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BT BT OP 1000SE BT OP 1000HSE BT OPW 1200SE BT OPW 1200HSE Master Service Manual – PDF DOWNLOAD
BT BT OP 1000SE BT OP 1000HSE BT OPW 1200SE BT OPW 1200HSE Master Service Manual – PDF DOWNLOAD
FILE DETAILS:
BT BT OP 1000SE BT OP 1000HSE BT OPW 1200SE BT OPW 1200HSE Master Service Manual – PDF DOWNLOAD
Language : English
Pages : 201
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
BT BT OP 1000SE BT OP 1000HSE BT OPW 1200SE BT OPW 1200HSE Master Service Manual – PDF DOWNLOAD
Master Service Manual (MSM) Product family OH................................................................................... 1 BT OP 1000SE BT OP 1000HSE BT OPW 1200SE BT OPW 1200HSE..................................................................... 1 Introduction to BT’s Service Manual............................................................................................. 2 Contents Master Service Manual (MSM)........................................................................................ 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 Document............................................................................................................ 4 Issued.............................................................................................................. 4 M-files.pdf..................................................................................................................... 0 Contents, M................................................................................................................. 6 1. Truck information.................................................................................................... 6 m1-175-gb1.pdf.............................................................................................................. 0 Operator’s manual....................................................................................................... 8 Valid from machine number:.......................................................................................... 8 T-code.............................................................................................................. 8 Model............................................................................................................... 8 Machine N .......................................................................................................... 8 Note................................................................................................................ 8 1. General.......................................................................................................... 8 1.1. Issued operator’s manuals.................................................................................. 8 T-kod....................................................................................................... 8 Ordering no................................................................................................. 8 Valid for machine number.................................................................................... 8 m2-175.gb1.pdf.............................................................................................................. 0 General Product Information............................................................................................. 10 Valid from serial number:........................................................................................... 10 T-code.............................................................................................................. 10 Model............................................................................................................... 10 Serial No........................................................................................................... 10 Notes............................................................................................................... 10 1. Presentation of the truck........................................................................................ 10 1.1. Intended application of the truck.......................................................................... 11 1.2. Forbidden application of the truck......................................................................... 11 2. Truck data....................................................................................................... 12 Model designation............................................................................................... 12 OP.............................................................................................................. 12 OPW............................................................................................................. 12 3. Truck dimensions................................................................................................. 13 3.1. OP1000SE/OP1000HSE......................................................................................... 13 Dimensions.................................................................................................. 14 OP 1000SE................................................................................................... 14 OP 1000HSE.................................................................................................. 14 Dimensions OP 1000SE........................................................................................ 14 3.2. OPW1200SE/OPW1200HSE....................................................................................... 15 Dimensions.................................................................................................. 16 OPW 1200SE.................................................................................................. 16 OPW 1200HSE................................................................................................. 16 Dimensions OPW 1200SE....................................................................................... 16 4. Identification plate............................................................................................. 17 Item............................................................................................................ 17 Text............................................................................................................ 17 Unit............................................................................................................ 17 Item............................................................................................................ 17 Text............................................................................................................ 17 Unit............................................................................................................ 17 5. Main components.................................................................................................. 18 1. Identification plate: With model designation, serial number, year of manufacture, weight witho............... 18 2. Mast......................................................................................................... 18 3. Emergency lowering valve: Valve for emergency lowering under the guard....................................... 18 4. Load carrier................................................................................................. 18 6. Controls and instruments......................................................................................... 19 6.1. OP1000..................................................................................................... 19 6.2. OPW1200.................................................................................................... 19 1. Adjustable writing surface............................................................................... 20 2. Right-hand deadman's handle.............................................................................. 20 3. Emergency switch off..................................................................................... 20 4. Joystick for driving forwards/backwards, travel brake and lifting/lowering of the operator cage.......... 20 5. Ignition................................................................................................. 20 6. Indication “steering wheel straight” Indication ”truck OK”............................................... 20 7. Vertical setting of the control panel.................................................................... 20 8. Horn..................................................................................................... 20 9. Lifting/lowering controls, initial lift (not OPW)........................................................ 20 10. Left-hand deadman's handle.............................................................................. 20 11. Steering wheel.......................................................................................... 20 6.2.1. Right-hand deadman's handle (2)...................................................................... 20 6.2.2. Emergency switch off (3)............................................................................. 20 NOTE!................................................................................................... 20 6.2.3. Joystick for driving forwards/backwards, travel brake and lifting/lowering of the operator........... 20 6.2.4. Horn (8)............................................................................................. 20 6.2.5. Left-hand deadman's grip (10)........................................................................ 21 6.2.6. Steering wheel (11).................................................................................. 21 12. Battery controller and hour meter................................................................... 22 13. Warning lamp (flashes when the driver grips the right-hand deadman’s handle)........................ 22 14. Emergency switch off................................................................................ 22 6.2.7. Battery controller and hour meter (12)............................................................... 22 6.2.8. Emergency driving function........................................................................... 22 1. Follow the indicating lamp's 2 second interval, located on the instrument panel, or if a buzze....... 23 2. Move the joystick to its maximum forward position (driving) immediately after turning the igni....... 23 3. Move the joystick to its maximum backwards position (driving) within 2 seconds. Keep the joyst....... 23 4. Move the joystick to its maximum right-hand position (braking) within 2 seconds. Keep the joys....... 23 5. Move the joystick to its neutral position and wait until the lamp flashes three times or the b....... 23 6. You can now drive the truck at a low speed. Drive carefully as the truck has several of its mo....... 23 6.2.9. Emergency switch off (14)............................................................................ 23 NOTE!................................................................................................... 23 6.2.10. Emergency lowering valve............................................................................ 23 6.2.11. Button for continued lift with lifting height limit (accessory) (15)................................ 24 WARNING!................................................................................................ 24 6.2.12. Button for wire guided operations (accessory) (16).................................................. 24 6.2.13. Button for working light (accessory) (17)........................................................... 24 6.2.14. Evacuation line..................................................................................... 24 6.3. Control lever OPW with lifting table (accessory)........................................................... 25 1. Indication ”truck OK”.................................................................................... 25 2. Right-hand deadman's handle.............................................................................. 25 3. Emergency switch off..................................................................................... 25 4. Button for the box lock.................................................................................. 25 5. Button for the lift table up and down.................................................................... 25 6. Horn..................................................................................................... 25 7. Joystick for driving forwards/backwards, travel brake and lifting/ lowering of the operator cage......... 25 8. Indication “steering wheel straight”..................................................................... 25 6.3.1. Right-hand deadman's handle (2)...................................................................... 25 6.3.2. Button for the box lock (4).......................................................................... 26 6.3.3. Button for the lift table up and down (5)............................................................ 26 m4-175.gb1.pdf.............................................................................................................. 0 Technical data.......................................................................................................... 28 Valid from serial number:........................................................................................... 28 T-code.............................................................................................................. 28 Model............................................................................................................... 28 Serial No........................................................................................................... 28 Notes............................................................................................................... 28 Model............................................................................................................... 28 OP 1000SE/HSE....................................................................................................... 28 OPW1200SE/HSE....................................................................................................... 28 Drive motor..................................................................................................... 28 Transmission/gear change........................................................................................ 28 Drive wheel..................................................................................................... 28 Support arm wheel............................................................................................... 29 Hydraulic unit, main lift....................................................................................... 29 Hydraulic unit, forks........................................................................................... 29 Fuses........................................................................................................... 30 Batteries....................................................................................................... 31 Travel speeds................................................................................................... 31 Lift-/lower speeds.............................................................................................. 31 Current usage................................................................................................... 32 Weight.......................................................................................................... 32 Note:....................................................................................................... 32 m6-gb.pdf................................................................................................................... 0 Ordering Spare Parts.................................................................................................... 34 m7-175.gb1.pdf.............................................................................................................. 0 Quality Parts........................................................................................................... 36 Valid from serial number:........................................................................................... 36 T-code.............................................................................................................. 36 Model............................................................................................................... 36 Serial No........................................................................................................... 36 1. Issued Quality Parts............................................................................................. 36 Model........................................................................................................... 36 Order number.................................................................................................... 36 Issued.......................................................................................................... 36 m8-175.gb1.pdf.............................................................................................................. 0 Recommended Spare Parts (RSP)........................................................................................... 38 Valid from serial number:........................................................................................... 38 T-code.............................................................................................................. 38 Model............................................................................................................... 38 Serial No........................................................................................................... 38 1. Issued RSP....................................................................................................... 38 Model........................................................................................................... 38 Serial no....................................................................................................... 38 Issued.......................................................................................................... 38 P-files.pdf..................................................................................................................... 0 Content, P.................................................................................................................. 42 1. Preventive Maintenance............................................................................................... 42 p1-175.gb1.pdf.............................................................................................................. 0 Introduction, maintenance............................................................................................... 44 1. Safety regulations with maintenance work......................................................................... 44 WARNING!........................................................................................................ 44 WARNING!........................................................................................................ 45 WARNING!........................................................................................................ 45 NOTE!........................................................................................................... 45 CAUTION!........................................................................................................ 45 2. Cleaning and washing............................................................................................. 46 NOTE!........................................................................................................... 46 2.1. External cleaning.......................................................................................... 46 NOTE!....................................................................................................... 46 2.2. Cleaning the motor compartment............................................................................. 46 NOTE!....................................................................................................... 46 2.3. Electrical components...................................................................................... 47 NOTE!....................................................................................................... 47 3. Safe lifting..................................................................................................... 47 WARNING!........................................................................................................ 47 p2-175.gb1.pdf.............................................................................................................. 0 Preventive maintenance.................................................................................................. 48 Valid from serial number:........................................................................................... 48 T-code.............................................................................................................. 48 Model............................................................................................................... 48 Serial No........................................................................................................... 48 Notes............................................................................................................... 48 1. Maintenance chart................................................................................................ 48 Item............................................................................................................ 48 Work to carry out............................................................................................... 48 Interval in hours........................................................................................... 48 5........................................................................................................... 48 20.......................................................................................................... 48 80.......................................................................................................... 48 160......................................................................................................... 48 250......................................................................................................... 48 500......................................................................................................... 48 1000........................................................................................................ 48 Interval in days/weeks/months............................................................................... 48 1 d......................................................................................................... 48 1 w......................................................................................................... 48 1 m......................................................................................................... 48 2 m......................................................................................................... 48 3 m......................................................................................................... 48 6 m......................................................................................................... 48 12 m........................................................................................................ 48 p3-175.gb1.pdf.............................................................................................................. 0 Oil and grease specification............................................................................................ 56 Valid from serial number:........................................................................................... 56 T-code.............................................................................................................. 56 Model............................................................................................................... 56 Serial No........................................................................................................... 56 Notes............................................................................................................... 56 Lubricant........................................................................................................... 56 Specification....................................................................................................... 56 > - 15 C............................................................................................................ 56 < - 15 C............................................................................................................ 56 S-files.pdf..................................................................................................................... 0 Content, S.................................................................................................................. 58 1. Service instructions................................................................................................. 58 2550-175.gb1.pdf............................................................................................................ 0 Transmission, Gear...................................................................................................... 60 Valid from serial number:........................................................................................... 60 T-code.............................................................................................................. 60 Model............................................................................................................... 60 Serial No........................................................................................................... 60 Notes............................................................................................................... 60 1. General.......................................................................................................... 60 2. Gear components/data............................................................................................. 61 2.1. Component identification................................................................................... 61 Pos No...................................................................................................... 61 Component................................................................................................... 61 2.2. Technical gear data........................................................................................ 62 Truck type.................................................................................................. 62 OP 1000SE/HSE............................................................................................... 62 OPW 1200SE/HSE.............................................................................................. 62 2.3. Dismantled gear............................................................................................ 63 3. Dismantling/fitting.............................................................................................. 64 3.1. Dismantling of drive unit from truck:...................................................................... 64 1. Open the doors of the motor compartment.................................................................. 64 2. Lift up the truck using a jack so that the wheel is lifted off the ground, then block under th........... 64 3. Drain off the oil from the drive gear.................................................................... 64 4. Remove the motor cables and the speed measurement cables................................................. 64 5. Loosen and remove the M10 bolts that hold the drive unit on the chassis.................................. 64 6. Lift out the drive unit from the truck with mechanical aid............................................... 64 7. Place the drive unit on a bench or the like.............................................................. 64 3.2. Fitting the drive unit in truck:........................................................................... 64 1. Lift the drive unit into position on the chassis......................................................... 64 2. Bolt the drive unit in position using the M10 bolts and tightening torque of 145 Nm. The bolts........... 64 3. Fit the motor cables and the speed measuring cables...................................................... 64 4. Fill the drive gear with oil............................................................................. 64 5. Lower the truck to the floor............................................................................. 64 3.3. Dismantling the drive motor and the gear:.................................................................. 65 1. Dismantle the drive wheel (1) from the gear.............................................................. 65 2. Separate the drive motor and the gear by removing the 5 motor bolts (2).................................. 65 3.4. Fitting the drive motor and the gear:...................................................................... 65 1. Fit a new O-ring (3) on the drive motor’s bearing retainer............................................... 65 2. Fit together the drive motor and drive gear taking care not to damage the O-ring. Tighten the ........... 65 3. Fit the drive wheel. The wheel nuts (1) should be tightened crosswise at a torque of 88 Nm............... 65 4. Oil level check/replacing........................................................................................ 66 4.1. Check/filling of oil....................................................................................... 66 4.2. Oil replacement............................................................................................ 67 1. Drain off the old oil by removing the drainage plug (1).................................................. 67 2. Use a new copper seal (2) when the drainage plug is refitted............................................. 67 3. Fill up oil in accordance with filling instructions...................................................... 67 4. Check that no leakage occurs from the drainage plug...................................................... 67 5. Repairs.......................................................................................................... 68 5.1. Exchange of drive shaft sealing ring....................................................................... 68 5.1.1. Dismantling:......................................................................................... 68 1. Drain the gear of oil................................................................................ 68 2. Dismantle the drive unit from the truck as set out in chapter 3.1.................................... 68 3. Remove the drive wheel from the gear................................................................. 68 4. Remove the lower gear cover.......................................................................... 68 5. Loosen the drive shaft nuts. Remove the nuts, locking washers and spacer ring........................ 68 6. Knock out the drive shaft using a brass punch and a hammer........................................... 68 7. Pull off the bearing from the drive shaft using a bearing puller..................................... 68 NOTE!................................................................................................... 68 8. Remove the seal ring from the drive shaft........................................................ 68 5.1.2. Assembly:............................................................................................ 69 1. Place the drive shafts outer bearing in the gear housing............................................. 69 2. Press the new seal ring in place in the gear housing. Be careful when pressing it in place so ....... 69 3. Press the drive shaft into the gear housing. Check that the splines on the drive shaft are ali....... 69 4. Place the spacer ring and locking washer onto the drive shaft end and screw in the shaft bolts....... 69 5. Before fitting the lower cover, change the O-ring. Fit the cover and tighten the bolts to 25 N....... 69 6. Fill up oil in accordance with filling instructions, section 4.1..................................... 69 7. Fit the drive wheel and tighten the wheel nut with a torque of 88 Nm. The wheel nuts should be....... 69 8. Fit the drive unit in the truck as set out in chapter 3.2............................................ 69 5.2. Leakage from the top cover................................................................................. 70 1. Dismantle the gear from the truck as described in section 3.1 and 3.3.................................... 70 2. Loosen all bolts holding the top cover to the gear housing............................................... 70 3. Remove the cover from the gear housing and clean the sealing surfaces of the cover and gear ho........... 70 4. Apply sealant type Curil K2 to the surfaces. Follow the instructions given on the container.............. 70 5. Fit the cover bolts and tighten with a torque of 25 Nm. The bolts should be greased prior to a........... 70 6. Fill up oil in accordance with filling instructions, section 4.1......................................... 70 7. Fit together the drive gear and the drive motor and fit the drive unit in the truck as describ........... 70 5.3. Leakage from the lower cover............................................................................... 71 1. Drain out the remaining oil from the drive gear.......................................................... 71 2. Dismantle the cover from the drive gear.................................................................. 71 3. Replace the seal on the drain plug and the O-ring on the cover........................................... 71 4. Fit the cover and tighten the bolts to a torque of 25 Nm. Ensure the O-ring is not damaged. Th........... 71 5.4. Replacing the wheel bolt................................................................................... 71 1. Dismantle the drive gear from the truck as described in chapter 3.1.and 3.3.............................. 71 2. Dismantle the drive shaft from the gear as described in chapter 5.1.1 (replacement of seal ring)......... 71 3. Press or knock out the damaged bolt from the drive shaft rim............................................. 71 4. Smooth away any burring around the bolt hole and press or knock the new bolt into place.................. 71 5. Fit the drive shaft into the gear as described in chapter 5.1.2.......................................... 71 NOTE!....................................................................................................... 71 6. Fit the drive gear/drive unit in the truck as described in chapter 3.4 and 3.2....................... 71 3370-175.gb1.pdf............................................................................................................ 0 Brake................................................................................................................... 72 Valid from serial number:........................................................................................... 72 T-code.............................................................................................................. 72 Model............................................................................................................... 72 Serial No........................................................................................................... 72 Notes............................................................................................................... 72 1. General.......................................................................................................... 72 1.1. Function................................................................................................... 73 2. Maintenance...................................................................................................... 73 2.1. Adjustment................................................................................................. 74 2.1.1. Procedure for adjustment:............................................................................ 74 1. Loosen the anchor bolts a little..................................................................... 74 2. Turn the nut anticlockwise and pull out the bolts a little. At the same time, check the gap wi....... 74 3. Pull the anchor bolts to 25 Nm and check the gap with the thickness gauge again...................... 74 4. Repeat the procedure for every brake segment......................................................... 74 5. Adjust the brake on motor No. 2...................................................................... 74 2.2. Change of brake disk....................................................................................... 75 2.2.1. Procedure for change:................................................................................ 75 1. Disconnect the brake’s electric cabling.............................................................. 75 2. Loosen and remove the six allen head cap screws and lift off the brake coil.......................... 75 3. Change the brake disk on the hub and visually check the wear on the friction plates. Also chan....... 75 4. Unscrew the bolts on the coil so that there is a gap between the coil and pressure plates when....... 75 5. Mount the coil and adjust the gap as per instructions in section 2.1................................. 75 6. Reconnect the electric cables again.................................................................. 75 4200-175.gb1.pdf............................................................................................................ 0 Wire guidance........................................................................................................... 76 Valid from serial number:........................................................................................... 76 T-code.............................................................................................................. 76 Model............................................................................................................... 76 Serial No........................................................................................................... 76 Notes............................................................................................................... 76 1. General.......................................................................................................... 76 2. Generator........................................................................................................ 77 2.1. Technical data............................................................................................. 77 Power supply................................................................................................ 77 Model LDU-22 220 V 50 Hz.................................................................................... 77 Model LDU-21 110 V 50/60 Hz................................................................................. 77 3. Antennae......................................................................................................... 78 3.1. Antenna wire............................................................................................... 79 4. Wire guidance card............................................................................................... 79 4.1. Components................................................................................................. 79 4.2. Connections................................................................................................ 80 Conn........................................................................................................ 80 Type........................................................................................................ 80 No.......................................................................................................... 80 Active...................................................................................................... 80 Function.................................................................................................... 80 Conn........................................................................................................ 80 Type........................................................................................................ 80 No.......................................................................................................... 80 Active...................................................................................................... 80 Function.................................................................................................... 80 4.3. Display.................................................................................................... 81 4.3.1. Input signals........................................................................................ 81 Segment................................................................................................. 81 Function................................................................................................ 81 4.3.2. Output signals/operating mode........................................................................ 81 ........................................................................................................ 81 Segment................................................................................................. 81 Function................................................................................................ 81 4.3.3. Error codes.......................................................................................... 82 Code........................................................................................................ 82 Description................................................................................................. 82 5. Diverse.......................................................................................................... 83 6. Description of function.......................................................................................... 84 6.1. Driving forwards........................................................................................... 84 6.2. Reversing.................................................................................................. 84 6.3. Control signals............................................................................................ 85 Operating mode.............................................................................................. 85 S........................................................................................................... 85 V........................................................................................................... 85 P........................................................................................................... 85 7. Adjustments...................................................................................................... 86 7.1. Adjustment instructions for A2............................................................................. 86 7.1.1. Adjusting the steering angle potentiometer:.......................................................... 86 1. Set the truck mechanically straight outside the narrow aisle, without requesting wire guidance....... 86 2. Adjust the ZERO potentiometer (2) on the A2 box so that the two LED’s comes on simultaneously........ 86 7.2. Adjustment instructions for A3............................................................................. 86 Menu........................................................................................................ 87 Description................................................................................................. 87 Range....................................................................................................... 87 7.2.1. steering angle setting............................................................................... 88 1. Start by placing the trucks steering wheel straight outside the aisle. Check the adjustments, ....... 88 2. Activate the setting mode............................................................................ 88 3. Auto-adjust the steering angle off-set in menu 1.2................................................... 88 7.2.2. Fine tuning the steering angle off-set............................................................... 89 1. Drive into the wire aisle backwards a few meters, with wire requested, then stop gently. Make ....... 89 2. Post-adjust the steering angle signal in menu 1.5.................................................... 89 3. Drive slowly in reverse direction and make sure that the LEDs (1) are symmetrically lit. If ne....... 89 7.2.3. Antenna offset adjustment reversing.................................................................. 89 1. Drive slowly backwards approx. 20 sec. and then stop gently.......................................... 89 2. Read of the value in the menu 10.7................................................................... 89 3. Set menu 6 to this value............................................................................. 89 7.2.4. Antenna offset adjustment forwards................................................................... 89 1. Drive forwards slowly for approx. 20 sec. and then stop gently....................................... 89 2. Read off the value in the menu 10.6.................................................................. 89 3. Multiply this value by a truck-specific constant witch is 2 for this truck type...................... 89 4. Set menu 4 to this newly calculated value............................................................ 90 7.2.5. Storing the parameters............................................................................... 90 1. Store the parameters in menu 9.3 after completed adjustment.......................................... 90 7.2.6. Antenna offset adjustment, 1-antenna mode............................................................ 90 1. Disconnect the cables from the aisle sensors (Inputs 109 and 110 on the A2 card) and the aisle....... 90 2. Drive slowly in reverse direction and at the same time read-off the value in menu 10.2 (angle ....... 90 3. Switch off wire guidance in the cabin and check that forwards is active (menu 10.0 r=reverse,F....... 90 4. Read-off the value in menu 10.2...................................................................... 90 5. Adjust menu 1.9 to this value........................................................................ 90 6. Store the parameters according to “Storing the parameters”........................................... 90 8. Installing a new wire guidance card.............................................................................. 91 POS............................................................................................................. 91 Truck model..................................................................................................... 91 ID number....................................................................................................... 91 1. Output X22:9 is activated if the unit “sees the wire” but the operator has not selected wire g........... 92 2. Output X22:8 is activated if the side-signal >75% of the permitted value. The output can be us........... 92 POS............................................................................................................. 92 Truck model..................................................................................................... 92 ID number....................................................................................................... 92 9. Trouble shooting................................................................................................. 93 9.1. Control signals............................................................................................ 93 9.1.1. Checking the reference signal........................................................................ 93 kHz..................................................................................................... 93 mA...................................................................................................... 93 9.1.2. Checking the side signal............................................................................. 93 9.1.3. Checking the steering angle signal................................................................... 93 5000-175.gb1.pdf............................................................................................................ 0 Electric system......................................................................................................... 94 Valid from serial number:........................................................................................... 94 T-code.............................................................................................................. 94 Model............................................................................................................... 94 Serial No........................................................................................................... 94 Notes............................................................................................................... 94 1. General.......................................................................................................... 94 2. List of symbols.................................................................................................. 94 Symbol.......................................................................................................... 94 Description..................................................................................................... 94 Function........................................................................................................ 94 Notes........................................................................................................... 94 2.1. Electric chart (1/10)...................................................................................... 98 2.2. Electric chart (2/10)...................................................................................... 99 2.3. Electric chart (3/10)......................................................................................100 2.4. Electric chart (4/10)......................................................................................101 2.5. Electric chart (5/10)......................................................................................102 2.6. Electric chart (6/10)......................................................................................103 2.7. Electric chart (7/10)......................................................................................104 2.8. Electric chart (8/10)......................................................................................105 2.9. Electric chart (9/10)......................................................................................106 2.10. Electric chart (10/10)....................................................................................107 3. Presentation of electric chart OP 1000/2 SE/HSE..................................................................108 3.1. Drive motor circuit (see electric chart 1/10)..............................................................108 3.2. Pump motors, cabin lift and initial lift, and also battery indicators and hour meters. (elec...............108 3.3. Steering servo (see electric chart 3/10)...................................................................109 3.4. Inputs to the electronic circuit board A2 (see electric chart 4/10)........................................110 3.5. Inputs to the electronic circuit board A2 (see electric chart 5/10)........................................110 3.6. Inputs to the electronic circuit board A2 (see electric chart 6/10)........................................111 3.7. Outputs from the electronic circuit board A2 (see electric chart 7/10).....................................111 3.8. Outputs from the electronic circuit board A2 (see electric chart 8/10).....................................112 3.9. Initial lift/lower, horn and lighting (see electric chart 9/10)............................................112 3.10. Wire guidance (see electric chart 10/10)..................................................................113 4. Function description electric system OP 1000/2 SE/HSE............................................................113 4.1. Start-up...................................................................................................113 4.2. Check of the operator's presence in the operator cabin.....................................................114 4.3. Deadman's handles..........................................................................................114 4.4. Driving forward-back.......................................................................................115 4.5. Travel speed...............................................................................................116 4.5.1. Outside narrow aisle:................................................................................116 4.5.2. In narrow aisle:.....................................................................................116 4.6. Brake......................................................................................................116 4.7. Steering...................................................................................................117 4.8. Cabin lift.................................................................................................117 4.9. Cabin lower................................................................................................118 4.10. Slack chain guard.........................................................................................118 4.11. Initial lift..............................................................................................118 4.12. Initial lower.............................................................................................119 4.13. Other.....................................................................................................119 4.14. Aisle-end brake (extra equipment).........................................................................120 5000-175.gb2.pdf............................................................................................................ 0 Electric system.........................................................................................................122 Valid from serial number:...........................................................................................122 T-code..............................................................................................................122 Model...............................................................................................................122 Serial No...........................................................................................................122 Notes...............................................................................................................122 1. General..........................................................................................................122 2. List of symbols..................................................................................................122 Symbol..........................................................................................................122 Description.....................................................................................................122 Function........................................................................................................122 Notes...........................................................................................................122 2.1. Electric chart (1/10)......................................................................................126 2.2. Electric chart (2/10)......................................................................................127 2.3. Electric chart (3/10)......................................................................................128 2.4. Electric chart (4/10)......................................................................................129 2.5. Electric chart (5/10)......................................................................................130 2.6. Electric chart (6/10)......................................................................................131 2.7. Electric chart (7/10)......................................................................................132 2.8. Electric chart (8/10)......................................................................................133 2.9. Electric chart (9/10)......................................................................................134 2.10. Electric chart (10/10)....................................................................................135 3. Description of electric system OP1000/2 SE/HSE with double command...............................................136 3.1. Drive motor circuit (see electric chart 1/10)..............................................................136 3.2. Pump motors, cabin lift and initial lift, and also battery indicators and hour meters (see e...............136 3.3. Steering servo (see electric chart 3/10)...................................................................137 3.4. Inputs to the electronic circuit board A2 (see electric chart 4/10)........................................138 3.5. Inputs to the electronic circuit board A2 (see electric chart 5/10)........................................138 3.6. Inputs to the electronic circuit board A2 (see electric chart 6/10)........................................139 3.7. Outputs from the electronic circuit board A2 (see electric chart 7/10).....................................140 3.8. Outputs from the electronic circuit board A2 (see electric chart 8/10).....................................140 3.9. Initial lift/lower, sound signals and lighting (see electric chart 9/10)...................................141 3.10. Wire guidance (see electric chart 10/ 10).................................................................141 4. Function description of electric system OP 1000/2 SE/HSE with double command.....................................142 4.1. Start-up...................................................................................................142 4.2. Check of the operator's presence in the operator's cabin...................................................142 4.3. Deadman's handle...........................................................................................143 4.4. Driving forward-back.......................................................................................143 4.5. Travel speed...............................................................................................144 4.5.1. Outside narrow aisle:................................................................................145 4.5.2. In narrow aisle:.....................................................................................145 4.6. Brake......................................................................................................145 4.7. Steering...................................................................................................145 4.8. Cabin lift.................................................................................................146 4.9. Cabin lower................................................................................................147 4.10. Slack chain guard.........................................................................................147 4.11. Initial lift..............................................................................................147 4.12. Initial lower.............................................................................................147 4.13. Other.....................................................................................................148 4.14. Aisle-end brake (extra equipment).........................................................................148 5000-177.gb1.pdf............................................................................................................ 0 Electric system.........................................................................................................150 Valid from serial number............................................................................................150 T-code..............................................................................................................150 Model...............................................................................................................150 Serial No...........................................................................................................150 Notes...............................................................................................................150 1. General..........................................................................................................150 2. List of symbols..................................................................................................150 ................................................................................................................150 Symbol..........................................................................................................150 Description.....................................................................................................150 Function........................................................................................................150 Notes...........................................................................................................150 2.1. Electric chart (1/10)......................................................................................153 2.2. Electric chart (2/10)......................................................................................154 2.3. Electric chart (3/10)......................................................................................155 2.4. Electric chart (4/10)......................................................................................156 2.5. Electric chart (5/10)......................................................................................157 2.6. Electric chart (6/10)......................................................................................158 2.7. Electric chart (7/10)......................................................................................159 2.8. Electric chart (8/10)......................................................................................160 2.9. Electric chart (9/10)......................................................................................161 2.10. Electric chart (10/10)....................................................................................162 3. DESCRIPTION OF ELECTRIC SYSTEM OPW 1200/2 SE/HSE.................................................................163 3.1. Drive motor circuit (electric chart 1/10)..................................................................163 3.2. Pump motor, cabin lift and also battery indicator and hour meter (electric chart 2/10).....................163 3.3. Steering servo (electric chart 3/10).......................................................................164 3.4. Inputs to the electronic circuit board A2 (electric chart 4/10)............................................164 3.5. Inputs to the electronic circuit board A2 (electric chart 5/10)............................................165 3.6. Inputs to the electronic circuit board A2 (electric chart 6/10)............................................166 3.7. Outputs to the electronic circuit board A2 (electric chart 7/10)...........................................166 3.8. Outputs to the electronic circuit board A2 (electric chart 8/10)...........................................167 3.9. Horn and lighting (electric chart 9/10)....................................................................167 3.10. Wire guidance (electric chart 10/10)......................................................................167 4. Function description electric system OPW 1200/2 SE/HSE...........................................................168 4.1. Start-up...................................................................................................168 4.2. Check of the operator's presence in the operator's cabin...................................................168 4.3. Deadman's handle...........................................................................................169 4.4. Driving forward-back.......................................................................................169 4.5. Travel speed...............................................................................................170 4.5.1. Outside narrow aisle:................................................................................170 4.5.2. In narrow aisle:.....................................................................................170 4.6. Brake......................................................................................................171 4.7. Steering...................................................................................................171 4.8. Cabin lift.................................................................................................172 4.9. Cabin lower................................................................................................172 4.10. Slack chain guard.........................................................................................173 4.11. Other.....................................................................................................173 4.12. Aisle-end brake (extra equipment).........................................................................174 5460-175.gb1.pdf............................................................................................................ 0 Transistor regulator....................................................................................................176 Valid from serial number:...........................................................................................176 T-code..............................................................................................................176 Model...............................................................................................................176 Serial No...........................................................................................................176 Notes...............................................................................................................176 1. Motor connections................................................................................................177 ................................................................................................................177 Terminal number.................................................................................................177 Function........................................................................................................177 2. Contact for control voltages.....................................................................................177 Terminal number.................................................................................................177 Con.............................................................................................................177 Function........................................................................................................177 LED no..........................................................................................................177 Colour..........................................................................................................177 Function........................................................................................................177 3. Safety checking..................................................................................................178 3.1. Check of the transistor regulator’s safety circuit.........................................................178 WARNING!....................................................................................................178 5710-175.gb1.pdf............................................................................................................ 0 Electronic circuit board................................................................................................180 Valid from serial number:...........................................................................................180 T-code..............................................................................................................180 Model...............................................................................................................180 Serial No...........................................................................................................180 Notes...............................................................................................................180 1. General..........................................................................................................180 2. Voltages on the electronic circuit board A2......................................................................180 Input...........................................................................................................180 Cable No........................................................................................................180 Description.....................................................................................................180 Active..........................................................................................................180 LED.............................................................................................................180 2.1. Functions on the display on the electronic circuit board A2................................................184 2.2. Programmable parameters....................................................................................185 2.3. Programming state..........................................................................................186 1. Hold one of the buttons VALUE or PARAMETER down when you start the truck (The key switch or em...........186 2. When you release the button, the display shows 0 or 1. If the display shows 0, press the butto...........186 3. After you have entered the programming state, the display will light a segment and let it “rot...........186 2.4. Selection of parameter.....................................................................................186 2.5. Selection of value.........................................................................................186 2.6. Programming of new value...................................................................................187 2.7. Exiting the programming....................................................................................187 2.7.1. Deadlocking:.........................................................................................187 2.7.2. Error codes..........................................................................................188 2.8. A2 Electronic circuit board................................................................................190 3. Adjusting instruction electric system OP/OPW.....................................................................191 3.1. Adjustment of mid-position steered wheel (drive wheel).....................................................191 3.2. Adjustment (offset) cabin lift.............................................................................191 3.3. Adjustment (offset) cabin lower............................................................................191 3.4. Adjustment of the drive motor’s pulse transducer...........................................................192 3.5. Adjustment (offset) steering motor, the A3 box.............................................................192 3.6. Adjustment of height measurement transducer................................................................192 3.7. A3 Steering servo..........................................................................................193 3.8. A3 Steering servo..........................................................................................194 3.8.1. Indications:.........................................................................................194 3.8.2. DIP switch gear:.....................................................................................194 3.8.3. P2: Potentiometer for adjustment of the steering motor’s offset......................................195 3.9. A5 Logic box valve steering initial lift/ lower............................................................196 4. Emergency drive function.........................................................................................197 1. Immediately after the switching on with the ignition key the joystick is moved to its front po...............197 2. Thereafter, within 2 seconds, the joy-stick is moved to its back position (travel). Hold there...............197 3. Thereafter, within 2 seconds, the joy-stick is moved to its most right position (brake). Hold ...............197 4. Move the joystick back to its neutral position and wait until the lamp has blinked three times...............197 5. You can now drive the truck at low speed. Drive carefully, as the truck has several of its sup...............197 6000-175.gb1.pdf............................................................................................................ 0 Hydraulic system........................................................................................................198 Valid from serial number:...........................................................................................198 T-code..............................................................................................................198 Model...............................................................................................................198 Serial No...........................................................................................................198 Notes...............................................................................................................198 1. General..........................................................................................................198 2. Function description.............................................................................................198 2.1. Cabin lift, joystick upwards...............................................................................198 2.2. Cabin lift, joystick downwards.............................................................................198 2.3. Hydraulic chart, cabin lift/lower..........................................................................199 2.4. Fork lift..................................................................................................200 2.5. Fork lower.................................................................................................200 2.6. Hydraulic chart, fork lift/lower...........................................................................201
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