BT Forklift BT CTX 1300SEi BT CTX 1300SEi-SF Service Manual 150103-040 – PDF

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BT Forklift BT CTX 1300SEi BT CTX 1300SEi-SF Master Service Manual 150103-040 – PDF DOWNLOAD

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BT Forklift BT CTX 1300SEi BT CTX 1300SEi-SF Master Service Manual 150103-040 – PDF DOWNLOAD

Language : English
Pages : 300
Downloadable : Yes
File Type : PDF

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BT Forklift BT CTX 1300SEi BT CTX 1300SEi-SF Master Service Manual 150103-040 – PDF DOWNLOAD

Master Service Manual Product family CT.................................................................................  1
	BT CTX 1300SEi BT CTX 1300SEi-SF....................................................................................  1
Contents Master Service Manual (MSM)....................................................................................  3
	Valid from serial number:...........................................................................................  3
		T-code..........................................................................................................  3
		Model...........................................................................................................  3
		Serial No.......................................................................................................  3
		Notes...........................................................................................................  3
	1 Document list.....................................................................................................  3
		Section.........................................................................................................  3
		C-code..........................................................................................................  3
		T-code..........................................................................................................  3
		Document........................................................................................................  3
		Issued..........................................................................................................  3
Introduction to BT’s Service Manual.....................................................................................  5
Contents, M.............................................................................................................  7
	1 Truck information.................................................................................................  7
Operator’s manual.......................................................................................................  9
	Valid from serial number:...........................................................................................  9
	T-code..............................................................................................................  9
	Model...............................................................................................................  9
	Serial No...........................................................................................................  9
	Notes...............................................................................................................  9
	1 General...........................................................................................................  9
		1.1 Issued operator’s manuals...................................................................................  9
			T-code......................................................................................................  9
			Model.......................................................................................................  9
			Serial number...............................................................................................  9
			Order number................................................................................................  9
			Issued......................................................................................................  9
General product information............................................................................................. 11
	Valid from serial number:........................................................................................... 11
		T-code.......................................................................................................... 11
		Model........................................................................................................... 11
		Serial No....................................................................................................... 11
		Notes........................................................................................................... 11
	1 Presentation of the truck......................................................................................... 11
		1.1 Intended application of the truck........................................................................... 11
		1.2 Forbidden application of the truck.......................................................................... 12
	2 Truck data........................................................................................................ 12
		Model designation............................................................................................... 12
		CTX 1300SEi (Fork skew)......................................................................................... 12
		CTX H (Fork skew)............................................................................................... 12
		Model designation............................................................................................... 14
		CTX 1300 SEi SF (tele fork)..................................................................................... 14
		CTX H SF (tele fork)............................................................................................ 14
	3 Truck dimensions.................................................................................................. 15
		Dimensions CTX 1300SEi.......................................................................................... 16
		CTX H........................................................................................................... 16
		Dimensions CTX 1300SEi SF....................................................................................... 18
		CTX H SF........................................................................................................ 18
	4 Identification plate.............................................................................................. 18
		Item............................................................................................................ 18
		Text............................................................................................................ 18
		Unit............................................................................................................ 18
		Item............................................................................................................ 18
		Text............................................................................................................ 18
		Unit............................................................................................................ 18
		Item............................................................................................................ 19
		Text............................................................................................................ 19
		Item............................................................................................................ 19
		Text............................................................................................................ 19
	5 Main components................................................................................................... 20
		1. Identification plate: With model designation, serial number, year of manufacture, weight witho............... 20
		2. Mast......................................................................................................... 20
		3. Emergency switch off......................................................................................... 20
		4. Emergency lowering valve: Valve for emergency lowering under the guard....................................... 20
		5. Load carrier................................................................................................. 20
		6. Initial lift mast............................................................................................ 20
		1. Identification plate: With model designation, serial number, year of manufacture, weight witho............... 21
		2. Mast......................................................................................................... 21
		3. Emergency switch off......................................................................................... 21
		4. Emergency lowering valve: Valve for emergency lowering under the guard....................................... 21
		5. Load carrier................................................................................................. 21
		6. Initial lift mast............................................................................................ 21
	6 Warning and information plates and symbols........................................................................ 22
		1. Attachment point for spring-loaded hooks..................................................................... 22
		2. Passengers prohibited........................................................................................ 22
		3. Identification plate......................................................................................... 22
		4. Joystick functions right..................................................................................... 22
		5. Joystick functions left...................................................................................... 22
		6. Do not walk under an elevated load........................................................................... 22
		7. Emergency lower.............................................................................................. 22
		8. Hydraulic oil filling........................................................................................ 22
		9. Risk of crushing............................................................................................. 22
		10. Lifting points.............................................................................................. 22
		1. Attachment point for spring-loaded hooks..................................................................... 23
		2. Passengers prohibited........................................................................................ 23
		3. Identification plate......................................................................................... 23
		4. Joystick functions right..................................................................................... 23
		5. Joystick functions left...................................................................................... 23
		6. Do not walk under an elevated load........................................................................... 23
		7. Emergency lower.............................................................................................. 23
		8. Hydraulic oil filling........................................................................................ 23
		9. Risk of crushing............................................................................................. 23
		10. Lifting points.............................................................................................. 23
Technical data.......................................................................................................... 25
	Valid from serial number:........................................................................................... 25
	T code.............................................................................................................. 25
	Model............................................................................................................... 25
	Serial No........................................................................................................... 25
	Notes............................................................................................................... 25
	Model............................................................................................................... 25
	CTX 1300SEi......................................................................................................... 25
	CTX 1300SEi-SF...................................................................................................... 25
		Drive motor..................................................................................................... 25
		Transmission/gear............................................................................................... 25
		Drive wheel..................................................................................................... 25
		Support arm wheels.............................................................................................. 26
		Hydraulic system, drive unit.................................................................................... 26
		Hydraulic system, fork unit..................................................................................... 26
		Fuses........................................................................................................... 27
		Batteries....................................................................................................... 28
		All models...................................................................................................... 28
		Travel speeds................................................................................................... 28
		Lifting/lowering speeds......................................................................................... 29
		Other speeds (unit speeds)...................................................................................... 29
		Power consumption............................................................................................... 29
		Weight.......................................................................................................... 30
Ordering Spare Parts.................................................................................................... 31
Quality Parts........................................................................................................... 33
	Valid from serial number:........................................................................................... 33
	T-code.............................................................................................................. 33
	Model............................................................................................................... 33
	Serial No........................................................................................................... 33
	Notes............................................................................................................... 33
	1 Issued Quality Parts.............................................................................................. 33
		T-code.......................................................................................................... 33
		Model........................................................................................................... 33
		Serial No....................................................................................................... 33
		Order number.................................................................................................... 33
		Issued.......................................................................................................... 33
Recommended Spare Parts (RSP)........................................................................................... 35
	Valid from serial number:........................................................................................... 35
	T-code.............................................................................................................. 35
	Model............................................................................................................... 35
	Serial No........................................................................................................... 35
	Notes............................................................................................................... 35
	1 Issued RSP........................................................................................................ 35
		T-code.......................................................................................................... 35
		Model........................................................................................................... 35
		Serial No....................................................................................................... 35
		Issued.......................................................................................................... 35
Contents, P............................................................................................................. 37
	1 Preventive Maintenance............................................................................................ 37
Introduction, maintenance............................................................................................... 39
	1 Safety regulations with maintenance work.......................................................................... 39
		WARNING!........................................................................................................ 39
		WARNING!........................................................................................................ 40
		WARNING!........................................................................................................ 40
		NOTE!........................................................................................................... 40
		CAUTION!........................................................................................................ 40
	2 Cleaning and washing.............................................................................................. 41
		NOTE!........................................................................................................... 41
		2.1 External cleaning........................................................................................... 41
			NOTE!....................................................................................................... 41
		2.2 Cleaning the motor compartment.............................................................................. 41
			NOTE!....................................................................................................... 41
		2.3 Electrical components....................................................................................... 42
			NOTE!....................................................................................................... 42
	3 Safe lifting...................................................................................................... 42
		WARNING!........................................................................................................ 42
Preventive Maintenance.................................................................................................. 43
	Valid from serial number:........................................................................................... 43
	T code.............................................................................................................. 43
	Model............................................................................................................... 43
	Serial No........................................................................................................... 43
	Notes............................................................................................................... 43
	1 Maintenance Chart................................................................................................. 43
		Pos............................................................................................................. 43
		Work to carry out............................................................................................... 43
			Interval in hours........................................................................................... 43
			5........................................................................................................... 43
			20.......................................................................................................... 43
			80.......................................................................................................... 43
			160......................................................................................................... 43
			250......................................................................................................... 43
			500......................................................................................................... 43
			1000........................................................................................................ 43
			Work to carry out........................................................................................... 43
			1 d......................................................................................................... 43
			1 w......................................................................................................... 43
			1 m......................................................................................................... 43
			2 m......................................................................................................... 43
			3 m......................................................................................................... 43
			6 m......................................................................................................... 43
			12 m........................................................................................................ 43
			0000........................................................................................................ 43
			Chasis...................................................................................................... 43
			0500........................................................................................................ 43
			Operator's cabin............................................................................................ 43
			0600........................................................................................................ 43
			Operating controls.......................................................................................... 43
			1700........................................................................................................ 44
			Drive motors................................................................................................ 44
			2550........................................................................................................ 44
			Drive unit.................................................................................................. 44
			3370........................................................................................................ 44
			Brakes...................................................................................................... 44
			3500........................................................................................................ 44
			Wheels...................................................................................................... 44
			5000........................................................................................................ 44
			Electric panel.............................................................................................. 44
			5110........................................................................................................ 45
			Battery..................................................................................................... 45
			6000........................................................................................................ 45
			Hydraulic system............................................................................................ 45
			6100........................................................................................................ 45
			Hydraulic unit, initial lift................................................................................ 45
			6120........................................................................................................ 45
			Hydraulic hoses............................................................................................. 45
			7100........................................................................................................ 45
			Mast........................................................................................................ 45
			7220........................................................................................................ 46
			Turret head fork unit....................................................................................... 46
Preventive Maintenance.................................................................................................. 51
	Valid from serial number:........................................................................................... 51
	T code.............................................................................................................. 51
	Model............................................................................................................... 51
	Serial No........................................................................................................... 51
	Notes............................................................................................................... 51
	1 Maintenance Chart................................................................................................. 51
		Pos............................................................................................................. 51
		Work to carry out............................................................................................... 51
			Interval in hours........................................................................................... 51
			5........................................................................................................... 51
			20.......................................................................................................... 51
			80.......................................................................................................... 51
			160......................................................................................................... 51
			250......................................................................................................... 51
			500......................................................................................................... 51
			1000........................................................................................................ 51
			Interval in days/weeks/ months.............................................................................. 51
			1 d......................................................................................................... 51
			1 w......................................................................................................... 51
			1 m......................................................................................................... 51
			2 m......................................................................................................... 51
			3 m......................................................................................................... 51
			6 m......................................................................................................... 51
			12 m........................................................................................................ 51
			0000........................................................................................................ 51
			Chasis...................................................................................................... 51
			0500........................................................................................................ 51
			Operator's cabin............................................................................................ 51
			0600........................................................................................................ 51
			Operating controls.......................................................................................... 51
			1700........................................................................................................ 52
			Drive motors................................................................................................ 52
			2550........................................................................................................ 52
			Drive unit.................................................................................................. 52
			3370........................................................................................................ 52
			Brakes...................................................................................................... 52
			3500........................................................................................................ 52
			Wheels...................................................................................................... 52
			5000........................................................................................................ 52
			Electric panel.............................................................................................. 52
			5110........................................................................................................ 53
			Battery..................................................................................................... 53
			6000........................................................................................................ 53
			Hydraulic system............................................................................................ 53
			6100........................................................................................................ 53
			Hydraulic unit, initial lift................................................................................ 53
			6120........................................................................................................ 53
			Hydraulic hoses............................................................................................. 53
			7100........................................................................................................ 53
			Mast........................................................................................................ 53
			7230........................................................................................................ 54
			Shuttle Fork Unit........................................................................................... 54
Oil and Grease Specification............................................................................................ 59
	Valid from serial number:........................................................................................... 59
	T code.............................................................................................................. 59
	Model............................................................................................................... 59
	Serial No........................................................................................................... 59
	Notes............................................................................................................... 59
	Lubricant........................................................................................................... 59
	Specification....................................................................................................... 59
Contents, S............................................................................................................. 61
	1 Service instructions.............................................................................................. 61
Chassis................................................................................................................. 63
	Valid from serial number:........................................................................................... 63
	T code.............................................................................................................. 63
	Model............................................................................................................... 63
	Serial No........................................................................................................... 63
	Notes............................................................................................................... 63
	1 General........................................................................................................... 63
		1.1 Lifting using lifting hooks or wires........................................................................ 63
		1.2 Lifting using a forklift.................................................................................... 63
			NOTE:....................................................................................................... 63
	2 BT CTX with dismantled mast....................................................................................... 64
		2.1 General..................................................................................................... 64
		2.2 Mounting the mast on the chassis............................................................................ 64
			2.2.1 Front chassis......................................................................................... 64
			2.2.2 Mast.................................................................................................. 64
				NOTE:................................................................................................... 66
Drive unit/gear......................................................................................................... 67
	Valid from serial number:........................................................................................... 67
		-............................................................................................................... 67
	T-kod............................................................................................................... 67
	Modell.............................................................................................................. 67
	Serial Nr........................................................................................................... 67
	Anm................................................................................................................. 67
	1. General.......................................................................................................... 67
	2. Gear components/data............................................................................................. 68
		2.1. Component identification................................................................................... 68
			Pos No...................................................................................................... 68
			Component................................................................................................... 68
		2.2. Technical gear data........................................................................................ 69
			Truck type.................................................................................................. 69
			CTX 1300.................................................................................................... 69
		2.3. Dismantled gear............................................................................................ 70
	3. Dismantling/fitting.............................................................................................. 71
		3.1. Dismantling of drive unit from truck....................................................................... 71
		3.2. Fitting the drive unit in truck............................................................................ 71
		3.3. Dismantling the drive motor and the gear................................................................... 72
		3.4. Fitting the drive motor and the gear....................................................................... 72
	4. Oil level check/replacing........................................................................................ 73
		4.1. Check/filling of oil....................................................................................... 73
		4.2. Oil replacement............................................................................................ 74
	5. Repairs.......................................................................................................... 75
		5.1. Exchange of drive shaft sealing ring....................................................................... 75
			5.1.1. Dismantling.......................................................................................... 75
				NOTE!................................................................................................... 75
			5.1.2. Assembly............................................................................................. 76
		5.2. Leakage from the top cover................................................................................. 77
		5.3. Leakage from the lower cover............................................................................... 77
		5.4. Replacing the wheel bolt................................................................................... 78
			NOTE!....................................................................................................... 78
Drive unit/gear......................................................................................................... 79
	Valid from serial number:........................................................................................... 79
	T code.............................................................................................................. 79
	Model............................................................................................................... 79
	Serial No........................................................................................................... 79
	Notes............................................................................................................... 79
	1 General........................................................................................................... 79
	2 Components/data of the drive unit and gear........................................................................ 80
		2.1 Component identification.................................................................................... 80
			Pos. No..................................................................................................... 81
			Component................................................................................................... 81
		2.2 Technical data.............................................................................................. 81
		2.3 Dismantled gear............................................................................................. 82
	3 Replacing the drive motor/drive gear.............................................................................. 83
		3.1 Dismantling of drive unit from truck........................................................................ 83
		3.2 Fitting the drive unit in truck............................................................................. 83
		3.3 Dismantling the drive motor and the gear.................................................................... 84
		3.4 Fitting the drive motor and the gear........................................................................ 84
	4 Oil level check/replacement....................................................................................... 85
		4.1 Checking/filling of oil..................................................................................... 85
		4.2 Oil replacement............................................................................................. 85
	5 Repairs........................................................................................................... 86
		5.1 Replacing the drive shaft sealing ring...................................................................... 86
			5.1.1 Dismantling........................................................................................... 86
				NOTE:................................................................................................... 86
			5.1.2 Assembly.............................................................................................. 87
				1. Place the drive shafts outer bearing in the gear housing............................................. 87
				2. Press the new sealing ring in place in the gear housing. Be careful when pressing it back in p....... 87
				3. Place the spacers of the shaft unit on the drive shaft, making sure the thickness is the origi....... 87
				4. Press the drive shaft with fitted spacers into the gear housing. Check that the splines on the....... 87
				5. Place the spacer ring on the drive shaft end and fit the shaft bolt. Always use a new bolt.The....... 87
				6. Before fitting the lower cover, replace the O-ring. Make sure the O-ring is free from damage. ....... 87
		5.2 Leakage from the top cover.................................................................................. 88
		5.3 Leakage from the lower cover................................................................................ 88
		5.4 Replacing the wheel bolt.................................................................................... 89
Magnetic brake.......................................................................................................... 91
	Valid from serial number:........................................................................................... 91
	T code.............................................................................................................. 91
	Model............................................................................................................... 91
	Serial No........................................................................................................... 91
	Notes............................................................................................................... 91
	1 General........................................................................................................... 91
		1.1 Function.................................................................................................... 92
	2 Maintenance....................................................................................................... 93
		2.1 Adjustment.................................................................................................. 93
			2.1.1 Adjustment procedure.................................................................................. 93
		2.2 Replacing the brake disc.................................................................................... 94
			2.2.1 Replacement procedure................................................................................. 94
Wire guidance........................................................................................................... 95
	Valid from serial number:........................................................................................... 95
	T code.............................................................................................................. 95
	Model............................................................................................................... 95
	Serial No........................................................................................................... 95
	Notes............................................................................................................... 95
	1 General........................................................................................................... 95
	2 Generator......................................................................................................... 96
		2.1 Technical data.............................................................................................. 96
			Power supply................................................................................................ 96
			Model LDU-22 220 V, 50 Hz................................................................................... 96
			Model LDU-21 110 V, 50/60 Hz................................................................................ 96
	3 Antennas.......................................................................................................... 97
		3.1 Antenna cable............................................................................................... 98
	4 Wire guidance logic card.......................................................................................... 98
		4.1 Components.................................................................................................. 99
		4.2 Connectors.................................................................................................. 99
			Connector................................................................................................... 99
			Ty- pe...................................................................................................... 99
			No.......................................................................................................... 99
			Active...................................................................................................... 99
			Function.................................................................................................... 99
			Connector...................................................................................................100
			Type........................................................................................................100
			No..........................................................................................................100
			Active......................................................................................................100
			Function....................................................................................................100
		4.3 Display.....................................................................................................100
			4.3.1 Input signals.........................................................................................100
				Segment.................................................................................................100
				Function................................................................................................100
			4.3.2 Output signals / operating modes......................................................................100
			Segment.....................................................................................................101
			Function....................................................................................................101
				4.3.3 Error codes.......................................................................................101
			Code........................................................................................................101
			Description.................................................................................................101
	5 Miscellaneous.....................................................................................................104
	6 Description of function...........................................................................................105
		6.1 Forward travel..............................................................................................105
		6.2 Reverse travel..............................................................................................105
		6.3 Control signals.............................................................................................106
			Operating mode..............................................................................................106
			L...........................................................................................................106
			A...........................................................................................................106
			P...........................................................................................................106
	7 Adjustments.......................................................................................................107
		7.1 Truck computer A2...........................................................................................107
			7.1.1 Steering angle........................................................................................107
			7.1.2 Proportional valves...................................................................................107
		7.2 Wire guidance logic card A3.................................................................................108
			Menu........................................................................................................108
			Description.................................................................................................108
			Area........................................................................................................108
			Display.....................................................................................................110
			Description.................................................................................................110
			7.2.1 Adjustment of the steering angle offset...............................................................111
			7.2.2 Fine adjustment of the steering angle offset..........................................................111
			7.2.3 Antenna adjustment for reverse travel.................................................................111
				Serial number...........................................................................................112
				K.......................................................................................................112
			7.2.4 Antenna adjustment for forward travel.................................................................112
				Serial number...........................................................................................112
				K.......................................................................................................112
			7.2.5 Final adjustment......................................................................................113
			7.2.6 Storing parameters....................................................................................113
			7.2.7 Antenna adjustment in the antenna 1 mode..............................................................113
	8 Installing a new wire guidance logic card.........................................................................115
		POS.............................................................................................................115
		Truck model.....................................................................................................115
		ID number.......................................................................................................115
		POS.............................................................................................................116
		Truck model.....................................................................................................116
		ID number.......................................................................................................116
	9 Troubleshooting...................................................................................................117
		9.1 Control signals.............................................................................................117
			9.1.1 Verifying the reference signal........................................................................117
				kHz.....................................................................................................117
				mA......................................................................................................117
			9.1.2 Verifying the lateral signal..........................................................................117
			9.1.3 Verifying the steering angle signal...................................................................117
	Electrical System...................................................................................................119
		Valid from serial number:.......................................................................................119
		T code..........................................................................................................119
		Model...........................................................................................................119
		Serial No.......................................................................................................119
		Notes...........................................................................................................119
		1 General.......................................................................................................119
1.1 Electric panel on chassis...........................................................................................119
1.2 Electrical panel, operator's cabin..................................................................................120
1.3 General description of the electrical system........................................................................121
	1.3.1 Drive motor circuit (sheet 1).................................................................................121
	1.3.2 Pump, cabin lift, battery indicator/hour counter (sheet 2)....................................................121
	1.3.3 Inputs to logic card A2 (sheet 3).............................................................................121
	1.3.4 Inputs to logic card A2 (sheet 4).............................................................................122
		NOTE:...........................................................................................................123
	1.3.5 Inputs to logic card A2 (sheet 5).............................................................................123
		NOTE:...........................................................................................................123
	1.3.6 Outputs from logic card A2 (sheet 6)..........................................................................124
	1.3.7 Outputs from logic card A2 (sheet 7)..........................................................................124
	1.3.8 Outputs from logic card A2 (sheet 8)..........................................................................125
	1.3.9 Horn, lighting, and fork pump motor (sheet 9).................................................................125
	1.3.10 Inputs to the logic card A4 (sheet 10).......................................................................125
	1.3.11 Outputs from the logic card A4 (sheet 10)....................................................................126
	1.3.12 Inputs to the logic card A4 (sheet 11).......................................................................126
	1.3.13 Outputs from the logic card A4 (sheet 11)....................................................................127
	1.3.14 Outputs from the logic card A4 (sheet 12)....................................................................128
	1.3.15 Wire guidance (sheet 13).....................................................................................128
	2 List of symbols and circuit diagrams..............................................................................129
2.1 Symbol list.........................................................................................................129
	Symbol..............................................................................................................129
	Description.........................................................................................................129
2.2 Electrical diagrams T code 161......................................................................................131
2.3 Electrical diagrams T code 311......................................................................................145
2.4 Component list......................................................................................................159
	Description.........................................................................................................159
	Designation - Function..............................................................................................159
	3 Description of function...........................................................................................164
3.1 Start...............................................................................................................164
3.2 Presence control....................................................................................................165
	3.2.1 Open cabin gates..............................................................................................165
	3.2.2 Closed cabin gates............................................................................................165
3.3 Dead man's handle...................................................................................................165
3.4 Forward/Reverse travel..............................................................................................165
3.5 Emergency drive position............................................................................................166
	NOTE:...............................................................................................................166
3.6 Travel speed........................................................................................................167
	3.6.1 Out of aisle..................................................................................................167
	3.6.2 In narrow aisles, rail steering:..............................................................................168
	3.6.3 In narrow aisles, wire guidance:..............................................................................168
3.7 Braking.............................................................................................................168
3.8 End-of-aisle brake..................................................................................................169
3.9 Steering............................................................................................................169
	NOTE:...............................................................................................................169
3.10 Lifting the cabin..................................................................................................170
3.11 Lowering the cabin.................................................................................................171
3.12 Slack chain guard..................................................................................................171
3.13 Turret head fork unit..............................................................................................171
	3.13.1 Traversing...................................................................................................172
	3.13.2 Rotation.....................................................................................................172
	3.13.3 Lifting/lowering the forks...................................................................................173
	3.13.4 Extra function...............................................................................................173
	3.13.5 Miscellaneous................................................................................................173
3.14 Shuttle Fork Unit..................................................................................................174
	1. Right dead man's handle not engaged..............................................................................174
	2. Joystick not centered............................................................................................174
	3. Right dead man's handle engaged..................................................................................174
	4. Forks moving left or right.......................................................................................174
	5. Forks moving up or down..........................................................................................174
	6. Computer error at start-up.......................................................................................174
	7. Safety relay malfunction.........................................................................................174
	8. Short-circuit on one of the outputs..............................................................................174
	3.14.1 Side-shift...................................................................................................174
	3.14.2 Lifting/lowering the forks...................................................................................175
	3.14.3 Miscellaneous................................................................................................175
3.15 Miscellaneous......................................................................................................175
	4 Adjustments.......................................................................................................176
4.1 Speed sensors (S55, S56)............................................................................................176
4.2 Traversing sensors (S57, S58).......................................................................................176
4.3 Height sensor (S90-S92, S104-S106)..................................................................................176
Display.................................................................................................................177
	Valid from serial number:...........................................................................................177
	T code..............................................................................................................177
	Model...............................................................................................................177
	Serial No...........................................................................................................177
	Notes...............................................................................................................177
	1 Display indications and pushbuttons...............................................................................177
		1. Indication “Truck OK”: The green LED comes on when the truck is ready for use................................177
		2. Indication “Straight articulated centre”: The green LED comes on when the truck is perfectly s...............177
		3. Indication “Truck in aisle”: The green LED comes on when the truck is in a narrow aisle......................177
		4. Indication “Wire guidance”: The yellow LED blinks when the truck is searching for the wire and...............177
		5. Indication “Forks not in home position”: The red LED lights when the forks are not in the ”hom...............178
		6. Indication “Open gate”: The red LED lights when the gate has not been closed and the right joy...............178
		7. Indication “Slack chain”: The red LED lights when there is slack in one of the cabin lifting c...............178
		8. Indication “Battery status”: The red LED lights when there is no more than 20% left of the bat...............178
		9. Enter button: Pushbutton used to store parameters............................................................178
		10. +/- button: Pushbutton used to change parameter values......................................................178
		11. Up/Down button: Pushbutton used to select parameters........................................................178
	2 Display menus.....................................................................................................179
		2.1 Normal position.............................................................................................179
		2.2 Emergency drive position....................................................................................179
			NOTE:.......................................................................................................179
		2.3 Programming position........................................................................................179
			2.3.1 Programmable parameters...............................................................................180
			Parameter...................................................................................................180
			Description.................................................................................................180
			Parameter...................................................................................................181
			Description.................................................................................................181
			Parameter...................................................................................................181
			Description.................................................................................................181
			Parameter...................................................................................................181
			Description.................................................................................................181
			Parameter...................................................................................................181
			Description.................................................................................................181
Transistor regulator....................................................................................................183
	Valid from serial number:...........................................................................................183
	T code..............................................................................................................183
	Model...............................................................................................................183
	Serial No...........................................................................................................183
	Notes...............................................................................................................183
	1 Transistor regulator..............................................................................................183
		1.1 Motor Connections...........................................................................................184
			Terminal number.............................................................................................184
			Function....................................................................................................184
		1.2 Control voltage contact.....................................................................................184
			Terminal number.............................................................................................184
			Connector...................................................................................................184
			Function....................................................................................................184
	2 Technical data....................................................................................................185
	3 LED indications...................................................................................................186
		LED No..........................................................................................................186
		Colour..........................................................................................................186
		Indicates.......................................................................................................186
		Diagnosis.......................................................................................................186
	4 Maintenance.......................................................................................................187
		NOTE:...........................................................................................................187
		4.1 Safety......................................................................................................187
			WARNING!....................................................................................................187
		4.2 Cleaning....................................................................................................187
	5 Safety inspection.................................................................................................188
		5.1 Check transistor regulator safety circuit...................................................................188
			WARNING!....................................................................................................188
Electronic card A2......................................................................................................189
	Valid from serial number:...........................................................................................189
	T code..............................................................................................................189
	Model...............................................................................................................189
	Serial No...........................................................................................................189
	Notes...............................................................................................................189
	1 General...........................................................................................................189
	2 A2 connection terminals and voltages..............................................................................190
		2.1 X91.........................................................................................................190
			Terminal....................................................................................................190
			Cable.......................................................................................................190
			Designation.................................................................................................190
			Active......................................................................................................190
			Input/ output...............................................................................................190
		2.2 X92.........................................................................................................191
			Terminal....................................................................................................191
			Cable.......................................................................................................191
			Designation.................................................................................................191
			Active......................................................................................................191
			Input/ output...............................................................................................191
		2.3 X93.........................................................................................................191
			Terminal....................................................................................................191
			Cable.......................................................................................................191
			Designation.................................................................................................191
			Active......................................................................................................191
			Input/ output...............................................................................................191
		2.4 X94.........................................................................................................192
			Terminal....................................................................................................192
			Cable.......................................................................................................192
			Designation.................................................................................................192
			Active......................................................................................................192
			Input/ output...............................................................................................192
		2.5 X95.........................................................................................................192
			Terminal....................................................................................................192
			Cable.......................................................................................................192
			Designation.................................................................................................192
			Active......................................................................................................192
			Input/ output...............................................................................................192
		2.6 X96.........................................................................................................193
			Terminal....................................................................................................193
			Cable.......................................................................................................193
			Designation.................................................................................................193
			Active......................................................................................................193
			Input/ output...............................................................................................193
		2.7 X97.........................................................................................................193
			Terminal....................................................................................................193
			Cable.......................................................................................................193
			Designation.................................................................................................193
			Active......................................................................................................193
			Input/ output...............................................................................................193
		2.8 X98.........................................................................................................194
			Terminal....................................................................................................194
			Cable.......................................................................................................194
			Designation.................................................................................................194
			Active......................................................................................................194
			Input/ output...............................................................................................194
		2.9 X99.........................................................................................................194
			Terminal....................................................................................................194
			Cable.......................................................................................................194
			Designation.................................................................................................194
			Active......................................................................................................194
			Input/ output...............................................................................................194
	3 A2 board adjustments..............................................................................................195
		3.1 Adjustment of steering centre position......................................................................195
		3.2 Adjustment of cabin lift (offset)...........................................................................195
		3.3 Adjustment of cabin lowering (offset).......................................................................195
	4 Error codes.......................................................................................................196
		4.1 Error types.................................................................................................196
			Error type..................................................................................................196
			Description / corrective measure............................................................................196
		4.2 Error codes.................................................................................................197
			Code........................................................................................................197
			11..........................................................................................................197
			Code........................................................................................................197
			12..........................................................................................................197
			Code........................................................................................................197
			13..........................................................................................................197
			Code........................................................................................................197
			14..........................................................................................................197
			Code........................................................................................................198
			15..........................................................................................................198
			Code........................................................................................................198
			16..........................................................................................................198
			Code........................................................................................................198
			17..........................................................................................................198
			Code........................................................................................................199
			18..........................................................................................................199
			Code........................................................................................................199
			21..........................................................................................................199
			Code........................................................................................................199
			22..........................................................................................................199
			Code........................................................................................................199
			23..........................................................................................................199
			Code........................................................................................................200
			24..........................................................................................................200
			Code........................................................................................................200
			25..........................................................................................................200
			Code........................................................................................................200
			26..........................................................................................................200
			Code........................................................................................................200
			27..........................................................................................................200
			Code........................................................................................................201
			30..........................................................................................................201
			Code........................................................................................................201
			31..........................................................................................................201
			Code........................................................................................................201
			32..........................................................................................................201
			Code........................................................................................................202
			33..........................................................................................................202
			Code........................................................................................................202
			34..........................................................................................................202
			Code........................................................................................................203
			35..........................................................................................................203
			Code........................................................................................................203
			40..........................................................................................................203
			Code........................................................................................................203
			41..........................................................................................................203
			Code........................................................................................................204
			42..........................................................................................................204
			Code........................................................................................................204
			43..........................................................................................................204
			Code........................................................................................................204
			44..........................................................................................................204
			Code........................................................................................................205
			45..........................................................................................................205
			Code........................................................................................................205
			50..........................................................................................................205
			Code........................................................................................................205
			51..........................................................................................................205
			Code........................................................................................................206
			52..........................................................................................................206
			Code........................................................................................................206
			53..........................................................................................................206
			Code........................................................................................................206
			60..........................................................................................................206
			Code........................................................................................................207
			61..........................................................................................................207
			Code........................................................................................................207
			62..........................................................................................................207
			Code........................................................................................................207
			63..........................................................................................................207
			Code........................................................................................................208
			64..........................................................................................................208
			Code........................................................................................................208
			70..........................................................................................................208
			Code........................................................................................................208
			71..........................................................................................................208
			Code........................................................................................................208
			72..........................................................................................................208
			Code........................................................................................................209
			73..........................................................................................................209
			Code........................................................................................................209
			74..........................................................................................................209
			Code........................................................................................................209
			100.........................................................................................................209
			Code........................................................................................................209
			101.........................................................................................................209
			Code........................................................................................................210
			102.........................................................................................................210
			Code........................................................................................................210
			103.........................................................................................................210
			Code........................................................................................................210
			104.........................................................................................................210
			Code........................................................................................................210
			105.........................................................................................................210
			Code........................................................................................................211
			106.........................................................................................................211
			Code........................................................................................................211
			107.........................................................................................................211
			Code........................................................................................................211
			108.........................................................................................................211
			Code........................................................................................................211
			109.........................................................................................................211
			Code........................................................................................................212
			111.........................................................................................................212
			Code........................................................................................................212
			112.........................................................................................................212
			Code........................................................................................................212
			113.........................................................................................................212
			Code........................................................................................................212
			114.........................................................................................................212
			Code........................................................................................................213
			120.........................................................................................................213
			Code........................................................................................................213
			121.........................................................................................................213
			Code........................................................................................................213
			122.........................................................................................................213
			Code........................................................................................................213
			123.........................................................................................................213
			Code........................................................................................................214
			124.........................................................................................................214
			Code........................................................................................................214
			125.........................................................................................................214
			Code........................................................................................................214
			126.........................................................................................................214
			Code........................................................................................................214
			130.........................................................................................................214
			Code........................................................................................................215
			131.........................................................................................................215
			Code........................................................................................................215
			132.........................................................................................................215
			Code........................................................................................................215
			133.........................................................................................................215
			Code........................................................................................................216
			134.........................................................................................................216
			Code........................................................................................................216
			135.........................................................................................................216
			Code........................................................................................................216
			136.........................................................................................................216
			Code........................................................................................................217
			137.........................................................................................................217
			Code........................................................................................................217
			138.........................................................................................................217
			Code........................................................................................................217
			139.........................................................................................................217
			Code........................................................................................................218
			141.........................................................................................................218
	5 Parameters........................................................................................................219
		5.1 Installing a new board in the truck.........................................................................219
		5.2 Programming parameters......................................................................................219
			NOTE:.......................................................................................................219
			Parameter...................................................................................................220
			Description.................................................................................................220
			Area........................................................................................................220
			Std.........................................................................................................220
			Parameter...................................................................................................220
			Description.................................................................................................220
			Area........................................................................................................220
			Std.........................................................................................................220
			Parameter...................................................................................................220
			Description.................................................................................................220
			Area........................................................................................................220
			Std.........................................................................................................220
			Parameter...................................................................................................221
			Description.................................................................................................221
			Area........................................................................................................221
			Std.........................................................................................................221
			Value.......................................................................................................221
			Stop buzzer sounding........................................................................................221
			Speed.......................................................................................................221
			Parameter...................................................................................................221
			Description.................................................................................................221
			Area........................................................................................................221
			Std.........................................................................................................221
Electronic card.........................................................................................................223
	Valid from serial number:...........................................................................................223
	T code..............................................................................................................223
	Model...............................................................................................................223
	Serial No...........................................................................................................223
	Notes...............................................................................................................223
	1 General...........................................................................................................223
	2 Connection terminals and voltages on A4...........................................................................224
		2.1 A4:100......................................................................................................224
			Terminal....................................................................................................224
			Cable.......................................................................................................224
			Designation.................................................................................................224
			Active......................................................................................................224
			Input/ output...............................................................................................224
			LED.........................................................................................................224
		2.2 A4:200......................................................................................................225
			Terminal....................................................................................................225
			Cable.......................................................................................................225
			Designation.................................................................................................225
			Active......................................................................................................225
			Input/ output...............................................................................................225
			LED.........................................................................................................225
		2.3 A4:300......................................................................................................225
			Terminal....................................................................................................225
			Cable.......................................................................................................225
			Designation.................................................................................................225
			Active......................................................................................................225
			Input/ output...............................................................................................225
			LED.........................................................................................................225
		2.4 A4:400......................................................................................................226
			Terminal....................................................................................................226
			Cable.......................................................................................................226
			Designation.................................................................................................226
			Active......................................................................................................226
			Input/ output...............................................................................................226
			LED.........................................................................................................226
		2.5 A4:500......................................................................................................226
			Terminal....................................................................................................226
			Cable.......................................................................................................226
			Designation.................................................................................................226
			Active......................................................................................................226
			Input/ output...............................................................................................226
			LED.........................................................................................................226
	3 A4 board adjustments, T code 161..................................................................................227
		3.1 Adjustment of turret movement (end position)................................................................227
		3.2 Adjustment of traversing movement (offset)..................................................................227
		3.3 Adjustment of shuttle movement (offset).....................................................................228
		3.4 Adjustment of traversing travel.............................................................................228
			Travel length...............................................................................................228
			DIP-switch..................................................................................................228
			(mm)........................................................................................................228
			1...........................................................................................................228
			2...........................................................................................................228
			3...........................................................................................................228
			4...........................................................................................................228
			5...........................................................................................................228
	4 Troubleshooting...................................................................................................229
		4.1 OK LED......................................................................................................229
	5 A4 board adjustments, T code 311..................................................................................229
		5.1 Adjustment of traversing movement (offset)..................................................................229
		5.2 Adjustment of traversing travel.............................................................................230
			Travel length...............................................................................................230
			DIP-switch..................................................................................................230
			(mm)........................................................................................................230
			1...........................................................................................................230
			2...........................................................................................................230
			3...........................................................................................................230
			4...........................................................................................................230
			5...........................................................................................................230
	6 Troubleshooting...................................................................................................231
		6.1 OK LED......................................................................................................231
			Code........................................................................................................231
			1...........................................................................................................231
			Code........................................................................................................232
			2...........................................................................................................232
			Code........................................................................................................232
			3...........................................................................................................232
			Code........................................................................................................232
			4...........................................................................................................232
			Code........................................................................................................232
			5...........................................................................................................232
			Code........................................................................................................232
			6...........................................................................................................232
			Code........................................................................................................233
			7...........................................................................................................233
			Code........................................................................................................233
			8...........................................................................................................233
Hydraulic system........................................................................................................235
	Valid from serial number:...........................................................................................235
	T code..............................................................................................................235
	Model...............................................................................................................235
	Serial No...........................................................................................................235
	Notes...............................................................................................................235
	1 Main lift/steering................................................................................................235
		1.1 General.....................................................................................................235
		1.2 Cabin Lift  right joystick upwards:........................................................................235
		1.3 Lowering the cabin - right joystick pressed down............................................................235
	2 Steering..........................................................................................................236
		2.1 Articulated centre cylinders................................................................................236
		2.2 Installing the articulated centre cylinders.................................................................237
		2.3 Hydraulic chart, chassis....................................................................................238
		2.4 Symbol list, chassis........................................................................................239
			Pos.........................................................................................................239
			Designation.................................................................................................239
		2.5 Decreasing the accumulator pressure.........................................................................240
	3 Initial lift, turret fork unit....................................................................................241
		3.1 General.....................................................................................................241
		3.2 Fork rotation...............................................................................................241
		3.3 Traversing movement.........................................................................................241
		3.4 Lifting/lowering the forks..................................................................................241
		3.5 Hydraulic chart, initial lift...............................................................................242
		3.6 Symbol list, initial lift...................................................................................243
			Pos.........................................................................................................243
			Designation.................................................................................................243
Hydraulic system........................................................................................................245
	Valid from serial number:...........................................................................................245
	T code..............................................................................................................245
	Model...............................................................................................................245
	Serial No...........................................................................................................245
	Notes...............................................................................................................245
	1 Main lift/steering................................................................................................245
		1.1 General.....................................................................................................245
		1.2 Cabin Lift - right joystick upwards:........................................................................245
		1.3 Lowering the cabin - right joystick pressed down............................................................245
	2 Steering..........................................................................................................246
		2.1 Articulated centre cylinders................................................................................246
		2.2 Installing the articulated centre cylinders.................................................................247
		2.3 Hydraulic chart, chassis....................................................................................248
		2.4 Symbol list.................................................................................................249
			Pos.........................................................................................................249
			Designation.................................................................................................249
		2.5 Decreasing the accumulator pressure.........................................................................250
	3 Initial lift, shuttle fork unit...................................................................................251
		3.1 General.....................................................................................................251
		3.2 Side-shift..................................................................................................251
		3.3 Lifting/lowering the forks..................................................................................251
		3.4 Hydraulic chart, initial lift...............................................................................252
		3.5 Symbol list.................................................................................................253
			Pos.........................................................................................................253
			Designation.................................................................................................253
Valve...................................................................................................................255
	Valid from serial number:...........................................................................................255
	T code..............................................................................................................255
	Model...............................................................................................................255
	Serial No...........................................................................................................255
	Notes...............................................................................................................255
	1 Valve for main lift/steering......................................................................................255
		1.1 General.....................................................................................................255
		1.2 Valve block.................................................................................................256
		1.3 Symbol list.................................................................................................257
			Pos.........................................................................................................257
			Designation.................................................................................................257
		1.4 Adjust of pressure guards S60-S62...........................................................................258
Valve...................................................................................................................259
	Valid from serial number:...........................................................................................259
	T code..............................................................................................................259
	Model...............................................................................................................259
	Serial No...........................................................................................................259
	Notes...............................................................................................................259
	1 Valve for initial lift/turret head fork unit......................................................................259
		1.1 General.....................................................................................................259
		1.2 Valve Block.................................................................................................260
		1.3 Symbol list.................................................................................................261
			Pos.........................................................................................................261
			Designation.................................................................................................261
Valve...................................................................................................................263
	Valid from serial number:...........................................................................................263
	T code..............................................................................................................263
	Model...............................................................................................................263
	Serial No...........................................................................................................263
	Notes...............................................................................................................263
	1 Valve for initial lift/shuttle fork unit..........................................................................263
		1.1 General.....................................................................................................263
		1.2 Valve Block.................................................................................................264
		1.3 Symbol list.................................................................................................265
			Pos.........................................................................................................265
			Designation.................................................................................................265
Mast....................................................................................................................267
	Valid from serial number:...........................................................................................267
	T code..............................................................................................................267
	Model...............................................................................................................267
	Serial No...........................................................................................................267
	Notes...............................................................................................................267
	1 Control/adjustment of the mast....................................................................................267
		1.1 Mounting....................................................................................................267
	2 Adjustment of rollers.............................................................................................268
		2.1 Cabin.......................................................................................................268
		2.2 Mast guides.................................................................................................269
		2.3 Inspection/adjustment of chains and cables..................................................................269
		2.4 Mast chains.................................................................................................270
			NOTE:.......................................................................................................271
		2.5 Cabin chains................................................................................................272
			NOTE:.......................................................................................................273
Initial lift of frame/mast..............................................................................................275
	Valid from serial number:...........................................................................................275
	T code..............................................................................................................275
	Model...............................................................................................................275
	Serial No...........................................................................................................275
	Notes...............................................................................................................275
	1 General...........................................................................................................275
	2 Tools.............................................................................................................275
		Tool number.....................................................................................................275
		N.B.............................................................................................................275
	3 Master cylinder...................................................................................................276
		3.1 Disassembling the cylinder..................................................................................276
		3.2 Disassembling the piston seal, guide ring, piston rod seal, support ring and O- ring........................276
		3.3 Fitting the piston seal, guide ring, piston rod seal, support ring and O-ring...............................277
		3.4 Disassembly and assembly of the brake valve for the lowering action.........................................277
		3.5 Assembly of the cylinder....................................................................................277
Turret head fork unit...................................................................................................279
	Valid from serial number:...........................................................................................279
	T code..............................................................................................................279
	Model...............................................................................................................279
	Serial No...........................................................................................................279
	Notes...............................................................................................................279
	1 General...........................................................................................................279
	2 Initial lift......................................................................................................280
		2.1 Lifting.....................................................................................................280
		2.2 Lowering....................................................................................................280
	3 Fork rotation.....................................................................................................281
	4 Traversing movement...............................................................................................282
	5 Inspection and maintenance........................................................................................283
		5.1 Outside Inspection..........................................................................................283
		5.2 Inspection..................................................................................................283
		5.3 Maintenance.................................................................................................283
	6 Adjustment of turret head fork unit...............................................................................284
		6.1 Lifting chains..............................................................................................284
		6.2 Fork carriage...............................................................................................284
		6.3 Adjustment of the gear flank play...........................................................................284
Shuttle Fork Unit.......................................................................................................287
	Valid from serial number:...........................................................................................287
	T code..............................................................................................................287
	Model...............................................................................................................287
	Serial No...........................................................................................................287
	Notes...............................................................................................................287
	1 General...........................................................................................................287
	2 Initial lift......................................................................................................288
		2.1 Lifting.....................................................................................................288
		2.2 Lowering....................................................................................................288
		2.3 Side-shift movement (traversing)............................................................................289
	3 Inspection and maintenance........................................................................................290
		3.1 Outside Inspection..........................................................................................290
	4 Inspection........................................................................................................290
		4.1 General.....................................................................................................290
		4.2 Lateral fork movement.......................................................................................291
	5 Maintenance/lubrication...........................................................................................291
		5.1 250 hours...................................................................................................291
		5.2 1000 hours..................................................................................................291
	6 Adjustment of fork unit...........................................................................................292
		6.1 Lifting chains..............................................................................................292
		6.2 Fork carriage...............................................................................................293
		6.3 Guide initial lift..........................................................................................293
			NOTE:.......................................................................................................294
		6.4 Adjustment of the gear flank play...........................................................................295
Lifting cylinder........................................................................................................297
	Valid from serial number:...........................................................................................297
	T code..............................................................................................................297
	Model...............................................................................................................297
	Serial No...........................................................................................................297
	Notes...............................................................................................................297
	1 General...........................................................................................................297
	2 Tools.............................................................................................................297
		Tool number.....................................................................................................297
		N.B.............................................................................................................297
	3 Lifting cylinder..................................................................................................298
		3.1 Disassembling the cylinder..................................................................................298
		3.2 Remove the piston rod seal and support ring from the lifting cylinder.......................................298
			NOTE:.......................................................................................................298
		3.3 Installing the piston rod seal and support ring on the lifting cylinder.....................................299
		3.4 Disassembling the rod from the lifting cylinder.............................................................299
		3.5 Installing the rod in the lifting cylinder..................................................................299
		3.6 Disassembly and assembly of the brake valve for the lowering action.........................................299
		3.7 Assembly of the cylinder....................................................................................300
			NOTE:.......................................................................................................300

S.S 06/24