Professional Documents
Culture Documents
General introduction 1
Operating principle 3
Parameters 4
Installation 5
Maintenance 6
Troubleshooting 7
Chassis C0000 8
Motors C1000 9
Hydraulics/Pneumatics C6000 14
Wiring diagram 19
Hydraulics schematics 20
Tools 21
Technical data 23
Index 24
1 General introduction
1
General introduction
The following warning levels and symbols are used in the repair manual:
DANGER
Indicates a dangerous situation that – if not avoided – will cause death or serious bodily injury.
WARNING
Indicates a dangerous situation that – if not avoided – could possibly cause death or serious bodily injury.
CAUTION
Indicates a dangerous situation that – if not avoided – will cause a slight or minor bodily injury.
NOTICE
Used in connection with actions that can cause material damage but not bodily injury.
1.2 Pictograms
1.2
Pictograms
Cleaning Measurement
Adjustment Welding
Disassembly/removal Assembly/installation
Open Close
Refilling Emptying
Update Charging
Lift Lower
Additional information under the pictogram can, for example, indicate the number of cable ties to be cut.
1.3 Abbreviations
1.3
Abbreviations
2.6 Software............................................................................................................................................................. 2 - 4
Only personnel trained in servicing and repair of this type of product are authorised to carry out service and repair activit-
2
ies.
▷ Always disconnect the battery when carrying out maintenance or repair work, unless otherwise stated in this re-
pair manual.
▷ Make sure that the place where service work is performed is a safe place. Follow the regulations.
▷ Keep the maintenance work site clean. Oil and water on the floor will make it slippery.
▷ Use the correct working posture. Service work often involves sitting on your knees or bending over forwards. Try
sitting on a toolbox, for example, to relieve the strain on your knees and back.
▷ Loose items and jewellery can get caught in moving parts. So never wear loose articles or jewellery when per-
forming maintenance or repairs.
▷ Exercise caution and always follow applicable local regulations when working at high heights.
▷ Use the correct tools for the work you are carrying out.
▷ Make sure that all safety equipment including guards and covers are properly secured and that they work as in-
tended before starting the repair work. If a guard or cover must be removed in order to perform the repair work,
extra care must be taken, and when the repair work is finished the guard or cover must be refitted.
▷ Use paper or a stiff piece of cardboard when checking for possible oil leaks. Do not use your hands.
▷ Use only new and clean oil for the drive gear.
▷ Do not flush solvents, etc. down the drain unless they are intended to be disposed of in this way. Follow local dis-
posal regulations.
▷ Prior to welding or grinding on painted surfaces, be sure to remove the paint at least 100 mm around the welding/
grinding area by using sandblasting equipment or paint remover.
▷ To maintain a high level of product safety and to minimise downtime, all current maintenance instructions must
be carried out.
▷ Always keep fire-fighting equipment close at hand, and do not use an open fire to check fluid levels or when
searching for leaks
▷ Always disconnect the battery before opening any covers to drive units or the electrical system.
▷ Always disconnect the battery prior to welding work using an electric welding unit. The welding current may dam-
age the battery.
Purpose
These work instructions describe how to work in a safe manner with components that are sensitive to electrostatic
chocks.
Scope
These work instructions apply to all that work with component or units that are sensitive to electrostatic chocks.
Procedure
Electrostatic discharges from people may destroy sensitive equipment. For this reason, one must follow the instructions
for packaging and earthing. Always pay attention to these precautionary instructions.
Electronic card are supplied in electrostatically protected packages or envelopes.
These packages carry the following symbol:
▷ Leave electrostatically sensitive equipment in their respective packaging until you can place them on an electro-
statically protected work area.
▷ Electrostatically sensitive equipment should only be handled when they are properly earthed.
▷ Store electrostatically sensitive equipment in their protective packaging or on electrostatically protected surfaces.
▷ Working with and charging batteries should always be performed in accordance with the safety instructions
provided by the battery manufacturer.
▷ Always use safety equipment to protect the eyes, face and skin while checking or handling batteries.
▷ Do not place any electrically conductive items on the battery terminals or their connections.
▷ Ensure there is a shower and an eye bath nearby in case an accident happens.
▷ Batteries generate explosive gases. Never use an open flame or other sources of ignition in close vicinity to a 2
battery.
▷ Do not place tools or other metal objects on the battery. This can cause a short-circuit and even an explosion.
▷ The battery must be used according to the battery manufacturer's instructions regarding ambient and working
temperatures. Otherwise there is a large risk that the battery is damaged and that it will soon have to be re-
placed.
▷ All lifting must be carried out on a level, non-slip and stable surface. Asphalt surfaces should be avoided if pos-
sible.
▷ To prevent the product moving while it is being lifted, it must not be lifted with anyone on the platform or with the
tiller arm in the lowered position.
▷ If the drive wheel which is braked, is being lifted, the other wheels must be blocked to stop the product from mov-
ing.
▷ Select the lifting point so that the lift is as light as possible, for example one corner at a time. If there are lifting
points indicated on the lower part of the chassis, these must be used to ensure balanced lifting.
▷ Make sure the surface where the jack is placed is clean and free of oil and grease.
▷ Make sure your hands and the jack lever are free of grease and oil.
▷ Only use the lever supplied with the jack. If the lever is too short, more exertion than is necessary will be re-
quired. If the lever is too long, there is a risk that the jack will be overloaded.
▷ Never work under a product that is not supported by trestles and secured by a lifting device.
▷ Never work under a raised product without it being properly supported on trestles.
Put trestles:
▷ as close to the lifted part of the chassis as possible in order to reduce the falling height if the product should col-
lapse.
Any modification of the product must be approved beforehand. No modification of product may be performed that may in-
fluence the capacity, stability and safety of the product without prior written approval from the manufacturer, its repres-
entative or successor.
In the case of the manufacturer no longer being in business and there being no successor, the user of the product may
arrange for modifications on the precondition that the user:
▷ makes sure that an engineer with expert knowledge of the product type and its safety designs, tests and imple-
ments the modification,
▷ files all documentation of the design, tests and implementation of the modification,
▷ approves and makes the applicable changes to the capacity plate, adhesive labels, markings and operator’s
manual,
▷ affixes a permanent and well visible sign to the product stating how the product has been modified, together with
the date of the modification and the name and address of the company that carried out the modification work.
2.6 Software
2.6
Software
Erroneous handling of the product systems and/or the external systems of the product may affect the safety of the
product and the environment.
1. Always make sure that the correct software is downloaded to the product.
3. Only adjust one parameter at the time when performing changes to the truck. Check the function after each ad-
justment.
▷ Lower the forks completely and keep pressing the button for another 5 - 10 seconds to relieve system pressure.
▷ Only fill the hydraulic system with new and clean oil.
3 Operating principle
3
Operating principle
3.1 Description
3.1
Description
The Operating principle section provides a general description on how the AutoShuttle functions work and how they are
interdependent. 3
Because the control structure of the product is so complex, it is not possible to describe all combinations. Similarly, it is
not possible to describe all influencing factors. Only a selection of such factors are indicated. A good aid is found in the
descriptive sections of the repair manual and in the parameter descriptions in particular.
4 Parameters
4
Parameters
Software: 7584588
4.1.1 Operator parameters 4
4.1.1.1 Log-in profiles
The operator parameters can be adjusted individually to the available log-in profiles. The parameter’s connection to the
operator is done by a combination of operator and parameter numbers where the single digit always corresponds to the
parameter.
The number of turns of the steering wheel that represents one turn of the drive wheel.
In increments of 1
The number of turns of the steering wheel that represents one turn of the drive wheel.
In increments of 1
The parameter shown via TruckCom is a combination of the sensitivity values low speed and for high speed.
Total value for low and high speed.
The parameter value can be calculated as (high * 256 + low), where low = steering ratio at low speed and high = steering
ratio at high speed. For example low = 8 and high = 15 gives a parameter value of (15 * 256 + 8) = 3848.
For parameters 2 and 3, 100% corresponds to travel speed. The maximum speed varies depending on the truck type.
Example:
If operator profile ‘1’ has parameter ‘2’ set to 80 %, operator profile‘2’ has their corresponding parameter ‘12’ set to 70 %,
the maximum travel speed is limited to:
The parameter is used to limit the maximum travel speed for the operator profile that is logged on.
The parameter is used to limit the maximum travel speed for the operator profile that is logged on.
4.1.1.4 Acceleration/Deceleration
These two parameters can be used to get a smoother acceleration/deceleration where the application or operator profile
so requires.
The parameter can be used to get a smoother acceleration where the application or operator profile so requires.
The parameter can be used to get a smoother deceleration where the application or operator profile so requires.
Use this parameter to determine the service interval of the truck. The buzzer sounds and a spanner is shown on the CID
when the service counter is at zero. The counter shows the time that has passed since the last service intervention. If an
earlier service intervention is required, simply activate this parameter without adjusting the time. If the value is set to '0',
then no service interval is set and the CID's hour meter screen does not show the 'S' field – Remaining time to service. 4
No. Designation Min Std. Max Step Unit
104 Time to automatic logout 0 20 120 1 min.
The parameter gives the time, in minutes, before automatic logout if the truck is inactive. If the value is set as ‘0’, logout
takes place after 4 hours.
Specifies the driving function when the door on the cold storage truck is open.
Value Type
0 Constant
1 Flashing 1 Hz
2 Flashing 2 Hz
Parameter 106 controls the warning lamp frequency [P5] on output X131:34.
The activation pattern for output X131:34 is set via parameter 115.
The warning lamp function is activated by factory parameter 1112.
Value Type
0 Constant
1 Flashing 1 Hz
Value Type
2 Flashing 2 Hz
The parameter specifies the activation pattern for the travel alarm, output X131:23
The activation pattern is activated as indicated in the table below.
The parameter specifies the activation pattern for the warning lamp [P5], output X131:34.
The activation pattern is activated as indicated in the table below.
The parameter specifies how the alarm is given when the collision sensor is activated.
Value Type
0 Repeated tone pulses
1 One tone pulse
For setting the collision sensor’s sensitivity, see parameters 110 and 111.
Parameter settings:
Value Function
4
0 Non-active
1 Active
4.1.2.1.2 Battery
Parameter 107 specifies the capacity of the battery on the truck. The parameter can also be used to compensate for dif-
ferent ways of driving by: • increasing the value to discharge the battery even more • reducing the value if the battery is
discharged too much. For recommended parameter settings, see the table below.
When setting parameter 107 in a truck with Reflex truck with Hawker Evolution batteries, BT recommends reducing the
recommended value for wet batteries by six (6) units. DANGER! Battery service life will be reduced if the value of para-
meter 107 is set too high. The standard setting of parameter 107 is set for normal truck handling. Other applications may
require a different setting of parameter 107. Check that the parameter setting is the correct one using the instructions be-
low. When checking the charging state on a discharged 48 V battery, its no-load voltage should be measured after a rest
period. The zero indication should appear at an open circuit voltage that must not fall below 2.02 V/cell or 48.48 V. See
the instructions below. Instructions for verifying parameter setting 1. Charge the battery. 2. Use the truck in its normal ap-
plication until the battery indicator shows a discharged battery (0% on the display). 3. Disconnect the battery from the
truck and allow it to rest for at least two hours. Note: Do not allow any charging or discharging during this time. 4. Meas-
ure the voltage on the battery at +20°C. If the voltage is less than Uend, (see the table below), the parameter value must
be reduced. If the value exceeds Uend considerably, the risk of causing damage to the battery is reduced. At the same
time, the operating time of the truck is reduced. If a longer operating time is required, the parameter value can be slightly
increased. 5. Each change should be followed up by a new verification of the parameter setting. Battery type Battery
voltage at rest, Uend Hawker Evolution 48.48 V
Parameter 108 is used to state the level of the battery's remaining capacity according to the CID battery charge symbol
when the acceleration and lift speed are limited to 70% of their maximum. A further, not parameter-controlled, limitation
occurs when the CID battery charge symbol shows 0 %. In this case, the following are limited: • Acceleration – 30% of
maximum performance • Lifting – 50% of maximum performance
The parameter indicates whether saved data from the collision sensor should be deleted upon login or not, and whether
to reset the BDI counter.
Value Function
0 Delete nothing
1 Delete histogram log
2 Clear collision log
3 Not used
4 Reset BDI
The parameter specifies at which level along the X-axis (fork/drive wheel direction) truck functions should be blocked
when there is a collision.
The parameter specifies at which level along the Y-axis (sideways truck functions should be blocked when there is a col-
lision.
The parameter specifies the condition for how the truck is to be taken into operation again after the impact sensors have
been triggered:
4
Value Function
0 Login with a special PIN code is required
1 The truck must be restarted
The PIN code required to reset the shock sensor is entered in the login profile Block:10, Profile:1
Value Type
0 Constant
1 Flashing 1 Hz
2 Flashing 2 Hz
Value Type
0 Constant
1 Flashing 1 Hz
2 Flashing 2 Hz
The parameter specifies the activation pattern for extra output X133:8.
NOTE:
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4 Parameters
Parameter list
The parameter specifies the activation pattern for extra output X133:23.
The activation pattern is activated as indicated in the table below.
4.1.2.2 Driving
4.1.2.2.1 General
The parameter can be used to produce a smoother deceleration when the application requires this for all operator pro-
files.
Two inputs on the SCU, X133:31 and X133:4, are used to reduce the travel speed. If one or both of the inputs is actuated
by a high signal from external sensors, speed is reduced according to this parameters.
The parameter manages the creep speed function in the travel direction control. The function can be configured via para-
meter 242.
Value Function
4
0 Inactivated
1 Activated
The parameter can be used to permanently reduce the truck’s maximum travel speed. This setting will apply to all oper-
ator profiles.
The parameter is used to adjusted the reduced travel speed, Min 1.5 km/h Max 8 km/h, when the forks are in the main lift
area. This parameter is only valid when the truck is equipped with height indication. If the truck does not have height in-
dication, the speed is always reduced to 4 km/h when the forks are in the main lift area.
This parameter is only relevant if parameter 1118 is set to 0.
This parameter is used to set which double-click function is available via the travel direction selector.
The parameter can be used to adjust the creep speed. Can only be lowered.
The parameter is used to specify the maximum speed for half-speed, max. 4 km/h. Can only be lowered.
The parameter is used to specify the maximum speed for safety speed, max. 1.3 km/h. Can only be lowered.
4.1.2.2.1.2 Reduced maximum travel speed over a certain lifting height and reach length
With the parameter pair 209/210, it is possible to activate and adjust a speed limitation when the forks are raised above a
certain height.
With the parameter pair 211/212, it is possible to activate and adjust a speed limitation when the reach carriage is exten-
ded beyond a certain length.
The parameter specifies the lift height at which speed reduction is activated.
Speed reduction is controlled by parameter 210.
The parameter indicates the travel speed to be applied when the forks are over a specified height.
The lift height at which speed reduction is activated is controlled by parameter 209.
The parameter indicates at which length of the reach movement speed reduction is activated.
Speed reduction is controlled by parameter 212.
The parameter indicates the travel speed to be applied when the reach carriage is extended beyond a specified length.
The reach movement length at which speed reduction is activated is controlled by parameter 211.
The parameter indicates the lift height at which the fork laser should come on.
The function is activated with factory parameter 1132, page 4 - 000.
This parameter handles the specified degree of deviation from 0° tilt at which the fork laser will be activated. The default
value is 10, which means that the fork laser is activated at 1° down and 1° up.