STILL STED Forklift XOP1 Workshop Manual - PDF DOWNLOAD

return to the table of workshop manuals

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Workshop Manual XOP1

80001

80002

80003

80004

First issue: Last revision:

08/03 07/01

WorkshopManual

XOP1

Id. no. 8 054 335

01

Foreword Foreword This workshop manual provides specifications and describes functional characteristics of the standard truck.

This provides you with a comprehensive documentation to ensure better understanding of the vehicle technology and so permit correct maintenance and repair work to be carried out.

50002

The workshop manual is always updated by supplementary sheets.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Updating of workshop manuals The industrial truck range is subject to continuous further development. This means that certain components or assemblies are exchanged or modified.

50003

To ensure that the holder of this manual always has the most up to date version of the documentation, it is important to abide by the following updating system.

50004

80004

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

1

Foreword Updating workshop manuals

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Exchanging faulty sheets If a particular page contains mistakes, for example due to altered setting values, the respective sheet must be exchanged.

A newly inserted sheet can be recognized by the altered left-hand baseline (1). Here, the date of compilation is updated in the line entitled Issue (2). In the line Replaces issue (3) is the compilation date of the sheet to be replaced. The sheet no. remains the same (4).

With every revision the first sheet will be replaced. In (9) you see the first issue and the date of the last revision. This tells you the revision state of the whole book.

Page baseline of the existing sheet Workshop Manual

Issue: 8/03 Replaces issue:

1

4

2 Page baseline of the corrected sheet Workshop Manual

Issue: 11/03 Replaces issue: 8/03

Insertion of supplementary sheets If new, modified or additional components are included in the series truck, it may be necessary to add one or more supplementary sheets.

The additional sheet is recognized by the lefthand and right-hand page baseline (5+6).

In the Issue line on the left-hand side is the compilation date (7). On the right, the supplementary sheet is marked by the sheet no. with continuous index (8).

In addition, the table of contents of the respective assembly must also be exchanged.

Newly compiled sheets, whether replacements or supplementary sheets, and the new tables of contents are sent by post to all known holders of workshop manuals.

sheet.no. 4-01

sheet-no.

4-01

3 Page baseline of the first sheet Workshop Manual

First issue: 8/03 Last revision: 11/03

N° id. -------

9

Page baseline of the existing sheet Workshop Manual

Issue: 8/03 Replaces issue:

sheet-no.

4-01

6

5 Page baseline of the supplementary sheet Workshop Manual

Issue: 11/03 Replaces issue:

sheet-no.

4-01

7

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

8

2

Foreword Remarks, imprint No guarantee claims arise as a result of working in accordance with the instructions contained in this manual.

This does not affect the guarantee stipulations.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

We are continuously involved in the further development of our industrial trucks. Please appreciate that this documentation is subject to alteration and error, and that no claims may be derived from information, illustrations and descriptions contained in the workshop manual.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

3

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Sections 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 99

Issue: Replaces issue:

Vehicle data Travel motor Drive wheel Gear Brake Idling wheels Hydraulic Cylinder Line break protection Hydraulic pump Aisle recognition Steering Vehicle control system (FZS) Operating panel End-of-aisle safety system (EASS) Speed sensor Braking monitor (ABÜ) Travel control Travel switch BDI/HM Travel control software Steering software Hand-held programming unit Maintenance

08/03

WorkshopManual

XOP1

Sheet no.

4

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Table of Contents Section

Contents Sheet Foreword ......................................................................................2 Updating of workshop manuals............................................2 Exchanging faulty sheets .....................................................3 Insertion of supplementary sheets .......................................3 Remarks, imprint ..........................................................................4 Sections........................................................................................5

1

Vehicle data Definition of vehicle model names...........................................1-01 Signs on the vehicle ................................................................1-02 Travel speed ...........................................................................1-03 Outside the aisle .............................................................1-03 Inside the aisle ................................................................1-03

2

Travel motor General....................................................................................2-01 Temperature monitor ...............................................................2-01 Technical data .........................................................................2-02 Terminals .................................................................................2-02 Removing the travel motor ......................................................2-03 Installation ...............................................................................2-04 Maintenance............................................................................2-05 General ...........................................................................2-05 Cleaning..........................................................................2-05 Visual inspection, replacing damaged parts ...................2-06 Checking the brush mechanism......................................2-08 Commutator ....................................................................2-09 Bearings..........................................................................2-09

3

Drive wheel General....................................................................................3-01 Removing the drive wheel .......................................................3-01 Installing the drive wheel .........................................................3-01

4

Gear Remove ...................................................................................4-01 Installing the gear ....................................................................4-02 Changing oil ............................................................................4-03 Oil change method ..................................................................4-04 Checking the oil level ..............................................................4-05 Lubricating the bogie bearing ..................................................4-05

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

5

Table of Contents

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Section

Contents

Sheet

5

Brake Electromagnetic spring brake ..................................................5-01 General ...........................................................................5-01 Function ..........................................................................5-02 Removal ..........................................................................5-03 Checking the rotor...........................................................5-03 Adjusting the brake clearance.........................................5-04 General...................................................................5-04 Adjustment process ................................................5-04 Adjusting the braking force..............................................5-05 Maintenance....................................................................5-06 Measuring the brake deceleration ...........................................5-07 General ...........................................................................5-07 Preparations for measurement........................................5-07 Evaluating the measurement ..........................................5-08

6

Idling wheels General....................................................................................6-01 Removal ..................................................................................6-01

7

Hydraulic Montagevorschrift ....................................................................7-01 Hydraulic circuit plan ...............................................................7-01 Block diagram for NO/HO........................................................7-02 Block diagram for NM/HM .......................................................7-03 Pump unit ................................................................................7-04 General ...........................................................................7-04 Components:...................................................................7-04 Electrically releasable non-return valve ..........................7-05 Replacing the carbon brushes (NO, NM) ........................7-06 Replacing the carbon brushes (HO, HM) ........................7-07 Removal ..........................................................................7-08 Removing the pump motor (NO, NM) .............................7-09 Removing the pump motor (HO, HM) .............................7-10 Adjustment Pressure release valve.................................7-11 Changing the hydraulic oil...............................................7-12 Bleeding the lift cylinders and the hydraulic system ................7-13 Procedure........................................................................7-13 Distributor block.......................................................................7-14 Bubble reservoir ......................................................................7-15 Hydraulic hoses .......................................................................7-16

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

6

Table of Contents

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Section

Contents

Sheet

8

Cylinders Cylinder support ......................................................................8-01 Main lift cylinder on NO/NM.....................................................8-02 Removal .........................................................................8-02 Dismantling ....................................................................8-03 Main lift cylinder on HO/HM.....................................................8-04 Removal .........................................................................8-04 Dismantling ....................................................................8-05 Additional lift cylinder on NM/HM.............................................8-06 Removal .........................................................................8-06 Dismantling ....................................................................8-07

9

Line break protection General....................................................................................9-01

10

Hydraulic pump General..................................................................................10-01 Removing ..............................................................................10-02 Dismantling............................................................................10-03

11

Aisle recognition General ..................................................................................11-01

12

Steering Block diagram of the steering system....................................12-01 Pin assignment ......................................................................12-02 Setpoint potentiometer, steering wheel .................................12-04 Replacing ......................................................................12-04 Setpoint potentiometer, steering knob ...................................12-05 Replacing ......................................................................12-05 Actual value potentiometer ....................................................12-06 Replacing ......................................................................12-06 Quick start .............................................................................12-07 Travel on curves function.......................................................12-08 Steering lock..........................................................................12-09

13

Vehicle control system (FZS) General..................................................................................13-01 Location .................................................................................13-01 Identification ..........................................................................13-01 Technical data........................................................................13-01 Guide to versions...................................................................13-02 Pin assignment ......................................................................13-03 Input/output assignment ........................................................13-06

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

7

Table of Contents

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Section

Contents

Sheet

13

Vehicle control system Error diagnosis........................................................................13-07 Flashing code, FZS2 ......................................................13-07 Table of functions, FZS2 .........................................................13-08 Application......................................................................13-08 Pedestrian operating mode ...........................................13-09 Switch-over, 2nd operating console ...............................13-10 Power outputs ................................................................13-11 Travel enable..................................................................13-12

14

Operating console Position of the operating elements .........................................14-01 Removal..................................................................................14-01 Installing..................................................................................14-01 Wheel position display ............................................................14-02 Adjustment .....................................................................14-02 Teaching in the FZS2 .....................................................14-02 2nd operating console ............................................................14-03 Pedestrian operating mode.....................................................14-04

15

End-of-aisle safety system (EASS) End-of-aisle safety system (EASS).........................................15-01 General ..........................................................................15-01 EASS Universal ......................................................................15-02 Error codes.....................................................................15-03 EASS Inductive.......................................................................15-04 Function .........................................................................15-04 Guide to the system .......................................................15-06 Monitoring .....................................................................15-07 Mounting the proximity switches ....................................15-08 Testing the proximity switches........................................15-08 Displays and pin assignment ........................................15-09 EASS Magnetic (bistable).......................................................15-10 Function .........................................................................15-10 Guide to the system .......................................................15-12 Monitoring ......................................................................15-13 Magnetic switch..............................................................15-14 Description.............................................................15-14 Bistable action .......................................................15-14 Switching magnet...........................................................15-15 Description.............................................................15-15 Handling instructions .............................................15-15 Displays and pin assignment .......................................15-16

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

8

Table of Contents Section

Contents

Sheet

Speed sensor General..................................................................................16-01 Terminals block connector X2 .......................................16-01 Signal sequence............................................................16-01 Testing the speed sensor.......................................................16-02

17

ABÜ - Braking monitor Block diagram........................................................................17-01 Pin assignment ......................................................................17-02 General..................................................................................17-04 Functions ...............................................................................17-05 Travel on curves............................................................17-05 Signal adaptation..................................................17-05 Flashing error codes..............................................................17-06

18

Travel control Block diagram for "Travel" .....................................................18-01 General..................................................................................18-02 Main current section - terminals ............................................18-03 Pin assignment ......................................................................18-04 Description of functions .........................................................18-07 Braking modes ..............................................................18-07 Table of operating modes..............................................18-07 Hour meter ....................................................................18-08 Service hour meter........................................................18-08 Battery discharge indicator............................................18-08 Monitoring function........................................................18-09 Error display ..........................................................................18-10 Test procedure.......................................................................18-10

19

Direction sender General..................................................................................19-01 Replacing...............................................................................19-01

20

BDI/HM General..................................................................................20-01 Pin assignment ......................................................................20-02 Function.................................................................................20-03 Error display ..........................................................................20-03 Battery discharge indicator ....................................................20-03 Hour meter.............................................................................20-04

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

16

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

9

Table of Contents

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Section

Contents

Sheet

21

Travel control software General..................................................................................21-01 Making a connection..............................................................21-01 Setting parameters ................................................................21-02 Test ........................................................................................21-03 Diagnosis...............................................................................21-03 "File" menu ............................................................................21-03 Summary of the most important parameters .........................21-05 Battery discharge curves .......................................................21-06 List of parameters..................................................................21-07 Description of parameters .....................................................21-12 Errors displayed with flashing code .......................................21-17 List of error codes..................................................................21-18 Tester Table ...........................................................................21-19

22

Steering software General..................................................................................22-01 Making a connection..............................................................22-02 Errors .....................................................................................22-03 Current errors................................................................22-03 Stored errors .................................................................22-03 Teaching in ............................................................................22-04 General .........................................................................22-04 Procedure......................................................................22-04 Setpoint potentiometer ..................................................22-05 Actual value potentiometer............................................22-06 Tester.....................................................................................22-09 Speed measurement.....................................................22-09 Amplifier data ................................................................22-10 Digital inputs and outputs ..............................................22-11 Travel on curves active .........................................22-11 Deadman ..............................................................22-11 Steering wheel/ -knob ...........................................22-11 Steering OK ..........................................................22-11 Steering motor contactor ......................................22-12 Safety relay...........................................................22-12 Potentiometer voltages .................................................22-13 Supply voltage of actual and setpoint values .......22-13 Setpoint voltage at the steering wheel..................22-13 Actual value voltages at the drive wheel ..............22-13 Table of errors........................................................................22-14

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

10

Table of Contents Section

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

23

Contents

Sheet

Hand-held programming unit General..................................................................................23-01 Operating elements ...............................................................23-01 Switching on ..........................................................................23-02 Switching off ..........................................................................23-02 Language selection ...............................................................23-03 Setting parameters ................................................................23-04 PROGRAM menu .........................................................23-04 Function ........................................................................23-05 Special program menu ..........................................................23-06 Resetting to initial settings ............................................23-07 Loading settings from the control system into the programming unit .............................................23-08 Loading settings from the programming unit into the control system. .................................................23-09 Deleting the diagnosis data...........................................23-10 Adjusting the display contrast .......................................23-11 Language selection.......................................................23-12 Displaying information about the programming unit......23-12 Displaying information about the control.......................23-12 Test menu..............................................................................23-13 Displaying current errors .......................................................23-14 Error history...........................................................................23-14

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

11

Table of Contents Section

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

99

Contents

Sheet

Maintenance General ...................................................................................99-01 Safety instructions ..................................................................99-02 Handling fuels and lubricants .........................................99-02 Brake ......................................................................................99-03 Functional check of the deadman brake ........................99-03 Functional check of the neutral brake ............................99-03 Functional check of the reversing brake ........................99-03 Maximum wear on the brake lining ................................99-03 Brake clearance .............................................................99-03 Battery ....................................................................................99-04 Checking the electrolyte level ........................................99-04 Checking the electrolyte density ....................................99-04 Cleaning the battery .......................................................99-04 Battery lock ....................................................................99-05 Battery charger...............................................................99-05 Operating elements ................................................................99-06 Ease of movement .........................................................99-06 Function test...................................................................99-06 Steering ..................................................................................99-07 Ease of movement .........................................................99-07 Reversed steering ..........................................................99-07 Steering angle ................................................................99-07 Switching-off in the event of error ..................................99-07 Toothed gear ring ...........................................................99-07 Lifting chains...........................................................................99-08 General ..........................................................................99-08 Checking the lifting chains for damage ..........................99-09 Checking the chain elongation .......................................99-13 Main lift ..................................................................99-13 Checking the chain elongation .......................................99-14 Additional lift ..........................................................99-14 Replacing the lifting chains ............................................99-15 Repairing the lifting chains .............................................99-15 Lubricating the lifting chains...........................................99-16 Cleaning the chains........................................................99-17 Hydraulic tank .........................................................................99-18 Volume ...........................................................................99-18 Seals ..............................................................................99-18

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

12

Table of Contents Section

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

99

Contents

Sheet

Maintenance Wheels....................................................................................99-19 Wear...............................................................................99-19 Wheel bearings ..............................................................99-19 Castor wheels ................................................................99-19 Motor.......................................................................................99-20 Carbon brushes..............................................................99-20 Checking the brush springs............................................99-20 Other maintenance work ................................................99-20 Gear........................................................................................99-21 Changing the gear oil .....................................................99-21 Noises ............................................................................99-21 Leaks..............................................................................99-21 Mast ........................................................................................99-22 Mast rollers.....................................................................99-22 Guide rollers...................................................................99-22 Windscreen ....................................................................99-22 Lifting cylinder ................................................................99-22 Guides, surfaces ............................................................99-22 Forks ..............................................................................99-22 Chain adjustment ...........................................................99-22 Pump assembly ......................................................................99-23 Carbon brushes..............................................................99-23 Oil level ..........................................................................99-23 Noises ............................................................................99-23 Soiling ............................................................................99-23 Lubrication ..............................................................................99-24 Lubricants.......................................................................99-24 Disposal .........................................................................99-24 Lubrication plan..............................................................99-25

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

13

Chapter 1

Vehicle data

Definition of vehicle model names

XOP1 NO (N iederhub ohne Zusatzhub) = low lift without additional lift)

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

80001

XOP1 NM (Niederhub mit Zusatzhub) = low lift with additional lift)

80002

XOP1 HO (Hochhub ohne Zusatzhub) = high lift without additional lift)

80003

XOP1 HM (Hochhub mit Zusatzhub = high lift with additional lift)

80004

Issue: Replaces issu

08/03 07/01

WorkshopManual

XOP1

Sheet no.

1 – 01

Chapter 1

Vehicle data

Signs on the vehicle

Nameplate

30117

Carrying load diagram

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

UVV check 30119

30118

30115

30116

Vehicle no. on chassis

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

1 – 02

Chapter 1

Vehicle data

Travel speed

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Outside the aisle • Type NO

always

vmax = 9.0km/h

• Type NM

Platform level < 0.5m

vmax = 9.0km/h

• Type NM

Platform level > 0.5m & steering straight-on

vmax = 4.0km/h

• Type NM

Platform level > 0.5m & steering > ±10°

vmax = 2.5km/h

• Type HO

Platform level < 1.2m

vmax = 9.0km/h

• Type HO

Platform level > 1.2m & steering straight-on

vmax = 4.0km/h

• Type HO

Platform level > 1.2m & steering > ±10°

vmax = 2.5km/h

• Type HM

Platform level < 0.5m

vmax = 9.0km/h

• Type HM

Platform level > 0.5m & steering straight-on

vmax = 4.0km/h

• Type HM

Platform level > 0.5m & steering > ±10°

vmax = 2.5km/h

Inside the aisle Always vmax = 9,0km/h

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

1 – 03

Chapter 2

Travel motor

General The drive motor used in this vehicle is a 24V shunt motor.

The armature and field coils are controlled separately by the travel controller.

The travel movement is initiated as follows: voltage is applied to the armature and the field is excited.

As soon as the armature voltage is equal to the battery voltage, the field current is reduced in order to achieve an increase in speed.

The current speed of the drive motor is determined by a current measurement (measuring shunt) in the travel controller.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Temperature monitor The drive motor has a temperature monitor (field coil resistor at normal temperature approx. 1.8Ω).

If the temperature is >90°C, deceleration is initiated by the MOT WRM parameter. If the temperature rises above 105°C, a traction cut-out is initiated by the Mot Hot parameter (see Software travel controle).

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

30122

Sheet no.

2– 01

Chapter 2

Travel motor

Technical data

2

Model designation Id. no.

Excitation type Voltage Rated output Rated speed Direction of rotation Protection / insulation class Field excitation Armature current On-period

GF 114 - F4 W8 408 250 shunt wound 24V 2000W 2700 rpm right / left JP 00 / 20 6V / 9A 104A S2 = 60min

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Terminals A1 A2 F1 F2

Armature winding start Armature winding end Field winding Field winding

3

1

30120

4 -

+

-

+

A1

A2

F1 F2

M Right rot. +

+

-

-

A1

A2

F1 F2

M Left rot.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

2– 02

Chapter 2

Travel motor

Removing the travel motor Note:

Because the brake (2) is mounted on the travel motor, the vehicle is no longer braked once the brake and the travel motor have been removed. For this reason, always secure the vehicle to prevent it rolling away!

4

• Pull out the battery plug.

• Remove power leads (3.

• Unplug speed sensor (9).

• Remove electro magnetic break (2)

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Remark: The connection point for the connection cable of the spring brake may be in the cable duct (4)!

• Remove the 8 screws (5).

• Screw the special eyebolt tool M6 (6), into the armature shaft (min. 20mm).

• Pull the rope (7) (special tool: pulley) through the eyebolt (6).

Remark: Ensure that the rope is pulled through correctly (8).

• Set the length (holding it tight with your hand is sufficient).

• Lift the travel motor out with a lever rod.

Note:

60222

48

6

7

41.5

M6x60 min. 20mm

Never work without the correct aids. A considerable amount of force is required to release the seal (1) between the travel motor and the gear.

62004

62005

• Remove the aids.

• Lift the travel motor out by hand.

Note:

8

2

When the travel motor has been removed, the opening left in the gear (2) must be closed off immediately, in order to prevent oil entering the inside of the gear.

9

3

3

5

00178

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

2– 03

Chapter 2

Travel motor

Installation To install the travel motor, follow the instructions for removal in reverse order.

It can be installed without the use of any special tools.

Note:

Only use screws of the prescribed length, otherwise the four-point bearing may be damaged!

Remark: Screw in and tighten the 8 screws (3) diagonally in several passes.

3 MA = 23Nm us Loctite

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

MA = 26Nm

1

2

62006

MA = 140Nm

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

2– 04

Chapter 2

Travel motor

Maintenance General Maintenance work between major overhauls consists of: • Cleaning • General visual inspection • Replacing damaged parts • Checking the brush mechanisms and commutators • Replacing the carbon brushes (whenever necessary).

30120

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

This work should be carried out at least every 500 operating hours or every 3 months.

We recommend entrusting a major overhaul of a motor to a workshop which specialises in work of this kind, since special tools and expertise are required for this work.

Note:

The battery plug must always be pulled out before work is started on the motor, in order to prevent short circuits and injury.

Cleaning • Remove the cover and take out the brushes (see Exchange of carbon brush).

• Clean the motor out thoroughly with compressed air (do not inhale the dust, always use a protective mask).

• Clean soiled commutators and brush mechanisms with a clean cloth moistened with petrol (do not use cleaning wool) and dry thoroughly.

00180

Remark: Do not lift the brush springs higher than necessary and do not bend them to the side.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

2– 05

Chapter 2

Travel motor

Maintenance Visual inspection, replacing damaged parts: • Check the gear ventilation channels (1) to ensure they are clean. Soiling decreases the air circuilation, which leads to raised temperatures in the motor and can possibly damage it.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

• Check the field and armature windings for signs of wear (e.g. overheating): dark-coloured, brittle or burned insulators, unsoldered commutators.

Motors which have this kind of overload damage must be replaced without delay.

1

62008

• If oil or grease are found in the motor (usually a paste of oil, oil vapour with dust and carbon dust), the cause must be ascertained and rectified immediately. The motor must be cleaned thoroughly.

Remark: Rapid carbon brush or commutator wear is generally found to be caused by oil.

The oil/grease burns in the commutator sparking and leaves behind a sharp-edged oil ash which has an abrasive effect.

The result of this is that the brushes may wear down far more than is permissible even before the next maintenance date is due.

00180

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

2– 06

Chapter 2

Travel motor

Maintenance The carbon brushes must be replaced when a residual length of 50% has been reached, which is equivalent to 15mm.

Length of a new carbon brush: 30mm An entire set of brushes must be replaced at the same time (4 brushes) • Pull out the battery plug.

• Remove the cover (4).

• Raise the brush spring (1) and hook in.

50034

• Pull out the brush on the connection cable (2).

1

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

• Disconnect the connection cable (3).

• Clean the commutator space (by blowing).

Caution

You must on no account inhale the carbon dust. Always wear a protective mask.

• Insert the new carbon brushes.

Note:

The motor should not be placed under a full load directly after the brushes have been replaced. The carbons run in relatively quickly under a low load.

Brush springs which are not adequately pre-tensioned cause the commutator to burn.

30120

4

3

2

30121

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

03 05 2– 07

Chapter 2

Travel motor

Maintenance Checking the brush mechanism, replacing the carbon brushes After the brush mechanism has been cleaned, it must be possible to move the brushes easily in their guides when the spring is lifted.

If one or more of the brushes stick, they must on no account be treated with emery paper or a similar material.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

If this is the case, the entire brush mechanism must be replaced, since it is possible that the brushes have been overheated.

It is also important that the brushes are not broken or worn at their running edges.

Remarks: • Always replace the entire set of brushes, taking the shortest brush as a measure for all of them.

• Only use original replacement carbons (see spare parts list!).

00180

• Do not let the brush springs fall onto the brushes when you are inserting the latter.

• If the brushes have not quite reached the minimum length, they should still be replaced, as their remaining useful life may be shorter than the interval to the next inspection.

• A maximum of 3 brush sets should be replaced one after another. After this, the motor must undergo a major overhaul (by a specialist workshop).

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

2– 08

Chapter 2

Travel motor

Maintenance Commutator The running surface of the commutator should be uniformly smooth and be grey-black in colour.

The commutator must not be worn down, corrugated or out of round.

If any of the characteristics mentioned above should occur, the commutator must be reworked (major overhaul).

Never work on it with a file, emery paper or other similar tools.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Bearings The ball-bearings do not need regreasing. The amount of grease they are filled with is sufficient for the maintenance periods between major overhauls.

The bearings must be replaced: 00180

• at every major overhaul • at the latest after a running time of 12,000 hours • life-long expected Always use the bearings in the spare parts list.

Note :

On risk of overloading when batteries discharged:

If the motor speed drops noticeably, work must be stopped immediately and the battery checked without delay. It should be recharged if necessary.

Never use the vehicle with low battery voltage!

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

2– 09

Chapter 3

Drive wheel

General New dimensions: 250 x 100mm The drive wheel must be replaced when • the running surface is very worn or out of round or cracks appear in it, • the dimater of the typer has decreased by 10% (smallest permissible tyre diameter: 225mm).

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Removing the drive wheel • Drive the vehicle up against a wall until the forks touch it, to prevent the vehicle from rolling away (1).

• Turn the steering until the wheel nuts are easily accessible.

• Pull out the battery plug.

• Release the wheel nuts (2) with the vehicle jacked up.

• Raise the vehicle in its centre (3) with a hydraulic lifter to a height of approx. 100mm.

• Use hardwood blocks to support the vehicle safely from below on both sides (4).

• Lower the hydraulic lifter and remove it.

• Unscrew the 5 wheel nuts (2).

• Remove the drive wheel.

62009

2

1 100mm 62010

Installing the drive wheel Before fitting the drive wheel, clean the wheel seat and check that it is in perfect condition.

• Push on the drive wheel and tighten the nuts by hand.

• Tighten the nuts diagonally in several passes with a dynamometric key.

Tightening torque: 140Nm.

62011

4 Issue: Replaces issue:

08/03 07/01

WorkshopManual

XOP1

3 Sheet no.

4

3 – 01

Chapter 4

Gear

Remove Remark: Once the travel motor has been removed, the vehicle is no longer braked and must be secured to prevent it from rolling away!

1

• Release the wheel nuts ( see Drive wheel).

Remark: When removing the gear, it is best to leave the drive wheel in place to begin with (drive wheel held in place with 2 nuts tightened by hand).

• Turn the steering anti-clockwise as far as it goes.

• Pull out the battery plug).

• Remove the travel motor )(see sheet travel motor).

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

• Remove the steering chain ).

• Drain off the gear oil .

• Turn the gear so that the wheel side is at the front and pull a rope through the ventilation slots (2).

• Remove the 6 screws M12 x 40 (1).

• Raise the vehicle by approx. 170mm (!) with a hydraulic lifter, and support the sinking gear with the rope at the same time (lean against the back of the chassis) .

• Use hardwood blocks to support the vehicle safely from below on both sides!

Remark: The centring ring (3) is not attached in any further way. Remove it lay it to one side.

62006

• Remove the hydraulic lifter.

2

• Remove the drive wheel.

• Pull the gear forwards under the chassis by tilting it.

Remark: Cover the gear opening (as a precaution to prevent the gear becoming soiled).

60232

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

4 – 01

Chapter 4

Gear

Installing the gear Remark: Before installing the gear, check that the gear opening and ventilation slots are clean. The photographs show the installation sequence.

• Place the gear and drive wheel ready for installation, as shown in the picture.

Ensure the rope is pulled through correctly.

• Guide the gear into the chassis by tilting it.

• Align the holes and tighten the rope.

60229

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

• Push on the drive wheel and tighten it by hand with 2 nuts.

• Align the gear with the rope (use foot to support) and set it against back of the chassis.

• Raise the vehicle with a hydraulic lifter and remove the wooden support block.

• Lower the vehicle and guide the gear with the rope.

Insert front screw M12x40 first.

• Lower the vehicle further and insert and tighten the other 5 screws.

60230

• Tighten the remaining drive wheel screws .

• Fill up the gear oil .

Remark: When the gear is installed, check that the gear opening and the ventilation slots are clean.

60231

60233

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

4 – 02

Chapter 4

Gear

Changing oil The first oil change must be carried out after approx.

200 operating hours.

All further oil changes should be made after approx.

2000 operating hours or once a year.

Caution: The gear oil must be drained off when the vehicle is warm, and can reach a temperature of 80° C. Take care not to burn yourself !

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Oils with the following viscosity classes are used: Standard oil: SAE 80/90 Ambient temperature: 0°C to 40°C Low temperature oil: Ambient temperature:

SAE 80W to - 26°C

Low temperature oil: Ambient temperature:

SAE 75W to - 40°C

Amount of oil needed for this gear:

1

1.5l

Remark: The given amount of oil is a guideline only.

The correct amount of oil is that required for the level to reach the lower edge of of filling hole (1).

Overfilling must be avoided, otherwise the seals will be damaged and it is possible that the operating temperature may not be maintained.

62012

The maximum permissible operating temperature is 80°C.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

01 4 – 03

Chapter 4

Gear

Oil change method • Turn the steering anti-clockwise until the oil drainage screw is easily accessible (2).

1

• Position an oil catchment vessel with a volume of at least 2.5l under the oil drainage screw (3) of the gear.

• Unscrew the oil filler cap (2) with a hexagon socket screw key (size 6).

2

• Unscrew the oil drainage screw (3) with the hexagon socket screw key (size 6) and drain off the oil.

62012

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Caution: Risk of burning!

The oil temperature can reach up to 80°C when the vehicle is in operation.

• Clean the magnet on the oil drainage screw (3) and screw it back in with a new sealing ring.

Note:

Tightening torque for oil filler cap (1) and drainage screw (3) MA= 22Nm.

• Fill with new gear oil up to the lower edge of the filler hole.

1

Remark: The gear oil can also be filled up or checked through the upper gear opening (travel motor removed.

62013

The oi level is correct, when the spur wheel (5) is immersed in the oil by about 1/3 of its height.

• Screw the oil filler cap (1) back in.

3

62016

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

02 4 – 04

Chapter 4

Gear

Checking the oil level Option 1 • Remove the oil filler cap (1).

• Make a touch test through the threaded hole of the filler cap. The gear oil level must reach the lower edge of the filler hole. Top the oil up if necessary.

Option 2 • Pull out the battery plug .

• Remove the travel motor (see Drive motor).

The brake and connection cables do not have to be disconnected!

1

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

• Check the gear oil level through the gear opening (2).

62013

The oillevel is correct, when the spur wheel (3) is immersed in the oil by about 1/3 of its height.

2

• Install the travel motor.

3

Lubricating the bogie bearing The bogie bearing should be lubricated twice a year through the two opposing lubricating nipples (4). It is particularly important to do this every time the gear has been cleaned (e.g. with steam jets).

62016

Grease type: all-purpose grease Amount of grease when bearing is dry: 50g

4

4

62014

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

03 4 – 05

Chapter 5

Brake

Electromagnetic spring brake General 1

The brake used in this vehicle is constructed using the deadman's principle.

It acts as both the service brake and the handbrake.

The spring brake is a closed-circuit brake with two friction surfaces. The braking force, which can be adjusted with a central adjusting device, is generated by spring resistance.

The brake is released electromagnetically.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

The brake clearance and the braking force of this brake can be adjusted.

Explanation of the nameplate BFK458 - 12 E Brake product group Spring brake Model Size Design adjustable Connection voltage 24V

Issue: Replaces issue:

08/03

30122

WorkshopManual

XOP1

Sheet no.

5 – 01

Chapter 5

Brake

Electromagnetic spring brake Function 1. Deadman's switch (1) in the surface not actuated: The compression springs (4) press the armature disc (2) axially against the rotor (3) and this in turn agains the surface A - B. 1

2. Deadman's switch actuated:

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

The coil in the magnetic brake is excited with direct current and the magnetic circuit between the armature disc (2) and the magnetic section is closed.

The armature disc (2) moves axially in the direction of the fixed magnetic section, the gap "a" is reduced to "zero" and the rotor (3) can be moved freely.

60071

4

5

3. Steering error when deadman's switch actuated: If a steering error occurs, internal relay (steering error relay) drops out and the brake moves into the braking position.

4. Braking error:

a B

A 60072

2

If the vehicle does not brake correctly (generator braking), internal relay K1 is opened in the braking monitor (ABÜ).

This causes the enable signal to be removed from the travel controller, in response to which it switches off the negative signal to the brake.

3

2+24V 1F11

Steering controller 24V

Steering error

Travel Control

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

5 – 02

Chapter 5

Brake

Electromagnetic spring brake Removal Caution: Once the brake has been removed, the vehicle is no longer braked, so the vehicle must be secured to prevent it rolling away.

• Pull out the battery plug.

• Disconnect the lead to the magnet at the connector.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Remark: The connector X29 (1) may be in the cable duct.

1

• Check the polarity and note the connections if necessary.

• Release the 3 hexagon socket screws (2) gradually in several passes.

• The magnet body (3) can now be lifted off.

• Pull off the rotor (4).

Checking the rotor Remark: Thickness of a new rotor: Replace when thickness is: (when worn symetrically)

10mm 8mm

Check: • Check ease of movement • that it is firmly seated on the hub (no play) • Condition of surface (porous, cracked)

30123

5 2

Remark: If the rotor causes noises during travel, check concentricity and bearing clearance of the armature shaft of the travel motor.

3

4

30124

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

5 – 03

Chapter 5

Brake

Electromagnetic spring brake Adjusting the brake clearance General Correct adjustment of the spring brake is on the one hand intended to guarantee a minimum clearance so that the rotor runs freely when the brake is released, while on the other allowing the largest possible degree of wear on the rotor (2).

1

a

The dimension "a" shows the gap which must be set to 0.4mm when the brake is set or readjusted (brake clearance).

60072

4

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Adjustment process

2

3

1. Move the adjusting sleeves (4) up into the magnet section.

2. Use the adjusting screws (1) to set dimension "a" to 0.4mm.

3. Check dimension "a" at at least 3 points with a feeler gauge (close to the screws (5)).

4. Do up the adjusting sleeves (4) back down and check dimension "a".

Repeat steps 2-4 if necessary.

Remark: Every time the lining is replaced a check must be made to ensure the rotor (2) runs freely on the hub (3).

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

5

Sheet no.

60077

5 – 04

Chapter 5

Brake

Electromagnetic spring brake Adjusting the braking force Correct adjustment of the braking force affects the length of the braking distance. For this reason, its adjustment must be checked after maintenance work or when the brake has been replaced.

1

2 36

The braking force can be checked with a dynometer (see Meassuring of brake deceleration).

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Turning the adjusting ring (1) with a hook spanner alters the amount of pressure exerted on the pressure elements (2), the compression springs (3) and the armature disc (4).

4

5

60072

As a result, the rotor (5) is pressed against the end shield of the travel motor with a greater or lesser degree of force during the braking process.

Anti-clockwise rotation of adjusting ring: --> Braking force reduced (distance longer) Clockwise rotation of adjusting ring: --> Braking force increased (distance shorter) Remark: If this adjusting device no longer allows a reduction in the braking force when this is needed, the outer compression springs (6) can be removed ifnecessary (see Dismantling the brake).These outer compression springs are positioned in pocket holes and cannot, therefore, be adjusted.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

5 – 05

Chapter 5

Brake

Electromagnetic spring brake Maintenance The following steps must be carried out or taken into account during maintenance work: 2 • Adjustment of the brake clearance.

• Adjustment of the braking force.

• Replace rotor (1) if chipped or unevenly worn.

1

• The rotor (1) must be able to run easily up and down on the hub (2).

• Clean all oil from the brake with compressed air.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

60073

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

5 – 06

Chapter 5

Brake

Measuring the brake deceleration General The brake deceleration value is measured with the dynometer , Id. no. W8 050 605.

2

This works on the principle of the pendulum, the accerleration and deceleration.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

During travel at a steady speed over an even surface, the pendulum always hangs vertically and shows zero on the dial. On acceleration, the pointer deflects to the right (clockwise) and on braking (deceleration), it moves to the left.

1 50115

Preparations for measurement Moisten the rubber sucker on the underside of the Dynometer, then use the lever to fasten the dynometer onto a horizontal surface.

The dial must face towards the driver's seat and be mounted in the direction of travel.

Before every deceleration measurement, the measuring case (2) must be tipped to move the measuring pointer (5) to zero. The correct zero position has been set by tipping the case when the measuring pointer can move almost a full turn to the the left (anti-clockwise) from zero and almost half a turn to the right.

50116

3

4

5

The maximum pointer (3) will be reset manually, by turning the knob at the centre of the dial clockwise, until the pointer is set as closely as possible to zero.

During the braking process, the maximum pointer moves to the maximum deflection point together with the measuring pointer and remains there when the other moves back .

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

5 – 07

Chapter 5

Brake

Measuring the brake deceleration Evaluating the measurement • Calculate the maximum vehicle speed (v = distance/time).

• Accelerate the vehicle with nominal load to vmax in fork direction.

• Stop the vehicle: 1. Dead-man break (regenerative brake) 2. Emergency break (electromagnetic brake)

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

• Check the braking deceleration value "F" off the dynometer (i.e. the maximum pointer reading).

• The allowed braking deceleration is >9% (tolerance +2%) Remark: The regenerative Dead-man brake must be >10%, otherwise the brake monitoring of the ABÜ-unit detects an error (Range from vmax to 3.2km/h).

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

5 – 08

Chapter 6

Idling wheels

General Dimensions when new: Ø 150 x 100mm The idling wheels must be replaced when • the surface is deeply pitted or out of round or is cracked • the tyre diameter has decreased by 10% (minimum permissible tyre diameter 135mm).

Removal

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

• Bring the support carriage or cab to a lift height at which the idling rollers are easily accessible.

• Support the support carriage or cab safely from below to prevent it falling.

• Jack up the vehicle and support it safely from below.

1 2

3

• Unscrew the screw (1).

4

• Pull out the safety pin (2).

80018

• Push out the bolts (3).

• Remove the idling wheel (4).

Remark: To reinstall the wheel, follow the instructions above in reverse order.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

6 – 01

Chapter 7

Hydraulic

Assembly instructions Main lift

Grease must on no account be used to help install components that have hydraulic oil flowing through them!

1 2

If grease is used, it is washed out by the warm oil and collects in the filter element. A layer of grease then covers the surface of the filter mesh so that within a very short time filtration is only carried out incompletely or not at all, and the oil flows through the bypass valve.

3

4

It is helpful to slick the components with hydraulic oil to make them easier to install.

5

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

10

6

Hydraulic circuit plan 7

NO, HO (Fig. 1) NM, HM (Fig. 2)

8 9 Fig. 1

Consisting of:

80042

1 Lift cylinder Additional lift

2 Line break protection 3 Diaphragm reservoir

Main lift

11

1

4 1-way directional valve 5 Throttle valve 6 Pressure-limiting valve

2

7 Electromotor with hydraulic pump

3

12

8 Filter 9 Tank 10 Non-return valve

4

11 Lift cylinder for additional lift

5

10 6 7 8 9

12 2/2 way directional valve

80043

Fig. 2 Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

7 – 01

Chapter 7

Hydraulic

Block diagram for NO/HO Consisting of

2+24V

1 Lifting switch

2+24V

2F1

1

3

2 Pump contactor 3 Lowering switch 4 Pump unit

FZS

5 Bubble reservoir

Curtis (ABÜ)

6 Lift cylinder for main lift 7 Hydraulic lead

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

6

EAZ

2

Remark: The directional valve and the lowering brake valve are on the pump block (8).

0V

5 7

8

4

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

80040

7 – 02

Chapter 7

Hydraulic

Block diagram for NM/HM

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Consisting of 2+24V

2+24V

1

Switch for lifting / mast load side

2

Switch for lowering / mast load side

3

Switch for lifting additional lift

4

Switch for lifting main lift

5

Pump contactor

6

Pump unit

7

Pump block

8

Bubble reservoir

9

2/2 way directional valve, additional lift

4

3

2F1

1

2

FZS Curtis (ABÜ)

EAZ

5 0V

10 2/2 way directional valve,main lift 11 Lift cylinder for main lift

11

12 Lift cylinder for additional lift

12

13 Distributor block Remark: The lowering and the lowering brake valve are on the pump block (7).

10

9

13 8

7 6

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

80041

7 – 03

Chapter 7

Hydraulic

Pump unit General Components: 1 Pump motor

2kW (Type NO, NM) 3kW (Type HO, NM)

2 Hydraulic pump

7

1

4

3 Hydraulic suction filter 4 Directional valve

9

5 Oil tank 6 Air filter

8

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

7 Carbon brushes

3 6

8 Pressure-limiting valve 9 Lowering brake valve

10

10 Pressure-limiting valve

Issue: Replaces issue:

08/03

WorkshopManual

2

5

XOP1

Sheet no.

80064

7 – 04

Chapter 7

Hydraulic

Pump unit Electrically releasable non-return valve (2/2 way valve) 1

The 2/2 way valve is a bevel-seated valve.

The directional valve illustrated here is a so-called NORMALLY CLOSED valve, i.e. when the coil (1) is not excited, the tapered pin (2) presses onto the slide (3) and closes the control hole in this way (A --> B).

2

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

If the coil (1) is now excited, it pulls the tapered pin (2) upwards. The oil pressure which has build up moves the slide (3) up and the oil can flow unhindered through the section A --> B.

80068

3

Coil resistance = 40Ω

B

83122

A

1

2

Ω

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

7 – 05

Chapter 7

Hydraulic

Pump unit Replacing the carbon brushes (NO, NM)

3

2

1

4

The carbon brushes must be replaced when a residual length of 11mm has been reached, which represents wear of 50%.

Length of a new carbon brush: 22mm An entire set of brushes must be replaced at the same time (4 brushes).

Removal 1. Pull out the battery plug.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

2. Unscrew the 2 hexagon bolts (1).

3. Screw in the hexagon bolt (5 x 30mm) (2) to help pull off the carbon brush lid (4) until a resistance can be felt.

80070

4. Use a screwdriver to help pull between the motor (3) and the carbon brush lid.

5

5. Use the hexagon screw and the screwdriver alternately to pull off the carbon brush lid.

6

6. Lift off the carbon brush spring (5) and pull out the carbon brushes.

7. Release the carbon brush spring (7) slowly.

7

8. Unscrew the fastening screw (6) of the carbon brush connection lug and remove the carbon brush.

9. Clean out the commutator space (blow it out free of oil).

Note:

Do not breathe in carbon dust.

To reinstall, follow the removal instructions in reverse order.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

80071

Sheet no.

7 – 06

Chapter 7

Hydraulic

Pump unit Replacing the carbon brushes (HO, HM) The carbon brushes must be replaced when they have worn down to a length of 50%.

1

2

Length of a new carbon brush: 22 mm The entire set of carbon brushes (4 brushes) must always be replaced.

Removal 1. Pull out the battery plug.

2. Unscrew and remove the cheese-head screw (1).

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

3. Remove the locking ring (2).

4. Remove the paper cover (3).

5. Unscrew the fastening screw (6) of the carbon brush connecting lug.

00226

3

6. Lift the carbon brush spring (4) and pull out the carbon brushes (5).

7. Slowly release the carbon brush spring (4).

8. Clean out the commutator compartment with oil-free compressed air.

Note:

Never inhale carbon dust.

00231

To install the new brushes, follow the instructions above in reverse order.

4 5 6

00229

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

7 – 07

Chapter 7

Hydraulic

Pump unit Removal 1. Pull out the battery plug 2. Remove the electrical cable (1) (key size 13).

3. Unscrew the hydraulic leads (2) and seal them off.

4. Release the 2 screws (3) on the back of the flange-mounted block (4) with key size 17, and lift the pump unit (5) out of the holder in the chassis.

5

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

5. To reinstall the pump unit, follow the installation instructions in reverse order.

80026

1 2

4 3

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

80041

7 – 08

Chapter 7

Hydraulic

Pump unit Removing the pump motor (NO, NM) 1. Pull out the battery plug .

2. Unscrew the 2 nuts .

2

3. Detach the connecting cable (1) from the motor (mark the cable).

1

4. Take down the motor carefully.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Remark: There is an assembly pin (3) in the lower part of the motor housing. Note this when reinstalling the pump motor. The assembly pin is generally on the side of the electrically releasable non-return valve.

80072

To reinstall the pump motor follow the removal instructions in reverse order, taking care to note the following points: 1. See the Remark above.

2. Push the motor shaft correctly onto the cross coupling (4).

3

80073

8/

4

80074

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

7 – 09

Chapter 7

Hydraulic

Pump unit Removing the pump motor (HO, HM) 1. Pull out the battery plug .

2. Disconnect the connecting cable (1) at the motor (mark the cable).

1

3. Remove the 3 hexagon socket screws (2).

4. Carefully remove the motor.

To install the pump motor, follow the instructions above in reverse order, taking into account the following points:

2

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

1. The connections must face towards the front.

00226

2. The motor shaft (3) must be pushed correctly onto the cross coupling (4).

4

00228

8/

3

00227

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

7 – 10

Chapter 7

Hydraulic

Pump unit Adjustment Pressure release valve 1. Connect the pressure manometer.

2. Unscrew the nut .

3. Lift the nominal load with the forks and determine the operating pressure.

1

Remark: The adjustment value for the maximum pressure is calculated from the operating pressure on lifting with the nominal load plus 10%.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

4. Move the lift to the upper end stop (bridge the lift cut-out) and adjust the maximum pressure with the adjusting screw (2).

Remark: If the vehicle is fitted with an additional lift, this can be used to move the lift to the end stop.

80079

5. Mount the nut (1) with the sealing ring and tighten.

For information on the exact maximum pressure values, see the information plate, which is mounted next to the vehicle's factory plate.

Recommended values for adjusting the pressure: Truck type Maximum press.

Op. press. w/o L. Op. press. w. L. Curr. cons. w/o L. Curr. cons. w. L.

NO ca.150 bar ca. 50 bar ca. ca.100 bar ca 75A ca.125A

2

HM ca. 200 bar 75 bar ca. 180 bar ca. 90A ca. 170A 80080

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

7 – 11

Chapter 7

Hydraulic

Pump unit Changing the hydraulic oil Interval: Type of oil used:

every 12 months HLP46 DIN 51524

Oil volume:

4.5 l

Procedure 1. Removal pump unit and leave it security.

2. Loosen oil tank and take motor with pump out in the direction to the top.

2. Dispose of the hydraulic oil correctly in accordance with the regulations.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

3. Clean the oil filter (1).

2

4. Replace the hydraulic suction filter (2) as required.

5. Fill the oil container with hydraulic oil.

6. Mount the oil container.

7. Check the hydraulic system for leaks.

8. Attach the oil information card.

9. Mount the cover.

3 80076

1

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

7 – 12

Chapter 7

Hydraulic

Bleeding the lift cylinders and the hydraulic system The lift cylinders of the hydraulic system should be bled when • the lift cylinders have been removed and installed again,

1

• a hydraulic lead or hose has been replaced,

2

• work has been carried out on the hydraulic system.

Procedure

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

1. Open the bleeder screw (1) (do not remove it).

2. Actuate the switch for lifting the hydraulics and move the cylinder to the end stop.

Remark: On vehicles with a lift cut-out, the end switch must be bridged so that the pump motor does not cut out.

80083

3. As soon as hydraulic oil comes out of the hole (2) without bubbles in it, the bleeder screw (1) can be closed again.

This process must be carried out on all the cylinders.

This entire procedure must be repeated if any of the hydraulic functions are not in order. hydraulic system.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

7 – 13

Chapter 7

Hydraulic

Distributor block The purpose of the distributor block (1) is to switch over the hydraulic oil flow from main lift to additional lift on vehicles with an additional lift (NM or HM).

The distributor block is made up of the following components: 1

2/2 way directional valve (main lift)

2

2/2 way directional valve (additional lift)

3

Bubble reservoir

4

5 2 1

2

3

1

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Technical data: Coil resistance values Test points pin 1 (4) against pin 2 (5) = 24.5Ω

4

80084

4

3

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

1

2

Sheet no.

7 – 14

80085

Chapter 7

Hydraulic

Bubble reservoir The bubble reservoir (1) is used to release and compensate pressure peaks in the hydraulic system which arise when the pump motor starts up.

1

The bubble reservoir is maintenance-free.

Note:

Do not open the bubble reservoir or replace the gas.

A faulty bubble reservoir must be disposed of correctly in accordance with the regulations, because of the gas filling.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

80086

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

7 – 15

Chapter 7

Hydraulic

Hydraulic hoses Hoses and hose assemblies are subject to natural ageing, even during storage and when they are subjected only to the permissible amount of stress. As a result, their storage life and operational life is limited .

In order to prevent the quality diminishing prem aturely during storage, please note the following :

Hose Inner layer

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

• Store hoses free of tension and laid out flat • Storage temperature +15°C to +25°C • Relative humidity 65 % • Store in a dust-free area • Avoid direct sunlight and UV light • Protect from sources of heat

• their natural position and movement should not be obstructed • During operation, they should not be strained by pulling, torsion or blockage caused by external influences.

• Avoid painting over hoses • Do not select a bending radius that is too small

Outer layer

80081

Intermediate layer

During the period of use, the hoses should be checked for ageing, age, cracks and damage at least once a year, and replaced if necessary.

When replacing faulty hoses, it is important to note that:

Insert

Wall of hose

Hose assembly Hose

Nipple

Holder

Union nut

80082

Hose end

Connection end

Hose fitting

Used hoses must not be used again.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

7 – 16

Chapter 8

Cylinders

Cylinder support Suitable trestles should be used for dismantling and supporting the cylinder components, so that their surface is not damaged.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Below, the special features of vehicle types NO, NM, HO and HM are described. (see Vehicle date/ Definition of vehicle model names).

61048

Issue: Replaces issue:

08/03 07/01

WorkshopManual

XOP1

Sheet no.

8 – 01

Chapter 8

Cylinders

Main lift cylinder on NO/NM Removal 1. Remove the support carriage .

2. Remove the cylinder (1) from its seat (2) on the chassis.

3. Remove the hydraulic hose (3) from the cylinder (1), and seal the cylinder and hydraulic hose with sealing plugs.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

4. To reinstall the cylinder, follow the removal instructions in reverse order.

Remark: On vehicles with an additional lift, the hydraulic hoses (4) must be removed from the additional lift cylinder (5). The hoses and cylinders must be sealed with sealing plugs.

2

5. After installation, the cylinders and the hydraulic system must be bled (see Hydraulic).

Remark: The line break protection is in the pressure connection of the main lift cylinder.

80032

1

6

3

4 Main lift 5

Additional lift

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

80034

Sheet no.

8 – 02

Chapter 8

Cylinders

Main lift cylinder on NO/NM Dismantling 1. Release the lock nut (1) with a hook spanner.

2. Release the cylinder head (2) with a hook spanner and unscrew it.

3. Pull the piston rod (3) up and out of the cylinder barrel (5).

4. Check the set of seals (4) in the cylinder head (2) and replace if necessary.

4

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Remark: The entire set of seals (4) must always be replaced.

2 5. To reassemble the cylinder, follow the dismantling instructions in reverse order.

4 3

1 Remark:

When ordering the set of seals, always state the Id. no. of the cylinder.

After assembly, the cylinder and the hydraulic system must be bled.

5

80035

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

8 – 03

Chapter 8

Cylinders

Main lift cylinder on HO/HM Removal 1

1. Remove the cab (1).

2. Remove the main lift chains (2).

3. Remove the trailing cable (3) from the guide rollers.

3

4. Lower the main lift cylinder (6).

5. Take off the (4) by removing the 2 cheese-head screws M10x12 (5).

4

6. Remove the main lift cylinder (6) from its seat on the chassis.

2

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

7. Unscrew the hydraulic hose (7), and seal the cylinder and hose.

6

5

8. To reinstall the cylinder, follow the removal instructions in reverse order.

Remark: On vehicles with an additional lift, the hydraulic hoses (9) must be removed from the additional lift cylinder (10). The hoses and cylinders must be sealed with sealing plugs.

Caution: The line break protection (8) is in the pressure connection of the main lift cylinder.

80036

7 6 9 8 Main lift 10

80034

Additional lift

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

8 – 04

Chapter 8

Cylinders

Main lift cylinder on HO/HM Dismantling 1. Unscrew the bearing fork (5).

2. Release the lock nut (1) with a hook spanner.

5

3. Release the clinder head (2) with a hook spanner and unscrew it.

4. Pull the piston rod (3) up and out of the cylinder barrel (6).

5. Check the set of seals (4) in the cylinder head (2) and replace if necessary.

80037

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Remark: The entire set of seals (4) must always be replaced.

6. To reassemble the cylinder, follow the dismantling instructions in reverse order.

3

4

Remark: When ordering the set of seals, always state the Id. no. of the cylinder.

4

After assembly, the cylinder and the hydraulic system must be bled .

2 1

5

80039

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

8 – 05

Chapter 8

Cylinders

Additional lift cylinder on NM/HM Removal 1. Remove the additional lift bracket (1).

2. Lower the additional lift cylinder.

3. Take off the retainer clip (3) by removing the 2 cheese-head screws M10x20.

4. Remove the additional lift cylinder from its seat (5).

5. Unscrew the hydraulic hoses (6) and seal the cylinder and hoses with sealing plugs.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

6. To reinstall the cylinder, follow the removal instructions in reverse order.

7. After installation, the cylinders and the hydraulic system must be bled.

2 3 5

4

80023

1

80023.1

6

Zusatzhub

80034

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

8 – 06

Chapter 8

Cylinders

Additional lift cylinder on NM/HM Dismantling 1. Unscrew the bearing fork (5).

2. Release the lock nut (1) with a hook spanner.

3. Release the clinder head (2) with a hook spanner and unscrew it.

5

4. Pull the piston rod (3) up and out of the cylinder barrel (6).

80038

5. Check the set of seals (4) in the cylinder head (2) and replace if necessary.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Remark: The entire set of seals must always be replaced.

4

6. To reassemble the cylinder, follow the dismantling instructions in reverse order.

Remark: When ordering the set of seals, always state the Id. no. of the cylinder.

After assembly, the cylinder and the hydraulic system must be bled.

2 4 3

1

6

80035

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

8 – 07

Chapter 9

Line break protection

General The line break protection (1) prevents an uncontrollable sinking movement if the hydraulic lead to the cylinder in question breaks. The line break protection is installed for the hydraulic hose (2) of the lift cylinder.

1 2

Type LB is a plate valve. When it is inactive, its valve plate is lifted from the valve seat by a spring and maintains a set flow cross-section.

The forces of flow resistance and dynamic pressure at the valve plate in the flow direction B -->F (operational or triggering direction) are subject to the counteracting force of the spring during normal operation and the valve remains open.

80033

Symbol

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

simplified

If the flow rate increases because a line has broken, the flow forces exceed the force of the spring and the valve closes immediately.

Valve for full support of the load

(F)

detailed

F

(B)

The valve plate largely covers the ring-shaped seat. Leakage through the fixing thread does not have any significant effect.

B 60545

The load remains in the lift position it has just reached. The fault can be rectified either immediately or after the load has been supported from below, depending how high the safety risk is.

The valve is then opened again by feeding hydraulic fluid into the consumer.

1 Remark:

The gap width S determines the point at which the valve is triggered. This is set by the manufacturer and may on no account be altered.

Remark:

A special tool is needed to remove the line break protection.

Id. no. W4 498 812 (3)

60552

80031

3

Issue: Replaces issue:

08/03 07/01

WorkshopManual

XOP1

Sheet no.

60104

9 – 01

Chapter 10

Hydraulic pump

General The hydraulic pump is an externally toothed gear pump.

The pump consists mainly of the pair of toothed gears, which is carried in 4 bearing bushes, and the housing with the front and rear cover. The drive shaft, which is sealed with a shaft rotary shaft seal, is inserted through the front cover.

The bearing forces are taken up by sliding bearings.

These are designed for high bearing pressures and have good emergency running properties, especially at low speeds.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

The delivery chambers are sealed internally in relation to the pressure, which gives optimum efficiency.

At the front end, the movable bearing bushes are pressurised by the operating pressure and pressed against the toothed gears to form a seal.

A

A

B

B

C

C

Delivery side

The pressurised pressure fields are limited by special seals.

The seal around the edge of the toothed gears is guaranteed with tiny gaps, which adapt when the toothed gears are pushed against the housing by the pressure.

Issue: Replaces issue:

08/03 07/01

WorkshopManual

XOP1

Intake side

Sheet no.

80075

10 – 01

Chapter 10

Hydraulic pump

Removing • Pull out the battery plug.

• Remove the pump unit ( see Hydraulic/ pump unit).

• Remove the pump motor (see Hydraulic/ pump motor) • Unscrew the 4 hexagon bolts (1).

• Remove the oil container (2).

• Unscrew the 4 hexagon bolts (3).

• Remove the hydraulic pump.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Remark: After reassembly, check the oil level (volume of oil approx. 4.5 l)

80076

3

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

2

Sheet no.

1

10 – 02

Chapter 10

Hydraulic pump

Dismantling Intake side

Sealing cover Housing

Drive side cover

3 parallel grooves Grooves for fluid leakage

Radial grooves

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

80077

Sealing and supporting elements Openings Drive shaft

High-pressure seal

Toothed gears Radial seal Delivery side 1. Pull the drive wheel off the shaft.

2. Release the hexagon socket screw.

3. Lift off the cover over the drive shaft.

Front centre rest Housing

Drive gear wheel

4. On apiercing press, press the shaft together with the ball bearing out of the bearing cap.

Mark the driven toothed gear and centre rest.

5. By pulling on the housing, remove from the housing the shaft with drive gear wheel, driven gear wheel and the front centre rest (use a protective jaw).

Driven toothed gear

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

80078

Sheet no.

10 – 03

Chapter 11

Aisle recognition

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

General Aisle recognition is activated when the vehicle drives into the rail guides. If both light sensors (1) are actuated, they register "Aisle recognition" with the FZS. It is still possible to steer.

Turning the steering knob or steering wheel into the centre position sets the drive wheel to "straight on".

After a pause of 3s, steering is no longer possible (see Steering/ Steering lock).

2-handed operation is now necessary. Actuating the 2-handed button enables the travel function again.

If the steering setpoint from the steering wheel is not at "straight on" when the vehicle leaves the aisle, the vehicle is stopped. The steering remains locked until the vehicle comes to a standstill. Travel can only be enabled again when the steering setpoint registers "straight on" (see Travel control/ Function table FZS2).

1

20400 20307

1

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

11 – 01

Chapter 12

Steering

Block diagram of the steering system + Battery F2

Setpoint

Actual value

5-stage potentiometer infinite

5-stage potentiometer infinite

2,2K

2,2K

2,2K

2,2K

Diagnosis notebook

Em.-stop R1

R2

R1

R2

X97

Key switch o >20°

Vehicle control

X1 19 6

X1 8

0V

9,2V

22

X1 10

X1 16 out in

2.5-6.5V

6.5-2.5V

24V

X1:24

Steering controller

X1 25 Coding inputs

X1

8.6-0.4V

Power supply

X1 21 X1 18

X1:1 0V

Contactor driver

X1:7

EEPROM

X1 4

X1:13 X1:15

Controller

Battery

Main contactor K1

M

Steering contactor ON

3F1

X1 9

X2 4 ABÜ 0V

X1 5

X3 5 0V

X1 23

1F11

X210 5 X3 9 10 X2 10 A

K

3K1

6 X3 4

D

X2:11

24V X2

2

Steering OK

X1 11

Travel speed

2 X1 3

Enable

3

Steering OK 0V

X2 4 1

Response, contact check

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

0.4-8.6V

20

24V

X116

4

Travel control 0V 24V

X1:9

X2 3 X1 4 X1 3 X3 1 X2 14

X1 8

Deadman

0V

1K34

El.magn. brake

0V

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

12 – 01

Chapter 12

Steering

Pin assignment X1:1 In

0V power supply for the Diagnosisplug of the steering controller.

X1:2 In

Supply voltage for releasing the brake.

If no +24V power is applied to X1:2 the brake cannot be released. The ABÜ detects an error. There is a 4.7kΩ resistor between 1+24V and X1:2 for the contact testing of the internal safety relay.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

X1:3 Out 0V power for switching on the steering contactor 3K. Is switched when the power supply for the steering controller is applied, setpoint and actual value are in the correct range and there are no internal errors.

X1:4 In

Coding Input: 0V and X1:21 (0V): Coding, version with steering wheel (default setting is steering knob, small steering modification)

X1:5 In

Travel speed As long as impulses are received at this input, the steering remains 100% active, even if the deadman switch is released. Without impulses, the anti-walk function is activated when the deadman switch is removed.

X1:6 Out 0V power supply for setpoint and actual value potentiometer X1:7 In

Diagnosis lead for PC

X1:8 Out Positive power supply for setpoint and actual value pot. approx. 9.3V. X1:9 In

Enable steering As soon as there is a difference between the setpoint and actual value, the steering is activated, even without the enable steering signal. If the deadman switch is released without a setpoint/actual value difference (when the vehicle is at a standstill), the power to the steering amplifier is switched off. In this way, a continuous flow of power caused by twisting of the drive wheel can be prevented when the vehicle is at a standstill. Without a setpoint/actual value difference, the drive wheel can be moved out of the home position by up to 15° by external influences.

X1:10 In Steering actual value 3R10/2 If the voltage is not within a range of 6.5 - 2.5V, K1 and 3K1 drop out (cable breakage fuse).

X1:11Out Steering OK (0V) If any of the following errors occur, the 0V signal is switched off: 1. Setpoint / actual value potentiometer faulty 2. Undervoltage for setpoint/actual value potentiometer 3. Contact test of internal safety relay negative 4. Internal error

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

12 – 02

Chapter 12

Steering

Pin assignment X1:12 In

n.c.

X1:13 Out Diagnosis lead for PC X1:14 Out n.c.

X1:15 Out Steering ok (24V) If any of the following errors occur, the 24V signal is switched off: 1. Setpoint / actual value potentiometer faulty 2. Undervoltage for setpoint/actual value potentiometer 3. Contact test of internal safety relay negative 4. Internal error

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

X1:16 Out Signal for steering angle >±10°, for the "Slow travel on curves" function X1:17 In

n.c.

X1:18 In

Coding Input: 0V= Version with steering knob (standard factory setting)

X1:19 In

Setpoint 3R11/1 If the voltage is not within a range of 0.4-8.6V, the internal safety relay and 3K1 drop out (cable breakage fuse)

X1:20 In

Setpoint 3R11/2 If the voltage is not within a range of 8.6-0.4V, the internal safety relay and 3K1 drop out

X1:21 In

Coding Input: 0V and X1:4 (0V): Coding, version with steering wheel (default setting is steering knob, small steering modification)

X1:22 In

Actual value 3R10/1 If the voltage is not within a range of 2.5-6.5V, the internal safety relay and 3K1 drop out (cable breakage fuse)

X1:23 In

Switchover from sensity to rough steering mode 0V (No working steering while stoping)

X1:24 In

Output X1:16 is read back. Monitoring of whether output X1:16 is actually active.

X1:25 In

24V power supply for the steering controller

X2:1 Out Motor RI X2:2 In

24V-main supply

X2:3 Out Motor LE X2:4 In

0V-main supply

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

12 – 03

Chapter 12

Steering

Setpoint potentiometer, steering wheel Replacing • Switch off the vehicle.

• Remove the setpoint potentiometer (1). To do so, unscrew the 2 screws (2) and slacken the 2 threaded pins (3). Remove the circlip (4).

• Turn the steering knob into the centre position.

• Plug in the new potentiometer.

• Switch the vehicle on again.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Note:

Since turning the setpoint potentiometer causes a difference between the set and actual values, this may cause uncontrolled steering movements!

• Set the measuring device to voltage measurement and measure the voltage between X1:2 (red) and X1:4 (white/red). The voltage range must be between 0 and 8.6V. • Now turn the shaft of the potentiometer until a value of 0V is set. The potentiometer values of 3R11/1 and 3R11/2 are now the same size.

1 2

10100

Remark: The shaft of the setpoint potentiometer is flattened on one side. It is important to ensure that the threaded pin (2) comes into contact with this flattened area when it is screwed in.

3

4

• Install the setpoint potentiometer in the steering actuator again without turning either of them.

Tighten the threaded pin (3) again.

• The upper and lower voltage limits must now be taught in with the notebook (see Software, Steering/Teaching-in).

• The friction force of the steering knob and its engagement in the centre detent can be adjusted with the adjusting screws (5).

1 2 3 20309

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

12 – 04

Chapter 12

Steering

Setpoint potentiometer, steering knob Replacing • Switch off the vehicle.

• Remove the setpoint potentiometer (1). To do so, unscrew the 2 screws (2) and slacken the 2 threaded pins (3). Remove the circlip (4).

• Turn the steering knob into the centre position.

• Plug in the new potentiometer.

• Switch the vehicle on again.

Since turning the setpoint potentiometer causes a difference between the set and actual values, this may cause uncontrolled steering movements!

• Set the measuring device to voltage measurement and measure the voltage between X1:2 (red) and X1:4 (white/red). The voltage range must be between 0 and 8.6V. • Now turn the shaft of the potentiometer until a value of 0V is set. The potentiometer values of 3R11/1 and 3R11/2 are now the same size.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Note:

5 1 3

2

4

20310

Remark: The shaft of the setpoint potentiometer is flattened on one side. It is important to ensure that the threaded pin (2) comes into contact with this flattened area when it is screwed in.

• Install the setpoint potentiometer in the steering actuator again without turning either of them.

Tighten the threaded pin (3) again.

• The upper and lower voltage limits must now be taught in with the notebook (see Software, Steering/Teaching-in).

• The friction force of the steering knob and its engagement in the centre detent can be adjusted with the adjusting screws (5).

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

12 – 05

Chapter 12

Steering

Actual value potentiometer Replacing

• Set the drive to straight-on (drive wheel parallel to the forks) • Switch off the vehicle • Remove the actual value potentiometer (3). To do so, unscrew the screw (1) and release the other screw (2).

• Plug in the new potentiometer.

• Switch the vehicle on again.

Since a difference has been made between the setpoint and actual value by turning the actual value potentiometer, uncontrolled steering movements may occur!

• Set the test device for voltage measurement and measure the voltage between X1:2 (red) and X1:4 (white/red). The voltage range should be between 0 and 8.7V. • Now turn the shaft of the potentiometer until a value of 0V is set. The potentiometer values for 3R10/1 and 3R10/2 are now equal.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Note:

Remark: The shaft of the actual value potentiometer is flattened on one side. It is important to ensure that the threaded pin (2) comes into contact with this flat area when it is screwed in.

10101

2

3

1

• Install the actual value potentiometer again without turning its shaft. Tighten the threaded pin (2) again.

• The upper and lower voltage limits must now be taught in with the notebook.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

12 – 06

Chapter 12

Steering

Quick start 1. Set the drive wheel to the straight-on position 2. Remove fuse 3F1 3. Set mechanical centre of steering wheel Set the steering wheel or steering knob to the mechanical centre position.

4. Set electrical centre of setpoint potentiometer Tester window, setpoint voltages at steering wheel: turn the setpoint potentiometer until the voltages at Potentiometer 1 and Potentiometer 2 are equal and install them without turning.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

5. Set electrical centre of actual value potentiometer Tester window, Actual value voltages at drive wheel: turn the actual value potentiometer until the voltages at Potentiometer 1 and Potentiometer 2 are equal and install them without turning.

6. Teach In Setpoint value Setpoint for end stops: Teaching in window, Setpoint potentiometer: turn the steering wheel to the left-hand end stop, then press CONTINUE. Turn the steering wheel to the right-hand end stop, then press CONTINUE. 7. Install fuse 3F1 again 8. Teach In Actual value Teaching in window, Actual value potentiometer. Turn the steering wheel (Setpoint) into the centre position. Turn the steered wheel (actual value) by tapping the fine adjustment keys to the straight-on position. Carry out travel test to check this setting.

Press CONTINUE, then move the steered wheel fully to the right and press CONTINUE. 9. Test the steering 10. Delete the error memory

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

12 – 07

Chapter 12

Steering

Travel on curves function As soon as the steering is turned to a steering angle >10°, the output signal of the steering controller at pin X1:16 is reduced from approx. 7.1V to a value of < 3.2V. This signal is converted into a 0V signal in the ABÜ and sent on to the travel control. This causes the travel control to change from travel mode 4 to travel mode 2.

As soon as the steering angle changes back to <9°, the vehicle is switched back to its normal speed.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Note:

Steering controller

OUT >± 10° X1 16

IN >± 10° X1 24

<3.2V or >7.1V X2 10

ABÜ

In In <3.2V --> Out 0V

The "deceleration on curves" function can be activated at a customer's request. To do so, set parameters "M2 Max FWD SPD" and "M2 Max REV SPD" to approx.

70%.

In >7.1V --> Out 24V

Out X2 11 0V or 24V

Travel control

X2 9 Mode input B

0V = Mode 2 24V = Mode 4

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

12 – 08

Chapter 12

Steering

Steering lock The steering is locked by the vehicle control system in the event of aisle recognition or in pedestrian mode. This is done by switching over the steering setpoint 1+2 to a setpoint 1+2 specified by the vehicle control system. This internal setpoint can be adjusted at trimmer potentiometer (2) on the vehicle control system. In this way, the internal setpoint 1+2 can be adapted closely to the voltage values of the setpoint potentiometer.

2

20300

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

The vehicle control system should register the same voltage to the steering controller when the steering is locked as with manual steering and the "straight-on" position (see Software Steering/ Potentiometer voltages).

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

12 – 09

Chapter 13

Vehicle control system

General The vehicle control system (FZS) monitors and controls all the functions that are not carried out by the travel control or ABÜ.

With the basic vehicle, there is a permanently wired Version 1 and for additional vehicle options a permanently programmed Version 2, which are referred to below as FZS1 (3) and FZS2 (1).

FZS2 has the same pin assignment as FZS1, and 2 additional terminals for a second operating console or other options. These terminals also act as terminal distributors.

1

20300

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Location In the cab on the mast side, behind a cover (2).

The position differs between the low lift (1) and highlift versions (3).

Identification Galvanised sheet steel housing, screwed in place.

Terminals on the front.

FZS2: 2 extra red LEDs, 2 connectors X34, X35.

Model: XOP1 V1 or XOP1 V2

2

20301

Technical data Rated voltage: 24V DC Permissible supply voltage: 12-32V DC Analogue inputs: 0-10V Digital inputs: 24V, positive switching Digital outputs: 24V, positive switching, 100mA short-circuit and overload protected 4 power outputs: 24V, positive switching, 2A short-circuit and overload protected wire breakage monitored Analogue output, steering setpoint: 4.65V±0.6V

Issue: Replaces issue:

08/03 07/01

Workshop Manual

XOP1

20302

3

Sheet no.

13 – 01

Chapter 13

Vehicle control system

Guide to versions This table shows which options FZS1 and FZS2 are used for.

XOP1 NO

XOP1 NM

XOP1 HO

XOP1 HM

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

X X X X X X X

Aisle recognition

ZAG

2nd operating console

Intermediate lift limit

Pedestrian mode

FZS1

FZS2

X X X X X

X X X X X X

X

X

X X X X

X X X X X X X

X X X X X

X

X

X X X X

X X X X X X X X X X X X

X X

X X X X X X X X X X X X X X X X X X X X X

Issue: Replaces issue:

X X X X X X

08/03

X X X X X X X X X X

X

X

X X X

X

X

X X X

X X X X X X X

X X X X X X X X X

Workshop Manual

X X X X X X X X X X

X

X

X X X

X

X

X X X

XOP1

X X X X X

Sheet no.

05 13 – 02

Chapter 13

Vehicle control system

Pin assignment

Trailing cables 1+2 -X31 10-pin -X30 18-pin

Options -X38 18-pin -X39 14-pin

1

1

1

1

2

2

2

2 LED1 main processor LED2 monitoring processor

Trimmer potentiometer Straight-on steering

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

-X34 18-pin

-X35 10-pin

-X32 18-pin

-X33 14-pin

1

1

1

1

2

2

2

2

(2nd operating console, load side) 1st operating console

Trailing cables 1and 2 -X31 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

FZS1 function 0V 1+24V +24V EMERGENCY-STOP 2 Pump contactor Lowering valve Main lift valve Additional lift valve n.c. (not connected) n.c.

Issue: Replaces issue:

08/03

-X30

FZS2 function 0V 1+24V +24V EMERGENCY-STOP 2 Pump contactor Lowering valve Main lift valve Additional lift valve SIO RxD SIO TxD

Workshop Manual

FZS1 function ABÜ enable Deadman OUT Travel DWS Travel LS NO/HO operation Travel setpoint 1.2 m switch, decel.

Setpoint steering 1 Setpoint steering + Setpoint steering 2 Setpoint steering Actual value steering 1 n.c.

Deadman 2 Chain switch LHS Chain switch RHS n.c. n.c.

XOP1

FZS2 function ABÜ enable Deadman OUT Travel DWS Travel LS NO/HO operation Travel setpoint 1.2 m switch, decel.

Setpoint steering 1 Setpoint steering + Setpoint steering 2 Setpoint steering Actual value steering 1 Aisle recognition EASS release Chain switch LHS Chain switch RHS Pedestrian mode OUT n.c.

Sheet no.

13 – 03

Chapter 13

Vehicle control system

Pin assignment Optionen

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

-X38 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

FZS1 function Barrier LHS Barrier LHS Barrier RHS Barrier RHS Barrier LHS Barrier LHS Deadman enable Deadman 1 Deadman 2 1.2 m switch 1.2 m switch Additional lift button Lifting button Lowering button EMERGENCY-STOP 2 n.c. (not connected) 0V +24V

-X39

FZS2 function Barrier LHS Barrier LHS Barrier RHS Barrier RHS Barrier LHS Barrier LHS Deadman enable Deadman 1 Deadman 2 1.2 m switch 1.2 m switch Additional lift button Lifting button Lowering button E-STOP 2 (from Id 427 821 n.c.)

0V 0V +24V

FZS1 function 0V Cab light 1+24V Working light +24V 0V Lowering button Upper end stop NO/ HO operation Intermediate lift Intermediate lift n.c. n.c. n.c.

EMERGENCY-STOP 2

FZS2 function 0V Cab light 1+24V Working light +24V 0V Input reserve Upper end stop NO/ HO operation Intermediate lift Intermediate lift n.c.

Input reserve 1 ABÜ pedestrian mode enable EMERGENCY-STOP 2

2nd operating console, load side -X34 Pin FZS1 function 1 2 3 4 5 6 7 d 8 cte e 9 nn co t 10 No 11 12 13 14 15 16 17 18

Issue: Replaces issue:

08/03

-X35

FZS2 function Travel setpoint 0V Travel setpoint Travel setpoint +5V Deadman OUT Travel/pedestrian DWS Travel/pedestrian LS Lifting button Lowering button 2-handed mode button Additional lift button Display 0V Display LHS Display straight-on Display RHS Setpoint steering + Actual value steering 1 Setpoint steering Setpoint steering 2

Workshop Manual

FZS1 function

XOP1

t No

co

te ec n n

d

FZS2 function 0V 1+24V EMERGENCY-STOP 1 Input reserve ABÜ pedestrian mode enable EMERG.-STOP 1, 1 EMERGENCY-STOP 2 Q button (acknowledge) Q button (acknowledge) Button op. console selection

Sheet no.

13 – 04

Chapter 13

Vehicle control system

Pin assignment

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Operating console 1, load or mast side -X32 -X33 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

FZS1 function Travel setpoint 0V Travel setpoint Travel setpoint +5V Deadman OUT Travel DWS Travel LS Lifting button Lowering button n.c. (not connected) Additional lift button Display 0V Display LHS Display straight-on Display RHS Setpoint steering + Actual value steering 1 Setpoint steering Setpoint steering 2

Issue: Replaces issue:

08/03

FZS2 function Travel setpoint 0V Travel setpoint Travel setpoint +5V Deadman OUT Travel DWS Travel LS Lifting button Lowering button 2-handed mode button Additional lift button Display 0V Display LHS Display straight-on Display RHS Setpoint steering + Actual value steering 1 Setpoint steering Setpoint steering 2

Workshop Manual

FZS1 function 0V 1+24V +24V Fleetmanager 1 Fleetmanager 2 EMERGENCY-STOP EMERGENCY-STOP 2 Q button (acknowledge) Q button (acknowledge) n.c.

Switch working light Switch working light n.c. n.c.

XOP1

FZS2 function 0V 1+24V +24V Fleetmanager 1 Fleetmanager 2 EMERGENCY-STOP EMERGENCY-STOP 2 Q button (acknowledge) Q button (acknowledge) Button op. console selection Switch working light Switch working light Pedestrian OUT n.c.

Sheet no.

13 – 05

Chapter 13

Vehicle control system

Input/output assignment

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

M = operating console, mast side L = operating console, load side Inputs:

Terminal -X32:5 -X32:6 -X34:5 -X34:6 -X38:9 -X38:8 -X38:11 -X30:1 -X32:7 -X34:7 -X38:13 -X32:8 -X34:8 -X38:14 -X32:10 -X34:10 -X38:12 -X32:9 -X34:9 -X39:7 -X39:10 -X30:16 -X30:15 -X33:8 -X35:8 -X38:6 -X30:13 -X33:10 -X35:10 -X39:6 -X35:4 -X30:18 -X33:14 -X39:11

Designation -1U20 -1U20 -1U20 -1U20 -1S25 -1S25 -1S23 -U50-X3:4 -2S1/10 -S11/22 -2S30 -2S29 -2S44 -2S46 -2S62 -2S63 -S3 -S20-S22 -3S22 -7S45 -7S46

Use M Travel switch DWS M Travel switch LS L Travel switch DWS/Pedestrian DWS L Travel switch LS/ Pedestrian LS Deadman switch Deadman switch 1.2 m switch ABÜ enable Lifting button Lowering button Additional lift button 2-handed mode button Lift stop (upper end stop) Intermediate lift Chain switch RHS Chain switch LHS Acknowledgement button Barriers LHS, RHS, LS Aisle recognition M Operating console selection L Operating console selection Pedestrian operating mode Res 2 (from Id 427 821 n.c.)

Res 4 (from Id 427 821 n.c.)

Res 5

Analogue:

-X30:12 -X32:16, 18 -X34:16, 18

-3R10 -3R11 -3R11

Steering actual value M Steering setpoint L Steering setpoint

Outputs:

Terminal -X30:3 -X30:4 -X31:5 -X31:6 -X31:7 -X31:8 -X32:12 -X32:13 -X32:14 -X34:12 -X34:13 -X34:14 -X30:17 -X33:13

Designation -1A10 -X1:12 -1A10 -X1:11 -2K1 -2Y21 -2Y20 -2Y23 -3H23 -3H20 -3H24 -3H23 -3H20 -3H24

Use Travel DWS Travel LS Pump contactor Lowering valve Main lift valve Additional lift valve M Display LHS M Display straight-on M Display RHS L Display LHS L Display straight-on L Display RHS Pedestrian mode, decel. 2.5 km/h

-X30:8,10

-3A20

Analogue:

Issue: Replaces issue:

08/03

Workshop Manual

low active

Steering setpoint

XOP1

Sheet no.

13 – 06

Chapter 13

Vehicle control system

Error diagnosis As well as the digital inputs and outputs, the FZS1 and FZS2 have internal switching functions that are necessary for the system to function correctly.

With both FZS, the inputs and outputs must be checked with a digital multimeter in the event of failure. Especial attention must be paid to the internal switching functions of the outputs.

The following logic tables are provided for assistance in this work.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Flashing code, FZS2 In the event of error, the FZS2 shows a flashing code on the 2 LEDs and the 2 red LEDs of the wheel position display (wheel position display: LED left = main processor, LED right = monitoring processor). If there are no errors, both LEDs on the FZS2 are illuminated continuously.

Normally, both LEDs show the same code but not at the same time.

Internal errors indicate a difference between the main processor and the monitoring processor. It may be possible to cancel these by switching off and then on again, but if not, the FZS must be replaced.

Remark: It is also possible for several errors to be displayed one after the other.

Example: LEDs 1+2 flash, error code 1.4, slack chain.

Error, LEDs 1+2 (main and monitoring processor) FE 1.1 FE 1.2 FE 1.3 FE 1.4 FE 1.5 FE 1.6 FE 1.7 FE 1.8

Run relay, monitoring processor off (internal error) Fault, run relay main process (internal error) Watchdog (internal error) Slack chain Chain breakage, LHS Chain breakage, RHS Teaching-in of wheel position display incorrect Fault, EEPROM writing (internal error)

FE 2.1 FE 2.2 FE 2.3 FE 2.4 FE 2.5 FE 2.6 FE 2.7 FE 2.8

Straight-on steering >6.2V Straight-on steering <3,7V Straight-on steering, sum >12V Straight-on steering, sum <8V Fault, output for internal relay and displays Fault, travel output Fault, output for pump / lowering Fault, output for main and additional valves

Monitoring of steering setpoint Check digital outputs (Shortcut, overload, brocken wire)

Error, LED2 (only monitoring processor) FE 3.1-4.8

Internal errors from monitoring processor

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

13 – 07

Chapter 13

Vehicle control system

Table of functions, FZS2 Application This table indicates the conditions (inputs and markers) that must be met for the function defined in the main column of the table to be executed.

Every sub-column (A, B, C, etc.) shows a possible switching function with the conditions marked in it (0, 1) (e.g.: Column A1, A2 = pedestrian operation, travel, drive wheel side).

In some of the main columns, there are also markers shown which are queried as a condition in a function (E.g.: columns P and U are queried in main column A as a condition.

Fields that are not marked do not have any influence on the result in a column.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Signal level: 0 = 0V (<1V) 1 = +24V (>12V) M = op.console, mast side L = op. console, load side

Connection result: S/R = Set/ reset B = flashing 2-3 Hz resp. 0 oder 1 Connection result 1..n per main column A

Digital Inputs FZS 1 Relay contact, main processor 2 Relay contact, monitoring processor 3 1.2 m switch 4 NO/HO operation 5 Example: 6 M Travel DWS The digital Output "Travel Setpoint 7 M Travel LS at pedestrian op. mode" will be 8 L Travel DWS / Pedestrian operating mode AS active, when all coditions in column 9 L Travel LS / Pedestrian operating mode LS A1 or A2 are set.

10 ABÜ enable 11 Pedestrian mode, deadman relay monitoring 1 12 Aisle recognition 15 Lifting button 16 Lowering button 17 Additional lift button 18 2-handed mode button Li/Lo/travel 2 21 Release button 22 Chain switch RHS 23 Chain switch LHS 24 Upper end stop 25 Intermediate lift Example: 26 Pedestrian operating mode, marker Flag "Pedestrian op. mode" 27 Deadman switch 1 28 Deadman switch 2 1 29 Barrier S >=1 19 M button, operating console selection Q 20 L button, operating console selection R 14 Steering actual value, analogue 30 REF Straight-on1 2 31 REF Straight-on2 13 M Steering setpoint, analogue 32 L Steering setpoint, analogue C Switch-over, operating console, load side marker Flags C1 Switch-over, operating console, flashing mode 3 S Chain breakage OK marker >=1 T Slack chain OK marker U Pedestrian mode, deadman relay OK marker O RUN relay marker R Deadman switch 1/2 OK marker 4 P Pedestrian operating mode

&



A

Main columns

P Pedestrian Pedestrian operating mode operating mode, travel setpoint

1 2

1 2 3 4 5 6 7 8 9 S S R R R R R R R

1 1

1 1

0 0 1 0 1

0 0 0 1 1

0 0 0 0 0 0

0 0 0 0 0 0

1 0 0 1

0 0 0 0 0 0

0 0 1 0 1 0 1 0 1 0 1

&

&

P

1 1 0 0 0 0

1 1 1 1 1 1 1 1 1 0 0 1 0 0 1

0 0 0 0

&

&

...

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

1 1 1 1

1 1 1 1

1 1 1 1 1 1 1 1 1

Sheet no.

U Ped. op. mode, Deadman OK 1 2 3 S S R X X X X X X X X X X 1 0X X X X X X X X X X X 1 1X X X X X X X X X X X X X X X X 1 1X X X

13 – 08

Chapter 13

Vehicle control system

Table of functions, FZS2 Pedestrian operating mode A Pedestrian operating mode, travel setpoint

P Pedestrian operating mode

A B

A B C D E F G H I J S S R R R R R R R

1 1

1 1

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Input 1 Relay contact main processor 2 Relay contact monitoring processor 3 1.2 m switch 4 NO/HO operation 5 6 M Travel DWS 7 M Travel LS 8 L Travel DWS / Pedestrian operating mode DWS 9 L Travel LS / Pedestrian operating mode LS 10 ABÜ enable 11 Ped. mode deadman relay monitoring 12 Aisle recognition 15 Lifting button 16 Lowering button 17 Additional lift button 18 2-handed mode button Li+Lo/travel 21 Release button 22 Chain switch RHS 23 Chain switch LHS 24 Upper end stop 25 Intermediate lift 26 Pedestrian operating mode marker 27 Deadman switch 1 28 Deadman switch 2 29 Barrier 19 M button, operating console selection 20 L button, operating console selection 14 Steering actual value, analogue 30 REF Straight-on1 31 REF Straight-on2 13 M Steering setpoint, analogue 32 L Steering setpoint, analogue C Switch-over, op. console, load wheel side marker C1 Switch-over, op. console, flashing mode S Chain breakage OK marker T Slack chain OK marker U Pedestrian mode deadman relay OK marker O RUN relay marker R Deadman switch 1/2 OK marker P Pedestrian operating mode A Pedestrian operating mode travel setpoint G Steering setpoint straight-on G1 M Steering setpoint RHS G1 M Steering setpoint straight-on G1 M Steering setpoint LHS G2 L Steering setpoint RHS G2 L Steering setpoint straight-on G2 L Steering setpoint LHS G3 Steering actual value RHS G3 Steering actual value straight-on G3 Steering actual value LHS G45 Monitoring setpoint straight-on *1 Switch-over operating console (set to EEPROM)

0 0 1 0 1

0 0 0 1 1

0 0 0 0 0 0

0 0 0 0 0 0

1 1 0 0 0 0

1 0 0 1

0 0 0 0 0 0

0 0 1 0 1 0 1 0 1 0 1

1 1 1 1 1 1 1 1 1 0 0 1 0 0 1

0 0 0 0

1 1 1 1

1 1 1 1

1 1

1 1 1 1 1 1 1 1 1

1 1 1 1

P Ped. op. mode, deadman OK A B C S S R X X X X X X X X X X 1 0 X X X X X X X X X X X 1 1 X X X X X X X X X X X X X X X X 1 1 X X X 1 0 X X X X X X X X X X X X X x = reset

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

13 – 09

Chapter 13

Vehicle control system

Table of functions, FZS2 Switch-over, 2nd operating console

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Input

C Switchover, op. console load side

CA Switch-over, operating console load side, flashing mode

1 2 S R

1 2 3 4 5 6 B B B B B B

1 Relay contact main processor 2 Relay contact monitoring processor 3 1.2 m switch 4 NO/HO operation 5 6 M Travel DWS 0 0 7 M Travel LS 0 0 8 L Travel DWS / Pedestrian operating mode DWS 0 0 9 L Travel LS / Pedestrian operating mode LS 0 0 10 ABÜ enable 11 Ped. mode deadman relay monitoring 12 Aisle recognition 15 Lifting button 0 0 16 Lowering button 0 0 17 Additional lift button 0 0 18 2-handed mode button Li+Lo/travel 0 0 21 Release button 0 0 22 Chain switch RHS 23 Chain switch LHS 24 Upper end stop 25 Intermediate lift limitation 26 Pedestrian operating mode marker 27 Deadman switch 1 0 0 28 Deadman switch 2 0 0 29 Barrier 19 M button, operating console selection 0 1 20 L button, operating console selection 1 0 14 Steering actual value, analogue 30 REF Straight-on1 31 REF Straight-on2 13 M Steering setpoint, analogue 32 L Steering setpoint, analogue C Switch-over, op. console, load wheel side marker C1 Switch-over, op. console, flashing mode S Chain breakage OK marker T Slack chain OK marker U Pedestrian mode deadman relay OK marker O RUN relay marker R Deadman switch 1/2 OK marker P Pedestrian operating mode 0 0 A Pedestrian operating mode travel setpoint G Steering setpoint straight-on G1 M Steering setpoint RHS G1 M Steering setpoint straight-on 1 1 G1 M Steering setpoint LHS G2 L Steering setpoint RHS G2 L Steering setpoint straight-on 1 1 G2 L Steering setpoint LHS G3 Steering actual value RHS G3 Steering actual value straight-on 1 1 G3 Steering actual value LHS G45 Monitoring setpoint straight-on *1 Switch-over operating console (set to EEPROM) S R

E Switchover, steering setpoint, mast side 1

F Switchover, steering setpoint, load side 1

G Switch-over, steering setpoint, straight-on 1 2 3 4 5 6 7 S S S S R R R

0 1 1 0

1 1 0 0 0 0

0 1 0 1 0 1 1 0 1 0 1 0

0

1

0 1

0

0

0 0 1 1 0 0

0

0

0 0

1

0 0

1

1

0 0

0 1

1

1 1 1 1 1 1 1

1

1 1 1 1 1 1 0

after 3s

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

13 – 10

Chapter 13

Vehicle control system

Table of functions, FZS2 Power outputs H Pump contactor 1 2 3 4 5 6 7 8 9

I Lowering valve 1 2 3

J Main lift valve 1 2

K Additional lift valve 1 2

0 0 1 0

1 0 0 1 0 0

1 0 0 1 1 1

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Input 1 Relay contact main processor 2 Relay contact monitoring processor 3 1.2 m switch 4 NO/HO operation 5 6 M Travel DWS 7 M Travel LS 8 L Travel DWS / Pedestrian operating mode DWS 9 L Travel LS / Pedestrian operating mode LS 10 ABÜ enable 11 Ped. mode deadman relay monitoring 12 Aisle recognition 15 Lifting button 16 Lowering button 17 Additional lift button 18 2-handed mode button Li+Lo/travel 21 Release button 22 Chain switch RHS 23 Chain switch LHS 24 Upper end stop 25 Intermediate lift 26 Pedestrian operating mode marker 27 Deadman switch 1 28 Deadman switch 2 29 Barrier 19 M button, operating console selection 20 L button, operating console selection 14 Steering actual value, analogue 30 REF Straight-on1 31 REF Straight-on2 13 M Steering setpoint, analogue 32 L Steering setpoint, analogue C Switch-over, op. console, load wheel side marker C1 Switch-over, op. console, flashing mode S Chain breakage OK marker T Slack chain OK marker U Pedestrian mode deadman relay OK marker O RUN relay marker R Deadman switch 1/2 OK marker P Pedestrian operating mode A Pedestrian operating mode travel setpoint G Steering setpoint straight-on G1 M Steering setpoint RHS G1 M Steering setpoint straight-on G1 M Steering setpoint LHS G2 L Steering setpoint RHS G2 L Steering setpoint straight-on G2 L Steering setpoint LHS G3 Steering actual value RHS G3 Steering actual value straight-on G3 Steering actual value LHS G45 Monitoring setpoint straight-on *1 Switch-over operating console (set to EEPROM)

Issue: Replaces issue:

08/03

1

0 1 0 0

0 1 0 0

1 1 0 0 1 0

1 1 0 0 0 1

1 1 0 0 1 1

0 1 0 0

1 1 0 0

0 1 0 1

1 1 0 1

1 0 0 1 1 0 1 1

1 1

1 1 1 1 1 1 1 1 1 1 1 1 0 0

1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0

1 1 1 1 1 1 1 1 1

1 1 1 1 1 1

1 1 1

1 1 1

1 1 1 1 1 1 1 1 1

1 1 1

1 1

1 1

0 0 0 0 0 0 0 0 0

0 0 0

0 0

0 0

Workshop Manual

XOP1

Sheet no.

13 – 11

Chapter 13

Vehicle control system

Table of functions, FZS2 Travel enable L Travel DWS

M Travel LS

N Decel. 2.5km/h

1 2 3 4 5 6 7 8 9 0 1 2 3

1 2 3 4 5 6 7 8 9 0 1 2 3

1 2 3 4 5 6 1 2 3 4 S S R R

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Input 1 Relay contact main processor 2 Relay contact monitoring processor 3 1.2 m switch 4 NO/HO operation 5 6 M Travel DWS 7 M Travel LS 8 L Travel DWS / Pedestrian operating mode DWS 9 L Travel LS / Pedestrian operating mode LS 10 ABÜ enable 11 Ped. mode deadman relay monitoring 12 Aisle recognition 15 Lifting button 16 Lowering button 17 Additional lift button 18 2-handed mode button Li+Lo/travel 21 Release button 22 Chain switch RHS 23 Chain switch LHS 24 Upper end stop 25 Intermediate lift 26 Pedestrian operating mode marker 27 Deadman switch 1 28 Deadman switch 2 29 Barrier 19 M button, operating console selection 20 L button, operating console selection 14 Steering actual value, analogue 30 REF Straight-on1 31 REF Straight-on2 13 M Steering setpoint, analogue 32 L Steering setpoint, analogue C Switch-over, op. console, load wheel side marker C1 Switch-over, op. console, flashing mode S Chain breakage OK marker T Slack chain OK marker U Pedestrian mode deadman relay OK marker O RUN relay marker R Deadman switch 1/2 OK marker P Pedestrian operating mode A Pedestrian operating mode travel setpoint G Steering setpoint straight-on G1 M Steering setpoint RHS G1 M Steering setpoint straight-on G1 M Steering setpoint LHS G2 L Steering setpoint RHS G2 L Steering setpoint straight-on G2 L Steering setpoint LHS G3 Steering actual value RHS G3 Steering actual value straight-on G3 Steering actual value LHS G45 Monitoring setpoint straight-on *1 Switch-over operating console (set to EEPROM)

1

1 0 0 0 1

1 0 0 0 1

1

1 0 0 0 1

1 0 0 0 1

1 0 0 0 1

1 0 0 0 1

0 0 1 0 1

0 0 1 0 1

1

0 0 1 0 1

0 0 1 0 1

0 0 1 0 1

0 0 1 0 1

0 0 1 0 1

0 0 1 1 1 1 0 0 1 1 1 1 0 0 0 0 1 0 1 0 0 1 0 1 0 0

08/03

0 1 0 0 1

0 1 0 0 1

1

0 1 0 0 1

0 1 0 0 1

0 1 0 0 1

0 1 0 0 1

0 0 0 1 1

0 0 0 1 1

1

0 0 0 1 1

0 0 0 1 1

0 0 0 1 1

0 0 0 1 1

0 0 0 1 1

1

1 1 1 1 1 1 0 1 1 1 1 1

0 1 0 1

0 0 0 1 0 0 1 0 0

1 1

1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 0 1 1 1 1 1 1 1 1 1 1 1 1 0 1 0 1 1 1 1 1 1 1 1 1 0 0

1 1 1 1 1 1 1 1 1 1 1 1 1 0 1 1 1 1 1 1 1 1 1 1 1 1 0 1 0 1 1 1 1 1 1 1 1 1 0 0

0 0 0 0 0 0 1 1 1 1 1 1

0 0 0 0 0 0 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 1

0 0 0 0 0 0

0 0 0 1 0 1 0 0 0 1 0 1 1

0 0 0 1 0 1 0 0 0 1 0 1 1

0 1 1 1 1 0

1 1 1 1 1 1 1 0 1 0 1 1 1 1 1 1 1 0 0 1 1 1 1 1 1 1

1 1 0 0

1 1 1 1 1 1 1 1 1 1

1 1

1 1

1 1 1 1

max. 3s

Issue: Replaces issue:

1

N Deadman OK

Workshop Manual

XOP1

max. 3s

Sheet no.

after 200ms

13 – 12

Chapter 14

Operating console

Position of the operating elements

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

1 1 Key switch 2 Wheel position display/ Error code 11 3 EMERGENCY-STOP button 10 4 Lifting button 5 Lowering button 6 Horn button 7 Travel setpoint generator 8 Operating console switch-over button 9 2-handed operation, additional lift (with load side operating console) Cabin light (with load side operating console) 10 2-handed operation, travel in aisle 11 Acknowledgement key

2

3

4 5 6

20306

9 8

7

Removal • Release the 2 screws (2), using a 4mm hexagon socket screw key.

• Remove the grip (1), using a 24mm open-ended spanner.

• Lift the operating console up and off.

• Disconnect the connection to the vehicle control system.

Installing

1

2

20301

Follow the instructions for removal in the opposite order.

Lower the operating console parallel to the wall of the cab, and ensure that the plastic guides are correctly seated.

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

14 – 01

Chapter 14

Operating console

Wheel position display

1

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

The vehicle control system (FZS) evaluates the voltage of the actual value potentiometer for the steering, and indicates the wheel position on 3 LEDs (1) on the operating console. Up to a steering angle of ±10° (±6°, FZS2), the green LED in the middle lights up. If the steering angle changes to > ±10° (> ±6°, FZS2), the red LED on the left or right-hand side lights up. If the steering is reduced to < ±9° (< ±5°, FZS2), the display changes back to "straight-on". In the event of failure, a flashing code may be shown (see Vehicle control system (FZS)/Error diagnosis).

If there are 2 operating consoles, only the wheel position display on the active operating console lights up (see Operating console/ 2nd operating console).

20301

2

Adjustment Adjustment of the wheel position display assumes correct adjustment of the steering (see Steering/ Commissioning). The wheel position display can be corrected on the FZS1 with the trimmer potentiometer (2) "Steering straight-on", and on the FZS2 by a teaching-in process.

The wheel position display is set in relation to straight-on travel so that the LED changes at the same steering angle to the left and right (3).

20300

±9° ±10° (±5°) (±6°)

Teaching in the FZS2 • Bring the steering into the "straight-on" position (travel test, moves freely, steering not locked).

• Stop the vehicle and switch it off.

• Press the buttons for lifting and lowering at the same time and switch on the vehicle. Wait until the green LED lights up.

• Press the button for lifting briefly - the green LED will flash. The current actual value is stored temporarily in the FZS. • Press the button for lowering briefly. The temporarily stored value is stored permanently as the reference voltage. The green LED lights up, the vehicle is ready for operation.

Issue: Replaces issue:

08/03 07/01

Workshop Manual

XOP1

3

90°

Sheet no.

01 14 – 02

Chapter 14

Operating console

Wheel position display Teaching-in the FZS2 If error code 1.7 appears, the teaching-in value is not within the permissible range.

Remark: If the vehicle is equipped with 2 operating consoles, the operating console on the mast side must be activated and teachingin carried out on this operating console.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

2nd operating console The vehicle can be fitted with a second operating console as an optional extra. The two operating consoles are identical in design and have the same functions. When the vehicle is switched on, the last operating console that was active is always activated.

The wheel position display only lights up on the active operating console. Switching over to the operating console on the opposite side is only possible when the wheel position is "Straight on" (see Vehicle control system (FZS)/ Table of functions, FZS2).

1 20303

To switch over, the steering is first set to "straight on" on the active operating console. No other functions may be selected. Then the "operating console selection" button on the operating console at the opposite side is actuated.

If the steering setpoint is "Straight on" on both the operating consoles, and the actual value for steering is also measured as "straight on", the switch-over is made immediately.

If not, one LED on the wheel position display of both operating consoles flashes during actuation of the buttons. If the LED is green, this means OK, while red is an indication that the steering setpoint must be corrected to either the left or right. The steering setpoint must be set to straight on with the button pressed, and this causes the operating console to be switched over.

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

14 – 03

Chapter 14

Operating console

Pedestrian operating mode This option allows the driver to walk beside and drive the vehicle at v=2.5km/h using an additional button (1) at the side of the operating console.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

In order to use this function, the steering must be in the "Straight-on" position. It is locked immediately when pedestrian operating mode is selected (see Steering/Steering lock).

No other functions may be selected. A safety relay in the vehicle control system bridges the deadman switch and sends out a travel enable signal for max. 3 seconds. When this time has come to an end, the vehicle can be moved forward again by pressing the buttons briefly again (1). When another function is selected, the pedestrian mode is reset (see Vehicle control system (FZS)/Table of functions, FZS2).

Pedestrian operating mode is only possible on vehicles with one operating console and a low lift design. For safety reasons, there are two additional emergency-stop switches (2) fitted at the left and right hand sides of the operating console.

1

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

2

20304

14 – 04

Chapter 15

EASS

End-of-aisle safety system (EASS) General The end-of-aisle safety system (EASS) is a device designed to assist the driver. Its purpose is to brake the vehicle to a speed of v=2.5km/h at the open and closed ends of aisles. As an option, a stop is also possible, i.e. after the vehicle has stopped, it can be driven towards the middle of the aisle at vmax and towards the end of the aisle at a speed of vRED (2.5km/h).

The options Absolute stop, EASS reflexli and EASS magnetic-diagonal are not availible.

This automatic braking feature is only effective inside an aisle.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Remark:

During automatic braking, it is essential to watch the left and right-hand rail switches.

If no rail switches are detected, the EASS module (4) is not active, i.e. the EASS module also checks all the inputs outside the aisle, but switches the outputs for deceleration and travel stop so that they are inactive.

As soon as a rail switch is detected, the outputs of the EASS module are activated.

If a zone will not be reset the reduction keeps active.

A zone detection is only posible while traveling.

If a rail switch fails in the fast travel zone, a travel stop is initiated.

The vehicle can then only be driven with the acknowledgement key (2) held down and at vRED until the error is rectified.

Note:

20308

1

2

If no rail switch is detected when the vehicle enters the aisle, no braking operation is carried out at the end of the aisle!

20306

Issue: Replaces issue:

08/03 07/01

Workshop Manual

XOP1

Sheet no.

15 – 01

Chapter 15

EASS

EASS Universal From April 2002, only the EASS-Uni module will be installed. It replaces the EASS magnetic, inductive, magnetic-diagonal and reflexli modules.

Remark:

The EASS-Uni module can be identified from the 8-pin connector X3, which is a 6-pin connector on all the older modules except for the EASS reflexli.

When this module is used to replace an "old" EASS module, the following changes must be made to the vehicle wiring: 1. Replace 6-pin connector X3 with an 8-pin connector X3.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Front plate:

2. The emergency-stop circuit of the truck must be connected via the EASS module (X3-5 supply lead, X3-6 connected).

3. The vehicle type must be set at connector X3, pin 7/8. >0< means the pin is not assigned. >1< means the pin is assigned with +24V.

2

1

2

X X3

X1

F4 F2 \RED

F3 F1 \STOP

OS LS

Q AS

GE2-Z2 S8

1

2 1

GE1-Z1 S7

S6 S4

S5 S3

S2

S1

X2

4. At connector X1, pin 13/14, the code for the EASS variant must be set.

5. At connector X2, pin 10, the EASS version must be set.

Connector/pin Pin X3:7 Pin X3:8

Vehicle type 1 0

Connector/pin X1:13 X1:14

Inductive 0 0

Connector/pin X2:8 X2:10

Delivered with EASS-Uni 0 0

Issue: Replaces issue:

08/03

Magnetic 1 0

Workshop Manual

Retrofitted to EASS-Uni 0 1

XOP1

Option Stop 1 0

Sheet no.

15 – 02

Chapter 15

EASS

EASS Universal Error codes

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

With LED F1-F4 15 errors can be displayed.

Error Incremental encoder 1 channel faulty, Connector not plugged in or v<0.3km/h in the direction of the end or centre of the aisle Travel switch direction is not the same as incremental encoder direction Sudden change of direction, with v>1.1km/h Travel switch: DWS= LS Ind., Magn., Magn.diag.: only one aisle end=0 Illogical switch statuses: Ind.: (inverse signals) Magn.: (S1-S4=1) Magn.diag.: (S1-S4=0, AND/OR S5-S8=0) Reflexli.: (with S1=0 OR S2=0 it applies that S3=1 AND S4=1 and vice versa, otherwise error; S5=0 AND S6=0 Ind.: plate offset too large Reflexli.:pulse length too long Magn.; Magn.diag.: no pairing of S1-S8 Brake ramp not OK Reflexli: Absolute stop, time stop, v-check outside end-of-aisle zone Magn. diag.: pulse length too long Reflexli.: both STOP signals S7 and S8 are the same (anti-chatter) Reflexli.: speed check Reflexli: Reflector type A/B not OK (reflector sequence illogical, distance of one reflector too long) Reflexli: Reflector type A/B: A/B distance too short Hardware error, EASS module faulty Remark: flashing error LEDs show a difference between main and monitoring processors -> switch vehicle off and then on again, carry out reference sequence.

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

F4 0

F3 0

F2 0

F1 1

No. 1

0 0 0 0 0

0 0 1 1 1

1 1 0 0 1

0 1 0 1 0

2 3 4 5 6

0

1

1

1

7

1 1 1 1

0 0 0 0

0 0 1 1

0 1 0 1

8 9 10 11

1 1

1 1

0 0

0 1

12 13

1 1

1 1

1 1

0 1

14 15

Sheet no.

15 – 03

Chapter 15

EASS

EASS Inductive Function

1

End-of-aisle zone End-of-aisle zone

GE1 apr. 7m

Fast travel zone

DWS LS

If both proximity switches reach the plates at the same time, the vehicle can be driven at max. speed as long as the travel direction is not changed.

In the version with the stop option (OS), the vehicle is stopped in the end-of-aisle zone.

After approx. 2 seconds the vehicle can be driven towards the end of the aisle at 2.5km/h and towards the middle of the aisle at vmax.

S3

S1

GE2

In the standard version, two inductive proximity switches (S1 and S3) are mounted, with which the steel plates are recognised.

When one proximity switch reaches the start of the second braking plate, the EASS module passes on the RED signal (deceleration low active) to the FPS and the vehicle is braked to a speed of 2.5km/h. If the vehicle is then driven in the opposite direction, it can be driven at maximum speed.

300mm

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Galvanized steel plates are laid in the aisles for recognition of the aisle end zones. These are offset by approx. 300mm towards the middle of the aisle and by a maximum of 60mm towards the end of the aisle. The steel plates (1) are approx. 7m long. The vehicle may not leave the plates towards the closed end of the aisle and should maintain a safety distance of 1m from the wall.

1

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

15 – 04

Chapter 15

EASS

EASS Inductive Function

1

End-of-aisle zone End-of-aisle zone

GE1 apr. 7m

Fast travel zone

DWS S3

S1

LS

Procedure in the event of errors If an error is detected, e.g. a rail switch or a proximity switch is faulty, the vehicle is braked to a standstill.

The vehicle can then be driven with the acknowledgement key (3) held down and at a speed of v=2.5km/h.

GE2

The vehicle is switched on in the fast travel zone If the vehicle is switched on in the fast travel zone, it can be driven in both directions at max. speed. The vehicle is braked to v=2.5km/h at both end-of-aisle zones. The vehicle's position in the aisle is ascertained from the plate offset and the direction in which it is currently being driven.

300mm

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

The vehicle is switched on on the floor plates If the vehicle is switched on over the floor plates (1) it is initially only possible to drive it in both directions at a speed of 2.5km/h. Not until the plate offset (2) of approx. 300mm or the flush plates are recognised can the vehicle's actual position be ascertained. Once this is established, travel at max speed towards the middle of the aisle is enabled.

2

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

15 – 05

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

300mm

End-of-aisle zone

ap. 7m

Towards middle of aisle

vmax

Towards middle of aisle After switching on Towards end of aisle

S3

S1

Fast travel zone

DWS

vRED

vRED

GE1

LS

vRED

End-of-aisle zone

vmax

vmax

vmax

vmax

vRED

vmax

vmax

vmax

S5 = 0 and S7 = 0 GE1 = 1 and GE2 = 1 EASS is active

S1 = 0 and S3 = 0

Fast travel zone

vmax

vmax

vmax Brake to STOP then vRED vmax

vmax

S1 = 1 and S3 = 0 or S1 = 0 and S3 = 1 S5 = 0 and S7 = 0 GE1 and GE2 =1 EASS is active

Plate offset zone

vRED (2.5km/h)

GE2

S5 = 0 and S7 = 0 GE1 and / or GE2 =1 EASS is active

S5 ,S7, either way GE1 = 0 and GE2 = 0 EASS is not active vmax

vmax

S1 = 1 and S3 = 1

End-of-aisle zone not absolute stop

S1, S3, either way

Towards middle of aisle Stop option Towards end of aisle

Speeds Towards end of aisle

S5,S7 Aisle recognition

Switch position S1,S3

Outside aisle

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Chapter 15 EASS

EASS Inductive Guide to the system

1

1

15 – 06

Issue: Replaces issue:

08/03 1 channel faulty Channels reversed

Plate offset > 300mm Towards end of aisle Towards middle of aisle Travel switch forw. and reverse at same time Travel direction is not same as incremental encoder direction Only one aisle recognition active Incremental encoder not plugged in Towards end of aisle Towards middle of aisle

Workshop Manual

XOP1

Sheet no.

End-of-aisle zone

ap. 7m

300mm

Error

Outside aisle

S3

S1

Fast travel zone

Error Error

vmax vRED

AS

GE2

Plate offset zone

GE1

LS

Error Error

vRED vRED

Error

Error

Error

Error

Error Error

Plate offset zone

Error

End-of-aisle zone

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

End-of-aisle zone

Error Error

vmax vmax

Error

Error

Fast travel zone

Chapter 15 EASS

EASS Inductive Monitoring

Remark: If an error occurs ( LED F on the EASS module goes out), the vehicle is brought to a standstill. It can be driven at 2.5km/h by holding down the acknowledgement key.

If an error occurs while the acknowledgement key is pressed, the vehicle is stopped. It can be driven at 2.5 km/h by holding down the acknowledgement key.

15 – 07

Chapter 15

EASS

EASS Inductive 2

Mounting the proximity switches The switching distance S (3) can be adjusted with the threaded pin (2) at the back of the proximity switch (1). The maximum distance from the top edge of the sensor to the ground is 40mm.

Remark:

83011

Only sensors with a switching distance of 35mm must be used. This with greather switching distance may be influenced by the vehicle chassis.

1

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

A switching distance of 30mm is pre-set in the factory.

This distance can, however, only be used if there is no unevenness in the floor and there are no obstacles or metal elements laid in the floor.

3 83010

Testing the proximity switches Test the switches when they are connected: • Check the power supply 24V: EASS module, Connector X2:1 0V: EASS module, Connector X2:2 • Push a metal plate under the sensor 61187

• The LED in the sensor housing and the relevant LEDs on the EASS module should light up (S1, S3).

2

F3 F1 \STOP

OS LS

Q AS

S6 S4 S2

Workshop Manual

XOP1

1

X1

F4 F2 \RED

GE2-Z2 S8

08/03

2

X X3

• The output signal (24V) from the sensors can be measured at terminals X1:3, X1:5 and X1:7, X1:9 of the EASS module against X2:2.

Issue: Replaces issue:

1

2 1

GE1-Z1 S7

X2

S5 S3 S1

Sheet no.

15 – 08

Chapter 15

EASS

EASS Inductive

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Displays and pin assignment LED \F \RED \STOP OS Q LS AS GE1 GE2 S8 S7 S6 S5 S4 S3 S2 S1

Description Error Deceleration 2.5km/h Travel stop Stop option Q key pressed (acknowledgement) Reverse direction Forward direction Rail switch 1 (aisle recognition) Rail switch 2 (aisle recognition) No function Proximity switch, absolute stop No function Proximity switch, absolute stop No function Proximity switch, reduction No function Proximity switch, reduction

Connector X1 1: 1+24V (to fuse F1, internal) 2: 0V 3: Input, switch S1 4: nc 5: Input, switch S3 6: nc 7: nc 8: nc 9: nc 10: nc 11: Input, aisle recognition 1 (GE1) 12: Input, aisle recognition 2 (GE2) 13: nc (Coding modul type) 14: nc (Coding modul type) Connector X3 1: 1+24V (fuse F1, internal) 2: 0V 3: Incremental encoder K1 4: Incremental encoder K2 5: nc 6: nc 7: 24V (Coding vehicle type) 8: nc (Coding vehicle type) Issue: Replaces issue:

08/03

Workshop Manual

Level low active low active low active high active high active high active high active high active high active high active high active high active high active

2

1

2

X X3

X1

F4 F2 \RED

F3 F1 \STOP

OS LS

Q AS

GE2-Z2 S8 S6 S4 S2

1

GE1-Z1 S7

2 1

X2

S5 S3 S1

Connector X2 1: 1+24V 2: 0V 3: Output, travel stop (low active) \STOP 4: Output, reduction (low active) \RED 5: Input, forwards travel, DE 6: Input, reverse direction, LE 7: Input acknowledgement key\Q 8: Input, stop option, OS 9: 1+24V (fuse F1, internal) 10: nc (24V= "old" EASS logic) 11: Output, internal stop relay 12: Output, internal stop relay 13: Output, internal reduction relay 14: Output, internal reduction relay Remark: If the stop option (OS) is activated, a bridge from X2:9 to X2:8 must be fitted on connector X2.

XOP1

Sheet no.

15 – 09

Chapter 15

EASS

EASS Magnetic (bistable)

End-of-aisle zone

S N

When a pair of magnetic switches reaches the switching magnets in the end-of-aisle zone (driving towards the end of the aisle), the EASS module sends the RED signal (reduced speed low active) on to the FPS and the vehicle is braked to a speed of 2.5km/h. If the vehicle is driven in the opposite direction, it can be driven at maximum speed.

End-of-aisle zone

S

N

Fast travel zone

GE1

S3,4

Endof

GE2

Braking magnets

When the aisle entrance is detected (GE1 or GE2), the vehicle can be driven towards the middle of the aisle at max. speed. If the vehicle is driven in the opposite direction, the speed is lowered to 2.5km/h (in the end-of-aisle zone). In the fast travel zone, the vehicle can be driven in both directions at vmax.

S1,2

In the standard version, two pairs of magnetic switches are mounted (S1, 2 and S3, 4). These are used for recognition of the braking magnets laid in the floor.

LS

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Switching magnets with a defined polarity (north pole or south pole up are fitted in the floor of the aisles for recognition of the end-of-aisle zones. The bistable magnetic switches mounted at the left and right of the vehicle underside are actuated by the switching magnets. The magnetic switches are closed by the north pole of the magnets. The south pole opens the magnetic switches. The last switching status of the magnetic switches remains stored in the system when the vehicle is switched off and then on again.

For safety reasons, a switching magnet always switches a pair of magnetic switches. The plausibility of the input signals from the magnetic switches is monitored continuously in the EASS module.

Braking magnets

Function

In the version with the stop option (OS), the vehicle is stopped in the end-of-aisle zone.

After about 2 seconds, the vehicle can be driven towards the end of the aisle at a speed of 2.5km/h and towards the middle of the aisle at vmax.

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

15 – 10

Chapter 15

EASS

EASS Magnetic (bistable)

S N

Braking magnets

1

Fast travel zone

GE1

S3,4

DWS S

N

1 End-of-aisle zone

S1,2 Braking magnets

Procedure in the event of errors If an error is detected, e.g. a rail switch or a magnetic switch is faulty, the vehicle is braked to a standstill.

The vehicle can then be driven with the acknowledgement key (1) held down and at a speed of v=2.5km/h.

GE2

The vehicle is switched on in the fast travel zone If the vehicle is switched on in the fast travel zone, it can be driven in both directions at max. speed. The vehicle is braked to v=2.5km/h at both end-of-aisle zones. The vehicle's position in the aisle is ascertained from recognition of the magnets and the direction in which it is currently being driven.

LS

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

The vehicle is switched on in the end-of-aisle zone When the vehicle is switched on in the end-of-aisle zone, it is initially only possible to drive it in both directions at a speed of 2.5km/h. Not until the north pole magnet (2) is recognised during travel towards the middle of the aisle, or the aisle exit is recognised (G1, GE2 to 0) can the vehicle's actual position be ascertained. Once this is established, travel at max speed towards the middle of the aisle and outside the aisle is enabled.

End-of-aisle zone

Function

2

20306

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

15 – 11

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

vmax vmax

vRED vRED

vmax

Sheet no.

End-of-aisle zone

S

N

Fast travel zone

GE1

S3,4

DWS

N

End-of-aisle zone

S

Braking magnets

vmax

Brake to STOP then after 2 sec. vRED vmax

LS

vmax

vmax

S1,2

vmax

vRED (2.5km/h)

GE2

vmax

S5 - S8 =1 GE1 and / or GE2 =1 EASS is active

S5 - S8 =1 GE1 = 0 and GE2 = 0 EASS is not active vmax

vmax

S1,2 = 1 and S3,4 = 0 or S1,2 = 0 and S3,4 = 1 S5 - S8 =1 GE1 = 1 and GE2 = 1 EASS is active

Fast travel zone

S1 - S4 =0

End-of-aisle zone

S1 - S4 =0

Braking magnets

Towards middle of aisle

Towards middle of aisle After switching on Towards end of aisle

Towards middle of aisle Time stop Towards end of aisle

Speeds Towards end of aisle

S5 to S8 Aisle recognition

Switch position S1 to S4

Outside aisle

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Chapter 15 EASS

EASS Magnetic (bistable)

Guide to the system

1

1

15 – 12

Remark:

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

End-of-aisle zone

S

N

Braking magnets

1 channel faulty Channels reversed

Towards middle of aisle

Switches S1,2 to S7,8 not paired Illogical switching statuses e.g. S1 to S4 = 1 Travel switch forw. and reverse at same time Travel direction is not same as incremental encoder direction Only one aisle recognition active Incremental encoder not plugged in Towards end of aisle

S3,4

S1,2

DWS

GE2

Error Error

vRED

vRED

Error

Error

N

End-of-aisle zone

S

Braking magnets

Error Error

vmax

vmax

Error

Error

Error

Error

Error

Error Error

Fast travel zone

End-of-aisle zone not absolute stop

Fast travel zone

GE1

LS

Error

Outside aisle

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Chapter 15 EASS

EASS Magnetic (bistable) Monitoring

1

1

If an error occurs (LED F on the EASS module goes out), the vehicle is brought to a standstill. It can be driven at 2.5km/h by holding down the acknowledgement key.

If an error occurs while the acknowledgement key is pressed, the vehicle is stopped. It can be driven at 2.5km/h by holding down the acknowledgement key.

15 – 13

Chapter 15

EASS

EASS Magnetic (bistable) Magnetic switch Description These are bistable switches that are actuated by a magnetic field without contact. Influence on the switching surface (1) by the north pole of a switching magnet switches the internal switch continuously to transmission.

Influence by the south pole of a switching magnet switches the internal switch continuously to interruption.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

The switching positions can be identified on the EASS module with LEDs S1 to S8. Transmission = the relevant LED on the EASS module lights up.

The magnetic field must be adjusted to the end surface (switching surface) of the housing. The distance should be betweeen 20 and 40mm. A centre offset at one side of a few millimetres (due to play and inaccuracy of the wire guidance system) does not have any effect on the switching safety.

1

Bistable action The magnetic switches are switched to status 1 (internal switch closed = transmission) by the north pole of a switching magnet. If the south pole of the switching magnet is then driven over, the magnetic switches are switched back to switching status Ø (internal switch open = no transmission) and vice versa.

The present switching status of the magnetic switch is retained even when the vehicle is switched off and then on again.

2

08/03

Workshop Manual

XOP1

2

X X3

F3 F1 \STOP

OS LS

Q AS

2 1

GE1-Z1 S7

S6 S4

S5 S3

S2

S1

Sheet no.

1

X1

F4 F2 \RED

GE2-Z2 S8

Issue: Replaces issue:

1

X2

15 – 14

Chapter 15

EASS

EASS Magnetic (bistable) Switching magnet Description The permanent magnets (1) have a north and a south pole, each at one of the round surfaces. The south pole is stamped with an "S" about 3mm in size or just one countersunk hole so that the two ends can be distinguished from one another. The one countersunk type can also be used in cold store environment.

The mounting hole (2) should be made with the dimensions shown to the right.

S N

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Handling instructions

ø33

1

s

• Permanent magnets may only be secured with countersunk screws made of brass, aluminium, V4A steel or plastic.

• When a magnet is mounted recessed in its mounting surface, it can be sealed in the hole with synthetic resin or silicone (3). It does not then need to be secured with a screw.

24

• It is possible to mount the magnet recessed in iron. However, a gap of at least 2 or even better 3mm must be maintained on every side.

• Permanent magnets are very brittle. For this reason, avoid levering, knocking them, etc. when handling them.

2 70517

3

70520

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

15 – 15

Chapter 15

EASS

EASS Magnetic (bistable)

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Displays and pin assignment LED \F \RED \STOP OS Q LS AS GE1 GE2 S8 S7 S6 S5 S4 S3 S2 S1

Description Error Deceleration to 2.5km/h Travel stop Stop option (time stop) Q key pressed (acknowledgement) Reverse direction Forwards direction Rail switch 1 (aisle recognition) Rail switch 2 (aisle recognition) Magnetic switch, absolute stop Magnetic switch, absolute stop Magnetic switch, absolute stop Magnetic switch, absolute stop Magnetic switch, reduction Magnetic switch, reduction Magnetic switch, reduction Magnetic switch, reduction

Connector X1 1: 1+24V (fuse F1, internal) 2: 0V 3: Input, switch S1 4: Input, switch S2 5: Input, switch S3 6: Input, switch S4 7: n.c.

8: n.c.

9: n.c.

10: n.c.

11: Input, aisle recognition 1(GE1) 12: Input, aisle recognition 2(GE2) 13: nc (Coding modul type) 14: nc (Coding modul type) Connector X3 1: 1+24V (fuse F1, internal) 2: 0V 3: Incremental encoder K1 4: Incremental encoder K2 5: n.c.

6: n.c.

7: 24V (Coding vehicle type) 8: n.c. (Coding vehicle type) Issue: Replaces issue:

08/03

Workshop Manual

Level low active low active low active high active high active high active high active high active high active low active low active low active low active low active low active low active low active

2

1

2

X X3

X1

F4 F2 \RED

F3 F1 \STOP

OS LS

Q AS

GE2-Z2 S8 S6 S4 S2

1

GE1-Z1 S7

2 1

X2

S5 S3 S1

Connector X2 1: 1+24V (fuse F1, internal) 2: 0V 3: Output, travel stop (low active) \STOP 4: Output, reduction (low active) \RED 5: Input, forwards travel \DE 6: Input reverse travel \LE 7: Input, acknowledgement key \Q 8: Input, stop option (time stop) \OS 9: 1+24V (fuse F1, internal) 10: n.c. (24V = "old" EASS logic) 11: Output, internal stop relay 12: Output, internal stop relay 13: Output, internal reduction relay 14: Output, internal reduction relay Remark:

XOP1

If the stop option (OS) is activated, a bridge from X2:9 to X2:8 must be fitted on connector X2.

Sheet no.

15 – 16

Chapter 16

Speed sensor

General The speed sensor is supplied with 12V by the brake monitoring board (ABÜ). At its outputs, it delivers voltages of approx. 1V or 11V, depending on its switching status.

The speed sensor uses two internal proximity switches to determine the speed of the drive motor.

The speed sensor is monitored constantly by the ABÜ (brake monitoring board).

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

If an error occurs (e.g. if a channel is faulty), this is recognised by the ABÜ board and electromagnetic braking is initiated immediately.

In the event of failure, the ABÜ board generates a flashing error code which is shown on the fault LED (see ABÜ/ Flashing error code).

10069

Terminals block connector X2 X2 : 1

pink

12V

X2 : 2

purple

Signal A1

X2 : 3

yellow

GND

X2 : 4

orange

Signal A2

Signal sequence U(V)

Phase shift 90°

11V

1V

t(s)

Signal A2

U(V)

30 pulses/revolution/channel

t(s)

Signal A1

Assembly: The mounting distance between the counting wheel and the sensor should be between 1 and 2 mm.

Issue: Replaces issue:

08/03 07/01

Workshop Manual

XOP1

Sheet no.

16 – 01

Chapter 16

Speed sensor

Testing the speed sensor Note:

Secure the vehicle to prevent it rolling away!

1. Jack up the vehicle far enough to free the drive wheel.

2. Switch on the vehicle.

Speed sensor 12V

Signal A2

Signal A1

0V

X2 1

X2 2

X2 4

X2 3

3. Check the power supply of the speed sensor between X2:1 (12V) and X2:3 (0V).

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Remark:

If less than 12V or no voltage is applied between X2:1 and X2:3, a further voltage measurement must be taken between X1:1 and X21:2 of the ABÜ.

If the measurement taken here is 10V, the line connections between the ABÜ and the sensor must be checked (line breakage, poor contact connection).

ap.9,5V ap.9,5V

V

V

12V V

pi

pu

or

ye

X1 1

X1 4

X1 3

X1 2

ABÜ

4. Press the deadman switch.

5. Accelerate the drive wheel very slowly. If this is not possible, turn the drive wheel by hand.

6. Check the sensor signals. The voltage between X2:2 (Signal A2) and X2:3 (0V), and the voltage between X2:4 (Signal A1) and X2:3 (0V) should be approx. 10V. If significantly less or no voltage is applied, the speed sensor is faulty.

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

16 – 02

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

X1:4

1K34

X3 1

K2

PIC

X2:8

Sheet no.

Battery discharge curve

X1:3

Pump OFF

0V=OK

X2:9

Switch-on test K1A

K1

Switch-on test K1

X2:7

&

Travel control

A

X1:9

X1:2

BSZ

X3 8

Steering angle < ±10°

1A10

X1:16

X3 10

2+24V

X1:2 GND

OK

EASS

standstill l

steering control

Enable

B1 OUT

K2

X2:12 X2:13

K1

Lifting

0V

2K1

X3:2

K2

X3 7

Lowering

FZS

X3 3

X1:4 X3 6 B

A1 OUT

X1:3 A

Speed sensor drive motor

X3:5 X2:4 10

ABÜ

X2:3 14 X2:1 X1:1 12V

X2 11

X2:2 X3:4

Reverse volt. protection diode

X2:5

X2:6

X3:9

24V

Deadman switch

Travel direction forw. reverse

A

FZS

0V

FZS

A

3K1

3F1

24V K1

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Chapter 17 ABÜ - Braking monitor

Block diagram

17 – 01

Chapter 17

ABÜ - Braking monitor

Pin assignment *A = Output *E = Input

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

X1 X1:1 A* X1:2 A X1:3 E* X1:4 E X1:5 A X1:6 A

12V power supply, speed sensor 0V power supply, speed sensor Channel 1 signal; speed sensor Channel 2 signal; speed sensor Not occupied Standstill detection for steering controller. As long as pulses are received at the steering controller, the steering remains active, even if the steering enable signal is removed.

X2 X2:1 X2:2 X2:3 E

1+24V power supply for ABÜ.

0V power supply for ABÜ.

Travel enable for 1A10 and supply voltage for travel direction switch via deadman switch.

X2:4 E Steering controller OK=0V. This is applied as soon as supply voltage is applied at the steering controller and there are no internal steering controller errors.

X2:5 E Coding: 24V = XOP1 X2:6 E Steering contactor 3K1 closed, i.e. steering contactor contact test is OK. X2:7 E Travel direction DWS X2:8 E Travel direction LS X2:9 E Signal from 1A10 to ABÜ to activate lift stop.

X2:10 E Signal from steering controller: Steering angle >10°, deceleration is initiated.

X2:11 A 0V are applied at this output when the voltage at X2:10 is <3.2V. 24V are applied when the voltage is >7.1V. X2:12 A Channel 1, speed sensor for EASS X2:13 A Channel 1, speed sensor for EASS X2:14 E If two deadman switches are fitted - query whether both deadman switches are pressed.

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

10355

Sheet no.

17 – 02

Chapter 17

ABÜ - Braking monitor

Pin assignment X3 X3:1 A X3:2 E X3:3 A X3:4 A

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

X3:5 A X3:6 E X3:7 E X3:8 A X3:9 E X3:10 A

If 24V are applied at X3:9 and K1 is closed, 24V should be applied here.

Supply for potential-free normally open contact K2 (selection of pump contactor) If K2 is closed, the same potential should be applied here as at X3:2 Power supply for deadman switch.

Condition is: K1 closed, X3:9=24V, switch-on test for K1 positive, 3K1 closed, steering OK signal=0V Inverted output of X2:3 for enable steering= 0V Start for the hour meter during lifting Start for the hour meter during lowering Connection of X3:6 and 7 via diodes for the hour meter in the travel control Foot contact of K1, is supplied by X3:10 Power supply for the travel control. 24V if the reverse polarity diode in the ABÜ is in order.

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

10355

Sheet no.

17 – 03

Chapter 17

ABÜ - Braking monitor

General Apart from monitoring the braking process, the ABÜ has the following functions: • Weel position display • Signal adaptation for the "Slow travel on curves" function The ABÜ monitors generator braking of the vehicle.

If the generator braking is not strong enough, the ABÜ opens internal relay K1, which causes the electromagnetic brake to be activated immediately.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

The actual vehicle speed is detected by a speed sensor.

These speed sensor impulses are offset against the braking time, which gives a delay time in m/ss.

The required delay time is stored as software in the ABÜ and is then continually compared with the actual delay time.

If there is a deviation downwards which is too large, relay K1 drops out and electromagnetic braking is initiated.

10355

A differentiation is made between this delays: 1. 0.5m/ss when the travel direction signal is removed --> Neutral braking is monitored, not reversing braking 2. 1.0m/ss when the deadman signal is removed K1 opens when: • The deadman is (no longer) actuated (X2:3=0V) and the speed is higher than 2.5km/h or the delay time is not within the range specified above.

• The travel direction is (no longer) selected (X2:7 and X2:8=0V) and the speed is higher than 2.5km/h or the delay time is not within the range specified above.

• One of the speed sensor channels is faulty or brocken wire monitoring.

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

17 – 04

Chapter 17

ABÜ - Braking monitor

Functions Travel on curves Signal adaptation As soon as a steering angle >10° is set, the output signal of the steering controller at pin X1:16 changes down from approx. 7.1V to a value of <3.2V. This signal is converted from 24V into a 0V signal in the ABÜ and sent on to the travel control. As a result, the travel control changes from Travel mode 4 to Travel mode 2 or from Travel mode 3 to Travel mode 1.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

As soon as the steering angle changes back to <9° again, the vehicle is returned to the normal speed.

Steering output = <3.2V

--> Output ABÜ = 0V

Steering output = >7.1V

--> Output ABÜ = 24V

Steering control

OUT >10°

IN >10°

X1 16

X1 24

<3,2V or. >7,1V X2 10

ABÜ

X2 11 0V or. 24V X2

Travel control

9 Mode Input B

0V = Mode 1, 2 24V = Mode 3, 4

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

17 – 05

Chapter 17

ABÜ - Braking monitor

Flashing error codes There is a red LED (1) on the ABÜ board. In the event of an error, this flashes up in a repeating rhythm of 8 pulses.

An error can be recognised from a longer switchingon impulse.

Remark:

1

If there are no errors, the red error LED shows the speed sensor impulses.

Once an error has been rectified, a keyswitch reset must be carried out.

Example: To indicate error 5:

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Error 1 2 impulse

3

4

5

6

8 long pause

7

Several errors can also be shown at once.

Example: Error 2 and Error 4:

Error 1 2 Pulses

10355

Error 3

4

5

6

7

8 long pause

The following errors can be displayed: Impulse 1: Speed too high on braking Check parameter in the travel control Impulse 2: No voltage at X3:9 (foot contact relay K1) Impulse 3: Relay K1 faulty Impulse 4: Output transistor V8 for X3:4 faulty Impulse 5: Internal transistordriver is defect Impulse 6: Deadman 1(X2:3) and Deadman 2 (X2:14) have different signals at input (mat switch version).

Impulse 7 Speed too high (e.g. speed sensor is producing unclear impulses).

Impulse 8: Speed sensor faulty

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

17 – 06

Chapter 18

Travel control

Block diagram for "Travel"

Steering controller 1F11

Steering X1 24 angle > 10°

Key switch

FZS

24V

X1 25 X1 16

F2

K1

1kΩ

X1 2

Steering OK

Steering OK X2 2

Emerg. Off 1F4

24V

0V

3F1

S2

X1 11

X1 15

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

3K1

X3 1 X2 10

1K34

X2:1 X2:11

U50 ABÜ

X2:4 X2:6

Voltage supply

1

14

FZS 12

X1 6

X1 15

11

X1 8

Travel dir. DWS

3

Travel dir. LS

4

Fahrsteuerung 1A10 I ≤ 5 Amp. or t >3 sec.

Currentsensor B-

X30:2 6 7

Enable

Throttle Type=2

Contactor contact test

IC

4 Deadman Out

Steering angle related deceleration

14 X1 16 X1 9 Mode Input B A

X1 4

Deadman 1+2 In X2:3 X2:14 X3

Setpoint apr. 0,4-4,5V

travel contactor

Control of

X3:10

1

M-

B+

D1

D2

M

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

18 – 01

Chapter 18

Travel control

General The travel control (1) is a control system that uses the power MOSFET technology and is micro-processor controlled.

The pulse control allows stepless control of the motor torque and motor speed for shunt motors.

1

The travel direction is achieved by reversing the polarity of the field in the motor, so that the travel direction contactors are no longer necessary.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

The travel control has an internal and an external safety monitor.

Errors are monitored with an LED (2) and a separate display.

Diagnosis and parameterisation can be carried out by using a Notebook or a programming unit.

00187

2

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

18 – 02

Chapter 18

Travel control

Main current section - terminals B+ is connected indirectly to the positive battery pole and directly with armature A1 of the motor via contactor 1K34.

4

3

16

9

2

1

8

1

Bis connected to the negative battery pole.

S1

S2

Mis connected to the armature A2 of the motor.

S1 / S2 is connected to shunt field F1 and F2 of the motor.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Remark:

The travel direction of the vehicle depends on the polarity of S1 and S2.

00189

B-

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

M-

Sheet no.

B+

18 – 03

Chapter 18

Travel control

Pin assignment

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

E = Input A = Output Connector X1 1E not connected (Pressure sensor) 2E Hour meter for lifting and lowering 3A Lift stop battery discharge indicator.

If the 0V signal is removed from this output, the battery has discharged down to 20%.

4A Negative control of travel contactor 1K34.

In order for 0V to be issued at this output, there must be 24V applied at X1:16, no internal errors and the contactor contact test 1K34 must be positive, deadman switch and travel direction must be actuated, deadman signal is delayed off for 10s 5A n.c. (Supply setpoint 5V)

X3

X1

4

3

16

9

2

1

8

1

10396

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

18 – 04

Chapter 18

Travel control

Pin assignment Connector X1

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Pin 6E

X3 Setpoint The voltage between X1:6 and negative must be approx. 3.3V when the travel transducer is in the neutral position and approx. 0V when fully deflected.

7A

n.c.

8A

0V supply for el.-magnetic brake 0V is applied to this pin when the deadman switch is actuated and a travel direction is selected. If the vehicle is already in motion and the deadman switch is released, the 0V voltage is not removed until the vehicle comes to a standstill or if the braking time extends beyond 3 secs. (e.g. if the vehicle were to roll down a ramp).

9E

X1

4

3

16

9

2

1

8

1

10396

Mode selection 2 There are four parameter modes in total.

Which mode is activated depends on the connection at pins X1:9 and 14 (see Vehicle control system/Description of functions).

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

18 – 05

Chapter 18

Travel control

Pin assignment Connector X1

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Pin 10

X3 n.c.

11E

Travel direction reverse

12E

Travel direction forwards

13

n.c.

14E

Mode selection 1 (see Pin X1:9)

15E

Enable When the deadman switch has been actuated, there should be 24V applied at this pin. The effect of this is that when the travel signal arrives, the electro-magnetic brake is released.

If the vehicle is already in motion, removal of the enable signal causes the generator brake to be initiated. When the vehicle is at a standstill, the electro-magnetic brake is applied.

16E

X1

4

3

16

9

2

1

8

1

10396

+24V power supply for the control section.

Connector X3 Pin 1 2A 3A 4A

n.c.

0V/ GND Data transfer +15V

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

18 – 06

Chapter 18

Travel control

Description of functions Braking modes The connected motor can be braked as the result of 5 different conditions:

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• Removal of the deadman switch signal (generator braking) • Removal of the travel direction signal (neutral braking).

• Change-over of the travel direction signal (reversing braking).

• Internal fault or external line breakage (electromagnetic brake).

• Travel on a curve (Option).

X3

Table of operating modes

X1

4

3

16

9

2

1

8

1

The operating mode is determined by the switching of pins X1:9 and X1:14.

Mode 1 applies automatically when pins 9+14 are not occupied.

Open: 0 = 0V Closed: 1= 24V By varying these two terminal pins, 4 different operating modes can be set.

Different parameter values can be programmed in each mode. The performance of the vehicle may be unfamiliar if an operating mode or parameter that was not wanted is selected due to a wrong connection.

Mode Input

10396

Speed

Function

Operating mode

B (X1:9)

A (X1:14)

km/h (default)

M1

0

0

2,5

Creep speed

M2

0

1

9

Travel on curves >10°

M3

1

0

4

h>1,2m + steering <10°

M4

1

1

9

vmax

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

18 – 07

Chapter 18

Travel control

Description of functions Hour meter There are two hour meters integrated in the travel control. They count the hours that pass a. while the key switch is switched on and b. during travel, lifting or lowering.

Which type of operating hours are shown can be set with parameters.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Service hour meter There are two service hour meters "Operation" (1or 2) and two service hour meters "Emergency" (3 or 4) integrated in the travel control. They count downwards from a previously set number (the maintenance interval) to zero. The hours that have passed are counted a. while the key switch is switched on (1) and b. during travel, lifting or lowering (2).

When zero hours is reached, FE 23 and "SERVICE" appears on the display , The red LED under the spanner symbol lights up, the speed is not reduced jet, the two service hour meters "Emergency" (3 or 4) starts to run.

If the emerencycounter (3 or 4) also is reached zero hours, emergency operating mode is initiated, i.e. the vehicle is reduced in accordance with the parameter value Trac Fault SPR. It is set to a default value of 100%, i.e. no reduction. The red LED under the spanner symbol flashes up. FE 23 and "SERVICE" appears on the display .

Battery discharge indicator There is a battery discharge indicator integrated in the travel control. In order for this to function correctly, the cut-off voltage, end charging voltage and charging factor must be programmed. If the battery voltage drops below a certain value (20% residual capacity), the lifting function is switched off.

In this case, the display shows 0% and the yellow LED on the display lights up.

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

18 – 08

Chapter 18

Travel control

Description of functions Monitoring function The travel control has an internal monitoring circuit and a safety monitor for external components.

The range of tests includes: • Potentiometer monitoring for cable breakage and short circuit and inadmissible values • Testing of the switching-on sequence • Short-circuit monitoring and overcurrent detection for the switching outputs (main contactor).

• Monitoring for contactor contacts welded together (main contactor).

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• Failure monitoring of the switching outputs.

• Overtemperature monitoring Current reduction from I max at 85°C to 0 at 95°C. • Undertemperature monitor Current reduction to 50% below -25°C. • Undervoltage (16V) Reduction of the travel current until voltage is no longer below the undervoltage limit (control system switches off below 16V).

• Short-circuit monitoring, B- to M- (MOSFET) • Overvoltage (45V) - control system switches off • Short-circuit monitor, drive motor

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

18 – 09

Chapter 18

Travel control

Error display The travel control can recognise certain internal or external errors. If an error is detected, the travel function is interrupted, braking is initiated and the error is shown on the status LED (1) and the Curtis display unit. Errors are displayed continuously in the form of a 2-figure flashing code.

If no errors are detected, the status LED flashes about once every 5 seconds.

The code is displayed until the error is reset by switching the control off and then on again (enable or key switch), on condition that the error has been rectified (see Travel control software/ Error messages).

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Remark:

1

10394

Only one error is ever shown at one time, and this is the last error to have occurred.

Example: Code"3.2" - Main contactor melted/stuck

*** **

3

_

*** **

2 __

3

_

*** **

2 __

3

_ 2

10395

Test procedure If the relevant voltage potential is applied to the following terminals, the connected motor will start. If not, either the motor or the travel control is faulty.

X1:6

Resistance reading between X1:6 and X1:7 < 5KΩ X1:7 Setpoint 0.4 - 8.6V X1:11 24V Travel direction LS X1:15 24V Enable via deadman X1:16 24V Power supply B0V Power supply B+ 24V Power supply

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

18 – 10

Chapter 19

Direction sender

General

2

4

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

The setpoint potentiometer is designed with an integrated travel direction switch for the travel direction signal. The potentiometer and travel direction switch are supplied with power by the vehicle control system, the setpoint and travel direction signal are adapted there and then passed on to the travel control.

• The travel direction switch is supplied with 10V when the deadman switch is actuated.

• The setpoint potentiometer is supplied with approx.

5V. The setpoint is between approx. 0.4V (neutral position) and 4.5V (vmax). When the potentiometer is disconnected, the supply voltage is approx. 12V. With the "pedestrian mode" option, the vehicle control system switches over to an internal setpoint.

Replacing 20311

• Remove the operating console cover.

• Disconnect the connector (1).

• Release the screw (2).

• Pull off the travel switch (3).

• Push on the new travel switch, aligning the flattened end of the shaft with the screw (2).

• Tighten the screw (2).

• In neutral position, both contacts of the travel direction switch must be open. Fine adjustments can be made by releasing the nut (4) and turning the travel switch (3). The travel direction signal can be displayed on the notebook (see Software for travel control/Tester).

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

1

Sheet no.

3

19 – 01

Chapter 20

BDI/HM

General The Curtis display unit displays the following data from the travel control: • Operating hours • Maintenance date • Remaining battery capacity • Error codes There are also three LEDs which display the following information: Red LED (1):

Service interval finished

Yellow LED (2): Flashes when battery discharged Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

10397

3

2

1

Green LED (3): Hour meter, is only shown for the first 3 seconds after switching on.

During this time, the green LED is illuminated.

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

20 – 01

Chapter 20

BDI/HM

Pin assignment Operating voltage Pin 5 = B+ (15V) min Pin 8 = B - (0V)

8

5

4

1

Data input Pin 6 = Data input

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Other pin assignments Pin 1 = Pin 2 = Pin 3 = Pin 4 = Pin 7 =

not occupied not occupied not occupied not occupied not occupied

10398

Basic data Operating voltage Operating temperature

Issue: Replaces issue:

08/03

15V min -10°C to +70°C

Workshop Manual

XOP1

Sheet no.

20 – 02

Chapter 20

BDI/HM

Function When the vehicle is switched on at the key switch, all 3 LEDs (green, yellow, red) light up for 3 seconds, then the operating hours are shown for 3 seconds and the green LED is on.

Then the red and green LEDs go out and only the yellow LED continues to be lit up continuously. In place of the operating hours, the remaining battery capacity is now shown in %.

10397

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Error display If an error has occurred, the red service LED flashes.

At the same time one of the errors from the error code table is shown on the display. The error code appears every 3 seconds alternating with the remaining battery capacity.

Any maintenance intervals that have come to an end are also treated as errors. The word "SERVICE" or FE23 appear on the display.

Battery discharge indicator The yellow LED is illuminated continuously after the switching-on test and when the hour meter display has gone out. When a remaining battery capacity of 20% is reached, this LED starts to flash. At the same time, the lifting function is interrupted.

When there are no errors, the remaining battery capacity is displayed as a %age.

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

20 – 03

Chapter 20

BDI/HM

Hour meter When the vehicle is switched on at the key switch, the green LED lights up for about 5 seconds and then goes out. This means that the hour meter is working.

Whether the total hours or the travel, lifting and lowering hours are displayed depends on how the travel control is programmed (parameter settings).

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Between 0 and 999 999 hours can be displayed.

When the maximum is reached, the display is automatically reset to 000 000 hours.

The operating hours can be set to a value of your choice. In order to do this, the following parameters in the travel control must be set accordingly ADJ HRS high ADJ HRS mid ADJ HRS low and adopted with SET TOTL HRS or SET TRAC HRS (ON/ OFF).

Issue: Replaces issue:

08/03

Workshop Manual

XOP1

Sheet no.

20 – 04

Chapter 21

Travel control software

General The travel control parameters can be set and diagnosis carried out either with the hand-held programming unit or a notebook.

Prerequisites for working with the notebook: Curtis PC Programmer is installed: Adapter (1) Id. no. 4 498 916 Adapter cable (2) Id. no. 5 456 433 10135

The adapter cable connects the notebook and vehicle control with each other. It is plugged in at the point where the display unit is usually connected during normal operation (3).

On the notebook the Com 1 connection is used.

2

1

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

3

Making a connection • Check that the battery plug is plugged in.

4

• Check that the key switch is switched on (the electrical power supply is guaranteed when there are 0 volts applied at B- (4) and 24 volts at X1:16 (5)).

5

20403

• After starting the Curtis PC Programmer, the start page of the travel control software now opens (6).

6

• Click on the (7) "Load parameters from the control into the PC" button.

The entire parameter set is now loaded from the travel control into the notebook, where it can be altered.

• If the connection has not been made correctly, this may be due to a faulty cable, adapter or control system. The error message (8) is displayed.

20404

7

8

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

20405

Sheet no.

01 21 – 01

Chapter 21

Travel control software

Setting parameters • Click with the mouse on "Setting parameters" (1) • Select the parameters you are looking for with the mouse pointer. Use the scroll bar (2) to run through the parameters more quickly.

For lift of parameters, please see Travel control Software, List of parameters).

• Mark a line with a mouse click. The background to the line turns blue.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• Under the table, either the selection option OFF/ON (3) is displayed, or a horizontal scroll bar (4), which can be used to change the marked value by clicking on it with the mouse.

1

2

10145

• When the parameter value has been changed, a button labelled "Undo" (5) appears, which can be used to reset the original value.

Remark:

Altered values are entered in the control system immediately and do not have to be saved or transferred with an extra command.

10141

3

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

10142

4

5

Sheet no.

02 21 – 02

Chapter 21

Travel control software

Test In the "Test" submenu, the input and output signals of the travel control can be checked (please see Travel control software, Tester table).

The button labelled "zoom" (1) can be used to enlarge the selected parameter on the display (2).

Diagnosis

1

10144

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

In the "Diagnosis" submenu, the saved and current errors can be read out.

The button labelled "Delete error memory" (3) can be used to reset the error memory. (see Travel control software, Table of errors).

2

"File" menu Clicking on the File menu (4) opens the following selection of functions:

20417

• Load from the control system: The parameters set stored in the travel control is loaded into the notebook.

• Save in the control system: The file that is already open or a file opened with the "Open file" command is loaded into the travel control. In this way, a parameter set that is stored in the data memory can be loaded into any vehicle of choice.

3

10143

4

10138

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

03 21 – 03

Chapter 21

Travel control software

"File" menu • Open file: A parameter set stored in the data memory of the notebook can be selected with this function and saved in any vehicle of choice.

• Save file under: With this command, a parameter set can be stored in any directory on the notebook under a customer name.

• Print: A selected parameter set file can be printed with this function.

10138

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• Exit: This command closes the PC programmer program.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

04 21 – 04

Chapter 21

Travel control software

Summary of the most important parameters

Explanation

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Parameter

Max. braking current in amps Acceleration rate in seconds Deceleration rate in seconds Maximum forwards speed as a % Maximum reverse speed as a % Creep speed as a %age of maximum speed Battery monitoring Battery monitoring Battery monitoring Operating hours input Operating hours input Operating hours input 00 21 50 = 2150h Operating hours, key switch (set=on/off) Operating hours, lifting, lowering, travel (set=on/off) Set hourmeter type (key switch=on, action=off) Service counter with key switch ON (h x100, 0=not active) Service counter with lifting, lowering, travel (h x100, 0=not active) Restart Service counter keyswitch (set=on/off) Restart service counter workinghours (set=on/off)

M1-4 BRAKE C/L ACCEL RATE DECEL RATE MAX FWD SPEED MAX REV SPEED CREEP SPEED FULL VOLTS EMTY VOLTS RESET VOLTS ADJ HRS LOW ADJ HRS MID ADJ HRS HIGH SET TOTAL HRS SET TRAC HRS HOURMETER TYPE SRVC TOTAL HRS SRVC TRAC HRS SRVC TOTAL SRVC TRAC

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

21 – 05

Chapter 21

Travel control software

Battery discharge curves Full Volts

- cell voltage when 100% charged

Empty Volts

- cell voltage when 20% charged

Reset Volts

- cell voltage for resetting the discharge indicator to 100%

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Battery type Lead - acid - wet PzS Lead - acid - wet CMS Increased capacity Hagen ,PWF,CWF,PzV Sonnenschein dryfit Varta Carat gel battery Gel batteries in general Data Dryflex Drypower 8WF 800 HL 48

Remark:

Full Volts U/cell 1.91 1.92

Empty Volts U/cell 1.67 1.72

Reset Volts U/cell 2.04 2.04

1.93 2.03 2.00 2.00 1.96 1.91

1.76 1.97 1.86 1.86 1.85 1.67

2.04 2.04 2.04 2.04 2.04 2.04

In the control, the values are entered as 3-figure number sequences, e.g.: 199 for 1.99 The values given in the table are the settings for standard loads.

In special cases with higher loads (high current consumption in a short time or cold store operation) deviations may occur, depending on the area of application. In cases of this kind, the battery manufacturer should be consulted directly.

The capacity of the battery does not have any effect on the parameters specified above.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

21 – 06

Chapter 21

Travel control software

List of parameters Depending on MODE INPUT A and B, parameter mode M1-M4 is active.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

No. Display 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

M1 DRIVE CURRENT M2 DRIVE CURRENT M3 DRIVE CURRENT M4 DRIVE CURRENT M1 BRAKE CURRENT M2 BRAKE CURRENT M3 BRAKE CURRENT M4 BRAKE CURRENT M1 ACCELERATION RATE M2 ACCELERATION RATE M3 ACCELERATION RATE M4 ACCELERATION RATE M1 DECELARATION RATE M2 DECELARATION RATE M3 DECELARATION RATE M4 DECELARATION RATE THROTTLE DECEL

18 19 20 21 22 23

M1 BRAKE RATE M2 BRAKE RATE M3 BRAKE RATE M4 BRAKE RATE INTERLOCK BRAKE RATE QUICK START

Explanation

Range

Maximum travel current

50A - Rated 50A - Rated 50A - Rated 50A - Rated 50A - Rated 50A - Rated 50A - Rated 50A - Rated 0.1 - 3 0.1 - 3 0.1 - 3 0.1 - 3 0.1 - 10 0.1 - 10 0.1 - 10 0.1 - 10 0.1 - 1.0

250 250 250 250 200 200 200 200 0.1 0.1 0.1 0.1 0.9 0.9 0.9 0.9 0.3

0.1 - 3 0.1 - 3 0.1 - 3 0.1 - 3 0.1 - 3 0 - 10

1.3 1.3 1.3 1.3 0.1 10

Maximum braking current

Acceleration rate

Deceleration on neutral braking

Potentiometer throttling on change-over from travel to braking Deceleration on reverse braking

Braking factor dependent on pressure sensor Throttle sensitivity

Value

= adjustable parameters

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

21 – 07

Chapter 21

Travel control software

List of parameters 2 No. Display 24 25 26 27 28 29 30 31 32 33

TAPER RATE M1 MAX FWD SPEED M2 MAX FWD SPEED M3 MAX FWD SPEED M4 MAX FWD SPEED M1 MAX REV SPEED M2 MAX REV SPEED M3 MAX REV SPEED M4 MAX REV SPEED CREEP SPEED

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Range

Change-over from braking to rolling Maximum forward travel speed

1 - 20 0% - 100% 0% - 100% 0% - 100% 0% - 100% 0% - 100% 0% - 100% 0% - 100% 0% - 100% 0% - 25%

20 36 100 52 100 36 100 52 100 5

5kΩ-0 (1), 0-5V (2) 0% - 40% 60% -100% 20% - 80% 1.6A - 10A

2

Maximum reverse travel speed

Speed that is set with the smallest throttle deflection Throttle type

34 THROTTLE TYPE 35 36 37 38

Explanation

THROTTLE DEADBAND THROTTLE MAX THROTTLE MAP FIELD MIN CURRENT

Width of neutral position of throttle r Width of maximum setting of throttle Throttle sensitivity at low speed Smallest permissible field current, affects the maximum speed Largest permissible field current, affects the maximum speed Affects the armature current and consequently the torque with load on starting-up Affects the armature current and consequently the torque with load at vmax Factor of current increase in proportion to specification from throttle

39 FIELD MAX CURRENT 40 FIELD MAP START 41 FIELD MAP 42 CURRENT RATIO

Value

25 100 40 8.8

Field Min Rated 25A - 300A

25

0% - 100%

70

1- 4

1

75

= adjustable parameters

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

21 – 08

Chapter 21

Travel control software

List of parameters 3

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

No. Display

Explanation

Range

How strongly vehicle should be braked when throttle setpoint is reduced slightly

Field Min rated Field Min rated Field Min rated Field Min rated 0% - 25% Off (0), Brake (1), KSI (2) Off(0), Brk(1), KSI(2), KSI, Brk,Fwd only(3) 0-3

1.5 2

On/Off

ON

0-40

10

On/Off

ON

Type 0-5 0-30

2 3

On/Off

ON

On/Off On/Off Empty - Reset Volts

OFF ON 191

43

M1 RESTRAINT *

44

M2 RESTRAINT *

45

M3 RESTRAINT *

46

M4 RESTRAINT *

47 48

LOAD COMPENSATION HIGH PEDAL DISABLE (HPD)

Load compensation No travel setpoint or deadman before key switch switched on

49

STATIC RETURN TO OFF (SRO)

Switching-on sequence key switch, deadman, travel direction required

50

SEQUENCING DELAY

51

MAIN CONTACTOR INTERLOCK MAIN OPEN DELAY

Delay while switching-on sequence is evaluated Main contactor is not switched on until deadman is pressed Main contactor drops out xx secs. after deadman is released Contact test Switching on or off

52 53 54 55

CONTACTOR DIAGNOSTICS AUXILIARY DRIVER TYPE AUXILIARY DRIVER DELAY

56

VARIABLE BRAKING

57 58 59

ANTI TIEDOWN POT LOW FAULT FULL VOLTS **

Output driver X1:8 is active low or high Delay between throttle neutral and switching off output driver X1:8 Generator braking dependent on throttle position or not Test, if Mode 1 is active when swiching on "Potentiometer error" error active or inactive Volts/cell when battery 100% charged

Value 17 17 17 17

0

0

* lower values may affect an ABÜ-error ** see Travel control software/ battery discharge curve

= adjustable parameters

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

21 – 09

Chapter 21

Travel control software

List of parameters 4 No. Display 60 61 63 64 65 66 67

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

68 69 70 71 72 73 74 75 76 77

Explanation

EMPTY VOLTS * RESET VOLTS *

Range

Volts/cell when battery discharged Volts/cell that have to be reached so that battery discharge indicator shows 100% again BDI DISABLE Deceleration when batt. cap. <20%. Depends on value entered under "BDI Limit Speed" ADJUST HOURS LOW Setting of hour meter, last 2 figures ADJUST HOURS MID Setting of hour meter, middle 2 figures ADJUST HOURS HIGH Setting of hour meter, first 2 figures, e.g. 2150h = 00 21 50 SET TOTAL HOURS Programming of hour meter switch lock with value of no. 64, 65, 66 (set= ON/ OFF) SET TRACTION HOURS Programming of hour meter for travel, lifting, lowering with value of no. 64, 65, 66 (set= ON/ OFF) HOURMETER TYPE Which of the two hour meters specified above should be shown on the display (Key switch=ON, action=OFF) SERVICE TOTAL HOURS Service hour meter set to count with key switch, (h x 100, 0 = not active) SERVICE TRACTION Service hour meter set to count with travel, HOURS lifting, lowering, (h x 100, 0 = not active) SERVICE TOTAL Reset service hour meter (set= ON/ OFF) SERVICE TRACTION Reset service hour meter for travel, lifting, lowering (set= ON/ OFF) DISABLE TOTAL HOURS Service hour meter, key switch, emerg. operation DISABLE TRACTION Service hour meter for travel, lifting lowering, HOURS emergency operation TRACTION FAULT SPEED Travel speed reduced to an entered percentage when counter level for emergency operation reached BDI LIMIT SPEED When BDI Disable to "ON", travel is reduced to the value entered here when batt. cap. 20% ** see Travel control software/ battery discharge curve

Value

0 - Full Volts Full Volts 300

167 204

On/Off

ON

0 - 99

0

0 - 99

0

0 - 99

0

On/Off

OFF

On/Off

OFF

On/Off

OFF

0.0 - 50

10

0.0 - 50

5 (=500h)

On/Off On/Off

OFF OFF

0 - 250

120

0 - 250

100

0 - 100%

100

0 - 100%

100

= adjustable parameters

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

21 – 10

Chapter 21

Travel control software

List of parameters 5

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

No. Display 78

WARM SPEED

79

MOTOR WARM x10 mΩ

80

MOTOR HOT x10 mΩ

81 82

MOTOR Ω COMP MAX REV REGEN

83

MAX FWD REGEN

84

MIN REV REGEN

85

MIN FWD REGEN

86

MAX LOAD VOLTS

87

MIN LOAD VOLTS

88

INT BRAKE DELAY

89

MAIN CONTACTOR INITIAL

90

PUMP METER

Explanation

Range

Value

Max. travel speed when the value entered in the "MOTOR WARM" parameter is reached When approx. 130°C is reached, the travel speed is reduced to the value entered in the "WARM SPEED" parameter When 150°C is reached, travel is switched off

0 - 100%

25

Motor Warm - 250

98

Motor Warm - 250 On/Off Min Rev Rated

102

Min FWD Rated

250

25A - Max Rev.

210

25A - MAX FWD

250

0.2 - 5.5

4.5

0.2 - 5.0

4

0.0 - 8.0

3

Temperature evaluation ON/OFF Maximum current used for braking in a braking operation actuated with deadman switch in LS travel direction Maximum current used for braking in a braking operation actuated with deadman switch in DWS travel direction Minimum current used for braking in a braking operation actuated with deadman switch in LS travel direction Minimum current used for braking in a braking operation actuated with deadman switch in DWS travel direction Maxiumum output voltage from pressure sensor Minimum output voltage from pressure sensor Delay until magnetic brake is activated after vehicle comes to a standstill Switching on of main contactor with key switch without enabling by deadman Error output 1 can be switched over to "Pump running" input

ON 210

On/Off

OFF

On/Off

ON

= adjustable parameters

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

21 – 11

Chapter 21

Travel control software

Description of parameters BRAKE C/L • Maximum armature braking current The brake current set here is not exceeded.

If braking is induced by removing the travel direction signal (neutral braking), the maximum braking current is composed of brake C/L (armature current) and 6A field current. If braking is induced by reversing the travel direction (reversing braking), the maximum braking current is composed of brake C/L and 25A (field current).

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

ACCEL RATE How fast the throttle reaches maximum speed when it is fully deflected.

FIELD MIN CURRENT The parameter set here specifies the minimum value for the field current. The smaller the field current in a series wound motor, the faster the vehicle runs (field weakening). For this reason, the parameter set here must not be changed!

The parameters Max FWD Speed and Max REV Speed determine the speed of the vehicle in %.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

26 21 – 12

Chapter 21

Travel control software

Description of parameters DECEL RATE DELAY Speed with which the vehicle is regulated down to the lower speed when the travel setpoint signal is removed.

MAX FWD SPEED • Maximum forward speed MAX REV SPEED • Maximum reverse speed

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

CREEP SPEED Maximum travel speed when throttle is deflected to 1st step.

FULL VOLTS • Factor for battery capacity calculation So that the remaining battery capacity can be calculated for different types of battery, the relevant factor must be selected (see Travel control/ Battery discharge curves).

EMPTY VOLTS • Lift stop This determines the cell voltage level at which the lift stop should be activated (see Travel control/ Battery discharge curves).

RESET VOLTS • Reset voltage for the battery discharge indicator This determines the cell voltage level at which the battery display is reset to 100% again after charging.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

27 21 – 13

Chapter 21

Travel control software

Description of parameters ADJ HRS LOW • Entry of operating hours This parameter displays the last 2 figures on the 6figure hour meter display.

ADJ HRS MID • Entry of operating hours This parameter displays the middle 2 figures on the 6-figure hour meter display.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

ADJ HRS HIGH • Entry of operating hours This parameter displays the first 2 figures on the 6figure hour meter display.

SET TOTAL HOURS • Program the entered operating hours to switch lock The operating hours entered under ADJ HRS low, mid and high can be programmed to the hour meter for "Key switch ON" with this parameter. To do so, set this parameter to "ON" and then to "OFF" again.

SET TRAC HOURS • Program the entered operating hours to travel, lifting and lowering The operating hours entered under ADJ HRS low, mid and high can be programmed to the hour meter for "Travel, lifting and lowering" with this parameter.

To do so, set this parameter to "ON" and then to "OFF" again.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

28 21 – 14

Chapter 21

Travel control software

Description of parameters

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

HOURMETER TYPE This parameter is used to select which of the hour meters should appear on the display. If this parameter is set to "ON", the key switch hours are displayed, and if it is set to "OFF", travel, lifting and lowering are displayed.

SRVC TOTAL HRS • Setting maintenance interval for key switch This parameter is used to set the maintenance interval for the "Key switch" service counter.

The system counts downwards from the figure entered here to zero as soon as the key switch is switched on. The value entered is multiplied by 100.

Example: You want the display to indicate that maintenance is due after 500 hours: Enter this number: 5

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

29 21 – 15

Chapter 21

Travel control software

Description of parameters

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

SRVC TRAC HRS • Set maintenance interval for "Travel, lifting and lowering" This parameter is used to set the maintenance interval for the "Travel, lifting and lowering" service counter.

The system counts downwards from the figure entered here to zero as soon as travel, lifting or lowering are selected. The value entered is multiplied by 100.

Example: You want the display to indicate that maintenance is due after 500 hours: Enter this number: 5 SRVC TOTAL • Reset service counter for key switch When the "key switch" service counter has run down to zero, the maintenance symbol and FE23 or "SERVICE" light up. To return to the normal status, this parameter must be set to "ON" and then "OFF".

SRVC Trac • Reset service counter for travel, lifting and lowering When the "Travel, lifting and lowering" service counter has run down to zero, the maintenance symbol and FE23 or "SERVICE" light up.To return to the normal status, this parameter must be set to "ON" and then "OFF".

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

30 21 – 16

Chapter 21

Travel control software

Errors displayed with flashing code When an error is detected, a status LED (1) indicates the type of error continuously in the form of a two-position flashing code.

When no errors have been detected, the status LED flashes about once every 5 seconds.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

The LED is located in the housing on the factory nameplate.

The code is indicated with this flashing signal until the error is reset by switching the control off/on (enable or key switch). This is on condition that the error has been rectified.

10394

1

Comment: Only one error is displayed at once, and this is always the last error to have occurred.

Example: Code"3.2" - Main contactor melted/stuck *** **

3

_

*** **

2 __

Issue: Replaces issue:

3

_

08/03

*** **

2 __

3

WorkshopManual

10395

_ 2

XOP1

Sheet no.

32 21 – 17

Chapter 21

Travel control software

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

List of error codes Code 43

Designation THERMAL CUTBACK

14

SRO

Start-up protection. Setpoint comes before travel dir. switch

23 23

HPD SERVICE TOTAL

23

SERVICE TRAC

23

TOTAL DISABLED

23

TRAC DISABLED

13 11

M- SHORTED CURRENT SHUNT FAULT FIELD OPEN MAIN CONTACTOR WELDED OVERVOLTAGE

Start-up protection. Setpoint comes before deadman 1st "key switch" service counter has run down.

Parameter 70 1st "Travel, lifting and lowering" service counter has run down. Parameter 71 2nd "Emergency operation, key switch" has run down. Parameter 74 2nd "Emergency operation, lifting, lowering, travel" has run down. Parameter 75 Short-circuit at M output to B-

33 32 42 44 31

22 34 21 44 44 20

ANTI TIEDOWN CONT COIL / FIELD SHORT HW FAILSAFE LOW BATTERIE VOLTAGE EMR REV WIRING MISSING CONTACTOR THROTTLE WIPER HIGH MOTOR HOT MOTOR WARM BDI LOW

24 21

TROTTLE WIPER LOW TROTTLE WIPER HIGH

12 41

Issue: Replaces issue:

08/03

WorkshopManual

Description Reduction due to excess temperature (120°C) or under temperature (-35°C) of the travel control

Error at internal current sensor Motor field coil interrupted Contact of 1K34 welded Battery voltage too high / emergency-stop pressed during travel or emergency-stop due to steering error MODE input 1 active on switching-on Contactor coil 1K34 has shorted Internal error Battery voltage too low Internal error Contactor coil 1K34 interrupted Throttle wiper error Motor temperature >160°C Motor temperature <90°C Battery discharge indicator registering less than 20% capacity Travel potentiometer voltage(wiper) too low Travel potentiometer voltage(wiper) too high

XOP1

Sheet no.

33 21 – 18

Chapter 21

Travel control software

Tester Table Designation THROTTLE % FIELD CURRENT ARM CURRENT FIELD PWM ARM PWM BDI % LOAD VOLTAGE BATT VOLTAGE MOT RES x10 mΩ

Description Throttle signal as %age of maximum speed Motor field current Motor armature current Motor field current Motor armature current Remaining battery capacity Pressure sensor voltage (not on XOP1) Battery voltage Temperature dependent resistance value of field coil Current heat sink temperature 1st service counter, switch lock.

Value must be multiplied by 25 (please see example) 1st service counter, switch lock.

Value must be added to the value above (please see example) 1st service counter, travel, lifting, lowering.

Value must be multiplied by 25 1st service counter, travel, lifting, lowering.

Value must be added to the value above Travel direction switch, FORWARDS Travel direction switch, REVERSE Mode input 1 active Mode input 2 active Deadman switch Belly switch (not fitted) Main contactor (1K34) active Auxiliary driver (brake output) active Control system operating modes

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

HEATSINK °C TOT SRVC X25 +TOT SRVC +SRVC X25 TRAC SRVC FORWARD INPUT REVERSE INPUT MODE INPUT A MODE INPUT B INTERLOCK EMR REV INPUT MAIN CONT AUX DRIVER SYS MODE

Display % A A % % % V V 58 22

on/off on/off on/off on/off on/off on/off on/off on/off 0-5

Example for parameters TOTSRVC X25 / +SRVC X25: TOT SRVC X25 = 17 +TOTSRVC = 10 With an entered maintenance interval of 500 hrs.: Issue: Replaces issue:

08/03

WorkshopManual

-> 17 x 25 ->

=

425 + 10 435 hrs.

500 - 435 = 65 hrs. until next maintenance.

XOP1

Sheet no.

34 21 – 19

Chapter 22

Steering software

General Diagnosis and settings are carried out with a notebook, an adapter cable and the service software Paradig LES24.

The adapter cable (1) Id. no. W8 409 559 is connected to the notebook COM1 and connector X99 (2) on the other side.

The service software has the following functions: • Setting up a connection For communication between the notebook and steering

2

20223

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• Display Errors Reading out current or stored errors.

• Teaching-in set and actual values Teaching in the middle and end positions of the set and actual value potentiometers.

• Tester menu Inputs and outputs, speeds, potentiometer voltages and amplifier can be checked.

• Settings Setting different wheel distances.

20224

1

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

22 – 01

Chapter 22

Steering software

Making a connection Prerequisites: • Battery plug plugged in.

• Key switch "On".

• Adapter cable Id. no. W8 409 559 connected at both ends.

• Software Paradig LS24 started.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Remark:

The relevant data will only be shown in the Vehicle type, Program version and Controller fields if a connection has really been made with the vehicle. If the connection has not been successful, these fields will be empty.

Click on "Connect"

XOP1

20225

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

22 – 02

Chapter 22

Steering software

Errors Current errors Clicking on "Error display" (Fehlerspeicher) opens the "Current errors" field.

This is not updated until you click on "Update values" (2) or "Cyclically update" (3).

All errors that are currently registered are then displayed. (see Steering software/ Errors)

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

1

2

3

4 20226

Stored errors Clicking on "Error memory" (4) opens the error memory.

Here, all the errors that have been stored since the errors were last deleted are displayed.

The error at the bottom of the list is the last error that occurred.

Under "Error frequency" (Fehlerhäufigkeit), you can read out how often an error has occurred since the errors were last deleted.

Once all maintenance work is complete, the error memory should be deleted by clicking on "Delete error memory" (Fehlerspeicher löschen).

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

22 – 03

Chapter 22

Steering software

Teaching in General Teaching in is needed when: • Setpoint or actual value potentiometer has been replaced.

• The reduced speed on curves function is initiated differently at each side.

• The steering controller has been replaced.

Procedure • Connect the notebook to the steering controller.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• Switch on the key switch.

• Click on "Connect" (Verbinden).

• Click on "Setpoint and actual value potentiometers" (Soll- und Istwertpotentiometer).

1

2

• The "Delete potentiometer settings" (1) window opens.

If the query "Carry out teaching in?" (2) is answered with "Yes" (3), all the values that have been taught in for the setpoint are deleted.

• The query "Operating panel mastside/ loadside?" (Bedienpult mastseite/ Bedienpult lastseite) appears.

3

When there are two operating panels, the Teaching in has to be carried out onto the panel on the mastside.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

22 – 04

Chapter 22

Steering software

Teaching in Setpoint potentiometer

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• As instructed in the dialogue field, first turn the steering wheel to the left as far as the mechanical stop and then click on "Continue" (1). The value is now adopted and stored as long as it is within the permissible range. This can be seen from the fact that the arrow for the direction of rotation (2) disappears.

• Now, as instructed in the dialogue field, turn the steering wheel to the right as far as the mechanical stop and then click on "Continue" (1). The value is now adopted and stored as long as it is within the permissible range. This can be seen from the fact that the arrow for the direction of rotation (2) disappears.

• If the value that is to be stored is not within the permissible range, the setpoint potentiometer must be set better mechanically, i.e. more accurately (see Steering/ Setpoint potentiometer).

2

1

Teaching in of the setpoint potentiometer is now complete, but because adjustment of the actual value potentimeter is affected by the setpoint, when "Continue" (1) is pressed, the option for setting the actual value potemtiometer is displayed automatically.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

22 – 05

Chapter 22

Steering software

Teaching in Actual value potentiometer

1

2

• Click on "Actual value potentiometer" (Istwertpotentiometer).

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• The "Delete potentiometer settings" (1) window opens.

If the query "Carry out teaching in?" (2) is answered with "Yes" (3), all the values that have been taught in for the actual value are deleted.

• Move the steering wheel (setpoint) into the centre position as instructed. This is equivalent to 2 1/8 revolutions, since the total turning distance is 4 1/4 revolutions.

When steering knob move into centre position.

Adopt the setting with "Continue" (4).

3

4

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

22 – 06

Chapter 22

Steering software

Teaching in Actual value potentiometer • As instructed, bring the drive into the measured position with the fine adjustment keys (1) and adopt the setting with "Continue" (2).

• As instructed in dialogue field (3), turn the steering wheel to the right and adopt the value with a mouse click on the "Complete" (4) button.

• Teaching in is now complete.

Since the old settings have now been overwritten, it is important to check thesteering settings, as instructed (5).

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

2

3

1

4

5 Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

22 – 07

Chapter 22

Steering software

Teaching in Actual value potentiometer • Check initiation of the deceleration function (Option): measured from the straight-on position, the speed should be reduced after >±10°.

The reduction should be initiated at the same point on both sides. If this is not the case, the Teaching in of the Actual value potentiometer must be corrected by the appropriate amount using the fine adjustment keys (1) and saved again. To do this, the vehicle must be jacked up and the deadman switch actuated.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Remark:

The value is only adopted and saved by the system if it is within the permissible range.

You can see this from the "Continue" button (2), which will be shaded grey. If the value you want to save is outside the permissible range, the actual value potentiometer must be set better mechanically (see Steering/ Actual value potentiometer).

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

2

Sheet no.

1

22 – 08

Chapter 22

Steering software

Tester

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Speed measurement

1

The current and the maximum speeds are shown in the "Speed measurement" window (1).

The speed is determined by the speed sensor, which is connected directly to the steering system.

To display the maximum speed, "Reset maximum speed" (2) must first be pressed, so that the relevant display field shows "0.0 km/h".

Clicking on "Start measurement" (3) starts the speed measurement, while "Stop measurement" (4) stops it. The highest speed measured in this period is shown in the "Maximum speed" display field (5).

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

3 4

5

2

Sheet no.

22 – 09

Chapter 22

Steering software

Tester Amplifier data Supply voltage (1) Supply voltage for the steering.

24V ±3.5V Mean motor current (2) a higher or lower motor current is set, depending on how fast the steering wheel is turned.

The maximum current is approx. 35A.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Amplifier temperature (3) The temperature sensor integrated in the steering measures the temperature of the steering amplifier. If this rises above 95°C, the output power is reduced to 50%.

1 2 3 4

5

6

PWM ratio (4) The steering motor is clocked by the amplifier transistors of the steering system. If the speed of the steering motor changes, the PWM (pulse width modulation) must also change proportionally.

100% PWM is equivalent to a fully opened amplifier transistor. In this case, the steering motor is supplied with 100% of the electrical power.

Remark:

None of the data shown in this field is updated until "Start measurement" (5) is pressed. The measuring process is completed with "Stop measurement" (6).

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

22 – 10

Chapter 22

Steering software

Tester Digital inputs and outputs Travel on curves active

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

If a steering movement of >±10° is made, the travel speed should be reduced. When the steering is turned back to "straight-on", the vehicle should be returned to maximum speed again when the steering angle is <±9°.

In short, the "Travel on curves active, Output" signal indicates that the steering has recognised that the vehicle is on a curve (3A20 X1:16 = approx. 7V).

The Input "Travel on curves active" is for safety purposes only (3A20 X1:24).

Deadman (3A20 X1:9) Without the "Enable steering" signal, the steering motor is not clocked.

The enable steering signal is generated by the deadman and ABÜ OK. This signal is inverted, i.e. 0V = enable steering.

Steering wheel/ -knob Depends on the hardware coding (see Steering/ Pin assignment).

Steering OK 3A20 X1:11 The "Steering OK" signal is sent when the power supply is applied, there is no internal excess temperature and no internal or external steering errors are registered.

Without this signal, the deadman switch cannot be supplied with power and consequently the brake cannot be released. Travel is not possible.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

22 – 11

Chapter 22

Steering software

Tester Digital inputs and outputs

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Steering motor contactor 3A20 X1:3 The steering contactor 3K1 is selected at negative with this output, if the contactor contact test has a positive result.

Contactor contact test: When the steering is switched on, a test is carried out to check whether there is already a 24V signal applied at X2:2 although the contactor coil is not selected. If this is the case, it means that the contactor contact has melted (error). If this is not the case, a negative signal is sent to X1:3 to switch on the steering contactor. The measurement at X2:2 should now be 24V. If an internal steering error occurs, the "steering motor contactor" output is switched off immediately.

Safety relay The internal safety relay closes when there are no internal faults (excess temperature, contactor driver, EPROM).

If the contact of the safety relay is closed, there should be 24V applied at 3A20 X1:15, on condition that terminal 3A20 X1:2 is supplied with 24V.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

22 – 12

Chapter 22

Steering software

Tester Potentiometer voltages Supply voltage of actual and setpoint values 3A20 X1:8 positive approx. 9.3V 3A20 X1:6 negative approx. 0V

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Setpoint voltage at the steering wheel The slider contact of potentiometer 1 and potentiometer 2 must always add up to the supply voltage. The actual total voltage is shown in the "Total" field (1).

The potentiometer consists of two anti-parallel coils with sliders. If the shaft of the potentiometer is turned, the voltages change contrary by the same proportion. The two potentiometer voltages are only the same at the electrical centre of the potentiometers (approx.

550Ω).

For this reason, a coil defect or wire breakage is detected immediately, since both voltages are monitored by the steering controller.

Actual value voltages at the drive wheel On vehicles with steering wheel the setpoint and actual value potentiometers for the steering are identical!

With steering knob a different setpoint potentiometer is used. The electrical function is equal (see Steering/ Steering knob).

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

22 – 13

Chapter 22

Steering software

Table Table of of errors errors Error no.

19

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

20 21

Description

Cause

One of the errors 20, 22, 23, 24, 25, 26 was registered briefly during switching-on of the steering controller (STG).

STG internal error Vehicle type has changed.

22

Data in parameter set is inconsistent.

23

No parameter set found for cable code.

24

Invalid vehicle code after switching-on.

26

Control has not been checked by manufacturer.

Issue: Replaces issue:

08/03

Rectification • If this error occurs sporadically and the controller goes into its normal operating condition, no reaction is necessary.

• STG has been installed in a different vehicle.

• Parameter assignment for STG start does not work correctly.

• There is no parameter set in the software version for the vehicle type read out of the cable coding

• Replace STG. • Check whether STG number matches vehicle type.

• Re-start.

If error remains, replace STG • Check whether STG number matches vehicle type.

• If OK: re-start.

• If error remains: Check vehicle code to 3X1:4,18 and 21.

• If error remains: replace STG • Check potential at pins X1:4, X1:18 and X1:21

• Cable coding: Pin: 21 18 4 0 0 1 1: GND (X1:1) 0: open (STG internally to +24V) • The control has not • If this occurs in a STG that is been marked as straight from the factory, having been checked please uninstall it again and by the manufacturer. A send it to our customer service certain entry is missing department. from the EEPROM.

WorkshopManual

XOP1

Sheet no.

15 22 – 14

Chapter 22

Steering software

Table of errors Error no.

27

Description

Cause

Rectification

Internal safety relay is closed during switchingon.

• Output X1:15 shorted to 24V.

• Use the diagnosis software / digital inputs and outputs/ safety relay to check whether the safety relay is driven.

• Check whether the relay contact has melted.

• Switch off the vehicle.

• Pull out connector X1 of the STG. • Connect ohmmeter to pins X1:15 and X1:2.

• If relay open, resistance should be "infinite".

• Check cable connections of outputs X1:15 and X1:2 (e.g. short to battery negative).

• Relay contact is stuck.

• Relay driver faulty.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

28

29

Internal safety relay opens during running time.

Steering contactor 3K1 is already closed during switching-on.

• Relay driver faulty.

• Relay itself is faulty.

• Short to battery negative in the supply leads.

• Short-circuit between X2:2 and 24V. • Contact has melted.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

• Check short-circuit between X2:2 and +24V. • Switch off the vehicle.

• Connect voltmeter at X2:2.

• Switch on the vehicle. If error 29 is displayed again and 24V are applied at X2:2, the cause may be a short in the cable harness or a melted steering contactor.

• Check coil 3K1.

Sheet no.

22 – 15

Chapter 22

Steering software

Table of errors Error no.

30

Description

Cause

Rectification

Driver of steering contactor 3K1 is faulty.

• Output X1:3 is not connected at relay pin 85 or 86.

• Switch off the vehicle and measure the resistance between X1:3 and 3K1 pin 85 or 86. If the reading is more than 500Ω there is a poor connection.

• Switch off the vehicle. There should not be a short-circuit between pin X1:3 and battery negative.

• Switch off the vehicle, disconnect the cable from 3K1 and measure the resistance between pins 85 and 86. If the resistance is >300Ω, the coil is in order.

• Output X1:3 shorts to battery negative.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• The coil of 3K1 has shorted.

31

32

Contact of 3K1 cannot be closed.

Motor connections confused.

• The internal contactor driver is faulty.

• No 24V at one of the two motor leads X2:1, X2:3 after the contactor is switched on.

• One of the two motor supply leads X2:1, X2:3 has shorted to battery negative.

• Motor connection cables X2:1 and X2:3 have been confused.

• Switch off the vehicle: Check that the motor leads are properly connected.

• Switch off the vehicle. Measure the resistance between 3K1 pin 30 and 24V: resistance should be almost 0Ω.

• Swap the motor connection leads X2:1 and X2:3.

• If this error occurs sporadically but the STG still works properly otherwise, do not change anything.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

22 – 16

Chapter 22

Steering software

Table of errors

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Error no.

33

Description

Cause

Rectification

The power section has shorted or is disconnected from the motor.

• One of the two motor supply leads X2:1 or X2:3 is not connected.

• Check motor connections X2:1 and X2:3.

•One of the two motor supply leads X2:1 or X2:3 has shorted to battery negative.

• If the motor is correctly connected, it is possible that the power section is faulty.

• The supply voltage for potentiometer X1:8 has shorted to 24V or battery negative.

• The battery voltage exceeds 32 V for longer than 2.5s after switching on.

• One of the pins X1:19 and/or X1:20 has shorted against battery negative or 24V or 9.3V.

• Check the carbon brushes.

34

Potentiometer supply voltage not in permissible range

35

Setpoint potentiometer voltage has shorted against battery negative or 24V or 9.3V.

• The supply leads of pins X1:19 and/or X1:20 have been interrupted.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

• Can occur as consequential error of errors 30 and 31.

• Switch on the vehicle and measure the voltage at pin X1:8. The voltage should be 9.3V ±0.1V. • Check leads for short-circuits.

• When the vehicle is switched on, the voltage displayed in the "Potentiometer voltages" window should be between 0.15V and 9.85V. These values also apply for measurement with a voltmeter at pins X1:19 and X1:20.

• Check the connecting leads between the setpoint potentiometer and STG for cable breakage and faulty plug-in connectors.

• In the event of a short-circuit against 24V, the setpoint potentiometer must also be replaced once the error has been rectified.

Sheet no.

22 – 17

Chapter 22

Steering software

Table of errors

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Error no.

36

37

38

Description

Cause

Rectification

Actual value potentiometer voltage has shorted against battery negative or 24V or 9.3V.

• One of the pins X1:10 • When the vehicle is switched and/or X1:22 has on, the voltage displayed in the shorted against battery "Potentiometer voltages" negative or 24V or window should be between 9.3V. 0.15V and 9.85V. These values also apply for measurement with a voltmeter at pins X1:10 and X1:22.

• The connecting leads • Check the connecting leads of pins X1:10 and/or between the setpoint X1:22 have been interpotentiometer and STG for rupted. cable breakage and faulty plug-in connectors.

• In the event of a short-circuit against 24V, the actual value potentiometer must also be replaced once the error has been rectified.

Temperature of the • The temperature of the • Check how the STG has been power section is power section has installed. Is it cooled too high. exceeded 85°C. adequately?

• Has the power section shortcircuited?

STG output "Travel • The STG output X1:16 • Check the cable harness and on curves" has has shorted to battery ABÜ input X2:10 for shortshort-circuited. negative or 24V for circuit. longer than 300ms.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

22 – 18

Chapter 22

Steering software

Table of errors

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Error no.

39

40

Description

Cause

Rectification

Both setpoint potentiometers show implausible values.

• The voltages of the twin setpoint potentiometer at pins X1:19 and X1:20 do not match.

• Loose contact.

• Check potentiometer connections for faulty cables and/or plug-in connectors.

Both actual value potentiometers show implausible values.

Issue: Replaces issue:

08/03

• In the event of a short-circuit against 24V, the actual value potentiometer must also be replaced once the error has been rectified.

• Fault in potentiometer. • With the vehicle moving, steer • If error 35 is also very slowly from one steering displayed at the same end stop to the other. If the time, please rectify this error always appears at the error first. same steering position, this indicates that the potentiometer is faulty.

• The voltages of the • Check potentiometer twin setpoint connections for faulty cables potentiometer at pins and/or plug-in connectors.

X1:10 and X1:22 do not match.

• Loose contact.

• In the event of a short-circuit against 24V, the actual value potentiometer must also be replaced once the error has been rectified.

• Fault in potentiometer. • With the vehicle moving, steer very slowly from one steering end stop to the other. If the error always appears at the same steering position, this indicates that the potentiometer is faulty.

• If error 35 is also displayed at the same time, please rectify this error first.

WorkshopManual

XOP1

Sheet no.

22 – 19

Chapter 22

Steering software

Table of errors Error no.

41

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

42

43

44

Description

Cause

Rectification

The "Steering OK" signal has shorted against battery negative during switching on.

• Signal X1:11 has • Switch off the vehicle. Check shorted against battery the resistance between X1:11 negative during and battery negative. The switching on. resistance should be in the megohm range.

• Check the cable harness for short-circuits. (also sporadic short-circuits).

The "Steering OK" • Signal X1:11 has • Check output X1:11. It should signal at X1:11 shorted against a be 0-active when the travel does not match the foreign potential during controller is enabled. Voltage internal control travel. at X1:11 approx. Ubatt. response signal.

• X1:11 should be at "1" when STG stopped. Voltage at X1:11 < 0.5 V. • Check the cable harness for short-circuits. (also sporadic short-circuits).

The actual value • The steering wheel • If this message appears potentiometer was has been moved when continuously, check whether outside the switched off. the steering positions for the permissible voltage left/right-hand steering angle range during switand straight-on are correct. ching-on.

• If this is not the case, teachingin of the steering must be repeated.

• This condition is corrected automatically on switching on. This error message is for information only.

The output to 3K1 • The output to 3K1 X1:3 • Check the cable harness for was shorted short-circuited for at permanent or sporadic shorting against 24V. least 110ms against of X1:3 against 24V. 24V.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

22 – 20

Chapter 22

Steering software

Table of errors Error no.

46

Cause

Rectification

Both battery voltage and potentiometer supply voltage are far below the permissible value.

• The conditions must be as follows for 400ms:

• Check the cable harness for permanent or sporadic shorting of X1:8 and X1:25 against battery negative.

• Battery voltage at X1:25 below 13V. • Potentiometer supply voltage at X1:8 below 7.9 V • Output X1:16 emits an incorrect logical level: e.g.: STG switches driver "On", but actual condition at pin is "Off" (or vice versa).

• Check charging and age of vehicle battery.

• Check for shorting of a different electrical assembly against battery negative.

• On-level at X1:16: 0.96V.

Faulty signal for "Travel on curves".

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

50

Description

• Driver is faulty • Lead for returning signal to X1:24 is faulty.

• Foreign potential on one of the cables leading out of X1:24 or travel controller.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

• Off-level at X1:16: 7.56 V. • Signal can be checked in the "Digital inputs and outputs/ Travel on curves active" window.

• Check connecting cable from X1:16 to X1:24 for breakage, shorting against 24V and battery negative and foreign potential.

• Check connecting cable from X1:24 to travel controller for breakage, shorting against 24V and battery negative and for foreign potential.

• If the cables are in order and the displays in the "Digital inputs and outputs/Travel on curves active" window are different, the driver is faulty.

Replace the controller.

Sheet no.

22 – 21

Chapter 22

Steering software

Table of errors Error no.

70

72

73

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

74

79

80

81

Description

Cause

Attempt to reset • Synchronisation of the the safety two processors was processor has fainot successful during led. start-up of the STG. Difference in check • Data transmission sums between the between the two two processors. processors is faulty after restarting the STG. Interference in data • Data transmission transmission between the two between the two processors is faulty. processors.

Cyclical data • No data transmission, transmission from data that is relevant for safety processor to safety sent from safety main processor is processor to main faulty. processor for more than 1000ms.

Safety processor • One of the error error message numbers 80 to 85 is registered for a displayed sporadically. short time.

Safety processor: • The PWM signal for Left-hand PWM motor control is too low signal does not or steers in the wrong match current direction. setpoint/actual value difference.

Safety processor: • The PWM signal for Right-hand PWM motor control is too low signal does not or steers in the wrong match current direction. setpoint/actual value difference.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Rectification • This is an internal controller error. If it only occurs sporadically, no reaction is necessary.

• This is an internal controller error. If it only occurs sporadically, no reaction is necessary.

• This is an internal controller error. If it only occurs sporadically, no reaction is necessary.

• Replace the controller.

• This is an internal controller error. If it only occurs sporadically, no reaction is necessary.

• This is an internal controller error. If it only occurs sporadically, no reaction is necessary.

• This is an internal controller error. If it only occurs sporadically, no reaction is necessary.

Sheet no.

24 22 – 22

Chapter 22

Steering software

Table of errors Error no.

82

83

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

84

85

Description

Cause

Rectification

Safety processor: •Data transmission This is an internal controller Difference in check between the two error. If it only occurs sums between the processors is faulty sporadically, no reaction is two processors. after restarting the necessary.

STG. Safety processor: •Synchronisation of the This is an internal controller two processors was error. If it only occurs not successful during sporadically, no reaction is start-up of the STG. necessary.

Reset sequence of the main processor is not correct.

Safety processor: •Sequence of data This is an internal controller transmission from the error. If it only occurs main processor not sporadically, no reaction is correct. necessary.

Data transmission from main processor not completed in time.

Safety processor: •Data transmission •Replace the controller.

Data transmission between the between the processors has not processors is not been used by the main used by the main processor for more processor. than 100ms.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

22 – 23

Chapter 22

Steering software

Table of errors Error no.

86

89

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

9x

and

27

9x

and

30

Description

Cause

Safety processor:

• The signal at X1:16 does not match the current steering angle.

Rectification

• If errors 34 or 35 are registered, please rectify these first.

Faulty signal for • Troubleshooting as for error 50 "Travel on curves". to ascertain generation of faults by foreign voltage.

Error message • Error number 90...99 • If this error occurs sporadically registered briefly displayed sporadically. and the controller goes into its during start-up of normal operating condition, no the controller. reaction is necessary.

Error found in • Function test of the • If this error occurs sporadically internal safety internal safety relay and the controller goes into its relay during startafter switching-on the normal operating condition, no up of the controller.

STG was faulty: reaction is necessary.

• Control by one of the • If one of these error two processors not combinations is registered possible. continuously, carry out troubleshooting as for errors 27 and 28 (see above).

• Relay does not open/ • If one of these error close. combinations is registered continuously, and also any of errors 72, 73 or 74, the controller must be replaced.

An error at 3K1 or • Function test of the • If this error occurs sporadically its driver found internal safety relay and the controller goes into its during start-up of after switching-on the normal operating condition, no the controller.

STG was faulty: reaction is necessary.

• Control by one of the • If one of these error two processors not combinations is registered possible. continuously, carry out troubleshooting as for errors 29, 30 and 31 (see above).

• 3K1 does not open/clo- • If one of these error se. combinations is registered continuously, and also any of errors 72, 73 or 74, the controller must be replaced.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

22 – 24

Chapter 22

Steering software

Table of errors Error no.

9x

Description

Cause

Rectification

Error found in the power section of the controller during start-up of the controller.

• Function test of the internal safety relay after switching-on the STG was faulty:

• If this error occurs sporadically and the controller goes into its normal operating condition, no reaction is necessary.

• Switching off by one of the two processors is not possible

• If one of these error combinations is registered continuously, carry out troubleshooting as for errors 29, 30, 31 and 33 (see above).

• If one of these error combinations is registered continuously, and also any of errors 72, 73 or 74, the controller must be replaced.

and

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

31

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

22 – 25

Chapter 23

Hand-held programming unit

General The following functions can be carried out with the hand-held programming unit (1):

1

• Programming the parameters for the travel control (PROGRAM).

2

• Online querying of statuses of the inputs and outputs and temperature of the travel control (TEST).

• Displaying current errors and errors that have occurred since the last time the diagnosis history was deleted (DIAGNOSTICS).

5

3

• Copying the control parameters.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

4 7

6

Operating elements • Display (2).

• PROGRAM button (3) for programming the parameters.

8

• TEST button (4) for online querying of statuses.

9

• DIAGNOSTICS button (5) for troubleshooting.

• SCROLL DISPLAY buttons (6) for scrolling the display up and down.

• CHANGE VALUE buttons (7) for changing the values.

• MORE INFO button (8).

• Socket (9) for plugging in the connecting cable that leads to the control system.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

23 – 01

Chapter 23

Hand-held programming unit

Switching on • Plug the connecting cable (1) into the socket (2).

• Plug the connector at the other end of the cable into the socket (3) of the Highpulse control (4).

Remark:

The deadman switch must not be actuated either during the vehicle switching-on process or during selection of the Special Diagnostics menu. If it is, the following message appears on the display:

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

ERROR CONNECTING TO THE CONTROL. TO RETRY PRESS SCROLL DOWN 2 • Switch on the vehicle with the key switch.

80087

Display: for approx. 7s: CURTIS PMC 1307 - 2102

1 4 2

3 1

3 4

Switching off Switch off the vehicle and disconnect the connection between the programming unit and the control.

10396

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

23 – 02

Chapter 23

Hand-held programming unit

Language selection The default language can be changed to German, English or numeric by pressing the VALUE UP or VALUE DOWN buttons in the special program.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

WITH VALUE UP OR VALUE DOWN GERMAN (ENGLISH) (NUMERIC)

CONTROL NO. 1243 - 43xx DATE OF MANUF. 03/00 a) SOFTWARE VERS. 00•04

Remark:

The data after the texts may differ from the examples shown here.

PRINT

80087

PROGRAM TEST OR DIAGNOSTIC

b) TO MENU SELECTION

Remark:

The display texts shown here in sections a) and b) are displayed alternately until a selection is made.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

23 – 03

Chapter 23

Hand-held programming unit

Setting parameters PROGRAM menu Press the "PROGRAM" button (1). The LED (2) in the top left-hand corner of the button lights up.

All the parameters are displayed with their values.

There are always 4 parameters shown on the display TRAVEL STRBG -> 250 SLOW TRAVEL STRBG 250 BRAKING STRBG 120 SLOW BRAKING STRBG 120

1

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

2

80087

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

23 – 04

Chapter 23

Hand-held programming unit

Setting parameters Function Only the parameter that is currently on the top line of the display can be changed.

The value can be changed with the "CHANGE VALUE" buttons (1).

Remark:

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

The LEDs at the tips of these buttons (2) indicate whether the value is at the upper or lower limit. If one of the diodes goes out, the adjusting limit has been reached.

The "MORE INFO" button shows an expanded version of the parameter display. A bar graph (4), the entered value (5), and the maximum (6) and minimum (7) possible values are displayed.

2 3

1

To scroll the list of parameters up or down, press the "SCROLL DISPLAY" buttons (3).

Remark:

2

The values entered here are intended purely as examples. In the actual adjustment process, the relevant values for the vehicle in question must be set.

80087

4

5 SLOW TRAVEL GESEH % 60 MIN

40

MAX

6

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

100

7

23 – 05

Chapter 23

Hand-held programming unit

Special program menu The following functions can be carried out with the special program: • Resetting to initial settings.

RESET SETTINGS SET CONTROL -> PROG SET PROGRAM-> CONTROL DELETE DIAG. HISTORY

• Loading control parameters into programming unit.

• Loading parameters from the programming unit into the control system.

• Deleting the diagnosis data.

• Adjusting the display contrast.

3

• Language selection.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• Displaying information about the programming unit.

• Displaying information about the control.

To enter the special program menu, press the PROGRAM (1) and MORE INFO (2) buttons at the same time.

1

The LED (3) on the PROGRAM button lights up.

The first 4 functions are shown on the display.

Only the function that is in position one on the display can be altered.

2

80087

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

23 – 06

Chapter 23

Hand-held programming unit

Special program menu To carry out a function, you must press the MORE INFO button (1).

Resetting to initial settings • Use the SCROLL DISPLAY buttons (2) to move RESET SETTINGS to the 1st position on the display (5).

RESET SETTINGS SET CONTROL -> PROG SET PROGRAM -> CONTROL DELETE DIAG. HISTORY

• Press MORE INFO (1).

The display text (5) appears.

80087

• When the VALUE UP button (3) is pressed, the display text (6) appears.

• When the VALUE DOWN button (4) is pressed, the display text (7) appears.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

5 RESET TO INITIAL SETTINGS? YES: VALUE UP CANCEL: VALUE DOWN

PLEASE WAIT ... automatic

6 ALL SETTINGS HAVE BEEN RESET TO INITIAL VALUES

7 FUNCTION 3

CANCELLED

2 4 1

80087

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

23 – 07

Chapter 23

Hand-held programming unit

Special program menu Loading settings from the control system into the programming unit • Use the SCROLL DISPLAY buttons (2) to move SET CONTROL -> PROG to the first position on the display.

• Press MORE INFO (1).

• The display text (5) appears.

• When the VALUE UP button (3) is pressed, the display text (6) appears.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• When the VALUE DOWN button (4) is pressed, the display text (7) appears.

5 SAVE ALL SETTINGS IN PROG? YES: VALUE UP CANCEL: VALUE DOWN

6 PLEASE WAIT ... automatic ALL SETTINGS FOR THE CONTROL STORED IN THE PROGRAMMING UNIT

3

7 FUNCTION CANCELLED

2 4 1

80087

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

23 – 08

Chapter 23

Hand-held programming unit

Special program menu Loading settings from the programming unit into the control system.

• Use the SCROLL DISPLAY buttons (2) to move SET PROGRAM -> CONTROL to the first position on the display.

• Press MORE INFO (1).

• The display text (5) appears.

• When the VALUE UP button (3) is pressed, the display text (6) appears.

• When the VALUE DOWN button (4) is pressed, the display text (7) appears.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

5 LOAD SETTINGS FROM PROGRAMMING UNIT? YES: VALUE UP CANCEL: VALUE DOWN

6 PLEASE WAIT ... automatic ALL SETTINGS HAVE BEEN LOADED FROM THE PROGRAMMING UNIT INTO THE CONTROL

7 FUNCTION 3

CANCELLED

2 4 1

80087

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

23 – 09

Chapter 23

Hand-held programming unit

Special program menu Deleting the diagnosis data • Use the SCROLL DISPLAY buttons (2) to move DELETE DIAG HISTORY to the first position on the display.

• Press MORE INFO (1).

• The display text (5) appears.

• When the VALUE UP button (3) is pressed, the display text (6) appears.

• When the VALUE DOWN button (4) is pressed, the display text (7) appears.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

5

DELETE CONTROL DIAGNOSIS HISTORY? YES: VALUE UP CANCEL: VALUE DOWN

6 PLEASE WAIT ... automatic DIAGNOSIS HISTORY IN CONTROL HAS BEEN DELETED

7

FUNCTION CANCELLED

3 2 4 1

80087

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

23 – 10

Chapter 23

Hand-held programming unit

Special program menu Adjusting the display contrast • Use the SCROLL DISPLAY buttons (2) to move DISPLAY CONTRAST to the first position on the display.

• Press MORE INFO (1).

• The display text (5) appears.

• When the VALUE UP button (3) is pressed (held down), the display turns darker.

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• When the VALUE DOWN button (4) is pressed (held down), the display turns brighter.

5 ADJUST THE DISPLAY CONTRAST DARKER: VALUE UP BRIGHTER: VALUE DOWN

3 2 4 1

80087

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

23 – 11

Chapter 23

Hand-held programming unit

Special program menu Language selection • The default language can be changed to German, English or numeric (Fig. 1) by pressing the VALUE UP or VALUE DOWN buttons in the special program.

Displaying information about the programming unit

3 2

• Use the SCROLL DISPLAY buttons (2) to move INFO PROGRAM UNIT to the first position on the display.

4 1

• Press MORE INFO (1).

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

• The display text shown in Fig. 2 appears.

80087

Remark:

The data shown here is intended purely as an example.

5

Displaying information about the control • Use the SCROLL DISPLAY buttons (2) to move CONTROL INFO to the first position on the display.

• Press MORE INFO (1).

SELECT LANGUAGE WITH VALUE UP OR VALUE DOWN GERMAN (ENGLISH) (NUMERIC)

• The display text shown in Fig. 3 appears.

6

2

3

2

4

7 1

PROGRAM UNIT DATE OF MANUF. SOFTWARE VER.

1307 - 2102 20 APR 95 00 - 08

CONTROL DATE OF MANUF. SOFTWARE VER.

1243 - xx MAR 00 xx -xx

8/

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

23 – 12

Chapter 23

Hand-held programming unit

Test menu In this menu, the real time information about the statuses of the inputs and outputs and the temperature of the control are displayed.

The MORE INFO button (2) can be used to display the information in the first position on the display on a larger scale.

1

The following information is shown: 3 Travel switch signal as a %age of the maximum speed

2

4 Battery voltage 5 Heat sink temperature

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

6 Deadman switch on/off 80087

7 Mode switch on/off 8 Belly switch 9 Forwards switch on/off 10 Reverse switch on/off 11 Forwards contactor on/off 12 Reverse contactor on/off

3 4 5 6

TRAVEL SWITCH % BATTERY VOLTAGE CONTROL TEMP BRAKE INPUT

0 23 21 OFF

7 8 9 10

FAST TRAVEL BELLY SWITCH FORWARDS INPUT REVERSE INPUT

ON OFF OFF OFF

11 12 13 14

FORW. CONTACTOR REVERSE CONTACTOR MAX TEMP °C MIN TEMP °C

OFF OFF 28 -10

13 Maximum measured heat sink temperature 14 Minimum measured heat sink temperature

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

23 – 13

Chapter 23

Hand-held programming unit

Displaying current errors When the DIAGNOSTIC button (1) is pressed, all the errors that are currently registered are shwon on the display.

Error history Pressing the DIAGNOSTIC (1) and MORE INFO (2) buttons at the same time takes you into the special diagnostic menu.

Here, a list of errors is displayed that have been detected by the control system since the last time the errors were deleted.

3 2

Copyright protected. No part of this manual may be reproduced in any form.

Copyright reserved.

Each error is only displayed once.

4 1

80087

BELLY ERROR CONT. DRV. EX. CURR.

Error on checking the belly switch Current through contactor driver too high

DIR. CONT. STUCK

Contacts of the direction contactor are stuck Start-up protection for travel switch triggered Hardware failure fuse triggered Battery voltage too low (< 16V) Short-circuit at M output to BInterruption of contactor control circuit Control has not detected an error Battery voltage too high Start-up protection for Reduction due to excess or low temperature Travel switch error, incorrect value Travel switch error, interruption in cable (see 'Travel control software)

START-UP PROT. HPD FAILURE FUSE U BATT TOO LOW M SHORT-CIRCUIT CONTACTOR INTERRUPTION NO ERROR EXCESS VOLTAGE START-UP PROT. SRO TEMPERATURE ERROR TRAVEL SW. ERROR 1 TRAVEL SW. ERROR 2

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

23 – 14

Chapter 99

Maintenance

General Maintenance work must be carried out when the period specified in the maintenance instructions comes to an end or is exceeded, or when the maintenance symbol (spanner symbol) on the display (1) lights up.

Before and during all maintenance work, appropriate measures must be taken to ensure that work is carried out safety.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Before carrying out work on the hydraulic system, ensure that the pressure has been released from the system by lowering the load bearing device to the floor.

00191

1

Before carrying out work on the drive system, ensure that the vehicle is securely jacked up and supported from below in order to prevent it rolling away or starting up when not intended.

In operating conditions where there is more dust in the atmosphere or the floors and aisles are heavily soiled, the maintenance intervals must be shortened.

The same applies for conditions with severe temperature fluctuations or continuous extreme temperatures.

Remark:

After all maintenance work, a test of the vehicle functions and condition must be carried out!

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

99 – 01

Chapter 99

Maintenance

Safety instructions Handling fuels and lubricants

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

The following fuels and lubricants are used in the vehicle: • Gear oil • Hydraulic oil • Battery acid.

There are comprehensive safety specifications prescribed for the use and handling of these substances. The most important points are: For gear oil and hydraulic oil • Avoid contact with the skin. It is particularly important not to let oil that escapes under pressure come into contact with the skin.

• Do not breathe in oil mist.

• Oils are a potential hazard for water. For this reason, always transport and collect oil in containers that conform with regulations.

• Do not spill oil if possible. If spillage does occur, bind the spilt oil with suitable materials.

• Dispose of waste that contains oil in accordance with environmental regulations.

For battery acid • Battery acid is poisonous, so never breathe in its vapours.

• Battery acid is caustic, so avoid contact with the skin without fail.

• Always rinse off any battery acid that is spilt or splashes onto the skin with copious amount of clear water.

• When handling battery acid, use safety clothing like protective gloves and clothing and a face mask. In the event that acid still comes into contact with the skin, wash it off immediately with copious amounts of cold water and call a doctor.

• An explosive mixture of gases can be produced during battery charging which may still be present once the charging process is complete. For this reason, ensure that the charging bay is well ventilated.

• Smoking and naked flames are prohibited within a range of 2m around the charged battery.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

99 – 02

Chapter 99

Maintenance

Brake Functional check of the deadman brake If the deadman switch is released during travel, the vehicle should be generator braked immediately.

Once it comes to a standstill, the mechanical brake should be applied automatically.

If the deadman switch is released at a standstill, the mechanical brake should be applied immediately.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Functional check of the neutral brake If the travel switch is released during travel, it should return automatically to the neutral position. The vehicle should be brought to a standstill with generator braking. Once it has been at a standstill for two seconds, the mechanical brake is applied.

30020

1

Functional check of the reversing brake If the travel switch is moved into the opposite direction during travel, the vehicle should be braked immediately with generator braking.

Maximum wear on the brake lining The brake lining (1) must be replaced when it reaches a residual thickness of 8mm (see Brake/ Brake lining).

30021

2

Brake clearance The brake clearance (2) increases by the same amount as the brake lining decreases. If the brake clearance is too large, the brake cannot be released any more. For this reason, it must be checked without fail whenever maintenance is carried out (see Brake/ Setting the brake clearance).

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

99 – 03

Chapter 99

Maintenance

Battery Checking the electrolyte level The electrolyte level (battery fluid) must reach the baffle (plastic grid under the stopper) but not rise above it.

Always check the electrolyte level in several cells, since it can differ greatly.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Checking the electrolyte density The electrolyte density is an indication of the degree to which the battery is charged, i.e. the greater the density, the higher the battery capacity. The electrolyte density is measured with an aerometer (1).

The electrolyte density must be tested after the battery has been charged. The electrolyte density should be between 1.22 and 1.27 kg/l after the battery is charged. A lower reading is not acceptable.

It may be necessary to top up the acid.

30022

1

Cleaning the battery The battery must be kept dry and clean. Any battery acid that runs out into the battery tray must be removed with a suction device (2).

Any corrosion that has formed on the terminals should be removed.

Clean any oil smears, dust or other soiling off the surface of the battery with a clean, dry cloth.

30023

2

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

99 – 04

Chapter 99

Maintenance

Battery Battery lock The battery lock mechanism must not be bent.

The sealing lips and rubber pads that hold the battery in its end position should be undamaged.

The battery should be held securely in its end position, even during fast travel around bends (please see chapter on Battery/Lifting and removing the battery).

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Battery charger The output voltage of the battery charger must match the battery voltage.

The current of the battery charger must match the battery capacity.

The insulation on the battery connecting cable must not have any bare patches. The charger should switch on automatically when it is connected with the battery. The charger must be set up in a place where good through-ventilation is guaranteed.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

05 99 – 01

Chapter 99

Maintenance

Operating elements Ease of movement The operating elements include: • Emergency-stop switch • Key switch • Steering wheel • Travel switch • Lifting button • Lowering button • Horn button • Deadman switch

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Function test All the operating elements must move smoothly and return automatically to their neutral position.

Switches must click firmly into position. Covers or cladding must not scrape against the operating elements.

The symbols on the operating elements must be clearly legible.

Replace damaged operating elements.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

06 99 – 01

Chapter 99

Maintenance

Steering Ease of movement It must be possible to turn the steering wheel with slight force. However, the steering wheel must not move out of its home position of its own accord.

The ease of movement can be adjusted. To do this, remove the cover (1). The adjusting nut (2) is located under the steering wheel.

Once the hexagon socket screw (3) has been released, the nut (2) for adjusting the steering wheel ease of movement can be varied.

30026

2 3

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Reversed steering If the vehicle is fitted with reversed steering, the relevant information notice (6) must be fixed to the vehicle.

Steering angle The maximum steering angle is set correctly when the vehicle travels in a circle around the so-called turning radius point, which is no larger than 100mm in diameter.

The turning radius point is between an imaginary centre line of both forks at the height of the load wheels.

6 30027

5

4

Switching-off in the event of error If there is an internal or external error in the steering controller, travel should be switched off.

This cut-out function must be checked during maintenance.

To do this, pull out block connector X5 of the actual value potentiometer. The steering should now be out of action and the mechanical brake activated.

Toothed gear ring

30028

The toothed gear ring (4) and the steering motor pinion (5) must be lubricated every 6 month.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

99 – 07

Chapter 99

Maintenance

Lifting chains General The lifting chains used for the main lift are multi-link chains, also known as flyer chains. Flyer chains are dimensioned in inches.

Chains tend to elongate during the course of time as a result of wear on the chain link pins. When the specified tolerance of 2% is exceeded, the chain must be replaced (see Lifting chains/ Checking the chain elongation).

In order to keep wear to a minimum, please always ensure that:

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

• The chains are cleaned regularly and then sprayed with a special chain spray.

• The chains are checked regularly to ensure they are correctly adjusted (tension).

• Any imbalance due to incorrect chain tension or faulty mechanical elements is avoided.

Note:

Chains are safety components. They must therefore be checked with particular care.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

99 – 08

Chapter 99

Maintenance

Lifting chains Checking the lifting chains for damage The lifting chains on the main lift must be checked for the following signs of damage: • Surface rust

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

20132

• Rust in the joints

20133

• Stiff links

20134

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

99 – 09

Chapter 99

Maintenance

Lifting chains Checking the lifting chains for damage • Twisted link pins

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

20135

• Loose link pins

20136

• Unacceptable external wear

20137

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

99 – 10

Chapter 99

Maintenance

Lifting chains Checking the lifting chains for damage • Damage

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

20138

• Broken link plates

20139

• Broken link pins

20140

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

99 – 11

Chapter 99

Maintenance

Lifting chains Checking the lifting chains for damage • Soiling

20141

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

• Wear in the link plate holes

20142

• Wear on a link pin

If any of these signs of damage are found, the chain must be replaced immediately, since damage of this kind can cause the chain to break before the wear limit for permissible chain elongation is actually reached (see Lifting chains/ Replacing the lifting chains).

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

20143

Sheet no.

99 – 12

Chapter 99

Maintenance

Lifting chains Checking the chain elongation Main lift

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Caution:

Even if the wear limit has not yet been reached, we recommend that all chains (load chains and control chains) on the main lift should be replaced every 5000 operating hours, for safety reasons. This is because negative effects on the chains are very difficult to ascertain, due to ageing and material fatigue!

Elongation of the load chains on the main lift must be tested while installed with at least 10% of the rated load. It must not be elongated by more than 2%. The chain must be cleaned before the measurement is taken. The measurement must be carried out in the working area of the chain. The max. permissible chain elongation of 2% is 5mm over 10 single links of a 1" chain (please see table below).

If a length of 259mm is exceeded over 10 single links of a 1" main lift chain, the wear limit has been reached. The chain must be replaced.

General table of measurements for inch gauge chains 34 single links equivalent to --> Chain pitch

34 links

1/2" (12.70mm)

431.80mm

5/8" (15.88mm)

539.75mm

3/4" (19.05mm)

647.70mm

1" (25.40mm)

863.60mm

Chains with different pitches can be calculated from this information

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

99 – 13

Chapter 99

Maintenance

Lifting chains Checking the chain elongation Additional lift Remark:

In deviation from the national German regulations BGG918 "Principles for testing industrial trucks", more extensive regulations apply for single load-bearing chains.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Caution:

The load chain of the additional lift must be replaced after 5000 operating hours at the latest!

Elongation of the load chain on the additional lift (1) must be tested while installed with at least 10% of the rated load. It must not be elongated by more than 2%.

The chain must be cleaned before the measurement is taken. The measurement must be carried out in the working area of the chain. The max. permissible chain elongation of 2% is 5mm over 10 single links of a 1" chain (please see table below).

If a length of 259mm is exceeded over 10single links of a 1" additional lift chain, the wear limit has been reached. The chain must be replaced.

General table of measurements for inch gauge chains 34 single links equivalent to --> Chain pitch

34 links

1/2" (12.70mm)

431.80mm

5/8" (15.88mm)

539.75mm

3/4" (19.05mm)

647.70mm

1" (25.40mm)

863.60mm

Chains with different pitches can be calculated from this information

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

99 – 14

Chapter 99

Maintenance

Replacing the lifting chains Note:

Always use original spare parts when replacing lifting chains!

When the lifting chains are replaced, the connecting bolts (1) between the chain anchor (2) and chain (3) must also be replaced.

The lifting chains for the main lift must always be replaced at the same time.

This is the only way to guarantee an even distribution of weight over both chains.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Repairing the lifting chains Repairs must not be carried out on the lifting chains.

Attaching additional chain links is not allowed, since the links that are added are not pre-stretched.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

10230

1

3

2

Sheet no.

99 – 15

Chapter 99

Maintenance

Lubricating the lifting chains How often lubrication is required depends on what the vehicle is used for and on the conditions in which it is used. With normal use in single-shift operation, the chains must be re-lubricated every 6 month or every 1000 operating hours.

In tougher and/or multi-shift operation, and in situations where heavy soiling occurs or in humid conditions, lubrication must be carried out more often.

The intervals must be shortened as appropriate for the situation, e.g. if the vehicle is used in two-shift operation, the intervals should be halved.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Note:

If the outside of the chain is so soiled that penetration of the lubricating oil cannot be guaranteed, the chain must be cleaned before lubrication (see Cleaning the chains).

"Stabylan 2001" lubricant (Id. no. W8 010 100) should be used for lubricating the lifting chains.

Remark:

If the vehicle is used in a cold store environment (-30°C), the lubrication intervals should be reduced to half the length, and in multi-shift cold store operation, intervals should be shortened to 1/4 or 1/6 of the standard length, according to the amount of use.

"Syntesco" lubricant should be used for lubricating the lifting chains of vehicles used in cold store conditions (Id. no. W8 036 220).

Remark:

Dirt should not adhere to the outside of the chains.

The chains are correctly lubricated if your finger is covered with a film of oil when you touch the chain and if the lubricant does not drip off the chain.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

99 – 16

Chapter 99

Maintenance

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Cleaning the chains If chains are covered with a layer of grease on the outside or if they are heavily soiled, new lubricant cannot penetrate through the layer of grease or dirt into the chain. This causes wear and allows corrosion to occur, which subsequently makes the chain links stiffen.

For this reason, it is essential to clean soiled chains before they are lubricated.

Chains should only be cleaned with paraffin derivates like diesel fuel, petroleum, cleaning naphtha, etc.

Cleaning with steam jets in combination with cold solvent cleaners or any kind of agents containing caustic or acidic substances is strictly prohibited. This kind of treatment can cause direct damage to the chains.

If cleaning the chains with steam jet equipment is absolutely unavoidable, you should proceed as follows: • Cleaning Only use steam jet equipment without adding any cleaning agents.

• Blowing out Immediately after a chain has been cleaned, all the water left on its surface and in the chain links should be removed with a compressed air blower.

The chain should be moved several times during this process.

• Spraying The chain should then be sprayed immediately with one of the preserving and lubricating agents recommended by us. The chain should also be moved often enough during this process to ensure that the preserving and lubricating agent does actually penetrate into the chain links.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

99 – 17

Chapter 99

Maintenance

Hydraulic tank Volume The hydraulic tank volume is appr. 4.5l.

Seals The tank and pump assembly are connected to each other with a screw-fit connection.

For additional protection around the joint, a hose clamp is fitted that must be checked for leaks (1).

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Filter The paper air filter (2) lets air flow into or out of the tank.

Hydraulic oil that has leaked out of the oil tank gums up gradually in the filter and blocks it off. When this happens, the filter must be replaced.

2

Soiled oil The hydraulic oil can become soiled by different materials: • Condensation water • Rubber that rubs off the hydraulic hoses • Metal splinters off the valve block 1

• Other dirt

80064

For this reason, the hydraulic oil must be replaced to schedule, or at the latest when the colour of the oil has turned darker than honey yellow.

Please displose of used oil correctly.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

99 – 18

Chapter 99

Maintenance

Wheels Wear The drive wheel must be replaced when the diameter has worn down to 225 mm.

It must also be replaced when: • The running surface is very pitted • The running surface is out of round • The running surface is cracked The tightening torque for the wheel bolts is 140Nm.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Wheel bearings When replacing the drive wheel, always check the wheel bearing.

To do so, jack up the vehicle, and chock it up securely, then take hold of the drive wheel with both hands and jiggle it. You should be able to feel that it is fitted firmly without any play.

Castor wheels Castor wheels must be replaced when the diameter has worn down to 135mm.

They must also be replaced when: • The running surface is very pitted • The running surface is out of round • The running surface is cracked.

1

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

80018

Sheet no.

99 – 19

Chapter 99

Maintenance

Motor Carbon brushes The carbon brushes must be replaced when they have worn down to the following length: Drive motor: 15mm Pump motor: 11mm Steering motor: 14mm The entire brush set (4 brushes) must always be replaced (see Drive motor/ Carbon brushes).

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Remark:

The motor should not be placed under a full load immediately after the carbon brushes have been replaced. The carbon brushes run in relatively quickly under a minimum load.

30039

Checking the brush springs Brush springs that are not adequately pre-tensioned can cause the commutator to burn. Ensure that the carbon brushes move easily in the shaft.

Other maintenance work As well as replacing the carbon brushes, motor maintenance includes the following points: • Cleaning (see Travel drive/ Maintenance) • Visual inspection (see Travel drive/ Maintenance) • Replacing damaged parts (see Travel drive/ Maintenance) • Checking the brush assembly and commutator (see Travel drive/ Maintenance).

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

99 – 20

Chapter 99

Maintenance

Gear Changing the gear oil The oil must be drained off when the vehicle is warm.

The maximum permissible operating temperature is 80C°.

Use new seals on the oil drainage screw. Tightening torque: 22Nm. The filling volume is about 1.5l (see Travel drive/ Oil change).

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Noises Noises are a sign of excessive wear or an internal fault. The problem may be that there is not enough oil in the gear or the wrong type, but it is more commonly due to mechanical action, e.g. driving over floor joints or rails (see Travel drive/ Maintenance).

Leaks Check the gear for leaks at the inlet and outlet screws, the screw holes, at the shaft outlet and the back cover.

If necessary, replace the seal or shaft ring.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

99 – 21

Chapter 99

Maintenance

Mast Mast rollers The mast rollers (1) must not be worn out or cracked.

Mast rollers with lubricating nipples must be lubricated with all-purpose grease.

Guide rollers Guide rollers must not be worn out or cracked. Guide rollers with lubricating nipples must be lubricated with all-purpose grease.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Windscreen

30040

1

The windscreen is on the one hand designed to protect the driver from drops of chain grease and draughts, and on the other hand to guarantee him a clear view of the forks. For this reason, the windscreen must be kept clean at all times.

Lifting cylinder The lifting cylinder must be inspected for leaks. If necessary, replace the set of seals.

Guides, surfaces

30041

The surfaces of the mast profiles that the guide and mast rollers run up and down continuously, must be cleaned regularly and then greased again, in order to keep wear to a minimum.

Forks The welded seams of the forks on the fork holder must be inspected for cracks.

Chain adjustment The chain tension must be adjusted with the main lift fully lowered. Tighten both chain tensioners until a slight tension can be felt.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

30033

Sheet no.

99 – 22

Chapter 99

Maintenance

Pump assembly Carbon brushes The carbon brushes must be replaced when they have worn down to 11 mm. Never replace single carbon brushes - always replace the entire set (see Travel motor/ Replacing the carbon brushes).

Oil level The oil level cannot be measured until all the cylinders have been retracted. The oil level should be between the minimum and maximum mark.

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Noises Screeching,whining or scraping noises caused by faulty bearings, if the oil level is too low or scuffing toothed gears in the pump must be rectified by replacing the worn parts.

80071

Soiling A mixture of abrasive dust from the carbon brushes and a fine oil vapour makes a very good electrically conductive connection. If this connection forms between the chassis and the positive or negative battery pole, this is referred to as a short to ground. It can cause various different faults. For this reason, clean all surface dust off the motors every time maintenance work is carried out.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

99 – 23

Chapter 99

Maintenance

Lubrication Lubricants The following lubricants should be used: Hydraulic oil HLP DIN 51524/T2 Id. no. 8 036 912 The refill opening for the hydraulic oil is marked with a symbol (1).

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Gear oil SAE 80 Id. no. 8 036 925

30035

All-purpose grease ESSO Beacon 2 Id. no. 8 010 107

1

Chain lubricant Stabylan 2001 Id. no. 8 010 100

Disposal If the vehicle described here has to be taken out of service, it is important to ensure that all the components are disposed of in accordance with the regulations (relevant components are marked with the symbol shown here (2)).

In particular the fuels used in the vehicle must be either recycled or disposed of in the correct manner.

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

30036

2

Sheet no.

99 – 24

Chapter 99

Maintenance

Lubrication Lubrication plan Grease the toothed gears in the steering with all-purpose grease (1): Every 6 months.

Grease bolster bearings with all-purpose grease (2): Every 12 months.

Lubricate the load wheel axle with all-purpose grease (3): Every 12 months.

1

4 2 5

Copy g p o e ed o p o this manual may be reproduced in any form.

Copyright reserved.

Lubricate all moving parts with oil: Every 6 months.

80028

Change the hydraulic oil (4): Every 12 months.

Change the gear oil (5): Every 12 months.

Chain spray (6): Every 6 months.

7 6

Keep the running surfaces in the mast profiles free of corrosion with a film of grease (7): Every 6 months.

80004

3

Issue: Replaces issue:

08/03

WorkshopManual

XOP1

Sheet no.

99 – 25