 "Braking ramp lift" Higher values mean a steeper ramp

R13 "Braking ramp lower" “
R14 "Accel. ramp lift" “
R15 "Accel. ramp lower" “
V12 "Speed max lift” Higher values mean a higher speed. Adjust- %
ment in % of the set control range of the flow
regulator
V13 "Speed max lower" “ %
V14 "Slowspeed lift" “ %
V15 "Slowspeed lower" “ %
I08 "Current min lift" Flow regulator offset, the minimum control cur- mA
rent for the function "Lifting aux. lift"
I09 "Current max lift" Maximum current for the function „aux. lift lift- mA
ing“
I18 "Current min lower" Minimum current for the function „aux. lift lifting“ mA
I16 "Current max lower" Maximum current for the function „aux. lift low- mA
ering
T04 "SwitchOnDelay Switching time 2Y32
2Y32"
D04 "RPM lift" Number of revolutions min-1

D05 "RPM lower" Number of revolutions min-1
20
11.2.10 M 07: Hydraulic System Synchr. Swivel

“Sideshift:”
R17 "Braking ramp" Higher value means steeper ramp
I12 "Current min 2Y31" see chapter 5,6 mA
I15 "Current max 2Y31" see chapter 5,6 mA
I17 "Current rest 2Y31" “ mA
V22 "Speed max right" Setting of the maximum speed for lateral tra- %
versing to the right; does not affect the sequen-
tial speed
V23 "Speed max left" Setting of the maximum speed for lateral tra- %
versing to the left; does not affect the sequen-
tial speed
V21 "Offset" %
"Swivel:“
R16 "Braking ramp" Higher value means steeper ramp
I10 "Current min 2Y30" mA
I11 "Current max 2Y30" mA
V19 "Speed max right" Max. velocity right %
V20 "Speed max left" Max. velocity left %
V16 "Slowspeed" %
V18 "Offset" %
D06 "RPM max. Syn- Number of rotations for maximum speed min-1
Swivel "
21
11.2.11 M 08: Geometry Synchr. Swivel

TI10 "TI Position A" Move to Teach- In Position A / Enter
(see chapter 6)
TI11 "TI Position B " Move toTeach- In Position B /Enter
TI12 "TI Position C" Move toTeach- In Position C /Enter
TI13 "TI Position D" Move toTeach- In Position D /Enter
G80 "Offset aisle" Quotation of the lateral safety clearance; this mm
value must be projected
G81 "Alpha1" Projected value
G82 "Radius1" Projected value
G89 "Startup angle syn." Projected value
P20 "Amplification cont" Dynamics of the control device can be adjusted
G87 "Cut-out height" Lifting height for synchronous cut-out mm
P82 "Stock zone cut-out" Stock zone for synchronous cut-out
(1=apron; 2=aisle; 255=everywhere)
11.2.12 M 09: Fork tine adjust. (FTA)

R40 "Braking ramp” Higher value means steeper ramp
R41 "Accel. ramp” “
I41 "Current min" Min current flow regulator valve mA
I42 "Current max" Max. current flow regulator valve mA
V40 "Speed max" Only one speed adjustable
22
11.2.13 M 10: Driving

V50 "Slowspeed 2.5 km/h Higher value means higher speed 0.01
km/h
V51 "Slowspeed 4.0 km/h “ 0.01
km/h
V52 "Aisle max speed” “ 0.01
km/h
V55 “Speed max apron” “ 0.01
km/h
V53 "Speed control aisle " When the set speed is reached, the drive con- 0.01
trol activity is automatically deactivated; the km/h
truck cannot exceed the set speed.
V56 “Speed control apron” Only active in apron 0.01
km/h
R51 "Accel. ramp" Higher value means steeper ramp
R50 "Brake return" “
R54 "Brake rollout" “
R56 "CCB manual min" “
R57 "CCB manual max" “
R58 "CCB EndAisle- Higher value means harder braking %
Safety"
23
11.2.15 M 12: Steering

P23 "Steering wheel Higher values mean a more direct transmis-
transmission." sion; range of adjustment: 5 - 80;
adj. 5: approx. 20 rotations for 180° steering
adj. 80: approx. 4 rotations for 180 ° steering
P24 "StraightAhead Corr" Used to correct steering offsets; range of digit
adjustment: -300 to +300 digits; see the
description for the adjustment of the steering
system sensor equipment
"Steering manual"
P00 "Steering speed" Higher values mean a higher maximum steer-
ing speed
P01 "Steering ramp" Higher values mean stronger acceleration and
a higher dynamics
P02 "Amplification" Higher values mean more aggressive steering;
if the value is too high, the steering controller
may start to vibrate!
P03 "Dead zone" Parameter used to set a hysteresis for manual
steering (steering reacts only when this value is
exceeded)
"Steering refer"
ing speed
a higher dynamism
exeeded)
"Steering IF apron"
ing speed
a higher dynamism
24

exeeded)
"Steering IF aisle"
ing speed
a higher dynamism
exeeded)
25
11.2.16 M 13: Pump

R52 "RPM Accel. ramp" min-1
R53 "RPM Braking ramp" min-1
P93 "Pressure 2B10" (bar) bar
11.2.17 M 15: Inductive Guidance

"MSS front:”
P100 “Frequency" Set wire frequency; select according to chapt. 6

P101 "Height" Reading height above ground mm
P102 "Current" Set wire current mA
P103 "Threshold" Threshold beyond which the wire signal is
safely detected
P104 "Hysteresis" Current threshold hysteresis
P105 "Algorithm" Calculation algorithm: height compensated=2,
current compensated =1
TI90 "Calibration" See chapter 6
"MSS rear:”
P106 “Frequency" Set wire frequency; select according to chapt. 6
P107 "Height" Reading height above ground mm
P108 "Current" Set wire current mA
P109 "Threshold" Threshold beyond which the wire signal is
safely detected
P110 "Hysteresis" Current threshold hysteresis
P111 "Algorithm" Calculation algorithm: height compensated=2,
current compensated =1
TI91 "Calibration" See chapter 6
TI92 "TI steering straight" Correction of straight ahead position of steer-

ing;
see chapter 6
TI93 "TI MSS deviation" Correction of side offset of the IF sensors; see
chapter 6
P121 "Corr.deviation MSS" Correction of distance between IF sensors mm
26

P122 "Corr.deviation axis" Correction of lateral offset of the longitudinal mm
axis of the truck
P112 "Gkp search" Importance of yaw angle during engaging
P113 "Bkp search" Importance of distance during engaging
P114 "Gkp apron" Importance of yaw angle during driving in the
apron
P115 "Bkp apron" Importance of distance during driving in the
apron
P116 "Gkp aisle" Importance of yaw angle during driving in the
aisle
P117 "Bkp aisle" Importance of distance during driving in the
aisle
P118 "Steering angle max" Limitation of max. steering angle during engag-
ing
P119 "SteerAngle min forw" Minimum steering angle for inclination towards
wire during forward engaging
P120 "SteerAngle min Minimum steering angle for inclination towards
back" wire during backward engaging
27
11.2.18 M 16: Driving cut-out

TI60 “Teach-In Height A” Move the main hoist frame to the desired lifting
height and confirm with ENTER.
G60 "Cut-out height A" height can be entered; this item can also be mm
used for fine adjustments (in the mm range
after the cut-out height has been determined by
applying the teach-in procedure).
P60 "Stock zone for A" Determine in which storage zone the driving
cut-out is to be effective.
P63 "Override for A" Specifies whether the cut-out function may be
overriden; override is effected by means of a
key in the control panel.
TI61 "Teach-In height B" Same as „A“

G61 "Cut-out height B" Same as „A“ mm
P61 "Stock zone for B" Same as „A“
P64 "Override for B" Same as „A“
TI62 "Teach-In height C" Same as „A“

G62 "Cut-out height C" Same as „A“ mm
P62 "Stock zone for C" Same as „A“
P65 "Override for C" Same as „A“
P66 "Zone LoadLDev cut" Stock zone for cut-out, if fork is not in starting
position; stock zone
P67 "Override LoadLDev" Yes/no
11.2.19 M 17: Lift cut-out

TI20 "Teach-In height A" Move the main hoist frame to the desired lifting
28

G40 "Cut-out height A" Using this item, the desired cut-out height can mm
be entered; this item can also be used for fine
adjustments (in the mm range after the cut-out
height has been determined by applying the
teach-in procedure).
P40 "Stock zone for A" Determine in which storage zone the lifting cut-
out is to be effective
P45 "Override for A" Defines whether the cut-out function may be
key in the control desk.


TI23 "Teach-In height D" Same as „A“

G43 "Cut-out height D" Same as „A“ mm
P43 "Stock zone for D" Same as „A“
P48 "Override for D" Same as „A“
TI24 "Teach-In height E" Same as „A“

G44 "Cut-out height E" Same as „A“ mm
P44 "Stock zone for E" Same as „A“
P49 "Override for E" Same as „A“
P56 "C-O active ML+AL Yes/no
E"
29

G45 "End ahead cut-out" The set ahead-end distance applies to all cut-
out heights.
11.2.20 M 18: Lowering Cut-Out

TI25 "Teach-In height A" Move the main hoist frame to the desired lifting
G46 "Cut-out height A" Using this item, the desired cut-out height can mm
be entered; this item can also be used for fine
adjustments (in the mm range after the cut-out
height has been determined by applying the
teach-in procedure).
P50 "Stock zone for A" Determine in which storage zone the lowering
cut-out is to be effective
P53 "Override for A" Defines whether the cut-out function may be
key in the control desk.


G49 "End ahead cut-out." Ahead end distance for all cut-out heights mm
30
11.2.21 M 19: Side Shift Cut-Out

G03 "2nd stacking depth Option: 2. Enter 2nd stacking depth right (code mm
right" number)
G04 "2nd stacking depth Option: 2. Enter 2nd stacking depth left (code mm
left" number)
P30 "2nd stacking zone" Stock zone, where 2nd stacking cut-out is
effective
11.2.22 M 20: Optipace

G50 “MIn. Height forward“ Optipace starts to reduce the speed for driving mm
forward during lifting.
Below min. height = full speed.
G51 “Max Height forward“ Optipace starts to increase the speed for driv- mm
ing forward during lowering.
Above max. height = slow speed.
G52 “MIn. Height back- Optipace starts to reduce the speed for driving mm
ward“ backward during lifting.
Below min. height = full speed.
G53 “Max Height back- Optipace starts to increase the speed for driv- mm
ward“ ing backward during lowering.
Above max. height = slow speed.
11.2.23 M 21: Options, Release Codes, Personnel

Protection System

“Truck-Codes”
C00 “EndAisle with stop” Enter release code
C01 “IF truck” Enter release code
C02 “Sideshift cut-out” Enter release code
C03 “ML lift cut-out A” Enter release code
C04 “ML lift cut-out B” Enter release code
C05 “ML lift cut-out C” Enter release code
C06 “ML lift cut-out D” Enter release code
C07 “ML lift cut-out E” Enter release code
31

C08 “EndAisle Autoreset” Enter release code
C09 “Optipace” Enter release code
C10 “ML AL Synchronous” Enter release code
C11 “Swivel synchronous” Enter release code
C12 “ML lower cut-out A” Enter release code
C13 “ML lower cut-out B” Enter release code
C14 “ML lower cut-out C” Enter release code
C15 “Drive cut-out A” Enter release code
C16 “Drive cut-out B” Enter release code
C17 “Drive cut-out C” Enter release code
C18 “Drive c-o LoadLDev” Enter release code
C19 “Drive c-o apron” Enter release code
C20 “nc20” Enter release code
C22 “Aisle recogn. wire” Enter release code
C23 “Aisle manual” Enter release code
“PersProtectSystem”
G68 “Sensor Height 1” Simulated height signal 1; over this height out- mm
put to PSA is ON
G69 “Sensor Height 2” Simulated height signal 2; over this height out- mm
put to PSA is ON
P83 “Warning light”
32
11.2.24 M 22: Hour meters

BZ00 "Movement duration" h
BZ01 "SwitchOn duration" h
BZ02 "Steering" h
BZ03 "Driving" h
BZ04 "Pump" h
11.2.25 M 23: Language

Selection:
Sprache (D) 0
Language (GB) 1
Langue (F) 2
Taal (NL) 3
Linguaggio (I) 4
Lengua (E) 5
Sprog (DK) 6
Sprag (N) 7
Sprak (S) 8
S04 Select No: Enter figure for desired language.
33
34
1 2 3 4 5 6 7 8
K1 W75
50 qmm
contactor
W77
12 Operating Diagrams
50 qmm W73 6 qmm

25 qmm 63A
W70 + + 3F1 +
1F1 250A 2F1 400A
X1
1
1A1 2A1 3A1

AC-Controller AC-Controller AC-Controller
driving pump steering
W70.1
+ U V W - U V W - U V W -
- G1
80 V
1
+ cable tree1W1 cable tree2W1 cable tree3W1
-
25 qmm 50 qmm 6 qmm
W71.1
U V W PE U V W PE U V W PE
2
M M M
X1 1M1 2M1 3M1
3~ 3~ 3~
driving motor pump motor steering motor
W71 50 V 50 V 50 V
7,5 kW 23 kW 1,25kW
2650U/min 2610U/min 3300 U/min
D-Unterlage erstellt mit PROMIS

S2-Betrieb S3-Betrieb S3-Betrieb
50 qmm
W74 W76 W78
25 qmm 50 qmm 6 qmm
#UBattDauer_80V
#UBatt 80V
U100
24 V DC
1
0V ZMP
0V DC
X11
X100
24 V valves
X8
F10
F19
2
drive compartment
1
U-Batt_perm. horn, main switch
1 2 6 3
(3) (8)
5A
5A
F20
U_Batt for release main contactor 3
F11
2
(4) U_Batt magtetic brake
3A
4
0 V power cabin (9)
3A
3
(5) 0 V power 2
F21
5
7
24 V valves cabin (10)
2
see page 3
mast cable
(6)
5A
F12
6
4
0 V working light U_Batt_perm. batt. meter
motherboard drive compartment VZA (U100)

8
(7) (11)
3A
5
0 V power 1/power 3
F22
7
9 12
24 V control cabin (12)
(8)
5A
8
0 V control cabin
(9)
F23
9
24 V lighting
X9
1
(10) 0 V batt. meter
5A
10
11
3
0 V reserve cabin (13)
X101
X12
cable tree
2
0 V controller, sensors
F24
1
(14)
1
Reserve
W4
F13
24 V sensors
3A
2
(15)
3A
2
0 V pers.protection system
3
(16)
X13
F14
4
5
24 V IF-sensors
F25
4
24 V Encoder main lift (17)
see page
3A
1
(1)
3A
X10
F15
O V Encoder main lift 0V Prop. valves

2
6
(2) drive compartment (18)
3A
F16
24 V pers.protection systems
X14
5
7
(19)
3A
F26
24 V fan 0V Prop. valves

1
drive compartment (20)

3A
F17
0 V fan 24 V control drive compartment

2
10
5
(21)
3A
F18
24 V flash light
11
(22)
3A
X15
F27
#80VFreigMotoren
see page
cable tree
5A
2
W1
7A1
10
6
X30
Out
24V
DC/DC-converter
24V DC
Dioden: 1N4004
DC-Wandler: Faston 6,3 isoliert
X12, X13, X14, X15 AMP Mate-N-Lok 2-polig
X11 AMP Mate-N-Lok 9-polig
X8, X9, X10, AMP Mate-N-Lok 5-polig
(4)
2
ZMP
0V
0V ZMP (5)
3
DC
0V
0V DC (6)
F30
80V
In
U_Batt
fuse board U 1
(7)
15A
see page
7
ON
7
(26)
U_Batt_perm before main contactor
X16
(2)
U_Batt after main contactor
1
(1)
3
(3)
Batt_GND
2
1 2 3 4 5 6 7 8
X198 (1) release main contactor (U_Batt)
1 8
U100 VZA 2 (2) GND spring released brake 2
(3) U-Batt_perm. horn, main switch 1
(4) U_Batt after main contactor 4
X298A
(5) 0V Power 4 5
(6) 24 V valves cabin 3
X11
2
(7) 0 V working light 7
3
(5) 6
4
motherboard cabin VZK (U200)
cable tree W41 (6) 9
5
fuse board U 1
6 U200
U1
(8) 1
7
(9) 5
8
3
X298B
9 (10) 4
10 (6) 3
(11)
(9) 6
(12) not in use (on clamping joint) in cable tree
W34
X4.1b X227.1 X227
1 (13) Channel A 1 (ye) 5
1
X295
Encoder 2 (14) Channel B 2 U3 (gy) 6
Connectors: cabin lift Filter
see page 5 (15) Index 2 (pk)

3 3 7
X4.1b: Mate-N-Lok 3-p.
X4.3: Mate-N-Lok 2-p. 3
X11: Mate-N-Lok 10-p. (16)
X216
X198: Mate-N-Lok 2-p. not in use (on clamping joint)
X201: Mate-N-Lok 2-p. GND (1) 2
X216: Mate-N-Lok 2-p.
X221: Mate-N-Lok 12-p. X4.3 X 201
X227: Mate-N-Lok 3-p. 1 (17) 2Y49 setpoint (OC) 1 (17) 6
X221
X227.1: Mate-N-Lok 3-p.
X295: Sub-Min-D 15-p. see page 19 2 (18) 2Y53 on 2 (18) 7
X298A: Mate-N-Lok 9-p.
X298B: Mate-N-Lok 6-p. in cable W91
1 2 3 4 5 6 7 8
see page 10
2
1
X199A X199B
X199 X299
1 (wt) CAN H 1
(bn) CAN L
2 2

3 (gn) Supply 3
4 (ye) Ground 4
5 (gy) emergency 1 release 5
6 (pk) emergency 1 feedback 6
U100 U200
7 (bu) emergency 2 release 7
8 (rd) emergency 2 feedback 8
9 (shield) 9
4
cable W5

Connectors:
X199B: Mate-N-Lok 2-p.
1 2 3 4 5 6 7 8
X105.1
X105
1 cabin lift below 0,3m (0 V) (1) 1 (bn) S11
2 0 V controller, sensors (2) 2 (bu) cabin lift
0,3m
switch
cable W38
X4.1b X4.2a
1 Channel A (ye) 1 (gn)
in mast cable 2 Channel B (gy) 2 (ye) B2
see page 3
3 Index (pk) 3 (pk) increm.
encoder
cabin lift
4
X13 nc
U100
1 24V (rd) 5 (bn)
fuse
U1 board 0V (bu) (wt)
2 6
see page 2
5
cable W7.1
X104 X104.2 X104.1
1 (1) 1 12 V (wt) 1 (wt) 1 B1
2 (2) 2 Pot. output (bn) 2 (bn) 2 potentiometer
cabin lift
3 (3) 3 0 V (gn) 3 (gn) 3

cable W104
Connectors: soldering tags
X4.1b:Mate-N-Lok 3-p.
X4.2a:Mate-N-Lok 6-p.
1 2 3 4 5 6 7 8
1
X8.1
(bk) 1 (1) aisle signal A1 2
X115
attention! S5.1
Aisle identification and AEB magnetic (bu) (2) 0V control
switch aisle
2 3
are not standard
reognition
in all trucks
(bk) 3 (3) aisle signal A2
S5.2

magnetic (bu) (4) 0V control
switch aisle
4
reognition
X8.2
(bk) 1 (1) aisle signal A3
S5.3
switch aisle
reognition 1
(bk) 3 (3) aisle signal A4 2
X116
S5.4
switch aisle
4 3
reognition
X118 attention!
cable tree W8 jumper, if no AEB
6
1 1
X20.1
(bk) 1 (1) Signal S6.1 2 2
S6.1
AEB (bu) 2 (2) 0V control 3 3
switch
4 4
X20.2
(bk) 1 (3) Signal S6.2 5 5
X118
S6.2
X118j
switch
7 7
X20.3
(bk) (5) Signal S6.3

1 8 8
Connectors: S6.3
X8.1: Mate-N-Lok 4-p. switch
X8.2: Mate-N-Lok 4-p. 10 10
X20.1: Mate-N-Lok 2-p. X20.4
X20.2: Mate-N-Lok 2-p. (bk) 1 (7) Signal S6.4 11 11
X20.3: Mate-N-Lok 2-p. S6.4
X20.4: Mate-N-Lok 2-p. AEB (bu) 2 (8) 0V control 12 12
X115: Mate-N-Lok 3-p. switch
X116: Mate-N-Lok 3-p. cable W10
1 2 3 4 5 6 7 8
clamping joint
(bk) (1) U_Batt magtetic brake (1) 1
X111
1Y1
(bu) (2) release brake (open collector, 0V) (2) 2
Brake
cable W14
V111 (BZW50-100 B)

X513 (1) 24 V flash light (1) 1
X113
4H4
1 (2) Flashlight Output ON (0V) (2) 2
Flashlight
cable W613
R113
thermistor NTC
21 (1)
S2a
Switch 22 (2)
7
Emergency
cable W102A
2
1
X102A
7A1 ON
ON
see page 2 DC/DC-
conv.
(3)
Connectors: A1 (1) release main contactor (U_Batt) (1)

12
A1: Faston 6,3 K1
X102
A2: Faston 6,3 cable W102
ON: Faston 6,3 coil
X102: Mate-N-Lok 12-p. main contactor V102 (BZW50-100 B) (2) 0 V power 2 (2) 4
X111: Mate-N-Lok 2-p. A2 6
X113: Mate-N-Lok 2-p. X149.1 (2)
X149.1: Mate-N-Lok 2-p. see page 9 1 (1)
2
1 2 3 4 5 6 7 8
auxiliary lift
1 X 25 (1) 24V valves drive compartment (1) 4
X130
2Y32
lifting 3 (3) 2Y33 on (3) 11
X132
2Y33 2 (2) 2Y32 on (2) 2
lowering
1N4003

X130
2Y34
main lift
lifting 3 (6) 2Y34 on (6) 10

2Y35 2 (5) 2Y35 on (5) 4
lowering
1N4003
X132
cable tree
W 47
1 X 33 (7) 24 V prop. valve (7) 5
2 Y 31
prop. valve 2 (8) setpoint (OC) (8) 6
all functions
1N4003
8
2 Y 36
valve 2 (10) 2Y36 on (10) 12
LAM
X130
1N4003
(11)
Connectors: 2 Y 52
valve 2 (12) 2Y52 on (12) 9
X25: valve plug pump idling
X32: valve plug 1N4003
X33: valve plug 2 Y 30

X27: valve plug prop. valve 3 (14) 2Y30 setpoint (OC) (14) 6
X28: valve plug swivelling
X29: valve plug 1N4003
X130: Mate-N-Lok 12-p. 1 X 133 24V valves drive compartment (15) 1
X112
X132: Mate-N-Lok 6-p. 2 Y 37
X110: Mate-N-Lok 3-p. valve 2 2Y37 on (16) 2
Swivelling
1N4003
zu X135 Pin 1 see page 9 see page 9
1 2 3 4 5 6 7 8
24V valves drive compartment
von X28 Pin 1
see page 8
cable W47
see page 8
X130
1 X 134 24 V prop. valve (13) 3
2Y49
prop. valve 2 (17) 2Y49 on
auxiliary lift
1N4003 1 X4.3
2 see page 3
1 X 135 (11)
2Y53
valve 2 (18) 2Y53 on
pump idling
1N4003
9
X149 X149.1
3 (4) Pressure > P_lim 2 (2) 6
X102
2 S 1
1 (5) 0 V 1 (1) 4
pressure
switch
see page 7
in cable W102
cable W47.1
X 34
(bk) 3 (1) 12 V supply 1

Connectors:
X110
X4.3: Mate-N-Lok 2-p. 2 B 10 (bu) 2 (2) 1 - 5V 2
X102: Mate-N-Lok 12-p. pressure (bn) 1 (3) 0 V 3
X110: Mate-N-Lok 3p. sensor
X130: Mate-N-Lok 12p.
X134: Ventilstecker
X135: Ventilstecker
X149: valve plug
X149.1: Mate-n-Lok 2-p.
1 2 3 4 5 6 7 8
X199A Ä3
CAN H (1) 6 X107.2
3 Channel A (1) 3 (bu)
see page 4 1 CAN L (2) 2
4 Channel B (2) 4 (wt) B3
2 (3)
X70
X74
CAN H 7
Ä 7 15V (3) 1 (rd) sensor
X199B CAN L (4) 3 bearing
1 8 0V (4) 2 (bk) driving
K100
(1) 1 motor
see page 42 14 11
2 X141
Drive control
1 high temp. (0V) (5) (wt)
X76
(2) 2 7
cable tree W5A 6 U100 S9
X76j siehe 0V (6) (wt) temp. switch
8 2 8
Blatt 23 driv. motor
1A1
VZA
7
X79
cable W18
cable tree W6A 4
U_Batt (48V) X51
3
(1)
Connectors: 1 U1
(1) 0V
X71
CAN H 6 X67 fuse
X51: Faston 6,3 4 (2) board
X52: Faston 6,3 CAN L (2) 2
X53: Faston 6,3 cable tree W19
X67: Faston 6,3 U_Batt (48V) X52
X68: Faston 6,3 1 (3) U1
X69: Faston 6,3 0V
X81
CAN L 3 X68 fuse
X70: Mini-Fit 8-p 4 (4) board
10
X71: Mini-Fit 6-p
X89
CAN H 7
X74: Mini-Fit 8-p X165 Ä3
2A1 AC-Controller
X76: Mini-Fit 12-p cable tree W5B CAN H 6 3 (1) Channel A 3 (bu)
X79: Mini-Fit 8-p
X81: Mini-Fit 6-p CAN L 2 4 (2) Channel B 4 (wt) B7
X84: Mini-Fit 8-p
pump
X86: Mini-Fit 12-p (3) (rd)
X84
7 15V 1 Sensor-
K101
X89: Mini-Fit 8-p 1 bearing
(3)
X91: Mini-Fit 6-p (4) (bk)
X86
X86j 14 11 8 0V 2
X94: Mini-Fit 8-p 2 pump motor
(4)
X95: Mini-Fit 8-p 2 (5) Pt100 + cable W20
X96: Mini-Fit 6-p siehe 5 (rd)
X107.2: Mate-N-Lok 9-p Blatt 23 (6) Pt100 - B1
6
X108.1: Mate-N-Lok 2-p cable tree W6A 6 (wt) Thermistor
X141: Mate-N-Lok 2-p Pt100

X165: Mate-N-Lok 9-p CAN L (3) 2
X199A: Mate-N-Lok 2-p 1 (5) U_Batt (48V) X54
AC-Controller
X199B: Mate-N-Lok 2-p (4)
X91
CAN H 6 U1
(6) 0V
X95
4 X69 fuse
Steering
attention! board
4
temperature switch in cable tree W19
3 2
steering motor X108.1
7 6
Ä1: div. Pins geändert see page 11 4 (1) Channel A 1
8
Ä2: Pins geändert
X94
cable tree W6A
K102
(5) (2)
X96
3A1
3 Channel B 2 see page 11/3
1
X96j siehe
14 11 (6) 3
Blatt 23 cable W21
1 2 3 4 5 6 7 8
X108.1
1 (gn)
see page 10/7 2 (ye)
X22.2

1 (wt) 0V control 5
2 (bn) 24 V control drive compartment 4
steering
encoder
3 (gn) Channel A 8
X22.2
B5
4 (ye) Channel B 6
(gy) Index
5 9
X108
9 (shield)
X22.1
1 (1) 1 (1) 12V 1
B4
2 (2) 2 (2) Pot. output 2
11
steering
potentiometer 3 (3) (3) 0 V controller, sensors
3 3
X114.1
(wt) 1 (bu) high temp. (0V) 1
X114
S8
temperature switch (wt) (rd) 0V
steering motor
2 2
Connectors:
X22.1: Mat-N-Lok 3-p
X22.2: Sub-Min-D 9-p cable
X108: Mat-N-Lok 9-p W12

X114: Mat-N-Lok 2-p
1 2 3 4 5 6 7 8

1 W 102.2 8
X 130
(1) 24 V Ventile (1)
X38
1
2 7
2 (2) 1 Y 2 ein (2)
K10
3 1
X39
1 (3) 24 V (3)
2
4 6
(4) emergency 1 release (4)
K11
8 X 25
1
X6
5 2
2 (5) 24 V (5)
X 24
6 7
(6) emergency 1 release (6)
K15
3
K1a
K1b 4
board safety LRB U2
12
K13 5
140 127
8 2
(7) release brake (open collector, 0V) (7)
9 2
(8) voltage breake LRB o.k. (8)
Connectors: Crimp 6,3
X 102.1
1 (1) U_Batt_perm before main contactor
W 102.1 (1)
X38: Mate-N-Lok 2-p F1 X 56
2 (2) U_Batt after main contactor (2)
X39: Mate-N-Lok 2-p X 53 fuse board U 1
3 (3) 24 V DC (3)
X6 : Mate-N-Lok 2-p K12;14 X 61
4 (4) 0 V DC (4)
X24: Mate-N-Lok 9-p X 65

X102.1: Mate-N-Lok 4-p
X40: Mate-N-Lok 4-p
X130: Mate-N-Lok 12-p
8X25: Mate-N-Lok 9-p 1 X 41
R4.. (1) voltage breake LRB (1)
X127: Mate-N-Lok 3-p 1Y2.2
R7
X140: Mate-N-Lok 2-p LRB
X 40
X56; X56; X61; X65 2
Crimp 6,3 W 102.3 BZW50-100B
X41: Mate-N-Lok 2-p
X42: Mate-N-Lok 2-p K1a 3 1Y2.3
(2) release brake (open collector, 0V) (2)
K1b LRB
X 42
1 2 3 4 5 6 7 8
X36
1 24 V IF-sensors (wt) 1
3 RxD: OC (bn) 31
4 0V (gn) 4
IF antenna
5 MPD Receive: 0V (ye) 14

front
8U1
6 MPD Receive: OC (gy) 34

7 TxD: OC (pk) 24
8 TxD: 24V (bu) 7
10 MPD Transmit: 24V (rd) 8
8X26
X37 cable tree 8W100
1 RxD: OC (wt) 32
13
2 24 V IF-sensors (bn) 2
4 0V (gn) 5
IF antenna
5 TxD: OC (ye) 12
rear
8U3
6 MPD Receive: 0V (gy) 15

7 MPD Receive: OC (pk) 36
9 TxD: 24V (bu) 30
10 MPD Transmit: 24V (rd) 9
8X26j

Connectors:
16 16
8X26
X36: Sub-Min-D 15-p.
X37: Sub-Min-D 15-p. 21 21
8X26: Sub-Min-D 37-p.
X36, X37 attention!
Do not open connector box,
because of integrated electronics ! Jumper, if no Wire Guidance !
1 2 3 4 5 6 7 8
0V control (wt) 1
24V steering (bn) 2
24 V valves steering lock (gn) 3
emergency stop channel 2 (ye) 4
safety module

emergency stop channel 1 (gy) 5
release relay SF1 + (pk) 6
1 K 15
X 109
release relay SF2 - (bu) 7
SIMO
feedback SF1 (24V) (rd) 8

release brake (open collector, 0V) (bk) 9
24V release emergency stop (vi) 10
24 V valves steering lock ( g y )( p k ) 11
breake relay + (from PSA) ( r d )( b u ) 12
release relay SF1 - ( w t )( g n ) 13
release relay SF2 + ( b n )( g n ) 14
feedback SF2 (24V) ( w t )( y e ) 15
X 143 J
release fast driving speed IN 1
14
release fast driving speed OUT 25
driving reverse release (OC) 2
jumper, if no PSA is installed

U_Batt driving 3
release driving forward 4
personal security system
U_Batt driving 5
release brake 1 IN 6
release brake 1 OUT 9
release brake 2 IN 7
release brake 2 OUT 8
X 143
24 V pwer supply 12
24 V pwer supply 13
A 10
PSA
0 V pers.protection system 10
aisle signal 14
aisle signal 22

release driving forward 20
release driving reverse 23
release fast driving from PSA 24
Connectors:
encoder signal Ch A 15
encoder signal Ch B 16
X109: SubM 15-p
lifting height 1 17
X143: SubM 25-p
lifting height 2 18
PSA inform. fast speed 19
1 2 3 4 5 6 7 8
U101
electronic board
X160 X150
SK-EA

U102
Bus card
U105
electronic board
X151
X161 SK-R
15
U103
electronic board
Connectors: X162
SK-VZA X152
X150: Harting 96-p.

X151: Harting 96-p.
X152: Harting 96-p.
X160: Harting 96-p.
X161: Harting 96-p.
X162: Harting 96-p.
1 2 3 4 5 6 7 8
13 X202.1 (1) barrier left closed (1) 1
X202
S 4
barrier switch 14 (2) 0 V control cabin (2) 2
left
cable W 24
13 X203.1 (1) barrier left and right closed (1) 1
X203
S 3
barrier switch 14 (2) barrier left closed (2) 2
right
cable W 25
13 (1) foot switch closed (input processor) (1) 1
S 12 14 (2) 0V (2) 2
X206
foot
43 (3) GND spring released brake (3) 3

button
44 (4) foot switch pressed (4) 4
cable W 26
foot switch
if no 2-nd
13 (1) foot switch closed (input processor) 1
jumper,
S 13 14 (2) 0V 2
X207
foot
43 (3) foot switch pressed 3
b u t2t o n
44 (4) 0 V power 2 4
cable W 27
X207 J
+ (1) horn on (UBattDauer (1) 1
X211
H 1
16
- (2) 0 V power 2 (2) 2
horn
1N4003 cable W 45
11 (1) left chain and right chain slack (1) 1
X204
S 14
slack chain 12 (2) chain left slack (2) 2
switch right
cable W 28
11 (1) chain left slack (1) 1
X205
S 15
slack chain 12 (2) 0V (2) 2
switch left
cable W 29
Connectors: 11

jumper, if no cutoff
S 16 (1) lifting cutoff roof (0V)
X202: Mate-N-Lok 2-p lifting cutoff
switch roof
X203: Mate-N-Lok 2-p switch 12
X206: Mate-N-Lok 4-p roof 1
X204: Mate-N-Lok 2-p 11 X210 J
X205: Mate-N-Lok 2-p S 17 1
X210
X210: Mate-N-Lok 2-p lifting cutoff
X211: Mate-N-Lok 2-p switch 12 (2) 0V 2
X202.1: Mate-N-Lok 2-p roof 2
X203.1: Mate-N-Lok 2-p cable W 30
1 2 3 4 5 6 7 8
13 (4) 24 V lighting (4) 1
switch
S 18 working 14
X209
lights
+ 1 (4)
working (4)
E 1 light - 2 (5) 0 V working light (5) 2
left side
X228
+ 1
working

E 2 light - 2 (5)
right side (5)
X229
X224
+ X224.1
cabin
E 4 light -
left
cable W 34
+ X224.2
cabin
17
E 5 light -
right cable W 61
X225
11 1 (6) 24V (6) 5
X220
Connectors: 4 H 2
acoustic 12 2 (7) acoustic signal on (0V) (7) 7
X228: Mate-N-Lok 2-p signal IF
X225: Mate-N-Lok 2-p 11 1 (8) 0V (8) 1
X295
X226: Mate-N-Lok 2-p 8 S 5

X209: Mate-N-Lok 2-p switch 12 2 (9) IF-emergency operation on (9) 8
X220: Mate-N-Lok 12-p IF-emerg.
X295: SubM 15-p X226
1 2 3 4 5 6 7 8
X 514.2
(wt) 1 (1) pot. A 12 V (1) 4
1
6 B 4 (bn) 2 (2) actual value A (2)
4
2
sensor (gn) 3 (3) pot. A 0 V (3) 6
X214
swivelling 3
(ye) 4 (4) pot. B 12V (4)
7
1
twin- (gy) 5 (5) actual value B (5)
8
potentiometer 2
(pk) 6 (6) pot. 0V (6) 9
3

X 512.1 X 812.1
(1)
1 (wt) 1 1
1
6 B 3 2 (bn) 2 (7) (7) actual value A (7) 2
2
sensor 3 (gn) 3
(3) 3
sideshift 3
4 (ye) 4
(4) 4
1
twin- 5 (gy) 5 (8) (8) actual value B (8)
5
18
potentiometer 2
6 (pk) 6
(6) 6
3
X212
cable W812.1
X 512.2 X 812.2
1 (wt) 1 (1) 7
1
6 B 2 2 (bn) 2 (9) (9) actual value A (9) 8
2
sensor 3 (gn) 3 (3) 9
aux. lift 3
4 (ye) 4 (4) 10
1
Connectors: twin- 5 (gy) 5 (10) (10) actual value B (10) 11

potentiometer 2
X212: Mate-N-Lok 12-p 6 (pk) 6 (6) 12
X214: Mate-N-Lok 9-p 3
X512.1: Mate-N-Lok 6-p cable W812.2
X512.2: Mate-N-Lok 6-p X514.1 X 814.1 cable tree W 90
X514.1: Mate-N-Lok 3-p (gn) 1 (1) 1 (4) 1
X514.2: Mate-N-Lok 6-p 6 B 5
X214
X812.1: Mate-N-Lok 6-p (rd) 2 (2) 2 (11) Signal 2
X812.2: Mate-N-Lok 6-p weight sensor
X814.1: Mate-N-Lok 3-p Potentiometer (ye) 3 (3) 3 (6) 3
cable W812.3
1 2 3 4 5 6 7 8
valve plug
1 X 43 24 V valves cabin (1) 1
2 Y 40
valve 2 valve 2 Y 40 on (0V) (2) 9
swivelling right
1N4003

(1)
1 X 44
2 Y 41
swivelling
1N4003
valve plug
cable W 91
X 221
valve plug
1 X 45 24 V valves cabin (4) 4
19
2 Y 42
sideshift right
1N4003
(4)
1 X 46
2 Y 43
Connectors: sideshift left
1N4003
X43: valve plug valve plug
X44: valve plug
X45: valve plug

X46: valve plug X 201
X201: Mate-N-Lok 2-p (17) 1 valve 2Y53 ein (18) 7
in cable W4
X221: Mate-N-Lok 12-p (18) 2 setpoint (OC) 2Y49 (17) 6
see page 3
1 2 3 4 5 6 7 8
U201
electronic board
X260 X250
SK-EA

U202
Bus card
U205
electronic board
20
X251
X261 SK-R
Connectors:
X251
0: Harting 96-p.

X251: Harting 96-p.
X260: Harting 96-p.
X261: Harting 96-p.
1 2 3 4 5 6 7 8
50 U-Batt_perm. horn, main switch (1) cable W61
S1
15/54 Battery Voltage 48V (2)
Key switch
30 V1 U_Batt for release main contactor (3)
X200
X128 X183
1
2 (2) (bk) 2
S2
3 (3) U_Batt for release main contactor 3
Emergency
c o n t r o l p a n el e
l ft side (1)
1 (1) U-Batt_perm. horn, main switch 1
S19

Switch 4 (5) horn on (UBattDauer 5
horn
cable tree W89
X200
X91
2 24 V (wt) 4
21
3 0 V (bn) 6
X91
1 CAN H (gn) 7
control panel 8 CAN L (ye) 8
right side
11
Connectors:
U106
X91: Sub-Min-D 9-p.
X128: CPC 4-p. 13
X200: Mate-N-Lock 15-p. X182
50: Faston 6,3 RxD

2
15/54: Faston 6,3
X182
30: Faston 6,3 3 TxD
X183: Mate-N-Lok 3-p. RS232
5 GND
1 2 3 4 5 6 7 8
X185 X184
1 (gn) CAN H (gn)
(ye) CAN L (ye) 5
2
U113
X185
X184
(gy) (gy) 4
APE
3 24 V
(wt) VCC (wt) 1
4
(bn) GND (bn) 2
5
9
cable W50
control panel
right side
U106
X187 X129
11 (gn) RxD (gn) 11
22
2 (wt) 24V (wt) 2
control panel
left side
X129
U110
X187
3 (bn) 0V (bn) 3
1 (ye) TxD (ye) 1
cable W52
Connectors:

X184 Sub-Min-D 15-p.
1 2 3 4 5 6 7 8
cable tree W6A
1X110
K100
X62 +24V DC (10) (7) 3
A1 A2
Freigabe Fahren
K101
(8) 3
Freigabe Pumpe
A1 A2
fuse board U 1
X62
D1 K102
(9) 9
Freigabe Lenken
A1 A2
X102
23
Relais für
Freigabe
Leistungsteile
siehe
Blatt 10

Nur bei Prototyp
Just for prototype
24
14 Hydraulic Diagram
Hydraulic schematic Vector C12.5 (double mast)
thread port closed by a screw
thread port open for the pipe

connecting
H4 Line break safety device 40 l/min

H26 Fill- and Ventilation filter
H18 Return flow filter
H10 Suction and locking valve
H9 Pressure converter
H6 Main valve
H3 Valve block
H2 Pump aggregate
H1 Oil tank
A48 Hydraulic motor
A7 Valve block swivelling
A4 Lowering brake valve
A3 Valve block with shock valves
1
Hydraulic schematic Vector C12.5 (triple mast)
thread port closed by a screw
thread port open for the pipe

connecting
4 Line break safety device 40 l/min

26 Fill- and Ventilation filter
18 Return flow filter
10 Suction and locking valve
9 Pressure converter
6 Main valve
3 Valve block
2 Pump aggregate
1 Oil tank
48 Hydraulic motor
7 Valve block swivelling
4 Lowering brake valve
3 Valve block with shock valves
2
Traverse/Rotate schematic Vector C12.5
A3 Dual relief valves block

A7 Load control valve
H3 Valve block
H13 Solenoid directional control valve 2-way/2-position NO=normally open
A48 Hydrostatic motor
2Y42 & 2Y43 Directional control solenoid cartridge valve 4-way/3-position
2Y30 3-way flow control valve/priority style
3
Hydraulic schematic Mainlift Vector C12.5
H1 Hydraulic Oil tank 90l

H2 Pump unit
H3 Valve block
H4 Hose burst valve
A4 Lowering control valve
H6 Ball valve
H9 Pressure transducer
H10 Check valve
H18 Return flow filter
H20 Pressure switches
H26 Filler and ventilation filter
210 Pressure relief valve
2Y30 3-way flow control valve pri-
ority style
2Y34; 2Y35 Solenoid valve poppet
type undirectional 2-way/2-position
NC=normally closed
2Y49 2-way flow control valve
4
Load control valve for fork rotation
Use and adjustments

1. Maintains the forks in the basic (drive-fast-free) position, when braking, too.
2. Brakes the speed rotation of the forks at the descending ramps ( at the end of the moving
rotation).
3. If the forks get hung at an obstacle while the trucks rolls, then arotation of the forks must be
possible.
4. Controls the moving of the rotation of fork and load. Prevents load from overrunning.
(The moving rotation must be uniform.)
The adjustment of the load control valve is a compromise between these opposing goals/objectives.
Pressure heigthning improves 1 and 2, but deteriorates 3 and 4.

Pressure reduction improves 3 and 4, but deteriorates 1 and 2.
5
Proportional solenoid priority flow control valve
A three-part proportional solenoid priority control valve establishes the flow to the priority circuit
(pri) and diverts the remaining flow to the secondary circuit (sec).
The priority valve is NC (normally closed). By not energized solenoid is the priority circuit closed.
If the solenoid is energized at its maximum (600mA), the secondary circuit is closed.
The regulated flow is independent of perssure at any of the three ports.
This valve is a virtual proportional solenoid flow divider.
It also permits the regulation of the flow to the secondary circuit if the primary circuit can bypass the
remaining flow to the tank.
A single pump can supply two circuits.
The blocking of the controlled flow blocks the bypass flow. Therefore, the primary condition to a cor-
rect working is that the bypassed oil can freely flow to the actor or the tank.
A second condition is that the input flow should not be greater than indicated.
Attention to the speed of the pump rotation!
Example of flow balance:

at BT Vector C10 Qmax = 22 l/min
at BT Vector C12.5 Qmax = 30 l/min
The solenoid is energized 300mA for a flow on the priority circuit of 5 l/min.
If the input flow is 15 l/min, then the flow to the secondary circuit is 10 l/min.
If the input flow is 20l/min, then the flow to the secondary circuit is 15 l/min.
6
HYDRAULIC SYMBOLS (ISO 1219 enlargement)

Pressure line
Pilot line Lowering control valve
Drain line (pipe breaking protection)
Subansambly demarcation 25 l/min adjusted
connection Solenoid proportional valve

thread port open for the pipe connecting 2-way flow control valve
thread port closed by a screw.
mini measuring device (for on-line operation.)
line connection Solenoid proportional valve

flexible line 3-way flow control valve / priority
style (The regulated flow is virtually
pipe - nominal size 10
independent of the pressure at any
line identify number
Flow restriction symbols.

Pressure relief valve
throttle (throttle point)
check valve adjusted pressure (max) 210 bar
manual on/off valves
Hydrostatic displacement machines Pressure transducer

two operating drives (pump/motor on
rotary direction)
displacement volume = 20 cm3 /R
Reversing hydrostatic motor Pressure switching

displacement volume = 315 cm3 /R
Cylinder Filler and ventilation filter
volume = 418 cm3 air required filtration grade = 3µm
Cylinder Return line filter
piston diameter = 50 mm oil required filtration grade

= 10µm absolute
Hose burst valve Electric motor (2M1)

(pipe breakage protection) rotary speed regulated from
27 l/min adjusted 200 rotations/ min as
2600 rotations/ min
7
8
BT C12.5: Functional Survey Hydraulics
Valves:
Valve Contro Usage Pin Ubatt (24V) Output PIN Valve Software-
lled by Plug Pin Output
2 Y 30 VZA Priority flow controller (prop. Valve for swivel) 3 (24V prop. valves) X130 6 X29 / 2 AA100
2 Y 31 VZA Priority flow controller (bypass flow) 5 (24V valves) X132 6 X33 / 2 AA101
2 Y 49 VZA Prop. Valve aux lift lowering X221 6 X133 / 2 AA200
2 Y 32 VZA Switching auxiliary lift to lifting the auxiliary 4 (24V valves) X130 11 X25 / 2 A102
lift
2 Y 33 VZA Switching auxiliary lift to lowering the auxiliary X132 2 X25 / 3 A103
lift
2 Y 34 VZA Switching main lift to lifting the main lift 5 (24V valves) X130 10 X32 / 3 A100
2 Y 35 VZA Switching main lift to lowering the main lift 3 (24V valves) X132 4 X32 / 2 A101
2 Y 36 VZA Switching valve for side shift X130/2 (24V valves) X130 12 X27 / 2 A104
2 Y 37 VZA Switching valve for swivelling X130/8 (24V valves) X130 7 X133 / 2 A106
2 Y 40 VZK Directional valve for swivelling right side 1 (24V valves) X221 9 X43 / 2 A200
2 Y 41 VZK Directional valve for swivelling left side X221 12 X44 / 2 A201
2 Y 42 VZK Directional valve for side shift right side 4 (24V valves) X221 11 X45 / 2 A202
2 Y 43 VZK Directional valve for side shift left side X221 10 X46 / 2 A203
2 Y 52 VZA Valve pump idle when lowering main lift 1 (24V valves) X130 9 X28 / 2 A105
2 Y 53 VZA Valve pump idle when lifting main lift X221 7 X /2 A205
Dambach Lagersysteme Gmbh & Co , KG Seite 1/2

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BT C12.5: Functional Survey Hydraulics
Valve usage during movements
Proportional valves Switching valves rpm Controlled by

Movement 2Y30 2Y31 2Y49 2Y32 2Y33 2Y34 2Y35 2Y36 2Y37 2Y40 2Y41 2Y42 2Y43 2Y52 2Y53 2M1
Softw. output AA100 AA10 AA200 A102 A103 A100 A101 A104 A106 A200 A201 A202 A203 A105 A205
1
Side shift left side X 0 0 0 0 0 X X 0 0 0 X 0 X X Prop control
Side shift right X 0 0 0 0 0 X X 0 0 X 0 0 X X Prop control
side
Rotate left side X 0 0 0 0 0 0 X 0 X 0 0 0 0 X Prop control
Rotate right side X 0 0 0 0 0 0 X X 0 0 0 0 0 X Prop control
Lifting aux lift X 0 X 0 0 0 0 0 0 0 0 0 0 0 X Pump rpm
Lowering aux lift 0 0 X 0 X 0 0 0 0 0 0 0 0 0 0 0 Prop control
Lifting main lift 0 0 0 0 0 X 0 0 0 0 0 0 0 0 X X Pump rpm
Lowering main 0 X 0 0 0 0 X 0 0 0 0 0 0 X X X Pump rpm
lift
Synchro swivel Rotating Side 0 0 0 0 0 X X X X X X 0 X X Side shift:
shift rpm, swivel:
Prop control
Synchro lifting X 0 0 X 0 X 0 0 0 0 0 0 0 0 X X Pump rpm
main and aux lift
Synchro lowering 0 X X 0 X 0 X 0 0 0 0 0 0 0 X X Pump rpm
main and aux lift
This survey only shows the actuation for the respective movement. The actuation between different movements is not shown.
note: X ... component is actuated

0 ... component is not acuated
Dambach Lagersysteme Gmbh & Co , KG Seite 2/2

Bearbeiter :Schrad TB-E DateiC:\TEMP\Hy-Funktionsübersicht (GB).doc 02-04-15 07:54
15 Driving- / Lifting- /
15 Driving- / Lifting- /
Steering control
the spare parts catalogue is not permitted
LED flashing codes
Table of error numbers and LED flashing codes


materials.
1
Steering control
2
Steering control
LED flashing codes

Each AC controller indicates occurring errors by the number of
flashing impulses (200 ms), followed by a break (1s), directly on
the AC-controller.
In addition, the faulty controller sends an error signal to the
SECAN control via CAN-Bus. The SECAN displays the error
number. The AC-controller-internal error code (also shown as
blink code) can be watched by an analog tag “MA...“ .
Survey of the errors and the analog tags of the AC-controllers
AC- error message analog tag error

control number
Steering Er 122 MA157
Driving Er 136 MA158
Pump Er 135 MA226
Example:
The pump controller indicates error number 7:

Diagnosis on the AC-controller:
On the pump controller, 7 flashing pulses, followed by a break
can be watched.
Diagnosis on the control panel:

On the control panel the error E135 is displayed. There is no
information about the controller-internal error.
Diagnosis on the Service-APE:

Call up the analogue tag MA226 in the APE-Status display. This
shows the number of flashing pulses (here: 7).
3
Steering control
Table of error numbers and LED flashing codes
F.- error type LED Cutoff time Possible rea- Measure

Nr. power stage son
impulse
/ break
- Watchdog 1:1 < 100 ms Fatal error Change the device
- RAM 1:3 power stage is Fatal error Change the device
error always disabled
- FLASH 3:1 power stage is Fatal error Change the device
error always disabled
2 New verson 2:1 power stage is Can only occur Follow the instructions
of system always disabled after system to download a system
software software down- software
load
3 Overcurrent 3:1 < 100 ms Power stage Check the torque
in the power was too long load. Check if the
stage driven on the parameter setting was
current limit changed
4 Undervolt- 4:1 3s Battery voltage Check the battery
age battery is less than voltage, charge the
U_BATT_MIN battery
5 Overvoltage 5:1 3 s (min. 0,1 s) Battery voltage Check the battery
battery is higher than voltage, Check the
U_BATT_MAX + / - battery clamps for
stability
6 Overtemper- 6:1 Operation in Check the torque load
ature / criti- overload margin of the motor. Check
cal was too long the motor current. It
temperature shall not exceed the
of motor nominal current for a
long time
7 Overtemper- 7:1 Operation in Check if the device is
ature / criti- overload margin mounted for a good
cal was too long heat dissipation.
temperature Check the motor cur-
of heatsink rent. It shall not
exceed the nominal
current for a long time
8, 9 free
10 Short circuit 10 : 1 Power stage
on digital out- locked, Digital
puts outputs current-
less
4
Steering control
F.- error type LED Cutoff time Possible rea- Measure

Nr. power stage son
impulse
/ break
18 EEPROM 18 : 1 < 100 ms Fatal error Change the device
error
11, free
12
13 Ground-Eror 13 -: 1 Power stage
locked, Digital
outputs current-
less
14 Encoder error 14 : 1 < 100 ms Incremental Check the incremen-
encoder or wir- tal encoder at the
ing damaged motor and the wiring
at X5 and X6
15 Wrong 15 : 1 < 100 ms Improper param- Correct the parame-
parameter eter setting ter setting
setting for U/f
characteristic
+ If errors can not be deleted by power-off or the measures men-

tioned upon, contact the manufacturer.
5
Steering control
6
19 Abbreviations
19 Abbreviations
Abbr./term Meaning
µma micrometer absolute
A Output (digital)
AA Output (analog)
ABS Cut-out
APE Display and programming unit
Apron Area outside the rackings
Bit Smallest digital unit of information, with state either "0" or "1"
BL Operating instructions
BMK Designation
Buffer Buffer memory
Bus Line-conducted data transfer system
Byte Code word, consisting of 8 bits
Calibrate Align, adjust
CAN Controller Area Network; bus system
CAN-open CAN-protocol language
CMOS Circuitry with field effect transistors (electrostatically sensitive))
Controller Coordinating control component
Decrement Reduction of a value by 1 counter unit
DN Nominal width (in mm)
DT Triple telescopic mast
E Input (digital) / Shortcut for „Error“
EA Input (analog)
EEPROM Electrically erasable EPROM
EMC=EMV Electromagnetic compatibility
End ahead Position preceding a mechanical end position
EPROM Erasable programmable read only memory; non-volatile memory
ESC Escape
EST Stacking depth
FFZ Industrial truck
FTG Flat telescopic fork
GESI End of aisle safety device
GND Ground potential
GSB Counter-current brake
HH main lift
IC Integrated circuit
IF Inductive guidance
IF-SECAN SECAN-controlled IF
Increment Increase of a value by 1 counter unit
LAM Load lifting device, attachment
1
19 Abbreviations
Abbr./term Meaning
LRB Load-bearing wheel brake
LSP Load centre
M Tag (digital)
MA Tag (analog)
MB Magnetic brake
Mbit/s Unit of measurement for the data transmission speed
MLS Microsensor for steering
MOS Circuitry with field-effect transistors (electrostatically sensitive)
MZ Status tag; can assume various values
NTC Temperature-dependent resistor (NTC resistor)
NV-RAM Non-volatile RAM; retentive RAM
Optipace Travelling speed limitation depending on lifting height and direc-
tion
PSA Personnel protection system
PT 100 Standard temperature transmitter, semiconductor-based
PTC Temperature-dependent resistor (PTC resistor)
RAM Random-Access-Memory
Redundancy Availability of multiple versions to increase reliability
Referierung Initiation process after starting the truck
Remanenz Speicherverhalten bei Spannungsausfall
SECAN Sensor-based CAN bus system
SF Rail guidance
SF relay Safety relay with guided contacts
SIMO Safety module
SK-CAN Plug-in card - CAN interface
SK-E/A Plug-in card - inputs/outputs
SK-EPROM Plug-in card - EPROM
SK-R Plug-in card - computer
SK-VZA Plug-in card - drive compartment processing unit
SMD Surface-mounted device; electronic components for surface
mounting
SSG Swivel/traverse fork
Sub-Min-D Standard design for electronic plug-and-socket connections
Synchronous Simultaneous swivelling and lateral traversing of the load lifting
device
TG Telescopic fork
TI Teach-in
Timeout Exceeding of the set time
TTL Transistor-transistor logic
UVV Regulation for the prevention of accidents
VDMA German association of machinery manufacturers
VZ Processing unit
VZA Processing unit - drive compartment
2
19 Abbreviations
Abbr./term Meaning
VZ-UDR/UDL Processing unit - control panel right/left side
VZK Processing unit - cabin
Watchdog Processor monitoring circuit
ZH Auxiliary lift
ZM Double mast
ZT Double telescopic mast
3
19 Abbreviations
4

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SERVICEMANUAL

10. Inputs, Outputs, flags

11. Service Parameters

12. Operating Diagrams

14. Hydraulic Diagrams

15. Driving-/ Lifting-/ Steering Control

Required measuring instruments and test equipment

Chapt. Theme Page

1.8 Supplied documentation 6

Indicates notes regarding safety that must be heeded to pre-

Indicates notes that must be heeded to prevent danger to

1.2 Loose parts

1.3 Basic truck

On WG-trucks, which are delivered lying, the WG-sensor below

1.4 Hoist frame

+ If several trucks are delivered at the samt time, pay attention

1.5 Load-lifting device (LAM)

+ If several trucks are delivered simultaneously, pay attention

+ The upright position results from the alignment of the pinion

1.6 Battery equipment

+ Moving the truck without battery power is described in the

- switch off the truck

1.7.2 Hydraulic system

- ventilate the main and auxiliary lifting cylinders (see sec-

1.8 Supplied documentation

Removal / installation of components other than those listed in

Chapt. Theme Page

Indicates notes regarding safety that must be heeded to pre-

Indicates notes that must be heeded to prevent danger to

3.1 Assembly arrangement

3.2 Components of the electrical system

3.3 Components in the drive compartment (rear view)

3.4 Components in the drive compartment (right

3.5 Technical data

Description Unit Value

Description Unit Value

Minimum brake release play mm 2,25 mm

3.5.2 Type structure

Capacity (kg) 1250 kg

Brake system drive wheel: Spring pressure brake/ load

+ Power- and Control fuses -> Operator’s Manual.

Required measuring instruments and test equipment

4.1 Safety instructions 3

4.5 Load-bearing axles 9

4.6 Load wheel brake 11

4.7 Mechanically released spring pressure

4.8 Drive unit 15

4.9 Swivelling forks 16

Indicates notes regarding safety that must be heeded to pre-

Indicates notes that must be heeded to prevent danger to

4.1 Safety instructions

Hydraulic functions (closing of main cock) is not a surfficient

Hoist frame locking device

 The hoist frame locking device (2) is attached to the right-hand

Carefully check the hoist frame locking device for damages

Activating the hoist frame locking device

- use an open-ended wrench to unscrew and remove the

- Tilt up the hoist frame locking device until it stops

Deactivating the locking device

- Tilt back the hoist frame locking device

The hoist frame locking device (2) is attached to the right-hand