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BT BT OM BT OMW BT OMC BT OMCW Master Service Manual - PDF DOWNLOAD
BT BT OM BT OMW BT OMC BT OMCW Master Service Manual - PDF DOWNLOAD
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BT BT OM BT OMW BT OMC BT OMCW Master Service Manual - PDF DOWNLOAD
Language : English
Pages : 233
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
BT BT OM BT OMW BT OMC BT OMCW Master Service Manual - PDF DOWNLOAD
Master Service Manual Product family OM................................................................................. 1 BT OM BT OMW BT OMC BT OMCW......................................................................................... 1 Introduction to BT’s Service Manual..................................................................................... 2 Contents Master Service Manual.......................................................................................... 4 Valid from serial number:........................................................................................... 4 T-code.............................................................................................................. 4 Model............................................................................................................... 4 Serial No........................................................................................................... 4 Notes............................................................................................................... 4 1. Document list.................................................................................................... 4 Section......................................................................................................... 4 C-code.......................................................................................................... 4 T-code.......................................................................................................... 4 Document........................................................................................................ 4 Issued.......................................................................................................... 4 Contents, M............................................................................................................. 6 1. Machine information.............................................................................................. 6 Operator’s manual....................................................................................................... 8 Valid from serial number:........................................................................................... 8 T-code.............................................................................................................. 8 Model............................................................................................................... 8 Serial No........................................................................................................... 8 Notes............................................................................................................... 8 1. General.......................................................................................................... 8 1.1. Issued operator’s manuals.................................................................................. 8 T-code...................................................................................................... 8 Order number................................................................................................ 8 Serial number............................................................................................... 8 2. Year of introduction............................................................................................. 9 Truck type...................................................................................................... 9 Machine number.................................................................................................. 9 Serial number................................................................................................... 9 Year of introduction............................................................................................ 9 Technical service data.................................................................................................. 10 Valid from serial number:........................................................................................... 10 T-code.......................................................................................................... 10 Model........................................................................................................... 10 Serial No....................................................................................................... 10 Notes........................................................................................................... 10 Model............................................................................................................... 10 OM.............................................................................................................. 10 OMW............................................................................................................. 10 OMC............................................................................................................. 10 OMCW............................................................................................................ 10 Drive motor..................................................................................................... 10 Transmission/gear............................................................................................... 10 Drive wheel..................................................................................................... 11 Support arm wheels.............................................................................................. 11 Hydraulic unit.................................................................................................. 11 Fuses........................................................................................................... 12 Batteries....................................................................................................... 12 All models...................................................................................................... 12 Driving speeds.................................................................................................. 13 Lifting/lowering speeds......................................................................................... 13 Current consumption............................................................................................. 14 Weight.......................................................................................................... 14 Ordering Spare Parts.................................................................................................... 16 Quality Parts........................................................................................................... 18 Valid from serial number:........................................................................................... 18 T-code.......................................................................................................... 18 Model........................................................................................................... 18 Serial No....................................................................................................... 18 Notes........................................................................................................... 18 1. Issued Quality Parts............................................................................................. 18 Model........................................................................................................... 18 Order number.................................................................................................... 18 Issued.......................................................................................................... 18 Recommended Spare Parts (RSP)........................................................................................... 20 Valid from serial number:........................................................................................... 20 T-code.......................................................................................................... 20 Model........................................................................................................... 20 Serial No....................................................................................................... 20 Notes........................................................................................................... 20 1. Issued RSP....................................................................................................... 20 Model........................................................................................................... 20 Serial No....................................................................................................... 20 Issued.......................................................................................................... 20 Contents, P............................................................................................................. 24 1. Preventive Maintenance........................................................................................... 24 Introduction, maintenance............................................................................................... 26 1. Safety regulations with maintenance work......................................................................... 26 WARNING!........................................................................................................ 26 WARNING!........................................................................................................ 27 WARNING!........................................................................................................ 27 NOTE!........................................................................................................... 27 CAUTION!........................................................................................................ 27 2. Cleaning and washing............................................................................................. 28 NOTE!........................................................................................................... 28 2.1. External cleaning.......................................................................................... 28 NOTE!....................................................................................................... 28 2.2. Cleaning the motor compartment............................................................................. 28 NOTE!....................................................................................................... 28 2.3. Electrical components...................................................................................... 29 NOTE!....................................................................................................... 29 3. Safe lifting of the truck........................................................................................ 29 WARNING!........................................................................................................ 29 Service schedule........................................................................................................ 30 Valid from serial number:........................................................................................... 30 T-code.......................................................................................................... 30 Model........................................................................................................... 30 Serial No....................................................................................................... 30 Notes........................................................................................................... 30 1. Maintenance chart................................................................................................ 30 Pos............................................................................................................. 30 Work to carry out............................................................................................... 30 Intervals in hours.......................................................................................... 30 5........................................................................................................... 30 20.......................................................................................................... 30 80.......................................................................................................... 30 250......................................................................................................... 30 500......................................................................................................... 30 1000........................................................................................................ 30 3000........................................................................................................ 30 Intervals in Days/Weeks/ Months............................................................................. 30 1 D......................................................................................................... 30 1 W......................................................................................................... 30 1 M......................................................................................................... 30 3 M......................................................................................................... 30 6 M......................................................................................................... 30 12 M........................................................................................................ 30 36 M........................................................................................................ 30 0000........................................................................................................ 30 Chassis..................................................................................................... 30 0500........................................................................................................ 30 Cabin....................................................................................................... 30 0640........................................................................................................ 30 Manoeuvring controls........................................................................................ 30 1700........................................................................................................ 31 Drive motor................................................................................................. 31 2550........................................................................................................ 31 Drive unit.................................................................................................. 31 3370........................................................................................................ 31 Brakes...................................................................................................... 31 3500........................................................................................................ 31 Wheels...................................................................................................... 31 5000........................................................................................................ 31 Electrical panel............................................................................................ 31 5110........................................................................................................ 32 Battery..................................................................................................... 32 5810........................................................................................................ 32 Pump motor.................................................................................................. 32 5830........................................................................................................ 32 Steering motor.............................................................................................. 32 6000........................................................................................................ 32 Hydraulic system............................................................................................ 32 7100........................................................................................................ 32 Mast........................................................................................................ 32 7160........................................................................................................ 33 Initial lift................................................................................................ 33 2. Lubrication chart................................................................................................ 35 Item............................................................................................................ 35 Service point................................................................................................... 35 Intervall/Running hours......................................................................................... 35 Lubricant....................................................................................................... 35 Volume.......................................................................................................... 35 250 h....................................................................................................... 35 500 h....................................................................................................... 35 1000 h...................................................................................................... 35 Oil and grease specification............................................................................................ 38 Valid from serial number:........................................................................................... 38 T-code.......................................................................................................... 38 Model........................................................................................................... 38 Serial No....................................................................................................... 38 Notes........................................................................................................... 38 Lubricant........................................................................................................... 38 Type of lubricant................................................................................................... 38 Specification....................................................................................................... 38 To be used for...................................................................................................... 38 > - 15 C............................................................................................................ 38 < - 15 C............................................................................................................ 38 Oil and grease specification............................................................................................ 40 Valid from serial number:........................................................................................... 40 T-code.......................................................................................................... 40 Model........................................................................................................... 40 Serial No....................................................................................................... 40 Notes........................................................................................................... 40 Lubricant........................................................................................................... 40 Type of lubricant................................................................................................... 40 Specification....................................................................................................... 40 To be used for...................................................................................................... 40 > - 15 C............................................................................................................ 40 < - 15 C............................................................................................................ 40 Contents, S............................................................................................................. 42 1. Service instructions............................................................................................. 42 Transmission, Gear...................................................................................................... 44 Valid from machine number: 287595AA-................................................................................ 44 1. General.......................................................................................................... 44 2. Gear components/data............................................................................................. 45 2.1. Component identification................................................................................... 45 Pos No...................................................................................................... 45 Component................................................................................................... 45 2.2. Technical gear data........................................................................................ 46 Truck type.................................................................................................. 46 OM 0.85..................................................................................................... 46 3. Dismantling/fitting of gear from/in truck........................................................................ 47 3.1. Dismantling:............................................................................................... 47 1. Remove the front cover plate of the chassis.............................................................. 47 2. Jack up the truck and block it in a safe manner.......................................................... 47 3. Remove the steering chain from the gear by removing the chain locks...................................... 47 4. Loosen and remove the six M12 bolts holding the gear to the motor plate.................................. 47 5. Lower the gear to the floor.............................................................................. 47 6. To remove the radial bearing from the gear there is eight M8 bolts to remove from the bearing ........... 47 3.2. Fitting:................................................................................................... 47 1. To fit the radial bearing to the gear, tighten all bolts symetric with a torque of 25 Nm. The ........... 47 2. Put the gear in position and make sure that the lower motor bearing and gear wheel is in its c........... 47 3. Fit the M12 bolts through the motor plate and tighten them 90 Nm. The bolts shall be lubricate........... 47 4. Mount the steering chain and adjust the slack according to the picture................................... 48 5. Lower the truck to the ground and fit the front cover plate.............................................. 48 4. Oil level check/exchange......................................................................................... 48 4.1. Check/filling of oil....................................................................................... 48 4.2. Exchange of oil............................................................................................ 49 1. Draining the old oil out of the gear is done by removing the lower gear cover completely................. 49 2. Change the O-ring seal at every oil change. Make sure that the new O-ring isn’t damaged when f........... 49 3. Fit the cover and tighten the bolts 25 Nm. The bolts shall be lubricated prior to assembly............... 49 4. Fill up oil in accordance with filling instructions...................................................... 49 5. Exchange of drive shaft seal ring................................................................................ 50 5.1. Dismantling:............................................................................................... 50 1. Remove the drive wheel from the gear..................................................................... 50 2. Remove the lower gear cover and drain the gear from oil.................................................. 50 3. Loosen the drive shaft nut. Remove the nut and spacer ring............................................... 50 4. Knock the drive shaft out. Gently with a brass drifter and a hammer...................................... 50 5. Pull the bearing off the drive shaft with tool 08-13022.................................................. 50 6. Check the bearing shims for damage. If they are damaged by the bearing tool measure the total ........... 50 7. Remove the seal ring from the drive shaft................................................................ 50 5.2. Assembly:.................................................................................................. 51 1. Place the drive shaft outer bearing in the gear housing.................................................. 51 2. Press the new seal ring in place in the gear housing. Be careful when pressing it in place so ........... 51 3. Place the shaft bearing shims on the drive shaft, having the same total thickness as the origi........... 51 4. Press the drive shaft , with shims, into the gear housing/ shaft bearing. Check that the splin........... 51 5. Place the spacer ring on to the drive shaft end and fit the shaft nut. Always use a new nut. T........... 51 6. Before fitting the lower cover, change the O-ring. Make sure that it is not damaged when fitte........... 51 7. Fill up oil in accordance with filling instructions, section 4.2......................................... 51 8. Fit the drive wheel and tighten the wheel nut with a torque of 90 Nm. The wheel nuts shall be ........... 51 6. Leakage from the top cover....................................................................................... 52 1. Dismantle the gear and radial steering ball bearing from the truck as described in section 3.1............... 52 2. After removing the radial bearing loosen all eleven bolts holding the top cover to the gear ho............... 52 3. Remove the cover from the gear and clean the surface of the cover and housing carefully...................... 52 4. Apply liquid sealant type Loc-Tite 574 to the surfaces. Follow the instructions given on the c............... 52 5. Fit the cover bolts and tighten with a torqe of 25 Nm.The bolts shall be lubricated prior to a............... 52 6. Fill up oil in accordance with filling instructions, section 4.2............................................. 52 7. Fit the gear and radial bearing to the truck as described in section 3.2..................................... 52 Electromagnetic brake................................................................................................... 54 Valid from machine number: 287595AA-................................................................................ 54 1. General.......................................................................................................... 54 2. Function......................................................................................................... 55 2.1. Releasing the brake........................................................................................ 55 2.2. Braking.................................................................................................... 55 3. Maintenance...................................................................................................... 56 3.1. Adjustment of gap.......................................................................................... 57 3.1.1. Adjustment procedure:................................................................................ 57 1. Loosen the tension of the four mounting bolts........................................................ 57 2. Turn the lock nuts anti-clockwise and tighten the bolts slightly while checking the gap with a....... 57 3. Tighten the mounting bolts 25 Nm..................................................................... 57 4. Recheck the gap with the feeler gauge................................................................ 57 3.2. Exchange of brake disc/magnetic coil....................................................................... 58 3.2.1. Exchange procedure:.................................................................................. 58 1. Disconnect the electrical wires of the brake......................................................... 58 2. Dismount the speed sensor mounted on top of the brake coil........................................... 58 3. Loosen and remove the four mounting bolts and remove the brake coil.................................. 58 4. Replace the brake disc on the hub/magnetic coil and make a visual check of the wear of the fri....... 58 5. Unwind the lock nuts on the coil at least 6 mm to make sure there is a gap between the coil an....... 58 6. Mount the coil on the motor end and carry out adjustment of the gap according to section 3.1......... 58 7. Reconnect the electrical wiring of the brake......................................................... 58 8. Fit the speed sensor................................................................................. 58 3.2.2. Transport securing screws............................................................................ 59 3.3. Check/adjustment of the braking force...................................................................... 60 Warning!.................................................................................................... 60 Wire guidance........................................................................................................... 62 Valid from serial number:........................................................................................... 62 T-code.............................................................................................................. 62 Model............................................................................................................... 62 Serial No........................................................................................................... 62 Notes............................................................................................................... 62 1. General.......................................................................................................... 62 2. Generator........................................................................................................ 63 2.1. Technical data............................................................................................. 63 Power supply................................................................................................ 63 Model LDU-22 220V 50Hz...................................................................................... 63 Model LDU-21 110V 50/60Hz................................................................................... 63 3. Antennae......................................................................................................... 64 3.1. Antenna wire............................................................................................... 65 4. Wire guidance card............................................................................................... 65 4.1. Components................................................................................................. 66 4.2. Connections................................................................................................ 66 Conn........................................................................................................ 66 Type........................................................................................................ 66 No.......................................................................................................... 66 Active...................................................................................................... 66 Function.................................................................................................... 66 Conn........................................................................................................ 67 Type........................................................................................................ 67 No.......................................................................................................... 67 Active...................................................................................................... 67 Function.................................................................................................... 67 4.3. Display.................................................................................................... 67 4.3.1. Input signals........................................................................................ 67 Segment................................................................................................. 67 Function................................................................................................ 67 4.3.2. Output signals/operating mode........................................................................ 67 ........................................................................................................ 68 Segment..................................................................................................... 68 Function.................................................................................................... 68 4.3.3. Error codes...................................................................................... 68 Code........................................................................................................ 68 Description................................................................................................. 68 5. Miscellaneous.................................................................................................... 70 6. Description of function.......................................................................................... 71 6.1. Driving forwards........................................................................................... 71 6.2. Reversing.................................................................................................. 71 6.3. Control signals............................................................................................ 72 Operating mode.............................................................................................. 72 S........................................................................................................... 72 V........................................................................................................... 72 P........................................................................................................... 72 7. Adjustments...................................................................................................... 73 7.1. Adjustment instructions for A2............................................................................. 73 7.1.1. Adjusting the steering potentiometer:................................................................ 73 1. Set the truck mechanically straight outside the narrow aisle, without requesting wire guidance....... 73 2. Adjust the ZERO potentiometer (2) on the A2 box so that the two LED’s comes on simultaneously........ 73 7.2. Adjustment instructions for A3............................................................................. 73 Menu........................................................................................................ 74 Description................................................................................................. 74 Range....................................................................................................... 74 7.2.1. Steering pot. setting................................................................................ 76 1. Start by placing the trucks steering wheel straight outside the aisle. Check the adjustments, ....... 76 2. Activate the setting mode............................................................................ 76 3. Auto-adjust the steering pot. offset in menu 1.2..................................................... 76 7.2.2. Fine tuning the steering pot. off-set................................................................ 76 1. Drive into the wire aisle backwards a few meters, with wire requested, then stop gently. Make ....... 76 2. Post-adjust the steering pot. signal in menu 1.5..................................................... 76 3. Drive slowly in reverse direction and make sure that the LEDs (1) are symmetrically lit. If ne....... 76 7.2.3. Antenna offset adjustment reversing.................................................................. 76 1. Drive slowly backwards approx. 20 sec. and then stop gently.......................................... 76 2. Read of the value in the menu 10.7................................................................... 76 3. Set menu 6 to this value............................................................................. 76 7.2.4. Antenna offset adjustment forwards................................................................... 77 1. Drive forwards slowly for approx. 20 sec. and then stop gently....................................... 77 2. Read off the value in the menu 10.6.................................................................. 77 3. Multiply this value by a truck-specific constant witch is 2 for this truck type...................... 77 4. Set menu 4 to this newly calculated value............................................................ 77 7.2.5. Storing the parameters............................................................................... 77 1. Store the parameters in menu 9.3 after completed adjustment.......................................... 77 7.2.6. Antenna offset adjustment, 1-antenna mode............................................................ 78 1. Disconnect the cables from the aisle sensors (Inputs 109 and 110 on the A2 card) and the aisle....... 78 2. Drive slowly in reverse direction and at the same time read-off the value in menu 10.2 (angle ....... 78 3. Switch off wire guidance in the cabin and check that forwards is active (menu 10.0 r=reverse, ....... 78 4. Read-off the value in menu 10.2...................................................................... 78 5. Adjust menu 1.9 to this value........................................................................ 78 6. Store the parameters according to “Storing the parameters”........................................... 78 8. Installing a new wire guidance card.............................................................................. 79 POS............................................................................................................. 79 Truck model..................................................................................................... 79 ID number....................................................................................................... 79 1. Output X22:9 is activated if the unit “sees the wire” but the operator has not selected wire g........... 80 2. Output X22:8 is activated if the side-signal >75% of the permitted value. The output can be us........... 80 POS............................................................................................................. 80 Truck model..................................................................................................... 80 ID number....................................................................................................... 80 9. Trouble shooting................................................................................................. 81 9.1. Control signals............................................................................................ 81 9.1.1. Checking the reference signal........................................................................ 81 kHz..................................................................................................... 81 mA...................................................................................................... 81 9.1.2. Checking the side signal............................................................................. 81 9.1.3. Checking the steering pot. signal.................................................................... 81 Electrical system....................................................................................................... 82 Valid from serial number:........................................................................................... 82 T-code.............................................................................................................. 82 Model............................................................................................................... 82 Serial No........................................................................................................... 82 Notes............................................................................................................... 82 1. General.......................................................................................................... 82 1.1. References:................................................................................................ 83 2. Symbols and circuit diagrams..................................................................................... 83 2.1. List of symbols............................................................................................ 83 Symbol...................................................................................................... 83 Description................................................................................................. 83 Symbol...................................................................................................... 83 Description................................................................................................. 83 2.2. Circuit diagram(1/8)....................................................................................... 85 2.3. Circuit diagram (2/8)...................................................................................... 86 2.4. Circuit diagram (3/8)...................................................................................... 87 2.5. Circuit diagram (4/8)...................................................................................... 88 2.6. Circuit diagram (5/8)...................................................................................... 89 2.7. Circuit diagram (6/8)...................................................................................... 90 2.8. Circuit diagram (7/8)...................................................................................... 91 2.9. Circuit diagram (8/8)...................................................................................... 92 2.10. List of components........................................................................................ 93 Symbol...................................................................................................... 93 Designation................................................................................................. 93 Function.................................................................................................... 93 Remark...................................................................................................... 93 3. Description of function.......................................................................................... 96 3.1. Ignition key in the 0 position............................................................................. 96 3.2. Ignition key in the I position............................................................................. 96 3.3. Driver presence control (outside narrow aisle)............................................................. 97 3.4. Driving.................................................................................................... 97 3.5. Driving in narrow aisle.................................................................................... 98 3.5.1. Driving in rail guided aisle......................................................................... 98 3.5.2. Driving in wire guided aisle......................................................................... 98 3.6. Steering................................................................................................... 98 3.7. Steering wheel indicator................................................................................... 98 3.8. Braking.................................................................................................... 99 3.8.1. Plug brake (electric)................................................................................ 99 3.8.2. Automatic plug braking (selectable parameter)........................................................ 99 3.8.3. Service brake........................................................................................ 99 3.8.4. Parking brake........................................................................................ 99 3.9. Cabin lift.................................................................................................100 3.10. Cabin gates...............................................................................................100 3.11. Front gate, only “walk through”...........................................................................100 3.12. Lift height limitation (option)...........................................................................100 3.13. Cabin lowering............................................................................................101 3.14. Initial lift..............................................................................................101 3.15. Initial lowering..........................................................................................101 4. Standard settings and adjustments................................................................................101 Electrical system.......................................................................................................102 Valid from serial number:...........................................................................................102 T-code..............................................................................................................102 Model...............................................................................................................102 Serial No...........................................................................................................102 Notes...............................................................................................................102 1. General..........................................................................................................102 1.1. References:................................................................................................103 1.2. General description of the electrical system...............................................................103 1.2.1. Battery, battery supply, power fuses (sheet 1).......................................................103 1.2.2. Drive motor circuit (sheet 2)........................................................................104 1.2.3. Inputs to the electronic card A2 (sheet 3)...........................................................104 1.2.4. Inputs till the electronic card A2 (sheet 4).........................................................105 1.2.5. Speed control, display communication, (sheet 5)......................................................105 1.2.6. Steering, extra equipment (sheet 6)..................................................................106 1.2.7. Outputs from the electronic card A2 (sheet 7)........................................................106 1.2.8. Wire guidance (sheet 8)..............................................................................106 2. Symbols and circuit diagrams.....................................................................................107 2.1. List of symbols............................................................................................107 Symbol......................................................................................................107 Description.................................................................................................107 2.2. Circuit diagram T-code 355, 457, 1/8.......................................................................109 2.3. Circuit diagram T-code 355, 457, 2/8.......................................................................110 2.4. Circuit diagram T-code 355, 457, 3/8.......................................................................111 2.5. Circuit diagram T-code 355, 457, 4/8.......................................................................112 2.6. Circuit diagram T-code 355, 457, 5/8.......................................................................113 2.7. Circuit diagram T-code 355, 457, 6/8.......................................................................114 2.8. Circuit diagram T-code 355, 457, 7/8.......................................................................115 2.9. Circuit diagram T-code 355, 457, 8/8.......................................................................116 2.10. Circuit diagram T-code 356, 458, 1/8......................................................................117 2.11. Circuit diagram T-code 356, 458, 2/8......................................................................118 2.12. Circuit diagram T-code 356, 458, 3/8......................................................................119 2.13. Circuit diagram T-code 356, 458, 4/8......................................................................120 2.14. Circuit diagram T-code 356, 458, 5/8......................................................................121 2.15. Circuit diagram T-code 356, 458, 6/8......................................................................122 2.16. Circuit diagram T-code 356, 458, 7/8......................................................................123 2.17. Circuit diagram T-code 356, 458, 8/8......................................................................124 2.18. List of components........................................................................................125 Symbol......................................................................................................125 Designation.................................................................................................125 Function....................................................................................................125 Remark......................................................................................................125 2.19. Electrical diagram Option Buzzer..........................................................................128 2.20. List of components........................................................................................129 Symbol......................................................................................................129 Designation.................................................................................................129 Function....................................................................................................129 Remark......................................................................................................129 2.21. Electrical diagram Option Gate warning....................................................................130 2.22. List of components........................................................................................131 Symbol......................................................................................................131 Designation.................................................................................................131 Function....................................................................................................131 Remark......................................................................................................131 2.23. Electrical diagram Option Extra hydraulic function........................................................132 2.24. List of components........................................................................................133 Symbol......................................................................................................133 Designation.................................................................................................133 Function....................................................................................................133 Remark......................................................................................................133 3. Description of function..........................................................................................134 3.1. Ignition key in the 0 position.............................................................................134 3.2. Start......................................................................................................134 3.3. Deadman’s handle...........................................................................................135 3.4. Driver presence control (outside narrow aisle).............................................................135 3.4.1. Open cabin gates.....................................................................................135 3.4.2. Closed cabin gates...................................................................................135 3.5. Driving....................................................................................................136 3.6. Driving in narrow aisle....................................................................................136 3.6.1. Driving in rail guided aisle.........................................................................136 3.6.2. Driving in rail guided aisle.........................................................................137 3.7. Travel speed...............................................................................................137 3.7.1. Outside narrow aisles:...............................................................................137 3.7.2. In narrow aisles, rail steering / wire guidance:.....................................................137 3.8. Steering...................................................................................................138 3.9. Steering wheel indicator...................................................................................138 3.10. Braking...................................................................................................138 3.10.1. Plug brake (electric)...............................................................................138 3.10.2. Automatic plug braking (selectable parameter).......................................................138 3.10.3. Service brake.......................................................................................139 3.10.4. Parking brake.......................................................................................139 3.11. End-of-aisle brake........................................................................................139 3.12. Cabin lift................................................................................................139 3.13. Cabin gates...............................................................................................140 3.14. Load sensing, only “OMW,OMCW”............................................................................140 3.15. Lift height limitation....................................................................................140 3.16. Cabin lowering............................................................................................140 3.17. Initial lift..............................................................................................140 3.18. Initial lowering..........................................................................................141 3.19. Slack chain guard.........................................................................................141 3.20. Miscellaneous.............................................................................................141 4. Standard settings and adjustments................................................................................141 Transistor regulator....................................................................................................142 Valid from machine number: 287595AA-................................................................................142 1. Transistor regulator.............................................................................................142 1.1. Motor connections..........................................................................................142 Terminal number.............................................................................................143 Function....................................................................................................143 2. Control circuit..................................................................................................143 Terminal- number................................................................................................143 Con.............................................................................................................143 Function........................................................................................................143 3. Technical specification..........................................................................................144 PARAMETER.......................................................................................................144 SETTING.........................................................................................................144 UNITS...........................................................................................................144 DESCRIPTION.....................................................................................................144 4. LED indications..................................................................................................145 LED No..........................................................................................................145 Colour..........................................................................................................145 Indicates.......................................................................................................145 Diagnosis.......................................................................................................145 5. Maintenance......................................................................................................146 5.1. Safety.....................................................................................................146 WARNING!....................................................................................................146 5.2. Cleaning...................................................................................................146 1. Remove power by disconnecting the battery................................................................146 2. Discharge the capacitors in the controller, by connecting a load (such as a contactor coil or ...........146 3. Remove all dirt or corrosion from the bus bar area. The controller should be wiped clean with ...........146 4. Make sure the connections to the bus bars are tight. Use two well insulated wrenches for this ...........146 6. Safety control...................................................................................................147 6.1. Checking the transistor regulator’s safety circuits........................................................147 Warning.....................................................................................................147 !.......................................................................................................147 Electronic card.........................................................................................................148 Valid from serial number:...........................................................................................148 T-code..............................................................................................................148 Model...............................................................................................................148 Serial No...........................................................................................................148 Notes...............................................................................................................148 1. Electronic card 149167 version -001and -002.....................................................................148 1.1. General....................................................................................................148 2. Connections......................................................................................................149 2.1. Connector no 1, display....................................................................................149 Terminal number.............................................................................................149 LED no......................................................................................................149 Connection..................................................................................................149 Active......................................................................................................149 Function....................................................................................................149 2.2. Connector no 2, cabin......................................................................................150 Terminal number.............................................................................................150 LED no......................................................................................................150 Connection..................................................................................................150 Active......................................................................................................150 Function....................................................................................................150 2.3. Connector no 3, height , speed and aisle indication........................................................151 Terminal number.............................................................................................151 LED no......................................................................................................151 Connection..................................................................................................151 Active......................................................................................................151 Function....................................................................................................151 2.4. Connector no 4, drive and steer signals....................................................................152 Terminal number.............................................................................................152 LED no......................................................................................................152 Connection..................................................................................................152 Active......................................................................................................152 Function....................................................................................................152 2.5. Connector no 5, wire guidance option.......................................................................153 Terminal number.............................................................................................153 LED no......................................................................................................153 Connection..................................................................................................153 Active......................................................................................................153 Function....................................................................................................153 2.6. Connector no 6, potentiometer circuits, voltage supply.....................................................154 Terminal number.............................................................................................154 LED no......................................................................................................154 Connection..................................................................................................154 Active......................................................................................................154 Function....................................................................................................154 2.7. Connector no 7, brake, valves, contactors..................................................................155 Terminal number.............................................................................................155 LED no......................................................................................................155 Connection..................................................................................................155 Active......................................................................................................155 Function....................................................................................................155 2.8. Connector no 8, power supply steering......................................................................155 Terminal number.............................................................................................155 LED no......................................................................................................155 Connection..................................................................................................155 Active......................................................................................................155 Function....................................................................................................155 3. LED’s, switches, potentiometer...................................................................................156 LED.............................................................................................................156 Colour..........................................................................................................156 Function........................................................................................................156 Switch..........................................................................................................156 Function........................................................................................................156 Potentiometer...................................................................................................156 Function........................................................................................................156 4. Display..........................................................................................................157 ................................................................................................................157 4.1. Time.......................................................................................................158 Function....................................................................................................158 Value.......................................................................................................158 4.2. Warning codes..............................................................................................159 Character...................................................................................................159 Error code..................................................................................................159 Warning!................................................................................................159 4.2.1. Warning codes without registering................................................................160 Code no.....................................................................................................160 Type of error...............................................................................................160 Probable cause..............................................................................................160 Effect on the truck.........................................................................................160 4.2.2. Warning codes with registering...................................................................162 Code no.....................................................................................................162 Type of error...............................................................................................162 Code no.....................................................................................................162 Type of error...............................................................................................162 4.3. Error codes................................................................................................163 Caracter....................................................................................................163 Error code..................................................................................................163 ........................................................................................................164 ........................................................................................................164 ........................................................................................................164 WARNING.................................................................................................164 !...................................................................................................164 4.3.1. Error codes with registering.....................................................................165 Code no.....................................................................................................165 Type of error...............................................................................................165 Probable cause..............................................................................................165 5. Running time.....................................................................................................166 Caracter........................................................................................................166 Time............................................................................................................166 6. Steering potentiometer (STEERPOT)................................................................................167 7. Parameters.......................................................................................................168 7.1. Programming parameters.....................................................................................168 Note!.......................................................................................................168 No..........................................................................................................168 Parameter type..............................................................................................168 Unit........................................................................................................168 Min/ Max....................................................................................................168 Std. value..................................................................................................168 Remarks.....................................................................................................168 Electronic card.........................................................................................................170 Valid from serial number:...........................................................................................170 T-code..............................................................................................................170 Model...............................................................................................................170 Serial No...........................................................................................................170 Notes...............................................................................................................170 1. Electronic card 149167 version -003 and -004.....................................................................170 1.1. General....................................................................................................170 2. Connections and voltage on A2....................................................................................171 2.1. Connector no 1, display....................................................................................171 Terminal number.............................................................................................171 LED no......................................................................................................171 Connection..................................................................................................171 Active......................................................................................................171 Function....................................................................................................171 2.2. Connector no 2, cabin......................................................................................172 Terminal number.............................................................................................172 LED no......................................................................................................172 Connection..................................................................................................172 Active......................................................................................................172 Function....................................................................................................172 2.3. Connector no 3, height , speed and aisle indication........................................................173 Terminal number.............................................................................................173 LED no......................................................................................................173 Connection..................................................................................................173 Active......................................................................................................173 Function....................................................................................................173 2.4. Connector no 4, drive and steer signals....................................................................174 Terminal number.............................................................................................174 LED no......................................................................................................174 Connection..................................................................................................174 Active......................................................................................................174 Function....................................................................................................174 2.5. Connector no 5, wire guidance option.......................................................................175 Terminal number.............................................................................................175 LED no......................................................................................................175 Connection..................................................................................................175 Active......................................................................................................175 Function....................................................................................................175 2.6. Connector no 6, potentiometer circuits, voltage supply.....................................................176 Terminal number.............................................................................................176 LED no......................................................................................................176 Connection..................................................................................................176 Active......................................................................................................176 Function....................................................................................................176 2.7. Connector no 7, brake, valves, contactors..................................................................177 Terminal number.............................................................................................177 LED no......................................................................................................177 Connection..................................................................................................177 Active......................................................................................................177 Function....................................................................................................177 2.8. Connector no 8, power supply steering......................................................................177 Terminal number.............................................................................................177 LED no......................................................................................................177 Connection..................................................................................................177 Active......................................................................................................177 Function....................................................................................................177 3. LED’s, switches, potentiometer...................................................................................178 LED.............................................................................................................178 Colour..........................................................................................................178 Function........................................................................................................178 Switch..........................................................................................................178 Function........................................................................................................178 Potentiometer...................................................................................................178 Function........................................................................................................178 4. Display..........................................................................................................179 ................................................................................................................179 4.1. Time.......................................................................................................180 Function....................................................................................................180 Value.......................................................................................................180 4.2. Warning codes/Error codes..................................................................................180 WARNING!....................................................................................................180 4.2.1. Warning codes........................................................................................180 Character...................................................................................................180 Warning code................................................................................................180 4.2.2. Error codes......................................................................................181 ....................................................................................................181 ....................................................................................................181 ....................................................................................................181 4.3. Parameters.................................................................................................181 4.4. Running time...............................................................................................182 4.4.1. Display the running meter reading and fork height....................................................182 Caracter....................................................................................................182 Time........................................................................................................182 5. Warning codes / Error codes......................................................................................182 WARNING.........................................................................................................182 !...........................................................................................................182 5.1. Warning codes without registering..........................................................................183 Kod.........................................................................................................183 11..........................................................................................................183 Kod.........................................................................................................183 12..........................................................................................................183 Kod.........................................................................................................184 13..........................................................................................................184 Kod.........................................................................................................184 14..........................................................................................................184 Kod.........................................................................................................185 15..........................................................................................................185 Kod.........................................................................................................185 16..........................................................................................................185 Kod.........................................................................................................186 17..........................................................................................................186 Kod.........................................................................................................186 18..........................................................................................................186 Kod.........................................................................................................187 21..........................................................................................................187 Kod.........................................................................................................187 22..........................................................................................................187 Kod.........................................................................................................188 23..........................................................................................................188 Kod.........................................................................................................188 25..........................................................................................................188 Kod.........................................................................................................189 26..........................................................................................................189 Kod.........................................................................................................189 27..........................................................................................................189 Kod.........................................................................................................190 30..........................................................................................................190 Kod.........................................................................................................190 31..........................................................................................................190 Kod.........................................................................................................191 32..........................................................................................................191 5.2. Warning codes with registering.............................................................................191 Kod.........................................................................................................191 50..........................................................................................................191 Kod.........................................................................................................192 51..........................................................................................................192 Kod.........................................................................................................192 52..........................................................................................................192 Kod.........................................................................................................193 53..........................................................................................................193 Kod.........................................................................................................193 54..........................................................................................................193 Kod.........................................................................................................194 55..........................................................................................................194 Kod.........................................................................................................194 57..........................................................................................................194 Kod.........................................................................................................195 58..........................................................................................................195 Kod.........................................................................................................195 59..........................................................................................................195 Kod.........................................................................................................196 60..........................................................................................................196 Kod.........................................................................................................196 61..........................................................................................................196 5.3. Error codes with registering...............................................................................197 Kod.........................................................................................................197 100.........................................................................................................197 Kod.........................................................................................................197 110.........................................................................................................197 Kod.........................................................................................................198 111.........................................................................................................198 Kod.........................................................................................................198 112.........................................................................................................198 Kod.........................................................................................................199 113.........................................................................................................199 Kod.........................................................................................................199 114.........................................................................................................199 Kod.........................................................................................................200 115.........................................................................................................200 Kod.........................................................................................................200 120.........................................................................................................200 Kod.........................................................................................................201 121.........................................................................................................201 Kod.........................................................................................................201 122.........................................................................................................201 Kod.........................................................................................................202 123.........................................................................................................202 Kod.........................................................................................................202 125.........................................................................................................202 Kod.........................................................................................................203 126.........................................................................................................203 Kod.........................................................................................................203 127.........................................................................................................203 Kod.........................................................................................................204 131.........................................................................................................204 Kod.........................................................................................................204 132.........................................................................................................204 Kod.........................................................................................................205 133.........................................................................................................205 Kod.........................................................................................................205 140.........................................................................................................205 Kod.........................................................................................................206 141.........................................................................................................206 6. Steering potentiometer (STEERPOT)................................................................................207 7. Parameters.......................................................................................................208 7.1. Programming parameters.....................................................................................208 Note!.......................................................................................................208 No..........................................................................................................209 Parameter type..............................................................................................209 Unit........................................................................................................209 Min/ Max....................................................................................................209 Std. value..................................................................................................209 Remarks.....................................................................................................209 Hydraulic system........................................................................................................212 Valid from machine number: 287595AA-................................................................................212 1. General..........................................................................................................212 2. Hydraulic diagram................................................................................................213 2.1. Symbols....................................................................................................214 Symbol......................................................................................................214 Description.................................................................................................214 Symbol......................................................................................................214 Description.................................................................................................214 2.2. Component description......................................................................................215 3. Description of function..........................................................................................216 3.1. Cabin lift.................................................................................................216 3.2. Cabin lowering.............................................................................................216 3.3. Fork lift..................................................................................................216 3.4. Fork lowering..............................................................................................217 3.5. Hydraulic data.............................................................................................217 3.5.1. Operating pressure...................................................................................217 3.5.2. Relief pressure......................................................................................217 3.5.3. Pump flow............................................................................................217 Valve block.............................................................................................................218 Valid from machine number: 287595AA-................................................................................218 1. General..........................................................................................................218 1.1. Komponents and descriptions................................................................................219 J...........................................................................................................219 2. Valves...........................................................................................................220 2.1. By-pass valveY30...........................................................................................220 2.2. Directional valves Y34, Y41, Y69 and Y70...................................................................221 2.3. Pressure relief valve......................................................................................221 Warning.....................................................................................................221 2.3.1. Adjustment...........................................................................................222 2.4. Emergency lowering valve...................................................................................222 Lifting chains..........................................................................................................224 Valid from serial number:...........................................................................................224 T-code..............................................................................................................224 Model...............................................................................................................224 Serial number.......................................................................................................224 Notes...............................................................................................................224 1. General..........................................................................................................224 2. Identifying the chains...........................................................................................224 3. Adjusting the lifting chains.....................................................................................225 3.1. Adjustment instructions....................................................................................225 4. Inspection of chain wear.........................................................................................226 4.1. Contour wear...............................................................................................226 Type of chain...............................................................................................226 Model.......................................................................................................226 Nominal plate height A (mm).................................................................................226 Minimum plate height B (mm).................................................................................226 Pitch T (mm)................................................................................................226 Nominal chain length for 20/30/50 plates (mm)...............................................................226 Maximum permitted chain length for 20/30/50 plates (mm).....................................................226 4.2. Stretching.................................................................................................226 5. Lubrication......................................................................................................227 NOTE!...........................................................................................................227 NOTE!...........................................................................................................227 5.1. Machines in normal operating temperatures..................................................................227 5.2. Machines in freezer environments...........................................................................227 Lift cylinder...........................................................................................................228 Valid from serial number:...........................................................................................228 T-code..............................................................................................................228 Model...............................................................................................................228 Serial number.......................................................................................................228 Notes...............................................................................................................228 1. General..........................................................................................................228 2. Tools............................................................................................................228 Tool number.....................................................................................................228 Note............................................................................................................228 3. Lift cylinder....................................................................................................229 3.1. Dismantling/assembling the cylinder from/in the mast.......................................................229 3.1.1. Dismantling..........................................................................................229 3.1.2. Assembling...........................................................................................230 NOTE!...................................................................................................230 Warning!................................................................................................230 3.2. Dismantling the cylinder...................................................................................231 3.3. Dismantling the piston rod seals, guide ring, guide ring holder and locking ring from the li...............231 3.4. Assembling the locking ring, piston rod seal, guide ring and guide ring holder in the lift c...............232 3.5. Dismantling and assembling the lowering brake valve........................................................232 3.6. Assembling the cylinder....................................................................................232 NOTE!.......................................................................................................232
S.S 06/24
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