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Service Manual BT Vector GB

Service manual BT Vector, model C10 GB

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Departament Comercial

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0% found this document useful (0 votes)

13 views

Service Manual BT Vector GB

Service manual BT Vector, model C10 GB

Uploaded by

Departament Comercial

Available Formats

Download as PDF, TXT or read online on Scribd

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SERVICE MANUAL

BT VECTOR GB

Model: C 10
Part number: 200421-040
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 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 commis-sioning. 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
- remove the oil reservoir lid and attach the air filter (see,
Operator’s Manual, chapter Transporting and storing the
truck)
© BT Industries AB 200421-040
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,
- 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.
- check that the auxiliary mast is upright along the long axis
of the truck using a bubble level (correct using the plates)

+ 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
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
- install the bridge for the battery support
- insert the battery
- insert the left- and right-hand battery screens
- connect the battery cables to the battery poles
- insert the truck plug into the battery socket
- check the charging state and water level of the battery
(-> operating instructions of the battery manufacturer)
- if necessary, insert the lateral battery covers

+ Moving the truck without use of the battery 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 main or auxiliary pump, commis-
sioning must be carried 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 tube connections for leaks, especially the cabin /
LAM connection
- ventilate the main and auxiliary lifting cylinders (see sec-
tion 5)
- check that the slack chain switch is functioning (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-offs 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
- Operating instructions
- Test protocol (factory settings)
- Wiring diagrams
- Hydraulic diagrams
- Spare parts catalogues

3 Technical Description

Removal / installation of components other than those listed in

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

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.

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

7
5
6
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)

3.3 Components in the drive compartment (rear view)

12 13
3
10
9

2
4
8

11
7 6

Pos Description
1 Lifting module block
2 Spring pressure brake
3 Steering controller
4 Pump controller
5 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

3.4 Components in the drive compartment (right view)

1 2

3 4

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

3.5 Technical data

3.5.1 Adjusting and testing data

Description Unit Value

Truck
Dead weight (without load) ca. kg 4900 - 5800
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 m/s 7,5
Synchr. swivelling/traversing 180° / limit s 10,0-12,0
position

B Drive system
Transmission i 18,0
- Transmission oil charge l 37
- Drive plate M16 / M12 Nm 185
Drive motor
- Output (KB 60 min) KW 5,2

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 brake disk (nominal) mm 13,0
Thickness of brake disk (minimum) mm 1,0

Description Unit Value

Brake release clearance mm 0,1 - 1,4

Max. stopping distance with/without load m 2,8 / 2,6

E Wheels / axles
Tyre diameter max. mm 240 / 343
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/ 60 / 100
max
Max. overpressure bar 210
Pump unit cm³ 21,5
Pump motor KW 13,5
Return filter µma 10,0
Attachment
Oil charge, attachment l/ 4,0
max
Overpressure bar 210
Steering system
Steering motor KW 0,8 (AC)
Lenkgetriebe i 46

J Electrical equipment
Battery voltage V 48
Control voltage V 24
Truck mains system Two circuit system
Fuses see operating instructions

3.5.2 Type structure

Description Value

Capacity (kg) 1000 kg

Load centre (mm) B 600 mm (Pallette size1200 x 1200)
Chassis (y, z, H, m, W) rail guided 1765, 230, 60, 1050 mm
Chassis (y, z, H, m, W) wire guided 1765, 260, 60, 1050 mm
L2 / XD dim. (1200 x 1200) rail guided Wa = 2017 / 3228 / 1072 mm
L2 / XD dim. (1200 x 1200) wire guided Wa = 2050 / 3260 / 1072 mm
Load bearing wheels (Ø x W) 2 x diameter 240 x 140 mm
Drive 5,2 KW standing AC-technics
Transmission i = 180, Pmax = 25000 N
Drive wheel (Ø x W) diameter 343 x 140 mm
Drive control system / end of aisle safety AC-controller 48 V, Control system VZA,
device end of aisle safety by DAMBACH
Double mast (ZT) hoist frame 2 Cylinders
Triple mast (DT) hoist frame not available
Lifting height h3 / h9 up to 5900 / 1800 mm
Lifting height h tot hges = 7500 mm
Lifting cylinder, piston / cyl. Ø Double mast: 2 x diameter 50 / 70 mm
Load lift. dev. - SSG / SSG-CF 10 hs = 40 mm
AST (1200 x 1200) AST - rail guided 1600 SA 75 AST 3 = 3840 mm
AST (1200 x 1200) AST - wire guided 1700 SA 125 AST 3 = 3900 mm
Auxiliary lift h9 SSG 1600 up to max. 1800 mm
Auxiliary-lift cyl. SSG 50 / 75 mm
Lift. control syst. - electr./hydr. AC / SECAN / Proportional valves
Hydraulic unit / motors 13,5 KW / 2200 rpm / 21,5 cm³
Electric control system 4 control systems: VZA, VZK, VZB, APE
with SECAN-Bus
Steering syst., manual / autom. Electric steering with AC-controller, AC-
steering motor, wire guidance with 1 front
sensor, 1 rear sensor
SF / IF-S inductive guidance Rail guidance: diameter: 80, 95, 140, 180 x
50; Inductive guidance

Description Value

Brake system drive wheel: Spring pressure brake/ load

wheels: hydr. brake system/
counter current brake/
end of aisle safety brake
Battery voltage 48 V 1 trough
Battery size, capacity 560 / 700 Ah
Battery size, weight 950 / 1130 kg
Battery trough, L 1032 mm
Battery trough, W 440 / 530 mm
Battery trough, H with/without holders 854 / 854 mm
Circuit B/B

3.5.3 Fuses

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

4 Mechanics
Removal / installation of components other than those listed in
the spare parts catalogue is not permitted.

Required measuring instruments and test equipment

- 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

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

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.

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.
The following measures can be taken to secure the hoist frame:
- Attach sufficiently strong chains to the hoist frame struts
(varnish and attachments may be damaged)
- Place sufficiently strong supporting frames between floor
trough and inner hoist frame
- Use the hoist frame locking device (only available for
newer trucks)

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
1 engaging of the hoist frame locking device during operation of
the truck.

Pos Item
2
1 Outer frame, right
3
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.

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.

4.1.2 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 control panel and in
the cabin barriers.

Never open gas pressure springs, danger of life! Defective gas

pressure springs must be exchanged completely.

4.2 Torque values for screwed connec-

tions
- -> Operator’s Manual, chapter Maintenance

4.3 Hoist frame and cabin

1
4.3.1 Screwed connection mast
The mast is connected to the chassis by screws (1)
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.
XX

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:

max. +/- 5 mm x h1 (mm). backw. tilting X (mm)

2200 6
2450 7
2700 8
2950 9
3200 10
h1
3450 10
3700 11
3950 12

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.
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 Ma = 75 Nm

fixed on factory site.

A re-adjustment on customer’s site
is not necessary.

Loctite 222

Lateral guide rollers

The adjustment of the correct hoist frame clearance is effected by insert-
ing or removing the shims (3) below the hoist frame rollers.
The shims are available in different
sizes.
Ma = 35 Nm
Only use shims with a maximum Loctite
size of 3,5 mm for the hoist 222

frame rollers.
,5˚
α=2

max. 0,5

Ma = 100
Nm

Ma = 35 Nm
s
Loctite 222

+ Chippings in the area of the guide profiles indicate that the clearance of
0,5 mm is too tight.

Slide pieces main and auxiliary lift

The slide pieces (5) at the lower hoist frame rollers
prevent rattling noises when the lifting gear is low-
ered.
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 5 6 7

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
8 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
9 - 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.

10 13 4.5 Load-bearing axles

11
12
4.5.1 Load-bearing axle of trucks without load wheel
brake

Pos. Bezeichnung
10 Full floating axle
14
15 11 Conical roller bearing
16
17 Ma = 77 Nm
18 12 Retaining ring
19 20
13 Load-bearing wheel
14 Cylindr. roller bearing
15 Conical roller bearing
16 Spacer
17 Shims
18 End piece
19 Washer
20 Screw

4.5.2 Load-bearing axle of trucks with load wheel brake

The brake drum in the load-bearing wheel has a diameter of 180
mm.
The shims (32) can be used to compensate the offset between
the brake shoes and the worn surface of the brake drum when
the wheel or the brake shoes are replaced.

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

Load bearing wheel

24
30
25

28 31

27
23 27

Pos Description
21 Vulkollan tyre
22 Wear mark
23 Load wheel brake
24 End piece
25 Screw
26 Washer
27 Wheel housing
28 Conical roller bearing
29 Distance bush
30 Full floating axle
31 Washers
32 Retaining ring

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 Dismounting of the brake

- Park the truck and render it safe
- Disconnect the brake electrically
- Jack up the truck, so that a load wheel comes free
- Dismount load wheel
- Remove the fixing screws and pull the brake from the load
wheel

+ 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

b thickness
s
9 Check the release play (s) and the lining thickness (b) of the
plates as follows:
7
- Dismount brake (see above)
- Connect the brake electrically to a 24V DC-supply, brake
will be activated
- Check lining thickness

6
5
4
2,3 1

+ 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

- Dismount 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.

4.7 Mechanically released spring pres-

36
sure brake
37
- All truck types are equipped with a magnetically released
spring pressure brake („magnetic brake“) on the drive sys-
38 tem.
39 - Releasing the brake mechanically
- The brake can be released mechanically if an electrical
40 release of the brake is no longer possible (e.g. after a volt-
age failure).
41
4.7.1 Components of the magnetic brake
42
Pos Description
43
36 Adjustment ring
44
37 Fastening screw
45
38 Magnet
39 Electrical connection
40 Spring
41 Anchor plate
42 Adjusting sleeve
43 Brake disk
44 Retaining ring
45 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 (47).
Stipulated value: s = 0.3 mm

46 Pos. Description

s 46 Adjustment ring
b
47 Adjusting sleeve
47 48 Brake shoes
48
b Lining thickness
50 Airgap

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 (48) 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 (46) by using a hook wrench:
46 y Adjusting ring (46) is screwed out: -> braking effect is reduced
Adjusting ring (46) 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.

4.8 Drive unit

49 4.8.1 Removal/installation of the drive unit

49a
For removal of the drive unit
- Disconnect the electrical connection lines of the drive
motor (49) and steering motors (49a)
50 only trucks with inductive guidance:
- Unscrew WG-claw mechanism
- Slightly lift the truck rear with hydraulic jack and prop it
51 properly.
- 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 (1).
- Carefully lower down the truck rear
- 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.

4.9 Swivelling forks

52 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)
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.
s 54 55 56
- 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
57 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.

5 Hydraulics
Removal / installation of components other than those listed in
the spare parts catalogue is not permitted.

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

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

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.

5 Hydraulics

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
42- S 350 475

5.2 Standard hydraulic diagrams

Hydraulic diagram Hi-Racker 100 - SF/WG see chapter 14.

5.3Safety instructions
Also pay attention to the safety instructions in chapter 4
Mechanics!

While performing any work on the hydraulic installation

- switch off the truck

- pull battery plug
- close main ball valve below battery
- lower main and auxiliary lift to the lower end limit

5.4Description of the hydraulic installa-

tion
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

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 / transport 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.

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
- 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 over voltage system converter control into
the battery.
Small lowering speeds of the main lift (below the slow revolu-
tions per minute) are controlled by a hydraulic flow controller to
guarantee a minimum number of revolutions per minute of the
unit.

Revolutions below 100 U/min damage the pump.

5.5Hydraulic installation on the chassis

3 3

H3(H1) 5 R P1 P2

5
H3(H2)
H3(R)

H3(B)
H3(R1)
H3(A) 4

H3(P)

RF
A1

2Y30
B1

6
2Y36

R2
R1
2Y3

D
1

H1
2Y34
2Y35

7
H2
2Y33
2Y32

9
P
R

H9
2.B10

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

12 2.B10

13 21 2Y32
2Y33
2Y52

R 1
14

21
15
19

20
16

5.6.2 Top view

13 12 15
21

2Y36

2Y30
2Y31

2Y32 2Y34
M R1 R2
2Y33 2Y35
H2 H1 B1

D A1

24 18

25
17

Pos. Description
12 Lifting module block H3
13 Fill- and ventilation filter H26
15 Tank
17 Manometer soiling display return flow filter H18
18 Return flow filter H18
21 Fixing clamp tank
22 Main valve H6 (below battery)
23 Emergency lowering screw auxiliary lift
24 Emergency lowering screw main lift
25 Screwed connection (G1/2) for tank refilling by pump

5.7 Tank
Oil reservoir, ventilation filter, return flow filter and lift module
block form a constructional unit.

+ Tank installation situation see chapter 5.

5.7.1 Oil filling

Oil amount (pressure liquid) in the tank: 60 liters
Complete amount of oil (tank+hydraulics system): to approx. 100
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. 60 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

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,
pos. 25.

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

5.7.5 Check hydraulic oil level

+ see Operator’s Manual, chapter Maintenance.

5.8Fill- and ventilation filter

The fill- and ventilation filter (27) with 3 µma prevents the tank
from the entrance of dirt from the surrounding area.
27 26
Never operate the truck without fill- and ventilation fil-
ter.

28 Max. + Assembly see operating instructions.

Pos. Description
29 Min.
26 Screwed cap
27 Air filter
28 Sieve filter
29 Chain

Oil level control

With lowered main and auxiliary lift the oil level in the sieve filter
(28) 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 development and early wearing on
the pump units.

The filter must be replaced at the latest at every change of the

hydraulics oil.
Examination:
- lift cabin with maximum speed
- remove screwing cap (26) of the filter when the pump is
working

+ If the noise level of the pump decreases noticeably, 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
30 with 10 µma.
Examination of the filter
Unscrew and exchange the complete filter cartridge (31), if the
31 indicator of the manometer (30) 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.

5.10Pump
The pump aggregat is mounted beolw the battery.
When lowering the main lif,t 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 H6 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 (only 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.

5.10.2Removing the pump aggregat

- switch off the truck and pull battery plugs
- remove battery (see operating manual chapter D)
- remove electric connections from pump motor
- close ball valve H6 (directly in front of the pump)
- unscrew hydraulic connections from the pump
- put blanks onto the leaking connection (DN 6)
- unscrew fastening screws of the pump unit
- remove the pump unit
- 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 the lifting and lowering of the
main lift
- pressure limiting for all hydraulic movements (exept the
load wheel brake)

5.11.1Swivelling and side shift

+ Directional valves 2 Y40 ...43 see illustration in chapter 5.13

The flow divisor 2 Y30 controls the speed of swivel and side
shift:
- 2 Y30 supplied with minimum flow: swivelling slow, side
shift fast
- 2 Y30 supplied with maximum flow: swivelling fast, side
shift slow

+ 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).

5.11.2Swivelling/side shift synchronous

For the synchronous movement constant current is given to
2Y30. The result is a constant lowering speed.
The rest amount of oil is supplied for the side shift movement.
The speed of the side shift is controlled by the proportional valve
2Y31 in parallel flow method.

5.11.3Main lift / auxiliary lift

The flow controller 2Y31 controls
- the lifting and lowering speed of the main lift below the
slow speed
- the lifting and lowering of the auxiliary lift over the total

speed range

5.11.4Pressure limiting valve

To adjust the pressure limiting valve (41)
- connect manometer to mini measurement connection (39)
- 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.

Lifting module block H3

A1
2Y30 32
42
B1

2Y36

41 R1
40

2Y31
D
M
33
39 H1
2Y34
2Y35
34
38
H2
2Y32
2Y33
35
37
R
H9
P 2.B10

Pos. Description
32 Mounting plate
33 Lowering limit screw of proportional valve 2Y31
34 Emergency lowering screw mainlift
35 Emergency lowering screw auxiliary lift
36 Pressure converter 2B10 (H9)
37 Way valve lifting (2Y32) and lowering (2Y33) the auxiliary lift
38 Way valve lifting (2Y34) and lowering (2Y35) the main lift
39 Mini measurement connection(M)
40 Proportional valve 2Y30
41 Pressure limiting valve
42 Way valve 2Y36 load carrying device supply
43 Flow divisor 2Y30 load carrying device swivel/side shift

5.12Lift cylinders (Main- and Auxiliary lift)

5.12.1Design of the cylinders

Main lift cylinder Auxiliary lift cylinder

14
16
13
13
12
12
11 11
10 10
9 9
8 8
7 7
6 6

5 5

4
4
3
3

2 15

Pos. Description Pos. Description

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)

+ 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

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.
1
2 - 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

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 opera-
tion 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 low-
ering screw
- let the emergency lowering screw opened
- screw out the ventilation screw (10) completely, that the oil
can run out completely.

5.13Hydraulic installation swivelling forks (SSG)

5.13.1Side view
72
70 82b
82a
71

83a

83b

76 77 78 79 80 81

5.13.2Front view

Pos. Description 72 82b

70 Auxiliary lift cylinder 82a
71 Valve block side shift A3 with 71
shock valves
72 Hydromotor side shift A48 84a
73 Pinion side shift
84b
74 Sensor side shift
75 Valve block swivelling A7 with
load holder valves
76 Lowering brake valve auxiliary lift
cylinder A4 85a 83a

77 Swivel chain 83b

78 Sensors swivelling
85b
79 Pressure pipe to swivel cylinder
80 Swivel cylinder
75
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
79
83b Adjusting screws for load holder 79
valves swivelling, right direction
84a Valve 2Y43: 80 80
side shift left direction
84b Valve 2Y42:
side shift right direction
85a Valve 2Y40:
swivelling right direction 81

85b Valve 2Y41:

swivelling left direction

15.13.3Adjusting the shock valves (side shift)

The shock valves (82a/b) in valve block A3 (71) protect the
hydromotor A48 (72) against overload.

+ The shock valves are adjusted on 100 bar limiting pressure

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):
- connect manometer to the mini measurement connection
of the lifting module block
- turn forks into starting position
- activate side shift, move the fork end against a solid obsta-
cle (e.g. against a wall)
- adjust pressure via adjusting screws (38a/b) so, that on
maximum rejection there is a maximum pressure of 150
bar.

+ While performing the side shift movement, the pressure

should be ca. 35 bar below. Otherwise the side shift mechanics
is sticking.
- carry out adjustments in both side shift directions
- pick up nominal load; check whether side shift works prop-
erly

5.13.4Adjusting the load holder valves (swivelling)

The load holder valves on the valve block A7 (75) work as a
counter burden during the swivel movement. It is prevented that
the forks swivel faster and further as it was provided by the
SECAN-control.
In addition the load holder valves lock the swivel cylinders (36) in
stop position.
If the load side pressure exceeds the value adjusted at the
adjusting screws (39a/b) the load holder valve opens without
delay. This is the case when increased swivel forces caused by
obstacles or deceleration values effect on the forks.

+ 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.

To adjust the load holder valve

- swivel the fork 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).
- pick up a nominal load and secure with straps, swivel the
forks out by app. 45° from the startup position
- 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).
- check and adjust with the fork in the right-hand and left-
hand swivelling positions.

Do not perform the brake test into load direction, otherwise the
forks may abruptly turn to the front.

- manually pull at the fork tip: the fork may not be swivelled.

+ 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.

5.13.5Swivelling cylinders
The seals must be replaced
- if oil escapes at the piston rod
- if oil flows via the transparent leakage hose (28) through
the inlet tube (25) into the compartment of the side shift
arm.

+ Each time the truck is serviced, check whether oil has flown
into the drain hose.

86 87 88 98 90 91 92 93

94 95 96 97 98 99 100

Pos. Description Pos. Description

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.

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.

6 Electrical equipment
Removal / installation of components other than those listed in
the spare parts catalogue is not permitted.

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) 16
6.6 Braking System 18
6.6.1 Safety circuit brakes 18
6.6.2 Description of the braking systems 19
6.6.3 Spring pressure brake 19
6.6.4 Load wheel braking system 20
6.6.5 Electrical braking system 23
6.6.6 General emergency stop 23
6.6.7 Functional emergency stop 23

6.7 Driving 24
6.7.1 Drive speeds 24
6.7.2 Adjustment of driving and electrical brake 25

6.8 Steering 26
6.9 Triggering of the pump unit 28
6.10 Proportional controllers 29
6.10.1 Temperature compensation: 31

6.11 Functional relations 32

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

6.12 Aisle recognition 36

6.12.1 Aisle recognition by Means of
Magnetic Switches 36
6.12.2 Aisle Recogniation via WG Wire
(Inductive Laying without Aisle
Recognition (IFoG)) 36

6.13 The service menu 37

6.14 Release of Options via Code
Numbers 37
6.15 End of aisle safety device
(Option) 38
6.16 Function Description 38
6.16.1 GESI with Manual Reset 38
6.16.2 GESI with Braking to Slow Speed
(Option) 38
6.16.3 GESI with Automatic Reset (Option) 35

6.17 Inductive guidance (WG) 39

6.17.1 Components 39
6.17.2 Tasks of the WG 40
6.17.3 Safety Supervision Functions of the WG 41
6.17.4 Starting and Setting of the WG 41
6.17.5 Safety concept 48
6.17.6 Monitoring the wire signal 49
6.17.7 Monitoring of the Steering Angle 50

6.17.8 Monitoring of the Actual Driving Speed 50

6.17.9 High speed release 50
6.17.10 Overview of Emergency Stop Criteria 50
6.17.11 Diagnosis 51

6.18 Interface for the Connection

of a Personnel Protection System
(PSA) 51
6.19 Automatic swivelling / side shift
synchronization 53
6.19.1 Geometric setting 53
6.19.2 Hydraulic Setting 56

6.20 Battery discharge monitor 57

6.21 Hour meters 58
6.22 Cut-outs 58
6.22.1 Lifting cut-outs and lowering cut-outs
(optional) 58
6.22.2 Side shift cut-out
(second stacking depth) 59
6.22.3 Drive cut-outs 59

6.23 Software administration 60

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.

© BT Industries AB 200421-040
4
Revolution rate Revolution rate
Sensor System sensor sensor
for load detection
3~ 3~
Sensor System Pump
for swivelling Drive motor motor

Sensor System AC AC
for lateral traversing drive control Drive sensor pump control

Sensor System
for aux. lifting system
Main lift sensors

Hydraulic valves

5
VZK VZA Hydraulic valves
6.0 Block diagram of the control concept

Processing unit:
6 Electrical equipment

Lighting Processing unit:

cabin drive compartment Mech. braking system

Several switches
Several sensors

Extension module
I/O MLS ML Extensions
1 S3

UDL UDR
Computer Computer AC control
serial connection control panel control panel steering motor
via CAN bus left right
serial connection
Panel elements right Revolution rate
parallel connection Panel elements left APE 3~ sensor
indirect connection Service tool

component with microcontroller Actual value sensor

steering system
6 Electrical equipment

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

CAN Transceiver 100 nF

CAN_L Gnd
CAN_H

CAN_H

RT CAN bus network RT

CAN_L
termination resistance termination resistance

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

6.3.3 Design of the VZA

9
2
3 4

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 controllers and the
CAN-bus connector modules
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. drive pulse control, steering sys-
tem 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

+ 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

Design of the VZK

12 10 11

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

+ 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 base-

plate; 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

+ One processing unit is integrated in both the right control desk

(UDR) and the left control desk (UDL).

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

ing instructions.
Tasks of the Computer Board in the UDR
The computer board is installed in the right side of the control
desk. It includes microcontroller, CAN bus connection modules,
RS232 communication components as well as EPROM and NV-
RAM.
- connection and signal processing of all control elements
- connection and control of all display elements
- 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 desk (UDL)
via RS232
- serial interface to the service laptop via RS232
Tasks of the Computer Board in the UDL
- The computer board UDL is istalled in the left side of the
control panel. It includes microcontroller as well as RS232
communication components.
- connnection and signal processing of all control elements
- serial interchange of data with the right control panel
(UDR) via RS232 Design of the Right Control Panel (UDR)

6.4 Design of the Right Control Panel (UDR)

23 34

21
33

32
20
31

28 19
27

Pos Description Pos Description

19 Safety sensor 27 Testspot Ground
20 Master switch 28 Connection safety sensor
21 Sensor board 29 Connection RS232
22 LED-Board 30 Connection Service-APE
23 Computer board UDR 31 Connection UDL
24 EPROM 32 Connection VZK
25 NV-RAM 33 Connection sensor board
26 Plug connection computer board 34 Connection master switch
UDR-LED board

Removal of the UDR

For removal, proceed as follows

- switch off truck
- disconnect power supply to 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
1 shown in the figure.
- loosen 5 hexagon recess screws (1)
- loosen 2 hexagon recess screws (2) at the master switch
2 - open bottom of the control panel to the left

Removal of the Sensor Board

- remove wire connector (3)

- turn plastic screws (4) by 90° and remove board

3
4

Removal of the UDP Computer Board

The UDR computer board is connected with the LED board

2 below by means of the plug connector (1).
- remove plug connector of the sensor board (2)
3
- remove plug connector VKZ (3)
4
- remove plug connector UDL (4)
5 - remove plug connector APE (5)
6 - remove plug connector RS232 (6)
- remove plug connector of safety sensor (7)

1 - remove 6 lock screws with washers

7 - remove board

Do not handle EPROM separately!

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.
11 The display is not designed for removal.

6.5 Design of the Left Control Panel (UDL)

5
4 6

3 8
7

9
2 10

1
13

Pos Bezeichnung Pos Bezeichnung

1 Safety sensor 8 Ground connection test spot
2 Master switch 9 Plug connection channel B
3 Sensor board 10 Plug connection channel A
4 Computer board UDL 11 Key switch horn
5 Connection RS232 12 EPROM
6 Testing spot RS232 13 Key switch emergency switch
7 Rated value emitter steering
wheel

Removal of UDL

For removal , proceed as follows

- switch off truck
- disconnect power supply to control panel
- screw off 4 lock screws of the control panel at the setting
1
mechanism
- remove control panel and place onto clean surface as
2
shown in the figure.
- loosen 4 hexagon recess screws (1)
- loosen 2 hexagon recess screws (2) at the master switch
- open low surface of the control panel to the right side

3 Removal of the Sensor Board

4 - see removal of UDR
5

6 7 Removal of UDL Computer Board

8
9 - remove plug connector of master switch (3)
- remove plug connector RS232 (3)
- remove plug connector of sensor board (4)
- remove plug connector of incremental emitter of steering
wheel (5, 6)
- remove wire connections key switch of horn (7)
- remove plug connector of safety sensor (8)
- remove 4 screws with washers
- remove board

Do not handle EPROM separately!

6.6 Braking System

6.6.1 Safety circuit brakes

load wheel
VZB: SK-BPR brake
24 V emergency
emergency stop 1 magnetic brake system
load wheel
emergency stop 2 brake
return signal 1
return signal 2 operating
system

VZK: SK-R
emergency stop 1
emergency stop 2
return signal 1 24 V
return signal 2 emerg. 1

VZA: SK- VZA

emerg. 2
release
end of aisle safety
CAN- BUS

SIMO

SF1 emergency stop

contacts
safety relay

SF2

feedbacks
to VZA

optional
releases and
external
feedbacks components
not capable
of communication
VZA: SK-R
emergency stop 1
emergency stop 2
return signal 1
return signal 2 Safety key pedal

feedback
to VZK

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
- load wheel brake system B, actuated via hardware-safety
circuit
- counter current brake, acutated via truck control system
SECAN and the motor controller DACI-TA
- automatic counter current brake system
- coasting brake system, actuated via truck control system
SECAN and the motor controller DACI-TA

6.6.3 Spring pressure brake

The braking is carried out via a mechanical braking system, that
is acrivated 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.

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
1 U_Batt_Permanent vai the contacts of these relays.
2 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
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:
- switch off 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

1 2 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
3
according to the individual truck.

As a principle. 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.

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 Sys-
tem
- 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.

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.

6.7 Driving
The driving function is carried out via a speed-controlled asyn-
chronous motor and a voltage system converter control.
The deallocation 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 deallocation of the speeds depends on the respective truck
states. see function table.
If the speed control is activated, the deallocation of the drive
movement is reduced, until the permitted speed is below the
allowed speed.

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.

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 3~
wheel truck control system motor control 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. inductive 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 sytem for the
asynchronous motor as a +/- 10V signal an.
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 referencing 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.

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
(referencing, manual steering, WG-steering) far-reaching identi-
cally on electrically rpm-controlled steering systems beim.

The standard control parameters, adjusted ex works, generally

must not be changed.

Interface for the voltage system converter control

The deallocation of the steering function is carried out as a 0V-
switching signal of the SECAN-control and is switched when:
- no emergency stop from the control system
- driving deallocation activated or truck is rolling
The set value from the SECAN is carried out as an analog signal
-10V...+10V . The direction of rotation is turned around.
An occuring fault in the voltage system converter control is
reported to the SECAN control via an error code interface. From
there, the error can be called via a tag. In addition, errors that
occur directly on the voltage system converter control are indi-
cated by LED.

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 deallocation of the pump is carried out as a 0V-switching
signal of the SECAN-control and is switched when:
- no emergency stop from the control system:
- no cut-out active (e.g. main lift cut-out)
There is only one direction of rotation. The direction signal is
transmitted via CAN bus. The rated value from the SECAN con-
trol 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 voltage system converter control is
reported to the SECAN via error message code interface. There
the error can be called via a tag (see chapter 15). In addition,
errors that occur directly on the voltage system converter control
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.

6.10Proportional 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 Hi-Racker 100 flow
valves are used, that means, the hydraulic output signal is a var-
iable 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 integraten 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

24 V 24 V

12 V average

6V 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.

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 %

100

grey:
75 adjustable values 100
example see text v_max 100

50
0 0

0 100 200 300 400 500

current I /mA
Imin Imax

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.

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.

6.10.1Temperature 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.
.

I
(output current)
compensation via software

resulting current curve

with constant actuation

actual current curve

with constant actuation

20 40 60 T / °C

6.11Functional relations
6.11.1Driving
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 steering 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 speed forward two-hand operation and h3 < h3crit forward
guided driving full speed backward two-hand operation and h3 < h3crit backward
guided driving 2,5 km/h forward two-hand operation and h3 > h3crit forward
guided driving 2,5 km/h backward two-hand operation and h3 > h3crit 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 direction).

6.11.2Manual steering
constraints for function release:
- truck on the apron
- WG-mode selected, truck not engaged with the wire
- two-hand operation actuated
- speed ≠ 0

6.11.3Lifting/Lowering of the main lift

general constraints for function release:
- doors closed
- chains not slack
- two-hand operation
- direction signal actuated
- set value actuated

Function Condition
release lifting full speed h3 < end ahead top load lifting device in startup posi-
tion referencing of main lift completed
release lifting slow h3 > end ahead top or load lifting device not in startup
speed position fault in the lifting system
release lowering full h3 > end ahead bottom or load lifting device in startup
speed position referencing not finished or 0,3 m-switch not
actuated (although main lift above 0,3 m)
release lowering slow h3 < end ahead bottom or load lifting device not in star-
speed tup position

6.11.4Lifting / Lowering auxiliary lift

general constraints for function release:
- doors closed
- chains not slack
- two-hand operation
- direction signal actuated
- set value actuated

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

6.11.5Side shift Right / Left

general constraints for function release:
- doors closed
- chains not slack
- two-hand operation
- direction signal actuated
- set value actuated
• 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.

6.11.6Swivelling Left / Right

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.

6.11.7Automatic synchronous swivelling/sideshift

Right/Left
general constraints for function release:
- doors closed
- chains not slack
- two-hand operation
- direction signal actuated
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.

6.12Aisle recognition
6.12.1Aisle 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

6.12.2Aisle Recogniation via WG Wire (Inductive Lay-

ing 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.

6.13The 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.

+ 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.

6.14Release 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.

6.15End of aisle safety device (Option)

An end of aisle safety device is integrated in the SECAN. This
device can be activated optionally.

6.16Function Description
6.16.1GESI 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.
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.
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 desk.
The current state of the GESI system is indicated by a multi-
color LED on the control desk (see the operating instructions).

6.16.2GESI with 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. manually using the button
2. automatically when leaving an aisle
3. automatically when changing the travel direction

+ Further option: braking to stand still, then slow speed with

automatic reset.

The following GESI error states that occur are detected and dis-
played on the APE:
- 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.

6.16.3GESI with Automatic Reset (Option)

Full speed is only released by the truck, 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 or driv-
ing over the GESI magnet on aisle entrance.

+ On WG- trucks without aisle recognition and on trucks with

light optical aisle recognition only GESI with manual reset is
available.

6.17Inductive guidance (WG)

6.17.1Components
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.
- Rated value transmitter for manual steering (set value sen-
sors for steering): Registers the movement of the steering
wheel on the control desk for manual steering; it is a
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 desk 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.

6.17.2Tasks 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 activated.

+ More detailed information regarding WG with aisle recognition

and WG without aisle recognition see operating manuals.

6.17.3Safety 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.

6.17.4Starting 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

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)

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“

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).

MLS rear
Drive wheel

MLS front
200 mm

Guide wire

- 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“.

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).

Drive wheel MLS rear

200 mm
MLS front

Guide wire

- 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.

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!

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“.
- switch off the truck

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.

6.17.5Safety 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
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 dia-
mond can also be designed for higher maximum speeds
© BT Industries AB 200421-040
48
6 Electrical equipment

(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.

Distance (MA148)

Skewing (MA147)

4
3
2
1

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

6.17.6Monitoring 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).

6.17.7Monitoring of the Steering Angle

The maximum rated value of the steering angle which is trans-
mitted from the SECAN control to the transverter control is lim-
ited 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.

6.17.8Monitoring 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.

6.17.9High 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)

6.17.10Overview 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)
- 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

6.17.11Diagnosis
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.

6.18Interface for the Connection of a Per-

sonnel 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.

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

6.19Automatic swivelling / side shift syn-

chronization
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.

6.19.1Geometric 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.

Teach-In sequence:
Axis of fork rotation The teach-in procedure must only be applied using the original
B C
A pallet.The synchronous function is only optimised for the teach-
in pallet size.
φ=φ _MAX
- Mark the forks center of motion at the left-hand stop for lat-
eral traversing on the floor.

Z=0 Z = Z_MAX

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.
Z = Z_MAX

Z=0 Z=Z_max
= vertical to axis of
fork rotation

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.
Z = Z_MAX

Z=0 Z=Z_max
= vertical to axis of
fork rotation

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.
Z=0 Z = Z_MAX

= vertical to axis of
fork rotation

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
Z=0 Z = Z_MAX
TI13, position D and confirm with ENTER.
= vertical to axis of
fork rotation

aisle width
6. Aisle offset
usable aisle width
- 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,
φ=φ _MAX 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
Z=0 Z = Z_MAX than the actual aisle width so that the fork collides with the
rack.

6.19.2Hydraulic 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 I13
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 = I13 - 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
- 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°).
© BT Industries AB 200421-040
56
6 Electrical equipment

+ 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.

6.20Battery 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.

6.21Hour 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 desk com-
puter 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.

6.22Cut-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:

6.22.1Lifting 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

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.

6.22.2Side 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.

6.22.3Drive 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.

6.23Software 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.

7 Sensors
Removal / installation of components other than those listed in
the spare parts catalogue is not permitted.

Required measuring instruments and test equipment

- 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

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.

7.1 Sensor units main lift

7.1.1 Potentiometer and incremental transmitter
1
The lift sensor unit consists of
2
- 10-turn dual gang-potentiometer (3), 2kOhm

3
- incremental transmitter (4), 1000 pulses/R (not visible in
illustration)
magnet switch 0,3 m (reference point)

4 Pos Description
1 Tension device
2 Toothed belt
3 Potentiometer
4 Incremental transmitter

+ Assembly of the lift sensor unit see spare parts catalogue, reg-
ister 14.

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
- 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

Calibration (Teach- In):

- switch on the truck
- 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

+ The incremental transmitter is not adjusted.

Checking the tension of the toothed belt

To check the thension of the toothed belt proceed as follows:
8
Tighten spring (5) until the height of the bush (4) is reached.
Attention

- Bolt (6) may not touch the mast bracket

- The end of the pitch of the screw thread (7) may not be
reached
- Ring (8) may not sit on top of the bush (bush must be mov-
7 ing with play)
6 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
5 Magnet switch
6 Plastic distance piece
7
5
7 Magnet

6
8 C-profile
8

Assembly
- mount the magnet switch (5) with plastic distance piece (6)
to the C- profile (8) centrically; cable output to the bottom;
strain relief cable
- mount the magnet (7) loosely to the C-profile (8), switching
distance ca. 10 mm; North pole (green) to the magnet
switch
- lift the cabin up to 300 mm
- adjust magnet centrically to the magnet switch and tighten
it

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, MA163 and EA104 normalized
- lift main lift up to 500 mm
- lower the main lift, until MA163 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: MA163 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
be no error mesage
At the upper end, read value of the incremental transmitter
MA164: It must be typed in (-5 mm) on parameter G22 main lift
height
example: MA164 top = 5500: then typ in 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
the incremental transmitter MA163.

7.2 Sensor units actual value steering

9 Before switching on the truck, make sure, that no second per-
son is working on the steering system, as after each switching-
Neu/new on a steering referencing 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 11 Marking boreholes for straight ahead position

+ Assembly of the steering sensor unit see spare parts cata-

logue, register 14.

Demounting the incremental transmitter

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

Mounting the incremental transmitter

L - 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
9e
- 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 potenti-

ometer
- drive wheel ligned up centrically (marking bore holes (11)
have to be ligned up)
- switch off the truck
- correctional parameters "steering straight ahead" P24
adjusted to the value "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.

Electrical setting
- set parameter P24 to "0" (see chapter 6.5.4)
- switch on the truck, the steering references.
- 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.

- 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 standardized and EA 107 hardware in the
service menu - status display
- EA 106 standardized has to display a value round ±20
(corresponds to ±2,0°);
- EA 107 hardware 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 refer-
ences
After the referencing, 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 configuration „K3 steering“ in service menu "M24 sta-
tus display“
- drive the truck on a test track (min. 20 m) and set 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.

Trucks with inductive guidance WG- S

On trucks with integrated WG-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, drive 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.
- After ending the adjustment, check, if the steering lock is
mounted centrically.

+ Assembly of the steering lock see spare parts catalogue, regis-

ter 02.

7.3 Sensor unit driving

Sensor element:
- special incremental transmitter (96 pulses/U)

12
13 Pos Description
14
12 Drive sensor
13 Coupling piece
14 Mounting frame

+ Assembly of the drive sensor unit see spare parts catalogue,

Assembly and mechanical adjustment

Requirements:
- drive unit ligned up centrically
- battery plug pulled off
- Use 2 M6 screws, attach the sensor (12) and the mounting
frame (14) to the two provided tapped holes on the drive
motor. Cable exit to the rear
- Connect the sensor shaft and the extended motor shaft via
a coupling piece (13). Make sure they are aligned. Tighten
the grub screws.
- Connect to plug X407.

+ Electrical adjustments are not required.

Checking the installation

- switch on the truck
- Ask another person to slowly drive the truck and watch the
shaft of the driving sensor unit; the assembly must run
„true“.
- Realign the sensors if the assembly is not running true.
- Checking the function:
- switch on the truck
- call service-display configuration „K3 steering“
- Drive the truck in forward and reverse direction for approx.
20 m and check whether the measured distance and the
measured speed are accurate.

7.4 Sensor bearings drive and pump motor

15a The sensor bearings in the drive and pump motor give rotor
15a
position, direction of rotation and speed to the control systems.

Exchanging a sensor bearing

15b - pull battery plug
- -disconnect the motor electrically
15c - drive motor: remove magnet brake (15a) (see chapter 4)
- remove 4 nuts (15b) from the anchour (15d) of the end
15d shield (plate without schaft output)
- remove end shield (15c); devide from stator lamination
with slight hammer blows

+ 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 pipe, 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

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

7.6 Sensor unit auxiliary lift

17a Sensor element

10-turn dual gang potentiometer (2k/2k)
17b

17d Pos Description

17c
17a Upper guide pulley
17b Toothed belt
17e 17c Carrier
17d Potentiometer
17e Lower guide pulley

+ 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
- mount mechanical elements according to the illustration
- tense toothed belt (17b) on the upper guide pulley (17a)
- mount carrier (17c)
- set the potentiometer (17d) to the left-hand stop
- turn back potentiometer by 1/2 revolution
- mount the potentiometer and tighten the tensioning ele-
ment

Checking the potentiometer-adjustment

- completely lower the forks
- switch off the truck
- measure resistance in processing unit cabin (VZK) on the
pulled plug between X212/Pin 8 and X214/Pin 6 as well as
between X212/Pin11 and X214/Pin 9 with ohmmeter

+ The potentiometer is correctly adjusted, if on both measure-

ment points a value between 0,1 - 0,3 KOhm can be measured.

Calibration (Teach- In)

- switch on the truck
- select service menu point "M05 auxiliary lift"
- follow all of the individual menu items according to the
order on the display (see also the description of the serv-
ice menu in chapter 6 and 11)

Checking the settings

- select configuration "K5 auxiliary lift" in the servicemenu
"M24 status display- configuration"
- 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
21 22 20 Hydromotor side shift
21 Side shift frame
22 Potentiometer
23 Pinion shaft side shift

+ Assembly of the side shift sensor unit see spare parts cata-
logue, register 08.

Assembly and mechanical adjustment

Requirements:
- move side shift unit (21) in right-hand end position

+ The hydraulic motor (21) must not be removed for installation

and removal purposes.
- set the potentiometer (22) to the right-hand stop
- turn back the potentiometer by 1/2 revolution
- screw the potentiometer with coupling and support to the
side shift frame

+ For demounting the attachment, position it in such a manner,

that the grub screws of the coupling are accessible.

Measure the potentiometer setting

- switch off the truck; side shift has to be placed at the left-
hand stop
- measure on VZK with pulled plug X212/Pin 2 and X214/
Pin 6 as well as between X212/Pin 5 and X214/Pin 9 with
ohmmeter. Permissible value: 0,1...0,4 kOhm

Calibration (Teach- In)

- switch on the truck
- select service menu "M02 side shift"
- follow all of the individual menu items according to the
order on the display (see also the description of the serv-
ice menu in chapter 6 and 11)

Checking the settings

- select configuration "K6 side shift" in the service menu
"M24 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
24 Potentiometer
25 Pinion of the potentiometer
26 Toothed belt
27 Pinion swivel axle
24
25

27 26

+
Assembly of the swivelling sensor unit see spare parts cata-
logue, register 08.

Assembly and mechanical adjustment

- move the forks to the right-hand stop
- always mount and demount sensor unit with potentiome-
ter, pinion and support
- set the potentiometer (24) to the right-hand stop and turn it
back by 1/2 revolution
- during the mounting make sure, that there is no clearance
on the toothed belt
- strain relief the cable connections; make sure that there
are no loops
- glue the fastening screws

Measuring of the potentiometer-setting

- switch off the truck; forks must be in center position
- measure in the VZK on pulled plug X214 between Pin 5
and Pin 6 as well as between Pin 8 and Pin 9 with ohmme-
ter. permissible value: 0,9...1,1 kOhm.

Calibration (Teach- In)

- switch on the truck
- select service menu "M03 Swivelling"
- follow all of the individual menu items according to the
order on the display (see also the description of the serv-
ice menu in chapter 6 and 11)

Checking the settings

- select configuration „K7 Swivelling" in the service menu
"M24 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.

8 System messages
Removal / installation of components other than those listed in
the spare parts catalogue is not permitted.

Required measuring instruments and test equipment

- 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

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.

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.Flow chart:

Message / trype 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 vehicle
states
Error during the operation Operation error; Display as
(after successful startup) error code
E xxx

Time of displaying different types of messages

power-On

startup o.k.? no Error message H xxx startup

Yes

message: sound sequence

operation

Message Online-help
operation o.k no
Error message Er xxx operation
yes (cyclical
program)

main switch no all messages are reset

on?

yes truck out of function

+ In case of malfunction always use the APE first for elimitation

of errors.

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 deallocate function is not Drive release signal transmit-
carried 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.

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 operating current was switched off.

8.1.4 Operating errors

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

Category of message Assembly concerned

Er100...Er199 VZA or its peripherals
Er200...Er299 VZK or its peripherals
Er300...Er399 UDR or its peripherals

Both the display and the service APE is capable to display sev-
eral errors that have occurred at the same time.
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).

8.1.5 Status analysis

In certain cases, it can happen, that the APE displays 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 socalled „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 actuating device 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“.

Flow chart: Status analysis

desired truck function fails

message? yes chapter 8

check operands
operator action MZ 111: right master switch
correctly executed MZ 112: left master switch
accordin to operating instructions

SECAN
recognizes operator no
action?

ja chapter 10
Check inputs of user action

chapter 10

choose relevant status flag 11
-> use chapter
(MZ xxx)
Service configurations

choose other
chapter8
relevant check status of flag
status flag

yes
j status as desired?
a

check conditions for Repair:

desired status Check missing condition

8.1.6 Flow chart: Systematic error diagnostics

malfunction

no no

Online-message? "H"-error? "Er"-error ?

yes yes yes Chapter 8

Status flag analysis

chapter 8 chapter 8 chapter 8

reason found? no

ja
yes all possibilities
checked?

eliminate error no
yes
ja

define error by means

test all functions of circuit diagramm;
error description to
service department

truck o.k.? no

yes
ja

submit truck to user

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, operation - Visual check SK-R
not possible - cross exchange SK-R(VZA)/SK-R(VZK)
H102 see H101 see H101
H103 see H101 see H101
H104 see H101 see H101
H105 see H101 see H101
H107 Computer-watchdog 1 can not close -check other components (e.g. personnel
safety circuit braking protection system)
-Truck remains in startup-status, opera- -check safety circuit braking
tion not possible -visual check SK-R
-cross exchange SK-R(VZA) <-> SK-R
(VZK)
H108 Computer-watchdog 1 can not close -Check safety circuit braking
safety circuit braking -Visual check SK-R
-Truck remains in startup-status, opera- -Cross check SK-R(VZA) <-> SK-R (VZK)
tion not possible
H109 Computer-watchdog 1 defective -visual check SK-R
-Truck remains in startup-status, opera- -cross exchange SK-R(VZA) <-> SK-R
tion not possible (VZK)
H111 see H109 see H109
H112 see H109 see H109
H113 Computer-watchdog 2 can not close the -check other components (e.g. personnel
safety circuit braking protection system)
-Truck remains in startup-status, opera- -check safety circuit braking
tion not possible -visual check SK-R
-cross exchange SK-R(VZA) <-> SK-R
(VZK)
H114 Computer-watchdog 2 can not open -check safety circuit braking
safety circuit braking -visual check SK-R
-Truck remains in startup-status, opera- -cross exchange SK-R(VZA) <-> SK-R
tion not possible (VZK)

Mesg. Description Possible measures

H115 Computer-watchdog 2 defective -visual checkSK-R
-Truck remains in startup-status, opera- -cross exchange SK-R(VZA) <-> SK-R
tion not possible (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, operation -VZ-check UDR
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, operation -VZ-check VZA and VZK
not possible
H120 CAN-bus controller defective -VZ-check VZA
Truck remains in startup-status, operation -visual check of VZA
not possible -cross exchange SK-R of VZA <-> SK-R
of VZK
H121 see H120 see H120
H122 CAN-bus communication with UDR and -CAN-check
VZK impossible -VZ-check VZA
Truck remains in startup-status, operation -visual checkVZA
not possible -cross exchange SK-R of VZA <-> SK-R
of VZK
-VZ-check SKR of VZK and SK-BPR
H123 CAN-bus communication with UDR -CAN-check
impossible -VZ-check VZA
Truck remains in startup-status, operation -visual check SK-BPR
not possible -cross exchange SK-CAN of VZA <-> SK-
CAN ofVZK
-VZ-check UDR
-cross exchange SK-CAN of SK-BPR
<-> SK-CAN of VZK
-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
-visual check SK-R of VZA
-cross exchange SK-R of VZA <-> SK-R
of VZK

Mesg. Description Possible measures

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, operation -visual check SK-R of VZA
not possible -cross exchange SK-R of VZA <-> SK-R
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
-visual check SK-R of 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
tion not possible -cross exchange SK-R of VZA <-> SK-R
of VZK
H133 operation brake by opening of the safety -check cabel connections of safety circuit
circuit for braking by the control system for braking
(SF2) is impossible -VZ-Check VZA
-Truck remains in startup-status, opera- -visual check SK-R of VZA
tion not possible -cross exchange SK-R of VZA <-> SK-R
of VZK
H134 Stopping the operation brake via closing -check other components (personnel pro-
of the safety circuit for braking by the tection system..)
control system (SF2)impossible -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-
-cross exchange SK-R of VZA <-> SK-R
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
H136 see H135 see H135
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

Mesg. Description Possible measures

H138 end of aisle switch forward, channel B, -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
H139 end of aisle switch backward, 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
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
-Truck remains in startup-status, opera- necessary
tion not possible
H155 SK-R defective -VZ-Check VZA
-Truck remains in startup-status, opera- -visual check SK-R
tion not possible -cross exchange SK-R of VZA <-> SK-R
of VZK
H156 see H155 see H155
H157 see H155 see H155
H158 see H155 see H155

8.2.2 Startup messages VZK

Mesg. Description Possible measures

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
-Truck remains in startup-status, opera- -visual check SK-R/SK-EPROM
tion not possible -cross exchange SK-R(VZK)/SK-R (VZA)
H202 see H201 see H201
H203 see H201 see H201
H204 see H201 see H201
H205 see H201 see H201
H206 see H201 see H201
H207 Computer-watchdog 1 cannot close -check other components (e. g. personnel
"safety circuit for braking“ protection system)
-Truck remains in startup-status, opera- -check safety circuit for braking
tion not possible -VZ-check VZK
-visual check SK-R/SK-EPROM
-cross exchange SK-R(VZK) <-> SK-R
(VZA)
H208 Computer-watchdog 1 cannot open -safety circuit Bremsen prüfen
"safety circuit for braking“ -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)
H209 SK-R defective -VZ-Check VZK
-Truck remains in startup-status, opera- -visual check SK-R / SK-EPROM
tion not possible -cross exchange SK-R of VZK <-> SK-R
of VZA
H213 Computer-watchdog 2 cannot close -check other components (personnel pro-
"safety circuit for braking“ tection system..)
-Truck remains in startup-status, opera- -check cable connections of the safety
tion not possible circuit for braking
-VZ-Check VZK
-visual check SK-R / SK-EPROM
-cross exchange SK-R of VZK <-> SK-R
of VZA

Mesg. Description Possible measures

H214 CAN-bus controller defective -check cable connections of the safety
-Truck remains in startup-status, opera- circuit for braking
tion not possible -VZ-Check VZK
visual check SK-R / SK-EPROM
-cross exchange SK-R of VZK <-> SK-R
of VZA
H215 Computer-watchdog 2 ddefective -VZ-Check VZK
-Truck remains in startup-status, opera- -visual check SK-R / SK-EPROM
tion not possible -cross exchange SK-R of VZK <-> SK-R
of VZA
H220 CAN-bus controller defective -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
cross exchange SK-R of VZK <-> SK-R
of VZA
H221 see H220 see H220
H222 CAN-bus communication with VZA and -CAN-check
UDR impossible -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
-cross exchange SK-R of VZK <-> SK-R
of VZA
-VZ-Check SK-R of VZA and SK-BPR
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
-cross exchange SK-R of VZK <-> SK-R
of VZA

Mesg. Description Possible measures

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-deallocation by outputs SF1/SF2 -VZ-check VZK
missing -visual check SK-R
-Truck remains in startup-status, opera- cross exchange SK-R of VZK <-> SK-R
tion not possible of VZA
H231 see H230 see H230
H232 24V-deallocation cannot be rejected by -VZ-check VZK
the output deallocation SF1 -visual check SK-R
-Truck remains in startup-status, opera- -cross exchange SK-R of VZK <-> SK-R
tion not possible of VZA
H233 24V-deallocation cannot be rejected by -VZ-check VZK
the output deallocation SF2 -visual check SK-R
-Truck remains in startup-status, opera- -cross exchange SK-R of VZK <-> SK-R
tion not possible of VZA

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...).

8.3 Operation messages VZA

+
8.3.1 Operation messages VZA
(SL) = self-deleting message

Mesg. Description Possible measures

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
-emergency stop: all movements locked,
braking
E102 CAN-communication disturbed: send see E100
buffer channel 1 overflow
-emergency stop: all movements locked,
braking
E103 CAN-communication disturbed: send see E100
buffer channel 2 overflow
-emergency stop: all movements locked,
braking
E104 CAN error see E100
-emergency stop: all movements locked,
braking
E105 CAN-error see E100
-emergency stop: all movements locked,
braking
E106 CAN error see E100
-emergency stop: all movements locked,
braking
E107 CAN-communication disturbed: send see E100
timeout
-emergency stop: all movements locked,
braking
E108 CAN-communication disturbed: timeout see E100
reception from UDR
-emergency stop: all movements locked,
braking
E109 CAN-communication disturbed: timeout see E100
reception from VZK
-emergency stop: all movements locked,
braking

Mesg. Description Possible measures

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 Deallocation 24V is missing (cut-out of -VZ-Check VZA
(SL) 24V-supply of the output drivers by watch- -visual check SK-R of VZA
dogs -cross exchange SK-R of VZA <-> SK-R
-mechanical braking to slow speed of VZK
-drive cut-out
E112 Deallocation 24V end of aisle safety- -VZ-Check VZA
(SL) channel A missing (cut-out of 24V-supply -visual check SK-R of VZA
spring pressure brake) cross exchange SK-R of VZA <-> SK-R of
-mechanical braking to slow speed VZK
-drive cut-outslow -end of aisle safety device: via service
menu check end of aisle safety- code
number release
E113 see E112 see E112
E114 drive sensor: deallocation signal is miss- - if drive supply voltage of drive sensor
ing and temperature o.k., check 24V-cable
-driving reduced to slow speed connection if necessary
-mechanical braking to slow speed -check 0V cable connection prüfen
-end of aisle safety braking no more via -check cable connection for deallocation
counter current, but via mechanical brake
E115 drive sensor: Timing signal channel 1 and -compare timing signal channel 1 and 2,
channel 2not synchronously check signal wiring, if necessary
-driving reduced to slow speed
-mechanical braking to slow speed
E116 drive sensor: Difference between direc- -compare direction signal channel 1 and
tion signal channel 1 and2 2, check signal wiring, if necessary
-driving reduced to slow speed
-mechanical braking to slow speed
E117 drive sensor: direction signal channel 1 -check direction signal channel 1, check
has changed while driving one direction signal wiring, if necessary
-driving reduced to slow speed
-mechanical braking to slow speed
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

Mesg. Description Possible measures

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
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-
connection or the measured value con-
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-
connection or the measured value con-
nection
-measure 12V-supply of potentiometer:
correct value: approx. 11,5V
-check coupling of potentiometer

Mesg. Description Possible measures

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
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)
E137 device driver, deallocation driving: VZA -status analysis (recovery switch acti-
(SL) actuates driver, but no feedback from the vated, device driver on SK-VZA defec-
driver tive?)
-drive cut-out, mechanical braking -visual check SK-VZA, change, if neces-
sary
E138 device driver deallocation driving: VZA see E137
(SL) switches off the driver, but still feedback
from the driver
-drive cut-out, mechanical braking
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

Mesg. Description Possible measures

E140 Resolution of the mechanical braking sys- see E139
tem: VZA switches off channel 1, but still
feedback from the SF-relay channel 1
-emergency stop: all movements locked,
braking
E 141 end of aisle safety: recognized only one -status analysis
channel deallocation (forward switch, -WG-truck: check deviation from wire
channel 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
E 142 end of aisle safety: recognized only one see E 141
channel deallocation (forward switch,
channel B has released)
-driving reduced to slow speed
E 143 end of aisle safety: recognized only one see E 141
channel deallocation
(backward switch, channel A has
released)
-driving reduced to slow speed
E 144 end of aisle safety: recognized only one see E 141
channel deallocation
(backward switch, channel B has
released)
-driving reduced to slow speed
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
-driving reduced to slow speed -check cabling of the switch
- VZ-Check VZA
-visual check VZA, replace VZA, if neces-
sary

Mesg. Description Possible measures

E 147 end of aisle safety: backward switch, -status analysis
channel A is released permanently -check backward 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 148 end of aisle safety: backward switch, -status analysis
channel B is released permanently -check backward switch, channel B
-driving reduced to slow speed -check cabling of the switch
- VZ-Check VZA
-visual check VZA, replace VZA, if neces-
sary
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
-driving reduced to slow speed
E 151 end of aisle safety: unpermissible combi- see E 150
nation of switches has released:
forward B, backward A
-driving reduced to slow speed
E 152 end of aisle safety: unpermissible combi- see E 150
nation of switches has released:
forward B, backward B
-driving reduced to slow speed
E 153 end of aisle safety: end of aisle safety- -drive the truck out of range of the magnet
switch forward A cannot be testet, or reflector, switch on again
because it is activated when switching on -status analysis
the truck -check end of aisle safety-switches
-driving reduced to slow speed -check cables
-VZ-vheck VZA
-visual check VZA, change, if necessary
E 154 end of aisle safety: end of aisle safety- see E 153
switch forward B cannot be testet,
because it is activated when switching on
the truck
-driving reduced to slow speed

Mesg. Description Possible measures

E 155 end of aisle safety: end of aisle safety- see E 153
switch backward A cannot be testet,
because it is activated when switching on
the truck
-driving reduced to slow speed
E 156 end of aisle safety: end of aisle safety- see E 153
switch backward B cannot be testet,
because it is activated when switching on
the truck
-driving reduced to slow speed
E 162 switch WG-locking system actuated while -check hydraulics/mechanics of the lock-
driving is switched off or: actuated in the ing system
apron (only trucks with aisle recognition) -adjust switch of steering locking system
-general emergency stop check switching point via status display
-check function of steering locking sys-
tem, change if necessary
E 163 WG-locking system not activated in the -check hydraulics/mechanics of the lock-
aisle (only trucks with aisle recognition) ing system
-general emergency stop -adjust switch of steering locking system
check switching point via status display
-check function of steering locking sys-
tem, change if necessary

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
Er165( Soiling filter has been activated (dealloca- -change filter cartridge
SL) tion-time delay approx. 10 minutes) -check switch, change if necessary
-only displayed on APE -check cables
-VZ-check VZA
-visual check SK-E/A of VZA
-cross exchange SK-E/A of VZA <-> SK-
E/A of VZK; change SK-E/A of VZA if nec-
essary
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-
-only displayed on APE essary
-if software problems SK-R of VZA:
detailled error description and VZA-soft-
ware-ident number to Service-department

Mesg. Description Possible measures

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
E168 WG-SECAN: error 2 Missing-Pulse-Sig- see E 167
nal micro steering sensor rear
-emergency stop: all movements locked,
braking
E 169 Motor temperature control via analog -let aggregat cool down, reduce load, if
(SL) input (Pull-Up) necessary
-only displayed on the SECAN-display -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 pedal key is not actuated, but brake -check pedal key 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
E 173 steering reference: steering locking -status analysis
mechanism was not opened -make mechanical parts of the locking
-steering deactivated device smoothy working
-check switch locking device feedback,
change if necessary
check cable
-VZ-check and visual check SK-EA of
VZA

Mesg. Description Possible measures

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 reference
E 175 voltage supply for analog sensor channel -measure voltage supply 12V
(SL) 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 for analog sensors chan- see E 175
(SL) nel 2 too low
-emergency stop: all movements locked,
braking
E 177 full speed released, but drive sensor -status analysis
(SL) doesn’t send pulses -check coupling sensor/motor shaft
-only displayed on APE -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

Mesg. Description Possible measures

E 179 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
E180 aisle recognition of track 3: unpermissible -status analysis
(SL) deviation between 1. and 2. recognition of -check magnet switches and cables track
the aisle recognition signal 3
-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 181 wire break at pressure sensor 1(2B10) -check pressure sensor, supply and cable
(SL) -only displayed on the APE prüfen
-VZ-Check VZA, check SK-E/A
-cross exchange SK-E/A of VZA <-> SK-
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

Mesg. Description Possible measures

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 rue, see
chapter 6 (when vmax-is exceeded:
E 193)
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
-emergency stop: all movements locked,
braking
E 187 WG: communication with micro steering -check micro steering sensor front + cable
sensor front disturbed -VZ-check VZA
-emergency stop: all movements locked, -visual check SK-VZA, change if neces-
braking sary
E 188 WG: communication with micro steering -check micro steering sensor rear + cable
sensor front disturbed -VZ-check VZA
-emergency stop: all movements locked, -visual check SK-VZA, change if neces-
braking sary
E189 WG: micro steering sensor front sends -check micro steering sensor front
internal error message
-emergency stop: all movements locked,
braking
E 190 WG: micro steering sensor rear sends -check micro steering sensor rear
internal error message
-emergency stop: all movements locked,
braking
E 191 WG: micro steering sensor front must be -newly calibrate micro steering sensor
(SL) re-calibrated front according to chapter 6
-full speed locked

Mesg. Description Possible measures

E192 WG: micro steering sensor rear must be -newly calibrate micro steering sensor
(SL) re-calibrated rear 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 pressure for load wheel brake too -check brake hydraulics according to
(SL) less chapter 6
-general emergency stop -check pressure sensor (s)
E 195 temperature drive motor too high
(SL)

8.3.2 Operation messages VZK

Mesg. Description Possible measures

E 200 CAN-communication disturbed: reception -CAN-check
buffer channel 1 overflow -VZ-check VZK
-emergency stop: all movements locked,
braking
E 201 CAN-communication disturbed: reception see E200
buffer channel 2 overflow
-emergency stop: all movements locked,
braking
E 202 CAN-communication disturbed: send see E200
buffer channel 1 overflow
-emergency stop: all movements locked,
braking
E 203 CAN-communication disturbed: send see E200
buffer channel 2 overflow
-emergency stop: all movements locked,
braking
E 204 CAN error see E 200
-emergency stop: all movements locked,
braking
E 205 CAN-error see E 200
-emergency stop: all movements locked,
braking
E 206 CAN error see E 200
-emergency stop: all movements locked,
braking
E 207 CAN-communication disturbed: send see E 200
timeout
-emergency stop: all movements locked,
braking
E 208 CAN-communication disturbed: timeout see E 200
reception from UDR
-emergency stop: all movements locked,
braking
E 209 CAN-communication disturbed: timeout see E 200
reception from VZA
-emergency stop: all movements locked,
braking

Mesg. Description Possible measures

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 Deallocation 24V missing (Switch-off of -VZ-check VZA

(SL) the 24V-supply of the output drivers by -visual check SK-R of VZK
watchdogs) -- cross exchange SK-R of VZK
-only displayed on the APE <-> SK-R of VZA
E 212 measured value-sensor unit auxiliary lift -check setting of sensor unit
(SL) potentiometer wire break detection (A/D- -status analysis
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)
-driving reduced to slow speed
-Lifting and lowering of the auxiliary lift
reduced to slow speed
E 214 measured value-sensor unit auxiliary lift -check setting of sensor unit
(SL) potentiometer 1: out of range (0, -status analysis
h3_max) -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)
-check coupling of potentiometer
E 215 measured value-sensor unit auxiliary lift see E 214
(SL) potentiometer 1: out of range (0,
h3_max)
-driving reduced to slow speed
-Lifting and lowering of the auxiliary lift
reduced to slow speed

Mesg. Description Possible measures

E 216 measured value-sensor unit auxiliary lift -check setting of sensor unit
(SL) potentiometer 1 and 2: deviation of the -status analysis
values too high -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)
-check coupling of potentiometer
-check potentiometer, change if neces-
sary
E 217 measured value-sensor unit side shift -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
-side shift reduced to slow speed high value: Interruption of the 0V-cable
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 218 measured value-sensor unit side shift see E 217
(SL) potentiometer 1: wire break detection (A/
D-value)
-driving reduced to slow speed
-side shift reduced to slow speed
E 219 measured value-sensor unit side shift -check setting of sensor unit
(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
low value: Interruption of the 12V- or the
measured-value cable connection
-measure 12V-supply of the potentiome-
ter (correct value: approx. 11,5V)
-check coupling of the potentiometer
E 220 measured value-sensor unit side shift see E 219
potentiometer 2: out of range
-driving reduced to slow speed
-side shift reduced to slow speed

Mesg. Description Possible measures

E 221 measured value-sensor unit side shift -check setting of sensor unit
(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
low value: Interruption of the 12V- or the
measured-value cable connection
-measure 12V-supply of the potentiome-
ter (correct value: approx. 11,5V)
-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
(SL) potentiometer 1: wire break detection (A/ -status analysis
D-value) -display analog input of potentiometer on
-driving reduced to slow speed APE
-swivelling reduced to slow speed high value: Interruption of the 0V-cable
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)
E223 measured value-sensor unit swivel see E222
(SL) potentiometer 2: wire break detection (A/
D-value)
-driving reduced to slow speed
-swivelling reduced to slow speed
E 224 measured value-sensor unit swivel -check setting of sensor unit
(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
low value: Interruption of the 12V- or the
measured-value cable connection
-measure 12V-supply of the potentiome-
ter (correct value: approx. 11,5V)
-check coupling of potentiometer
E 225 measured value-sensor unit swivel see E 224
(SL) potentiometer 2: out of range
-driving reduced to slow speed
-swivelling reduced to slow speed

Mesg. Description Possible measures

E 226 measured value-sensor unit swivel -check setting of sensor unit
(SL) potentiometer 1, 2: deviation of the -status analysis
measured values too high -display analog input of potentiometer on
-driving reduced to slow speedswivelling APE
reduced to slow speed high value: Interruption of the 0V-cable
-swivelling 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)
-check potentiometer cable
-check coupling of potentiometer
-check potentiometer, replace if neces-
sary
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
-when software problems occur: contact
customer service: exact error description
and VZK-software-identification number
(-> MA ...)
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
-when software problems occur: contact
customer service: exact error description
and VZK-software-identification number
(-> MA ...)

Mesg. Description Possible measures

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 SK-BPR-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 the customer 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 the customer service:
exact error description and VZK-software
ident number (-> MA...)
E 232 voltage supply of analog sensors channel -measure voltage supply 12V
(SL) 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 channel see E 232
(SL) 2 too low
-mergency stop: all movements locked,
braking

Mesg. Description Possible measures

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 point 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
-check master switch cable connection
-VZ-check UDR, replace if necessary
E 237 master switch left side: direction signals -status analysis
(SL) available, but set point 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
-check master switch cable connection
-VZ-check UDR, replace if necessary
E 238 master switch right side: set point availa- -status analysis
(SL) ble, but directional signal is missing -adjust sensors of master switch (teach-
-emergency stop: all movements locked, in)
braking -check function of the micro switches
-test master switches via configuration K
17
-check master switch cable connection
-VZ-check UDR, replace if necessary
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
-check master switch cable connection
-VZ-check UDR, replace if necessary

Mesg. Description Possible measures

E 240 master switch right side: direction signal -status analysis
(SL) available, but set point is missing -adjust sensors of master switch (teach-
-emergency stop: all movements locked, in)
braking -check function of the micro switches
-test master switches via configuration K
17
-check master switch cable connection
-VZ-check UDR, replace if necessary
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
E 244 pressure in pressure reservoir too low for -check pressure sensors and cable con-
load wheel brake nections (see chapter 5)
-emergency stop: all movements locked, -check hydraulic installation of load
braking wheel brake (see chapter 5)
E 245 wire break pressure sensor 2B11 -check cable connections and signal lev-
detected els of sensor, replace sensor,if necessary
-emergency stop: all movements locked, -check plugs for bad contacts
braking -check SK-EA: check input signal with
status display and compare with the sig-
nal level of the pressure sensor

8.3.3 Operation messages UDR

Mesg. Description Possible measures

E 301 Boot error of computer UDR -replace UDR-board (UDR or EPROM

-all functions locked defective)
-call the customer service

E 302 Timer on UDR board not synchronous -if the error occurs in standard operation:
with CanOpen Bus (20ms cycle). order UDR, UDL-update, call the cus-
message > 4 ms overdue tomer service

E 303 steering-evaluation detects different sig- -check cable connection between steer-
nals of incremental transmitter 1 and 2 ing unit and main board UDL
-general emergency stop - 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 absorption of current of -check cable connection betwee steering

both steering wheel sensors (rupture of unit and main board UDL
wire, short circuit in supply line) - turn steering wheel slowly and measure
the phase signals by means of a volt
meter

E 305 NV-RAM error during boot-up -inform service department

-all functions locked - carry out NV-RAM refresh and check
functions of the truck carefully (individual
parameters may have been changed and
cause undesirable processes)
- if this error occurs repeatedly, the main
board UDR must be replaced.
With „stop“ text format:
Never install an already used NV-RAM
component on a new UDR main board

Mesg. Description Possible measures

E 306 error NV-RAM during operation -inform service department

E 308 no release signal from VZK after start of -check CAN-connection (cable) to VZK
the 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 no synchronisation of UDR and VZK -CAN-Check

-all functions locked

E 310 CAN-bus error -CAN-Check

-all functions locked

E 311 CAN-hardware buffer overflow -re-start the truck

-all functions locked -contact the customer service, request
new UDR software

E 312 CAN-software bufferr overflow -re-start the truck

-all functions locked -contact the customer service, request
new UDR software

Mesg. Description Possible measures

E 313 CAN-software buffer overflow -re-start the truck

-all functions locked -contact the customer service, request
new UDR software

E314 Analog default settings do not corre- -cross exchange drive switch left/right
spond with the switching values -if the error does not diffuse:
check the signals at the plug connection
to the board
replace main board
Warning-text:
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 -if the error does not diffuse:
check the signals at the plug connection
to the board
replace main board
Warning-text:
Before starting the control panel: tighten
threaded fastener between UDL and
VZK, do not apply stress to cable con-
nection

E 316 self check reports error in the safety cir- -switch on the truck again
cuit for braking -check safety circuit for braking
-all functions locked

E 317 self check reports error in the safety cir- -switch on the truck again
cuit for braking -check safety circuit for braking
-all functions locked

Mesg. Description Possible measures

E 318 self check reports error in the safety cir- -switch on the truck again
cuit for braking -check safety circuit for braking
-all functions locked

E319 self check reports error in the safety cir- -switch on the truck again
cuit for braking -check safety circuit for braking
-all functions locked

E 320 self check reports error in the safety cir- -switch on the truck again
cuit for braking -check safety circuit for braking
-all functions locked

E 321 self check reports error in the safety cir- -switch on the truck again
cuit for braking -check safety circuit for braking
-all functions locked

E 322 self check reports error in the safety cir- -switch on the truck again
cuit for braking -check safety circuit for braking
-all functions locked

E 323 self check reports error in the safety cir- -switch on the truck again
cuit for braking -check safety circuit for braking
-all functions locked

Mesg. Description Possible measures

E 324 self check reports error in the safety cir- -switch on the truck again
cuit for braking -check safety circuit for braking
-all functions locked

E 325 self check reports error in the safety cir- -switch on the truck again
cuit for braking -check safety circuit for braking
-all functions locked

E326 self check reports error in the safety cir- -switch on the truck again
cuit for braking -check safety circuit for braking
-all functions locked

E327 self check reports error in the safety cir- -switch on the truck again
cuit for braking -check safety circuit for braking
-all functions locked

E 328 No RS232 connection between UDL and -Check cable connection between the
UDR right and the left part of the control panel.
- check voltage supply RS232
-RS232 check
also see description E329

E 329 Response message from UDL missing -Check able connection RS232
UDL is given a message for the synchro- -RS232 check
nization of UDR every 20 ms. The -check of voltage supply UDL (at the
response message from UDL must be testing point control board UDL)
received within 8 ms.
If the response has not been received
until the next SYNC signal, E328 is gen-
erated.
Errors in the UDR software may also cre-
ate an error message E329 (start cycle
lag)

Mesg. Description Possible measures

E 330 TxD and RxD at the right part of the con-

trol panel were connected with each
other for the check of the serial interface
UDR

E 331 Interruption of the UDR supply voltage -check able connection between VZK
recognized and VZA
-check power absorption of UDR

E 332 The UDL recognized a brief interruption -check able connection between VZK
of the supply voltage: At the end of the and VZA
start-up phase of thge UDR, it sent a sin- -check power absorption of UDR
gle release signal to the UDL. Only after
the reception of this release signal, proc-
ess data can be called

E 334 wrong software-version -check software deallocation codes

-all functions locked -order correct software or update

9 Equipment check
Removal / installation of components other than those listed in
the spare parts catalogue is not permitted.

Required measuring instruments and test equipment

- 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

9.7 DATASCOPE 30
9.7.1 General Description 30
9.7.2 Operating the DATASCOPE 30
9.7.3 Functions of the DATADCOPE 31
9.7.4 Data Storage 33
9.7.5 Transfer and Display of a
DATASCOPE Record 33

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.

9.1 General Information about System Diagnosis

9.1.1 Visual Inspection of Electronic Assemblies

Remove defective circuit board

Electrostatically sensitive components!

Straighten bent pins.

Plugs o.k.? no In case of mechanical damages:
Replace board

yes

Fuses Replace defective fuses;

no
o.k? if necessary, rebend fuse holders

yes
- Check whether the parts are
in right location (e.g. jumpers)
- Check the ID numbers of the
Plug-ins seated
no plug-in boards
correctly?
(e.g. EPROM-module)
- Firmly plug the parts in,
check whether they have contact
yes

Mechanical Do not repair!

yes
damage visible? Replace board

Components Do not resolder!

yes
loose? Replace board

Bumtspots
yes
yes Replace board
visible?

If possible, check by exchangig boards

Elektronic defect (see chapter 9.2)
Replace defective assembly

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)

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 Program-

ming Unit (APE)
9.2.1 Connection of the APE to the Truck
An external display and programming unit must be connected
with the right control pannel which allows for service operations
regarding the truck (error diagnosis 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 the manufacturer.

The APE is connected as follows:

- Switch off the truck

The cable connection from UDR to APE must not be plugged in

or out as long as the truck is switched on. Electronic compo-
nents might be destroyed.

- Connect the cable to UDR and tighten the screws of the

plug.
- Fix APE on the support at the cabin railing.
- Switch on the truck.
- As soon as the basic display appears (see „a) Basic Dis-
play“ on page 6), the service menu can be called (see „c)
Service Menu“ on page „7).

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 APE displays the message „Please
wait - initialization“. After approx. 10 seconds, the basic display
appears.
The basic displays provides various information about the stand-
ard operation of the truck.

+ Functions which are also displayed on the control panel, are

not shown in the picture.

BATT HEIGHT DATE TIME

80% 3,4m 01.10.01 14:25

F1 F2 F3 F4 F5 F6

:Access key functions from the basic display.

Keys Function Description

<F2> Selection infor- Display of errors, categorized
mation display according to processing unit
(VZA, VZK, VZ-UDR/UDL), as
well as series number and
software versions.
<F4> Contrast brighter When the key is pressed and
held, the display slowly
becomes brighter.
<F5> Contrast darker When the key is pressed and
held, the contrast of the dis-
play changes quickly (birght -
dark cycle)
<F1+F6> Service menu Function-related display of all
parameter settings, status dis-
play, options, datascope.

+ F1 + F6> means:
- F1> press and hold
- F6> press briefly
b) Information Display
Change from the basic display to
the information display is possi-
ble by pressing the key <F2>.
Status

The information display includes VZA

Error(s)
VZK
Error(s)
VZ-UDR/UDL
OK

the following information: E161

E164
H202

E171
- occurring errors, catego-
rized according to VZA,
VZK und VZ-UDR/UDL

+ All occurring errors are also

displayed on the control panel. Serial-No:
Version VZA:
Version VZK:
Version UDR:
102.435.001
3.01.01
3.01.01
3.01.01
Version UDL: 3.01.01

- Manufacturer series F1 F2 F3 F4 F5 F6
number of the truck
- Software version numbers
of VZA, VZK, VZ-UDR/
UDL.

+ Information about software administration see chapter 6.

All occurring errors are displayed for at least 1 second.

The information displayed can be left by pressing the key combi-
nation <F1+F4> and the menu from which the information dis-
play was called, is activated.

<F1+F4> means:
- <F1> press and hold
- <F4> press briefly
c) Service Menu
The service menu is activated by pressing the key combination
<F1+F6>.
At the first access to the service menu, the following access
code must be entered:

Access Code: 1848

Never give access code to unauthorized personnel!

+ The inquiry can be left by pressing <F1+F4> verlassen werden

(Escape Function). Input of the service code is done from left
to right. 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 setting the correct code in this way, confirm by pressing the
key <F6>.

The service menu shown here is

displayed.

+
M01 Control panel
After entering a wrong access M02
M03
Sideshift
Swivelling

code, a corresponding mes- M04

M05
Main lift (ML)
Auxiliary lift (AL)
M07 Hydraulics Synchr. Swivel
sage is transmitted. The truck M08
M09
Geometry Synchr. Swivel
Fork tine adjust. (FTA)
M10 Driving
must be switched on again M11
M12
Load wheel brake
Steering

before further use. M13

M15
Pump
Inductive Guidance
M16 Driving cut-out
M17 Lift cut-out
M18 Lowering cut-out
M19 Sideshift cut-out
M20 Optispeed
M21 Options
By pressing the keys <F2> or M22
M23
Hour Meters
Language

<F3>, the line cursor can be M24

M25
Status display
Datascope

transferred into the respective E00 Default All

line. Access to the selected func- F1 F2 F3 F4 F5 F6

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.

Changing of Parameters in the Function Menus

+ As an example, the function

menu „M04 Main Lifting“ is
displayed.
TI06 Teach-In top
TI07 Teach-In bottom
G20 End ahead top 300
By pressing the keys <F2> or G21
G22
End ahead bottom 300
Height 5400

<F3>, the line cursor can be R08

R09
Braking ramp lift 30
Braking ramp lower 20
R10 Accel. ramp lift 20
transferred into the respective R11
V08
Accel. ramp lower 15
Speed max lift 100
V09 Speed max lower 100
line. Activation of the selected V10
V11
Slowspeed lift
Slowspeed lower
64
29
I04 Current min lift 120
parameter is done by pressing I05
I06
Current max lift 490
Current min lower 200
I07 Current max lower 500
the key <F6>. D00
D01
RPM max lift
RPM min lift
2500
2500
D02 RPM Prop. lift 950

+
D03 RPM Prop. lower 550
V30 Switch speed RPM Prop. 17

E01 Default
The character cursor appears.
F1 F2 F3 F4 F5 F6

Character Cursor
The character cursor marks only
one decimal digit of a setable
parameter. It blinks and marks an
active function (parameter value TI06 Teach-In top
TI07 Teach-In bottom
can be changed). G20
G21
End ahead top
End ahead bottom
300
300

+
G22 Height 5400
R08 Braking ramp lift 30
R09 Braking ramp lower 20
For changing the value, press R10
R11
Accel. ramp lift
Accel. ramp lower
20
15
V08 Speed max lift 100
the keys <F2> or <F3>. Holding V09
V10
Speed max lower
Slowspeed lift
100
64
V11 Slowspeed lower 29
a key is equal to the repeated I04
I05
Current min lift
Current max lift
120
490

pressing of the key. I06

I07
Current min lower
Current max lower
200
500
D00 RPM max lift 2500
D01 RPM min lift 2500
D02 RPM Prop. lift 950
D03 RPM Prop. lower 550
V30 Switch speed RPM Prop. 17

With input fields with several dig- E01 Default

MIN: 0 MAX: 1000

its, e.g. in the editing of a
number, the cursor can be trans- F1 F2 F3 F4 F5 F6
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.

Interruption of Alterations
The alteration process can be interrupted by pressing the key
combination <F1+F4> (escape function). The originally set value
remains.

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

In the service menu „M24 Status Display“, alle operands availa-
ble in the truck control (inputs, outputs, tags) can be called and
can be 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.

+ 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. M24 Status display

Z00 EA
Z01 EA100

- Press <F6> (ENTER) to Z03

Z04
EA100 1008

Z05 MZ100 FA GA Fast

activate the line; the char- Z06
Z07
MZ100 95

Z08
acter cursor appears. (see Z09
Z10
Z11
Z00) Z12
Z13
Z14
Z15
- Press <F2> or <F3> to Z16

Delete all inputs

select the type of the oper- Change display

and (E, EA, A, AA,...)

- Press <F6> (ENTER) to
F1 F2 F3 F4 F5 F6
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).

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.

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.

Deleting all Existing Inputs

To delete all existing inputs in the status display:
- Select command line „Delete all inputs“ by pressing the
keys <F2> or <F3>
- Confirm by pressing <F6>
•

Change of Display with Status Tags

To change the display of status tags
- Select command line „Change Display“ by pressing the
keys <F2> or <F3>
- Confirm by pressing <F6>

+ 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 chap-
ter 10 „Control Status“.

Press the keys <F1+F4> to exit the status display.

56
57
58

9.2.4 Structure of the APE

Pos. Description Pos. Description

54 Cover sheet 58 Converter board
55 Upper cover case 59 APE-motherboard
56 LC-display 60 O-ring
57 Flat cable 61 Bottom case

Always pull off the upper cover (55) vertically, do not pry.

Structure of the APE Motherboard

Fuse X185
5V-supply (UDR)
1A medium response sensitivity
Fuse
24V-Supply
Plug connector 1A medium response
Flat cable to sensitivity
LCD-Module

GAL-component
plug-in type

EPROM
(APE-Programme)
plug-in type

The EPROM must not be handled separately.

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)
- incorrectly installed jumpers on the CAN controller cards
- 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

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..

VZB
Main board right control panel
8 2 2
9 9 9
120 Ohm Service APE

27 1 1
2 1 2
8 9
1 5 5
0
5 24 X90
(Sub37-p.) X185(Sub9-p.)
(gn)

(ge)

Control panel X184(Sub9-p.)

3 4 X91
( Sub15-p.)
nc (GROUND)
(7)

(8)

(SUPPLY)

Cable W89
CAN +

CAN -

7 8 9 10
X200 (Mate 15-p.)

VZK
SK-R

120 Ohm SK-CAN

Cabin
No
Jumper

1 2 3 4
X299 (Mate 9-p.)
(ws)

SUPPLY (gn)

GROUND (ge)
(br)

mast cable W199 (shielded)

CAN +

CAN -

9 1 2 3 4
X199 (Mate 9-p.)

VZA
SK-CAN SK-R

120 Ohm Drive

Jumper compartment

9.3.3 Flowchart CAN-Check

CAN fault Remarks

Switch device off

and on again

Sporadic fault,
caused by e.g.
Fault still Overflow of the
no
present? CAN buffer.
Equipment is ready
for operation again
yes

Switch off the device

Check the plug

connections of the bus

- correct slot?
- Plug engaged?
Plug connectors ok? no Eliminate fault - Plug corroded or soiled
- Shielding correctly connected?
- Leads properly in the pins?
- Isolation ok?
yes

Assemblies - VZ-check (section 9)

plugged in correctly? no Eliminate fault
- Visual inspection (section 9)

yes

Jumpers plugged - Jumpers plugged on SK-CAN

no Eliminate fault
in correctly for VZA and VZB
- No Jumper for VZK

yes

1 Remarks

Resistance test
X199/pins 1-2 2 x 120 ohm in parallel
(VZA/VZB terminators)

CAN bus
approx. 60 Ohm? no fault This pocedure only checks the
lines "CAN +" and "CAN -";
yes if necessary, check all connectors
Remove plug X299 with wiring diagram "CAN bus"
with disconnected plugs
ohm test
Resistance test: (lines"Supply", "Ground")
X199 / Pin 1-2
in the base of the board

approx. 120 Ohm? (VZA terminator)

yes
no

Fault in the bus

VZK <-> VZB
(in cabin)
possible;
eliminate fault

Resistance test:
Widerstandsmessung:
X199
X299 / Pin 1-2
in Mastkabel-Stecker
im the mast cable plug

yes approx. 120 Ohm?

no
CAN bus ok
Fault in the bus
VZK <-> VZA
Section 9 (over mast)
Interchange SK-CAN possible
eliminate fault
Fault on VZ-assembly

Fault found? no

yes

VZ-Check - VZ-check (see section 9)

Eliminate fault - Visual inspection (see section 9)
Visual inspection

9.4 RS232-Check
9.4.1 General Information
The data transfer between processing unit drive compartment
(VZA), processing unit cabin (VZK) and processing unit control
panel right (VZ-UDR) is done via CAN bus. (see structure CAN
bus).
The communication between the right control panel (UDR) and
the left control pannel (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.

Left control panel Right control panel

(UDL) (UDR)
Communication-

Communication -
Rx (1) Tx
Component

Component
D D
Tx (2) Rx
D D

VZ-UDL VZ-UDR

The computer boards (VZ) of both UDL and UDR are equipped
with a RS232 communication component for the data inter-
change between the right and the left control panel.
Every 20 ms, the UDR is sent a message for synchronization
from VZK. This message is transferred by the RS232 communi-
cation component of the UDR via a lineg (1) to the RS232 com-
munication component of the UDL (TxD-UDR sends to RxD-
UDL).
Within the specified period (max. 8 ms), these messages must
be answerd by UDL. In this process, response messages are
returned to UDR via line (2). (TxD-UDL sends to RxD-UDR). If
the response is not given until the next SYNC signal, a RS232

+
communication error signal is transmitted.
RS232 errors see chapter 8 „System Messages“

9.4.3 Process of the RS232-Check

If a RS232 error message has been transmitted, the location of
the error on either the right or the left control panel can be deter-
mined by means of a function CRC-RS232“ which is predefined
in the service menu M01.

Switch off truck before disconneting the plugs or inserting the

connection between the individual pins.

Switch off truck

Disconnect RS232 from plug X129 to UDR

Connect to UDR, X129, bridge between

Pin 1 and Pin 11

Switch on truck

Check Function RS232 (with UDR)

- disconnect plug X129, bridge between
pin 1 and pin 11

is E330
no replace computer board VZ-UDR
displayed?

yes

Check voltage supply RS232

- disconnect plug X187, measure between
Pin 2 und Pin 3
- Plug master switch: UDL:Pin1 and GND

Check cable connection RS232

24V OK? no Check plug X129 UDR externally
replace computer board VZ-UDR if necessary

yes

Check 5V UDL:
- Testpoint RS232 UDL: Pin 1 and Pin 5
Disconnect all plugs from the computer
board VZ-UDL, repeat check.
5V OK? no 5V OK:
--> last disconnected component defective
5V not OK, all plugs disconnected
yes --> replace computer board VZ-UDL

Ohmic measure RS232 to UDL

- Testpoint RS232 UDL: bridge to Pin 2, Pin 3
- disconnect plug X129 UDR
- Measurement at Pin 1 and Pin 11

Check cable connection RS232

1,2 Ohm OK? no Check plug X187
replace computer board VZ-UDL if necessary

yes

!VZ-Check

Check resting voltage RS232:

- Plug X129 cabel: disconnect Pin 1, Pin 11
- Measurement 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

approx. -8V OK? UDR sends no messages

no
Replace computer board VZ-UDR

yes

Check operating voltage RS232 (TxD UDL):

- Testpoint RS232 UDL: Pin 3 and Pin 4

UDL sends no messages

approx. -7V OK? no
Replace computer board VZ-UDL

yes

inform central service

9.5 VZ-Check
The VZ-Check applies to the processing units in the drive com-
partment, (VZA), as well as in the cabin (VZA).

+ 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 metallic, 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

Design VZA

Free terminal SK-EA SK-VZA SK-R

(for options)

EMV 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

Interface board VZA

This area is covered by the EMV hood

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
VZB
- with VZK: no reception from
VZB
blinking red CAN-Controller successfully CAN-Check
+green tested, but Check of the not sending
- with VZA: no reception from processing unit
VZK and VZB
- with VZK: no reception from
VZA and VZB
blinking red CAN-Controller successfully CAN-Check
+ blinking tested, but Check other processing units
green - with VZA: no reception from
VZK and VZB
- with VZK: no reception from
VZA and VZB

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.

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.

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.

9.6 Check of Control Panel

9.6.1 Check master switch

Cross exchange master switch (UDL <--> UDR):

Error
yes Replace defective master switch
follows?

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 computer board

yes no
24V OK?

Check analog signals:

- Initial position: between Pin 8 and Pin 2: +5V
- direction signals: between Pin 6 and Pin 2: 0-5V yes
between Pin 7 and Pin 2: 0-5V
- rated value: between Pin 4 and Pin 2: 0-10V

Check cable connection and plug

Signals OK? no
replace masterswitch, if necessary

yes

replace computer board

Pin allocation of the drive switch plug on the computer board.

Pin 2: +0V (Gnd)
Pin 5: +24V (Supply
Pin 4: Pegging (0V in initial position, approx. +10V at full peg-
ging)
Pin 8: Digital signal for initial position (+5V in initial position)
Pin 6, 7: Direction signals (+5V or 0V)

9.6.2 Check of the steering wheel sensor unit

Cross exchange plug connectors channel A, channel B :

yes error messages

changes?

Check voltage supply:

- plug steering wheel channel A: between Pin ? and Pin ?
- plug steering wheel channel B: between Pin ? and Pin ?

?V OK? no Replace computer board UDL

yes

Voltage measurement of the analog signals:

- Channel A: between Pin ? and Pin?: 0V; 4,8V
- Channel B: between Pin ? und Pin?: 0V; 4,8V

When the steering wheel is turned slowly, the

voltage change must be recognizable

Signals OK? no replace steering wheel sensor unit

yes

No error;
Check plug connection again for loose contact

9.6.3 Check of the Key Switches

All key switches on the panel can be checked by calling the cor-
responding control panel configuration.

+ Design of the configuration for the right and left control panel
see chapter 11.

9.7 DATASCOPE
9.7.1 General description
The DATASCOPE allows the storage and view the temporal
course of control operands.
The recording is activated directly by the APE over the service
menu. For this operation there is no PC/Laptop required.
The DATASCOPE PC software provides the graphical analysis
of the recorded data. For this, the recordings are first transferred
by the RS 232 connection (9-pin Sub-D-plug at the right side of
control desk) from SECAN control to the PC/Laptop .
The PC/Laptop prepares information by producing a text file for
plaintext view, and a graphical view of the data.

9.7.2 Operating the DATASCOPE

The DATASCOPE is operated

by the function keys F1...F6 on
the APE.

+
M25 Datascope

Menu entrance to the DATA- Record

E20 START
E21 STOP
SCOPE see chapter 6 APE E22 CONTINUE
E23 TRANSFER
operation. Data
D00 ERE 184
D01 MA 247
D03 MA 248
D04 MA 149
D05 MA 150

Opposite illustration shows an D06

D07
MA 113

example of a DATASCOPE Trigger

T00 ERE 184 = 1
T01
parameter view on the APE. T02
T03

See „Datascope application Periods

S07 Scanning period / 20 ms 5
S06 Run-out period / 20ms 25
example“ on page 31 for the
description of the example. F1 F2 F3 F4 F5 F6

9.7.3 Functions of the DATASCOP

Display Function Remarks

message
START Start of - Move line cursor to line „START“
recording - Start measuring by <F6>.
During a measuring no data of DATASCOPE menu can be
changed.
The menu can be left. In the background, measuring is contin-
ued then.
STOP Stop of During a measuring only the STOP function is active.
recording
CONTINUE Recording is Multiple measuring is possible; the number of recordings is lim-

+
continued ited by the memory.
With full memory, all measurings are overwritten.
Analog operands need more memory than digital operands.
TRANSFER Writing Transfer of the recordings to the PC/Laptop
recordings
D00 - D07 Signals to be - Change to edit mode by <F6> (small cursor)
recorded - Choose signal type by <F2> and <F3> ; possible types:
Input digital / Analog Normiert / Analog Hardware
Output Digital / Analog Normalized /Analog Hardware
Tag Digital / Analog Normalized /Analog Hardware
Tag State Value
Error recognized / Value
Parameter
- Take type by <F6>
- Edit signal number by <F2>, <F3>, <F4> und <F5>
- Take value by <F6>
- End / Reentry by <Ctrl-F4>
T00 - T03 Trigger Operation is same as for „Signals to be recorded“
conditions - Enter Operand and Value
Up to four independent trigger conditions are possible
"Steuergröße" (same type as for data selection)
"Vergleichsoperator" (comparator smaller, equal, bigger)
"Konstante" (full figure value between -32767 und +32767, fit-
ting to operand!)
- End / Reentry by <Ctrl-F4>
S07 Scanning time For short signals take 20 ms scanning time.

+
in 20ms units
The bigger the scanning time unit, the longer is the possible
recording time.

S06 Run-out-time Prolongs the recording after the STOP triggerpoint.

in 20ms units

+ Leave all menus by <F1 + F4>

Datascope application example

Problem:
While driving in the aisle, the error E184 (truck out of WG-safety
diamond) occurs intermittantly. Therefore the behaviour of the
truck when driving on the wire must be examined with data-
scope.
Conditions:
- The recording should stop automatically, when the error
E184 occurs.
- The adjustment of the scan time (time inbetween two
scans) will be increased to 100 ms, so that a longer
recording is possible. This is possible, as the error E184
stays long enough. In case of short (flashing) errors, the
scan time must be
reduced, not to „lose“ the error inbetween two scan points.
- The run-out time (recording time after the error has
occured) should be 0.5
seconds.
- Recorded signals:
- D00:ERW184 recording
of the occured error E184
(0=OK; 1=error)
M25 Datascope
- D01:MA147: angle posi- Record
E20 START
tion between truck and E21
E22
STOP
CONTINUE

wire E23

Data
TRANSFER

D00 ERE 184

- D02:MA148: distance D01
D03
MA
MA
247
248
D04 MA 149
between center axle of D05
D06
MA
MA
150
113
D07
the truck and the wire Trigger
T00 ERE 184 = 1
T01
- D03:MA149: set value T02
T03

steering Periods
S07 Scanning period / 20 ms 5
S06 Run-out period / 20ms 25

- D04:MA150: actual value

steering F1 F2 F3 F4 F5 F6

- D05:MA128: drive speed

Setting of the stop conditions
(Trigger):
- T00:ERW184=1The recording should be terminated, when
the error occurs.
Setting of the scanning period:
- S07 scaning period: 100 ms (5 x 20ms = 100 ms)
Setting of the of the run-out period:
- S06:25: run-out period: 500 ms (25 x 20ms = 500 ms)

9.7.4 Data storage

SK- R without battery-buffered memory
All recordings and settings (apart from scanning and tracking
time) are only available until the next power-off.
SK- R with battery-buffered memory
All recordings and settings are also stored after power-off /
power-on until
- they are overwritten by another recording because of lim-
ited memory
- the user starts a new recording session.

+ A recording, which is running when the truck is switched off,

will be determined correctly. When the truck is restarted, a new
recording will be started.

The batteries on the rear side of the SK-R board (VZA, VZK)
may only be mounted during measuring operations. Use only
batteries of the type BR2032 oder CR2032 (lithium, 3V).

9.7.5 Transfer and Display of a DATASCOPE Record

After termination of the record on the vehicle either by triggering
(see application example) or manually, the transfer of to a Lap-
top/PC can be started.

+ The PC software which is required and also the connecting

cable are available from the manufacturer.

Proceed as follows:
- Start PC
- Connect cable with the serial interface of the PC
- Connect cable with the serial interface (RS232) of UDR
At the PC:
- Start Datascope software
- Select menu „Datascope“--> „Transfer“
- Determine and confirm path and file name for the file to be
transferred

+ The Datascope software is ready for the reception of the data

At the truck:
- Select Menu DATASCOPE -->“TRANSFER“

+ The recorded file is transferred to the PC

At the PC:
- Select menu „Datascope“-->“Convert“
- Select and confirm transferred file (.BIN)
- Select menu „Datascope“-->“Display“
- Select and confirm converted file (.DSC)
The recorded file is displayed and can be evaluated

10 Inputs, outputs,
flags
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 control system (DACI 27
10.5.8 MZ 108: End of aisle safety device 28
10.5.9 MZ 110: Slack chains 28

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: Main lift lowering 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 pre-

vent danger to personnel.

Indicates notes that must be heeded to prevent danger to

materials.

+ Indicates explanations.

10 Inputs, outputs, flags

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) proc-
ess operands. The processing unit control panel (VZB) is only applied for transmission of
operating actions on VZA and VZK and the displaying of informations.

Each operand consists of

- short description (SD): 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“ )

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

10.2Inputs
10.2.1Digital inputs VZA

SD Description
E100 key switch options
E101 key GESI 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 SAFETY SENSOR Left
E113 Master switch left outside
E114 Master switch left insidet
E115 Key auxiliary lift
E116 Key Main lift auxiliary lift Diagonal
E117 SAFETY SENSOR Right
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
E127 switch aisle recognition 2 , 1.recording
E128 switch aisle recognition 2 , 2.recording

SD Description
E129 switch GESI forward channel A
E130 switch GESI forward channel B
E131 switch GESI backward channel A
E132 switch GESI 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
E142 sensor unit steering measured value 3B3 Index
E143 switch S11 main lift below 0,3 m (initiation)
E145 U supply 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 GESI channel A (internal)
E150 return signal 24V release signal GESI 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)

10.2.2Digital inputs VZK

SD. Description
E200 key switch option
E201 key GESI 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 SHIFT
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 SAFETY SENSOR right
E218 Master switch right inside
E219 Master switch right outside
E225 door switch (serial circuit S4, S5) 1. recording
E226 door switch (serial circuit S4, S5) 2. recording
E227 slack chain switch (serial circuit 1. recording
E228 slack chain switch (serial circuit 2. recording)
E229 pedal key1
E230 pedal key2
E231 switch lifting stop driver protection hood
E232 key switch WG Emergency operation
E233 E_Option_X295_11
E234 E_Option_X295_10
E235 E_Option_X295_13

SD. Description
E254 Option X295:7 (occupied by optional functions main lift-incremental transmitter)
E255 Option X295:5 (occupied by optional functions main lift-incremental transmitter)
E256 return signal safety relay 1 opened to VZK
E257 return signal safety relay 2 opened to VZK
E258 return signal 24V release signal watchdog

10.2.3Analog inputs VZA

SD Description Unit
EA100 steering speed
EA101 steering acceleration
EA102 temperature sensor computer 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)
EA109 EA_potentiometer_ 3_/1 (free)
EA110 EA_potentiometer_ 3_/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

10.2.4Analog inputs VZK

SD Description Unit
EA200 auxlift measured value potentiometer 1 digit
EA201 auxlift measured value potentiometer 2 digit
EA202 side shift measured value potentiometer 1 mm
EA203 side shift measured value potentiometer 2 mm
EA204 swivelling measured value potentiometer 1 0,01°
EA205 swivelling measured value potentiometer 2 0,01°
EA206 ---
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

+ (2) not used on Hi-Racker 100

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 reserve 1
A107 release signal controller main lift
A108 flash light 4H5
A109 ---
A110 Option X170:1

SD Description
A111 Option X170:3
A112 release signal load wheel brake (valve 1Y2)
A113 release signal controller driving
A114 release signal controller steering
A115 release signal WD relay
A116 release signal full speed
A117 release steering lock
A118 personnel protection system simulation aisle switch 2
A119 personnel protection system information low speed
A120 personnel protection system simulation mast witch 1
A121 personnel protection system simulation mast switch 2
A122 release signal battery discharge control
A123 release signal safety circuit braking SF-Relais1
A124 release signal safety circuit braking SF-Relais2

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 2Y45 (Reserve 2)
A206 valve 2Y46 (Reserve 3)
A207 valve 2Y47 (Reserve 4)
A208 valve 2Y48 (Reserve 5)
A209 valve 2Y50 (Reserve 6)
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_/1 V
AA103 rated value steering 0,01°

10.3.4Analog outputs VZK

SD Description Unit
AA200 Reserve1
AA201 prop valve 1Y2.1 load wheel brake mA
AA202 writer output 2

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 lifting initiation OK
M108 key switch WG emergency operation
M109 two hand operation
M110 M_Default
M111 hand operation left
M112 load carrying device in startup position
M113 main lift active
M114 aux lift 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 GESI-braking active
M128 safety-relais no access

SD Description
M129 truck in the aisle
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 stop
M140 WG Teach-In
M141 M_code_00
M142 M_code_01
M143 M_code_ 02
M147 M_code_ 03
M148 M_code_ 04
M149 M_code_ 05
M150 M_code_ 06
M151 M_code_ 07
M152 M_code_ 08
M153 M_code_ 09
M154 M_code_ 10
M155 M_code_ 11
M156 M_code_ 12
M157 M_code_ 13
M158 M_code_ 14
M159 M_code_ 15
M160 M_code_ 16
M161 M_code_ 17
M162 M_code_ 18
M163 M_code_ 19

SD Description
M164 M_code_ 20
M165 M_code_ 21
M166 M_code_ 22
M167 M_code_ 23
M168 M_code_ 24
M169 M_code_ 25
M170 M_code_ 26
M171 M_code_ 27
M172 M_code_ 28
M173 M_code_ 29

SD Description
M222 load carrying devide basic position
M223 load carrying devide basic position right
M224 load carrying devide basic position left
M225 aux lift end ahead top
M226 aux lift end ahead bottom
M227 swivelling end ahead left
M228 swivelling end ahead right
M229 Reserve 1
M230 main lift active
M231 aux lift active
M232 foot switch
M233 barriers closed
M234 overload
M235 LED STOP VZK
M236 M_code_ 00
M237 M_code_ 01
M238 M_code_ 02
M239 M_code_ 03
M240 M_code_ 04
M241 M_code_ 05
M242 M_code_ 06
M243 M_code_ 07
M244 M_code_ 08
M245 M_code_ 09
M246 M_code_ 10
M247 M_code_ 11
M248 M_code_ 12
M249 M_code_ 13
M250 M_code_ 14
M251 M_code_ 15
M252 M_code_ 16
M253 M_code_ 17

SD Description
M254 M_code_ 18
M255 M_code_ 19
M256 M_code_ 20
M257 M_code_ 21
M258 M_code_ 22
M259 M_code_ 23
M260 M_code_ 24
M261 M_code_ 25
M262 M_code_ 26
M263 M_code_ 27
M264 M_code_ 28
M265 M_code_ 29

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 Incremental encoder steering (A) hardware
MA114 Incremental encoder steering (B) hardware
MA115 control difference steering hardware
MA116 steering number of rotations measured value hardware
MA117 status drive steering hardware
MA118 master switch left rated value hardware
MA119 master switch right rated value hardware
MA120 prop valve swivel 2Y30 mA
MA121 prop valve 2Y31 mA
MA122 Position aux lift mm
MA124 steering angle
MA125 steering angle preset from control panel 0,1°

SD Description Unit
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 (1038=standstill; 1030=forward; 1031=back- hardware
ward)
MA132 OPTISPEED height max mm
MA133 GESI braking distance mm
MA134 pressure sensor 2B10 bar
MA135 GESI braking curve limit mm
MA136 GESI braking curve difference mm
MA137 GESI braking deceleration %
MA138 GESI release speed 0,01 km/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 0,1°
MA148 WG-distance mm
MA149 WG-steering angle rated value 0,1°
MA150 WG-steering angle measured value 0,1°
MA151 WG-distance mm
MA152 GESI direction hardware
MA153 GESI switch point 1 hardware
MA154 GESI distance mm
MA155 WG-speed 0,01 km/h
MA156 driving internal set value slope hardware
MA157 AC steering controller error code hardware

SD Description Unit
MA158 AC driving controller error code hardware
MA159 aisle track 1 setoff hardware
MA160 aisle track 2 setoff hardware
MA161 aisle track 3 setoff hardware
MA162 parameter set steering hardware
MA163 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 before initiating (rough adjustment) mm
MA212 residual capacity %
MA214 revolutions pump 2M1 1/min
MA215 driving direction (1038=standstill; 1030=forward; 1031=back- hardware
ward)
MA216 rated value synchronous control hardware
MA217 set value synchronous control hardware
MA218 pressure sensor 2B10 bar
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 pump status hardware
MA225 revolution rate pump measured value hardware
MA226 AC steering controller error code hardware
MA227 position aux. lift mm
MA228 difference controller synchronous hardware
MA229 safety distance left when swivelling mm
MA230 safety distance left when swivelling mm
MA231 distance main lift incremental transmitter mm
MA232 speed main lift incremental transmitter 0,01 km/h

SD Description Unit
MA245 limit value revolutions hardware
MA246 rest capacity battery

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 E243 E244
offen
006 END: Zwei- two hand operation in aisle not OK M109
hand GA M110
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 GESI
070 FA STOP GESI has taken control over truck MZ108 GESI
GESI
087 Fahren GESI GESI counter current brake active MZ108 GESI
GSB
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 basic pos
in basic position M223 basic pos right
M223 basic pos left
091 FA VF 2.5 creep speed in apron at h3 > 3000mm EA218 main lift Incr.
or steering angle > 10Grad EA204 aux lift Poti
092 FA GA 2.5 creep speed, because critical h3 in aisle EA218 main lift Inkr.
h3krit EA204 aux lift Poti
MZ103
094 FA VF 4.0 speed limited to 4 km/h at h3 > 500 mm and EA218 main lift Inkr.
h3 < 3000 mm EA204 aux lift Poti

No. Tag Description Examine

095 FA GA fast speed wit 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 ref.
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 stop in apron
Heben MZ219 main lift Hydr
MZ217 Hydr.block
101 FA STOP pressure of load wheel brake not sufficient E161
LRB return signal pressure switch missing: lift up
main lift
148 FA GA WG fast speed wit WG in aisle released MZ113
Schnell MZ103
149 FA GA WG WG-emergency creep speed in aisle MZ113
2.5
152 FA STOP Err driving error detected, driving locked
153 FA Schl Err creep speed because of drive error
167 FA VF STOP lift height depending drive cut-out EA218 main lift INK
H3 normally adjusted to 5M EA204 aux lift Poti
--------------------------------------------------- -------------------
with code release depending on param. P68 nur mit Code19
179 FA VF WG creep speed, because WG in search opera- MZ113
2.5 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 WG wire left configuration K13
WG Faed (only WG trucks)
237 FA SCHL HH creep speed predefined, main lift not creep speed condi-
KEINE JUST adjusted, main lift initiation tions

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 E247
Fußtaster E248
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 pressure in pressure reservoir not sufficient E161
LRB Druck for braking configuration K14
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 movent load carrying dev. MZ217 hydr. block
LAM
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

10.5.3MZ 102: Steering

Nr. Tag Description Examine

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
fahrt entrance MZ103
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 Ref.
ierung
145 Lenken steering locked because of error error message EXXX
STOP Err
146 Lenken WG steering in WG-operation while truck is driv- only WG
Fahrt ing
147 Lenken WG steering in WG-operation while truck is stand- only WG
Stand ing

10.5.4MZ 103: Aisle/ Apron

Nr. Tag Description Examine

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 or WG-claw not activated configuration K11
021 Gang Aisle situation was detected and wheel is in aisle recognition
straight ahead position. On WG-trucks addi- configuration K11
tionally the claw has to be activated
A: by aisle recognition switch
B: by WG-wire
022 Vorfeld apron situation detected and drive speed aisle recognition
adjusted configuration K11

10.5.5MZ 104: Steering controller

Nr. Tag Description Examine

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

Nr. Tag Description Examine

073 Lenk. HOCH- turn steering wheel into startup position left configuration K16
LAUF
077 LRef STOP poti error (wire break ) error message
Er0 EXXX
078 LRef STOP error deviation poti, incremental transmitter error message
Er1 EXXX
079 LRef Initial. initialization phasis: configuration K16
081 LRef Index- wait, until steering sensors are in stand-still configuration K16
suche 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

10.5.7MZ 106: Drive control system (DACI

)

Nr. Tag Description Examine:

MZ100 driving
A113 driverelease
A114 Release for-
ward
A115 Release
reverse
A115 Release fast
drvie
MA100 Set value
MA130 Direction
MA128 Speed
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

10.5.8MZ 108: End of aisle safety device

Nr. Tag Description Examine

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. E147
sung Depending on the GESI-Type braking until E148
creep speed or stop. E149
A: GESI with man. Resetkey: E150
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. E102
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

10.5.9MZ 110: Slack chains

Nr. Tag Description Examine

011 Schlaffkette chains slack or slack chain switch not OK E245
E246
012 Ketten straff chains under tension

10.5.10MZ 111: control panel left side

Nr. Tag Description Examine

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

10.5.11MZ 112: control panel right side

Nr. Tag Description Examine

000 Ruhestellung no function chosen configuration K17
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 L synchronous shift left chosen configuration K17
118 Synchron-S synchronous shift right chosen configuration K17
R

10.5.12MZ 113: WG

Nr. Tag Description Examine

185 WG Hand manual operation configuration K13
186 WG wire search requested configuration K13
Anforderung
187 WG Ein- wire search in operation configuration K13
fädeln
188 WG Ausge- wire search not successful configuration K13
fädelt
189 WG Vorfeld WG-driving in apron configuration K13
190 WG Ga Ein- aisle entrance; wait for return signal from configuration K13
fahrt activated steering lock
191 WG Ga fast drive WG in aisle configuration K13
Schnell
192 WG Ga Ausf leaving the aisle v>2,5 km/h configuration K13
Schn
193 WG Ga Ausf leaving the aisle v<2,5 km/h configuration K13
Schl
194 WG Notb WG-emergency operation : manual opera- configuration K13
Hand tion
195 WG Notb WG-emergency operation: wire search configuration K13
Anfor requested
196 WG Notb WG-emergency operation: wire search in configuration K13
Fädel operation
197 WG Notb WG-emergency operation: wire detected; configuration K13
Vorfeld conditions apron;
wait for switch emergency operation =off
198 WG NStop WG-emergency operation: aisle signal configuration K13
Ga Sig
199 WG NStop WG-emergency operation: wire signal lost ->error message
Draht
201 WG NStop WG-emergency operation: claw (steering ->error message
Vo Kl lock) activated in apron
202 WG NStop WG-emergency operation: claw (steering ->error message
Ga Kl lock) not activated in aisle
219 WG Einfahrt activated claw; fullspeed locked; automatic configuration K13
steering
220 WG Schnell activated claw; fullspeed released; auto- configuration K13
matic steering

Nr. Tag Description Examine

221 WG Ausfahrt activated claw, steering automatically configuration K13
222 WG Ausf lift claw, steering automatically configuration K13
Klaue

10.5.13MZ 114: WG estimation value; estimation gear angle/distance in apron

Nr. Tag Description Examine

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

10.5.14MZ 115: WG strategy

Nr. Tag Description Examine

208 WG LNK manual steering configuration K13
Manuell
209 WG LNK wire search; swivelling to wire; positive configuration K13
Schw Pos steering angle
210 WG LNK wire search; swivelling to wire; negative configuration K13
Schw Neg steering angle
211 WG LNK Lin steering via linear controller configuration K13
Regl

10.5.15MZ 116, 117, 118, 119

+ Only for test purposes of the manufacturer.

10.6Control system states of the VZK

10.6.1MZ 200: Lifting the main lift

Nr. Tag Description Examine

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 E243
offen E244
005 END: Zwei- Stop two hand operation violated M109
hand M110
M111
008 END: Stillstd lift cut-out in apron, when truck is driving MA130
VF (diagonal drive lock)
009 END: Über- Stop overload (not HR100)
last
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 basic position: M222
LAM lifting only in creep speed M223
M224
048 HH H SL end ahead top reached: lifting only in creep EA218
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 M132
batt
052 HH H lift cut-out has been activated MZ215
Abschaltung
053 HH H critical height reached, but drive speed still EA218
END:h3 krit above 2,5 km/h M122
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 E249
FSD

Nr. Tag Description Examine

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 EA218

177 Schleich Teach-In in operation: only creep speed configuration K4
TEACHIN movements

10.6.2MZ 201: Main lift lowering

Nr. Tag Description Examine

001 STP: Notstop emergency stop error detected error message
EXXX
002 STP: Ketten chains not under tension MZ214
M119
003 STP: Tür at least 1 barrier is opened E243
offen E244
005 END: Zwei- Stop two hand operation violated M109
hand M110
M111
008 END: Stillstd lowering cut-out in apron, while truck is driv- MA130
VF ing (diagonal drive lock) configuration K4
010 STP: Code Software emergency stop error message
e.g. while loading of default values EXXX
044 HH S SL end ahead bottom reached: lowering only in EA218
Vorende creep speed M121
045 HH S Schnell maximum lowering speed permitted configuration K4
047 HH S Schl load carrying device not in basic 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

Nr. Tag Description Examine

177 Schleich Teach-In-procedure running: movements configuration K4
TEACH IN only in creep speed

10.6.3MZ 202: Lifting auxiliary lift

Nr. Tag Description Examine

001 STP: Notstop emergency stop error detected error message
EXXX
002 STP: Ketten chains are not under tension MZ214
M119
003 STP: Tür at least 1 barrier is opened E243
offen E244
005 END: Zwei- Stop two hand operation violated M109
hand M110
M111
008 END: Stillstd Lift cut-out in apron, when truck is in move- MA130
VF ment (diagonal drive lock) configuration K5
009 END: Über- Stop overload (not HR100) error message
last EXXX
010 STP: Code Software emergency stop error message
e.g. error while loading of default values EXXX
037 ZH H Schl load carrying device not in basic position: M222
LAM aux lift lifting only in creep speed M223
M224
configuration K5
038 ZH H SL end ahead top reached: creep speed EA204
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 EA204
configuration K5
177 Schleich Teach-In-procedure running: movements configuration K5
TEACHIN only in creep speed
217 ZH HEBEN aux lift-cut-out has been activated configuration K5
ENDE ABS

Nr. Tag Description Examine

218 ZH end ahead of cut-out height reached: creep configuration K5
HEB10EN speed
VORENDE
ABS

10.6.4MZ 203:Lowering the auxiliary lift

Nr. Tag Description Examine

001 STP: Notstop emergency stop error detected error message
EXXX
002 STP: Ketten chains are not under tension MZ214
M119
003 STP: Tür at least 1 barrier is opened E243
offen E244
005 END: Zwei- Stop two hand operation violated M109
hand M110
M111
008 END: Stillstd lowering cut-out in apron, when truck is in MA130
VF operation (diagonal drive lock)
010 STP: Code Software emergency stop error message
e.g. while loading of default values EXXX
034 ZH S Schl load carrying device not in basic position: M222
LAM aux lift lowering only in creep speed M223
M224
035 ZH S SL end ahead reached: creep speed EA204
Vorende M226
036 ZH S Schnell maximum lowering speed permitted configuration K5
040 ZH Senken cut-out: lower limit reached EA204
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
177 Schleich Teach-In-procedure running: movements configuration K5
TEACHIN

10.6.5MZ 204: Swivelling

Nr. Tag Description Examine

001 STP: Notstop emergency stop error detected error message
EXXX
002 STP: Ketten chains not under tension MZ214
M119
003 STP: Tür at least 1 barrier is opened E243
offen E244
005 END: Zwei- Stop two hand operation violated M109
hand M110
M111
007 END: Still- MA130
stand
010 STP: Code Software emergency stop error message
e.g. while loading of default values EXXX
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 EA218
4m EA204
configuration K7
027 DR L SL end ahead left reached: creep speed EA208
Vorende M227
028 DR R SL end ahead right reached: creep speed EA208
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
177 Schleich Teach-In-procedure running: movements configuration K7
TEACHIN only in creep speed

10.6.6MZ 205: Side shift

Nr. Tag Description Examine

001 STP: Not- emergency stop error detected error message
stop EXXX
002 STP: Ketten chains not under tension MZ214
M119
003 STP: Tür at least 1 barrier is opened E243
offen E244
007 END: Still- truck has to stand still MA130
stand
010 STP: Code Software emergency stop error message
e.g. while loading of default values EXXX
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 error message
Err EXXX
165 SS Schl Err error detection reports: side shift only in configuration K6
creep speed
177 Schleich Teach-In-procedure running: movements configuration K6
TEACHIN only in creep speed

10.6.7MZ 206: Synchronous swivelling

Nr. Tag Description Examine

001 STP: Notstop emergency stop error detected error message
EXXX
002 STP: Ketten chains not under tension MZ214
M119
003 STP: Tür at least 1 barrier is opened E243
offen E244
005 END: Zwei- Stop two hand operation violated M109
hand M110
M111
007 END: Still- truck has to stand still MA130
stand
010 STP: Code Software emergency stop error message
e.g. while loading of default values EXXX
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

Nr. Tag Description Examine

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

Nr. Tag Description Examine

000 Ruhestellung Module without activation and function configuration K6,K9
ended
014 SLEEP Module without activation and function configuration K6,K9
054 Schieben function side shift right configuration K6,K9
rechts
055 Schieben function side shift left configuration K6,K9
links
063 Druck Abbau pressure reduction after movement configuration K6,K9
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

Nr. Tag Description Examine

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.

10.6.11MZ 211: Synchronous swivelling hydraulic control

Nr. Tag Description Examine

000 Ruhestellung Module without activation and function configuration K8,K9
ended
014 SLEEP Module without activation and function configuration K8,K9
063 Druck Abbau pressure reduction after movement configuration K8,K9
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)
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

Nr. Tag Description Examine

000 Ruhestellung Module finished without activation and func- configuration K9
tion
032 ZH Heben Auxiliary lift lifting preselected configuration K18
033 ZH Senken Auxililiary lift lowering active configuration K9
041 HH Heben Main lift lifting active configuration K9
042 HH Senken Main lift lowering active configuration K9

10.6.13MZ 213: Control panel right side

Nr. Tag Description Examine

000 Ruhestellung Module finished without activation and func- configuration K9
tion
030 Drehen Swivelling right active configuration K9
rechts
031 Drehen links Swivelling left active configuration K9
054 Schieben Shifting right active configuration K9
rechts
055 Schieben Shifting left active configuration K9
links
085 Fahren Vor- Driving forward preselected configuration K17
wärts
086 Fahren Driving backward preselected configuration K17
Rückwärts
117 Synchron-S Synchronous shift left active configuration K9
L
118 Synchron-S Synchronous shift right active configuration K9
R

10.6.14Slack chains

Nr. Tag Description Examine

011 Schlaffkette Chains slack or chain switch not OK
012 Ketten straff Chains tight

10.6.15MZ 215: Lift cut-out main lift

Nr. Tag Description Examine

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 E103
height cut-out
127 HH ABS Stop cut-out at height A carried out configuration K4
A

Nr. Tag Description Examine

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

10.6.16MZ 216:Pump motor controller

Nr. Tag Description Examine

059 Pumpe: AN Pump unit activated
060 Pumpe: AUS Pump unit off

10.6.17 MZ 217: Hydraulic lift module block function

Nr. Tag Description Examine

000 Ruhestellung no function active configuration K9
030 Drehen swivel right active configuration K9
rechts
031 Drehen links swivel left active configuration K9
032 ZH Heben lifting the aux lift active configuration K9
033 ZH Senken lowering the aux lift active configuration K9
041 HH Heben lifting the main lift active configuration K9
042 HH Senken lowering the main lift active configuration K9
054 Schieben side shift right active configuration K9
rechts
055 Schieben side shift left active configuration K9
links
117 Synchron-S L swivel synchr. left active configuration K9
118 Synchron-S swivel synchr. right active configuration K9
R

10.6.18MZ 218: Side shift cut-out

Nr. Tag Description Examine

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

Nr. Tag Description Examine

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

10.6.19MZ 219: Main lift hydraulic controller

Nr. Tag Description Examine

000 Ruhestellung Module without activation and function configuration K4
ended
014 SLEEP Module without activation and function configuration K4
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
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

11 Service parameters
Removal / installation of components other than those listed in
the spare parts catalogue is not permitted.

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

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

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.

11 Service parameters

11.3 Service display configurations

+ Remarks in column „unit“:

(1) Size not standardized; only hardware signal available

11.1.1 K1: Operating hour meters, battery monitor

Operand Description Unit

MA100 Operating hour meters BZ 0 h
MA101 Operating hour meters BZ 1 h
MA102 Operating hour meters BZ 2 h
MA103 Operating hour meters BZ 3 h
MA104 Operating hour meters BZ 4 h

EA117 Measuring input battery voltage VZA V

MA110 Battery voltage filtered V
MA111 Calculated rest battery capacity %
M132 1= Deep discharging recognized

11.1.2 K2: Driving / brakes

Oper- Description Unit

and
MZ100 Status driving
MZ101 Status brake
MZ106 Status Drive control DACI
MA127 Rated value drive control 0.01V
MA128 Driving velocity (km/h) 0.01km/h
E169 0 =temperature driving motor too high
MZ171 State of Drive system control Driving: 0 = OK/ any others = Error
MA130 Driving direction (85=forward; 86=backward; 0=standing)
MA158 Error code Schwarzmüller drive control (1)

+ See also K14: Safety circuit brake

11.1.2 K3: Steering

Oper- Description Unit

and
MZ102 Status steering
MZ104 Status steering control
MZ105 Status steering reference
MA125 Steering angle specified rated value/° 0.1°
AA104 Steering rated value (±10V) 0.01°
EA106 Actual-value sensor steering potentiometer 0.1°
EA107 Actual-value sensor steering incremental transmitter 0.1°
M126 Steering angle drive wheel less than ±10°
M127 Steering angle drive wheel straight ahead
MZ116 Status of drive control steering: 0 = OK/otherwise error
MA157 Error code drive control steering (Schwarzmüller) (1)

11.1.4 K4: Main lift

Oper- Description Unit

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 rated value min-1
MA225 Revolution rate pump actual value min-1
AA101 Set point prop. valve 2Y31 mA
MA232 Main lift velocity/ 0.01m/s
M2070 1 = Main lift reference ok
EA104 Main lift sensor potentiometer mm
EA212 Main lift sensor incremental transmitter (only software) mm
E143 Main lift sensor switch 0,3 m (0 = higher than 0,3m)
MZ220 Status drive control pump: 0 = OK/otherwise error
MA226 Error code drive control pump (1)

11.1.5 K5: Auxiliary lift

Oper- Description Unit

and
MZ202 Status aux. lift lifting
MZ203 Status aux. lift lowering
MZ210 Status aux. lift hydraulic system
MZ216 Status pump control
MA214 Revolution rate pump rated value/ min-1 min-1
MA225 Revolution rate pump actual value/ min-1 min-1
AA101 Set point prop. valve 2Y31/mA mA
EA200 Aux. lift sensor potentiometer 1 mm
EA201 Aux. lift sensor potentiometer 2 mm
MZ220 Status drive control pump: 0 = OK/otherwise error
MA159 Error code drive control pump (Schwarzmüller) (1)

11.1.6 K6: Side shift

Oper- Description Unit

and
MZ205 Status side shift
MZ209 Status side shift hydraulic system
MZ216 Status pump control
MZ218 Status shift cut-out
MA214 Revolution rate pump rated value min-1
MA225 Revolution rate pump actual value min-1
AA101 Set point prop. valve 2Y31 mA
EA202 Side shift sensor system potentiometer 1 mm
EA203 Side shift sensor system potentiometer 2 mm
MM222 1 = LAM in starting position

11.1.7 K7: Swivelling

Oper- Description Unit

and
MZ204 Status swivelling
MZ208 Status swivelling hydraulic system
MZ216 Status pump control
MZ116 Status hydraulic block
MA214 Revolution rate pump rated value min-1
MA225 Revolution rate pump actual value min-1
AA100 Set point prop. valve 2Y30 mA
EA204 Sensor system swivelling potentiometer 1 °x10
EA205 Sensor system swivelling potentiometer 2 °x10
EA103 Pressure sensor 2B10 bar
M222 1 = LAM in starting position

11.1.8 K8: Swivelling side shift synchronization

Oper- Description Unit

and
MZ208 Status synchronous swivelling
MZ211 Status synchronous swivelling hydraulic
MZ216 Status pump control
MZ116 Status hydraulic block
MA214 Revolution rate pump rated value min-1
MA225 Revolution rate pump actual value min-1
AA100 Set point prop. valve 2Y30 mA
AA101 Set point prop. valve 2Y31 mA
EA202 Sensor system side shift potentiometer 1 mm
EA208 Sensor system swivelling potentiometer 2 °x10
MA228 Synchronous control difference mm
MA229 Distance reserve left mm
MA230 Distance reserve right mm

11.1.9 K9: Hydraulik components part 1 (motions)

Oper- Description Unit

and
A100 Valve 2Y34
A101 Valve 2Y35
A102 Valve 2Y32
A103 Valve 2Y33
A104 Valve 2Y36
A105 Valve 2Y52
A117 Valve 1Y4
A200 Valve 2Y40
A201 Valve 2Y41
A202 Valve 2Y42
A203 Valve 2Y43
AA101 Prop. valve 2Y30 mA
AA102 Prop. valve 2Y31 mA
EA119 Pressure sensor 2B10 bar

Oper- Description Unit

and
MZ217 Status hydraulic block
EA105 Rotations pump actual value min-1

11.1.10 K10: Load wheel brake

Oper- Description Unit

and
A112 Release load wheel brake
E140 Load wheel brake active
E145 Supply voltage OK

11.1.11 K11: Aisle recognition

Oper- Description Unit

and
MZ103 Status aisle / apron
E125 Aisle recognition track 1, switch A
E126 Aisle recognition track 1, switch B
E127 Aisle recognition track 2, switch A
E128 Aisle recognition track 2, switch B
E152 Aisle recognition track 3, switch A
E153 Aisle recognition track 3, switch B
MA159 Distance measuring offset aisle recognition track 1 mm
MA160 Distance measuring offset aisle recognition track 2 mm
MA161 Distance measuring offset aisle recognition track 3 mm
MA131 Stock zone (1)
M129 Truck in the aisle

11.1.12 K12: End of aisle braking

Oper- Description Unit

and
MZ108 Status end of aisle braking
MZ100 Status driving
E129 key end of aisle A1
E130 key end of aisle A2
E131 key end of aisle B1
E132 key end of aisle B2
MA133 Braking distance counter-current braking mm
EA113 Actual travelling speed 0,01km/h
MA136 Difference between actual and permissible speed mm
MA137 Measured mean deceleration %
MA138 Speed in the brake-activating moment 0.01km/h
(starting speed)

11.1.13 K13: Inductive guidance (IF)

Oper- Description Unit

and
MZ113 Status IF
MZ114 Status IF 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 IF steering angle rated value 0,1°
MA150 IF steering angle actual value 0.1°
EA113 Travelling speed 0.01km/h
E163 Switch feedback claw (1 = claw open)
E250 Switch IF emergency
A204 Acoustic signal IF

11.1.14 K14: Safety circuit brakes

Oper- Description Unit

and
MZ100 Status driving
MZ101 Status brake
E229 Feedback pedal key 1 (1 = pressed)
E230 Feedback pedal key 2 (1 = pressed)
A123 Release safety relay 1 by VZA (1 = released)
A124 Release safety relay 2 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)

+ See also K10 hydraulic components2 (load wheel brake)

11.1.15 K15: Personnel protection system (PSA)

Oper- Description Unit

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
A120 Aisle signal to PSA
A121 Slow speed signal by SECAN to PSA
A122 Height signal 1 by SECAN to PSA
A123 Height signal 2 by SECAN to PSA

11.1.16 K16: AC-control systems

Oper- Description Unit

and
MZ216 Status pump control
A106 Release rotating direction main lift
A107 Release regulator main lift
AA105 Revolution rate pump rated value min-1
EA105 Revolution rate pump min-1

MZ106 Status drive control

A113 Release regulator driving
AA100 Rated value driving
EA113 Travelling speed 0.01km/h

MZ104 Status regulator steering

A125 Release regulator steering
AA104 Rated value steering 0.01°
EA107 Actual value steering angle position 0.1°

11.1.17 K17: Right control panel

Oper- Description Unit

and
E102 Key GESI reset
E103 Key lifting cut-out override
E104 Key slack chain override
E105 Key tine adjustment device
E107 Key 2. stacking depth
E115 Key aux. lift
E109 Key Main / aux. lift synchronously
E117 Key two-handed operation right
E218 Direction switch of master switch right, inside
E219 Direction switch of master switch right, outside
MA221 digit
Rated value master switch right

MZ112 Status master switch right

11.1.18 K18: Left control panel

Oper- Description Unit

and
E103 Key driving override
E106 Key steering straight-on / IF-operation
E108 Key synchronous swivelling
E116 Key Main/aux. lift synchr. in the aisle
E110 Key lateral traversing
E111 Key swivelling
E112 Key two-handed operation left
E113 Direction switch of master switch left, outward
E114 Direction switch of master switch left, inward
MA220 Rated value master switch left digit
MZ111 Status master switch left
Key synchronous swivel with central position cut-out

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

11.2.2 Shortcuts in parameter

Short cut. Meaning

CO Cut-out
RR Revolution rate
I Current
ML Main lift
LBD Load bearing device brake
LWB Load wheel brake
SMS 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

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
M11 Load wheel brake
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 Optispeed
M21 Options
M22 Hour Meters
M23 Language

M24 Status display

M25 Datascope

E00 Default All

M27 Development

11.2.5 M 01: Control panel

PNr. APE text Meaning / measure Unit

“Master switches”
TI70 “TI left inward” Move left lever downwards to the stop; then
acknowledge with ENTER
TI71 “TI left outward” Move left lever upwards to the stop; then
acknowledge with ENTER
TI72 “TI right outward” Move right lever downwards to the stop; then
acknowledge with ENTER
TI73 “TI right inward” Move right lever upwards to the stop; then
acknowledge with ENTER
E40 NV CRC Refresh
S30 Refresh CRC NVRAM IF Error Er 230 appears, give information to the
service department befor activating the refresh
function. See chapter 8, Er 230)
CRC-RS232 Test RS232-function of right control panel side
(UDR) see chapter 9.
“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:

11.2.6 M 02: Sideshift

PNr. APE text Meaning / measure Unit

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 current regula-
tor.
V01 "Speed max right" “
V02 "Slowspeed left" “
V03 "Slowspeed right" “
I00 "Current min 2Y30" Current regulator offset, minimum control cur- mA
rent 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

E01 “Default” Default settings (standard values) are loaded

11.2.7 M 03: Swivelling

PNr. APE text Meaning / measure Unit

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

R06 "Accel. ramp" “
V04 "Speed max left" Higher values equal a higher speed. Setting in %
% of the set control range of the curent regula-
tor.
V05 "Speed max right" “ %
V06 "Slowspeed left" “ %
V07 "Slowspeed right" “ %
I02 "Current min 2Y30" Current regulator 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

E01 “Default” Default settings are loaded

11.2.8 M 04: Main lift

PNr. APE text Meaning / measure Unit

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 current regulator 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"

E01 Default default settings are loaded

11.2.9 M 05: Auxiliary lift

PNr. APE text Meaning / measure Unit

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

E01 “Default” default settings are loaded

11.2.10 M 07: Hydraulic System Synchr. Swivel

PNr. APE text Meaning / measure Unit

“Sideshift:”
R17 "Braking ramp" Higher value means steeper ramp
R19 "Accel. 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
V21 "Offset" In the circumference of zero %

"Swivel:“
R16 "Braking ramp" Higher value means steeper ramp
R18 "Accel. 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 "

E01 “Default” default settings are loaded

11.2.11 M 08: Geometry Synchr. Swivel

PNr. APE text Meaning / measure Unit

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

PNr. APE text Meaning / measure Unit

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
G83 "Alpha2" Projected value
G84 "Radius2" Projected value
G85 "Alpha3" Projected value
G86 "Radius3" 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" Storage zone for synchronous cut-out

11.2.12 M 09: Fork tine adjust. (FTA)

PNr. APE text Meaning / measure Unit

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

E01 “Default” Default settings are loaded

11.2.13 M 10: Driving

PNr. APE text Meaning / measure Unit

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"

E01 “Default” Default settings are loaded

11.2.14 M 11: Load wheel brake (LWB)

PNr. APE text Meaning / measure Unit

P130 "pressure 2B11 LWB” See chapter 5 bar
V58 "Braking effect" “ %
I13 "Current min 1Y2.1" “ mA
I14 "Current max 1Y2.1" “ mA

11.2.15 M 12: Steering

PNr. APE text Meaning / measure Unit

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)
P04 "Bias voltage" Minimum value, that is necessary to actuate
the steering aggregate (with AC devices addi-
tional amplification of the set value)
"Steering refer"
P05 "Steering speed" Higher values mean a higher maximum steer-
ing speed
P06 "Steering ramp" Higher values mean stronger acceleration and
a higher dynamism

PNr. APE text Meaning / measure Unit

P07 "Amplification" Higher values mean more aggressive steering;
if the value is too high, the steering controller
may start to vibrate!
P08 "Dead zone" Parameter used to set a hysteresis for manual
steering (steering reacts only when this value is
exeeded)
P09 "Bias voltage" Minimum value, that is necessary to actuate
the steering aggregate (amplifies the set value)

"Steering IF apron"
P10 "Steering speed" Higher values mean a higher maximum steer-
ing speed
P11 "Steering ramp" Higher values mean stronger acceleration and
a higher dynamism
P12 "Amplification" Higher values mean more aggressive steering;
if the value is too high, the steering controller
may start to vibrate!
P13 "Dead zone" Parameter used to set a hysteresis for manual
steering (steering reacts only when this value is
exeeded)
P14 "Bias voltage" Minimum value, that is necessary to actuate
the steering aggregate (amplifies the set value)

"Steering IF aisle"
P15 "Steering speed" Higher values mean a higher maximum steer-
ing speed
P16 "Steering ramp" Higher values mean stronger acceleration and
a higher dynamism
P17 "Amplification" Higher values mean more aggressive steering;
if the value is too high, the steering controller
may start to vibrate!
P18 "Dead zone" Parameter used to set a hysteresis for manual
steering (steering reacts only when this value is
exeeded)
P17 "Bias voltage" Minimum value, that is necessary to actuate
the steering aggregate (amplifies the set value)
E01 “Default” Default settings are loaded

11.2.16 M 13: Pump

PNr. APE text Meaning / measure Unit

R52 "RPM Accel. ramp" min-1
R53 "RPM Braking ramp" min-1
P93 "Pressure 2B10" (bar) bar

E01 “Default” Default settings are loaded

11.2.17 M 15: Inductive Guidance

PNr. APE text Meaning / measure Unit

"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

PNr. APE text Meaning / measure Unit

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
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

E01 “Default” Default settings are loaded

11.2.18 M 16: Driving cut-out

PNr. APE text Meaning / measure Unit

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.
Possible settings: 0 - 255
Setting "255" means that the cut-out function is
always effective
Detailed explanations regarding aisle recogni-
tion and storage zones are printed in chapter 6.
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

PNr. APE text Meaning / measure Unit

TI20 "Teach-In height A" Move the main hoist frame to the desired lifting
height and confirm with ENTER.

PNr. APE text Meaning / measure Unit

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
Possible settings: 0 - 255
Setting "255" means that the cut-out function is
always effective
Detailed explanations regarding aisle recogni-
tion and storage zones are printed in chapter 6.
P45 "Override for A" Defines whether the cut-out function may be
overriden; override is effected by means of a
key in the control desk.

TI21 "Teach-In height B" Same as „A“

G41 "Cut-out height B" Same as „A“ mm
P41 "Stock zone for B" Same as „A“
P46 "Override for B" Same as „A“

TI22 "Teach-In height C" Same as „A“

G42 "Cut-out height C" Same as „A“ mm
P42 "Stock zone for C" Same as „A“
P47 "Override for C" Same as „A“

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“

PNr. APE text Meaning / measure Unit

P56 "C-O active ML+AL Yes/no
E"

G45 "End ahead cut-out" The set ahead-end distance applies to all cut-
out heights.

11.2.20 M 18: Lowering Cut-Out

PNr. APE text Meaning / measure Unit

TI25 "Teach-In height A" Move the main hoist frame to the desired lifting
height and confirm with ENTER.
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
Possible settings: 0 - 255
Setting "255" means that the cut-out function is
always effective.
Detailed explanations regarding aisle recogni-
tion and storage zones can be found in chapter
6.
P53 "Override for A" Defines whether the cut-out function may be
overriden; override is effected by means of a
key in the control desk.

TI26 "Teach-In height B" Same as „A“

G47 "Cut-out height B" Same as „A“ mm
P51 "Stock zone for B" Same as „A“
P54 "Override for B" Same as „A“

TI27 "Teach-In height C" Same as „A“

G48 "Cut-out height C" Same as „A“ mm
P52 "Stock zone for C" Same as „A“
P55 "Override for C" Same as „A“

PNr. APE text Meaning / measure Unit

G49 "End ahead cut-out." Ahead end distance for all cut-out heights mm

11.2.21 M 19: Side Shift Cut-Out

PNr. APE text Meaning / measure Unit

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: Optispeed

PNr. APE text Meaning / measure Unit

G50 “Height forwMinLoad” Diagonal driving height in load direction without mm
load on forks
G51 “Height backMin- Diagonal driving height in bachward direction mm
Load” without load on forks
G52 “Height forwMax- Diagonal driving height in load direction with mm
Load” maximum load on forks
G53 “Height backMax- Diagonal driving height in bachward direction mm
Load” with maximum load on forks
P68 “Height c-o apron” Driving cut-out in apron mm
P69 “Override c-o apron” Override of driving cut-out in apron

11.2.23 M 21: Options, Release Codes, Personnel

Protection System

PNr. APE text Meaning / measure Unit

“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
C08 “EndAisle Autoreset” Enter release code
C09 “OPTISPEED” Enter release code

PNr. APE text Meaning / measure Unit

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
C21 “Overload” Enter release code
C22 “Aisle recogn. wire” Enter release code
C23 “Aisle manual” Enter release code
C24 “nc24” Enter release code
C25 “nc25” Enter release code
C26 “nc26” Enter release code
C27 “nc27” Enter release code
C28 “nc28” Enter release code
C29 “nc29” 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”

11.2.24 M 22: Hour meters

PNr. APE text Meaning / measure Unit

BZ00 "Movement duration" Readout of values possible h
BZ01 "SwitchOn duration" Readout and editing of values possible h
BZ02 "Steering" Readout and editing of values possible h
BZ03 "Driving" Readout and editing of values possible h
BZ04 "Pump" Readout and editing of values possible h

11.2.25 M 23: Language

PNr. APE text Meaning / measure Unit

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.

11.2.26 M24: Status display

+ In this sub menu, system variables can be displayed.

PNr. APE text

+ 11.2.27 M 25: Datascope

Meaning / measure Unit

“Record”
E20 Start See chapter 9
E21 Stop
E22 Continue
E23 Transfer

"Data"
D00
D01
D02
D03
D04
D05
D06
D07

"Triggering”
T00
T01
T02
T03

S07 "Scan time x 20 ms”

S06 "Run-out time ms”

50 qmm
Ä2
contactor
50 qmm W73 W77
25 qmm 50A 6 qmm
12 Operating Diagrams

W70 + + 3F1 +
1F1 160A 2F1 300A
X1
1

1A1 2A1 3A1

AC-control AC-control AC-control
12 Operating Diagrams

driving pump steering

1
+ cable tree1W1 cable tree2W1
-
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 28V 24V 28V
4,5kW 13,5kW 0,8kW
1500U/min 2200U/min 3600U/min
50 qmm
W74 W76 W78
25 qmm 50 qmm 6 qmm
Ä1: Fuse 3F1 on control unit pump
12 Operating Diagrams

Perm.Batt. Voltage 48V

2 of 22

Battery Voltage 48V

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
F20
3

U_Batt for release main contactor

F11

2
(4) 3A U_Batt magtetic brake
4

0 V power cabin (9)

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)

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

3
0 V reserve cabin (13)

X101
X12
cable tree

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

6
(2) drive compartment (18)
3A
F16

24 V pers.protection systems
X14
5

(19)
3A
F26

24 V fan 0V Prop. valves

drive compartment (20)

F17

0 V fan 24 V control drive compartment

5
(21)
3A
F18

24 V flash light
11

(22)
3A
X15

F27

48V Release motorconrols

see page

cable tree
5A
2

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
X30 AMP Mate-N-Lok 4-polig
X16 AMP Mate-N-Lok 3-polig
X8, X9, X10, AMP Mate-N-Lok 5-polig
X101 AMP Mate-N-Lok 12-polig
X100 AMP Mate-N-Lok 12-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 cont
X16

(2)
U_Batt after main cont
1

(1)
3

(3)
Batt_GN

X298A
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
(5) 0V Power 4 5
(6) 24 V valves cabin 3
X11
2
(7) 0 V working light 7
3
12 Operating Diagrams

(5)

motherboard cabin VZK (U200)

(6) 9
5 cable tree W4
fuse board U 1

6
X298B
U1
7 (8) 1

3
8 (9) 5
9 (10) 4
10 (6) 3
(9) 6
X4.1b X227.1 X227 X295
1 (13) Channel A 1 (ye) 5
Encoder (14) Channel B U3 1 (gy)
2 2 6
cabin lift Filter
see page 5 (15) Index 2 (pk)
Connectors: 3 3 7
X4.1b: Mate-N-Lok 3-p. 3
X11: Mate-N-Lok 10-p. (11,12,16,17,18) in cable tree
X198: Mate-N-Lok 2-p. not in use (on clamping joint) W34
X216: Mate-N-Lok 2-p.
X227: Mate-N-Lok 3-p.
X227.1: Mate-N-Lok 3-p. X216
X295: Sub-Min-D 15-p. GND (1) 2
X298A: Mate-N-Lok 9-p.
X298B: Mate-N-Lok 6-p.
1 2 3 4 5 6 7 8
see page 10
4 of 22

2
1

X199A X199B
X199 X299
1 (wt) CAN H (wt) 1
(bn) CAN L (bn)
motherboard drive compartment VZA (U100)

2 2

motherboard cabin VZK (U200)

3 (gn) Supply (gn) 3
4 (ye) Ground (ye) 4
5 (gy) emergency 1 release (gy) 5
12 Operating Diagrams

© BT Industries AB 200421-040
6 (pk) emergency 1 feedback (pk) 6
U100 U200
7 (bu) emergency 2 release (bu) 7
8 (rd) emergency 2 feedback (rd) 8
9 (shield) 9

4
cable W5
Connectors:
X199: Mate-N-Lok 9-p.
X299: Mate-N-Lok 9-p.
X199A: Mate-N-Lok 2-p.
X199B: Mate-N-Lok 2-p.
1 2 3 4 5 6 7 8
5 of 22

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
motherboard drive compartment VZA (U100)

X4.1b X4.2a
1 Channel A (ye) 1 (gn)
in mast cable 2 Channel B (gy) 2 (ye) B2
see page 3
12 Operating Diagrams

Index (pk) (pk) increm.

© BT Industries AB 200421-040
3 3
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
Connectors: W104 soldering tags
X4.1b:Mate-N-Lok 3-p.
X4.2a:Mate-N-Lok 6-p.
X13: Mate-N-Lok 2-p.
X104: Mate-N-Lok 6-p.
X104.1: Mate-N-Lok 3-p.
X104.2: Mate-N-Lok 3-p.
X105: Mate-N-Lok 2-p.
X105.1: Mate-N-Lok 2-p.
1 2 3 4 5 6 7 8
1
X8.1
6 of 22

(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

motherboard drive compartment VZA (U100)

magnetic (bu) (4) 0V control
switch aisle
4
reognition
X8.2
(bk) 1 (1) aisle signal A3
S5.3
magnetic (bu) (2) 0V control
switch aisle
2
12 Operating Diagrams

X116
S5.4
magnetic (bu) (4) 0V control
switch aisle
4 3
reognition
X118 attentio
cable W8 jumper, if no AE

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
AEB (bu) 2 (4) 0V control 6 6
switch
7 7
X20.3
(bk) 1 (5) Signal S6.3 8 8
Connectors: S6.3
AEB (bu) 2 (6) 0V control 9 9
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
X118: Mate-N-Lok 12-p.
1 2 3 4 5 6 7 8
Ä1: W102B integriert clamping joint
7 of 22

(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)

motherboard drive compartment VZA (U100)

X513 24 V flash light (1) 1

X113
4H4
1 Flashlight Output ON (0V) (2) 2
Flashlight
12 Operating Diagrams

7
S2a
Switch 22 (2)
Emergency
cable W102A

2
1
X102A
7A1 ON

ON
see page 2 DC/DC-
conv.
(1)
Connectors:
(1) release main contactor (U_Batt) 12
A1: Faston 6,3
A2: Faston 6,3 K1

X102
ON: Faston 6,3
X102: Mate-N-Lok 12-p. coil
X102A: Mate-N-Lok 2-p. main contactor V102 (BZW50-100 B) (2) 0 V power 2 (2) 4
X111: Mate-N-Lok 2-p.
X113: Mate-N-Lok 2-p. A2 cable W102
X513: Mate-N-Lok 2-p.
1 2 3 4 5 6 7 8
auxiliary lift

1 X 25 valve plug (1) 24V valves drive compartment (1) 4

X130
2Y32
8 of 22

lifting 3 (3) 2Y32 on (3) 11

X132
2Y33 2 (2) 2Y33 on (2) 2
lowering
1N4003

motherboard drive compartment VZA (U100)

1 X 32 valve plug (4) 24V valves drive compartment (4) 5

X130
2Y34
main lift

lifting 3 (6) 2Y34 on (6) 10

2Y35 2 (5) 2Y35 on (5) 4
lowering
1N4003

X132
12 Operating Diagrams

© BT Industries AB 200421-040
cable
W 15 "a"
1 X 33 valve plug (7) 24 V prop. valve (7) 5
2 Y 31
prop. valve 2 (8) setpoint (OC) (8) 6
all functions
1N4003

8
1 X 27 valve plug (9) 24V valves drive compartment (9) 2
2 Y 36
valve 2 (10) 2Y52 on (10) 12
LAM

X130
1N4003
1 X 28 valve plug (11) 24V valves drive compartment (11) 1
2 Y 52
valve 2 (12) 2Y30 on (12) 9
pump idling
Connectors: 1N4003
X25: valve plug 1 X 29 valve plug (13) 24 V prop. valve (13) 3
X32: valve plug 2 Y 30
X33: valve plug prop. valve 2 (14) setpoint (OC) (14) 6
X27: valve plug swivelling
X28: valve plug 1N4003
X29: valve plug
X34: Mate-N-Lok 3-p.
X130: Mate-N-Lok 12-p. 3 X 34 (1) Voltage 5V 1
X132: Mate-N-Lok 6-p.

X110
X110: Mate-N-Lok 3-p. 2 B 10 2 (2) 1 - 5V 2
pressure 1 (3) 0 V 3
sensor
cable
W 110
1 2 3 4 5 6 7 8
X199A
CAN H (1) 6 X107.2
3 Channel A (1) 3 (bu)
9 of 22

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 motor
see page 42 14 11
2 X141

Drive control
2 X76 1 high temp. (0V) (5) 7 (wt)
cable tree W5A 6 U100 S9
X76j siehe 0V (6) (wt) temp. switc
8 2 8 driv. moto
Blatt 23

1A1
VZA
7

X79
cable W18
4
U_Batt (48V) X51
3
Connectors: 1 (1) U1
12 Operating Diagrams

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

9
X71: Mini-Fit 6-p

X89
CAN H 7
X74: Mini-Fit 8-p X165
X76: Mini-Fit 12-p cable tree W5B CAN H (1) Channel A (bu)

2A1 AC-control
6 3 3
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
X91: Mini-Fit 6-p (4) (bk)

X86
X86j 14 11 8 0V 2
X94: Mini-Fit 8-p 2 pump motor
X95: Mini-Fit 8-p 2 (5) Pt100 + cable W20
X96: Mini-Fit 12-p siehe 5 (rd)
X107.2: Mate-N-Lok 9-p Blatt 23 (6) Pt100 - B1
6
X108.1: Mate-N-Lok 2-p 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) X53
X199B: Mate-N-Lok 2-p (4)

X91
CAN H U1

AC-control
6
(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 siehe

X94
Blatt 23 K102
(2)

X96

3A1
3 Channel B 2 see page 11
1
X96j 14 11 3
cable W21
1 2 3 4 5 6 7 8
X108.1
1 (gn)
10 of 22

see page 10/7 2 (ye)

X22.2

motherboard drive compartment VZA (U100)

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
5 (gy) Index 9
12 Operating Diagrams

X108

10
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
X108: Mat-N-Lok 9-p
X108.1: Mat-N-Lok 2-p Achtung: Kabel ändert sich voraussichtlich
X114: Mat-N-Lok 2-p mit neuer Lenksensorik W12
X114.1: Mat-N-Lok 2-p
1 2 3 4 5 6 7 8

motherboard drive compartment VZA (U100)

11 of 22

1 cable W 102.2 8

X 130
(1) 24 V Ventile (1)
X38

1
2 7
2 (2) 1 Y 2 ein (2)
K10
Siehe Dokumentation 3 1
X39

see documentation 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
12 Operating Diagrams

K13 5

140 127
8 2
(7) release brake (open collector, 0V) (7)

11
9 1
(8) voltage breake LRB o.k. (8)
Crimp 6,3

X 102.1
1 (1) U_Batt_perm before main contactor (1)
F1 X 56
2 (2) U_Batt after main contactor (2)
X 53 fuse board U 1
3 (3) 24 V DC (3)
K12;14 X 61
4 (4) 0 V DC (4)
Connectors: X 65
cable W 102.1
X38: Mate-N-Lok 2-p
X39: Mate-N-Lok 2-p
X6 : Mate-N-Lok 2-p 1 X 41
R4.. (1) voltage breake LRB (1)
X24: Mate-N-Lok 9-p 1Y2.2
R7
X102.1: Mate-N-Lok 4-p LRB

X 40
X40: Mate-N-Lok 4-p 2
X130: Mate-N-Lok 12-p cable W 102.3 BZW50-100B
8X25: Mate-N-Lok 9-p
X127: Mate-N-Lok 3-p K1a 3 1Y2.3
(2) release brake (open collector, 0V) (2)
X140: Mate-N-Lok 2-p K1b LRB
X56; X56; X61; X65 X 42
Crimp 6,3
X41: Mate-N-Lok 2-p
X42: Mate-N-Lok 2-p
1 2 3 4 5 6 7 8
X36
12 of 22

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

motherboard drive compartment VZA (U100)

7 TxD: OC (pk) 24
8 TxD: 24V (bu) 7
12 Operating Diagrams

8X26
X37 cable tree 8W100
1 RxD: OC (wt) 32

12
2 24 V IF-sensors (bn) 2
4 0V (gn) 5
IF antenna
rear 5 TxD: OC (ye) 12
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 Guidanc
1 2 3 4 5 6 7 8
13 of 22

0V control (wt) 1
24V steering (bn) 2
24 V valves steering lock (gn) 3
emergency stop channel 2 (ye) 4
safety module

motherboard drive compartment VZA (U100)

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
12 Operating Diagrams

13
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
0 V pers.protection system 11
aisle signal 14
aisle signal 22
release driving forward 20
release driving reverse 23
release fast driving from PSA 24
0 V pers.protection system 21
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
14 of 22

U101
electronic board
X160 X150
SK-EA

motherboard drive compartment VZA (U100)

12 Operating Diagrams

electronic board
X151
X161 SK-R

14
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
15 of 22

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

motherboard cabin VZK (U200)

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
12 Operating Diagrams

jumper,
S 13

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

15
- (2) 0 V power 2 (2) 2
horn
1N4003 cable W 45
11 (1) chein left and right slack (1) 1

X204
S 14
slack chain 12 (2) chein left slack (2) 2
switch right
cable W 28
11 (1) chein 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
X207: Mate-N-Lok 4-p
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: Fastin-Faston 2-p roof 2
X203.1: Fastin Faston 2-p cable W 30
1 2 3 4 5 6 7 8
13 (4) 24 V lighting (4) 1
16 of 22

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

motherboard cabin VZK (U200)

E 2 light - 2 (5)
right side (5)
X229
12 Operating Diagrams

16
E 5 light - - cable W 61
right
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
X229: Mate-N-Lok 2-p
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
X224: Mate-N-Lok 2-p
Ä1: Kabel W61
1 2 3 4 5 6 7 8
X 84
(wt) 1 (1) pot. A 12 V (1) 4
17 of 22

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
dual-gang (gy) 5 (5) actual value B (5)
8
potentiometer 2
(pk) 6 (6) pot. 0V (6) 9
3

motherboard cabin VZK (U200)

X 85
(1)
(wt) 1 1
12 Operating Diagrams

© BT Industries AB 200421-040
1
6 B 3 (bn) 2 (7) (7) actual value A (7) 2
2
sensor (gn) 3
(3) 3
sideshift 3
(ye) 4
(4) 4
1
dual-gang (gy) 5 (8) (8) actual value B (8)

17
5
potentiometer 2
(pk) 6
(6) 6
3

X212
X87
(wt) 1 (1) 7
1
6 B 2 (bn) 2 (9) (9) actual value A (9) 8
2
sensor (gn) 3 (3) 9
aux. lift 3
(ye) 4 (4) 10
1
Connectors: dual-gang (gy) 5 (10) (10) actual value B (10) 11
potentiometer 2
X84: Mate-N-Lok 6-p (pk) 6 (6) 12
X85: Mate-N-Lok 6-p 3
X87: Mate-N-Lok 6-p
X214: Mate-N-Lok 9-p cable tree W 83
X212: Mate-N-Lok 12-p 1

X214
2
analog input reserve 3
1 2 3 4 5 6 7 8
18 of 22

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

motherboard cabin VZK (U200)

(1)
1 X 44
2 Y 41
valve 2 valve 2 Y 41 on (0V) (3) 12
12 Operating Diagrams

swivelling

X 221
valve plug
1 X 45 24 V valves cabin (4) 4

18
2 Y 42
valve 2 valve 2 Y 42 on (0V) (5) 11
sideshift right
1N4003
(4)
1 X 46
2 Y 43
valve 2 valve 2 Y 43 on (0V) (6) 10
Connectors: sideshift left
1N4003
X43: valve plug valve plug
X44: valve plug
X45: valve plug 3
X46: valve plug reserve output
6
prop. valve
X221: Mate-N-Lok 12-p
1 2 3 4 5 6 7 8
19 of 22

U201
electronic board
X260 X250
SK-EA

motherboard cabin VZK (U200)

12 Operating Diagrams

electronic board

19
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) in W34
S1
20 of 22

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
12 Operating Diagrams

S19

X200
X91
2 24 V (wt) 4

20
3 0 V (bn) 6

X91
1 CAN H (gn) 7
11 CAN L (ye) 8

control panel
right side
11
Connectors:

U106
X91: Sub-Min-D 9-p.
X128: CPC 4-p. 13
X182: Sub-Min-D 9-p.
X200: Mate-N-Lock 15-p. X182
50: Faston 6,3 2 RxD
15/54: Faston 6,3

X182
30: Faston 6,3 3 TxD
X183: Mate-N-Lok 3-p. RS232
5 GND
Ä2: Kabel S1 geändert
1 2 3 4 5 6 7 8
"a" "a"
21 of 22

X185 X184
1 (wt) CAN H (wt)
(bn) CAN L (bn) 5
2
U113

X185

X184
(gn) (gn) 4
APE

3 24 V
(ye) VCC (ye) 1
4
(gy) GND (gy) 2
5
9
cable W50
12 Operating Diagrams

right side
U106
X187 X129
11 (ye) RxD (ye) 11

21
2 (bn) 24V (bn) 2

control panel
left side

X129
U110

X187
3 (gn) 0V (gn) 3
1 (wt) TxD (wt) 1
cable W52
Connectors:
X185: Sub-Min-D 9-p.
X184 Sub-Min-D 15-p.
X129 Sub-Min-D 15-p.
X187 Sub-Min-D 15-p.
1 2 3 4 5 6 7 8
22 of 22

X110
K100
X62 +24V DC 3
A2 A1
Freigabe Fahren
K101
3
Freigabe Pumpe
A2 A1
fuse board U 1
12 Operating Diagrams

D1 K102
9
Freigabe Lenken
A2 A1

X102

22
Relais für
Freigabe
Leistungsteile
siehe
Blatt 10
Nur bei Prototyp
Just for prototype
Side shift Swivelling Auxiliary lift Main lift

H4 Line break safety device 27 l/min (h3<=4400 mm)

H4 Line break safety device 34 l/min (h3 > 4400 mm)
14

1
H26 Fill- and Ventilation filter
H18 Return flow filter
14 Hydraulic Diagram

© BT Industries AB 200421-040
H10 Suction and locking valve
H9 Pressure converter
H6 Main valve
H4 Line break safety device
H3 Lift module block
H2 Pump aggregate
H1 Oil tank
A48 Hydraulic motor
the spare parts catalogue is not permitted.

A7 Valve block
A4 Lowering brake valve
A3 Valve block with shock valves
Connection signs:

Threaded connection, closed

Hydraulic Diagram

Threaded connection,
open at tube connector side
Removal / installation of components other than those listed in
14 Hydraulic Diagram

Traverse/Rotate schematic Vector C10

Traverse/Rotate schematic Vector C12.5

Hydraulic schematic Vector C10

Hydraulic schematic Vector C12.5 (triple mast)

Hydraulic schematic Vector C12.5 (double mast)

Hydraulic schematic Mainlift Vector C10

Hydraulic schematic Mainlift Vector C12.5

Mainlift Vector C12.5

Mainlift Vector C10

15 Driving- / Lifting- /
Steering control
Removal / installation of components other than those listed in
the spare parts catalogue is not permitted

LED flashing codes

Table of error numbers and LED flashing codes

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.

LED flashing codes

Each AC controlerl 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 a collection error message
“E...“ to the SECAN control via CAN-Bus. The error number can
be watched by an analogue tag “MA...“ .
Survey of the collection errors and the analogue tags of the AC-
controllers

AC- error message analogue tag error

control number
Steering Er 122 MA 157
Driving Er 136 MA 158
Pump Er 135 MA 159

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 collection error E135 is displayed.
There is no information about the controller-internal error.

Diagnosis on the Service-APE:

Call up the analogue tag MA159 in the Servicemenu M24 „Sta-
tus display“. This shows the number of flashing pulses (here: 7).

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

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 incremental
encoder or wir- encoder at the motor
ing damaged 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.

19 Abbreviations

Abbr./term Meaning
µma micrometer absolute
A Output (digital)
AA Output (analogue)
ABE Display and operating unit
ABS Here: Cut-out
APE Display and programming unit
Apron Area outside the high rack
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
Claw Mechanical steering angle limitation
CMOS Circuitry with field effect transistors (electrostatically sensitive))
Controller Coordinating control component
CR Carriage return; confirms entries
DACI AC-control of SCHWARZMÜLLER company
Decrement Reduction of a value by 1 counter unit
DN Nominal width (in mm)
DT Triple telescopic mast
E Input (digital)
EA Input (analogue)
EABZ Discharge indicator / operating hour meter
EEPROM Electrically erasable EPROM
EM Single mast
EMC=EMV Electromagnetic compatibility
End ahead Position preceding a mechanical end position
EPROM Erasable programmable read only memory; non-volatile memory
Er Error
ESC Escape
DAMBACH SH Hi-Racker 100 GB 23.03.00

EST Stacking depth

FFZ Industrial truck
FTG Flat telescopic fork
GB Counter-current brake
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

19.1

Abbr./term Meaning
Increment Increase of a value by 1 counter unit
LAM Load lifting device, attachment
LR Load-bearing wheel
LRB Load-bearing wheel brake
LSP Load centre
M Tag (digital)
MA Tag (analogue)
MB Magnetic brake
Mbit/s Unit of measurement for the data transmission speed
MFH Multi-function lever
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
Optispeed Travelling speed limitation depending on lifting height and direc-
tion
Pin Kontaktstift
Pot Potentiometer, preset resistor
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 Bewegung zur Suche des Referenzpunktes (Bezugspunktes)
Remanenz Speicherverhalten bei Spannungsausfall
RM Checkback, checkback signal
SECAN CAN bus system sensor
SF Rail guidance
SF relay Safety relay with guided contacts
SIMO Safety module
SK-BPR Plug-in card - control desk computer
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

19.2

Abbr./term Meaning
UVV Regulation for the prevention of accidents
VDMA German association of machinery manufacturers
VZ Processing unit
VZA Processing unit - drive compartment
VZB Processing unit - control desk
VZK Processing unit - cabin
Watchdog Processor monitoring circuit
ZH Auxiliary lift
ZM Double mast
ZT Double telescopic mast
DAMBACH SH Hi-Racker 100 GB 23.03.00

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