SA - OMNI (GB) - V1.2 Pag 226 - 452

Hydraulics
Lift module block
8.10.7 Lift module block H3
1
16
2Y33/2Y32
H2
2
C 2Y49
3
15 2Y37
A
2Y30/2Y52
4
R2 5
M
14
D 6
13 E B 7
2Y36
2Y31 8
R1
12
2Y34/2Y35
9
H1
11
2Y53 10
Fig. 8-9: Lift module block H3
1 Control valve for lifting (2Y32) and 9 Pressure switch for slack chain/chain
lowering (2Y33) auxiliary lift break (H20)
2 Prop. valve for lowering auxiliary lift 10 Control valve for reducing pressure
(2Y49) 2Y53 (normally open)
3 Control valve for swivel (2Y37) 11 Control valve for lifting (2Y34) and
lowering (2Y35) main lift
4 Opening limit for 2Y30 12 Current controller for lowering main lift
(2Y31)
5 Test connector 13 Control valve for sideshift (2Y26)
6 Damper H9 (2B10) 14 Pressure control valve
7 Opening limit for 2Y31 15 Proportional valve with priority direc-
tion (2Y30) and control valve (2Y52)
8 Emergency lowering valve for main lift 16 Emergency lowering valve for auxil-
iary lift
8-214 Version 1.2, 12.07.2006

Hydraulics
Lift cylinders (main and auxiliary lift)
8.11 Lift cylinders (main and auxiliary lift)
8.11.1 Design of the cylinders
1 15
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9
9
10 10
11
11 12
12 13
16
13
14
Fig. 8-10: Section through the lift cylinder
1 Lock washer 9 Casing pipe

2 Dirt skimmer 10 Cylinder rod
3 U-seal 11 Retaining ring (upper stop)
4 Bleed screw 12 Lower cylinder rod guide
5 Copper seal 13 Cylinder endpiece
6 Cylinder rod guide bands 14 Pipe-break protection
7 O-ring 15 Mounting holes
8 Screw-in flange 16 Load-lowering valve
Version 1.2, 12.07.2006 8-215

Hydraulics
8.11.2 Bleeding the cylinder
The bleeding of the lift cylinder must be repeated until the lift movement runs vi-
bration-free.
Lift the cabin (or auxiliary lift with load) approx. 0.5m
DANGER!
Uncontrolled movement of components. The lifting
gear may lower when bleeding!
• During all work in the area of the cylinder, observe the
instructions in Working under lifted frame"” on page 7-
104.
Slightly loosen bleed screw (Fig.: 8-10 on page 8-215; pos. 4).
Note
The screw has a short thread so do not unscrew it too
far.
Bleed until the oil exits bubble-free

Tighten the bleed screw
Note
If the bleed screw does not seal without leaks then re-
place the copper washer (Fig.: 8-10 on page 8-215;
pos. 5) under the screw.
8-216 Version 1.2, 12.07.2006

Hydraulics
8.11.3 Replacing the sealing
Note
always replace the entire sealing kit and guide kit.
Always make sure that no dirt can fall into the opened
cylinder.
To replace the sealing

Lift the cabin until the pole lock can be inserted (Working under lifted frame"” on
page 7-104).
Remove the lock washer (Fig.: 8-10 on page 8-215; pos. 5)
Lower the cabin via the main lift emergency lowering valve (Fig.: 8-9 on page 8-
214; pos. 8) to the pole lock
Slightly loosen bleed screw (Fig.: 8-10 on page 8-215; pos. 4).
Note
The screw has a short thread so do not unscrew it too
far.
Lower the cylinder via the main lift emergency lowering valve to the lower end
position and then close the emergency lowering valve
Using a hook wrench, release the screw-in flange (Fig.: 8-10 on page 8-215;
pos. 8)
Rotate the screw-in flange to the left and remove upwards
Replace the dirt ring (Fig.: 8-10 on page 8-215; pos. 2) , the U-seal (pos. 3), the
cylinder rod guide bands (pos. 6) and the O-ring (pos. 7)
Replace the bleed screw (pos. 4) as well as the sealings for the bleed screw
(pos. 5); do not tighten the screws
Note
Observe the correct fitting position of the dirt skimmer
(dirt skimmer upwards) and the U-seal acc. to Fig.: 8-10
on page 8-215 (sealing lip downwards).
Version 1.2, 12.07.2006 8-217

Hydraulics
Check the starting chamfer of the cylinder rod and smooth if required so that the
sealings and guides of the screw-in flange are not damaged when fitting on.
Note
Lightly oil the dirt skimmer, the U-seal, the cylinder rod
guide bands, the O-ring and the cylinder rod; this facili-
tates the assembly.
Open the bleed screws
Note
If the bleed screws are not opened then the sealings
may be damaged.
Carefully fit the screw-in flange (Fig.: 8-10 on page 8-215; pos. 8) onto the cyl-
inder rod (pos. 10) and tighten
Note
When fitting the screw-in flange onto the cylinder rod,
the O-ring must not graze the thread of the cylinder pipe,
otherwise it will be damaged.
Tighten the bleed screws

Carefully activate the lift main lift until the cylinder is raised
Mount the lock washer (pos. 1) with saw ring
Make a visual check of the screws at the pole strap; Loctite fitting!
Activate lift main lift for a short time
Bleed the cylinder via the bleed screw (pos. 4)
Pull the cabin out of the pole lock
Once more deactivate the pole lock (Working under lifted frame"” on page 7-
104)
Completely lower the cabin
Check the performance of the main lift and re-bleed the cylinder
Check the tightness of the cylinder
8-218 Version 1.2, 12.07.2006

Hydraulics
8.11.4 Removing and installing the main lift cylinder
8.11.4.1 Removing
Fig. 8-11: Cylinder fixing
1 Screws 2 Pole strap
Lift and secure the cabin

Unscrew the screws of the pole strap, push up the strap to the bleed screws
(Fig.: 8-10 on page 8-215; pos. 4)
Attach the cylinder to the lifting gear using a belt to the cylinder head beneath
the pole strap
Note
Secure the cylinder well so that it can not fall down dur-
ing later procedures. Until pulling out, bind the cylinder
head to the pole.
Release the lower fixing screw

Release the adjusting piece and lower as when replacing the sealing
Carefully pull out the cylinder using lifting gear and place to the side
Version 1.2, 12.07.2006 8-219

Hydraulics
8.11.4.2 Installing
Installation is in the reverse order of steps.
Note
When inserting the cylinder, make sure that the bleed
screws are easily accessible.
When installing the bolted connections of the pole strap,
only tighten after the cylinder is fixed in lowered condi-
tion at the top and bottom. This ensures that the cylinder
is not installed twisted. Secure the bolted connections
with Loctite 243.
DANGER!
Loose bolted connections. If the pole strap is loose
then the main lift cylinder may get bent.
• Make a regular visual check of the bolted connections,
at least once per year.
• Do not retighten the screws as this destroys the loctite
sealing.
8.11.5 Replacing the lower cylinder rod guide
If the upper cylinder rod guide and the sealings wear prematurely after replace-
ment then the lower cylinder rod guide is probably defective and must be replaced.
Remove the cylinder

Remove the cylinder head
Pull out the cylinder rod
Remove the lock washer (Fig.: 8-10 on page 8-215; pos. 1)
Replace the lower cylinder rod guide (Fig.: 8-10 on page 8-215; pos. 12)
Assembly is in reverse order.
Bleed the cylinder
8-220 Version 1.2, 12.07.2006

Hydraulics
8.11.6 Pipe-break protection / Load-lowering valve
Triggering of the pipe-break protection (Fig.: 8-12 on page 8-222; pos. 1) at the
main lift cylinder as well as the load-lowering valve (Fig.: 8-10 on page 8-215;
pos. 16) at the auxiliary lift cylinder is an emergency function that is triggered by a
lowering speed of the main lift that is not permitted. The delay values that ensue
represent an increased load to the hydraulics and mechanics of the vehicle.
Use of a pipe-break protection guarantees in case of a pipe break in the hydraulic

lines of the main lift (Fig.: 8-12 on page 8-222) that there is an emergency stop of
the cabin (lowering stop), independent of the height. As soon as the lowering
speed of the cabin exceeds the value of 0.6 m/s, the pipe-break protection is me-
chanically activated and a lowering stop is triggered. In this condition, any addi-
tional possibility of lowering the cabin is excluded (even using the emergency
lowering valve at the lift module block).
The lowering limit screw in the main lift module block is set at the factory in such
a way that the pipe-break protection can only trigger when a line between the main
module block and the main lift cylinder is actually damaged, i.e. in case of a pipe
break.
§ Note
Never operate the cylinder without the pipe-break pro-
tection/load-lowering valve. In case of a new cylinder,
check the presence of the pipe-break protection.
If a pipe-break protection has triggered then search for
the cause of this and remedy it before putting the vehicle
back into operation. Examine all hydraulic and mechan-
ical components of the lifting gear carefully for damage
(particularlyRemoving and installing the main lift cylin-
der"” on page 8-219).
If the pipe-break protection/lowering brake valve triggers
during operation or setup work at the lifting/load-lower-
ing valve without there being damage at a hydraulic line
then the setting of the lowering limit screw at the lift mod-
ule block must be checked and corrected when neces-
sary
If a pipe-break protection has triggered several times
then the cause should be found and remedied (replace-
ment). The screws for fixing the pole strap should then
also be replaced
The pipe-break protection/load-lowering valve must not
be adjusted or repaired. If the pipe-break protection/
load-lowering valve have to be replaced then only origi-
nal parts that have been set at the factory, checked and
test-stamped may be used.
Version 1.2, 12.07.2006 8-221

Hydraulics
1 3
Fig. 8-12: Position of pipe-break protection

1 Housing with pipe-break protection on the inside
2 Hydraulic line from the hydraulic pump
3 Pipe-break protection
8.11.6.1 Overview of types
Pipe-break protection of main lift cylinder
Security against line

Piston diameter ID Number
break
[mm] Type
45 LB2C-27 196685
50 LB2C-34 196686
55 LB3C-40 100606
60 LB3C-50 417785
70 LB3C-40 100606
75 LB3C-50 102283
Tab. 8-2: Overview of types of pipe-break protection
8-222 Version 1.2, 12.07.2006

Hydraulics
Load-lowering valve of auxiliary lift cylinder
Security against line

Piston diameter ID Number
break
[mm] Type
50 SB23C-25 120744
55 SB25C-30 142401
60 SB25C-37 142441
Tab. 8-3: Overview of types of load-lowering valve
8.11.6.2 Procedure when the pipe-break protection has triggered
When the hydraulic line is leaky
Secure the cabin against sagging using suitable supports.

Replace leaky hydraulic components and pipe-break protection.
Put the hydraulics into operation and check for tightness.
Once more free-run the cabin with the lift main lift function and remove the sup-
ports
Carry out a function test.
If the reason for triggering is unsure
If the pressure lines of the main line cylinder are not burst (lowering speed exceed-
ing 0.6 m/s has been caused in this case by other reasons) hen the cabin can be
lifted via the „Lift main lift“ function.
In such cases (no pipe break), the „Lower main lift“ function must be analyzed ex-
actly to avoid dangers. The pipe-break protection must also be replaced in this
case!
Version 1.2, 12.07.2006 8-223

Hydraulics
8.11.6.3 Installing the pipe-break protection
There is a pipe-break protection for each of the two lifting cylinders in the connec-
tion line. Pipe-break protection is installed at the factory. The setting of the pipe-
break protection is only carried out by the manufacturer.
Specially made tools are used for installing and removing the pipe-break protec-
tion. The tools can be requested fromATLET.
Fig. 8-13: Pipe-break protection and special tools

1 Pipe-break protection
2 Special tools
8.11.7 Emptying the lift cylinder
Completely lower the main and auxiliary lift using the emergency lowering
screw; Keep the emergency lowering screw opened.
Completely unscrew the bleed screw to allow the oil to completely drain off.
8-224 Version 1.2, 12.07.2006

Hydraulics
Hydraulic installation of the traverse fork (RFZ)
8.12 Hydraulic installation of the traverse fork (RFZ)
8.12.1 Side view
1 2 3 4 5 6 7 8
9 10 11 12 13 14
Fig. 8-14: Hydraulic installation of the RFZ (side view)
1 Swivel valve block A7 with load stabi- 8 Sideshift sensor

lizer valve
2 Set screws for load stabilizer valve for 9 Load-lowering valve of auxiliary lift
swiveling to the left cylinder A4
3 Set screws for load stabilizer valve for 10 Swivel sensor
swiveling to the right
4 Valve block for sideshift A3 with shock 11 Swivel chain
valves
5 Set screw for shock valve for side- 12 Pressure line to the swivel cylinder
shiftto the right
6 Hydraulic motor for sideshift A48 13 Transparent leakage tube for swivel
cylinder
7 Toothed shaft for sideshift 14 Swivel cylinder
Version 1.2, 12.07.2006 8-225

Hydraulics
8.12.2 Front view
14 1
13
12
11
10
9 2
8 3
4 4
5
5
6
6
Fig. 8-15: Hydraulic installation of the RFZ (front view)
1 Set screw for shock valve for sideshift 8 Valve 2Y41: swing to left
to the right
2 Set screws for load stabilizer valve for 9 Valve 2Y40: swing to right
swiveling to the left
3 Set screws for load stabilizer valve for 10 Valve 2Y42: Sideshift to right
swiveling to the right
4 Pressure line to the swivel cylinder 11 Valve 2Y43: Sideshift to left
5 Swivel cylinder 12 Valve block for sideshift A3 with shock
valves
6 Transparent leakage tube for swivel 13 Set screw for shock valve for sideshift
cylinder to the left
7 Swivel valve block A7 with load stabi- 14 Hydraulic motor for sideshift A48
lizer valve
8-226 Version 1.2, 12.07.2006

Hydraulics
8.12.3 Setting the shock valves (sideshift)
The shock valves valve block A3 (Fig.: 8-14 on page 8-225; pos. 4) protect hydrau-
lic motor A48 (Pos. 6). If the pressure difference between the oil feed and the oil
flowback for the sideshift movement exceeds 100 bar then the shock valves open
automatically and limit the pressure on the feed end so that the pressure differ-
ence is always kept to 100 bar. The hydraulic motor can withstand a pressure dif-
ference of more than 100 bar (approx. 130 bar).
Note
The shock valves are set to 100 bar pressure difference
limitation at the factory.
If the sideshift movement runs correctly then the shock valves do not need to be
set.
Setting the shock valves (e.g. after repairs)
Note
Carry out the settings in both sideshift directions. The
setting must be made at the rated load.
Connect the manometer at the minimess connection of the lift module block
Completely tighten the adjusting screws (Fig.: 8-15 on page 8-226; pos. 1 and
13)
Bring the forks into their initial position
Activate the sideshift and read-off the normal working pressure (note the value))
Drive the ends of the forks against a fixed hindrance (e.g. against a wall)
Completely open the adjusting screws (do not unscrew))
Slightly tighten the adjusting screws; Once more drive the forks against a fixed
hindrance and measure the pressure
Tighten the screws until the pressure has reached a normal working pressure
of +30 bar
Load the rated load and make sure that the sideshift movement runs correctly
Tighten the counter-nut of the adjusting screw
Version 1.2, 12.07.2006 8-227

Hydraulics
8.12.4 Setting the load stabilizer valve (swiveling)
Fig. 8-16: Load stabilizer valve (swiveling)
The load stabilizer valves on valve block A7 (Fig.: 8-14 on page 8-225; pos. 1)
have the following functions:
• They lock the swivel cylinders in all stop positions .

• They prevent the forks from swiveling out faster or wider than set in the SE-
CAN control.
• They prevent the forks from swiveling out in the direction of the load when
braking the vehicle or in the drive direction when accelerating the vehicle.
• If the forks are not in the initial position and are in contact with the shelf then
make sure that the forks do not give when reversing the vehicle in order to
avoid danger of tilting.
Note
If the forks are not sufficiently locked in normal (correct)
operation then the load stabilizer valve must be reset. A
load stabilizer valve with correct setting is delivered as
replacement part.
If the load stabilizer valve is set too tight then this results
in jerky rotational movement and imbalanced synchro-
nous movement.
8-228 Version 1.2, 12.07.2006

Hydraulics
To set the load stabilizer valve

Pull the forks to the side and check whether they remain locked in any stopping
position (at least 5 min.)
Swing the forks by approx. 45 degrees from the initial position to the front; Drive
the sideshift against a fixed hindrance: The forks must swing out; if required,
slightly loosen the adjusting screws (Fig.: 8-15 on page 8-226; pos. 2 and 3) and
secure
Load the rated load and secure with straps
Move the vehicle in the drive direction. The forks must not swing out; if required,
slightly tighten the adjusting screws and secure.
WARNING!
Uncontrolled fork movements
• Only carry out a brake test afterwards in the load direc-
tion; otherwise, the forks can not swing forwards .
Note
If the described settings of the load stabilizer valve can
not be correctly carried out then remove and replace it.
The setting value of the old load stabilizer valve can be
used as an approximate value for the new valve
Version 1.2, 12.07.2006 8-229

Hydraulics
8.12.5 Swivel cylinder
The sealing must be replaced when
oil escapes from the cylinder rod

oil flows over the transparent leakage tube (Fig.: 8-15 on page 8-226; pos. 6)
into the chamber of the sideshift arm
Note
During all maintenance work, you should check to see
whether oil has flowed into the leakage tube.
8 9 10 11 12 13 14 15
7 6 5 4 3 2 1
Fig. 8-17: Swivel cylinder
1 Connection for leakage tube 9 Thread ring

2 Cylinder seal 10 Cylinder rod guide
3 O-ring 11 Pressure connection
4 Guide bands 12 Cylinder jacket
5 O-ring 13 Cylinder rod
6 Seal 14 Cylinder
7 Dirt skimmer 15 Bore hole for face pin wrench
8 Bore hole for face pin wrench
8-230 Version 1.2, 12.07.2006

Hydraulics
If there is oil in the leakage tube then the oil in the sideshift arm should also be let
off.
Pull off the leakage tube from the two swivel cylinders and activate swiveling
determine which swivel cylinder is leaky; Replace the sealing
8.12.6 Replacing the sealing
Remove the cylinder

Plug face pin wrench AMF 764/40-80 into the bore holes (Fig.: 8-17 on page 8-
230; pos. 8)
Unscrew the threaded ring (pos. 9)
Pull out the cylinder rod (pos. 13) with the cylinders (pos. 14) and cylinder rod
guide (pos. 10)
Plug the face pin wrench AMF 764/40-80 into the bore holes (pos. 15)
Unscrew the cylinders from the cylinder rod
Remove the O-ring (pos. 3); grease and insert the new O-ring
Screw the cylinder back on to the cylinder rod
Remove the sealing kit and guide kit (pos. 2-7)
Grease and mount a new set
Note
Fitting position of dirt skimmer (pos. 7): sealing lip out-
wards
Fitting position of seal (pos. 6): sealing lip inwards
Make sure that no edges or running surfaces of the cyl-
inder are dirty or damaged otherwise the new sealings
will be destroyed when assembling.
; Re-installing the cylinders
Check the connection nipple for the leakage tube

Re-install the cylinders
For additional information, please see:

• Adjustment of the swivel chains"” on page 7-159
Version 1.2, 12.07.2006 8-231

Hydraulics
Drawings of hydraulic components
8.13 Drawings of hydraulic components
8.13.1 Lift module of combined block KPL
Fig. 8-18: Lift module of combined block KPL
8-232 Version 1.2, 12.07.2006

Hydraulics
8.13.2 Hydraulic control unit
Fig. 8-19: Hydraulic control unit
Version 1.2, 12.07.2006 8-233

Hydraulics
8.13.3 Hydraulic installation in the bogie
Fig. 8-20: Hydraulic installation in the bogie
8-234 Version 1.2, 12.07.2006

Hydraulics
Version 1.2, 12.07.2006 8-235

Hydraulics
8-236 Version 1.2, 12.07.2006

Electrical equipment
Chapter index
Chapter 9
Chapter index
9.1 Block diagram of the control concept .....................................241

9.2 CAN bus description...............................................................242
9.3 Components of the control systems .......................................244
9.4 Structure of the DPU ..............................................................245
9.5 Cabin processing unit (CPC) ..................................................246
9.6 Control panel ..........................................................................250
9.7 Operation of the APE .............................................................260
9.8 Brakes ....................................................................................271
9.9 Driving ....................................................................................275
9.10 Steering ..................................................................................278
9.11 Triggering of the hydraulic system .........................................280
9.12 Functional relations ................................................................284
9.13 Aisle detection and storage zones .........................................289
9.14 Release of options via code numbers ....................................293
9.15 Aisle end stop (option)............................................................294
9.16 Functional description ............................................................295
9.17 IG (induction guidance) .........................................................298
9.18 Interface to PPS connection (personnel protection system) ..308
9.19 Automatic swiveling / sideshift synchronization......................310
9.20 ***Battery discharge monitor ..................................................318
9.21 Hour meters............................................................................319
9.22 Cut-outs ..................................................................................320
9.23 Sensor units main lift ..............................................................322
9.24 Sensor units actual value steering .........................................329
9.25 Sensor bearing drive- and steering motor (control system)....336
9.26 Temperature sensor drive and pump motor ...........................341
9.27 Sensor unit auxiliary lift (version B) ........................................342
9.28 Sensor unit sideshift ...............................................................344
9.29 Sensor unit swiveling..............................................................347
9.30 Controlling the hydraulic system ............................................349
9.31 Control of the hydraulic system (HR1200-1400) ....................352
Version 1.2, 12.07.2006 9-237

9-238
9.1
Auxiliary Auxiliary Hydraulics Sensors
Sensors components components
Hydraulics CPC DPU

Controller Expansions Controller / IO
cabin Drive compart-
Block diagram of the control concept
ment
Pole cable
Fig. 9-1: Block diagram of the control concept

IG (inductive
APE Control Data logger
AC controller AC controller AC controller

GPR
Driving pump steering
3~ 3~ 3~
Block diagram of the control concept
Diagnosis, on-site configuration

Drive motor Pump motor Steering motor
Diagnosis, remote configuration
Version 1.2, 12.07.2006

CAN bus description
9.2 CAN bus description
9.2.1 CAN bus features
CAN = Controller Area Network (e.g. cars)
LAN = Local Area Network (e.g. stacker crane installations, chemical industry)
WAN = Wide Area Network (e.g. telephone networks)
• serial bus system

• transmission medium: twisted pair wiring
• important bus functions like data generating, synchronization, error detec-
tion are implemented from hardware side
• multi master capable means that all the processing units are equipped with
equal rights
• normal network distance: up to 40 m
• extension of the network up to approx. 1500 m possible when using re-
duced data transfer rates
• maximum data transfer rate: 1Mbit / s with a distance of 40 m
• high transfer safety
Meanwhile the CAN bus has established acceptance in many industrial fields.
Especially cars, commercial vehicles, agricultural machines, devices in medicine

technology, textile machines and smaller industrial installations are getting
equipped with CAN bus control systems.
All the involved control units are connected to the bus system in the same way (
physical coupling conform to ISO 11898):
Microcontroller
CAN Controller
TX0 TX1 RX1
5V
TxD RxD Ref V

CC
CAN Transceiver 100 nF
CAN_L Gnd
CAN_H
CAN_H
RT CANBusleitung
CAN bus network RT
CAN_L
Terminating resistor
Abschlußwiderstand Terminating resistor
Abschlußwiderstand
Fig. 9-2: CAN-bus plan Connection of a CAN node
Version 1.2, 12.07.2006 9-239

Overview of CAN BUS/RS232
9-240
CAN bus description
Programming Programming
unit unit
Fig. 9-3: CAN topology in the vehicle

CAN
expansion
Distributor
Distributor
CPC
DPU
CAN
expansion IG
Drive compart- Cabin

ment
Optional possible
Version 1.2, 12.07.2006

Components of the control systems
9.3 Components of the control systems
9.3.1 General information concerning the components
The entire control system consists of the three processing units:
• DPU (drive compartment processing unit)

• CPC (cabin processing unit)
• CPU (control panel processing unit)
The following pages describe the structure of the processing units and the individ-
ual components.
9.3.2 Drive compartment processing unit (DPU)
Function of the DPU
• connection and processing of all information arriving in the drive compart-

ment
• connection and control of all actuators located in the drive compartment
• serial exchange of data via CAN bus with the computers in the cabin
• connection of extension modules
• safety functions in accordance with the safety concept
Version 1.2, 12.07.2006 9-241

Structure of the DPU
9.4 Structure of the DPU
1 2 3 4 5 6 7 8
Fig. 9-4: Design DPU
1 Release relay 5 IG evaluation box (option)

2 Main contactor 6 The safety module (SIMO) contains the two
safety relays SF1 and SF2
3 DC DC converter 7 I/O module
4 Drive compartment distributor 8 Master controller
9-242 Version 1.2, 12.07.2006

Cabin processing unit (CPC)
9.5 Cabin processing unit (CPC)
9.5.1 Function of the CPC
• connection and processing of all information arriving in the cabin

• connection and control of all actuators located in the cabin
• serial exchange of data via CAN bus with the computers in the DPU and
CPU via CAN bus
• connection of extension modules
• safety functions in accordance with the safety concept
9.5.2 Structure of the CPC
1 2
Fig. 9-5: Design of CPC
1 Cabin distributor
2 Cabin controller
Version 1.2, 12.07.2006 9-243

9.5.3 Plug arrangement distributor board cabin
Fig. 9-6: Plug arrangement distributor cabin
9-244 Version 1.2, 12.07.2006

9.5.4 Control panel processing unit (CPU) and APE
Note
The functions of the control panel and the display and
programming unit (APE) are described in the operating
instructions.
Function of the CPU
The CPU board is mounted on the bottom plate of the right half of the control pan-
el. It contains the micro controllers, CAN bus connection modules, EPROM and
the NV-RAM.
• connection and signal processing for all operating elements

• connection and control of all display elements
• serial exchange of data with the APE and the computers in the cabin and
the drive compartment via CAN bus
1 2
4 3
Fig. 9-7: Design CPU
1 EPROM 4 X171
2 X90 5 5V supply 1A fuse, medium slow
3 NV-RAM 6 24V supply 1A fuse, medium slow
Version 1.2, 12.07.2006 9-245

Control panel
9.6 Control panel
9-246 Version 1.2, 12.07.2006

Control panel
9.6.1 Fixing of the control panel
View from load side, cover plate in front of gas pressure spring removed („right“
and „left“ refers to the view of the in the cabin).
1 2 3 4
5
8
Fig. 9-8: Control panel mount
1 Velcro fastener for APE fixing

2 APE
3 Control panel left side
4 4 mounting screws control panel left side
5 Support plate of the panel
6 Connection cable panel
7 Gas pressure spring for panel adjustment
8 4 mounting screws control panel right side
Version 1.2, 12.07.2006 9-247

Control panel
9.6.2 Disassembly / assembly of the control panel right side
Disassembly at closed control panel
Lifting of the key caps (24)
with screw driver

mount caps by pressing (snap sealing)
Disassembly at opened panel:
Preparation:
take off APE (velcro fastener)

pull off plug DSub (30)
unscrew right control panel from the support
unscrew fixing screws of the bottom cover (29), remove bottom cover
Dismantle of the board 2 / right side (34)
unscrew cable connector

loosen screws (35)
turn plastic screws (33) by ¼ revolution anticlockwise (snap sound)
Removal of the master switch (25) with potentiometer
remove board 2 / right side (34)

pull off cable connection from master switch potentiometer
loosen fixing screws (32) from the potentiometer (do not loose the distance
plates!)
loosen grub screw (size 1.5) in the red lever
pull off red lever
Dismantle of the board 1 / right side (36)

turn 6 plastic screws (37) by ¼ revolution anticlockwise (snap sound)
9-248 Version 1.2, 12.07.2006

Control panel
24 27 25 26
30
28 29
25
32 33 34
31
35
36
37
Fig. 9-9: Right control panel side
24 Push button 31 Button two-hand operation

25 Master switch driving 32 Screws
26 Control panel cover 33 Plastic screws
27 Potentiometer master switch 34 Board 2 / right side
28 CPU-board 35 Screws
29 Bottom cover 36 Board 1 / right side
30 Connector plug 37 Plastic screws
Version 1.2, 12.07.2006 9-249

Control panel
Remove button for two-hand operation (31)
(only if cable is defective) unscrew cable connector from board 1 / right side (36)
screw out the button by turning the black ring anticlockwise
unsolder cable connectors
when the cables must be changed, connect a piece of wire to the cable-end be-
fore pulling the old cables through the cable channel.
Remove push button support (24) from the cover
remove the respective board

loosen fixing screw (using a wrench size 18 mm)
Assembly at opened control panel
; Assembly is carried out in reverse order!
Special features:
Installation of the master switch (25) (with potentiometer)
insert the shims (if available)

insert the potentiometer
plug the red handle onto the potentiometer
tighten grub screw (size 1.5)
fix the potentiometer with the screws (32)
install board 2 / right side (34)
plug in the cable connector
Installation of the board 2 / right side (34)
Note
When installing the board, make sure that no LEDs will
be not damaged.
9-250 Version 1.2, 12.07.2006

Control panel
Installation of the two-hand operation button (31)
(when changing the cable) pull in new cable through the cable channel (connect
a piece of wire to the cable end before pulling the old cables)
(only if the cable has been replaced) fix cable connector on board 1 / right side
(36) with screws
solder cables to the button
before the installation: turn the button 4 rotations anticlockwise (cable is twisted)
screw the button clockwise into the support (cable is stretched again)
Version 1.2, 12.07.2006 9-251

Control panel
9.6.3 Disassembly / Assembly of the control panel left side
Note
The figures with the appropriate positions are on the
next pages.
Disassembly at closed control panel
Removal of the steering wheel
take off the white cap from the wheel (39)

open the countersunk screw
take off the wheel
; Assembly is carried out in reverse order.
Disassembly at opened control panel
Preparation:
take off APE (velcro fastener)

pull off plug DSub (42), unscrew connector plug AMP CPC (43)
unscrew left control panel from support
unscrew fixing screws of the bottom cover (41), remove cover
Dismantling the board 2 / left side (48)

turn plastic screws (47) ¼ turn anti-clockwise. (makes a snapping noise)
Dismantling the EMERGENCY OFF key (46)
unplug cable from the key (46)

turn key (46) by ¼ revolution and unplug it
Dismantling the horn key (52)
See EMERGENCY OFF key.
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Control panel
Dismantling of the board 1 / left side (51)
turn plastic screws (50) ¼ turn anti-clockwise. (makes a snapping noise)
Removing the master switch (45) with potentiometer
remove board 2 / left side (48)

remove EMERGENCY OFF key (46)
pull off cable connection from master switch potentiometer
loosen fixing screws (49) from potentiometer (do not loose distance plates!)
loosen grub screw (size 1.5) in the red lever
pull off red lever
Disassembling the steering transmitter (40)
disassemble steering wheel (39)

unscrew cable connection from board 1 / left side (51)
loosen 4 fixing screws from steering transmitter (40)
Removing button for two-hand operation (44)
see control panel right side.
Assembly at opened control panel
Special features:
Installing the master switch (45) (with potentiometer)

installation of the EMERGENCY OFF key (46) and the horn key (52)
Installing the two-hand operation button (44)
Version 1.2, 12.07.2006 9-253

Control panel
38 39 53 42 43
40
41 44
45 46 47 48
49
44
50
52 51
Fig. 9-10: Left control panel side
38 Cover 46 EMERGENCY OFF switch

39 Steering wheel 47 Screws
40 Steering transmitter 48 Board 2 / left side
41 Bottom cover 49 Screws
42 Plug DSub 50 Screws
43 Plug AMP CPC 51 Board 1 / left side
44 Button two-hand operation 52 Key, horn
45 Master switch lifting
9-254 Version 1.2, 12.07.2006

Control panel
9.6.4 Structure of the APE
54
55
56
57
58
59
60
61
Fig. 9-11: Structure of the APE
54 Cover sheet
55 Upper cover case
56 LC-display
57 Flat cable
58 Converter board
59 APE motherboard
60 O-ring
61 Bottom case
Note
Always pull off the upper cover (55) vertically.
Version 1.2, 12.07.2006 9-255

Operation of the APE
9.7 Operation of the APE
9.7.1 Displays and menus on the APE
The APE provides the following functions:
• basic display
• operator menu (battery, height, date and time)
• information display
• test page for the control panel
• service menu
9.7.2 Basic display
After switching on, the APE displays the message „Please wait - initialization“. Af-
ter 10 seconds the basic display appears.
Note
The basic display (see illustration) is provided for normal
operation of the vehicle.
The following key functions are available in the basic display:
Keys Function
<F1+F2> Selection info display (quit by pressing <F1+F4>)
<F4> Contrast darker
<F5> Contrast brighter
<F1+F6> Password display (quit by pressing <F1+F4>)
<F1+F3> SDO-editor
Please do not change anything!
The SDO-editor is not important for the service technician
(quit by pressing <F1+F4>)
<F1+F5> Control panel display

<F6> Service display configuration: M01

Adjustment
Date and time
9-256 Version 1.2, 12.07.2006

Schranke offen!
3h 0kg
F1 F2 F3 F4 F5 F6
Fig. 9-12: APE basic display
The key combination <F1+F6> for the access to the service menu is only to be
used by service personnel. With the first access, an access-code has to be en-
tered.
Each submenu can be quit by pressing <F1+F4>.
Note
After a wrong access-code has been entered, the vehi-
cle has to be re-started before further use.
Version 1.2, 12.07.2006 9-257

9.7.3 Key functions in editable menus
Selecting a menu item
select row by pressing <F2> or <F3>

confirm with <F6>
Note
The first row (headline) cannot be edited
Cursor
For the marking of input values, two different cursors are used:
• line cursor
• digit cursor
Line cursor
A line cursor marks a complete line. By pressing <F6> (ENTER) the function of
this line will be activated (e.g. an editing process).
Digit cursor
The digit cursor marks only a small part of the complete line. It flashes steadily and
marks an active function. After that, the keys <F2> and <F3> are used to change
the value.
In certain cases, e.g. while editing a number, the cursor can be moved to the de-
sired position by pressing the keys <F4> or <F5>.
Value input
During the input of a value the permitted range for the input will be displayed in the
last line of the display.
Note
Holding a key corresponds to repeatedly pressing the
button.
9-258 Version 1.2, 12.07.2006

Cancel / Escape
Every function can be canceled by the combination <F1+F4> (Escape-function).

Each menu can be left with this combination.
<F1+F4> means:
• <F1> actuate and keep pressed

• <F4> actuate
When <F1+F4> is pressed repeatedly, the user will be in the basic display.
9.7.4 Information display
The information display can be selected via basic display by <F1+F2>.
The information display contains the following information:
• occurring errors, divided into DPU, CPC and CPU (see chapter 8)
• serial number of the vehicle
1. software version numbers of DPU, CPC, CPU and APE
Quit the information display via <F1+F4>. The basic display will be activated.
Status
VZA VZK VZB

Error(s) Error(s) ok
Er161 H202
Er164
Er171
Serial-No: 018.005.430
Version VZA: 2.03.12
Version VZK: 2.04.17
Version VZB: 2.07.04
Version APE: 2.08.14
F1 F2 F3 F4 F5 F6
Fig. 9-13: Information display
Version 1.2, 12.07.2006 9-259

9.7.5 Control panel test page
To check all keys and switches on the control panel, there is a test page for the
control panel available. The test page can be selected via <F1+F5> from the basic
display.
The following functions are displayed graphically:
• function of the master switches

• function of the function keys
• function of the two-hand operation
• function of the steering wheel
Not displayed:
• function of the horn key

• function of the EMERGENCY OFF switch
Testing control panel functions
• press the corresponding control element

• while observing the display on the APE
Testing the master switch
• press the required master switch on a screen
§ Note
A line on the test display shows the selected direction. A
second line shows the set value in %.
To guarantee a maximum control, the value should start
at 0 and proceed continuously to 100.
Press any APE-key (except F1) to quit the test display.
9-260 Version 1.2, 12.07.2006

9.7.6 Service menu
Via service menu the vehicle configurations can be determined, all parameter ad-
justments can be taken and various diagnosis displays can be called.
DANGER!
Danger of life by improper operation
• Never hand over the vehicle to the operator when the
service menu is activated.
• Always switch off the vehicle, so that the basic display
is active after restarting the vehicle.
• Before handing over the vehicle to the operator make
sure that all vehicle functions work without errors!
• Never give this access code to unauthorized persons!
When the service menu is selected the first time, an access code is requested.
The access code is provided during the service training.
Note
After entering an inadmissible access code, the vehicle
has to be restarted again.
After the correct code has been entered, the service menu appears on the dis-
play. It provides the following functions:
• submenus for configuration

• status display
9.7.6.1 Submenu M01 "Control panel"
Date/Time as well as the discharging control can be configured in the submenu

“control panel“.
Version 1.2, 12.07.2006 9-261

9.7.6.2 Submenus with hydraulic topics
In the submenus “hydraulics“ the movements of each hydraulically actuated func-

tion can be adjusted, especially:
• starting ramps
• braking ramps
• maximum speeds
• creep speeds
• control ranges for the proportional valves
• number of rotations of the pump unit
A description of the activation of the current controller and the meaning of the in-
dividual setting parameters is in Proportional valve"” on page 9-277.
§ Note
The values for the startup and braking ramps as well as
the values for the actuation ranges should not be
changed compared with the values in the acceptance
certificate. All speeds of the functions can be adjusted
via speed parameters.
9.7.6.3 Submenu steering
The following adjustments are possible in the submenu steering:
• transmission of the steering wheel
With this function the transmission ratio for the steering wheel can be adjusted
customer-specific.
Higher values mean: more steering rotation per 180° wheel position
Note
A higher adjustment of the transmission ratio for the
steering wheel should only be done if the customer asks
for it!
• straight ahead correction
9-262 Version 1.2, 12.07.2006

If the electrical center position does not suit the mechanical center position, a cor-
rection can be carried out (Adjustment of the steering sensor unit"” on page 9-
326).
• setting of the control parameters for the steering
For the different steering situations, different sets of parameters can be adjusted:
• manual steering
• IG (induction guidance)-steering apron and IG (induction guidance)-steer-
ing aisle
The most important adjustment parameter for the service is the amplification.
This can influence the aggressiveness of the steering. Higher settings mean more
aggressive steering.
Note
The preadjusted values of the parameters for the ampli-
fication may not be changed! If problems with the steer-
ing function occur (e.g. on extremely rough or slippery
floors) the steering behavior can be adjusted via these
control parameters.
9.7.6.4 Submenu driving
All settings for the driving and brake function can be made in the driving menu:
Version 1.2, 12.07.2006 9-263

9.7.6.5 Configuration
Select function by pressing <F2> / <F3> and confirm with <Enter>.
Following functions are available in the service menu:
Keys Cursor Function

<F2> line cursor select next line (down)
digit cursor decrease value
<F3> line cursor select next line (up)

digit cursor increase value
<F4> line cursor -

digit cursor select next decimal position
<F1+F5> line cursor delete actual value status display

digit cursor select decimal position below
<F6> line cursor submenu:

call submenu
parameters:
edit (switch-over to character cursor)
teach-in:
start TeachInprocedure
edit:
digit cursor saving actual value (if valid)
return to line select
teach-in:
save value
<F1+F4> line cursor main menu:

switch to basic display
submenu:
switch to main menu
digit cursor cancel edited value

<F1+F3> line cursor switch to status display

digit cursor -
9-264 Version 1.2, 12.07.2006

Plausibility check
On pressing <F6> (ENTER) only valid values are accepted. Wrong values are re-
jected. A corresponding status message is displayed at the bottom of the display.
The minimum and maximum setting values are also displayed here.
TI06 Teach-In top

TI07 Teach-In bottom
G20 End ahead top 300
G21 End ahead bottom 300
G22 Height 5400
R08 Braking ramp lift 30
R09 Braking ramp lower 20
R10 Accel. ramp lift 20
R1 1 Accel. ramp lower 15
V08 Speed max lift 100
V09 Speed max lower 100
V10 Slowspeed lift 64
V11 Slowspeed lower 29
I04 Current min lift 120
I05 Current max lift 490
I06 Current min lower 200
I07 Current max lower 500
D00 RPM max lift 2500
D01 RPM min lift 2500
D02 RPM Prop. lift 950
D03 RPM Prop. lower 550
V30 Switch speed RPM Prop. 17
1 F1 F2 F3 F4 F5 F6
Fig. 9-14: Status messages

1 Display area min and max values

• Service parameters in Setup work"” on page 10-357.
Version 1.2, 12.07.2006 9-265

9.7.6.6 Status display
This menu can be used as online-diagnosis-system. It allows the displaying of dif-

ferent control parameters of the SECAN-control (SECAN operands) on the control
panel display. Die The status display can be called up with <F1+F3> and canceled
with <F1+F4>.
Arranging the status display
select desired line to display a certain operand by <F2> or <F3>

activate line by pressing <F6> (ENTER)
select operand type via <F2> or <F3> (E, EA, A, AA,...)
confirm with <F6> (ENTER)
select counter number of the operand: select decimal position via <F4> or
<F5>, increase or decrease value via <F2> or <F3>.
confirm with <F6> (ENTER)
M26 Zustandsanzeige
Z00 EA 101 512

Z01 EA100 1008
Z03
Z04
Z05
Z06
Z07
Z08
Z09
Z10
Z11
Z12
Z13
Z14
Z15
Z16
Alle Einträge löschen
F1 F2 F3 F4 F5 F6
Fig. 9-15: Status display
Note
While an operand is selected or edited, the displayed
states of the operands are not actualized.
9-266 Version 1.2, 12.07.2006

Brakes
9.8 Brakes
9.8.1 Braking system description
Available braking systems:
• spring-loaded brake system, actuated via safety circuit

• load wheel brake system, actuated via vehicle control system
• counter current brake, actuated via vehicle control system SECAN and the
AC-motor controller
• automatic counter current brake system
• coasting brake system, actuated via vehicle control system SECAN and the
AC- motor controller
9.8.2 Spring-loaded brake system
The braking is carried out via a mechanical braking system, that is activated via
spring pressure and released electrically.
To release the brake, there is a safety circuit installed, that can be effected by hard-
and software side. On the safety module (SIMO), there are two safety relays,
whose contacts control the coil of the magnetic brake.
There are two different mechanisms for triggering the spring pressure brake:
• Components that are integrated into the vehicle steering system and thus
into the communication system do not act directly on the braking circuit by
means of their release contacts, but instead switch the safety relays. Moni-
toring of the correct switching function is effected by means of feedback
contacts of the relays.
• Components that are not integrated into the communication system directly
act on the braking circuit by means of their release contacts. Also in this
case, via signal return line, it can be checked, if a braking has been actuated
or not.
The mechanical braking system serves as an emergency braking, as well as a

stopping brake and is activated always, if one component, that is integrated into
the safety circuit, releases an emergency stop.
Version 1.2, 12.07.2006 9-267

Brakes
9.8.3 Load brake system
In addition to the spring-loaded brake system the vehicles are equipped with an
electrical load wheel braking system.
The system consists of the following components:
• multiple plate brake in both load wheels (description see chapter 4)

• control cable
Note
The load wheel brake is released when the vehicle is
switched off.
9.8.4 Actuation of the load wheel brake
Control is via the PWM control outputs. They are controlled parallel to the trigger-
ing of the spring-loaded brake.
9.8.5 Setting of the load wheel brake
The load wheel brake is set via the corresponding parameter or fixed value.
9-268 Version 1.2, 12.07.2006

Brakes
9.8.6 Electrical braking system
All the vehicles are equipped with an electrical braking system (regenerative), that
can be adjusted in its braking effectiveness via service menu. The following brak-
ing states are differentiated:
• coasting brake, when the operator releases the control lever; (adjustable)
• reduce brake, when the driver leads the control lever slowly back, to get a
slower speed or when the vehicle is automatically switched from normal
speed to creep speed, e.g. with masterspeed; (adjustable)
• manual counter current brake, when the driver moves the control lever in re-
verse direction. The braking effectiveness is increased linear with the move-
ment of the control lever in reverse direction. The limit values (min / max
braking) are adjustable in the service menu.
• automatic counter current brake, effective with aisle end stop
For smooth transitions of the brake phases
• set coasting brake and reduce brake to the same value

• set also the min-value of the counter current brake to this value
The regulations for the braking distance to be adjusted, always refer to a maximum
activated counter current brake.
Version 1.2, 12.07.2006 9-269

Brakes
9.8.7 General emergency stop
General emergency stop is a status, where the vehicle control system switches all
functions into a secure status. No vehicle-movement is possible. The cause for
this emergency stop can have several reasons:
• a serious problem was detected by the control system; error message, that
is assigned to the category emergency stop (see error table).
In this case, the safety braking circuit is opened from hardware side.
• chains are slack or broken (release of emergency stop by vehicle control

system)
• safety barriers are opened (release of emergency stop by vehicle control
system)
• external component has released emergency stop
• other cause (vehicles with special components)
9.8.8 Functional emergency stop
This kind of emergency stop disables only the function concerned; all other func-
tions can be used normal or in creep speed.
The cause of a functional emergency stop is always a function-related failure in

the control system. The emergency stop is released by the vehicle control system.
9-270 Version 1.2, 12.07.2006

Driving
9.9 Driving
The driving function is carried out via a speed-controlled asynchronous motor and
an AC-controller.
Release of the driving function is implemented both via the CAN bus and as a sig-
nal from the SECAN control and is switched through when:
• no emergency stop from the computer system is active

• the foot switch is pressed
• no driving cut-out is active (e.g. lifting height related driving cut-out)
The driving directions are released by the control via CAN to the AC-controller.
The set value is transmitted from the control via CAN.
The rotation feedback of the drive motor to the AC-controller is carried out by a
sensor bearing with 64 pulses/R.
An occurring fault in the AC-controller is reported to the SECAN-control via an er-

ror code interface. From there, the error code can be called via a tag. Additionally,
directly on the AC-controller occurring failures are displayed on a flashing LED.
9.9.1 Drive speeds
There are four adjustable drive speeds:
• creep speed 2.5 km/h with fixed surveillance

• increased creep speed 4.0 km/h with fixed surveillance
• maximum speed in the apron with adjustable surveillance
• maximum speed in guided operation with adjustable surveillance
The release of the speeds depends on the respective vehicle states. See function
table.
If the speed control is activated, the release of the driving motion is reduced, until
the permitted speed is below the allowed speed.
Version 1.2, 12.07.2006 9-271

Driving
9.9.2 Masterspeed and Masterspeed Plus (option)
In the guided state (narrow aisle), the driving speed is reduced to creep speed (2.5
km/h) depending on the weight (option), driving direction and the lift height (h3).
For this, weight detection is required. After calibrating the weight detection, the fol-
lowing parameters must be set in the M21 Masterspeed menu (Service menu /
Setting parameter"” on page 10-358). The corner points are set separately accord-
ing to the driving direction.
Note
The maximum weight is taken from the Load Sensor
menu.
Switch-over height h3 to crawl
G52/G53
e.g.
7.0 m
G50/G51 Load max.

No Masterspeed
5.5 m
4.5 m
Weight
P21/P22 Load max.
= min. load
approx. 100 kg applies with-
Fig. 9-16: Assignment of the parameters
9-272 Version 1.2, 12.07.2006

Driving
9.9.3 Adjustment of driving motion and electrical brake
The adjustment can be done in the menu “Driving“.
As the vehicles are speed-controlled, it is only necessary to edit the speed in km/
h for the desired parameter. The vehicle itself controls onto this speed, indepen-
dent from load or temperature.
Start-up acceleration can also be set to a limited degree. This should be done at
the customer according to local conditions and the operators wishes.
The permitted values of the electrical brake are written down in the acceptance
certificate.
§ Note
For reasons of stability, the brake action must not be ad-
justed higher than permitted. The adjusted deceleration
has to be proofed and documented by the use of a de-
celeration device.
Version 1.2, 12.07.2006 9-273

Steering
9.10 Steering
The steering system is a purely electrical system.
It consists of a steering controller with a speed controller for an asynchronous mo-

tor.
Fahrzeugsteuerung AC-Motor- 3~
(SECAN) steuerung Motor
Lenkrad
Lenkwinkel-Vorgabe
Sensorlager
IF
Potentiometer
Lenkwinkel-Erfassung
Inkrementalgeber
Fig. 9-17: Steering system (the sensor systems for feedback can be of different types)
The steering controller can either operate on a manual set value (turning the steer-
ing wheel) or a set value from a connected guidance system (e.g. wire guidance).
As a nominal value indicator (steering wheel) is used a double sensor bearing with
64 impulses per rotation. The nominal value indicators are evaluated in the control
panel. The vehicle control system thereby generates a set value (speed) which
can then be transmitted to the AC controller via CAN.
Various sensor systems can be used for detecting the steering angle of the
steered wheel:
• Double (redundant) conductive plastic potentiometer

• Digital absolute-value device
• High-resolution incremental transmitter
• Sensor bearing of the steering motor
Depending on the equipment, various different systems or even combinations of

systems can be used. The redundant conductive plastic potentiometer is used as
the standard system.
9-274 Version 1.2, 12.07.2006

Steering
Adjustment of the steering
The sensor system is set in accordance to the description in Sensor units actual
value steering"” on page 9-325. The steering behavior and the control parameters
can be set via the service menu).
In the service menu, the control parameters for the different steering states are ad-
justable.
The steering control parameters for the special operating states (manual steering,
IG-steering) are largely identical on electrically rpm-controlled steering systems.
§ Note
The standard control parameters, adjusted ex works,
generally must not be changed.
Interface for the steering AC-controller
The release signal of the steering function is sent from the SECAN-control to the
AC-steering-controller via CAN bus, if:

• driving release signal activated or vehicle is rolling
The set value from the SECAN is also sent to the AC-steering-controller via CAN
bus.

ror code interface. From there, the error code can be called via a tag. In addition,
failures occurring directly on the AC-controller are indicated by means of a flashing
LED.
Version 1.2, 12.07.2006 9-275

Triggering of the hydraulic system
9.11 Triggering of the hydraulic system
9.11.1 Triggering of the pump unit
The pump unit is designed as a speed-controlled three-phase current asynchro-

nous motor, like the drive motor and steering motor.
The advantage of the speed control is, that with a certain set value there is an ex-
actly defined amount of oil for hydraulic movements assured.
The number of rotation signal for the motor is generated in the SECAN-control.
There are functions, that are triggered by a constant number of rotations, where
the speed of the function can be controlled via proportional hydraulics by the op-
erator. In addition, there are functions, that are used with variable number of rota-
tions, that means, the operator controls the speed of the functions via number of
rotations of the motor. Then the according hydraulic circuits are opened complete-
ly.
Interface AC-controller
The pump is activated via two activation paths:
• CAN bus
• Hardware path (redundant safety switch-off path))
The release of the pump is sent from the SECAN-control via CAN bus, when:

• no cut-out active (e.g. lifting cut-out)
The set value from the SECAN-control is also transmitted via CAN-bus.
The feedback for the number of rotations of the pump unit to the AC-controller is
done by a sensor bearing with 80 impulses.

ror code interface. From there, the error code can be called via a tag. Additionally,
directly on the AC-controller occurring failures are displayed on a flashing LED.
While lowering the main lift pump unit works as a generator and returns energy
into the battery. The power of the feedback current depends on the applied load
and the adjusted lowering speed.
9-276 Version 1.2, 12.07.2006

9.11.2 Proportional valve
The hydraulic movements in the Hi-racker 1200/1400 AC are controlled in one of

two ways:
• Variable pump speed at constant valve opening of the proportional valve,

e.g. for the main lift
• Variable valve opening of the proportional valve at constant pump speed,
e.g. for the sideshift
The corresponding valves are integrated into the hydraulic blocks.
Functioning description:
The proportional valve controls the flow-oil volume owing to the electrical input sig-
nal applied on it.
A current, running through a magnet coil, creates a magnetic force in the valve,
that moves the internal slide proportionally to the current and lets an according oil
flow pass.
The control- and power electronic (amplifier) of the proportional valves is com-
pletely integrated into the SECAN-control-system. The required variable current
for the proportional function is created via pulse width modulation (PWM), that
means by an impulse order with different ON/OFF ratio at constant frequency (see
illustration).
24 V 24 V
12 V
1 1
6V
Fig. 9-18: Pulse width modulation
1 average
The signal level can be determined through button ratio. The pulse frequency is
so high that the coil can not follow every pulse. The magnet therefore forms the
middle valve of the signal pulse. The width of the ON-impulses in relation to the
width of the OFF-impulses determines the average value and thus the signal level.
Version 1.2, 12.07.2006 9-277

The voltage impulses are converted into suitable signals for the flow valves by the
power electronics.
It is assured, that temperature changes of the coil, and thus resistance changes,
as well as fluctuations in the power supply have no effect on the control current.
Also friction forces, that can cause hysteresis are avoided by a so-called dither
signal, an AC-signal that is superimposed onto the control signal. The adjusted
dither frequency is approx. 50 Hz, the dither amplitude is approx. 50% of the con-
trol signal.
General information for the adjustment of the proportional

valve
Note
This only applies to movements that are controlled via
the proportional valve.
The normal, useable range of the proportional valve is approx. between 150 mA
and 550 mA, that means with an activating current of 150 mA the valve begins to
open, with an activating current of 550 mA, it is fully opened. As all the different
hydraulic functions have different activating ranges, but are actuated by the same
valve or control lever, for each function a special current range can be defined,
within the activating takes place.
In this way the full range of the control lever stays in disposition for the opening
and function of the proportional valve.
Transmission Actuation
actuation (%) control lever
Valve opening (%)
(%)
Gray background:
adjustable values
100
For example, see text
75 100
Vmax
v_max 100
50
0 0
25
0 100 200 300 400 500 Current I (mA)

min
Imin IImiax
max
Fig. 9-19: Control design
9-278 Version 1.2, 12.07.2006

The control range (Imin and Imax) can be set separately in the hydraulics menu. In
these menus there are initial settings for the proportional valve and they can be
only readjusted for fine tuning of the movement (e.g. lowering speed). The set
fine-adjustment of the speed (e.g. lowering speed is now set in the hydraulics
menu as a % of the scale!
Example lowering auxiliary lift:
Minimum current value: 250 mA

Maximum current value: 450 mA
To reach the desired lowering speed of 0,3 m/s for example, in the menu item
"v_max_lowering" the % value of the scale can be adjusted. If, e.g. the value
"75%" is set, this means: At a full deflection of the control lever, the current con-
troller is controlled at 75% of the available control range, e.g. in our example at
400 mA!
With this kind of activating for each movement an optimum dosage can be
reached.
Version 1.2, 12.07.2006 9-279

Functional relations
9.12 Functional relations
9.12.1 Driving
General release conditions:
• doors closed
• footswitch actuated
• chains not slack
• direction signal actuated
• set value present
• release of safety circuit of brake
Function Condition
driving apron full speed h3 + h9 < 0,5 m, steering angle < rq and LLD (load
lifting device) in initial position
driving apron 4.0 km/h 0.5 m dh3 + h9 d3,0 m and steering angle < rq
driving apron 2.5 km/h 3.0 m < h3 + h9 dhcrit (*) or h3 + h9 > hcrit (*) and
steering angle drq
guided driving full speed for- two-hand operation, h3 < h3crit forward and LLD in
ward initial position
guided driving full speed back- two-hand operation, h3 < h3crit backward and LLD in
guided driving 2.5 km/h for- two-hand operation, h3 > h3crit forward or LLD not in
guided driving 2.5 km/h back- two-hand operation, h3 > h3crit backwards or LLD not
ward in initial position
(*) hcrit is the critical lifting height for the apron. It is pre-adjusted vehicle specific
and documented in the acceptance certificate of the vehicle.
h3crit_forward/backward are the critical lifting heights for the guided operation of
the vehicle.
Note
The actual permitted driving speed can be influenced by
further function modules (IG, PPS).
9-280 Version 1.2, 12.07.2006

9.12.2 Manual steering
• vehicle in the apron

• two hand operation actuated or
• driving speed z 0
9.12.3 Lifting / lowering the main lift
• doors closed
• two-hand operation
Function Condition
release lifting full speed h3 < end ahead top, load lifting device in initial posi-
tion, initialization of main lift completed
release lifting slow speed h3 > end ahead top or load lifting device not in initial
position or failure in the lifting system or initialization
of main lift not completed
release lowering full speed h3 > end ahead bottom and load lifting device in initial
position
release lowering slow speed h3 < end ahead bottom or load lifting device not in ini-
tial position or failure in the lifting system; initialization
of main lift not completed (above 0.3 m)
Version 1.2, 12.07.2006 9-281

9.12.4 Lifting/lowering the auxiliary lift
• doors closed
Function Condition
release lifting full speed h9 < end ahead top and load lifting device in initial po-
sition
release lifting slow speed h9 > end ahead top and load lifting device not in initial
position or failure in the lifting system
release lowering full speed h3 > end ahead bottom and load lifting device in initial
position
release lowering slow speed h3 < end ahead bottom load lifting device not in initial
position or failure in the lifting system
9-282 Version 1.2, 12.07.2006

9.12.5 Sideshift right / left
• doors closed
Note: In the end position of the selected direction, the movement is stopped.
Function Condition
release sideshift full speed the sideshift position is not in the end ahead range of
selected direction
release sideshift slow speed the position of the sideshift is in the end ahead range
of selected direction
9.12.6 Swiveling right / left
• doors closed
Note: In the end position of the selected direction, the movement is stopped.
Function Condition
release swiveling full speed the sideshift position is not in the end ahead range of
selected direction
release swiveling slow speed the position of the sideshift is in the end ahead range
of selected direction
Version 1.2, 12.07.2006 9-283

9.12.7 Automatic synchronous swiveling right / left
• doors closed
The synchronous movement is a controlled automatic procedure. In case of a de-

tected collision, the swivelling motion stops and the pallet is returned into the ve-
hicle contour by the sideshift movement.
9-284 Version 1.2, 12.07.2006

Aisle detection and storage zones
9.13 Aisle detection and storage zones
9.13.1 Aisle detection (standard and optional)
For the narrow aisle recognition, the Hi-Racker 1200/1400 AC can be equipped
with different aisle recognition systems. In general, locking magnet switches are
used, which are switched on by north pole and off by south pole. The floor instal-
lation of the aisle magnets can be taken from the drawing. As an option, light-op-
tical aisle detection can be used.
Overview track widths:
As a standard, there are three aisle detection tracks supported:
track 1: 170 mm
track 2: 280 mm
track 3: 690 mm
The aisle detection is done via double installed magnet switches (redundancy).
Note
Adjustments of the aisle detection on already existing
warehouses are possible as an option.
Version 1.2, 12.07.2006 9-285

Aisle codes
From the three aisle recognition tracks, eight different storage zones according to
the following table can be realized by combination.
Code val-
Storage zone Track 3 Track 2 Track 1
ue
0 (apron) 1 0 0 0
1 (aisle 1) 2 0 0 1
2 (aisle 2) 4 0 1 0
3 (aisle 3) 8 0 1 1
4 (aisle 4) 16 1 0 0
5 (aisle 5) 32 1 0 1
6 (aisle 6) 64 1 1 0
7 (aisle 7) 128 1 1 1
everywhere 255
Each storage zone consists of a combination of the 3 available tracks. As this is a

dual digit system, each storage zone relates to a dual digit. The decimal calcula-
tion , corresponding to the dual digit is the storage zone. To build up combinations
of storage zones, for each storage zone a code must be created as follows:
Code value = two high storage zone, i.e.: Code value = 2storage zone
Example: storage zone 5
Aisle track 1 and 3 --> dual digit 101 --> decimal digit 5 --> code value = 2 5 = 32
It is possible to assign individual special functions (e.g. lift cut-offs) to individual

storage zones.
Combinations of storage zones
To build up combinations of storage zones, the sum of the single code values has
to be created.
Example:
A customer has got 4 storage zones, apron, aisle 1, aisle 2 and aisle 3.
In aisle 2 and aisle 3 a main lift cut-out at 4500 mm has to be installed. Therefore,
in the service menu main lift cut-out the following value has to be entered:
storage zone = code value aisle 2 + code value aisle 3 = 4 + 8 = 12
With this, the main lift cut-out is only in aisle 2 and in aisle 3 active.
9-286 Version 1.2, 12.07.2006

Installation of the floor magnets (GESI + aisle detection 1))
Achtung! Bei vxmax = 10,5 km/h

1) = 7.200 mm
Einbau quer zur

Fahrtrichtung
Quadermagnet GESI
Nord
Süd
Gangerkennung
Rundmagnet Vergussmasse
Gangerkennung Wichtig:
Bei GESI-Magnet Nordpol
immer nach oben montieren!
Nordpol GESI GESI
rückwärts vorwärts Prüfung mit Rundmagnet:
Abstoßung Nord-Nord
Südpol
b = 2.000 bei Systemrichtung
vorwärts (in Lastrichtung)
Vergußmasse
b = 150 bei Systemrichtung

rückwärts
b = 2.000 bei Systemrichtung

vorwärts/rückwärts
N: Nordpol (Ansenkung oben)

S: Südpol (Ansenkung unten)
a = Spurbreite
690 mm 3. Spur
Regalständer 280 mm 2. Spur
Umsetzgang 170 mm 1. Spur
Fig. 9-20: Installation of the floor magnets (GESI + aisle detection)
Note
All distances are customer-specific. Observe vehicle
documentation!
Version 1.2, 12.07.2006 9-287

9.13.2 Wire guidance with aisle detection (IGwoA)
As standard there is no aisle detection installed in the Hi-Racker 1200/1400 AC

with IG.
The following points must be heeded:
• activation of the IG-guidance without aisle detection (IGwoA) using code 01

and code 22
• if only code 01 is released, the vehicle is operated in the normal manner, i.e.
with separate aisle detection (IG-guidance with aisle recognition, IGwA)
• after the vehicle has successfully engaged on the wire, the state marker
MZ232 is set to "95" (vehicle in aisle). All functions that are only permitted
in aisles (e.g. diagonal driving) are released
• this "aisle detection" is not embedded into the aisle coding system or the
storage zone described in Aisle detection (standard and optional)"” on page
9-285.
• if other aisle-dependent additional functions, e.g. aisle-dependent lifting cut-
offs or sideshift cut-offs are required, aisle detection magnets and aisle de-
tection switches must be installed
In special cases, it is possible by releasing the option code 23 to use the
engaged state as a storage zone for releasing additional functions. Howev-
er, a previous safety-techical inspection is indispensable.
• for IG without aisle detection, certain safety-related notes are important.
These are included in the operating instructions and must be heeded!
9-288 Version 1.2, 12.07.2006

Release of options via code numbers
9.14 Release of options via code numbers

In the Hi-Racker 1200/1400 AC software there are already optional functions inte-
grated, that can be activated by input of the correct code number in the service
menu.
Note
Stored options see Setup work"” on page 10-357.
For each option there is an own vehicle-specific code number.
To release the options proceed as follows:
• The code number for the function to be released must be known.

• In the service menu, select the required code ID corresponding to the code
number M15 „Option code 0-15" or M16 „Option code 16-29".
• Enter the five-digit code number via UP-/DOWN-keys and confirm with “EN-
TER“
Note
If an incorrect code number is entered then all functions
are blocked. To be able to continue to work, the vehicle
must be switched off and then back on.
The code numbers for options installed from factory side are mentioned in the ac-
ceptance certificate.
For options that have to be installed afterwards, the according code number has
to be purchased / obtained from the manufacturer.
§ Note
The purchased code number has to be written down in
the acceptance certificate.
Version 1.2, 12.07.2006 9-289

Aisle end stop (option)
9.15 Aisle end stop (option)

In the SECAN-control there is an end of aisle protection device (GESI) integrated,
that can be activated and configured optionally
The GESI-system is largely integrated into the SECAN-concept, that is, no exter-
nal control components need to be integrated. As standard, the trigger system
consists of 4 solenoid switches, each with two active switches for each travel di-
rection.
All further GESI-specific information are taken from the sensor system of the ve-
hicle. As standard, the counter-current brake is activated when the GESI-system
has been triggered. The second braking circuit (magnetic brake) is automatically
switched on if defects have been detected in the counter-current brake system. Si-
multaneously, a corresponding system message appears. Triggering the brake
system and monitoring is carried out via two channels.
9-290 Version 1.2, 12.07.2006

Functional description
9.16 Functional description
9.16.1 GESI with manual reset (code 0 activated)
The vehicle brakes down from full speed to standstill automatically before it reach-
es the end of the aisle. Driving can be continued only after an active manual reset.
Standard.
At the braking procedure has ended, the operator must acknowledge the GESI-
function (reset) before the normal driving function is released again. A button is
provided for this purpose on the control panel (R15 console segment right side).
The actual status of the GESI is shown on the control panel (APE). As soon as the
vehicle breakdown to standstill, the message “RESET GESI“ appears on the APE.
The reset function can be activated by pressing the button R15 on the right side
of the console segment.
V m/sek.
Vmax
t sek.
GESI Reset
Version 1.2, 12.07.2006 9-291

9.16.2 GESI with auto-reset (code 8 activated)
a) Braking to creep speed
Standard function, however:

• the vehicle brakes down from full speed to creep speed (not standstill)
• full speed only possible after reset
• reset conditions:
1. automatically when leaving the aisle
2. as soon as the vehicle drives backwards (inverse direction) and passes the
GESI magnets in the floor
Full speed is released when the danger zone has been left between the GESI
magnet and the aisle departure magnet (aisle detection). Between GESI magnets
and aisle recognition magnets the vehicle can be driven only in creep speed.
V m/sek.
Vmax
Vschleich
t sek.
GESI
b) Braking to standstill then creep speed (option) (code 0+8)
The vehicle automatically brakes down to standstill and can then automatically be
driven in creep speed.
For reset conditions see a).
V m/sek.
Vmax
Vschleich
t sek.
GESI
9-292 Version 1.2, 12.07.2006

Note
On IG-vehicles with aisle detection by wire and on vehi-
cles with aisle detection by light cells, is available only
GESI with manually reset.
Following GESI error status are recognized and shown on the APE:
• failure of one or both channels

• to big difference between both channels
• weak brakes (brake distance too long)
• driving speed too high (brake distance too long)
• error of the control system or sensors
9.16.3 GESI with positioning set-up (distance measurement)
As a special application, it is possible with GESI and an additional aisle detector

to set up a positioning system. After driving over the GESI magnet and the magnet
of the second aisle detector, it is possible to set a distance after which the vehicle
stops. Only driving in the opposite direction is possible.
You are welcome to use this option for correct positioning at transfer stations or as
a mandatory stop system before walls.
Version 1.2, 12.07.2006 9-293

IG (induction guidance)
9.17 IG (induction guidance)
9.17.1 System overview IG (induction guidance)
The IG system consists of the following components:
Sensors
• Front microsteering sensor (MSS): mounted in front of the load-bearing

wheel axle it determines inductively the distance to the guide wire (with al-
ternating current).
• Rear microsteering sensor (MSS): mounted behind the drive wheel axle it
determines inductively the distance to the guide wire (with alternating cur-
rent).
• Analysis unit: This electronic system analyzes the signals from MSS in front
and behind and calculates a distance signal. This distance signal is trans-
mitted to the SECAN II control system via CAN bus.
• Sensor bearing drive motor: Registers the driving speed and direction. The
signals are transmitted via CAN bus (see chapter 7).
• Measured value-steering sensor: Registers the steering-angle of the drive
wheel. The signals are transmitted to SECAN-control-system (see chapter
7).
• Nominal value indicator for manual steering (set value sensors for steering):
Registers the movement of the steering wheel on the control panel for man-
ual steering; it is a standard part of the SECAN-control-system.
Actuators
• Steering system: Adjusts the steering angle of the drive wheel; in the Hi-
Racker 1200/1400 AC, it is designed as an electrical steering system as
standard.
• Mechanical brake: Permits braking of the vehicle to a standstill. It is activat-
ed in case of an emergency stop; together with the claw, it prevents a colli-
sion of the vehicle with the rack. The mechanical brake system is
constructed so, that it closed (brake active) if the power supply fails. It is
controlled and monitored using two channels.
• Mechanical steering angle limitation (optional claw): It limits mechanically
the steering angle of the drive wheel to a preset range (± 1°). It is activated
(claw falls down) when entering an aisle; together with the mechanical
brake system, it prevents a collision of the vehicle with the rack due to un-
controlled steering if the steering system fails. The claw is designed so that
it is activated (claw falls down) if the power supply fails.
9-294 Version 1.2, 12.07.2006

SECAN-vehicle control system
• Drive compartment processing unit (DPU): In addition, the algorithms of the

IG track control are calculated.
• Control panel processing unit (CPU): The operating and display elements
for the IG are integrated in CPU. In addition, the nominal value indicator for
manual steering is analyzed there.
9.17.2 Tasks of the IG
The IG (induction guidance) coordinates the steering, according to the operating

mode selected by the operator:
• in manual operation, the steering angle is always manually preset by the op-
erator
• in IG operation mode, the steering angle is automatically preset. The vehi-
cle is at first engaged onto the IG wire and then drives so that the distance
and angle of the long axis of the vehicle compared to the IG guide wire is as
small as possible.
• Manual operation is only possible in the apron (exception: emergency op-
eration in aisle).
• in IG operation with aisle detection (IGwA) fast driving in an aisle is only
possible if the vehicle was successfully engaged onto the wire in the apron,
an aisle signal is available and the claw is activated (vehicles with claw
only).
in IG operation without aisle detection (IGwoA) full speed is possible if the ve-
hicle was successfully engaged onto the wire and the claw is activated.
Note
More detailed information regarding IG with / without
aisle detection see operating instructions.
Version 1.2, 12.07.2006 9-295

Safety functions of the IG
The IG-SECAN controls the following statuses:
• the aisle signal may only be switched on after a successfully IG wire en-
gagement (vehicles with aisle detection via magnet switches)
• inclination of the vehicle to the IG wire
• distance of the vehicle center to the IG wire
• maximum value for distance in combination with inclination must not be ex-
ceeded
• dynamic adjustment of the valid maximum values for distance and inclina-
tion to the current driving speed
• measurement of the valid distance of the IG sensors
• maximum actual value of steering angle dq
If these requirements are not fulfilled, an immediately emergency stop of the vehi-
cle is released.
The control of the remaining components of the SECAN-system (e.g. the steering
system, driving sensor system and the steering incremental transmitter) is part of
the SECAN-safety concept.
9.17.3 Operation of the IG
Note
Description see operating instructions. Pay attention to
the differences between wire guidance with aisle recog-
nition (IGwA) and wire guidance without aisle recogni-
tion (IGwoA).
When engaging the vehicle onto the wire pay attention, that the first sensor moves
towards the wire according to the driving direction. So long as both sensors are
not shown on the APE do not engage the IG button, the vehicle can not be en-
gaged onto the wire.
The SECAN-control can cancel the engaging procedure, if
• the engaging angle is too large

• other conditions do not permit engaging
In this case, the online help text “IG not engaged“ appears and the brake is acti-
vated. Pressing the IG button sets the vehicle back to manual operation.
9-296 Version 1.2, 12.07.2006

9.17.4 Safety concept of the emergency stop diamond
In an aisle (at IGwA), the position of the vehicle with respect to the IG wire is mon-
itored using an emergency stop diamond. The following parameters are included
in the diamond calculation:
• vehicle geometry
• reaction and dead times
• braking delay
• driving speed
• starting conditions
Each vehicle has a vehicle-specific emergency stop diamond, based on its maxi-
mum inclination and maximum distance from the wire. The diamond is permanent-
ly programmed in the EPROM. This emergency stop diamond is designed for a
maximum driving speed of 8.0 km/h in an aisle as standard. Optionally, the emer-
gency stop diamond can also be designed for higher maximum speeds (pay atten-
tion to the acceptance certificate!).
The emergency stop diamond works dynamically to guarantee that the availability
of the vehicle is as high as possible: On driving with lower speed, higher deviations
are allowed than in driving with higher speed.
The vehicles are equipped with the new IG 5 system.
The IG 5 system functions as follows:
The control does not trigger an emergency stop if the vehicle is running in
diamond 4 (> 7 km/h), in diamond 3 (> 5 km/h till 7 km/h) or in diamond 2 (>
2.5 km/h till 5 km/h), i.e. even if the emergency stop diamond has been
passed (distance to the wire and inclination to big). The permitted driving
speed is automatically reduced till the next biggest emergency stop dia-
mond is effective. At the same time the software calculate a bigger steering
angle (that suits to this speed) allowing the vehicle to come back onto the
wire. As soon as the safety conditions are fulfilled, the software switched-
over to the next bigger accepted driving speed.
An emergency stop is released, if the emergency stop diamond for the lowest pro-
vided driving speed is passed.
An emergency stop is released, if
• the combination of the inclination (angle of the vehicle to the wire) and dis-
tance to wire for a driving speed below 2,5 km/h, is outer of the defined safe-
ty diamonds
• the vehicle exceeds the maximum permitted speed (v_max).
Version 1.2, 12.07.2006 9-297

Abstand (MA148)
Schrägstellung (MA147)
4
3
2
1
Diamond 1: v < 2.5 km/h
Diamond 2: 2.5 km/h < v < 5.0 km/h
Diamond 3: 5 km/h < v < 7.0 km/h
Diamond 4: 7.0 km/h < v < v_max
9.17.5 Wire signal control
Apron: In the apron, the maximum permitted deviation from the wire approximate-
ly corresponds to the range of the MSS. If an MSS loses the wire signal (e.g. also
if the engaging angle is too large), the vehicle is stopped (no error, thus no emer-
gency stop!). After braking to a standstill and pressing the IG button, the operator
can continue driving in manual operation and retry moving the vehicle onto the
wire.
Aisle: If an MSS loses the wire signal in the aisle, an emergency stop is released
(with Er183 or Er184).
9-298 Version 1.2, 12.07.2006

9.17.6 Steering angle control
The maximum set value of the steering angle which is transmitted from the SE-
CAN-control to the AC-controller is limited to +/- 1° .
The actual value of the steering angle which is transmitted by the incremental
transmitter of the steering to the SECAN-control, must also be limited to max. +/-
1°.
Additionally, the measured actual steering angle of the incremental transmitter is

compared with the value of the absolute value emitter (steering angle potentiom-
eter).
If the maximum actual steering angle is exceeded, or if a specified tolerance be-

tween incremental transmitter and potentiometer of the steering system (actual
value difference) is exceeded, an emergency stop will occur, regardless of the
present driving speed.
9.17.7 Mechanical lock device (claw, if available)
The claw is normally down (locked) by means of a spring, to open the claw (dis-
locked) and hold in this position, it must be electrically energized.
Note
The mechanical lock device is deliverable as an option.
9.17.8 Actual driving speed control
The actual driving speed is transmitted from the sensor bearing of the drive motor
to the SECAN-control via the AC-controller. If the maximum permissible speed
(which is adjustable) is exceeded, an emergency stop is initiated.
9.17.9 Full speed release
In IG operation mode, the following requirements for releasing high speed must be
fulfilled:
• an aisle signal is present (only IGwA)

• claw, if available, is reported as locked (down)
• the guidance behavior on the wire is sufficient, i.e. the inclination and dis-
tance are within the projected emergency stop diamond
Version 1.2, 12.07.2006 9-299

9.17.10Overview of emergency stop conditions
The following IG specific conditions are considered as emergency off situations:
• communication problems with a micro steering sensor (MSS)

• internal error in a micro steering sensor (MSS)
• error message from a micro steering sensor (MSS) (f.e. loss of wire)
• violation of the emergency stop diamond
• exceeding of the maximum permissible steering angle at IG (induction
guidance) drive (regardless of the actual driving speed)
• exceeding of the maximum speed
• internal error in the steering sensor system (e.g. broken wire)
• internal error in the driving sensor system
• internal error in the SECAN-control
• internal error in the driving-controller
• internal error in the steering-controller
• emergency stop is released by an external component, e.g. personnel pro-
tection system
9.17.11Diagnosis
The IG is fully integrated into the SECAN-control-system, i.e. all SECAN-diagno-

sis-options are available. Using the status display, all relevant inputs/outputs/tags
can be displayed ONLINE on the APE-display.
9.17.12Setting the IG
The parameters are set on the service menu "IG".
Before commissioning and setting, the correct code number for releasing the IG
function must be input.
The setting of the IG should occur according to the following steps:
1st step: initial setting of the micro steering sensors
Call up menu element M17 „IF“.

Enter the correct frequency and the height between lower edge of the sensor and
the floor for both steering sensors.
9-300 Version 1.2, 12.07.2006

Set both parameter P55 and P56 to „0“
For the control parameters P57 to P65, enter the initial settings as follows:
P57: 250 P58: 130

P59: 500 P60: 180
P61: 250 P62: 80
P63: 600 P64:300 P65: 300
With the basic parameters, good IG operation is normally possible for all vehicles.
Step 2: setting the steering parameters
The steering parameters on the menu M07 Steering should be set to the values
entered on the acceptance certificate
Step 3: calibration of the front micro steering sensor
The initial setting (configuration) of the MSS (step 1) must be completed before
the calibration.
Calibration of the front MSS:
Drive the front MSS next to the lead wire (min. 300 mm). The vehicle angle to the
lead wire should be approx. 5° - 10°. Set the drive wheel straight ahead with man-
ual steering. The cabin should be slightly lifted (approx. 100 mm)
Call up menu element "M17 IG" - „TI41 Calibration MSS front“. Confirm with EN-
TER; Text "Calibrate...End = ENTER" appears.
With the MSS in front, now drive slowly over the wire with constant speed. Angle
approx. 5° - 10°. Stop as soon as the micro steering sensor is more than 300 mm
from the lead wire.
Complete the calibration procedure with ENTER.
MLS hinten
Antriebsrad
MLS vorne
200 mm
300 mm
Leitdraht
Fig. 9-21: TeachInmicro steering sensor front
Version 1.2, 12.07.2006 9-301

Step 4: calibration of the rear micro steering sensor
Drive the rear MSS next to the lead wire (min. 300 mm). Set the drive wheel to 90°
with manual steering
Call up menu element "T143 IG" "Calibration MSS rear". Confirm with ENTER;
Text "Calibrate...End = ENTER" appears.
With the MSS behind, now drive slowly over the wire with constant speed. Angle
90°. Stop as soon as the micro steering sensor is more than 200 - 300 mm from
the lead wire.
Complete the calibration procedure with ENTER.
Antriebsrad MLS hinten
mm
200 mm
300
MLS vorne
Leitdraht
Fig. 9-22: TeachInmicro steering sensor rear
5th step: basic functional test (apron)
Check the correct distance measurement for both sensors:
Call up MA 231 and MA 232 in the state display
Position the vehicle parallel to the wire so that MA231 and MA232 each display 50
mm.
Measurement of the actual deviation from the middle of the sensor to the wire. The
permitted deviation between the actual measurement and the display value is 5
mm.
9-302 Version 1.2, 12.07.2006

Then:
Position the vehicle parallel to the wire so that MA231 and MA232 each display 10
mm.
Measurement of the actual deviation from the middle of the sensor to the wire. The
permitted deviation between the actual measurement and the display value is 1
mm.
If these tolerances are not adhered to, the sensors must be re-calibrated.
Now you can try to engage the wire and to drive; to do this,
Press IG button and drive on the wire; vehicle must engage. If the sensors have
detected the wire, the corresponding displays must appear on the APE.
6th step: manual correction of the steering straight ahead setting
The parameter P19 on the steering menu must be set to "0".
Engage vehicle until the engaged state is displayed.
Call up MA218 (steering setting incl. correction value) on the state display.
Drive slowly on the wire in both directions, observing MA218. There should be a
vibration around the null point. If this is not the case, enter the value in P19 around
which the steering angle vibrates with reverse sign.
example: It is observed that during IG driving, MA218 vibrates around the value "-
6". Then a value of "+6" must be entered to correct the steering straight ahead set-
ting in P19.
After a change, the driving behaviour must be checked again.
7th step: optimization of the control parameters P57-P63
If the vehicle drives on the wire in satisfactory fashion, then normally no further
correction is necessary. If too-strong fishtailing movements are detected, then you
can try to optimize the driving behaviour via the parameters P62 and P63. It takes
some experience and instinct to find the optimal setting.
8th step: setting of the claw (only optional)
If the IG function without claw is set optimally, then the claw can be installed and
set. Decisive is that with absolute middle positioning of the steered wheel (check
via MA128), the claw is installed in the middle. Then the feedback switch can also
be installed and connected correctly.
Finally, test the IG functions with claw; especially the transition states into and out
of the aisle should be checked several times.
Version 1.2, 12.07.2006 9-303

Interface to PPS connection (personnel protection system)
9.18 Interface to PPS connection (personnel protec-

tion system)
9.18.1 General information
§ Note
As a safety component, a PPS must have precisely de-
fined interfaces to the vehicles control system and the
electric system. Systems that are not sufficiently
planned, implemented or documented endanger the op-
erators safety and affect the operational safety and
availability of the vehicle.
It is not permitted to use other interfaces for the integra-
tion of personnel protection systems into the Hi-Racker
1200/1400 AC vehicle. The SECAN-control-system car-
ries out extensive checks during run-up and operation,
triggering fault messages for any unauthorized manipu-
lation of the safety system!
Read the PPS documentation for the respective vehicle
before performing service work on a vehicle.
The documentation for the integration of a PPS into a
system vehicle must be provided by the manufacturer of
the PPS!
9-304 Version 1.2, 12.07.2006

Interface to PPS connection (personnel protection system)
9.18.2 ATLET-High-rise stacker with control system SECAN 2
Interface to personnel protection system; Signal description
Model Pin
No. Function
at vehicle side (X104)
1 Power supply U Batt duration protect with 5 A 1
2 Power supply 0 V GND Battery minus 2
3 Power supply 24 V protect with 5 A 3
4 Power supply 0 V DC DC-converter minus 4
5 Separation of brake circuit IN 5
6 Separation of brake circuit OUT 6
7 Release of driving direction 1 of PPS Input (24V) 7
8 Full speed release from PPS Input (24V) 8
9 Release of driving direction 2 of PPS Input (24V) X135:4
10 Vehicle in aisle (infosignal) Output (24V) 10
11 Lift height signal (programmable) Output (24V) 11
12 Free Free 12
Tab. 9-1: Interface to personnel protection system;
Note
The brake circuit can be directly separated via pin 5/6.
For vehicles without PPS, a strap plug is required. This
bridges the brake, drive release 1 and 2 as well as the
full speed release.
The signals are on a 12-pin Molex Minifit plug connector
(X104 male), as well as on X135 pin 4.
Version 1.2, 12.07.2006 9-305

Automatic swiveling / sideshift synchronization
9.19 Automatic swiveling / sideshift synchronization

The software for the Hi-Racker 1200/1400 AC already provides for automatic
swiveling/traversing synchronization in narrow aisle. This option is activated by
code release (service menu M15 „Options 0-15“ or M16 „Options 16-29“).
This function allows pallets to be automatically swiveled in the aisle in approx. 10

to 12 seconds by pressing the function key “Synchronous“ and simultaneously ful-
ly actuating the right-hand master switch.
§ Note
The function must be projected by the manufacturer of
the vehicle, i.e. setting parameters and safety distances
must be calculated on the basis of the geometric data.
9.19.1 Geometric adjustment
Adjustment of the geometric data is carried in the service menu M10 “Geometry
synchr. swivel“.
In this menu, 6 geometric values that have been calculated by the manufacturer
of the vehicle must be adjusted.
These values are written down in the appropriate project sheet included with the
acceptance certificate.
§ Note
A planned parameter record always relates to a vehicle.
Furthermore, it is only valid for one pallet size. The use
of other pallet sizes can cause the vehicle to collide with
the racks!
The geometric data can also be adjusted by using a TeachInprocedure if the pro-
jected parameters are unknown or if the function is to be adapted to pallet sizes
other than the projected size. This adjustment is also carried out in the menu “Ge-
ometry synchr. swivel“.
For this purpose, the attachment must be brought into three calibration positions,
which are then confirmed using the “ENTER“ key.
§ Note
Application of the TeachInprocedure must not be contin-
ued if the projected geometric values are known and
have been entered via the service menu. The values de-
termined by the TeachInprocedure are less accurate
than the calculated values.
9-306 Version 1.2, 12.07.2006

1. TeachInprocedure:
The TeachInprocedure must only be carried out using the original pallet. The syn-
chronous function is only optimized for the TeachInpallet size.
• take pallet
• lift the cabin 30 cm from the floor
• bring forks to initial position (sideshift left)
• mark on the floor the fork rotation center with left sideshift (1)
X
B C
A
φ=φ _MAX
Z=0 Z = Z_MAX
X Axis of fork rotation
Version 1.2, 12.07.2006 9-307

2. Calibration point, position A:
• align the rear fork carrier edge (point A) exactly above the marked vertical
point of the forks axis of rotation (point 1)
• in the service menu M10 “Geometry synchr. swivel“ select item position A
and confirm with ENTER
Z=Z_max
Z = Z_MAX
Z=0
=Y
y Vertical to axis of fork rota-

tion
3. Calibration point, position B:
• align the rear pallet edge (point B) exactly above the marked vertical point
of the forks axis of rotation (point 1)
• in the service menu M10 “Geometry synchr. swivel“ select item position B
Z = Z_MAX
Z=0 Z=Z_max
=Y
9-308 Version 1.2, 12.07.2006


tion
4. Calibration point, position C:
• align the front pallet edge (point C) exactly above the marked vertical point
of the forks axis of rotation (point 1)
• if the front edge cannot be exactly aligned with the vertical point for geomet-
rical reasons, continue with calibration position D
• in the service menu M10 “Geometry synchr. swivel“ select item position C
Z=0 Z = Z_MAX
=Y

tion
Version 1.2, 12.07.2006 9-309

5. Calibration point, position D:
• calibration point D may only be used if it was not possible to set calibration
point C
• align the front pallet edge (point D) with the transverse line crossing the ver-
tical point of the forks axis of rotation (point 1)
• in the service menu M10 “Geometry synchr. swivel“ select item position D
Z=0 Z = Z_MAX
=Y

tion
9-310 Version 1.2, 12.07.2006

6. Aisle offset:
• This menu item is used to adjust the contour (usable aisle width) in which
the movement is carried out. This value is calculated by the manufacturer
and written down in the project sheet and acceptance certificate. If an incor-
rect value is read in, malfunctions (collision) cannot be excluded. Adjusting
a value that is too low causes the system to frequently detect imminent col-
lisions of one of the edges with the usable aisle width. If the value is too
high, it may happen that the usable aisle width applied by the system is larg-
er than the actual aisle width so that the fork collides with the rack.
A
B
φ=φ _MAX
Z=0 Z = Z_MAX
A aisle width
B usable aisle width
Version 1.2, 12.07.2006 9-311

9.19.2 Hydraulic adjustment
The adjustment can be done in menu “Hydraulic system synchr. swivel“.
The procedure is designed in such a manner that the swiveling function is carried
out at a constant speed and the sideshift function is adjusted accordingly. If there
is danger of collision, the swiveling function is switched off until the sideshift move-
ment has brought the pallet back into the aisle contour.
Adjustment procedure:
• drive the hydraulic system to normal operation temperature

• put in or TeachInthe geometric values; set the startup angle to 10°
• set the aisle offset to high value (e.g. 500)
• set the control amplification according to acceptance certificate (do not
change!)
• set the synchronous rotation according to acceptance certificate
Note
The following adjustments are only valid for the adjusted
number of rotations. If the number of rotations is
changed later, repeat all the settings.
• Set the hydraulic parameters according to acceptance certificate

• adjust parameter D12: in the beginning of the synchronous movement, only
the swiveling movement is started. Adjust D12 so that you get a speedy
start (D12 = 200 ... 250)
• adjust parameter V19 so that the turning movement lasts approx. 12 sec-
onds
• set I20 to the value 120 mA (this value is for stabilizing the synchronous
movement and can be changed if necessary)
• adjust aisle offset according to the acceptance certificate
• if max. sideshift speed is not sufficient (leaving contour, swiveling stops), in-
crease D06 slightly
• test procedure with and without load, if necessary correct with V19 and D06
or adjust the initial angle of the sideshift movement a bit (max. 15 degrees).
Movement can be displayed by MA 220 and MA 221 using the status dis-
play.
9-312 Version 1.2, 12.07.2006

Note
Adjustment of the synchronous movement requires ex-
perience because with different geometries of attach-
ments, different parameter values are required.
Practicing and experimenting makes a lot of sense.
Note
The speed of the movements can change with a chang-
ing oil temperature.
When a pumping movement occurs while synchronous movement under load, the
two adjustment screws of the load stabilizer valves can be opened slightly. Then
the stability of the locking of the swivel axis is reduced.
WARNING!
Adjust the load stabilizer valve this way that the forks
(with load) will not rotate while braking.
Version 1.2, 12.07.2006 9-313

***Battery discharge monitor
9.20 ***Battery discharge monitor

In the Hi-Racker 1200/1400 AC, the discharge monitor is integrated into the con-
trol system. The discharge monitor can be adapted to different types of batteries:
• PzS-G
• PzS-H/L
• PzS maintenance-free
The adjustment can be made in the service menu M18 "Battery".
The main lift cut-out occurs at a residual capacity of below 30%. To avoid high mo-
tor current from 60% on the number of rotations of the main lift movement is re-
duced linearly. The reduction at 30% residual capacity is 10% of the adjusted
number of rotations for the main lift.
Note
If the function is faulty, or after replacing the distributor
board of the drive compartment or of the master comput-
er, you must carry out a calibration.
Calibration
Purpose The test input of the discharge monitor must be calibrated for correct results This
is done in the battery monitor menu.
Procedure Switch the vehicle on. The current charging state of the battery is insignificant.
Keep the vehicle switched on or 5 minutes without carrying out a function.
With a calibrated multimeter, measure the battery voltage directly at the battery
(main protection - minus pins).
Note the measured value (precision at least 0.1 volt).
In the service menu call up the M18 battery menu.
In the input field Batterie_U_Mess enter the measured and noted value of the
battery voltage (input occurs in 10 mV steps; example: 83.45V corresponds to
8345).
Carry out the Teach in function.
; Calibration is completed. Check this as follows:
Call EA203 in the Status display.

; The current test value is displayed. This must agree with the test value of the
previously run test with the multimeter. If this is not the case then you must
repeat the calibration.
9-314 Version 1.2, 12.07.2006

Hour meters
9.21 Hour meters

Several operating hour meters are integrated into the control system:
BZ00: general movement time

BZ01: general switch-on time
BZ02: steering
BZ03: driving
BZ04: pump
The operating hours BZ00 are also indicated in the basic display. The operating
hour meters can also be displayed by calling up "state display".
All operating hour meters can also be reset or readjusted in the service menu M19
“Hour meters“.
Note
After the reset function has been confirmed for all oper-
ating hour meters, the data are lost and cannot be re-
stored!
§ Important note!
After replacing the master computer, the data from
the old computer must be re-loaded.
Version 1.2, 12.07.2006 9-315

Cut-outs
9.22 Cut-outs
The following cut-outs are available as an option and can be activated in the ser-
vice menu via input of the according code number.
9.22.1 Lifting cut-offs and lowering cut-outs (optional)
On the Hi-Racker 1200/1400 AC in the software 5 different lifting cut-offs and 3 dif-
ferent lowering cut-outs prepared, that can be configured freely.
The lifting and lowering cut-outs can be configured in the service menus M12 “Lift-
ing cut-out“ and M14 “Lowering cut-out“.
The following parameters can be adjusted separately for each

lifting- and lowering cut-out:
• cut-out height; either via TeachInprocedure or via numerical input

• override by a key switch: yes or no
• storage zone(s), in which the respective lift cut-off should be effective; up to
8 different storage zones (aisles) and all combinations of these are avail-
able(Aisle detection and storage zones"” on page 9-285).
The following parameters can be adjusted for all cut-outs:
• end ahead function, that is the distance in mm, where each cut-out starts to
slow down (accelerate) the movement
If a lifting cut-out is active, the operator gets a message by a red blinking STOP-
LED on the control panel and an explaining help text “Lift cut-off“.
Note
Lifting cut-offs can work correctly only if the sensor units
of the main lift are properly adjusted.
9-316 Version 1.2, 12.07.2006

Cut-outs
9.22.2 Sideshift cut-out (second stacking depth)
On the OMNI 120/140 AC a sideshift cut-out with override is prepared in the soft-
ware.
Important note!
Important: This option is not a fine positioning system.
The available precision of the cut-out distance depends
on how easy the attachment works, the adjusted speeds
and eventually from the load. In each case a precision of
±15 mm is reached.
Code release is in menu M15 „Options 0-15“ or M16 „Options 16-29“. The adjust-
ment of the option is done in the service menu M19 "Sideshift cut-out“
There, for both directions separately a cut-out distance in mm from the end po-
sition can be adjusted. As the mechanical and hydraulical assumptions of the at-
tachment are never identically for both sides it can happen, that to reach identical
cut-out distances for the left and ride side, different values have to be put in.
The actual cut-out distances must always be verified! The function depends on the
swiveling position of the attachment.
On return of the attachment the movement is done till to the mechanical end stop.
The condition “Extend“ is detected for sideshift to the left if the rotation angle of the
load lifting device is between 0° and 90° and for sideshift to the right if the rotation
angle of the load lifting device is between 90° and 180°.
The cut-out can be overridden using a button in the control panel. Activation of the
override function only requires that the button is installed correctly; a release by
the software is not required.
9.22.3 Driving cut-outs
• There are 3 freely programmable drive cut-outs; i.e.: After releasing a drive
cut-out, you can specify the lift height above or below which the drive func-
tion is to be locked. Furthermore, for each driving cut-out a valid storage
zone can be defined. It can be defined whether the driving cut-out can be
overridden or not. The driving cut-out can be adjusted in menu M13 „Driving
cut-out“.
• A further height-depending drive cut-out for the apron is available as a stan-
dard option.
• As a standard option there is also a cut-out available for the attachment not
being in initial position.
Version 1.2, 12.07.2006 9-317

Sensor units main lift
9.23 Sensor units main lift

The lift sensor unit consists of
• Laser odometer
• Magnet switch 0.3 m (reference point)
9.23.1 Laser odometer
DANGER!
Danger of eye injury due to visible laser light of laser
protection class 2
• Do not look directly into the laser beam!
• The enclosed stickers (laser warning) must be attached
in the immediate vicinity of the device.
• Observe the care and warning instructions on the prod-
uct label.
• Do not deflect the laser beam.
• Only work on the sensors or the lift frame when the elec-
tronics is switched off.
In case of emergency, press EMERGENCY OFF switch.
Administer first aid and summon a doctor.
The optical laser odometer system is comprised of the housing with the laser and
a reflection sheet (depending on the model of the vehicle) onto which the laser
beam hits or a part of the vehicle frame that assumes this function . If the main lift
is activates then the distance between these two components changes and there-
by the length of the laser beam. This change is used internally for determining the
lift height.
The laser odometer system can be configured differently. In the present case, the
initial configuration "Current output 4..20 mA" is used.
The laser is fixed depending on the model of the vehicle:
• At the top at the lift frame. In this case, the laser is fixed to the housing and
the reflection sheet in the lift frame is also moved during a lift movement.
• In the cabin In this case, the housing is moved together with the laser if
there is a lift movement. The laser beam hits the frame component.
9-318 Version 1.2, 12.07.2006

9.23.1.1 Arrangement
Version: Laser at lift frame
1
5
Fig. 9-23: Installing the laser at the lift frame
1 Cover 4 Output of laser beam

2 Operating keys 5 Laser beam
3 Display 6 Console with fixing screws
Fig. 9-24: reflection sheet at the lift frame
Version 1.2, 12.07.2006 9-319

Version: Laser at cabin floor
Fig. 9-25: Laser installation at cabin floor
9.23.1.2 Assembly and configuration
Assembly is carried out when switched off using the fixing screws at positions as
shown in Arrangement"” on page 9-319.
Laser odometers delivered by ATLET are already preconfigured. Configuration is

according to the details of the manufacturer.
Example for IFM OID100
All parameters must be left in the factory settings of the manufacturer except for
the parameters listed in the following table.
Parameter Value
OU2 I (this means current output)
AEP 6500
Tab. 9-2: Parameter

• Operating instructions of the manufacturer
9-320 Version 1.2, 12.07.2006

9.23.1.3 Adjustment
Laser at lift frame
Move cabin to the lower end position.

Set the housing with the laser in such a way that the laser beam hits the middle
of the reflection sheet.
Move the cabin and check whether the reflection point stays on the sheet and
does not „wander“.
Laser at cabin floor
Move cabin to the upper end position.

Set the housing with the laser in such a way that the laser beam hits the middle
of the frame component
Move the cabin and check whether the reflection point stays on the frame com-
ponent and does not „wander“.
9.23.1.4 Calibration (Teach- In)
WARNING!
• To avoid mechanical damages it is not allowed to carry
out the TeachInat the mechanical end position.
switch on the vehicle

Select service menu M05 "Main lift"
Select menu item TI19 “TI HH top“ and start TeachInby pressing ENTER; the
cursor bar starts flashing. In the lower part of the menu page, you see the hard-
ware value read into the laser sensor (4..20 mA)
move cabin to the top mechanical end position
for TeachIntop lower the cabin 1 till 2 cm from the mechanical end position
confirm with ENTER
Note
In this menu item, creeping speed is predefined. With
the correct taking over of the value the flashing of the
cursor will be stopped.
Version 1.2, 12.07.2006 9-321

Continue with menu item TI21 „TI HH bottom“ as described in the above.
All further parameters in menu M05 can be adjusted via UP / DOWN keys
9-322 Version 1.2, 12.07.2006

9.23.2 Reference switch 0,3 m
Because of safety reasons, a magnet switch is installed, which switches at a cabin

height of 0,3 m ± 3 cm.
4
1
3
2
Fig. 9-26: Reference switches
1 Magnet switch
2 Plastic distance piece
3 Magnet
4 C-profile
Assembly
mount the magnet switch (1) with plastic distance piece (2) to the C- profile (10)
centrically; cable output to the bottom; strain relief cable
mount the magnet (3) loosely to the C-profile (4), switching distance approx. 10
mm; north pole (green) to the magnet switch
lift the cabin up to 300 mm
adjust magnet centrically to the magnet switch and tighten it
Version 1.2, 12.07.2006 9-323

9.23.3 Startup and check of the main lift sensor units
Note
Parameters see service menu, chapter 12.
mount the magnet for the 0,3 m-switch so, that the switch point is at 300 mm +/
- 5 mm, when lifting
in Parameter G22 the lift height h3, with which the teach in above was carried
out
type in the end ahead distance values into parameters G20 and G21

• Overview of parameters in Setup work"” on page 10-357
Checking the 0.3 m-switch
Slowly start up the main lift. Switch-over must be in the range between
300±20mm. Observe E200 and EA201 when doing this.
9-324 Version 1.2, 12.07.2006

Sensor units actual value steering
9.24 Sensor units actual value steering
CAUTION!
Danger of crushing by steering movement
• When switching on the vehicle, always make sure that
no second person is working on the steering
9.24.1 Overview of sensor elements
Version A - Double- Potentiometer
3
1
Fig. 9-27: Sensor elements
1 Sensor unit
2 Potentiometer (2×)
3 Marking boreholes for straight ahead position

• For assembly of the steering sensor, refer to the spare parts catalogue
Version 1.2, 12.07.2006 9-325

9.24.2 Adjustment of the steering sensor unit
Important note!
an extra person is required when making the setting.
Assembly of the sensor unit
The steering movement is generated by the steering motor and transmitted via a
gear to the drive wheel. The sensor unit is also moved via a drive gear. The sensor
unit contains two potentiometers that are moved via the transmission gear and that
detect the steering movements.
1 2
6
4
Fig. 9-28: Aligning the drive wheel
1 Cover
2 Drive gear
3 Transmission gear
4 Potentiometer (2×)
5 Index bore hole
6 Carrier for potentiometer
9-326 Version 1.2, 12.07.2006

Presetting the drive wheel and the sensor unit
For the later TeachInprocedure, it is necessary that the drive wheel be in the
straight position and the sensor unit in the middle.
3 1
Fig. 9-29: Aligning the drive wheel
1 Bore hole for straight ahead position

2 Drive plate
3 Gear for steering movement with marking bore hole
Set the drive wheel so that the marking bore hole of the gear is flush with the
bore hole on the drive plate.
Version 1.2, 12.07.2006 9-327

Fig. 9-30: Measure the total resistance

Loosen the plug connection and measure the total resistance of the potentiom-
eter between pin 1 and pin 3. Halve and note the value.
Measure the total distance between pin 1 and pin 2. At ± 0,2k: this must cor-
respond to the previously-indicated half total resistance. If this is not the case
then the two fixing screws of the sensor unit must be loosened. The sensor unit
is then twisted in their oblong holes until the test value is within the tolerance
range .
Fig. 9-31: Aligning the sensor unit
1 Sensor unit
2 Fixing screws
9-328 Version 1.2, 12.07.2006

Teach-In
The TeachInprocedure is at the APE and is for fine adjustment. Here the middle
and end positions are defined + 90° and -90°.
Middle position
Call up the M07 Steering menu.

Select the line for TI13 and press Enter.
; The line flashes. The TeachInmode is active. The lower edge of the display
indicates the current hardware values (0..24V). The values for the potenti-
ometer in the middle setting should be in the range from 10000 - 12000 (cor-
responds to 10V-12V).
Example display
TI 10662 10558
TI = Teach In 10662 = 10.6 V Poti A 10658 = 10.5 V Poti B
Tab. 9-3: Example at the display

Move the drive wheel until the marking bore hole of the gear is flush with the
bore hole on the drive plate (Aligning the drive wheel"” on page 9-327). This is
done in the TeachIn mode by pressing button R15 for GESI reset and R14 for
lift override on the control panel.
Once the drive wheel is aligned, press on the APE on Enter.
; The values of the current setting are accepted.
Version 1.2, 12.07.2006 9-329

Wheel settings right / left
Depending on the driving direction, select line TI15 or TI17 and press on Enter.
; The line flashes. The TeachIn mode is active. The current values are shown
at the bottom corner of the display. Now drive the drive wheel with the control
panel buttons R15 and R14 until it is parallel to the ram protector. Measure
the distances to do this.
The values for the potentiometer should be in the range 2500 - 4500 for the
right wheel position and 18000 - 20000 for the left wheel position.
1 2
Fig. 9-32:
1 Front end guard

2 Distance measurements
Once the drive wheel is aligned, press on the APE on Enter.

; The values of the current setting are accepted.
Repeat this procedure for the other drive directions.
; The TeachInprocedure is completed.
9-330 Version 1.2, 12.07.2006

Test drive for straight ahead run
Note
The straight run must be exact for use in the narrow
aisle.
Carry out a test run for straight ahead. If smaller corrections are required, this
can be done in steps of 0.1° via parameter P19.
Alternatively, with precise straight driving, the TeachIn for the middle setting
can be repeated.
Version 1.2, 12.07.2006 9-331

Sensor bearing drive- and steering motor (control system)
9.25 Sensor bearing drive- and steering motor (con-

trol system)
The torque signals from the traction drive are generated from the sensor bearing
inside the drive motor. From there, they are transmitted to the AC-controller, which
then passes the signals directly via CAN-bus (CAN-open-protocol) into the SE-
CAN-control-system.
The sensor bearings in the drive and steering motor give rotor position, direction
of rotation and speed to the control systems.
9.25.1 Sensor bearing on the drive motor
Disassembly of the sensor bearing
Switch off the vehicle

pull out battery plug
disconnect the drive motor electrically
remove spring-loaded brake (1)
Fig. 9-33: Sensor bearing drive motor_1
1 Spring-loaded brake
Remove brake disk (2) (Fig.: 9-34 on page 9-333)

remove rubber sealing ring (3)
9-332 Version 1.2, 12.07.2006

Fig. 9-34: Sensor bearing of drive motor_2
2 Brake disk 3 Seal ring
remove screws (4, 5)

pull off the end shield from the motor
remove pinion (6)
remove screws (7)
6
7
5 4
Fig. 9-35: Sensor bearing of drive motor_3
4 Screw 6 Pinion
5 Screw 7 Screw
Version 1.2, 12.07.2006 9-333

pull of the end shield (8) from the anchor (9)
WARNING!
Do not damage the windings and the stator circuit.
remove sensor bearing with a pulling-off device from the shaft end
mount new sensor bearing in correct position
Note
Press bearing onto the shaft with a bush that exactly fits
onto the inner ring of the bearing.
Make sure that the connection cables are pulled through
the opening of the end shield correctly. Do not damage
the windings and the stator circuit when mounting.
9-334 Version 1.2, 12.07.2006

9.25.2 Sensor bearing of the steering motor
Disassembly of the sensor bearing
Switch off the vehicle

pull out battery plug
disconnect the steering motor electrically
remove screws (10)
remove cover (11)
11
10
10 Screw
11 Cover
Version 1.2, 12.07.2006 9-335

12
12 Sensor bearing
pull out sensor bearing (12)
9-336 Version 1.2, 12.07.2006

Temperature sensor drive and pump motor
9.26 Temperature sensor drive and pump motor
9.26.1 Drive motor
The temperature sensor is connected electrically on plug X4.(16).
The temperature sensor is integrated in the stator winding and has the following
specifications:
Switching mode: Opening contact

Type: S01.120.05.0300
Nominal switching temperature: 120° C
Tolerance: +/-5°C
WARNING!
An exchange is not possible!
9.26.2 Pump motor
Mounting of a temperature sensor
A PT 100 - feeler is stuck on the winding of the stator (17) to observe the temper-
ature of the pump motor. Evaluation of the temperature sensor is via the AC con-
troller.
Note
The 2-component balancing cement can be supplied by
the manufacturer.
knead together the two components of the balancing cement 1:1 yellow and
blue
§ Note
Work fast, the cement is hardening fast!
press the cement onto the upper side of the temperature sensor
Thread the temperature monitor through the cable inlet of the bearing shield
and stick to the copper winding with mastic.
Version 1.2, 12.07.2006 9-337

Sensor unit auxiliary lift (version B)
9.27 Sensor unit auxiliary lift (version B)

Sensor element
• Wire actuated potentiometer
19d 19e
19a 19b 19c
19a Wire actuated potentiometer 19d Fixing screw

19b Rope 19e Plug X87
19c Carrier
Note
Assembly of the auxiliary lift sensor unit see spare parts
catalogue.
9-338 Version 1.2, 12.07.2006

Sensor unit auxiliary lift (version B)
Assembly and mechanical adjustment
lower forks to the bottom end

if the sensor unit of the auxiliary lift has to be changed, dismount the complete
unit first by removing the fixing screws (19d) and the carrier (19c)
mount the new wire actuated potentiometer using the fixing screws (19d)
mount carrier (19c)
CAUTION!
In order to avoid electrical and mechanical damages
don´t let go the wire!
Calibration (Teach- In)

Select service menu M04 "Auxiliary lift“
Work through the menu items as shown in the display
Checking the settings
Select analog input EA206 on the service menu "Status display"

lift and lower the cabin once over the entire lifting height and check whether the
vehicle behavior and the input are correct
repeat the adjustment in case of deviations
§ Note
The calibration also has to be carried out after a CPC-
control component has been changed.
Version 1.2, 12.07.2006 9-339

Sensor unit sideshift
9.28 Sensor unit sideshift

Sensor element
• 10-turn dual gang potentiometer (2kOm / 2kOm)
22
21
20
20 Potentiometer 22 Locking piston

21 Wormscrew
Note
Assembly of the sideshift sensor unit see spare parts
catalogue.
9-340 Version 1.2, 12.07.2006

Requirements:
move sideshift arm in right-hand end position
Note
The hydraulic motor must not be removed for installation
and removal purposes.
set the potentiometer (20) to the left-hand stop

turn back potentiometer by 1/2 revolution
tighten grub screws (21) (shifted by 180°)
§ Note
For demounting the attachment, position it in such a
manner that the grub screw (21) of the coupling are ac-
cessible.
Measuring of the potentiometer-setting
switch off the vehicle; sideshift has to be placed at the left-hand stop
measure on potentiometer with pulled plug X512/pin 2 and pin 3 as well as be-
tween X512/pin 5 and pin 6 with ohmmeter. Permissible value: 0,1...0,4 kOhm.

Select service menu M02 “Slide“
perform the TeachInon left hand end stop position and on right hand end stop
position
Version 1.2, 12.07.2006 9-341

Select analog inputs EA 210 or EA 211 in the service menu "Status display“
actuate sideshift left and right side; check vehicle behavior and parameter for
correctness
on vehicles with the option “second stacking depth“ the cut-out position right
and left has to be entered separately. Always measure the actual cut-out posi-
tion as the adjusted value and the actual value do not correspond exactly
repeat adjustment if deviations occur
§ Note
Calibration must also be carried out after a CPC control
component has been replaced.
9-342 Version 1.2, 12.07.2006

Sensor unit swiveling
9.29 Sensor unit swiveling

Sensor element
• 3-turn dual gang potentiometer (2kOm / 2kOm)
24 25
23
23 Potentiometer 25 Support
24 Pinion of the gear
Note
Assembly of the swiveling sensor unit see spare parts
catalogue 08.
move the forks to the center position

always mount and dismount sensor unit completely with potentiometer, pinion
and support
turn potentiometer (23) in center position (1,5 revolution)
measure on potentiometer on pulled plug X514.2 between pin 2 and pin 3 as
well as between pin 5 and pin 6 with ohmmeter. Permissible value: 1,0 kOhm
install potentiometer and tighten screws of the support (25)
Strain relief cable Do not form any free loops
Version 1.2, 12.07.2006 9-343

Sensor unit swiveling
Measuring of the potentiometer-setting
Measure on potentiometer on pulled plug X514.2 between pin 2 and pin 3 as

well as between pin 5 and pin 6 with ohmmeter. Permissible value: 0.9...1.1 kO-
hm.

Select service menu M03 „Turn"
Work through the menu items as shown in the display
Select analog inputs EA 208 or EA 209 in the service menu "Status display
swivel left and right once each and check the vehicle behavior and the input val-
ues for correctness
repeat the adjustments, if deviations occur
§ Note
The calibration also has to be carried out after a CPC-
control component has been changed.
9-344 Version 1.2, 12.07.2006

Controlling the hydraulic system
9.30 Controlling the hydraulic system
9.30.1 Introduction
A multitude of FFZ functions are carried out with the help of hydraulic components
(black/white valves (bw valves), current regulators).
• Turn
• Thrust
• Auxiliary lift
• main lift
• Lift main lift and auxiliary lift at the same time
• Synchronous turning
As is apparent from the hydraulic plan, all hydraulic functions are controlled by a
joint hydraulic valve block. This thus functions as a bottleneck. This requires a co-
ordination of the function flow in order to prevent mutual influencing.
The coordination and the
The FFZ software takes over the control and monitoring of the function flow (move-
ments). It subdivides the total flow into software modules that follow one after an-
other (partial sections). Each partial section depends on the previous one. In order
for all functions to proceed according to the same pattern, the following scheme
was developed:
9.30.2 Overview: Control of hydraulic functions by software modules
All functions are triggered by the user via the control lever and function keys.
The control and monitoring of the function flow (movement) by software modules
occurs in the following sequence.
1. Operator module
2. Function module
3. Coordination module (called the hydraulic block below)
4. Hydraulic module
The output of the set values determined by the software modules occurs via hard-
ware outputs.
Version 1.2, 12.07.2006 9-345

Operator module
In the operator module, the functions, movement direction and pre-set speed are
specified by the operator via function keys and control lever steering. The pre-set
target value results from these.
Function module
In the function modules (turning, thrusting, auxiliary lift, etc.) the pre-set speed is
limited based on safety considerations (emergency stop, fault, etc.) and end stops.
After this, the function attempts to reserve the hydraulic block for itself. The pre-
set target value results from these.
Hydraulic block reservation module
The task is the coordination of the hydraulic functions in the hydraulic block. Since
all hydraulic movements are controlled by the same hydraulic block, the use of the
block components must be coordinated. The hydraulic block reservation module
takes over the function of the coordinator on the software side. It blocks the indi-
vidual movements against one another in order to prevent mutual influence. It en-
sures orderly completion of a function (brake ramps) before a new function begins.
If a function is reserved in the hydraulic block, then it transmits the function target
value to the hydraulic module.
Hydraulic module
The hydraulic modules realize the flow controls of the hydraulic functions. They
ensure the control of the required bw valves and current regulators. They pre-
scribe torques for the pump and specify braking and acceleration ramps for start-
ing and stopping.
Torque and current regulator set values
Function set Set value

value
Operator
module
Function module, Hydraulic mod- BW valve current

Hydraulic block
e.g. turn ule, e.g. turn regulator
reservation
Pre-set Specification
value set value
from the pump
Fig. 9-36: Torque and current regulator set values
9-346 Version 1.2, 12.07.2006

9.30.3 Fault analysis hydraulic functions
The fault analysis occurs according to the same scheme for every hydraulic func-
tion. The function flow is determined by the operator module, as well as the asso-
ciated function and hydraulic modules. These are carried out as state controls, that
is, they are in a defined state during a program cycle. By observing this state via
the corresponding state markers, a first localisation of the fault cause can be
made.
Procedure
Step1: Observation of the state marker of the operator module:
The selection function is displayed. OK next with Step 2.

The selection function is not displayed. Check whether function keys, control lever
are in order.
Step 2: Observation of the state marker of the function module:
Here the pre-set speed is determined based on safety considerations and end cut-
outs. From the state it is possible to see whether the hydraulic module is activated,
and at what speed.
If the function module is in a state in which one movement is released:
• There is an activation of the hydraulic module

If the speed displayed via the state (e.g.: turn fast etc.) matches the expect-
ed speed. Continue with step 3.
If the speed displayed via the state (e.g.: turn creep etc.) does not match the
expected speed. The cause can be read out from the state markers.
If the function module is in a state in which no movement is released:
• There is no activation of the hydraulic module

• The cause can be determined from the current state.
Step 3: Hydraulic module
From the state it is evident which actions the hydraulic module is currently execut-
ing. The actions corresponding to the state (outputs for valves, current regulators
and pump) can be read from the overview of the use of the valves for the corre-
sponding function.
Version 1.2, 12.07.2006 9-347

Control of the hydraulic system (HR1200-1400)
9.31 Control of the hydraulic system (HR1200-1400)
9.31.1 Valve overview
Loca-
Valve Usage
tion
2 Y 30 DPU Flow divider (current regulator for turning)
2 Y 31 DPU Current regulator bypass
2 Y 49 DPU Lower current regulator ZH
2 Y 32 DPU Switch ZH to auxiliary lift LIFT
2 Y 33 DPU Switch ZH to auxiliary lift LOWER
2 Y 34 DPU Switch HH to main lift LIFT
2 Y 35 DPU Switch HH to main lift LOWER
2 Y 36 DPU Switch valve LLD shift
2 Y 37 DPU Switch valve LLD turn
2 Y 40 CPC Direction valve for swivel right
2 Y 41 CPC Direction valve for swivel left
2 Y 42 VZK Direction valve for thrust right
2 Y 43 CPC Direction valve for thrust left
2 Y 52 DPU Valve pump idle HH lower
2 Y 53 DPU Valve pump idle HH lower
Tab. 9-4: Valve overview
9-348 Version 1.2, 12.07.2006

HH+ZH
HH+ZH Synchron HH ZH Turn Turn Thrust Thrust Softw. Move-
Synchron HH lift ZH lift
lower turning lower lower right left right left ed. ment
lift
0 X Turn 0 0 0 X X X X X AA201 2Y30

Pro-
Version 1.2, 12.07.2006

por-
X 0 Thrust X 0 0 0 0 0 0 0 AA202 2Y31
tional
X 0 0 0 0 X AA200 2Y49 valve
0 X 0 0 0 0 X 0 0 0 0 A211 2Y32
X 0 0 0 0 X 0 0 0 0 0 A212 2Y33
0 X 0 0 X 0 0 0 0 0 0 A215 2Y34
X 0 0 X 0 0 0 0 0 0 0 A216 2Y35
0 0 X 0 0 0 0 0 0 X X A202 2Y36
BW
0 0 X 0 0 0 0 X X X X A205 2Y37
valves
0 0 X 0 0 0 0 X 0 0 0 A228 2Y40
Tab. 9-5: Overview: usage of the valves for individual movements

0 0 X 0 0 0 0 0 X 0 0 A229 2Y41
0 0 X 0 0 0 0 0 0 X 0 A230 2Y42
0 0 X 0 0 0 0 0 0 0 X A231 2Y43
0 0 0 X 0 0 0 0 0 0 0 A203 2Y52
X X X X X 0 0 0 0 X X A204 2Y53
X X X X X 0 X X X X X 2M1 Speed
DRZ DRZ SS:/DRZ DRZ DRZ prop DRZ prop prop prop prop
DR Prop Regu-
lation
9.31.2 Overview: usage of the valves for individual movements
9-349
These settings are only valid for the respective movement itself.
For in-between states e.g. for pressure reduction, other constellations are re-
quired, for which you must consult the overview for the respective movement.
)** The torque is specified in U/min Max. U/Min
Explanation
X means activation
0 means no activation
--- means not required for this movement.
9-350 Version 1.2, 12.07.2006

2b 2a 1h 1g 1f 1e 1d 1c 1b 1a
Del.-No.
Free lift lift Free lift lift Main lift Main lift Main lift Main lift lift Main lift lift Main lift lift Main lift lift Main lift Function/
fast START lower lower v< lower fast creep.(out- STOP creep. fast START E.-Mag-
P ERP200U RP/- min. 200U P 200- RP/- 200- P ERP200U 2M1
Version 1.2, 12.07.2006

(+) RP/+ - - - - - - - - 2Y30
- - RP/- P RP/(+) RP/+ - - - - 2Y31
(+) + - - - - - - - - 2Y32
- - - - - - - - - - 2Y33
Cyclogram Hi - Racker 120/140
- - - - - - (+)/- (+) (+) + 2Y34

- - (+)/- (+) (+) + - - - - 2Y35
- - - - - - - - - - 2Y36
- - - - - - - - - - 2Y37
- - - - - - - - - - 2Y40
- - - - - - - - - - 2Y41
- - - - - - - - - - 2Y42
- - - - - - - - - - 2Y43
- - - - - - - - - - 2Y49
- - (+)/- (+) (+) + - - - - 2Y52

9.31.3 Cyclograms (from the hydraulic point of view)
- - (+)/- (+) (+) + (+)/- (+) (+) + 2Y53
- - - La La La - La La La
2B10
La La - - - - - - - -
2B11
9-351
3f 3e 3d 3c 3b 3a 1g 2f 2e 2d 2c
Del.-No.
9-352
UHF lift UHF lift Var. 2 HH. Var. 1 HH. UHF lift UHF lift Free lift Free lift Free lift Free lift lift Free lift lift Function/
STOP creep. lift fast(Fh/ lift fast(Fh/ fast START lower lower fast lower STOP creep. E.-Mag-
RP/- 200- P to 400U (P) P ERP200U - - - RP/- 300-400U 2M1

RP/- RP/+ +=EW RP/EW2/- RP/+ RP - - - RP/- P 2Y30
- - - - - - - - - - - 2Y31
(+)/- (+)/+ (+) (+)/- (+) + - - - (+)/- (+) 2Y32

- - - - - - (+)/- (+) + - - 2Y33
(+)/- (+)/+ (+)/- (+) (+) + - - - - - 2Y34

- - - - - - - - - - - 2Y35
- - - - - - - - - - - 2Y36
- - - - - - - - - - - 2Y37
- - - - - - - - - - - 2Y40
- - - - - - - - - - - 2Y41
- - - - - - - - - - - 2Y42
- - - - - - - - - - - 2Y43
- - - - - - P/- P P - - 2Y49
- - - - - - - - - - - 2Y52
(+)/- (+)/+ (+)/- (+) (+) -/+ - - - - - 2Y53
La/- La/+ La/- La La La - - - - -

2B10
La/- La/+ La La/- La La - La La - La

2B11
Version 1.2, 12.07.2006

4f 4e 4d 4c 4b 4a 3k 3j 3i 3h 3g
Del.-No.
Thrust left Thrust left Thrust Thrust Thrust re- Thrust UHF lower Var 2 FL. Var 1 HH. UHF lower UHF lower Function/
(l) creep (l.) fast right (r) right (r) chts (r) fast START STOP lower lower fast creep. E.-Mag-
(+) (+) (+)RP/- (+) (+) RP 400U RP/- RP/- (P) P 200-600=P 2M1
Version 1.2, 12.07.2006

P P RP/- P P 500 mA - - - - - 2Y30
- - - - - - RP/- RP/EW/- +=EW RP/(+) RP/+ 2Y31
- - - - - - - - - - - 2Y32
- - - - - - (+)/- (+) (+)/- (+) + 2Y33
- - - - - - - - - - - 2Y34
- - - - - - (+)/- (+)/- (+) (+) + 2Y35
(+) (+) (+)/- (+) (+) + - - - - - 2Y36
(+) (+) (+)/- (+) (+) + - - - - - 2Y37
- - - - - - - - - - - 2Y40
- - - - - - - - - - - 2Y41
- - (+)/- (+) + - - - - - - 2Y42
(+) + - - - - - - - - - 2Y43
- - - - - - RP/- (+) RP/EW2/- +=EW RP/+ 2Y49
- - - - - - - +/- + + + 2Y52
(+) (+) (+)/- (+) (+) - - +/- + + + 2Y53
La La La/- La La - La/- La/- La/- La La

2B10
- - - - - - La/- La/- La/- La La

2B11
9-353
6c 6b 6a 5d 5f 5e 5d 5c 5b 5a 4g
Del.-No.
9-354
Turn. (l) as Syn. Turn. (l) Turn left (l) Turn left (l) Turn left (l) Turn right Turn right Turn right Turn Thrust left Function/
of ap- thrust/turn. approx. STOP creep fast (r) STOP (r) creep (r) fast START (r) (l.) STOP E.-Mag-
RP 200U/- P to 500U RP 300U (+)/- (+) (+) (+)/- (+) (+) RP 300U (+)/RP/- 2M1
RP/EW2/- +=EW1 RP RP/- P P RP/- P P RP RP/- 2Y30
+=EW/- - +=EW - - - - - - - 2Y31
- - - - - - - - - - - 2Y32
- - - - - - - - - - - 2Y33
- - - - - - - - - - - 2Y34
- - - - - - - - - - - 2Y35
(+)/- (+) + - - - - - - - (+)/- 2Y36

(+)/- (+) + (+)/- (+) (+) (+)/- (+) (+) + (+)/- 2Y37
- - - - - - (+)/- (+) + r=+/ - 2Y40
(+)/- (+) + (+)/- (+) + - - - /l=+ - 2Y41
- + - - - - - - - - - 2Y42
- - - - - - - - - - (+)/- 2Y43
- - - - - - - - - - - 2Y49
- - - - - - - - - - - 2Y52
- + - - - - - - - - (+)/- 2Y53
- La - - - - - - - - La/-
2B10
La/- La La La/- La La La La La La -
2B11
Version 1.2, 12.07.2006

7 6m 6l 6k 6j 6i 6h 6g 6f 6e 6d
Del.-No.
EMER- Syn.: Syn.: Syn.: Syn.: Syn.: Syn.: Syn.: Turn (r) as Syn. Turn. (r) Function/
GENCY Thrust End Thrust End Thrust Ac- Thrust Ac- Thrust Thrust Ac- Thrust Ac- of approx. thrust/turn. approx. E.-Mag-
- 300U 300U P to 500U P to 500U P to 500U P to 500U P to 500U RP 200U/- P to 500U RP 300U 2M1
Version 1.2, 12.07.2006

- EW2 EW1 EW2 EW2 EW2 EW2 EW1 RP/EW2/- +=EW1 RP 2Y30
- +=EW +=EW - - - - - +=EW/- - +=EW 2Y31
- - - - - - - - - - - 2Y32
- - - - - - - - - - - 2Y33
- - - - - - - - - - - 2Y34
- - - - - - - - - - - 2Y35
- (+) (+) (+) (+) (+) (+) (+) (+)/- (+) + 2Y36
- (+) (+) (+) (+) (+) (+) (+) (+)/- (+) (+) 2Y37
- # # - (+) - - - (+)/- (+) + 2Y40
- # # - (+) - - - - - - 2Y41
- - - # # * # # - - - 2Y42
- - - # # * # # - + - 2Y43
- - - - - - - - - - - 2Y49
- - - - - - - - - - - 2Y52
- - - + + + + + - + - 2Y53
- - - La La La La La - La -
2B10
- La La - - - - - La/- La La
2B11
9-355
Explanations
ERP = E. control ramp
RP = Adjustable ramp
P = Proportional (via lever)
EW = Adjustable value
a. Gs = outside of initial position
6a = START from the initial position (for in-between positions the last situation is
repeated)
(*) Main lift: for ZT pole corresponds to h3 = 10,000 mm lift path Ù 5.000 mm poti path (1/2*h3)
(*) Main lift: for ZT pole corresponds to h3 = 10,000 mm lift path Ù 3.250 mm poti path (1/3*h3)
9-356 Version 1.2, 12.07.2006

Setup work
Chapter index
Chapter10
Setup work
Chapter index
10.1 Service menu / Setting parameter ......................................... 360

10.2 List of the service menu ........................................................ 363
Version 1.2, 12.07.2006 10-357

Setup work
Service menu / Setting parameter
10.1 Service menu / Setting parameter
10.1.1 Abbreviations used for parameter types
Ab-
Meaning Remark
brev.
BZ Operation hour meters
C Codes Release codes for options
D Number of rotations
I Currents
G Geometry
P General parameters
R Ramps Standard setup range 1...100
V Velocity Setting in % of maximum range
S System
T Times
TI TeachIn Value determined via TeachIn process
M Menu
E Command
10-358 Version 1.2, 12.07.2006

Setup work
10.1.2 Abbreviations in parameter display texts
Ab-
Meaning
brev.
Cut-out current cut-out
RPM Speed
I Current
ML Main lift
LLD Load lifting device
LWB Load wheel brake
MSS IG micro steering sensors
TF Telescopic fork
TI Teach-In
V Speed
AL Auxiliary lift
TAE Tine adjustment equipment
CCB Countercurrent braking
10.1.3 Division of the parameters in levels
Level Meaning
1 Is not a safety-relevant parameter
• an incorrect setting will only influence the function of the vehicle minimally
or not at all
• the function of the vehicle should be checked after each change
• the changed parameters must be documented
2 Parameters that are partially safety-relevant

• an incorrect setting can influence the function of the vehicle and lead to
damaging of components
• the function of the vehicle should be checked after each change
3 Parameters that are absolutely safety-relevant

• changes to these parameters may only be made after consulting with the
central support dept. in order to avoid damage to property or personal injury
• danger of personal injury
• all functions of the vehicle must be checked
Version 1.2, 12.07.2006 10-359

Setup work
10.1.4 Minimum and maximum values
§ Note
The values of the acceptance certificate are binding for
entering new parameters. Enter required changes in the
acceptance certificate including the name and date.
Note
The minimum and maximum values for the respective
parameter are shown on the APE. They are therefore
not listed in the following tables.
10-360 Version 1.2, 12.07.2006

Setup work
List of the service menu
10.2 List of the service menu
Menu Function group

M01 Control panel
M02 Shift
M03 Turn
M04 Auxiliary lift
M05 Main lift
M06 Driving
M07 Steering
M08 Main lift / synchronous lift auxiliary lift / lower
M09 Sync. swivel hydraulics
M10 Sync. swivel geometry
M11 Pump
M12 Lift cut-outs
M13 Driving cut-outs
M14 Lowering cut-out
M15 Options 0-15
M16 Options 16-29
M17 IG
M18 Battery
M19 Operation hour meters
M20 Load
M21 Masterspeed
M22 PPS
Tab. 10-1: List of service menus
Note
The sequence of the individual parameters in the menus
on the vehicle may deviate from the lists below.
Version 1.2, 12.07.2006 10-361

Setup work
10.2.1 M 01: Control panel
PNo. APE display text Meaning / Measures Unit

DATE / TIME For setting, see the operating Instructions
S12 Year “
S11 Month “
S10 Day “
S16 Hours “
S15 Minute “
S14 Seconds “
TX01 Sprache (D) : 0
TX01 Language (GB) : 1
TX02 Langue (F) : 2
TX03 Taal (NL) : 3
TX04 Lingua (I) : 4
TX05 Lengua (E) : 5
TX06 Sprog (DK) : 6
TX07 Sprag (N) : 7
TX08 Sprak (S) : 8
TX09 Lengua (P) : 9
S04 Select No: Enter number for selected language S04
Tab. 10-2: Parameters of service menu; Submenu M01 "Control panel"
Note
Help messages are displayed in the selected language.
Service menu: German on setting „0“; English on setting „1“ - „9“
10-362 Version 1.2, 12.07.2006

Setup work
10.2.2 M 02: Sideshift
APE display
PNo. Meaning / Measures Unit
text
TI01 TI left Drive to end position at left and confirm
TI03 TI right Drive to end position at right and confirm
G02 front part dim Enter correct size: b15 - 80 mm mm
G00 end ahead Distance before end mm
G01 End Position before the end when the initial position is mm
recognized
R00 Braking ramp A higher setting means a steeper ramp; Setting
range: 1 - 100
R02 Accel. ramp “
V00 Speed max left A higher setting means a higher speed. Setting in
% of the set switch-off range of the current regula-
tor
V01 Speed max right “
V02 SlwSpeed left “
V03 SlwSpeed right “ %
I00 I min 2Y30 Current regulator offset; minimum start current for MA
the function
I01 Current max Highest permissible starting current for the func- MA
2Y30 tion
D08 RPM speed Required rate of rotation for max. speed min-1
T05 Time valve closed Switch-off delay time of directional valve for pres- m/sec
sure reduction
Tab. 10-3: Parameters of service menu; Submenu M02 Traverse
Version 1.2, 12.07.2006 10-363

Setup work
10.2.3 M 03: Turn

TI05 TI left Drive to end position at left and confirm
TI07 TI right Drive to end position at right and confirm
G10 End ahead Enter distance before end °
G11 End Position before the end when the initial position is °
recognized
R04 Braking ramp A higher setting means a steeper ramp
R06 Accel. ramp “
V04 Speed max left A higher setting means a higher speed. Setting in %
% of the set selector range of the current regulator
V05 Speed max right “ %
V07 SlwSpeed right “ %
V06 SlwSpeed left “ %
I02 Current min 2Y30 Current regulator offset; minimum start current for MA
the function
I03 Current max 2Y30 Highest permissible starting current for the func- MA
tion
D07 RPM max. Required rate of rotation for max. speed min-1
Tab. 10-4: Parameters of service menu; Submenu M03 Turn
10-364 Version 1.2, 12.07.2006

Setup work
10.2.4 M 04: Auxiliary lift

TI09 TI bottom drive to end position ZH at bottom /confirm
TI11 TI top drive to end position ZH at top /confirm
G30 End ahead top Distance before end at top mm
G31 End ahead bottom Distance before end at bottom mm
G32 Height Dimension h9 mm
R12 Braking ramp lift A higher setting means a steeper ramp
R13 Braking ramp lower “
R14 Accel. ramp lift “
R15 Accel. ramp lower “
V13 Speed max lower A higher setting of the current controller means a %
higher speed
V14 SlwSpeed lift A higher setting of the current controller means a %
higher speed
V15 SlwSpeed lower “ %
I08 I min lift Current regulator offset; Minimum starting current MA
for the ZH lift function
I09 I max lift Highest starting current for lift auxiliary lift function MA
I18 I min lower Min. starting current for auxiliary lift lower MA
I16 I max lower Max. starting current for auxiliary lift lower MA
D04 RPM lift Speed for auxiliary lift fast min-1
D11 RPM lift slow Speed for auxiliary lift before end min-1
Tab. 10-5: Parameters of service menu; Submenu M04 Auxiliary Lift
Version 1.2, 12.07.2006 10-365

Setup work
10.2.5 M 05: main lift

TI21 TI bottom Drive main lift to end position at bottom /confirm
TI19 TI top Drive main lift to end position at top /confirm
G20 End ahead top Distance before end at top mm
G21 End ahead bottom Distance before end at bottom mm
G22 Height
R08 Braking ramp lift A higher setting means a steeper ramp
R09 Braking ramp lower “
R10 Accel. ramp lift “
R11 Accel. ramp lower “
V09 Speed max lower Higher settings of the current controller means a %
higher speed
V11 SlwSpeed lower “ %
I06 I min lower Current controller offset, minimum starting current MA
for the lower main lift function
I07 I max lower Highest permissible starting current for the lower MA
main lift function
D18 RPM max lift Speed of pump in creeping lift min-1
D00 RPM max. lift Speed of pump for fast lift of main lift min-1
D01 RPM max. lower Speed of pump for fast lower of main lift min-1
D03 RPM prop. lower Speed of pump for lowering in proportional opera- min-1
tion
Tab. 10-6: Parameters of service menu; Submenu M05 Main Lift
10-366 Version 1.2, 12.07.2006

Setup work
10.2.6 M 06: Driving

V50 Slwspeed 2.5 Creeping speed 0.01 km/h
V51 SlwSpeed 4 Increased creeping speed 0.01 km/h
V52 Speed max aisle Max. speed in aisle 0.01 km/h
V55 Speed max apron Max. speed in apron 0.01 km/h
R51 Accel. ramp A higher setting means a steeper ramp
R50 Braking ramp “
R60 Endaisle brake ramp “
R57 CCB manual max. Max. brake value at countercurrent brake
Tab. 10-7: Parameters of service menu; Submenu M06 Driving
Version 1.2, 12.07.2006 10-367

Setup work
10.2.7 M 07: Steering

TI15 TI Steer right TeachIn steering turned 90° right
TI13 TI Steer middle TeachIn steering in the middle setting
TI17 TI Steer left TeachIn steering turned 90° left
P18 wheel transmission A higher setting means more direct translation;
Setting range: 5 - 30;
Setting 5: approx. 20 revs for 180° steering deflec-
tion
Setting 30: approx. 4 revs for 180 ° steering de-
flection
P19 Straight ahead corr To correct a steering offset; Setting range -30° to 0,1°
+ 30°; see Description of Setting of Sensor Steer-
ing
Steering manual
P02 Amplification Higher settings mean more aggressive steering; if
the setting is too high then the steering controller
may start to swing!
P01 Steering ramp Higher settings mean a harder acceleration and
higher dynamic
P00 Steering speed A higher setting means a higher maximum steer-
ing speed
Steering IG apron
may start to swing!
higher dynamic
ing speed
Steering IG aisle
may start to swing!
higher dynamic
ing speed
Tab. 10-8: Parameters of service menu; Submenu M07 Steering
10-368 Version 1.2, 12.07.2006

Setup work
10.2.8 M 08: Synchronous main and auxiliary lift

TX16 -- Main lifting syn.
D16 RPM min lift syn Minimum speed for lift of main lift min-1
D17 RPM max. lift Maximum speed for lift of main lift min-1
D13 RPM lift slow Speed for lift of main lift with creeping min-1
D19 RPM min lower Minimum speed of pump at main lift lowering min-1
D15 RPM max lower Maximum speed for lowering of main lift min-1
D14 RPM lower slow Speed of pump at main lift lowering with creeping min-1
TX17 -- Aux lifting syn. --
V61 SlwSpeed AL lift A higher setting of the current controller means a %
higher speed
V63 Speed max AL lift “ %
V62 SlwSpeed AL lower “ %
V60 Speed max AL lower “ %
Tab. 10-9: Parameters of service menu; Submenu M08 Synchronous main and auxiliary lift
Version 1.2, 12.07.2006 10-369

Setup work
10.2.9 M 09: Traverse synchronous hydraulic

D12 RPM min sideshift Minimum RPM for synchronous sideshift min-1
D06 RPM max sideshift Maximum RPM for synchronous sideshift min-1
TX19 -- Sideshift syn --
R21 RPM braking ramp A higher setting means a steeper ramp
R22 RPM Accel. ramp “
I20 Current const. 2Y31 See Hydraulic adjustment"” on page 9-312 MA
V21 Offset No meaning %
TX18 -- Swivel syn --
I10 Current min 2Y30 Min. starting current MA
I11 Current max 2Y30 Max. starting current MA
R16 Braking ramp A higher setting means a steeper ramp
R18 Accel. ramp “
V18 Offset No meaning %
V16 SlwSpeed Humping speed in range before the end %
V19 Speed max Humping speed %
Tab. 10-10: Parameters of service menu; Submenu M09 Traverse synchronous hydraulic
10-370 Version 1.2, 12.07.2006

Setup work
10.2.10M 10: Sync. swivel geometry

G80 Offset aisle Detail of the lateral safety clearance in mm; The
value must be planned
G89 Startup angle Angle of rotation from which the fork swivels °
G87 Cut-out height Lift height for switch off synchronous mm
P47 Zone cut-out Storage zone for synchronous switch off; Identifi-
cation according to storage zone system (see
Chap. 9) 0-255
G82 Radius 1 Planned size or teach-In

G84 Radius 2 Planned size or TeachIn
G86 Radius 3 Planned size or TeachIn
G81 Alpha 1 Planned size or TeachIn
P16 Amplification Dynamic of the controller can be set
TI23 TI Position A Drive / confirm TeachIn position A
(see Chapter 9)
TI25 TI Position B Drive / confirm TeachIn position B
TI27 TI Position C Drive / confirm TeachIn position C
TI29 TI Position D Drive / confirm TeachIn position D
Tab. 10-11: Parameters of service menu; Submenu M10 Sync. swivel geometry
10.2.11M 11: Pump

D20 RPM min Minimum pump speed min-1
Tab. 10-12: Parameters of service menu; Submenu M11 Pump
Version 1.2, 12.07.2006 10-371

Setup work
10.2.12M 12: Lifting cut-out (activation by code)

G45 End ahead The set path before the end (mm) applies to all
cut-out heights
TI45 TI co lift A Using the main lift, drive to the required lift height
and confirm with ENTER;
G40 A height The required cut-out height can be directly en- mm
tered here; also useful for fine correction in the
mm range after TeachIn of the cut-out height
P20 A Zone Set in which storage zones the lifting cut-out is to
be effective (see Electrical equipment"” on page
9-237):
Setting possibilities: 0 - 255
At the setting “255“, the switch off is always effec-
tive. For an exact explanation on the aisle detec-
tion and storage zones, see Chapter 9.
P25 A override Set whether the lifting cut-out may be bridged;
Bridging is via buttons in the control panel
(0 = no; 1 = yes)
TI47 TI co lift B as in „A“

G41 B height as in „A“ mm
P21 B zone as in „A“
P46 B override as in „A“
TI49 TI co lift C
G42 C height as in „A“ mm
P22 C zone as in „A“
P27 C overriding as in „A“
TI51 TI co lift D as in „A“

G43 D height as in „A“ mm
P23 D zone as in „A“
P28 D override as in „A“
TI53 TI co lift E as in „A“

G44 E height as in „A“ mm
P24 E zone as in „A“
P29 E override as in „A“
Tab. 10-13: Parameters of service menu; Submenu M12 Lifting cut-out (activation by code)
10-372 Version 1.2, 12.07.2006

Setup work
10.2.13M 13: Drive cut-out (activation by code)

TI55 TI drive ABS A Using the main lift, drive to the required lift height
Warning: The leading sign determines whether
the cut-out is effective above or below this
height.Positive leading sign means: Cut-out
above the set height; Negative leading sign: Cut-
out below the set height.
P37 A Zone Set in which storage zones the lifting drive cut-out
is to be effective (see Chapter 9):
P40 A override Set whether the drive cut-out may be bridged;
(0 = no; 1 = yes)
TI57 TI co drive B as in „A“

TI59 TI co drive C as in „A“

P42 C override as in „A“
P43 Zone co LoadLDev Cut-out when LAM is not in initial position; Storage
zone according to storage zone system (1-255)
1 = apron
2 = aisle
255 = everywhere)
P44 Override co LoadLDev Override the cut-out
(0 = no; 1 = yes)
Tab. 10-14: Parameters of service menu; Submenu M13 Drive cut-out (activation by code)
Version 1.2, 12.07.2006 10-373

Setup work
10.2.14M 14: Lowering cut-out (activation by code)

G49 Before the end ABS. The set path before the end (mm) applies to all
cut-out heights
TI61 TI co lower A Using the main lift, drive to the required lift height
P30 A Zone Set in which storage zones the lifting cut-out is to
be effective (see Electrical equipment"” on page
9-237):
P33 A override Set whether the lifting cut-out may be bridged;
(0 = no; 1 = yes)
TI63 TI co lower B as in „A“

TI65 TI co lower C
P35 C override as in „A“
Tab. 10-15: Parameters of service menu; Submenu M13 lowering cut-out (activation by code)
10-374 Version 1.2, 12.07.2006

Setup work
10.2.15M 15: Option codes 0-15

FFZ code
C00 GESI standstill Release code GESI with braking to a stop and
manual reset
C01 IF Release code IG
C02 Sideshift cut-out Release code of reach travel cut-out
C03 ML lift cut-out A Release code of lift main lift cut-out A
C04 ML lift cut-out B Release code of lift main lift cut-out B
C05 ML lift cut-out C Release code of lift main lift cut-out C
C06 ML lift cut-out D Release code of lift main lift cut-out D
C07 ML lift cut-out E Release code of lift main lift cut-out E
C08 Endaisle autoreset Release code GESI with braking to creep speed
and auto-reset
C09 Masterspeed Release code of MasterSpeed
C10 ML AL synchron Release code of main lift auxiliary lift synchron
C11 Swivel syn Release code of synchron swiveling
C12 ML lower cut-out A Release code of lower main lift cut-out A
C13 ML lower cut-out B Release code of lower main lift cut-out B
C14 ML lower cut-out C Release code of lower main lift cut-out C
C15 Drive cut-out A Release code of drive cut-out A
Tab. 10-16: Parameters of service menu; Submenu M15 Option codes 0-15
Version 1.2, 12.07.2006 10-375

Setup work
10.2.16M 16: Option codes 16-29

C16 Drive cut-out B Release code of drive cut-out B
C17 Drive cut-out C Release code of drive cut-out C
C18 Drive cut-out Release code drive cut-out if load lifting device not
LoadLDev in initial position
C19 Drive cut-out apron Release code bridging drive cut-out in advance
via a set lift height (parameter P45 on the Master-
speed menu)
C20 Code: 20 n.c. Release code special function
C21 Overload Release code for activation of the overload func-
tion
C22 Aisle recogn. Wire Release code IG without aisle detection
Tab. 10-17: Parameters of service menu; Submenu M16 Option codes 16-29
10-376 Version 1.2, 12.07.2006

Setup work
10.2.17M 17: IG (induction guidance)

Rx MSS frequency 1 Wire frequency for MSS 1; Hz
Rx MSS frequency 2 Wire frequency for MSS 2; Hz
Rx MSS height 1 Read height MSS 1 (front) above the floor (dis- mm
tance lower edge sensor - floor)
Rx MSS height 2 Read height MSS 2 (rear) above the floor (dis- mm
tance lower edge sensor - floor)
P56 Offset axis Offset for both MSS with respect to vehicle length mm
axis
P55 Offset MSS Offset for offset MSS 1 / MSS 2 to one another mm
TI41 Calib MSS front TeachIn for calibration MSS 1 front
See Electrical equipment"” on page 9-237
TI43 Calib MSS end TeachIn for calibration MSS 2 rear
See Electrical equipment"” on page 9-237
P57 GKp engage IG regulation parameters: Weighting gear angle
during engaging
P58 BKp engage IG regulation parameters: Weighting distance dur-
ing engaging
P59 GKp apron IG regulation parameters: Weighting gear angle
for driving on the apron
P60 BKp apron IG regulation parameters: Weighting distance for
driving on the apron
P61 GKp aisle IG regulation parameters: Weighting gear angle
for driving in the aisle
P62 BKp aisle IG regulation parameters: Weighting distance for
driving in the aisle
P63 Steering angle max. Restriction of the maximum steering angle during 0,1°
engaging
P64 Steering angle min Minimum steering angle for swiveling to the wire
forw. during engaging in the forwards direction
P65 Steering angle min Minimum steering angle for swiveling to the wire
backw. during engaging in the backwards direction
Tab. 10-18: Parameters of service menu; Submenu M17 Induction guidance (IG)
Version 1.2, 12.07.2006 10-377

Setup work
10.2.18M 18: Battery

R59 Batt. Volt mes. Enter measured battery voltage with calibrated 0,01V
multimeter.
TX20 0 : PzS-G Normal wet cell PzS-G
TX21 1 : PzS-H Performance-enhanced wet cell PzS H/L
TX22 2 : PzS maintenance- Maintenance-free lead-gel battery
free
P50 Battery type Enter battery type (0 -1 - 2)
Tab. 10-19: Parameters of service menu; Submenu M18 Battery
10.2.19M 19: Hour meters

BZ00 general movement Value can be read out / counts acc. to DIN h
time
BZ01 switchOn duration Value can be read-out and changes / counts as h
long as Power on
BZ02 Steering Value can be read-out and changes / counts as h
long as steering active
BZ03 Driving Value can be read-out and changes / counts as h
long as drive active
BZ04 Pump Value can be read-out and changes / counts as h
long as pump active
TI31 Load Default Par The working parameters stored in Flash are being
loaded. Warning: The current parameters will be
overwritten and cannot be reloaded.
TI33 Load client Par The customer-specific parameters stored via TI35
in Flash are being loaded. The current parameters
will be overwritten and cannot be reloaded.
TI35 Save client Par Save the current customer-specific parameter set
in the vehicle's Flash. The previously-saved pa-
rameter set will be overwritten.
Tab. 10-20: Parameters of service menu; Submenu M19 Hour meters
10-378 Version 1.2, 12.07.2006

Setup work
10.2.20M 20: Load sensors

P54 Max weight Enter the weight at which the overload should be kg
shown
P80 Calibration weight Enter the weight at which TeachIn is to be used kg
TI37 TI load min TeachIn with empty fork (fork should be lifted
slightly)
TI39 TI load max TeachIn with applied calibration weight. The cali-
bration weight used should be at least 500 kg
Tab. 10-21: Parameters of service menu; Submenu M20 Load sensors
10.2.21M 21: MasterSpeed

G52 Height slwspeed fwd Lift height for fast driving in load direction if no load mm
on the fork
G53 Height slwspeed bwd Lift height for fast driving in drive direction if no mm
load on the fork
G50 Height speed red fwd Lift height for fast driving in load direction if full mm
load on the fork
G51 Hight speed red bwd Lift height for fast driving in drive direction if full mm
load on the fork
P45 Height cut-out apron Lift height for drive cut-out on apron; can be mm
changed after release via option code 19
Tab. 10-22: Parameters of service menu; Submenu M21 Masterspeed
10.2.22M 22: PPS (personal protection system)

G54 PPS height info Switches the corresponding output to the interface mm
for personal protection systems if h3>set value.
Tab. 10-23: Parameters of service menu; Submenu M22 PPS (personal protection system))
Version 1.2, 12.07.2006 10-379

Setup work
10-380 Version 1.2, 12.07.2006

Diagnosis
Chapter index
Chapter 11
Diagnosis
Chapter index
11.1 Visual check of electronics components ............................... 382

11.2 Fuse check ............................................................................ 383
11.3 CAN check ............................................................................ 384
11.4 System messages ................................................................. 387
11.5 Operational messages .......................................................... 391
11.6 Inputs, outputs. Noter ............................................................ 401
11.7 State analysis and operating states ...................................... 416
Version 1.2, 12.07.2006 11-381

Diagnosis
Visual check of electronics components
11.1 Visual check of electronics components

Before an electronic component is replaced, a check should be made for external-
ly-visible damage. On the one hand, this can contribute to an unambiguous diag-
nosis; on the other hand it can provide hints about the causes of the failure. Under
certain circumstances, the component can be repaired with simple tools.
The following points must be checked:
Test step Measures

Plug connector in order ? Straighten out bent pins;
in case of mechanical damage, replace circuit
board
Are the fuses ok? Replace defective melt inserts; check fuse holders
to make sure they are seated tightly
Attachments correct ? Check whether all jumpers are in the correct slots;
Check whether all plug connections make good
contact
Check for mechanical dam- In case of visible mechanical damage, do not re-
age pair. Replace components!
Check for loose components Do not re-solder loose components; replace com-
ponent!
Burn spots visible ? Attempt to determine the cause. What conductor
path or what area of the component is damaged.
Cause possibly due to incorrectly-dimensioned
fuse?
Only if the visual check provides no hint of a malfunction should the component be
replaced.
For the after-the-fact determination of the fault cause at the manufacturer's plant,
it is absolutely necessary to prepare a detailed description of the malfunction. Fur-
thermore, the operating conditions under which the fault occurs or occurred must
be named.
Only with this information can a quick determination of the cause of failure and
thus a product improvement in the ongoing series be guaranteed.
11-382 Version 1.2, 12.07.2006

Diagnosis
Fuse check
11.2 Fuse check

The vehicle's electrical circuits are protected by melting fuses against damage due
to overload and short circuit.
Note
For information about main and fine fuses, see Chapter
F of the operating instructions.
WARNING!
Only change out fuse inserts when the vehicle is
switched off (danger of injuries and property dam-
age).
Before changing out main fuses, pull battery plug (danger of short circuit when sol-
dering and tightening the bolted connections).
For the continuity test with the multimeter, the fuse inserts must be taken out of the
fuse holder.
Burned-through or not-occupied flat-plug fuses on the fuse board are also indicat-
ed when the associated control LED goes out.
Before exchanging fuse inserts
• check the affected current path for short circuit with the multimeter
• remove damage to the electrics and electronics
When changing the strip fuse inserts, note:
• do not forget any washers

• tighten bolted connections well
Version 1.2, 12.07.2006 11-383

Diagnosis
CAN check
11.3 CAN check
11.3.1 Structural design
The topology of the CAN bus is apparent in the circuit diagram Sheet 0.2.
With respect to the pin and wire assignments, note the respective detail pages of
the circuit diagram.
For vehicles with CAN-open systems, the AC controllers for steering, drive motor
and pump are integrated into the vehicle's CAN bus system.
For CAN bus errors in a component, a corresponding fault message is displayed

on the APE. For each component, an individual system message is displayed, with
which faulty components can be identified easily.
In addition, the converters and vehicle control components display faulty states via
component-related LEDs.
Causes of CAN faults
Possible causes of CAN faults are
• incorrectly-mounted jumpers (for activating the termination resistance)

• defective hardware components in the CAN bus system
• faults in the wiring (e.g. hi-lo signals mixed up)
• incorrect software versions or incorrect parameter sets for drive controller,
steering controller or pump controller, APE or control panel
• fault in the shielding
• strong external interference
Shielding of the pole cable
The shielding of the CAN bus line over the pole is required for adherence to EMC
provisions.
The CAN data transmission is possible without shielding, due to the legal regula-
tions, however, not permissible, because external electronic components may be
interfered with.
Note
In case of missing of incorrectly-plugged jumpers on the
components, data transmission can function neverthe-
less. However, then it will be more sensitive to interfer-
ence.
11-384 Version 1.2, 12.07.2006

Diagnosis
CAN check
11.3.2 Procedure for fault analysis for CAN interference
Basic principles
• Check the current software version of all three AC controllers

(Version_2xxxx and up).
• Observe flashing codes on drive, pumps and steering control (see chapter
15)
• Check cable connections (CAN wiring and power supply)
• Check the hardware components of the CAN bus system
• Check the wiring
• Check the jumpers for activation of the termination resistance
Measurements
The following simple measurements serve the further investigation of interference

in the CAN bus system:
Measurement of the termination resistance
In the standard vehicle, the CAN bus is terminated in the control panel (120 Ohm)
and on the DPU distributor board (120 Ohm)
Procedure for measurement:
1. Disconnect battery plug

2. On the plug connector X112 (when plugged in), measure the ohmic resis-
tance between pin 1 and pin 2 with the multimeter. A resistance of 60 Ohm
+/- 5 Ohm must be measured.
Measures:
If a larger resistance is measured (especially 120 ohms), a necessary ter-
mination resistance is not active.
If a larger resistance is measured (especially 40 ohms), an additional termi-
nation resistance is not activated.
In both cases, suitable additional measures must be taken to locate which
termination resistances are missing or are additional activated. For this, in-
dividual plug connectors can also be pulled and components and net sec-
tions measured separately.
Version 1.2, 12.07.2006 11-385

Diagnosis
CAN check
Measurement of the voltage level
For a normally-equipped vehicle, the voltage level of CAN_Hi is approx. 2.8V, of

CAN-Low approx. 2.3V.
Procedure for measurement:
In the switched-on state with the multimeter (0..20V DC) on X112 Pin1
(CAN_Hi) and Pin 2 (CAN_Low), measure against GND. The above men-
tioned voltage values must be set
If significantly lower values are measured, this may indicate a defective
CAN transceiver in a component. By pulling the CAN wiring from individual
components and repeated measurement, it is possible to locate the defec-
tive component.
If identical voltage is measured for CAN_Hi and CAN_Low, this can indicate
a short circuit between CAN_Hi and CAN_Low. Furthermore, there could be
a mix-up of CAN_Hi and CAN_Low somewhere on the network.
Note: For vehicles with additional or reduced equipment on the CAN net-
work, the voltage levels can show other values. However, there must al-
ways be a difference between CAN_Hi and CAN_Low of at least 0.2 V.
11-386 Version 1.2, 12.07.2006

Diagnosis
System messages
11.4 System messages
11.4.1 Fault types
The display and programming unit (APE) is the central tool for fault seeking. Here,
faults detected by the SECAN controller are displayed in the form of a fault code
or a help text, depending on the type and time of the fault. The activation of the
fault display on the APE is described in the vehicle's operating instructions.
Message/fault type Type of the display

Fault during boot-up (after switching Boot-up fault; Display as fault code Erxxx
on)
Important messages for the operator: Online help; Plain text in the respective lan-
guage of the country
- Request an operator action
- Information about limit states
Error during operation (after success- Operating error; Display as fault code Erxxx
ful boot-up) (Er = Error)
Note
In case of malfunctions, always consult the APE first for
troubleshooting.
A direct boot-up fault message, operating fault message or online help message
is only possible if the SECAN controller detects one of the following situations:
Fault example
Mechanical fault Slack chain switch activated
A triggered function provided no feed- Drive release is given, however no drive

back function (IG claw does not vent)
Illegal combinations of input signals Simultaneous drive switch signal forwards

and backwards
Limit values exceeded Drive sensor detects too-high driving speed
Fault in the electronics or CAN communi- CPC receives no answer from the DPU
cation
Fault in the sensors Wire break actual value potentiometer

steering
Version 1.2, 12.07.2006 11-387

Diagnosis
System messages
Some faults cannot be detected by the SECAN controller.

example: Command button auxiliary lift failed
Note
If despite malfunction there is no fault display, the cause
can be determined with the help of the state analysis de-
scribed in Chapter 8.
11-388 Version 1.2, 12.07.2006

Diagnosis
System messages
11.4.2 Online help
Note
For APE notes, see operating instructions Chapter E.
11.4.3 Boot-up fault
After switching on the operating voltage, the individual components carry out an
automatic test. The communication via CAN bus is established
During boot-up, the states of the controller system are displayed on the multi-co-
lour LED of the master controller. If the system halts during boot-up, the colour and
flashing messages of the LED may indicate possible faults.
Flow scheme of boot-up:
No. LED Controller state

0 Flashing green 5Hz No operating system in CR0020
0 Flashing green 5Hz Loading operating system in CR0020
0 Green Operating system loaded, programme not yet
loaded
201 Red CAN initialization
202 Blue Boot-up of all CAN nodes; Waiting for CPU
If boot-up halts in this state: check CAN connec-
tions! Most likely, CAN-Hi and CAN-Low are
mixed up or bridged somewhere.
204 Magenta (pink) Waiting for all feedback
205 Sending vehicle configuration to APE/CPU
206 Waiting time after sending a configuration mes-
sage
207 Cyan (light blue) Loading parameters
208 Loading and checking option codes from Flash
209 Loading help texts
212 Sending vehicle configuration to APE/CPU
213 Waiting time after sending a message. Jump
back to 212 until complete.
210 (opt.) Red Initializing inductive guidance (if present)
203 Red-green flash- Preoperational State; Adjust required CAN pa-
ing (slow 0.5 Hz) rameters; Wait for participants on the bus
(CR2012, CR0302)
211 Yellow Waiting for drive controllers on the bus
215 Start cyclical operation mode
220 Flashing blue 2Hz Cyclical operation mode (operational state);
Controller system is ready for operation
Version 1.2, 12.07.2006 11-389

Diagnosis
System messages
§ Note
The internal CPU boot-up errors are displayed as Er
faults on the APE (Er300...).
In case of faults during boot-up, the last colour code remains.
Note on state 202 (blue): Check CAN connections! Most likely, CAN-Hi and CAN-
Low are mixed up or bridged somewhere.
11-390 Version 1.2, 12.07.2006

Diagnosis
Operational messages
11.5 Operational messages
11.5.1 General remarks on operating messages
After successful boot-up, the SECAN controller checks the vehicle constantly for
illegal states. Faults detected are displayed as operating faults ("Er" faults) on the
APE.
The APE can display several errors which occur simultaneously.
Depending on the fault type, operating fault messages are self-deleting (AU-
TORESET), manually-deletable (MANRESET) or not self-deleting (NORESET).
Note
"Self-deleting" error messages disappear as soon as the
fault cause has been removed.
Fault messages with MANRESET can be reset by the operator with a key combi-
nation. The vehicle can then be moved again immediately if the fault no longer ex-
ists. Faults of this type do not affect the vehicle's safety system.
NORESET fault messages are also displayed again after fault elimination. They
only disappear after the operating voltage is switched off. These faults normally af-
fect the vehicle's safety system.
Non self-deleting fault displays can also make faults which appear briefly visible
(storage function).
The following table of operating messages describes the meaning, device reaction
and reset type of each message.Below there is a brief explanation of the individual
points:
Meaning of the device reactions:
• EMERGENCY STOP: All device functions are locked; Brake is engaged

• CREEP: Affected function or all functions are reduced to creep speed
• DISPLAY: Error is only displayed, all device functions are completely avail-
able
Meaning of the reset types:
• NORESET: Fault can only be deleted by switching off and on

• MAN_RESET: Manual reset; Fault can be deleted by activating a key com-
bination
• AUTORESET: Fault deletes itself automatically if fault conditions are no
longer fulfilled
Version 1.2, 12.07.2006 11-391

Diagnosis
Message Description Possible Causes and Measures

Er200 Meaning: Not active presently not active
Reaction of engine: -
Reset type: -
Er201 Meaning:System error presently not active
Reaction of engine: EMERGENCY
STOP
Reset type: NO RESET
Er202 Meaning: Error input module - Wrong wiring of inputs
- Laser sensor for lift height configured wrongly
- Inadmissible component connected with input module
STOP
Er203 Meaning:code Incorrect state of the software!
Message to DLS-KD
STOP
Er204 Meaning:Enabling 24V - Check power supply
- Check fuses
- Check wiring
STOP
Er205 Meaning:Error of the nominal value in- e.g.: Nominal value for forward and backward movement
dicator on the left side of the control are simultaneous;
panel Analyse through EAM diagnosis!
Nominal value indicator can't be repaired. --> Replace
STOP
Er206 Meaning:Error of the nominal value in- e.g.: Nominal value for forward and backward movement
dicator on the right side of the control are simultaneous;
panel Analyse through EAM diagnosis!
Nominal value indicator can't be repaired. --> Replace
STOP
Er207 Meaning:Error of security module (SI- Check correct wiring of SIMO (including adapter!)
MO)
STOP
Er208 Meaning:Error output module Check if outputs have had a short circuit
STOP
Er209 Meaning: Not active
Reset type: -
11-392 Version 1.2, 12.07.2006

Diagnosis

Er210 Meaning:CAN error CPU No signal from CPU to CAN BUS
- Check CPU software version (V5.xx)
- CAN Check
STOP
- Check wiring
Er211 (SL) Meaning:CAN error CR0302 -No signal from module Cr0302 to CAN bus
Reaction of engine: EMERGENCY - CAN Check
STOP - Check wiring
Check software version of CR0302 (possible only with
download programme)
Er212 (SL) Meaning:CAN error CR2012 -No signal from module Cr2012 to CAN bus
Reaction of engine: EMERGENCY - CAN Check
STOP - Check wiring
Er213 Meaning:CAN error, converter of -No signal from converter of pump motor to CAN bus
pump motor
- CAN Check
Reaction of engine: EMERGENCY - Check wiring
STOP
- Observe flashing code of the converter
Er214 Meaning:CAN error converter drive -No signal from converter drive motor to CAN bus
motor
- CAN Check
STOP
- Observe flashing code of the converter
Reset type: NORESET
Er215 Meaning:CAN error converter steering -No signal from converter of steering motor to CAN bus
motor
- CAN check
STOP - Observe flashing code of the converter
Er216 Meaning:CAN error of IG module -No signal from IG module to CAN bus
Reaction of engine: EMERGENCY - CAN check
STOP - Check wiring
If no IG is installed, check bridge connector X108!
Er217 Meaning:CAN bus OFF CAN bus of the master has switched off due to too-strong
disturbance on the bus - check brake and freewheel diodes
STOP - CAN check cabling
Reset type: NO RESET - Check external perturbation
Er218 Meaning:CAN bus Warning CAN bus of the master has switched off due to too-strong
disturbance on the bus - check brake and freewheel diodes
STOP - CAN check cabling
Reset type: NO RESET - Check external perturbation
Er219 Meaning: Not active presently not active
Reset type: -
Version 1.2, 12.07.2006 11-393

Diagnosis

Er220 Meaning: aisle end protection (GESI) - Driving speed too high or
violation of the braking curve
- Braking action of the el. brake too low
With the corresponding parameters on the "Drive" menu,
STOP
the driving speed and brake action can be adjusted!
Er221 Meaning:Aisle-end protection (GESI) -Check mechanical application of the GESI switch
one-channel triggering of switch for-
-Check whether track width of the magnets matches the
wards A
track width of the switches
- Check with EA diagnosis (E209) whether switch triggers
STOP
at all (manual check with magnet)
one-channel triggering of switch for-
wards B
STOP
one-channel triggering of switch back-
ward A
STOP
illegal switch combination forwards -
reverse
STOP
illegal switch combination forwards -
- Check whether cabling is correct
reverse
- Check with EA diagnosis (E207-E210) whether switch
triggers at all (manual check with magnet)
STOP
permanent triggering of one or several
- Check whether cabling is correct
switches
- Check with EA diagnosis (E207-E210) which switches are
Reaction of engine: CREEPING
permanently triggered:
Reset type: MANRESET
Reset via manual activation with magnet or through re-
newed driving over the trigger magnets in the aisle.
Er227 Meaning:Error in the converter pump - Observe flashing code of the converter pump
Reaction of engine: EMERGENCY (see appendix)
STOP
reset type: NO RESET
11-394 Version 1.2, 12.07.2006

Diagnosis

Er228 Meaning:Error in the converter drive - Observe flashing code of the converter drive
Reaction of engine: EMERGENCY (see appendix)
STOP
Er229 Meaning:Error in the converter steer- - Observe flashing code of the converter steering
ing
(see appendix)
STOP
Er230 Meaning:sensors sideshift poti 1: Wire -EAM diagnosis (EA210-EA211)
break detection
- Check cabling
Reaction of engine: CREEP
-Check adjustment of sensors and repeat TeachIN
reset type: MANRESET
-Check potentiometer connection
-Check potentiometer; replace if necessary
Er231 Meaning:sensors sideshift poti 2: Wire -EAM diagnosis (EA210-EA211)
break detection
- Check wiring
Er232 Meaning:sensors sideshift poti 1: Ille- -EAM diagnosis (EA210-EA211)
gal value range
- Check cabling
Er233 Meaning:sensors sideshift poti 2: Ille- -EAM diagnosis (EA210-EA211)
gal value range
- Check cabling
Er234 Meaning:sensors sideshift illegal dif- -EAM diagnosis (EA210-EA209)
ference between poti 1 and poti 2
- Check cabling
Er235 Meaning:sensors turn poti 1: Wire -EAM diagnosis (EA208-EA211)
break detection
- Check cabling
Version 1.2, 12.07.2006 11-395

Diagnosis

Er236 Meaning:sensors turn poti 2: Wire -EAM diagnosis (EA208-EA211)
break detection
- Check cabling
Er237 Meaning:sensors turn poti 1: Illegal -EAM diagnosis (EA208-EA209)
value range
- Check wiring and repeat TeachIN
-Check adjustment of sensors
Er238 Meaning:sensors turn poti 2: Illegal -EAM diagnosis (EA208-EA209)
value range
- Check cabling
Er239 Meaning:sensors sideshift illegal dif- -EAM diagnosis (EA208-EA210)
ference between poti 1 and poti 2
- Check cabling
E240 Meaning:sensors - Check high reference switch with cabling
main lift reference switch was not de-
- Check magnet
tected in the height range of 200-400
mm - Check lift height detection with laser sensor and, if neces-
sary, set and teach in
Er241 Meaning:sensors - Check cabling of laser sensor

main lift wire break laser sensor
- Check configuration of laser sensor
- EAM diagnosis EA 201
- repeat Teach-In
Er242 Meaning:sensors main lift - Check cabling of laser sensor

value of laser sensor outside of the le-
- Check configuration of laser sensor
gal range
reset type: MANRESET - repeat TeachIN
Er243 Meaning:sensors auxiliary lift - Check cabling AL-poti

wire break poti auxiliary lift
- Check mech. application AL-poti
- repeat TeachIN
11-396 Version 1.2, 12.07.2006

Diagnosis

Er244 Meaning:sensors auxiliary lift - Check cabling AL-poti
value poti AL outside of the legal range
- repeat TeachIN
Er245 Meaning:sensors load - Check cabling poti load
value poti load outside of the legal
range
reset type: MANRESET - repeat TeachIn
Er246 Meaning:sensors steering illegal dif- - Check cabling steering potis
ference between poti
- Check mech. application of steering potis
1 and poti 2
- EAM diagnosis EA 200 and EA 204
STOP - repeat TeachIN
Er247 Meaning:plausibility driving motion -Check whether there is an operating error
driving activated but no speed signal
- EAM diagnosis with the relevant values for the driving mo-
Reaction of engine: EMERGENCY tion (see EAM list).
STOP
Er248 Meaning:sensors steering wire break - Check cabling steering potis
of a steering poti
- Check mech. application of steering potis
- EAM diagnosis EA 200 and EA 204
STOP
Er249 Meaning: Inductive guidance (IG) -Check IG wire and signal generator; observe display in IF
loss of the wire signal during IG guid- signal generator
ance
-Measure wire deviation;
-Check IG steering behaviour and setting
STOP
Er250 Meaning: Inductive guidance (IG) vio- -Measure wire deviation and inclination
lation of the emergency stop diamond
-Check IG steering behaviour and setting
- Check steering straight ahead setting, if necessary, reset
STOP
reset type: NO RESET - Adjust maximum speed in the aisle, if necessary adjust
the emergency stop diamond
Er251 Meaning: Inductive guidance (IG) - Check steering straight ahead setting, if necessary, reset
legal steering angle exceeded
- Check regulation parameters of the steering regulator and
Reaction of engine: EMERGENCY reset if necessary
STOP
Version 1.2, 12.07.2006 11-397

Diagnosis

Er252) Meaning: Inductive guidance (IG) -Check whether there is an operating error
plausibility problem between aisle sig-
- Check setting IG regulator and steering regulator
nals and IG state (aisle signal, al-
though not yet engaged) - EAM diagnosis with the values relevant for IG
STOP
Er253 Meaning: Inductive guidance (IG) claw - Check setting steering and claw with acknowledgment
in aisle not inserted switch
STOP
Er254 Meaning: Inductive guidance (IG) claw - Check setting claw with acknowledgment switch
in apron not inserted
STOP
11-398 Version 1.2, 12.07.2006

Diagnosis
11.5.2 Operational messages CPU
Message Description Possible measures

Er301 Boot error of computer CPU -Replace CPU board (CPU or EPROM defective)
->all functions blocked -Consult customer service dept.
Er302 Fault in the synchronisation of the -Check software version of the controls and the CAN com-
CAN bus system puter and update if required
-Observe flashing codes on drive, pumps and steering
control (see chapter 15)
-SK-R check (DPU and CPC; see Chapter 9.1 and 9.2)
-Check cable connections (CAN wiring and power supply)
-Check the hardware components of the CAN bus system
(see chapter 9.4.1)
-Consult customer service dept.
Er303 Steering unit detects different signals -Check the cable connection between the steering unit
from sensor bearings 1 and 2 and the motherboard of the left half of the control panel
->general emergency stop -Slowly turn the steering wheel and measure the switching
of the phase signals with a voltmeter
-Check the power supply of both sensors (corrosion,
crimping, faulty positions at the cable or plugs, etc.)
Er304 Non-permitted current consumption of -Check the cable connection between the steering unit
the steering wheel sensor at channel and the motherboard of the left half of the control panel
A
-Slowly turn the steering wheel and measure the switching
(wire-brake, short circuit in supply of the phase signals with a voltmeter
line)
Er305 Error in NV-RAM during boot proce- -Switch the vehicle back on
dure
-Enter access code
->all functions blocked
-Enter access code
-Observe service instruction on APE
-Press buttons F1+F6 simultaneously and keep pressed
until the service menu appears on the APE
-Check CPU board replace if necessary
Er307 Non-permitted current consumption -Check the cable connection between the steering unit
from steering wheel sensors at chan- and the motherboard of the left half of the control panel
nel B
-Slowly turn the steering wheel and measure the switching
->all functions blocked of the phase signals with a voltmeter
Er309 Warm start of computer during opera- -Restart the vehicle

tion
->all functions blocked
Version 1.2, 12.07.2006 11-399

Diagnosis
Message Description Possible measures

Er314 Analog value does not agree with the -Cross swap master switch left/right
switch values (master switch at right)
-If the error does not resolve:
Swap check of the signals at the plug connector to the
motherboard
Warning:
Before putting the control panel into operation:
Screw the connection CPU to CPC; do not stress the ca-
ble connection
Er315 Analog value does not agree with the -Cross swap master switch left/right
switch values (master switch at left)
-If the error does not resolve:
Swap check of the signals at the plug connector to the
motherboard
Warning:
Before putting the control panel into operation:
Screw the connection CPU and CPC; do not stress the ca-
ble connection
Er328 No RS232 connection between the -Check the cable connection between the right and left
left half of the control panel and the halves of the control panel
CPU
-Check the RS232 power supply
-RS232 check
See also description of Er329
Er329 Temporary interruption of communi- -Check RS232 cable connection

cation between CPU and left half of
-RS232 check
control panel
-Check power supply to left half of control panel (at the
Note: This error may also occur as a
control point of the left half of the control panel)
result of the error Er328
Er330 TxD and RxD at the right half of the If the error occurs without bridge plug:
control panel have been connected to
-remove left half of the control panel
each other for checking the serial in-
terface If the error goes out:
replace computer board at left half of control panel, other-
wise
-replace motherboard CPU
Er331 Interruption of supply voltage to CPU -Check cable connection between CPC and DPU
-Check cable connection between CPC and CPU
-Check for loose contact
-Check for short-circuit
Er332 Interruption to the supply voltage of -Check the cable connection between the CPU and the
left half of the control panel left half of the control panel
-Check for loose contact
-Check for short-circuit
11-400 Version 1.2, 12.07.2006

Diagnosis
Inputs, outputs. Noter
11.6 Inputs, outputs. Noter
11.6.1 General remarks about inputs, outputs, flags
Each operand consists of
• Abbreviation: 1-3 capital letters (A, AA, E, EA, ERE, ERW, M, MA, MZ, P)
• 3-digit counter
Short
de-
Operand Description
scrip
tion
A Digital output Control signals that can assume two states, “0“ or „1“;
e.g. activations of B/W valves, blinkers, etc.
AA Analog output, Continuous output signals, e.g. nominal values for cur-
standardised rent controller and AC controls, standardised in the re-
spective physical unit.
AA# Hardware analog The continuous output signals digitised (0 ... 1023), be-
output fore standardisation.
E Digital input Signals from the electrics of the vehicle that may as-
sume the states „0“ or „1“ (ON or OFF), e.g. switches,
buttons, responses from electronic components.
EA Standardised ana- All external signals that deliver continuous values to

log input the controller, e.g. potentiometer. Standardised means
that the measured continuous value (EA#) has already
been converted into a physical unit, e.g. lift height in m,
load in kg, etc.
EA# Hardware analog Analog signals read in directly (voltages or currents).

input The analog signals are converted into digital informa-
tion (0 ... 1023 or 0...4095) by an A/D conversion .
ERE Error detected Especially in case of errors that are only short in time,
the existence of the error can be detected on the ser-
vice menu M24 „state display“ by editing ERE with the
corresponding error number. („1“ if error detected, oth-
erwise „0“)
ERW Error value Duration of the error signal
M Digital flag Parameter generated within the control that is gained

from other parameters, e.g. is generated from the con-
tinuous signal of the lift height detection of the digital
flag „top apron“.
MA Analog flag Continuous parameter generated within the control.
MA# Hardware analog Digitised analog flag (0 ... 1023), without standardisa-
flag tion.
MZ Flag state Indicates in which state (work step) a vehicle function

or component currently is.
Version 1.2, 12.07.2006 11-401

Diagnosis
Short
de-
Operand Description
scrip
tion
P Parameter The respectively set vehicle parameter.
11.6.2 Abbreviations of inputs, outputs and flags
Im-
Meaning
age
E Digital inputs
A Digital outputs
EAM digital inputs, outputs and flags
AA Analog outputs
EA Analog inputs
M Digital flags
MD Digital flags
MA Analog flags
MZ Condition flag
Tab. 11-1: Abbreviations
11.6.3 Abbreviations in parameter display texts
Im-
Meaning
age
ABS Switch off
DR Turn
DRZ Speed
I Current
IG Inductive guidance
GESI End of aisle stop
HH main lift
LLD Load lifting device
LRB Load wheel brake
MFH Multifunction lever
11-402 Version 1.2, 12.07.2006

Diagnosis
Im-
Meaning
age
MSS Micro steering sensors
RL Reverse
RM Response
SIMO Safety module
SS Sideshift arm
SYNC Synchron(ous)
TF Telescopic fork
TI Teach-In
V Speed
V2 creep speed
V4 Max. speed
VL Forward run
AL Auxiliary lift
ZVG Tines offset device

Tab. 11-2: Abbreviations
Version 1.2, 12.07.2006 11-403

Diagnosis
11.6.4 Digital inputs
Mod-
No. Meaning
ule
CR0020
E200 Reference switch main lift
E201 Reserve
E202 Release drive PPS reverse
E203 Reserve
E204 Reserve
E205 Incr. main lift channel A (option)
E206 Incr. main lift channel B (option)
E207 GESI reverse A
E208 GESI reverse B
E209 GESI forwards A
E210 GESI forwards B
E211 Reserve
11-404 Version 1.2, 12.07.2006

Diagnosis
Mod-
No. Meaning
ule
E216 CPU Turn control key
E217 Slide control key
E218 Turn control key synchronously
E219 Control key IG or steering straight ahead
E220 Control key main lift - auxiliary lift diagonal preselection
E221 Control key option
E222 Control key deadman left
E224 Control key main lift - auxiliary lift diagonal
E226 Control key auxiliary lift
E227 Control key slack chain override
E228 Control key override traversing cut-out (2nd stacking depth)
E229 Control key travel override
E230 Control key lift override
E231 Control key GESI reset
E232 Direction signal control lever 1_1
E239 Control key deadman right
Version 1.2, 12.07.2006 11-405

Diagnosis
Mod-
No. Meaning
ule
E240 CR0302 Switch slack chain 1
E241 Switch slack chain 2
E242 Door switch 1
E243 Door switch 2
E244 Switch lift cut-off overhead guard
E245 Key switch, IG emergency operation
E246 Foot switch 1
E247 Foot switch 2
E248 Reserved for toggle
E249 Reserved
E250 Reserved
E251 Reserved
E252 Key switch option 1
E253 Key switch option 2
E254 Switch slack chain 3 (only for _DT)
E255 Switch slack chain 4 (only for _DT)
11-406 Version 1.2, 12.07.2006

Diagnosis
Mod-
No. Meaning
ule
E256 CR2012 Switch aisle detection 1_1
E257 Switch aisle detection 1_2
E260 Switch acknowledgment claw
E261 Input of PPS drive release forwards
E264 Acknowledgment contact brake relay 1
E265 Acknowledgment contact brake relay 2
E266 Input of PPS drive release reverse
E267 Switch pressure for detection slack chain/chain break
Version 1.2, 12.07.2006 11-407

Diagnosis
11.6.5 Digital outputs
Mod-
No. Meaning
ule
A200 CR0020 Reserve
A201 Reserve
A202 Valve 2Y36
A203 Valve 2Y52
A204 Valve 2Y53
A205 Valve 2Y37
A206 Indicator 1
A207 Indicator 2
A208 Lift magnet jaw
A209 Safety relay 1
A210 Safety relay 2
A211 Valve v2Y32
A212 Valve 2Y33
A213 Reserve
A214 Reserve
A215 Valve 2Y34
A216 Valve 2Y35
A217 Analog or dig
A218 Analog or dig
A219 Reserve
A220 Reserve
A221 Reserve
A222 Reserve
A223 Reserve
11-408 Version 1.2, 12.07.2006

Diagnosis
Mod-
No. Meaning
ule
A224 CR0302 Reserve
A225 Reserve
A226 Reserve
A227 Reserve
A228 Valve 2Y40
A229 Valve 2Y41
A230 Valve 2Y42
A231 Valve 2Y43
A232 Valve 2Y44
A233 Valve 2Y46
A234 Valve 2Y47
A235 Signal horn for indicating the IG wire state (peeper)
A236 Reserve
A237 Reserve
A238 Reserve
A239 Reserve
A240 CR2012 Release converter
A241 Output to PPS: Info creeping
A242 Info about PPS aisle signal
A243 Info about PPS lift height < set value
A244 Reserve
A245 Reserve
A246 Reserve
A247 Reserve
Version 1.2, 12.07.2006 11-409

Diagnosis
11.6.6 Analog outputs
No. Module Meaning

AA200 CR0020 PWM 0 2Y49
AA201 CR0020 PWM 1 2Y30
AA202 CR0020 PWM 2 2Y31
AA203 CR0020 PWM 3 reserve
AA204 CR0020 PWM 4 current-controlled load wheel brake 1
AA205 CR0020 PWM 5 current-controlled load wheel brake 2
11.6.7 Analog inputs
No. Module Meaning

EA200 CR0020 Sensors steering poti 1
EA201 CR0020 Sensors main lift laser
EA202 CR0020 Pressure sensor 2B10
203 CR0020 Test value of battery voltage
EA204 CR0020 Sensors steering n poti 2
EA205 CR0020 Reserve
EA206 CR302 Sensors auxiliary lift poti
EA207 CR302 Sensors load poti
EA210 CR302 Sensors sideshift poti 1
EA211 CR302 Sensors sideshift poti 2
EA212 CR302 Reserve
EA213 CR302 Reserve
11-410 Version 1.2, 12.07.2006

Diagnosis
11.6.8 Digital flag
No. Meaning
MD200 Internal
MD201 Internal
MD202 Vehicle in aisle
MD203 Two-hand connection active
MD204 Buttons main lift - auxiliary lift - active synchronously
MD205 Overload detected
MD206 Hydraulic LLD active
MD207 Main lift active
MD208 Cabinets closed
MD209 Chains tight
MD210 Foot switch active
MD211 Battery switch-off active
MD212 Main lift under h_3 critical
MD213 Driving speed < creeping (2.5 km/h)
MD214 Steering straight ahead
MD215 Steering angle within 10^
MD216 Main lift below 3
MD217 Countercurrent braking active
MD218 Aisle end zone active
MD219 GESI braking necessary
MD220 GESI switch forwards A active
MD221 GESI switch forwards B active
MD222 GESI switch reverse A active
MD223 GESI switch reverse B active
MD224 IG emergency operation
MD225 IG switch active
MD226 IG TeachInactive
Version 1.2, 12.07.2006 11-411

Diagnosis
11.6.9 Analog flag
Standardiza-
No. Meaning
tion
MA200 Drive revolution actual value min-1
MA201 Drive revolution set value min-1
MA202 Drive forwards speed limit 0.1 km/h
MA203 Speed limit_ type
MA204 Driving speed actual value 0.1 km/h
MA205 Driving direction
MA206 GESI direction
MA207 GESI trigger speed
MA208 Nominal value nominal value indicator right
MA209 Nominal value nominal value indicator left
MA210 Storage zone
MA211 Revolution pump actual value min-1
MA212 Revolution pump nominal value min-1
MA213 Revolution pump limit value min-1
MA214 Remaining capacity battery %
MA215 Lift height H3 critical for v_max mm
MA216 Lift height H3 critical for v_red mm
MA217 GESI brake path measurement mm
MA218 Steering angle actual value 0.1°
MA219 Lift height main lift / mm mm
MA220 Aisle reserve left (for synchronous swiveling) mm
MA221 Aisle reserve right (for synchronous swiveling) mm
MA222 Synchronous turning - turning nominal value
MA223 Synchronous turning - thrust nominal value
MA224 IG yaw angle 0.1°
MA225 IG distance mm
MA226 MSS status (0=no MSS has detected wire; 1= MSS in front has detected wire
2=MSS rear has detected wire; 3= both MSS have detected wire)
MA227 Reserve
MA228 IG path measurement mm
11-412 Version 1.2, 12.07.2006

Diagnosis
Standardiza-
No. Meaning
tion
MA229 IG maximum legal driving speed 0.1 km/h
MA230 IG: Steering angle nominal value 0.1°
MA231 IG MSS forwards distance mm
MA232 IG MSS rear distance mm
MA233 Internal
MA234 Internal
MA235 Missing PDO from CR0302
MA236 Missing PDO from CR2012
MA237 Missing PDO from CPU
MA238 Missing PDO from IG
MA239 Missing PDO from steering controller
MA240 Missing PDO from drive controller
MA241 Missing PDO from pump controller
MA242 SyncTime 1
MA243 SyncTime 2
MA244 Sync turn control value
Version 1.2, 12.07.2006 11-413

Diagnosis
11.6.10Condition flag (MZ)
No. Meaning
MZ200 Component
MZ201 Parameter - Load
MZ202 Load help texts
MZ203 EMERGENCY STOP
MZ204 Turn
MZ205 Thrust
MZ206 Auxiliary lift
MZ207 main lift
MZ208 Main lift reference (only optional)
MZ209 Swivel traverse synchronisation
MZ210 Drive
MZ211 Drive controller
MZ212 Steering
MZ213 Steering regulator
MZ214 Brake
MZ215 GESI
MZ216 IG
MZ217 Turn hydraulics
MZ218 Sideshift hydraulics
MZ219 Auxiliary lift hydraulics
MZ220 Main lift hydraulics
MZ221 Main lift - auxiliary lift - diagonal hydraulics
MZ222 Auxiliary lift diagonal
MZ223 Main lift diagonal
MZ224 Swivel - traverse synchronisation hydraulics
MZ225 Swivel - traverse synchronisation turn hydraulics
MZ226 Swivel - traverse synchronisation thrust hydraulics
MZ227 Pump 2M1
MZ228 Chains
MZ229 Control lever right
MZ230 Control lever left
MZ231 Attachment LLD
MZ232 Aisle detection
11-414 Version 1.2, 12.07.2006

Diagnosis
No. Meaning
MZ233 TASK
MZ234 Steering reference (optional)
MZ235 SIMO
MZ236 IG controller
MZ236 IG estimator
Version 1.2, 12.07.2006 11-415

Diagnosis
State analysis and operating states
11.7 State analysis and operating states
11.7.1 State analysis
In particular cases, the APE can display no message despite the occurrence of a
malfunction.
example:
The auxiliary lift operating button has failed. The SECAN controller cannot
detect the operator's intention to lift the auxiliary lift. The desired lift move-
ment is not carried out, and no message appears.
In such cases, the cause of the fault can be determined by a state analysis.
Note
Via the APE, the so-called "state flags" can be queried.
These describe the momentary state of a vehicle func-
tion.
Whether a particular state is achieved depends on particular conditions. These

conditions are specified by the controller software.
Section 11.7.2 describes all states which can be assumed by state flags.
WARNING!
The sequence of the listed states does not absolutely
describe the function flow in the vehicle.
If a desired vehicle state is not achieved, the error can be determined by investi-
gating the relevant state flags.
example:
The vehicle only drives at creep speed.
The relevant state flag here is MZ210: Drive.
In addition, depending on the situation, the investigation of additional state
flags may be necessary;
e.g.: MZ232: Aisle / apron or MZ215 aisle end stop
Note
Via the APE, the so-called "state flags" can be queried.
These describe the momentary state of a vehicle func-
tion.
11-416 Version 1.2, 12.07.2006

Diagnosis
WARNING!
For defective vehicles, the danger of uncontrolled or
unexpected movements of the vehicle is especially
high.
• Before activating vehicle functions, always be sure that
there are no people in the danger zone.
11.7.2 Table of states
No. Meaning
0 Standby
1 SLEEP
2 INIT
3 Start
4 Run-up
5 Lag
6 Active
7 End
8 STOP
9 Release
10 Wait
11 Fast
12 Reserve
13 Reserve
14 Reserve
15 Reserve
16 Drive forwards
17 Drive in reverse
18 Reserve
19 Reserve
20 STOP - emergency stop
21 STOP - chain break
22 STOP - cabinets open
Version 1.2, 12.07.2006 11-417

Diagnosis
No. Meaning
23 STOP - illegal software
24 STOP error
25 STOP code
26 STOP- overhead guard
27 Reserve
28 Reserve
29 Reserve
30 CREEP - errors
31 CREEP - LLD not in initial position
32 CREEP - TEACHIN active
35 D1Reserve
36 D2Reserve
37 Reserve
38 Reserve
39 Reserve
40 Creep - switch off
41 Stop - switch off
42 END - standstill
43 END two-hand
44 END two-hand aisle
45 Pressure discharge
46 Reserve
47 Reserve
48 Reserve
49 Reserve
50 Turn front end left
51 Turn front end right
52 Turn STOP above 4 m lift height on the apron
53 Turn right
54 Turn left
55 Turn end due to main lift-auxiliary lift
56 Thrust right
11-418 Version 1.2, 12.07.2006

Diagnosis
No. Meaning
57 Thrust left
58 Reserve
59 Thrust end right
60 Thrust end left
61 Lift auxiliary lift
62 End lift auxiliary lift
63 Auxiliary lift creep due to LLD not in initial position
64 Auxiliary lift end with LLD not in initial position
65 Lower auxiliary lift
66 Lower auxiliary lift end
67 Creep front end upwards
68 Creep front end downwards
69 Reserve
70 Lift main lift
71 Lower main lift
72 Lower main lift via revolution
73 Lower main lift pause
74 Lift main lift stop due to deeply-discharged battery
75 Lift main lift end above h3 critical
76 Lift main lift creep front end downwards
77 Slack chain
78 Reserve
79 Reserve
80 END overload
81 END standstill apron
82 END stop upwards
83 Lift auxiliary lift END switch off
84 Lift main lift - auxiliary lift synchronously (diagonally)
85 Lower main lift - auxiliary lift synchronously (diagonally)
86 Synchronous turning right
87 Synchronous turning left
88 Synchronous turning middle position
Version 1.2, 12.07.2006 11-419

Diagnosis
No. Meaning
89 Synchronous turning collision left
90 Synchronous turning collision right
91 Synchronous turning collision left and right
92 Synchronous turning sideshift left
93 Synchronous sideshift right
94 Reserve
95 Aisle
96 Aisle exit
97 Aisle entrance
98 Apron
100 Tine adjustment equipment apart
101 Tine adjustment equipment together
102 Reserve
103 Reserve
104 Reserve
105 Reserve
106 Reserve
107 Drive STOP GESI
108 Drive STOP lift on the apron
109 Drive STOP IG has disengaged
110 Drive CREEP main lift not aligned
111 Drive STOP no steering on the apron
112 Drive GESI braking
113 Drive STOP load wheel brake
114 Drive CREEP after GESI braking before reset
115 Drive STOP brake
116 Drive CREEP PPS
117 Drive CREEP IG on the apron
118 Drive STOP forwards through PPS
119 Drive STOP reverse through PPS
120 Drive FAST aisle
121 Drive CREEP due to IG in the aisle
11-420 Version 1.2, 12.07.2006

Diagnosis
No. Meaning
122 Drive CREEP over h3 critical in the aisle
123 Drive FAST apron
124 Drive CREEP at 4.0 km on the apron
125 Drive CREEP at 2.5 km on the apron
126 Drive STOP due to h3 limit height achieved on the apron
127 Drive STOP steering
128 Reserve
129 Reserve
130 Brake ventilated
131 Brake due to driving
132 Brake due to LRB
133 Brake due to PPS
134 Brake due to LLD
135 Brake due to GESI
136 Brake due to foot switch
137 Brake due to external component
138 Brake due to GESI emergency stop
139 Reserve
140 GESI standstill
141 GESI braking active
142 GESI creep speed active
143 IG hand
144 IG requested
145 IG engaged
146 IG disengaged
147 IG entrance
148 IG aisle entrance
149 IG fast drive in the aisle
150 IG fast drive
151 IG exit
152 IG emergency operation hand
153 IG emergency operation requested
Version 1.2, 12.07.2006 11-421

Diagnosis
No. Meaning
154 IG emergency operation engaged
155 IG emergency operation apron
156 IG emergency stop wire loss
157 IG emergency stop steering angle too large
158 IG emergency stop diamond violation
159 IG emergency stop aisle signal before engaged
160 IG emergency stop claw on the apron
161 IG emergency stop no claw in the aisle
162 Steer IG
163 IG steering manual
164 IG apron
165 IG aisle exit fast
166 IG exit V2
167 Reserve
168 Reserve
169 Reserve
170 Converter drive wait
171 Converter drive forwards countercurrent
172 Converter drive reverse countercurrent
173 Converter drive in reverse
174 Converter drive forwards
175 Converter drive discharge forwards
176 Converter drive discharge reverse
177 Converter drive forwards speed limit
178 Converter drive reverse speed limit
179 IG estimation MSS behind
180 IG steering optimal radius positive
181 IG steering optimal radius negative
182 IG steering linear regulator
183 IG estimation with both MSS
184 IG estimation required
185 IG estimation with MSS in front
11-422 Version 1.2, 12.07.2006

Diagnosis
No. Meaning
186 Reserve
187 Reserve
188 Reserve
189 Reserve
190 Reserve
191 Reserve
192 Reserve
192 Reserve
193 Reserve
194 Reserve
195 Reserve
196 Reserve
197 Reserve
198 Reserve
199 Reserve
200 Internal
201- Internal
255
Version 1.2, 12.07.2006 11-423

Diagnosis
11-424 Version 1.2, 12.07.2006

Optional equipment
Chapter index
Chapter 12
Optional equipment
Chapter index
PPS laser scanner installation 428

End of aisle stop 432
Version 1.2, 12.07.2006 12-425

Optional equipment
PPS laser scanner installation
12.1 PPS laser scanner installation

Model OMNI/Hi-Racker/Vector 100
Chassis frame width b2 t 1,450 mm
Standard cab/standard fork
Chassis frame width b2 <1,450 mm
Switch off cab 100 mm before bottom end

h1+50 mm, h3-100 mm, h7+100 mm
Stop on chassis frame
Special free lift truck
Standard fork
Model OMNI/Hi-Racker/Vector 120

h1+40 mm, h3-80 mm, h7+80 mm
Special fork heel +80 mm
Model OMNI/Hi-Racker/140

h1+25 mm, h3-50 mm, h7+50 mm
Special free lift truck
Standard fork
12-426 Version 1.2, 12.07.2006

Optional equipment
PPS equipment
Fig. 12-1: Complete installation of PSS equipment
Version 1.2, 12.07.2006 12-427

Optional equipment
PPS equipment
Fig. 12-2: Installation of scanner for PSS equipment
12-428 Version 1.2, 12.07.2006

Optional equipment
Fig. 12-3: Scanner position relative to load wheel width

1 Scanner
2 Additional installation positions: +50; +100; +150; +200
Version 1.2, 12.07.2006 12-429

Optional equipment
End of aisle stop
12.2 End of aisle stop
12.2.1 Placement of floor magnets
The placement is carried out relative to the braking distance.
Braking distance table
Driving speed
km/h 12.00 11.00 10.00 9.00 8.00 7.00 6.00 5.00 4.00 3.00 2.50 1.00
m/s 3.33 3.06 2.78 2.50 2.22 1.94 1.67 1.39 1.11 0.83 0.69 0.28
%g m/s2 Braking distance

12.00 1.18 5.05 4.27 3.56 2.90 2.32 1.80 1.35 0.96 0.64 0.38 0.27 0.06
11.00 1.08 5.48 4.63 3.85 3.15 2.51 1.95 1.45 1.03 0.68 0.41 0.29 0.06
10.00 0.98 6.00 5.06 4.21 3.44 2.74 2.12 1.58 1.12 0.74 0.44 0.32 0.07
9.001 0.88 6.63 5.59 4.65 3.79 3.02 2.34 1.74 1.23 0.81 0.48 0.34 0.07
8.00 0.78 7.41 6.25 5.19 4.23 3.37 2.60 1.94 1.37 0.90 0.53 0.38 0.08
7.00 0.69 8.42 7.10 5.90 4.80 3.82 2.95 2.19 1.54 1.01 0.59 0.42 0.08
6.00 0.59 9.77 8.24 6.83 5.56 4.42 3.41 2.53 1.78 1.16 0.67 0.48 0.09
5.00 0.49 11.66 9.82 8.14 6.62 5.26 4.05 3.00 2.11 1.37 0.79 0.56 0.11
4.00 0.39 14.49 12.20 10.11 8.21 6.51 5.01 3.71 2.60 1.68 0.97 0.68 0.13
3.00 0.29 19.21 16.71 13.39 10.87 8.61 6.62 4.89 3.42 2.21 1.26 0.89 0.16
2.00 0.20 28.65 24.10 19.94 16.18 12.81 9.83 7.25 5.05 3.26 1.85 1.30 0.22
1.00 0.10 56.96 47.89 39.61 32.11 25.39 19.46 14.32 9.97 6.40 3.62 2.53 0.42
1
Tab. 12-1: Braking distance table; standard
12-430 Version 1.2, 12.07.2006

Optional equipment
End of aisle stop
Calculation of the braking distance
The calculation is based on the following formula:
v2
s = v t + ----------
2a
with
s = braking distance [m]

v = driving speed [m/s]
t = brake response time [s]
a = braking acceleration [m/s2]
g = gravity acceleration = 9.81 [m/s2}
Conversion of speed from [km/h] to [m/s]
v [km/h] = 3.6 · v [m/s]
Conversion of speed from [m/s] to [km/h]
v [m/s] = 1/3.6 · v [km/h]
The braking acceleration is generally given in percent of the gravity acceleration.
9% g = 0.883 m/s2
10% g = 0.981 m/s2
11% g = 1.079 m/s2
12% g = 1.177 m/s2
Sample calculation of the braking distance
A vehicle travels at 12 km/h within the rack aisle. GESI braking is set to 10%. What
is the braking distance of the vehicle when crossing the GESI magnet?
The calculation assumes a response time of 0.1 s between triggering and start of
braking.
12-· 2
§ --------
12 km e h © 3 6¹
s = ------------------------- 0 1 s + ---------------------- = 6 m
3 6 2 0 981
The pure braking distance measures 6 m. Hence, the GESI magnets must be
placed at 6 m plus the length of the attachment and loading or distance of GESI
switch to rear of the vehicle from the end of the aisle for the vehicle to stop before
any part of the vehicle protrudes beyond the aisle.
Version 1.2, 12.07.2006 12-431

Optional equipment
End of aisle stop
Placement drawing

• Placement of floor magnets"” on page 7-123
12-432 Version 1.2, 12.07.2006

List of Figures
Fig. 1-1: Lubrication pointsOMNI 120/140 AC .................................................................................... 12

Fig. 1-2: Lubrication points swivel/traverse fork.................................................................................. 13
Fig. 1-3: Lubrication points telescopic fork, example.......................................................................... 14
Fig. 1-4: Type plate ............................................................................................................................. 18
Fig. 3-1: Responsibility and qualifications of the personnel................................................................ 32
Fig. 3-2: vehicle geometry .................................................................................................................. 35
Fig. 3-3: Symbol (Reference: DIN 4002) ............................................................................................ 40
Fig. 3-4: Inspection sticker.................................................................................................................. 41
Fig. 4-1: Components of the E system ............................................................................................... 44
Fig. 4-2: Components in the drive compartment................................................................................. 45
Fig. 4-3: Swivel/traverse fork .............................................................................................................. 46
Fig. 4-4: Telescopic fork...................................................................................................................... 48
Fig. 5-1: Proof of training; example..................................................................................................... 58
Fig. 5-2: Requirements of the truck .................................................................................................... 59
Fig. 5-3: Vertical transport with appropriate truck ............................................................................... 63
Fig. 5-4: Sample images..................................................................................................................... 64
Fig. 5-5: Attachment points................................................................................................................. 65
Fig. 5-6: Lift device and turn ............................................................................................................... 66
Fig. 5-7: Loading situation truck ......................................................................................................... 67
Fig. 5-8: Strap mounting on pole foot ................................................................................................. 72
Fig. 5-9: Strap mounting at cab .......................................................................................................... 73
Fig. 5-10: Secure pole cable................................................................................................................. 73
Fig. 5-11: Secure boxes ....................................................................................................................... 74
Fig. 5-12: Edge protection .................................................................................................................... 74
Fig. 5-13: Lift chassis............................................................................................................................ 75
Fig. 5-14: Loosen brake........................................................................................................................ 75
Fig. 5-15: Secured chassis ................................................................................................................... 76
Fig. 5-17: Brace auxiliary lift pole.......................................................................................................... 77
Fig. 5-18: Pole on wooden blocks ........................................................................................................ 78
Fig. 5-19: Protect power supply chain .................................................................................................. 79
Fig. 5-20: Lift pole ................................................................................................................................. 79
Fig. 5-21: Move first end of the pole into the container......................................................................... 80
Fig. 5-22: Place first end of the pole ..................................................................................................... 80
Fig. 5-23: Remove first lifting gear........................................................................................................ 81
Fig. 5-24: Second end of the pole on heavy-duty rollers ...................................................................... 81
Fig. 5-25: Continue moving pole into the container .............................................................................. 82
Fig. 5-26: End of pole beyond the wooden blocks................................................................................ 82
Fig. 5-27: Place second end of the pole ............................................................................................... 83
Fig. 5-28: Secure lower end of the pole................................................................................................ 84
Fig. 5-29: Secure upper end of the pole ............................................................................................... 84
Fig. 5-31: Preservation compound OKS datasheet .............................................................................. 87
Fig. 5-32: Preservation compound OKS safety data sheet................................................................... 88
Fig. 5-33: Hydraulic system .................................................................................................................. 89
Fig. 5-34: Hydraulic system - pipework................................................................................................. 90
Fig. 5-35: - Front view.......................................................................................................................... 91
Fig. 7-1: Hoist frame lock device ...................................................................................................... 105
Fig. 7-2: Loosen the hoist securing screw ........................................................................................ 106
Fig. 7-3: Inclination ............................................................................................................................ 111
Fig. 7-4: Lateral guide rail ..................................................................................................................114
Fig. 7-5: Lined guide rail C-profile......................................................................................................115
Fig. 7-6: U-rail UNP 100 (DIN 1026)..................................................................................................116
Fig. 7-7: L-rail 100 x 65 x 9 (standard)...............................................................................................116
Version 1.2, 12.07.2006 433

Fig. 7-8: U-rail UNP 65 (DIN 1026) ................................................................................................... 117
Fig. 7-9: U-rail UNP 65 (DIN 1026) ................................................................................................... 118
Fig. 7-10: Overview of guide rail variants............................................................................................ 119
Fig. 7-11: Drive-in and aisle situation.................................................................................................. 120
Fig. 7-12: Sensors for scanning the guide wire for induction guidance .............................................. 121
Fig. 7-13: Placement of floor magnets ................................................................................................ 123
Fig. 7-14: Guide wire course A (continuous course in row) ................................................................ 124
Fig. 7-15: Guide wire course B (separate course parallel guidance) .................................................. 125
Fig. 7-16: Guide wire routing and wire design .................................................................................... 126
Fig. 7-17: Allocations to tolerance description .................................................................................... 129
Fig. 7-18: Chassis and lift frame ......................................................................................................... 130
Fig. 7-19: Tie rods ............................................................................................................................... 131
Fig. 7-20: Permissible lateral tilting ..................................................................................................... 133
Fig. 7-21: Rear guide roller ................................................................................................................. 135
Fig. 7-22: Lateral guide roller .............................................................................................................. 136
Fig. 7-23: Slide piece .......................................................................................................................... 137
Fig. 7-24: Setting the roller spacing .................................................................................................... 138
Fig. 7-25: Load axle and Multiple disc brake ...................................................................................... 140
Fig. 7-26: Load wheel and load brake................................................................................................. 141
Fig. 7-27: LRB with wheel ................................................................................................................... 143
Fig. 7-28: Brake (cross-section).......................................................................................................... 144
Fig. 7-29: LRB..................................................................................................................................... 145
Fig. 7-30: LRB with loosened screws.................................................................................................. 146
Fig. 7-31: Single parts LRB ................................................................................................................. 147
Fig. 7-32: Design of the magnetic brake ............................................................................................. 149
Fig. 7-33: Setting the air gap............................................................................................................... 150
Fig. 7-34: Setting the air gap............................................................................................................... 151
Fig. 7-35: Drive aggregate .................................................................................................................. 153
Fig. 7-36: Traction drive ...................................................................................................................... 154
Fig. 7-37: Sideshift drive ..................................................................................................................... 155
Fig. 7-38: Bar sideshift ........................................................................................................................ 157
Fig. 7-39: Standard telescopic fork (TF).............................................................................................. 162
Fig. 7-40: Hydraulic motor standard telescopic fork............................................................................ 163
Fig. 7-41: Flat telescopic fork (FTF).................................................................................................... 163
Fig. 7-42: Single hoist frame ............................................................................................................... 164
Fig. 7-43: Double pole......................................................................................................................... 165
Fig. 7-44: Power transmission of telescope ........................................................................................ 166
Fig. 7-45: Design of telescope ............................................................................................................ 167
Fig. 7-46: Drive schematic .................................................................................................................. 169
Fig. 7-47: Chain adjuster..................................................................................................................... 169
Fig. 7-48: Fork telescope .................................................................................................................... 170
Fig. 7-50: Components of the bearing of the drive shaft ..................................................................... 171
Fig. 7-51: Fork telescope .................................................................................................................... 172
Fig. 7-52: Middle section with toothed rack......................................................................................... 172
Fig. 7-54: Drive shaft........................................................................................................................... 173
Fig. 7-55: Check chain length ............................................................................................................. 177
Fig. 7-56: Chain link with corrosion and corrosion tears ..................................................................... 178
Fig. 7-57: Chain link with fatigue cracks ............................................................................................. 179
Fig. 7-58: Tight chain links .................................................................................................................. 179
Fig. 7-59: Protruding or Turned Pins................................................................................................... 180
Fig. 8-1: Hydraulic plan without swiveling and tine adjustment......................................................... 196
Fig. 8-2: Hydraulic plan with swiveling and tine adjustment.............................................................. 197
Fig. 8-3: Top view of the bogie .......................................................................................................... 198
Fig. 8-4: Side view of the tank control unit ........................................................................................ 199
434 Version 1.2, 12.07.2006

Fig. 8-5: Lift module block................................................................................................................. 200
Fig. 8-6: Filler and breather .............................................................................................................. 204
Fig. 8-7: Return flow filter.................................................................................................................. 206
Fig. 8-8: Flow divider ........................................................................................................................ 209
Fig. 8-9: Lift module block H3 ........................................................................................................... 214
Fig. 8-10: Section through the lift cylinder .......................................................................................... 215
Fig. 8-11: Cylinder fixing ..................................................................................................................... 219
Fig. 8-12: Position of pipe-break protection ........................................................................................ 222
Fig. 8-13: Pipe-break protection and special tools.............................................................................. 224
Fig. 8-14: Hydraulic installation of the RFZ (side view) ...................................................................... 225
Fig. 8-15: Hydraulic installation of the RFZ (front view)...................................................................... 226
Fig. 8-16: Load stabilizer valve (swiveling) ......................................................................................... 228
Fig. 8-17: Swivel cylinder.................................................................................................................... 230
Fig. 8-18: Lift module of combined block KPL .................................................................................... 232
Fig. 8-19: Hydraulic control unit .......................................................................................................... 233
Fig. 8-20: Hydraulic installation in the bogie ....................................................................................... 234
Fig. 9-1: Block diagram of the control concept ................................................................................. 238
Fig. 9-2: CAN-bus plan Connection of a CAN node ......................................................................... 239
Fig. 9-3: CAN topology in the vehicle ............................................................................................... 240
Fig. 9-4: Design DPU........................................................................................................................ 242
Fig. 9-5: Design of CPC.................................................................................................................... 243
Fig. 9-6: Plug arrangement distributor cabin..................................................................................... 244
Fig. 9-7: Design CPU........................................................................................................................ 245
Fig. 9-8: Control panel mount ........................................................................................................... 247
Fig. 9-9: Right control panel side ...................................................................................................... 249
Fig. 9-10: Left control panel side ........................................................................................................ 254
Fig. 9-11: Structure of the APE ........................................................................................................... 255
Fig. 9-12: APE basic display............................................................................................................... 257
Fig. 9-13: Information display ............................................................................................................. 259
Fig. 9-14: Status messages ................................................................................................................ 265
Fig. 9-15: Status display ..................................................................................................................... 266
Fig. 9-16: Assignment of the parameters............................................................................................ 272
Fig. 9-17: Steering system (the sensor systems for feedback can be of different types) ................... 274
Fig. 9-18: Pulse width modulation....................................................................................................... 277
Fig. 9-19: Control design .................................................................................................................... 278
Fig. 9-20: Installation of the floor magnets (GESI + aisle detection)................................................... 287
Fig. 9-21: TeachInmicro steering sensor front .................................................................................... 301
Fig. 9-22: TeachInmicro steering sensor rear ..................................................................................... 302
Fig. 9-23: Installing the laser at the lift frame...................................................................................... 319
Fig. 9-24: reflection sheet at the lift frame .......................................................................................... 319
Fig. 9-25: Laser installation at cabin floor ........................................................................................... 320
Fig. 9-26: Reference switches ............................................................................................................ 323
Fig. 9-27: Sensor elements................................................................................................................. 325
Fig. 9-28: Aligning the drive wheel...................................................................................................... 326
Fig. 9-29: Aligning the drive wheel...................................................................................................... 327
Fig. 9-30: Measure the total resistance .............................................................................................. 328
Fig. 9-31: Aligning the sensor unit ...................................................................................................... 328
Fig. 9-32: ........................................................................................................................................... 330
Fig. 9-33: Sensor bearing drive motor_1 ............................................................................................ 332
Fig. 9-34: Sensor bearing of drive motor_2 ........................................................................................ 333
Fig. 9-35: Sensor bearing of drive motor_3 ........................................................................................ 333
Fig. 9-36: Torque and current regulator set values ............................................................................. 346
Fig. 12-1: Complete installation of PSS equipment ............................................................................ 427
Fig. 12-2: Installation of scanner for PSS equipment ......................................................................... 428
Fig. 12-3: Scanner position relative to load wheel width..................................................................... 429
Version 1.2, 12.07.2006 435

436 Version 1.2, 12.07.2006
List of Tables
Tab. 1-1: Maintenance plan ................................................................................................................... 8

Tab. 1-2: Maintenance list swivel/traverse fork...................................................................................... 9
Tab. 1-3: Maintenance list telescopic fork............................................................................................ 10
Tab. 1-4: Oils ....................................................................................................................................... 11
Tab. 1-5: Greases ................................................................................................................................ 11
Tab. 1-6: Table of special tools............................................................................................................ 17
Tab. 3-1: Vehicle configuration for determining the load capacity tables with ZT pole ........................ 35
Tab. 3-2: Basic load capacity for vehicles acc. to Tab.: 3-1 on page 3-35 with ZT pole...................... 36
Tab. 3-3: Load capacity for vehicles acc. to Tab.: 3-1 on page 3-35 with DT pole .............................. 37
Tab. 3-4: Permissible load capacity HiRacker 1400 DT (h1=5500mm) from stability trials ................. 37
Tab. 3-5: Permissible load capacity of the SSG depending on the lift height h9 ................................. 38
Tab. 4-1: Adjusting and test values ..................................................................................................... 52
Tab. 4-2: Type structure ...................................................................................................................... 54
Tab. 5-1: Weight overview ................................................................................................................... 69
Tab. 7-1: Ground requirements.......................................................................................................... 109
Tab. 7-2: Measurement tolerances .................................................................................................... 110
Tab. 7-3: Measurement tolerances .................................................................................................... 110
Tab. 7-4: Dependence of static and dynamic inclination ................................................................... 112
Tab. 7-5: Overview of tolerances ....................................................................................................... 127
Tab. 7-6: Backward tilting .................................................................................................................. 132
Tab. 7-7: Master Speed Plus parameter............................................................................................ 186
Tab. 8-1: Torques of the cone packing connection and stud end with thread ................................... 193
Tab. 8-2: Overview of types of pipe-break protection ........................................................................ 222
Tab. 8-3: Overview of types of load-lowering valve ........................................................................... 223
Tab. 9-1: Interface to personnel protection system;........................................................................... 305
Tab. 9-2: Parameter........................................................................................................................... 320
Tab. 9-3: Example at the display ....................................................................................................... 329
Tab. 9-4: Valve overview ................................................................................................................... 348
Tab. 9-5: Overview: usage of the valves for individual movements................................................... 349
Tab. 10-1: List of service menus.......................................................................................................... 361
Tab. 10-2: Parameters of service menu; Submenu M01 "Control panel" ............................................ 362
Tab. 10-3: Parameters of service menu; Submenu M02 Traverse ...................................................... 363
Tab. 10-4: Parameters of service menu; Submenu M03 Turn............................................................. 364
Tab. 10-5: Parameters of service menu; Submenu M04 Auxiliary Lift................................................. 365
Tab. 10-6: Parameters of service menu; Submenu M05 Main Lift....................................................... 366
Tab. 10-7: Parameters of service menu; Submenu M06 Driving ......................................................... 367
Tab. 10-8: Parameters of service menu; Submenu M07 Steering....................................................... 368
Tab. 10-9: Parameters of service menu; Submenu M08 Synchronous main and auxiliary lift............. 369
Tab. 10-10:Parameters of service menu; Submenu M09 Traverse synchronous hydraulic ................ 370
Tab. 10-11:Parameters of service menu; Submenu M10 Sync. swivel geometry ............................... 371
Tab. 10-12:Parameters of service menu; Submenu M11 Pump.......................................................... 371
Tab. 10-13:Parameters of service menu; Submenu M12 Lifting cut-out (activation by code) ............. 372
Tab. 10-14:Parameters of service menu; Submenu M13 Drive cut-out (activation by code)............... 373
Tab. 10-15:Parameters of service menu; Submenu M13 lowering cut-out (activation by code).......... 374
Tab. 10-16:Parameters of service menu; Submenu M15 Option codes 0-15...................................... 375
Tab. 10-17:Parameters of service menu; Submenu M16 Option codes 16-29.................................... 376
Tab. 10-18:Parameters of service menu; Submenu M17 Induction guidance (IG).............................. 377
Tab. 10-19:Parameters of service menu; Submenu M18 Battery........................................................ 378
Tab. 10-20:Parameters of service menu; Submenu M19 Hour meters ............................................... 378
Tab. 10-21:Parameters of service menu; Submenu M20 Load sensors ............................................. 379
Tab. 10-22:Parameters of service menu; Submenu M21 Masterspeed .............................................. 379
Tab. 10-23:Parameters of service menu; Submenu M22 PPS (personal protection system)) ............ 379
Tab. 11-1: Abbreviations...................................................................................................................... 402
Tab. 11-2: Abbreviations...................................................................................................................... 403
Version 1.2, 12.07.2006 437

Tab. 12-1: Braking distance table; 1 standard ...................................................................................... 430
438 Version 1.2, 12.07.2006

Notes
DAMBACH Lagersysteme GmbH & Co. KG
Adolf-Dambach-Straße
D-76571 Gaggenau
Telephone +49-7225-64-01
Fax: +49-7225-64-188
Internet: http://www.dambach.de
E-mail: info@dls.dambach.de

SA - OMNI (GB) - V1.2 Pag 226 - 452

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Hydraulics

Lift module block

8.10.7 Lift module block H3

Fig. 8-9: Lift module block H3

8-214 Version 1.2, 12.07.2006

8.11 Lift cylinders (main and auxiliary lift)

8.11.1 Design of the cylinders

Fig. 8-10: Section through the lift cylinder

1 Lock washer 9 Casing pipe

Version 1.2, 12.07.2006 8-215

8.11.2 Bleeding the cylinder

 Bleed until the oil exits bubble-free

8-216 Version 1.2, 12.07.2006

8.11.3 Replacing the sealing

To replace the sealing

Version 1.2, 12.07.2006 8-217

 Open the bleed screws

 Tighten the bleed screws

8-218 Version 1.2, 12.07.2006

8.11.4 Removing and installing the main lift cylinder

Fig. 8-11: Cylinder fixing

1 Screws 2 Pole strap

 Lift and secure the cabin

 Release the lower fixing screw

Version 1.2, 12.07.2006 8-219

Installation is in the reverse order of steps.

8.11.5 Replacing the lower cylinder rod guide

 Remove the cylinder

8-220 Version 1.2, 12.07.2006

8.11.6 Pipe-break protection / Load-lowering valve

Use of a pipe-break protection guarantees in case of a pipe break in the hydraulic

Version 1.2, 12.07.2006 8-221

Fig. 8-12: Position of pipe-break protection

8.11.6.1 Overview of types

Pipe-break protection of main lift cylinder

Security against line

Tab. 8-2: Overview of types of pipe-break protection

8-222 Version 1.2, 12.07.2006

Load-lowering valve of auxiliary lift cylinder

Security against line

Tab. 8-3: Overview of types of load-lowering valve

8.11.6.2 Procedure when the pipe-break protection has triggered

When the hydraulic line is leaky

 Secure the cabin against sagging using suitable supports.

If the reason for triggering is unsure

Version 1.2, 12.07.2006 8-223

8.11.6.3 Installing the pipe-break protection

Fig. 8-13: Pipe-break protection and special tools

8.11.7 Emptying the lift cylinder

8-224 Version 1.2, 12.07.2006

8.12 Hydraulic installation of the traverse fork (RFZ)

8.12.1 Side view

1 Swivel valve block A7 with load stabi- 8 Sideshift sensor

Version 1.2, 12.07.2006 8-225

8.12.2 Front view

8-226 Version 1.2, 12.07.2006

8.12.3 Setting the shock valves (sideshift)

Setting the shock valves (e.g. after repairs)

Version 1.2, 12.07.2006 8-227

8.12.4 Setting the load stabilizer valve (swiveling)

Fig. 8-16: Load stabilizer valve (swiveling)

• They lock the swivel cylinders in all stop positions .

8-228 Version 1.2, 12.07.2006

Bleed until the oil exits bubble-free

Open the bleed screws

Tighten the bleed screws

Lift and secure the cabin

Release the lower fixing screw

Remove the cylinder

Secure the cabin against sagging using suitable supports.

oil escapes from the cylinder rod

Remove the cylinder

Check the connection nipple for the leakage tube