Mitsubishi Forklift RB14N2S RB14N2HS RB16N2 RB16N2H RB16N2S RB16N2HS RB16N2C RB16N2HC Service Manual by www.heydownloads.com

SERVICE MANUAL RB14N2S, RB14N2HS RB16N2, RB16N2H, RB16N2S RB16N2HS, RB16N2C, RB16N2HC RB20N2H, RB20N2X RB25N2X

English

622075-EN C

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

Only adequately trained service persons are allowed to carry out service operations. The terms of the warranty prescribe appropriate maintenance of the truck. Use original spare parts. It is recommended that you sign a maintenance agreement with the truck dealer, who can also supply spare parts. Only professional service ensures long-term, trouble-free truck operation. Service program monitoring becomes easier if you enter the service dates in a service logbook. Contact our service organisation or your truck dealer for qualified, authorized and efficient maintenance service. Copyright © 2018 by Mitsubishi Forklift Trucks. All rights reserved. Mitsubishi Forklift Trucks® is a registered trademark of Mitsubishi Heavy Industries®, Inc. All brand or product names are or may be trademarks of, and are used to identify products and services of, their respective owners. Unauthorized copying and lending are prohibited.

Mitsubishi Logisnext Asia Pacific Pte. Ltd. No. 1, Tuas West Street Singapore 637444

MCFA

MCFE B.V.

2121 W. Sam Houston Pkwy. N.

Hefbrugweg 77

Houston, TX 77043-2305

1332 AM Almere

USA

The Netherlands

Approvals and version history REVISION

DATE

DESCRIPTION OF CHANGE

APPROVED BY

04.11.2014

First issue

R&D

14.07.2017

Second issue

R&D

02.02.2018

Third issue

R&D

These are the original instructions.

Revision: C

Document ID: 622075-EN

2 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

Contents Contents ............................................................................................................................. 3 1 2

Foreword ................................................................................................................ 12 How to read this manual ....................................................................................... 13 2.1

Safety-related signs ................................................................................. 13

2.2

Symbols and abbreviations ...................................................................... 13

2.3 3

2.2.1

Safety symbols................................................................................................ 13

2.2.2

Other symbols and abbreviations .................................................................... 15

Units ......................................................................................................... 15

Safety instructions ................................................................................................ 16 3.1

Safety requirements for industrial trucks ................................................. 16

3.2

Repairs and structural modifications ........................................................ 17

3.3

Service area safety .................................................................................. 17

3.4

Personal safety ........................................................................................ 18

3.5

Work safety .............................................................................................. 18

3.6

Operating temperature ............................................................................. 20

General information .............................................................................................. 21 4.1

Truck models covered by this manual ..................................................... 21

4.2

Identification plates on the truck .............................................................. 21

4.3

Overview of the truck ............................................................................... 24

4.3.1

Overhead guard .............................................................................................. 24

4.3.2

Cabin .............................................................................................................. 25

4.3.3

Emergency exits (cabin truck) ......................................................................... 25

4.3.4

Operating devices ........................................................................................... 26

4.3.5

Control panel................................................................................................... 27

4.3.6

Steering wheel ................................................................................................ 27

4.3.7

Arm rest .......................................................................................................... 28

4.3.8

Display panel .................................................................................................. 30

4.3.9

Truck operation modes.................................................................................... 32

4.3.10

Truck display ................................................................................................... 33

4.3.10.1

Display control buttons .................................................................................... 34

4.3.10.2

Main view of the truck display.......................................................................... 34

4.3.10.3

Hierarchy of the truck display menus ............................................................... 43

4.3.11

Pedals ............................................................................................................. 47

4.3.12

Operator’s seat ............................................................................................... 49

4.3.13

Drive unit, hydraulic system and instrument panel ........................................... 50

4.3.13.1

Instrument panel ............................................................................................. 51

4.3.13.2

Hydraulic system ............................................................................................. 52

4.3.13.3

Motor compartment ......................................................................................... 53

4.3.14

Sensors........................................................................................................... 53

4.3.15

Reach carriage................................................................................................ 55

4.3.16

Mast ................................................................................................................ 55

Revision: C

Document ID: 622075-EN

3 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

4.3.17

Service Manual

Load backrest ................................................................................................. 56

Mechanical maintenance ...................................................................................... 57 5.1

5.2

Lifting points ............................................................................................. 57 5.1.1

Jack points ...................................................................................................... 57

5.1.2

Hoist points ..................................................................................................... 58

How to tow the truck................................................................................. 59 5.2.1

Release the magnetic brake manually ............................................................. 60

5.3

Transportation .......................................................................................... 61

5.4

Assembly and commissioning .................................................................. 63 5.4.1

Install the mast ................................................................................................ 63

5.5

Order spare parts ..................................................................................... 66

5.6

How to clean the truck ............................................................................. 66

5.7

Truck covers ............................................................................................. 67

5.8

5.7.1

Remove the machinery cover .......................................................................... 68

5.7.2

Remove the front bumper................................................................................ 68

5.7.3

Remove the floor plate .................................................................................... 68

5.7.4

Open the machinery top cover ........................................................................ 69

5.7.5

Open the instrument panel .............................................................................. 70

5.7.6

Remove the gas spring of the instrument panel ............................................... 71

5.7.7

Remove the instrument panel cover ................................................................ 72

5.7.8

Remove the control panel ............................................................................... 73

5.7.9

Remove the cup holder ................................................................................... 73

5.7.10

Remove the reach carriage cover.................................................................... 73

Steering wheel ......................................................................................... 74 5.8.1

5.9

Transmission gear.................................................................................... 75 5.9.1

5.10

5.12

5.14

5.11.1

Disassemble the traction wheel ....................................................................... 79

5.11.1.1

Replace the wheel shaft bolts.......................................................................... 79

5.11.2

Assemble the traction wheel............................................................................ 81

Corner supports ....................................................................................... 81

Replace the corner supports ........................................................................... 82

Load wheels ............................................................................................. 82 5.13.1

Remove the load wheels ................................................................................. 83

5.13.2

Electric load wheel brakes (High performance model, optional for Standard model) ............................................................................................. 84

5.13.3

Adjust the load wheel brakes (High performance model, optional for Standard model) ............................................................................................. 85

Battery roller frame................................................................................... 89 5.14.1

5.15

Lubricate the slewing bearing .......................................................................... 77

Traction wheel .......................................................................................... 78

5.12.1

5.13

Remove the transmission gear ........................................................................ 76

Slewing bearing........................................................................................ 77 5.10.1

5.11

Remove the steering wheel ............................................................................. 74

Remove the battery roller frame ...................................................................... 89

Reach carriage ......................................................................................... 90 5.15.1

Lubricate the rollers of the reach carriage ....................................................... 90

5.15.2

Adjust the guidance rollers of the reach carriage ............................................. 91

5.15.3

Sensors of the reach carriage ......................................................................... 93

5.15.4

Remove the reach carriage ............................................................................. 94

5.15.5

Remove the reach cylinder .............................................................................. 95

Revision: C

Document ID: 622075-EN

4 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

5.15.6

5.16

5.17

5.16.1

Detailed construction ..................................................................................... 103

5.16.2

Maintenance of the mast ............................................................................... 104

5.16.2.1

Daily maintenance......................................................................................... 104

5.16.2.2

Monthly maintenance .................................................................................... 104

5.16.2.3

Annual maintenance (1,000 h) ...................................................................... 104

5.16.3

Lubricant recommendations .......................................................................... 105

5.16.3.1

Mast chains ................................................................................................... 105

5.16.3.2

Mast channels ............................................................................................... 105

5.16.4

Remove the lifting carriage ............................................................................ 105

5.16.5

Remove the mast .......................................................................................... 108

5.16.6

Disassemble the mast ................................................................................... 112

5.16.7

Fork inspection.............................................................................................. 118

5.16.8

Mast chains ................................................................................................... 122

5.16.8.1

Inspect the mast chains................................................................................. 123

5.16.8.2

Examine the tension of the mast chains ........................................................ 129

5.16.8.3

Adjust the mast chains .................................................................................. 130

5.16.8.4

Replace the mast chains ............................................................................... 130

5.16.9

Guidance rollers ............................................................................................ 133

5.16.9.1

Adjust the guidance rollers ............................................................................ 134

5.16.9.2

Replace the guidance rollers ......................................................................... 134

5.16.10

Main rollers ................................................................................................... 136

5.16.10.1

Replace the main rollers................................................................................ 136

5.16.11

Free lift cylinder ............................................................................................. 138

5.16.11.1

Replace the free lift cylinder .......................................................................... 138

5.16.11.2

Sealing housing of the free lift cylinder .......................................................... 141

5.16.11.3

Bleed out the air from the free lift cylinder ..................................................... 142

5.16.12

Side cylinders................................................................................................ 144

5.16.12.1

Replace the side cylinders ............................................................................ 144

5.16.12.2

Sealing housing of the side cylinder .............................................................. 147

5.16.12.3

Bleed out the air from the side cylinders ........................................................ 149

5.16.13

Tilt cylinders .................................................................................................. 151

5.16.13.1

Remove the tilt cylinders ............................................................................... 151

5.16.13.2

Sealing housing of the tilt cylinder ................................................................. 153

5.16.14

Sideshift cylinder ........................................................................................... 154

5.16.14.1

Remove the piston of the sideshift cylinder ................................................... 155

5.16.14.2

Sealing housing of the sideshift cylinder ........................................................ 156

Load backrest......................................................................................... 157

Remove the load backrest ............................................................................. 157

Operator’s seat....................................................................................... 158 5.18.1

5.19

Replace the reach carriage hoses ................................................................... 97

Mast ....................................................................................................... 102

5.17.1

5.18

Service Manual

Replace the seat switch ................................................................................ 158

Arm rest.................................................................................................. 160 5.19.1

Remove the arm rest ..................................................................................... 160

5.19.2

Open the arm rest ......................................................................................... 162

5.19.3

Remove the arm rest levers .......................................................................... 162

5.19.4

Remove the arm rest buttons ........................................................................ 163

Revision: C

Document ID: 622075-EN

5 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

5.20

Service Manual

Cabin ...................................................................................................... 164 5.20.1

Cabin covers ................................................................................................. 164

5.20.1.1

Remove the instrument panel cover .............................................................. 165

5.20.1.2

Remove the ceiling cover .............................................................................. 167

5.20.1.3

Remove the left side cover ............................................................................ 168

5.20.1.4

Remove the right side cover .......................................................................... 168

5.20.1.5

Remove the operator door cover ................................................................... 169

5.20.2

Operator door................................................................................................ 170

5.20.2.1

Replace the gas spring of the operator door .................................................. 171

5.20.2.2

Remove the operator door ............................................................................ 172

5.20.2.3

Replace the lock of the operator door ............................................................ 173

5.20.2.4

Adjust the operator door ................................................................................ 175

5.20.3

Roof window ................................................................................................. 176

5.20.3.1

Open the roof window ................................................................................... 176

5.20.3.2

Remove the roof window ............................................................................... 177

5.20.3.3

Replace the sunroof wipers ........................................................................... 177

5.20.3.4

Remove the motor of the roof window wipers ................................................ 178

5.20.3.5

Remove the roof window lock........................................................................ 179

5.20.4

Cabin seals ................................................................................................... 180

5.20.5

Heater ........................................................................................................... 181

5.20.5.1

Remove the heater........................................................................................ 181

5.20.5.2

Adjust the heater ........................................................................................... 183

5.20.6

Loudspeakers ............................................................................................... 184

5.20.6.1

Replace the loudspeakers ............................................................................. 184

5.20.7

Cabin windows .............................................................................................. 185

Electrical operation ............................................................................................. 186 6.1

How to use the schematic diagram ........................................................ 186

6.2

Power supply.......................................................................................... 189

6.3

Safety circuit (emergency stop button) .................................................. 189

6.4

Key switch .............................................................................................. 189

6.5

Traction .................................................................................................. 190

Battery maintenance ........................................................................................... 191 7.1

Safety regulations concerning the handling of lead-acid batteries ........ 192

7.2

Battery maintenance .............................................................................. 193 7.2.1

Daily maintenance......................................................................................... 193

7.2.2

Weekly maintenance ..................................................................................... 193

7.2.3

Monthly maintenance .................................................................................... 193

7.2.4

Annual maintenance ..................................................................................... 194

7.2.5

General maintenance .................................................................................... 194

7.2.6

Storage ......................................................................................................... 194

7.2.7

Malfunctions .................................................................................................. 194

7.2.8

How to clean batteries ................................................................................... 194

7.3

Requirements for battery charging areas .............................................. 196

7.4

Charge the battery ................................................................................. 198

Revision: C

Document ID: 622075-EN

6 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

7.5

Measure the specific gravity of the battery ............................................ 201

7.6

Acquire a new battery ............................................................................ 201

7.7

Replace the battery ................................................................................ 201 7.7.1

Guide the battery connector cables ............................................................... 206

7.7.2

Quick battery replacement ............................................................................ 206

Electric system maintenance ............................................................................. 207 8.1

8.2

8.3

8.4

Display panel .......................................................................................... 207 8.1.1

Emergency stop button ................................................................................. 208

8.1.1.1

Emergency stop button functionality check .................................................... 208

8.1.2

Key switch..................................................................................................... 209

8.1.2.1

Key switch functionality check ....................................................................... 209

Pedals .................................................................................................... 210 8.2.1

Operator presence pedal............................................................................... 210

8.2.1.1

Operator presence pedal functionality check ................................................. 211

8.2.1.2

Remove the operator presence pedal ........................................................... 211

8.2.2

Accelerator pedal .......................................................................................... 212

8.2.2.1

Accelerator pedal functionality check ............................................................ 213

8.2.2.2

Remove the accelerator pedal....................................................................... 213

8.2.3

Brake pedal ................................................................................................... 214

8.2.3.1

Brake pedal functionality check ..................................................................... 215

8.2.3.2

Remove the brake pedal ............................................................................... 215

Instrument panel .................................................................................... 216 8.3.1

Discharge the controllers ............................................................................... 217

8.3.2

Vehicle controller........................................................................................... 218

8.3.3

Vehicle controller connectors ........................................................................ 218

8.3.3.1

CNA external connector ................................................................................ 219

8.3.3.2

CNB external connector ................................................................................ 221

8.3.4

Traction controller ......................................................................................... 222

8.3.5

Traction controller connectors ....................................................................... 223

8.3.5.1

CNA external connector ................................................................................ 224

8.3.5.2

Description of the power connections ............................................................ 225

8.3.6

Pump controller ............................................................................................. 225

8.3.7

Pump controller connectors ........................................................................... 226

8.3.7.1

CNA external connector ................................................................................ 227

8.3.7.2

Description of the power connections ............................................................ 228

8.3.8

Steering controller ......................................................................................... 228

8.3.9

Steering controller connectors ....................................................................... 229

8.3.9.1

CNA external connector ................................................................................ 230

8.3.9.2

Description of the power connections ............................................................ 231

8.3.10

Fuses ............................................................................................................ 231

8.3.11

Additional fuses with the cabin ...................................................................... 233

Motor compartment ................................................................................ 234 8.4.1

Traction motor ............................................................................................... 234

8.4.1.1

Remove the traction motor ............................................................................ 235

8.4.1.2

Lubricate the traction motor axle splines ....................................................... 236

8.4.1.3

Temperature sensor check ............................................................................ 237

Revision: C

Document ID: 622075-EN

7 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

8.5

8.6

Service Manual

8.4.1.4

HALL sensor ................................................................................................. 238

8.4.2

Steering motor .............................................................................................. 239

8.4.2.1

Remove the steering motor ........................................................................... 240

8.4.2.2

Temperature sensor check ............................................................................ 240

8.4.2.3

HALL sensor ................................................................................................. 241

8.4.3

Magnetic brake ............................................................................................. 243

8.4.3.1

Coil resistance measurement ........................................................................ 244

8.4.3.2

Install the magnetic brake ............................................................................. 244

8.4.3.3

Adjust the air gap of the magnetic brake ....................................................... 245

8.4.4

Release the magnetic brake manually ........................................................... 246

Pump motor............................................................................................ 247 8.5.1

Pump motor (Standard model) ...................................................................... 247

8.5.2

Pump motor (High performance model)......................................................... 248

8.5.3

Replace the pump motor ............................................................................... 249

8.5.4

Lubricate the pump axle splines .................................................................... 249

8.5.5

Replace the HALL sensor ............................................................................. 251

Sensors .................................................................................................. 252 8.6.1

Steering wheel sensor ................................................................................... 252

8.6.1.1

Steering wheel sensor functionality check ..................................................... 252

8.6.1.2

Steering control safety circuit check .............................................................. 253

8.6.2

Steering reference sensor ............................................................................. 254

8.6.2.1

Steering reference sensor functionality check ............................................... 255

8.6.3

Reach end stop, retract limit, retract end stop and reach limit switch ............. 255

8.6.3.1

Reach end stop, retract limit, retract end stop and reach limit switch functionality check ......................................................................................... 256

8.6.4

Battery lock sensor........................................................................................ 256

8.6.4.1

Battery lock sensor functionality check .......................................................... 257

8.6.5

Pressure sensor ............................................................................................ 257

8.6.5.1

Pressure sensor functionality check .............................................................. 258

8.6.6

Height reference sensor ................................................................................ 258

8.6.6.1

Height reference sensor functionality check .................................................. 259

Electric system adjustments and measurements ............................................ 260 9.1

Calibrate the arm rest levers .................................................................. 260

9.2

Insulation resistance test ....................................................................... 260 9.2.1

Test voltage .................................................................................................. 260

9.2.2

Insulation tester check................................................................................... 260

9.2.3

Measure the insulation resistance ................................................................. 261

9.2.3.1

Insulation resistance of the truck ................................................................... 261

9.2.3.2

Insulation resistance of the battery ................................................................ 262

Hydraulic operation ............................................................................................. 263 10.1

Hydraulic symbols .................................................................................. 267

10.2

Hydraulic oil recommendations .............................................................. 268

10.3

Maintenance points of the hydraulic system .......................................... 270

10.3.1

Replace the hydraulic oil return filter (sieve) .................................................. 270

10.3.2

Clean the hydraulic oil suction filter ............................................................... 271

Hydraulic system .................................................................................... 272 Revision: C

Document ID: 622075-EN

8 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

10.4.1

10.5

Hydraulic valve unit ................................................................................ 275 10.5.1

Valve M1 ....................................................................................................... 277

10.5.2

Valve M3, M4, M7 and M8 ............................................................................ 277

10.5.3

Valve M2, M5, M6, M9 and M10 .................................................................... 278

10.5.4

Emergency lowering valve ............................................................................ 278

10.5.5

Set the lifting pressure................................................................................... 279

10.5.6

Disassemble the valves................................................................................. 280

Location of the service socket................................................................ 281 11.1.1

Connect TruckTool to the service socket ....................................................... 282

Parameter descriptions ...................................................................................... 283 12.1

VCM master ........................................................................................... 283

12.2

Traction controller .................................................................................. 300

12.3

Pump controller ...................................................................................... 301

12.4

EPS controller ........................................................................................ 303

Alarm codes ......................................................................................................... 305 13.1

VCM ....................................................................................................... 306 13.1.1

VCM master alarms ...................................................................................... 306

13.1.2

VCM slave alarms ......................................................................................... 383

13.2

Traction controller .................................................................................. 435

13.3

Display ................................................................................................... 479

13.4

Pump controller ...................................................................................... 489

13.5

EPS ........................................................................................................ 533

13.6 14

Disassemble the hydraulic system ................................................................ 274

TruckTool Diagnostics ........................................................................................ 281 11.1

Service Manual

13.5.1

EPS master ................................................................................................... 533

13.5.2

EPS slave ..................................................................................................... 587

Arm rest controller .................................................................................. 635

Service data ......................................................................................................... 690 14.1

Special tightening torques ...................................................................... 690

14.2

Tightening torque for standard bolts and nuts ....................................... 690

14.3

Maintenance check list ........................................................................... 692

14.4

Lubrication .............................................................................................. 696 14.4.1

Hydraulic oil .................................................................................................. 696

14.4.2

Transmission oil ............................................................................................ 697

14.4.3

Heavy duty grease for slewing bearing .......................................................... 697

14.4.4

Pump axle splines ......................................................................................... 697

14.4.5

Traction motor axle splines ........................................................................... 697

14.4.6

Lubrication points .......................................................................................... 697

14.4.7

Mast chains ................................................................................................... 697

14.4.8

Mast channels ............................................................................................... 697

14.5

Hazardous waste and disposal .............................................................. 697

14.6

Special tools ........................................................................................... 698

14.7

Storage ................................................................................................... 701 14.7.1

Return the truck to operation ......................................................................... 701

Decommissioning ................................................................................... 701 Revision: C

Document ID: 622075-EN

9 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

Options ................................................................................................................. 702 15.1

Special color labels ................................................................................ 704

15.2

Customer design labels ......................................................................... 704

15.3

Truck display languages ........................................................................ 705

15.4

Accessory rack ....................................................................................... 706

15.5

15.4.1

Install the accessory rack .............................................................................. 707

15.4.2

Install the list bracket..................................................................................... 707

15.4.3

Install the computer rack ............................................................................... 708

15.4.4

Install the rear view mirror ............................................................................. 708

Accessory rack under the truck floor ...................................................... 709 15.5.1

15.6

Reading lamp ......................................................................................... 709 15.6.1

15.7

Install the plexiglass safety cover to the overhead guard ............................... 726

Left shoulder protection plate ................................................................. 727 15.16.1

15.17

Install the steel safety net to the overhead guard........................................... 725

Plexiglass safety cover for the overhead guard ..................................... 726 15.15.1

15.16

Install the drive alarm .................................................................................... 724

Steel safety net for overhead guard ....................................................... 724 15.14.1

15.15

Install the operator compartment fan ............................................................. 722

Drive alarm (programmable) .................................................................. 723 15.13.1

15.14

Install the blue spot rear light......................................................................... 719

Operator compartment fan ..................................................................... 721 15.12.1

15.13

Install the working lights ................................................................................ 717

Blue spot rear light ................................................................................. 719 15.11.1

15.12

Install the warning light with an extension arm ............................................... 715

Working lights ......................................................................................... 717 15.10.1

15.11

Install the warning light .................................................................................. 713

Warning light with an extension arm ...................................................... 715 15.9.1

15.10

Install the audio system ................................................................................. 711

Warning light .......................................................................................... 713 15.8.1

15.9

Install the reading lamp ................................................................................. 710

Audio system .......................................................................................... 711 15.7.1

15.8

Install the accessory rack under the floor ...................................................... 709

Install the left shoulder protection plate ......................................................... 728

Fire extinguisher ..................................................................................... 728 15.17.1

Install the fire extinguisher ............................................................................. 729

15.18

Cold storage modification ...................................................................... 730

15.19

Hot storage modification ........................................................................ 730

15.20

DC-DC converter .................................................................................... 731 15.20.1

15.21

15.22

Battery changing device for 2 batteries.................................................. 734 15.21.1

Remove an empty battery with the battery changing device for 2 batteries ........................................................................................................ 735

15.21.2

Install a charged battery with the battery changing device for 2 batteries ...... 737

Battery connector + cables .................................................................... 739 15.22.1

15.23

Replace the battery connector....................................................................... 740

Charger connector ................................................................................. 741 15.23.1

15.24

Install the DC-DC converter........................................................................... 731

Replace the charger connector ..................................................................... 742

Extra valve with hosing to fork carriage ................................................. 743 Revision: C

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15.25

Fork positioner with sideshift .................................................................. 743

15.26

Fork carriage strengthening part ............................................................ 744

15.27

Fork camera with 7” LCD color display .................................................. 744

15.28

Telescopic forks ..................................................................................... 745

15.29

Sideshift and tilt centering ...................................................................... 745 15.29.1

Sideshift centering direction, sideshift centering midpoint and tilt centering sensor ........................................................................................... 746

15.29.1.1

Sideshift centering direction, sideshift centering midpoint and tilt centering sensor functionality check .............................................................. 747

15.30

Load weight indicator ............................................................................. 748

15.31

Active Sway Control (ASC) .................................................................... 749 15.31.1

Lowering cut-off...................................................................................... 750

15.33

Operator’s seat options and accessories ............................................... 750 15.33.1

Arm rest ........................................................................................................ 751

15.33.2

Backrest extension for MSG65/MSG75 ......................................................... 752

15.33.2.1

Backrest extension adjustment ...................................................................... 752

15.33.3

Seat belt for MSG20 seat .............................................................................. 753

15.33.3.1

Install the seat belt ........................................................................................ 753

15.34

PIN code access to the Start switch ...................................................... 754

15.35

Abbot 2 ................................................................................................... 754 15.35.1

Troubleshooting ............................................................................................ 749

15.32

15.36

Service Manual

Install the Abbot 2 ......................................................................................... 755

Lifting height pre-selection ..................................................................... 756 15.36.1

Define the lifting height target levels .............................................................. 757

15.36.2

How to unstack with the lifting height pre-selection........................................ 758

15.36.3

How to stack with the lifting height pre-selection ........................................... 758

Technical specification ....................................................................................... 760 16.1

RB14N2S, RB14N2HS, RB16N2S, RB16N2HS and RB16N2 .............. 761

16.2

RB16N2H, RB16N2C, RB16N2HC, RB20N2H, RB20N2X and RB25N2X ............................................................................................... 765

16.3

Mast heights ........................................................................................... 769

Index ..................................................................................................................... 771

APPENDIX A: Stickers ................................................................................................... 774

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Service Manual

Foreword This service manual is a guide for servicing lift trucks. The long productive life of your lift truck depends on regular and proper servicing, consistent with the instructions provided in this service manual. Before starting to test, repair or rebuild a lift truck, read the respective sections of this manual carefully and familiarize yourself with all of the components. The descriptions, illustrations and specifications contained in this manual are for lift trucks with serial numbers in effect at the time of printing. Trucks are constantly being developed. The graphic illustrations in this manual may differ slightly from the actual design of the truck. The manufacturer reserves the right to modify the design, equipment and technical features without prior notice and without any obligations. For your convenience, the instructions are grouped by systems as an easy reference. Unauthorized copying and lending of this material is strictly prohibited. DANGER Read this manual before you operate or do maintenance on the truck. After you have read this manual, store it in a safe, dry place for later use. A truck can cause serious accidents unless you are sufficiently familiar with its operation and unless you know its operating and maintenance instructions. To get more copies of the instruction book, speak to your dealer.

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Service Manual

How to read this manual 2.1

Safety-related signs

The following table explains the safety-related signs used in this document. DANGER

DANGER indicates a hazard with a high level of risk which, if not avoided, will result in serious injury or death.

WARNING

WARNING indicates a hazard with a medium level of risk which, if not avoided, could result in serious injury or death, or damage to your machine.

CAUTION

CAUTION indicates a hazard with a low level of risk which, if not avoided, could result in minor or moderate injury or damage to your machine.

NOTE: Notes are used to indicate important information and useful tips.

2.2

Symbols and abbreviations

2.2.1

Safety symbols

Hazard symbols These symbols indicate a hazardous situation or action. Symbols are used to warn of situations, which can cause environmental damage and personal injury. General hazard symbol

General warning sign

Hazard symbols

Explosion and fire hazard

Revision: C

Corrosive hazard

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Battery hazard

Service Manual

Electrical hazard

Prohibited action symbols These symbols are used in warnings and notifications to indicate an action that should not be taken. The prohibited action symbols are presented below.

No smoking

General symbol for prohibited action

Limited or restricted access

Do not touch

Mandatory action symbols These symbols are used in warnings and notifications to indicate an action that must be taken. The mandatory action symbols are presented below.

Wear eye protection

Read the manual or instructions

General symbol for mandatory action

Doctor symbol

Batteries marked with this sign must be recycled.

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2.2.2

Service Manual

Other symbols and abbreviations

SYMBOL OR ABBREVIATION

DESCRIPTION

Option

COM

Common terminal

Normally closed terminal

Normally open terminal

R1/4

Taper pipe thread (external) 1/4 inch (formerly PT1/4)

RC1/8

Taper pipe thread (external) 1/8 inch (formerly PT1/8)

G1/4A

Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)

Rp1/8

Straight pipe thread (internal) 1/8 inch (formerly PS1/8)

2.3

Units

SI units are used in this manual. The following table shows the conversion of SI units to customary units. ITEM

SI UNIT

METRIC UNIT

YARD-POUND UNIT

Force

0.102 kgf

0.225 lbf

Pressure

1 MPa

10.1972 kgf/cm2

145.038 psi

Torque

1Nm

0.102 kgf m

0.7376 lbf ft

Length

1 mm 1m

0.039 inch 3.281 feet

Weight

1 kg

2.205 lb

Temperature

1°C

°F=1.8 x °C+32

Volume

0.264 US.gal.

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Service Manual

Safety instructions WARNING The correct and safe maintenance of these lift trucks as recommended by the manufacturer is given in this document. Read this manual before you do any maintenance on these trucks. Incorrect performance of maintenance operations is dangerous and can cause injury or death.

After making this product available for the market, the manufacturer cannot be held responsible for modifications made by the customer or user and the consequences thereof, which may alter the conformity of the product with the CE marking.

Do not make changes or repairs that can weaken the structure of the truck or put safety at risk.

Do not operate the truck unless you have read and understood the instructions in the operation manual. Incorrect truck operation is dangerous and can cause injury or death.

Knowledge of the system and/or its components is important before you remove or disassemble the components.

The following sections list some basic precautions that should always be observed.

3.1

Safety requirements for industrial trucks

The truck meets the essential requirements of Machinery Directive 2006/42/EC and EMC Directive 2014/30/EU. The truck is designed and constructed according to European safety standards EN ISO 3691-1, EN 16307-1, EN 1175-1 and EN 12895. The most important regulations and guidelines are given in these instructions. As regulations can vary from country to country, familiarize yourself with the regulations and standards applicable to your country.

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3.2

Service Manual

Repairs and structural modifications WARNING

After making this product available for the market, the manufacturer cannot be held responsible for modifications made by the end user and the consequences thereof, which may alter the conformity of the product with the CE marking.

To keep the EC Declaration Of Conformity issued by the original truck manufacturer, no modifications or alterations to a powered industrial truck, which could affect, for example, capacity, stability or safety requirements of the truck, must be made without the prior written approval of the original truck manufacturer, its authorized representative, or a successor thereof. This includes the changes affecting, for example, braking, steering, visibility and the addition of removable attachments. When the manufacturer or his successor approves a modification or alteration, the manufacturer or his successor must also make and approve the appropriate changes to the capacity plate, decals, tags and operation and maintenance manuals. If the end user arranges a modification or alteration without the prior written approval of the original truck manufacturer, its authorized representative, or a successor, the end user must: •

arrange for the modification or alteration to be designed, tested and done by an engineer(s) expert in industrial trucks and their safety

•

maintain a permanent record of the risk assessment, design, test(s) and implementation of the modification or alteration

•

approve and make appropriate changes to the capacity plate(s), decals, tags and operation and maintenance manuals

•

put a permanent and readily visible label to the truck stating how the truck has been modified or altered, together with the date of the modification or alteration and the name and address of the organization that accomplished those tasks, and

•

where appropriate, create a new EC Declaration Of Conformity and sign it.

3.3

Service area safety

•

Keep the service area clean. Oil, grease, and water make the floor slippery.

•

If possible, make all repairs with the truck parked on a level, hard surface.

•

Before you start to work on the truck, hang a Do not Operate sign in the operator compartment.

•

The truck must always be supported on jacks, if someone works under it.

•

Do not work on any truck that is supported only by lift jacks or a hoist. Always use jack stands or other supports to support the truck before doing any disassembly.

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Service Manual

•

Lower the forks or other implements to the ground before performing any work on the truck. If this cannot be done, make sure the forks or other implements are blocked correctly to make sure that they do not fall unexpectedly.

•

Use steps and grab handles (if applicable) when you mount or dismount a truck. Clean mud or debris from the steps, walkways or work platforms before use. Always face the truck when you use steps, ladders and walkways. When it is not possible to use the designed access system, use ladders, scaffolds, or work platforms to perform safe repair operations.

•

To avoid back injury, use a hoist when you lift components that weigh 23 kg (51 lb) or more. Make sure that all chains, hooks, slings, etc., are in good condition and of the correct capacity. Make sure that all hooks are positioned correctly. Lifting eyes are not to be side-loaded during a lifting operation.

•

Make sure that all protective devices including guards and shields are properly installed and functioning correctly before you start a repair. If a guard or shield must be removed to perform the repair work, be even more careful than usually.

•

Always support the mast and carriage to keep the carriage or attachments raised when you perform maintenance or repair work that requires the mast to be in the lifted position.

3.4

Personal safety DANGER

Do not lift or transport anyone on the forks or a load pallet that is on the forks. There is a risk of falling, danger to life! Do not let anyone, under any circumstances, walk or stand under the forks. Do not place any part of your body between the mast structures or any moving parts of the truck.

•

Remove all rings, watches and other pieces of metal jewellery before you start to work on the truck. If a metal object touches an electrically conductive part, it can cause a short circuit or a serious burn.

•

Always, wear protective glasses and protective shoes when you work around trucks. In particular, wear protective glasses when you use a hammer or sledge on any part of the truck or its attachments. Use welding gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose fitting or torn clothing.

3.5 •

Work safety

Unauthorized truck modification is not permitted. Modifications or alterations to a powered industrial truck, which could affect, for example, capacity, stability or safety requirements of the truck, must not be made without the prior written approval of the original truck manufacturer, its authorized representative, or a successor thereof.

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Service Manual

This includes changes that have an effect on, for example, braking, steering, visibility and the addition of removable attachments. When the manufacturer or his successor approves a modification or alteration, the manufacturer or successor must also make and approve appropriate changes to the capacity plate, stickers, tags and operation and maintenance manuals. Only if the truck manufacturer is no longer in business and there is no successor in the interest to the business, can the operator arrange for a modification or alteration to a powered industrial truck, provided that the operator: a.

arranges for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in industrial trucks and their safety,

maintains a permanent record of the design, test(s) and implementation of the modification or alteration,

approves and makes appropriate changes to the capacity plate(s), decals, tags and instruction handbook, and

puts a permanent and readily visible sticker to the truck that shows the manner in which the truck was modified or altered, together with the date of the modification or alteration and the name and address of the organization that accomplished those tasks.

•

Set the power of the truck to OFF and disconnect the battery connector before you open the cover of the motor compartment or the electrical system.

•

Release all pressure in the air, oil or water systems before you disconnect or remove lines, fittings or related items. Release the residual pressure when you remove a pressurized device.

•

If it is necessary to work at height during maintenance work, make sure that you use applicable access equipment and follow the safety instructions of the equipment manufacturer.

•

With sit-on trucks, remove the seat when you do servicing to the truck.

•

Before you operate, lubricate or repair the truck, read all warning plates and stickers on the truck.

•

Do not use your hands to find oil leaks.

•

To prevent burns, be careful of the hot sections and hot fluids in lines, tubes and compartments, also when the truck is idle or OFF.

•

Only use clean oil in the hydraulic system. Always fill the oil through the oil filter.

•

Do not mix different lubricants. It is possible that different brands of lubricants are not be compatible with each other. Only use lubricants recommended by the manufacturer.

•

Repairs that need welding must be done only with the applicable reference information and by personnel trained in welding procedures. Determine the type of metal and select the correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of the parent metal.

•

When you weld, always disconnect the battery and electronic devices. Remove all paint from a 10 cm radius from the welding point to avoid creating toxic gases during welding.

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Service Manual

•

Use the correct lifting procedures when you remove components.

•

Be careful when you remove cover plates. Gradually, remove the last 2 bolts or nuts at the opposite ends of the cover or device. Before you remove the last 2 bolts or nuts, turn the cover loose to release springs or other pressures.

•

Be careful when you remove filler caps, breathers and plugs on the truck. Put a cloth around the cap or plug to make sure that you do not become sprayed or splashed by liquids under pressure. Be aware that the liquids spray and splash more easily immediately after you have stopped the truck, because the fluids are very hot.

•

Only use well-maintained tools. Also, make sure that you use the tools in a correct way.

•

Reinstall all fasteners with the same part number. If a replacement is necessary, do not use a fastener of lesser quality.

•

Do not cause damage to the wiring during the removal process. Do not use damaged wiring. When you install the wiring back, make sure the wiring does not touch sharp corners or hot parts. Put all wiring away from the oil pipe.

•

Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or hit high pressure lines or install ones that are bent or damaged. Examine all lines, tubes and hoses carefully. Pin hole (very small) leaks can cause a high velocity oil stream that cannot be seen near the hose. This oil can go through the skin and cause personal injury. Use a cardboard or paper to find pin hole leaks.

•

Tighten connections to the correct tightening torque. Make sure that all heat shields, clamps and guards are installed correctly to prevent excessive heat, vibration or rubbing against other parts during operation. Protective shields against oil sprays onto hot exhaust components in the event of a line, tube or seal failure must be installed correctly.

•

Do not operate the truck, if a rotating part is damaged or touches another part during operation. All high speed rotating components that are damaged or altered must be examined for balance before you use them again.

3.6

Operating temperature

The ambient operating temperature range of the truck is +5...+25°C. The truck can be operated at a temperature of 0...+45°C for short periods. The recommended humidity is 30...95% (noncondensing). CAUTION Do not move a damp truck into a freezer storage! Let the truck dry before you do! If you move a damp truck into a freezer storage, there is a risk of malfunction because of ice accumulation!

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Service Manual

General information 4.1

Truck models covered by this manual

This service manual includes the service instructions of the truck models given below: •

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X - Reach Truck - a three wheel, sit-on operated electric forklift truck that has sophisticated controls for operating, steering and load handling.

NOTE: In Chapters 4 to 14 this manual gives service instructions for the basic truck model. All material related to optional features is available in Chapter 15.

4.2

Identification plates on the truck CAUTION

Make sure that all the plates and stickers on the truck are legible and securely attached.

Figure 1 shows the plates and stickers of the truck and their locations. For more details on the plates and stickers of the truck, see APPENDIX A.

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Service Manual

Figure 1. Plates and stickers of the truck overview

1. 2. 3. 4.

General warning sticker Type plate and capacity plate Mast operation warning sticker Battery maintenance sticker

5. 6. 7.

Battery type plate Hydraulic oil tank filling cap sticker Hoist point indication sticker

Figure 2. Emergency exit sticker

Emergency exit sticker

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Service Manual

The type plate of the truck includes this information: •

CE mark

•

Manufacturer name and address

•

Truck model

•

Serial number

•

Year of manufacture

•

Rated capacity (kg)

•

Battery minimum and maximum mass (kg)

•

Battery terminal voltage (V)

•

Nominal power (kW)

The capacity plate of the truck includes this information: •

Load center distance (mm)

•

Maximum lifting height (mm)

•

Actual capacity (kg) at maximum lifting height

•

Lifting height (mm) for rated capacity

•

Rated capacity (kg)

The capacity plate of the attachment (if applicable) includes this information: •

Special load center distance

•

Maximum lifting height (mm)

•

Actual capacity (kg) at maximum lifting height

•

Lifting height (mm) for rated capacity

•

Rated capacity

NOTE: If a plate or sticker is damaged, replace it with a new identical sticker. When you send an order for a sticker, include the serial number of the truck in your order. CAUTION Make sure that the type plate and capacity plate have corresponding information. Make sure that the capacity plate and the type plate of the attachment have corresponding information. When you operate a truck that has attachments, you must always make sure that the capacity of the truck is sufficient.

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4.3

Overview of the truck

4.3.1

Overhead guard

Service Manual

The overhead guard gives protection to the truck operator and provides a good visibility out of the operator compartment.

Figure 3. Overhead guard overview

WARNING The overhead guard is a safety device. Do not make modifications to the overhead guard that can make the structure weaker. Do not cut, bend, drill or weld the overhead guard. There is a risk of loss of the protection function.

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4.3.2

Service Manual

Cabin

The cabin gives protection to the truck operator against noise, dust and weather.

Figure 4. Cabin overview

CAUTION Do not operate a cabin truck with the door or the roof window open.

4.3.3

Emergency exits (cabin truck)

In an emergency, exit the truck through the operator door. If the operator door cannot be used, exit the truck through the roof window. See the emergency exits in Figure 5. For instructions on how to open the roof window, see Section 5.20.3.1. WARNING The emergency exit is intended for situations where the primary exit is not available because of hazards or obstructions.

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Service Manual

Figure 5. Emergency exits overview

4.3.4

Operating devices

Figure 6. Operating devices overview

1. 2. 3.

Arm rest Truck display Pedals

Revision: C

4. 5. 6.

Steering wheel Operator’s seat Battery connector

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4.3.5

Service Manual

Control panel

Figure 7. Control panel overview

1. 2.

Steering wheel Arm rest

4.3.6

3. 4.

Truck display Accessory switches

Steering wheel

Figure 8. Steering wheel overview

The truck is equipped with a fully electrical steering system. The steering wheel has no direct mechanical connection to the traction wheel. The steering motor turns the traction wheel. •

Steering direction:

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Service Manual

When you move forward (to the direction of the traction wheel), turn the steering wheel clockwise to steer the truck right. Turn the steering wheel counterclockwise to steer the truck left. •

Steering sensitivity: The steering sensitivity changes steplessly according to the traction speed. The lower the traction speed, the higher the steering sensitivity. The higher the traction speed, the lower the steering sensitivity.

•

Curve cutback speed: When you turn the traction wheel more than 15°, the traction controller starts to decrease the traction speed gradually. When you turn the traction wheel to point straight forward, the maximum traction speed is enabled.

4.3.7

Arm rest

Figure 9. Arm rest overview 1. 2. 3. 4.

Lift lever Reach lever Tilt lever Sideshift lever

Revision: C

5. 6. 7. 8.

Fork adjustment switches (optional) F2 button Driving direction selection switch Horn

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Service Manual

Table 1. Control functionalities CONTROL

FUNCTIONALITY DESCRIPTION

Lift lever

Use the lever with your right hand. Pull the lever to lift the forks. The more you pull the lever, the higher the lifting speed. Push the lever to lower the forks. The more you push the lever, the higher the lowering speed. The lever automatically goes back to the central position, when it is released.

Reach lever

Use the lever with your right hand. Push the lever to move the mast forward. Pull the lever to move the mast rearward. The lever automatically goes back to the central position, when it is released.

Tilt lever

Use the lever with your right hand. Pull the lever to tilt the mast or load up. Push the lever to lower the mast or load to a level position. The lever automatically goes back to the central position, when it is released.

Sideshift lever

Use the lever with your right hand. Push the lever forward to move the forks or load to the left. Pull the lever rearward to move the forks or load to the right. The lever automatically goes back to the central position, when it is released.

Fork adjustment switches (optional)

The fork adjustment devices are optional. The available options include telescopic forks and a fork positioner.

F2 button

Push the F2 button to give an additional feature for these levers: • • •

Lift lever + F2 button: Pre-height selector Tilt lever + F2 button: Tilt auto centering Sideshift lever + F2 button: Sideshift centering

Driving direction selection switch

Use the switch to select the driving direction. Also, you can hold the switch down, to operate the truck in the slow speed mode.

Horn

Push the button to give a warning sound.

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4.3.8

Service Manual

Display panel

Figure 10. Display panel overview

1. 2. 3. 4.

Emergency stop button Start switch/key switch Display control buttons Truck display

5. 6. 7. 8.

Operator compartment fan switch (optional) Reading lamp switch (optional) Warning light switch (optional) Working lights switch (optional)

NOTE: In a truck with the cabin, there is the switch for the sunscreen wipers in the position of the operator compartment fan switch.

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Service Manual

Table 2. Control functionalities CONTROL

FUNCTIONALITY DESCRIPTION

Emergency stop button

Push the emergency stop button to disconnect the power supply of the truck. To release the button, turn it clockwise. Use the emergency stop button in the following cases: • •

Start switch/key switch

If there is a short circuit or some other electrical malfunction. If there is an accident.

Turn the start switch clockwise to switch on the electrical system of the truck. The PIN query appears on the truck display. Turn the start switch counterclockwise to switch off the electrical system of the truck. A removable key switch is an optional accessory. The key switch switches the electrical system of the truck on and off. The start switch/key switch positions are: • • •

0 = Power off (power can be still connected to certain electronic devices) I = Power on, Eco mode I = Power on, Pro mode (For more information on the operation modes, see Section 4.3.9)

Display control buttons

Use these buttons to enter the PIN code and to navigate in the truck display menus. For information about the truck display and the display control buttons, see Section 4.3.10.

Truck display

For information about the truck display, see Section 4.3.10.

Operator compartment fan switch Reading lamp switch Warning light switch Working lights switch

These accessory switches are used for the optional features such as operator compartment fan, reading lamp, warning light and working lights.

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4.3.9

Service Manual

Truck operation modes

The truck can be operated in two operation modes: •

Eco mode The Eco mode is the easy truck operation mode for inexperienced truck operators, for training and for long truck operation periods. In the Eco mode, the truck does not immediately respond to sudden actions of the truck operator and so the truck movements are smoother. In the Eco mode, the truck operation is more economic than in the Pro mode.

•

Pro mode The Pro mode is the professional truck operation mode for experienced truck operators. In the Pro mode, the truck responds to the actions of the truck operator quicker than in the Eco mode. Experienced truck operators can operate the truck more efficiently in the Pro mode.

Use the key switch/start switch to select the operation mode, see Figure 11.

Figure 11. Truck operation modes

1. 2.

OFF Eco mode

Pro mode

The truck operation modes can be modified according to specific customer needs by a service engineer.

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4.3.10

Service Manual

Truck display

Figure 12. Truck display overview

Truck display

Display control buttons

NOTE: After you have set the power of the truck to ON, but before you start to operate the truck, wait until the main view is shown on the truck display.

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Service Manual

4.3.10.1 Display control buttons

Figure 13. Display control buttons overview

1. 2. 3.

Browse up / PIN code 1 button Browse right / PIN code 2 button Browse down / PIN code 3 button

4. 5. 6.

Browse left / PIN code 4 button Exit / Esc button Enter button

Date and time or messages

4.3.10.2 Main view of the truck display

Figure 14. Main view of the truck display

1. 2.

Battery discharge indicator Center information area

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Service Manual

In normal operating situations, the main view of the truck display shows the battery discharge indicator, date and time and the center information area with speed, direction and height information.

NOTE: The truck display looks different, if you have one or more of the following options installed to your truck: load weight indicator, lifting height pre-selection or sideshift and tilt centering. For more information on the options, see chapter 15.

Truck display icons When the truck display shows a message, icons are shown in the bottom left-hand corner of the truck display. The icons vary according to the message type. The seat belt icon for optionally available seat belt safety device is shown in the right hand side of the truck display beside the center information area. See Table 3. Table 3. Truck display icons ICON

DESCRIPTION Alarm message icon (red)

Warning message icon (yellow)

Informational message icon (blue)

Service warning icon (yellow)

Temperature warning icon (yellow)

Seat belt icon

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Service Manual

Battery discharge indicator The battery discharge indicator shows the battery discharge level. When the battery discharge level is at 100-20%, the bars of the indicator are shown in green color. When the battery discharge level drops below 20%, two bars are shown in the indicator and the color of the indicator bars changes to yellow. Also, an exclamation mark icon on a yellow background is displayed in the bottom left-hand corner of the truck display to indicate low battery discharge level, see Figure 15. When the battery discharge indicator turns to yellow, you must charge the battery as soon as possible.

NOTE: When the battery discharge indicator turns to yellow, the operation mode of the truck is set to Eco mode. For more information on the operation modes, see Section 4.3.9.

Figure 15. Battery discharge level low

When the battery discharge level drops below 10%, only one bar is shown in the indicator and the color of the battery discharge indicator bars changes to red. Also, an exclamation mark icon on a red background is displayed in the bottom left corner of the truck display, see Figure 16. When the battery discharge indicator turns to red, the battery is nearly empty and needs to be charged immediately.

NOTE: When the battery discharge indicator changes to red, the lift function is disabled.

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Service Manual

Figure 16. Battery discharge level almost empty

Center information area

Figure 17. Center information area overview

1. 2.

Speed indicator Height indicator

Driving direction indicator

In a normal operating situation, the center information area displays the speed and height indicators. In addition, the driving direction of the truck is indicated with two arrows on the opposite sides of the center information area. If no driving direction is set, the arrows are blinking. When the driving direction is set, the selected direction is indicated with a solid blue colored arrow and the other arrow turns gray.

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Service Manual

Parking brake indicator The parking brake indicator is displayed in the bottom left-hand corner of the truck display. The parking brake must be engaged before the operator leaves the truck.

Figure 18. Parking brake indicator overview

Main view of the truck display in information, warning and error message situations In case of information, warning or error messages, the main view of the truck display changes to highlight the important information. Informational message An informational message gives instructions to the operator. In case of an informational message, the color of the stripes in the main view changes to blue and an exclamation mark icon with blue background is shown in the bottom left-hand corner of the truck display. Date and time are replaced with the appropriate informational message. See Figure 19.

Figure 19. Main view with an informational message

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Service Manual

Warning message In case of a warning message, the color of the stripes in the main view changes to yellow and an icon with yellow background is shown in the bottom left-hand corner of the truck display. The icon changes according to the type of the warning message, see the list of the icons in Table 3. Date and time are replaced with the appropriate warning message. See Figure 20.

Figure 20. Main view with a warning message

Alarm message In case of an alarm message, the color of the stripes in the main view and the background of the center information area change to red and an exclamation mark icon with a red background is shown in the bottom left-hand corner of the truck display. In the center information area, the appropriate error code replaces the speed and height. In the alarm code: •

The first digit(s) indicate the source of the error (20xxxx).

•

The letter in the middle indicates that this is an alarm (xxAxxx).

•

The rest of the digits provide the actual error code (xxx216).

Date and time are replaced with the appropriate alarm message. See Figure 21.

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Service Manual

Figure 21. Main view with an alarm message

Fatal error or communication error If the truck display detects a fatal error (for example, the memory is corrupted), a fatal error message is displayed to the operator. See Figure 22. In case of a fatal error, contact the service personnel.

Figure 22. Fatal error

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Service Manual

In case of a communication problem with the vehicle controller, a communication error message is displayed to the operator. See Figure 23. In case of a communication error, contact the service personnel.

Figure 23. Communication error

PIN query The truck can be configured to a PIN query mode. The PIN query mode requires the operator to provide a PIN code before the truck can be operated. The PIN code consists of 5 digits and it can contain digits from 1 to 4. The PIN code is entered to the system with the Browse/PIN code buttons, see Figure 13. The PIN code system of the truck allows 10 different PIN codes to be programmed. The PIN code device can be used to prevent persons who have not received truck training from operating the truck. The 3 pre-programmed PIN codes are: •

User rights 1, default slot 1, PIN code = 14321. This is the normal operation mode.

•

User rights 2, default slot 2, PIN code = 12341. This operation mode only allows the use of the Eco operation mode.

•

User rights 3, default slot 3, PIN code = 11111. This is the emergency mode: only slow driving speed and fork lifting are allowed.

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Service Manual

For instructions on how to program new PIN codes, see the TruckTool user manual.

Figure 24. PIN query

Sleep mode If the truck is configured to use the sleep mode when idle, the truck display also includes the sleep mode view. In the sleep mode, the truck display shows the battery discharge level and the operating hours. See Figure 25.

Figure 25. Sleep mode

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Service Manual

Service mode The service mode view is shown on the truck display, when service personnel have deactivated the truck during service, and the truck cannot be operated. For instructions on how to activate the Service mode, see the instructions of TruckTool.

Figure 26. Service mode

4.3.10.3 Hierarchy of the truck display menus

Figure 27. Hierarchy of the truck display menus

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Service Manual

Selection view The selection view enables the operator to access instructions, view basic information about the status of the truck and adjust certain settings. To go to the selection view, push the Enter button in the main view of the truck display. To return to the main view, push the Exit / Esc button.

Figure 28. Selection view

1. 2. 3.

Instructions Truck information Date and time adjustment

4. 5.

Brightness setting Lifting height pre-selection (optional)

The selection view shows the five icons: instructions, truck information, date and time adjustment, brightness setting and lifting height pre-selection (optional).

NOTE: Lifting height pre-selection is an optional feature. In a standard truck, this selection is greyed out to indicate that the option is not in use. For more information about the lifting height pre-selection option, see Section 15.36.

To move the selection from one icon to another, use the Browse left/right buttons. To confirm your selection, push the Enter button. To return to the main view, push the Exit / Esc button.

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Service Manual

Instructions view

Figure 29. Instructions view

The instructions view provides instructions for the truck operator. Browse through the pages with the Browse left/right buttons. Truck information view

Figure 30. Truck information view (pages 1…3)

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Service Manual

The truck information view provides information about the truck, such as software and hardware versions, usage and service data and an error log. Browse through the pages with Browse left/right buttons. The service data page shows the number of hours until the next maintenance. If the maintenance time has already passed, a minus sign is displayed before the number of the hours to indicate how many hours have passed from the maintenance time. The service data page also shows the date of the next annual inspection. If the inspection date has already passed, the date is shown in yellow color. A new date for the annual inspection is set with TruckTool. For instructions on how to set the date, see the TruckTool user manual. The error log shows the last 16 errors that have occurred in the operation of the truck. Use Browse up/down buttons to scroll the error log. The most recent error is shown on top of the list. The error code count increases if the same error occurs in the system several times consecutively. When a new error occurs, a new line is added to the list. Brightness setting view

Figure 31. Brightness setting view

In the brightness setting view, the operator can adjust the brightness of the truck display. Adjust the brightness using the Browse left/right buttons. Push the Enter button to save the adjustment. Push the Exit / Esc button to discard the changes and leave the brightness setting view.

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Service Manual

Date and time adjustment view

Figure 32. Date and time adjustment view

Date and time adjustment is done one digit at a time. Use the Browse left/right buttons to move from one digit to another. From the last digit of time, the selection moves to the first digit of date and from the last digit of date to the first digit of time. Use the Browse up/down buttons to adjust the active digit.

4.3.11

Pedals

Figure 33. Pedals overview

1. 2.

Accelerator pedal Brake pedal

Revision: C

Operator presence pedal

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Service Manual

Table 4. Pedal functionalities CONTROL

FUNCTIONALITY DESCRIPTION

Accelerator pedal

Use the accelerator pedal with your right foot. The more you push the accelerator pedal, the higher the driving speed. NOTE: Handle the accelerator pedal gently. Push the brake pedal down smoothly to slow your driving speed. The truck is equipped with a regenerative braking system, which charges the battery and slows down the speed of the truck in the following situations:

Brake pedal

• • • •

When the brake pedal is pushed. When the driving direction changes. When the accelerator pedal is released. When the operator presence pedal is released. NOTE: Practice braking with and without a load. Operator presence pedal

To operate the truck, push the operator presence pedal down to the operating position. NOTE: The truck cannot be operated unless the operator presence pedal is pushed down. Optional foot-operated driving direction selection function may be integrated into the operator presence pedal. The truck changes its driving direction when the pedal is lifted and pushed back down. When you start to operate the truck, you must select the initial driving direction with the driving direction selection switch in the arm rest.

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4.3.12

Service Manual

Operator’s seat

Three different seat alternatives are available: •

MSG20 - Basic seat, mechanical suspension and weight adjustment, 20% vibration reduction

•

MSG65 - Standard seat, flat mechanical scissor suspension and weight adjustment, 45% vibration reduction

•

MSG75 - High performance seat, flat pneumatical scissor suspension and weight adjustment, 55% vibration reduction

Figure 34. Operator’s seat overview

1. 2.

MSG20 MSG65

MSG75

CAUTION Before starting to operate the truck, remove the plastic cover on top of the operator’s seat. The truck can be damaged by the electrostatic discharge (ESD) that can develop if the truck is operated on an operator’s seat covered in plastic.

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4.3.13

Service Manual

Drive unit, hydraulic system and instrument panel

Figure 35. Drive unit, hydraulic system and electrical system overview

1. 2.

Instrument panel Hydraulic system

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Drive unit

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Service Manual

4.3.13.1 Instrument panel

Figure 36. Instrument panel overview

1. 2. 3. 4. 5. 6. 7.

Fuse box Pump controller Traction controller Steering controller Main contactor for motor controllers Steering motor fuse Controller fan

Revision: C

8. 9. 10. 11. 12. 13.

Horn relay Service socket Main contactor for control circuits Contactor for cabin heater Contactor for window heaters Fuse box (cabin)

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Service Manual

4.3.13.2 Hydraulic system

Figure 37. Hydraulic system overview

1. 2. 3.

Hydraulic pump Pump motor Pressure sensor

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4. 5. 6.

Hydraulic oil tank Valve unit Reach cylinder

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Service Manual

4.3.13.3 Motor compartment

Figure 38. Motor compartment overview

1. 2. 3.

Magnetic brake Traction motor Steering motor

4.3.14

4. 5.

Traction motor HALL sensor Steering motor HALL sensor

Sensors

An inductive proximity sensor is an electronic proximity sensor, which detects metallic objects without touching them. The sensor consists of an induction loop. Electric current generates a magnetic field that collapses, thus generating a current that falls asymptotically toward zero from its initial level, when the electricity input ceases. The inductance of the loop changes according to the material inside it and, since metals are much more effective inductors than other materials, the presence of metal increases the current flowing through the loop. This change can be detected by sensing circuitry, which can signal to some other device whenever metal is detected. The magnetic reed switch is an electrical switch operated by an applied magnetic field. It consists of a pair of contacts on ferrous metal reeds in a hermetically-sealed glass envelope. The contacts can be normally open, closing when a magnetic field is present, or normally closed and opening when a magnetic field is applied. The switch can be actuated by a coil, making a reed relay or by bringing a magnet near to the switch. Once the magnet is pulled away from the switch, the reed switch goes back to its original position.

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Service Manual

Figure 39. Sensor locations

1. 2. 3. 4.

Steering wheel sensor Steering reference sensor Reach end stop, retract limit, retract end stop and reach limit switch (4 pcs) Sideshift centering direction and sideshift centering midpoint (with the option Sideshift and tilt centering)

5. 6. 7. 8. 9.

Battery lock sensor Pressure sensor (with the option Load weight indicator) Height reference sensor Tilt centering sensor (with the option Sideshift and tilt centering) Lift pulse encoder

The truck uses the following sensors: •

Steering wheel sensor

•

Steering reference sensor

•

Reach end stop, retract limit, retract end stop and reach limit switch

•

Sideshift centering direction and sideshift centering midpoint (optional)

•

Battery lock sensor

•

Pressure sensor (optional)

•

Height reference sensor

•

Tilt centering sensor (optional)

•

Lift pulse encoder

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4.3.15

Service Manual

Reach carriage

Figure 40. Reach carriage overview

The truck is equipped with a reach carriage, which enables the operator to extend the forks to reach the load better.

4.3.16

Mast

Figure 41. Mast overview

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4.3.17

Service Manual

Load backrest

Figure 42. Load backrest overview

The truck is equipped with a load backrest.

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Service Manual

Mechanical maintenance 5.1

Lifting points CAUTION

Lift or jack up the truck and put rigid stands or other supports below it. Apply wheel chocks to the load wheels to make sure that the truck does not move.

5.1.1

Jack points

Figure 43 below indicates the correct jack points for lifting the truck up for maintenance.

Figure 43. Jack points

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5.1.2

Service Manual

Hoist points

Figure 44 below indicates the correct hoist points for hoisting the truck up for maintenance. Make sure that the capacity of the lifting device is sufficient. CAUTION When you hoist the truck, the reach must be retracted.

Figure 44. Hoist points

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5.2

Service Manual

How to tow the truck

A tow rope around the front bumper can be used to temporarily tow the truck. Release the magnetic brake manually before towing the truck. See Section 5.2.1.

Figure 45. How to tow the truck

To tow the truck: 1. Insert a tow rope around the front bumper. Check that the tow rope is securely attached. 2. Tow the truck slowly. Do not pull the truck with a sudden movement; it can cause the rope to break. CAUTION Do not use the truck to tow trailers. It is not rated for that purpose.

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5.2.1

Service Manual

Release the magnetic brake manually

NOTE: To access the magnetic brake, open the machinery cover.

To release the magnetic brake.

1. Insert two M6x50 screws in to the holes.

2. Turn the screws until the brake disk is released.

To restore the magnetic brake.

1. Loosen the screws until the brake disc is engaged.

2. Remove the screws.

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5.3

Service Manual

Transportation

When transporting the truck, it is important that you secure it safely to prevent it from moving. Also, put supports to the traction wheel and lower the mast. The transport of the truck can be arranged in three ways: •

Mast installed to the truck

•

Mast tilted towards the overhead guard

•

Mast removed from the truck. CAUTION Make sure that you do not attach the ropes so that they go across sharp edges. The ropes can break and cause an accident.

Figure 46 below shows how to secure the truck safely for transportation with the mast installed to the truck.

Figure 46. Securing the truck for transportation with the mast installed to the truck

Figure 47 below shows how to secure the truck safely for transportation with the mast tilted towards the overhead guard.

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Service Manual

Figure 47. Securing the truck for transportation with the mast tilted towards the overhead guard

Figure 48 below shows how to secure the truck safely for transportation with the mast removed from the truck.

Figure 48. Securing the truck for transportation with the mast removed from the truck

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5.4

Assembly and commissioning

5.4.1

Install the mast

Service Manual

WARNING The assembly of the mast, commissioning of the truck and guidance of the operator must be carried out by personnel trained and authorized by the manufacturer.

CAUTION Note the correct number of the shim plates between the mast and the bearing housing. Do not add or remove the shim plates.

Attach a lifting device on top of the mast and tighten the lifting ropes/chains. NOTE: Make sure that you use applicable lifting devices and follow the safety instructions given by the lifting device manufacturer.

2. Move the mast to its correct position beside the truck. 3. Make sure that you leave a gap of 5 mm between the bearing housing and the reach carriage so that you can install the bearing housing.

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Service Manual

4. Install the shim plates that come with the truck. 5. Install the bearing housing.

6. Use a lifting device to lower the mast. 7. Install the bolts that attach the bearing housings to the truck frame. The correct tightening torque is 197 Nm.

8. Install the shafts that secure the mast to the reach carriage. 9. Install the locking pins to the shafts.

10. Install the mast mounting bracket to the truck frame. NOTE: Make sure that the washer is in the correct position! 11. Install the bolts that attach the mast mounting bracket to the truck frame. The correct tightening torque is 197 Nm.

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Service Manual

12. Connect the hydraulic connectors. 13. Connect the connectors.

14. Install the hydraulic oil hoses on the mast side. NOTE: Make sure that you connect the correct hose pairs. Matching hose pairs are marked with colored bands.

15. Connect the height reference sensor wires.

16. Remove the lifting device.

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5.5

Service Manual

Order spare parts

When ordering spare parts, always contact your maintenance centre. Only use original spare parts. To ensure that you receive the correct parts, include the following information in your order: •

Truck type

•

Serial number of the truck

•

Order number of the part

•

Name of the part

•

Number of parts ordered

5.6

How to clean the truck

It is important that you keep the truck clean. With regular cleaning, you can prevent damage to the truck and help make the life span of the truck long. WARNING Do not clean the truck with flammable cleaning liquids.

CAUTION Do not clean the electric devices of the truck with water. Water can cause damage to the electric devices.

Before you start to clean the truck: •

Disconnect the battery connector.

•

Take precautions against spark formation.

•

If you use water jet or pressure washer to clean the truck, put covers on the electric and electronic devices to make sure that no water touches the devices.

To clean the truck: •

After you put covers on the electric and electronic devices, you can use water to clean the truck.

•

To clean the electric devices, use low pressure compressed air or suction. Make sure that your compressor has a water separator. You can also use an antistatic brush to clean the electric devices.

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5.7

Service Manual

Truck covers WARNING

Never operate the truck without the covers in place.

CAUTION Before you open the covers of the truck, turn the key switch to the OFF position and disconnect the battery connector.

Figure 49. Truck covers overview

1. 2. 3. 4.

Machinery cover Front bumper Floor plate Machinery top cover

Revision: C

5. 6. 7. 8.

Instrument panel cover Control panel Cup holder Reach carriage cover

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5.7.1

Service Manual

Remove the machinery cover

1. Remove the screws. 2. Remove the machinery cover.

5.7.2

Remove the front bumper

1. Remove the screws. 2. Remove the front bumper. The front bumper is heavy, be careful when you remove it.

5.7.3

Remove the floor plate

1. Remove the 5 screws that attach the floor plate to the truck.

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Service Manual

2. Lift the floor plate on its side.

3. Disconnect the pedal connectors. 4. Remove the floor plate.

5.7.4

Open the machinery top cover

1. Remove the floor plate, see Section 5.7.3. 2. Remove the machinery cover, see Section 5.7.1. 3. Disconnect the seat switch connector. 4. Remove the two screws behind the seat.

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Service Manual

5. Open the machinery top cover. 6. Open the support bracket.

5.7.5

Open the instrument panel

1. Push the locking button of the instrument panel.

2. Turn the handle outwards to release the lock of the instrument panel. CAUTION: The instrument panel rises automatically.

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Service Manual

3. Lift the instrument panel up.

5.7.6

Remove the gas spring of the instrument panel

1. Remove the battery, see Section 7.7. 2. Open the instrument panel, see Section 5.7.5. 3. To secure the instrument panel, attach it to the overhead guard with a rope.

4. Remove the circlips. 5. Remove the shaft. 6. Remove the gas spring.

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5.7.7

Service Manual

Remove the instrument panel cover

1. Remove the cup holder. For instructions, see Section 5.7.9. 2. Open the instrument panel. For instructions, see Section 5.7.5. 3. Remove the 2 screws at the bottom of the instrument panel.

4. Close the instrument panel. 5. Remove the 4 screws that attach the instrument panel cover to the instrument panel. 6. Lift the instrument panel cover up.

7. Disconnect the connectors. 8. Remove the instrument panel cover.

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5.7.8

Service Manual

Remove the control panel

1. Remove the cup holder. For instructions, see Section 5.7.9. 2. Remove the steering wheel, see Section 5.8.1. 3. Disconnect the connectors. 4. Remove the screws. 5. Remove the control panel.

5.7.9

Remove the cup holder

1. Push down the clip on the side of the cup holder. 2. Remove the cup holder.

5.7.10

Remove the reach carriage cover

1. Move the reach carriage forward. 2. Remove the screws. 3. Remove the reach carriage cover.

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5.8

Steering wheel

5.8.1

Remove the steering wheel

Service Manual

1. Remove the 2 bolts that hold the steering wheel in position.

2. Disconnect the steering wheel connector. 3. Remove the steering wheel.

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5.9

Service Manual

Transmission gear

Figure 50. Transmission gear overview

During maintenance, examine the transmission gear for any leaks. Transmission oil

SAE 80W/90, API GL-4

Total transmission oil quantity

2.75 L

CAUTION Transmission oil is dangerous waste that must be discarded accordingly.

NOTE: Do not mix different lubricants. It is possible that different brands of lubricants are not be compatible with each other. Only use lubricants recommended by the manufacturer.

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5.9.1

Service Manual

Remove the transmission gear

1. Remove the traction motor. For instructions, see Section 8.4.1.1.

2. Remove the front bumper. For instructions, see Section 5.7.2. 3. Jack the truck up. For instructions, see Section 5.1.1. 4. Remove the 8 screws that hold the transmission gear.

5. Remove the transmission gear.

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5.10

Service Manual

Slewing bearing

Figure 51. Slewing bearing overview

During maintenance, examine the following: •

The bearing rotates easily when the traction wheel is raised up.

•

The mounting bolts of the drive unit are tightened properly.

5.10.1

Lubricate the slewing bearing

Figure 52 shows the lubrication point of the slewing bearing. For the lubrication of the slewing bearing, use lubrication grease Spheerol LC 2 that contains lithium-calcium thickeners and mineral oil.

Figure 52. Lubrication point of the slewing bearing

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Service Manual

NOTE: If the steering is set to 180°, you must switch it to 360° to lubricate the slewing bearing completely. The default setting is 360°. For instructions on how to change the setting, see the instructions of TruckTool.

5.11

Traction wheel CAUTION

Before you install the traction wheel, make sure that the wheel shaft, the face of the rim mounting, the wheel nuts and wheel shaft bolts are clean, free from grease and undamaged.

NOTE: To access the traction wheel, lift the truck up (see the correct lifting points in Section 5.1 of this manual) and remove the machinery cover (see Section 5.7.1) and the front bumper (see Section 5.7.2) and turn the transmission gear so that there is enough space for you to access and remove the wheel.

NOTE: You can set the steering to 360° or 180° (the traction wheel turns 360° or 180°). For instructions on how to change the setting, see the instructions of TruckTool. The default setting is 360°.

Figure 53. Traction wheel overview

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Service Manual

Examine the wear of the traction wheel: •

The diameter of a new traction wheel is 360 mm.

•

When the diameter of the traction wheel reaches 350 mm, replace the traction wheel. Also examine the wear of the corner supports and replace them, if needed. For instructions, see Section 5.12.

5.11.1

Disassemble the traction wheel

1. Remove the five rounded cone nuts that hold the traction wheel. 2. Remove the traction wheel. 3. Examine the condition of the wheel shaft bolts. Replace the bolts, if needed. For instructions, see Section 5.11.1.1 below.

5.11.1.1 Replace the wheel shaft bolts

Figure 54. Wheel shaft bolts overview

If the wheel shaft bolts of the traction wheel are defective, you need to replace them.

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Service Manual

1. Unscrew the defective wheel shaft bolt.

2. Use for example a rod or a crowbar to lock the wheel shaft.

3. Wet the new wheel shaft bolt with Loctite 243.

4. Install the new wheel shaft bolt. 5. Tighten the new wheel shaft bolt. The correct tightening torque is 27 Nm.

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5.11.2

Service Manual

Assemble the traction wheel

1. Align the hole pattern of the rim with the wheel shaft bolts and slide the traction wheel into place. 2. Install the five rounded cone nuts and tighten them. The correct tightening torque for the nuts is 80 Nm.

5.12

Corner supports

Figure 55. Corner supports overview

The clearance between new corner supports and the ground is 16 mm. In trucks with a mast height 7,500 mm and over, make sure that the clearance between the corner supports and the ground is no more than 20 mm. In trucks with a mast height under 7,500 mm, the wear of corner supports is irrelevant.

NOTE: Always examine the wear of the corner supports when you replace a worn out traction wheel.

Revision: C

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Service Manual

NOTE: To access the traction wheel, lift the truck up (see the correct lifting points in Section 5.1 of this manual). Also, remove the machinery cover (see Section 5.7.1) and the front bumper (see Section 5.7.2) and turn the transmission gear so that there is enough space for you to access and remove the wheel.

5.12.1

Replace the corner supports

1. Remove the bolt that holds the corner support in position. 2. Remove the corner support.

To install the corner supports, repeat the steps in the reverse order.

5.13

Load wheels

Figure 56. Load wheels overview

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5.13.1

Service Manual

Remove the load wheels

1. Lift the truck up on jacks. 2. Remove the plastic cover plate from the load wheel.

3. Bend 1 tooth of the locking washer open.

4. Open the locking nut with a special hook tool (see Section 14.5).

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Service Manual

5. Remove the locking nut and the locking washer. 6. Remove the load wheel.

To install the load wheels, repeat the steps in the reverse order.

5.13.2

Electric load wheel brakes (High performance model, optional for Standard model)

Figure 57. Electric load wheel brakes overview

The load wheel brakes are proportional electric brakes. They also enable programming of the breaking force through the controller.

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5.13.3

Service Manual

Adjust the load wheel brakes (High performance model, optional for Standard model)

1. Measure and make sure that the bushing is 0.8 mm below the machined surface in each of the three holes, into which the bushing springs and screws will be installed. NOTE: The depth of the bushing should be exactly the same in all three holes.

2. Pull the plate halfway over all three spring bushings.

3. Use three temporary screws as table supports. Turn only two turns each.

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Service Manual

4. Glue the three air gap springs to their positions on the brake ring with Loctite 270.

5. Lower the wheel over the assembly slowly and parallel to the table

6. Install the three spring bushings.

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Service Manual

7. Use Loctite 270 at the ends of the three screws.

8. Turn the three screws. NOTE: Do not push!

9. Remove the three temporary screws.

10. Tighten the screws. The tightening torque for the three screws is 25 Nm +/- 2,5. NOTE: Do not push!

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Service Manual

11. Install the load wheel. 12. Install the locking washer. 13. Install the locking nut. See Section 5.13.1 for instructions on removing and installing load wheels.

14. Install the circlip. Tighten and lock the nut (see Section 5.13.1).

15. Examine that the clearance of all three screws is small. Push the screws with your finger and the screw is locked.

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5.14

Battery roller frame

5.14.1

Remove the battery roller frame

Service Manual

1. Remove the battery. For instructions, see Section 7.7. 2. Remove the rollers from the frame.

3. Remove the screws that attach the battery roller frame to the truck. 4. Disconnect the sensor connector. 5. Lift the battery roller frame up.

To install the battery roller frame, repeat the steps in the reverse order.

NOTE: When you install the rollers back to the frame, be careful not to drop the roller into the roller hole! It may cause damage to components underneath.

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5.15

Service Manual

Reach carriage

Figure 58. Reach carriage overview

1. 2. 3.

Guidance roller Main roller Sensors

5.15.1

4. 5.

Hydraulic oil hose Reach cylinder

Lubricate the rollers of the reach carriage

NOTE: You must remove the battery roller frame before you can lubricate the rollers of the reach carriage.

Figure 59. Lubrication points of the reach carriage

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5.15.2

Service Manual

Adjust the guidance rollers of the reach carriage

NOTE: Remove the battery roller frame before you adjust the guidance rollers of the reach carriage.

Figure 60. Adjust the vertical guidance rollers of the reach carriage

Adjustment

Tightening

To adjust the guidance rollers:

1. Lift the back roller against a 0.1 mm feeler gauge.

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Service Manual

2. Adjust the guidance roller.

3. Tighten the guidance roller.

Figure 61. Adjust the horizontal guidance rollers of the reach carriage

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Service Manual

Adjust the guidance rollers so that the reach carriage is as close to the middle position as possible. Measure the position of the reach carriage at the narrowest points, see the correct measuring points in Figure 62.

Figure 62. Reach carriage measuring points

5.15.3

Sensors of the reach carriage

Figure 63. Sensors of the reach carriage overview

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5.15.4

Service Manual

Remove the reach carriage CAUTION

Before you disconnect any hydraulic pipes or hoses, make sure that all pressure is released from the hydraulic system.

1. Remove the mast. For instructions, see Section 5.16.5. 2. Remove the banjo bolts. 3. Remove the hoses. 4. Disconnect the wire.

5. Disconnect the reach cylinder from the motor compartment. See steps 5-8 in Section 5.15.5. 6. Remove the screw that holds the shaft in place. 7. Remove the shaft from the motor compartment. 8. Remove the spacer.

9. Remove the front bumper from the truck. See Section 5.7.2.

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Service Manual

10. Remove the bolts. 11. Remove the stoppers.

12. Use a hand pallet to remove the reach carriage.

5.15.5

Remove the reach cylinder CAUTION

Do not remove the reach cylinder on a slope! Always, make sure that the surface you are working on is flat and downright.

1. Remove the reach carriage cover. For instructions, see Section 5.7.10.

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Service Manual

2. Remove the hoses. 3. Remove the screw that holds the shaft in place. 4. Remove the shaft from the reach carriage.

5. Remove the front bumper from the truck. See Section 5.7.2. 6. Remove the screw that holds the shaft in place. 7. Remove the shaft from the motor compartment. 8. Remove the spacer. 9. Remove the reach cylinder through the motor compartment. CAUTION: Make sure you do not break the reach carriage sensors.

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5.15.6

Service Manual

Replace the reach carriage hoses

Figure 64. Reach carriage hoses

1. 2.

Banjo bolt Return hose

3. 4.

Pressure hose Hydraulic connector

When you replace the reach carriage hoses, it is important that the new hose is of the same length as the old one. Also, the new hose must be placed to the same position as the old one. To make sure that the new hose is of the correct length and correctly positioned, use the old hose to measure the new hose (see instructions below). You must also make sure that the hoses are in the correct order (for the correct order, see Figure 64).

1. 2. 3. 4.

Move the reach carriage to the forward position. Remove the floor plate, see Section 5.7.3. Remove the machinery top cover, see Section 5.7.4. Remove the machinery cover, see Section 5.7.1.

5. Mark the hoses and the wire at the side of the hose fastener.

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Service Manual

6. Cut the cable ties that hold the hoses in the hose fastener.

7. Remove the banjo bolt. 8. Disconnect the electric connections.

9. Spread the sides of the hose guide and remove the hose bracket.

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Service Manual

10. Disconnect the hydraulic connector. 11. Remove the old hose.

12. Remove the protective spiral.

13. Measure the new hose and make sure that it is of the same length as the old hose.

14. Draw a mark to the new hose according to the old hose.

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Service Manual

15. Wrap the protective spiral around the new hoses.

16. Connect the banjo bolt.

17. Guide the hose from the motor compartment side to the reach carriage side.

18. Install the hose bracket.

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Service Manual

19. Pull the hoses straight. Make sure that the hydraulic connector end of the pressure hose faces down and that the hydraulic connector end of the return hose faces up.

20. Guide the cable through the hose fastener. Make sure that the marks on the hoses are aligned and in the correct position at the side of the hose fastener. 21. Attach the hoses to the hose fastener with cable ties.

22. Guide the hose through the hose guide.

23. Connect the hydraulic connector.

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5.16

Service Manual

Mast WARNING

Mast maintenance work possibly requires work at height. Make sure that you use applicable access equipment and follow the safety instructions of the equipment manufacturer. Risk of falling.

CAUTION To service masts, you must be qualified to work on both mechanic and hydraulic systems.

Make sure that you use applicable lifting devices and follow the safety instructions given by the lifting device manufacturer. Make sure that the capacity of the used lifting device is sufficient.

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5.16.1

Service Manual

Detailed construction

Figure 65. Detailed construction of the integral triplex mast

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Mast Second internal mast First internal mast Lifting carriage Integrated side piston Free lift cylinder Sideshift cylinder Tilt cylinder Chain Chain anchor

Revision: C

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Chain wheel Chain guide Hose wheel Chain yoke Guidance roller Main roller Slide stopper Hydraulic oil hose Hose fastener Height reference sensor

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5.16.2

Service Manual

Maintenance of the mast

This section explains the regular maintenance procedures for masts. With regular maintenance, you can make sure that the truck and its mast remain in good working condition and safe for its operators.

5.16.2.1 Daily maintenance •

Examine the mast externally for oil leaks.

•

Examine all the wheels for damages or outer wear.

•

Turn the start switch on and lift and lower the forks to test the operation of the lifting hydraulics.

•

Make sure that all the fastenings of the mast chains are in order.

•

Examine the condition of the forks. For instructions, see Section 5.16.7.

•

Visually examine the condition of the welds. Focus on the welds of the lifting carriage.

5.16.2.2 Monthly maintenance •

Examine the tightness of all the screws, nuts and pipe / hose connections.

•

Examine the tension of the mast chains. All chain pairs must have equal tension to ensure proper load distribution and mast operation. For instructions on how to examine the mast chain tension and adjust the chains, see Section 5.16.8.2 and 5.16.8.3.

•

Apply grease on all unpainted areas in the mast channels.

•

Visually examine the condition of the welds. Focus on the welds of the lifting carriage.

5.16.2.3 Annual maintenance (1,000 h) •

Clean and lubricate the mast chains. The main and free lift chains have been lubricated at the factory. Avoid removal or contamination of the factory-applied lubrication. Do not wash, sandblast, etch, steam clean or paint the chains. If the chains require lubrication, see the lubricant recommendations in Section 5.16.3.1.

•

Examine the chains for elongation. For instructions, see Section 5.16.8.1.

•

Examine all the cylinder fastenings.

•

Examine the cylinders for any damages, nicks, marring or scratches.

•

Examine the fork base for cracks and wear.

•

Examine the welds of the fork carriage for cracks.

•

Examine the cross-member welds of outer and internal masts for cracks.

•

Examine the welds of the tilt cylinders and masts for cracks.

•

Examine the outer masts and cylinder support for cracks.

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•

Examine the lift bracket welds for cracks.

•

Examine the rollers, roller pins and welds for cracks and damage.

•

Examine the overhead guard for deformation, cracks and damage.

5.16.3

Lubricant recommendations

This section provides recommendations on the lubricants used in mast maintenance.

NOTE: Do not mix different lubricants. It is possible that different brands of lubricants are not compatible with each other. Only use lubricants recommended by the manufacturer.

5.16.3.1 Mast chains For the best chain life, use graphite or molybdenum type lubricants (for example sprays), which evaporate, leaving the graphite or molybdenum on the chain. CAUTION Using oil or grease to lubricate the chains in dusty or sandy operating conditions can cause dirt particles to stick to the chains and result in rapid wear from abrasion.

5.16.3.2 Mast channels For the lubrication of the mast channels, use lubrication grease NLGI No. 2 containing molybdenum disulphide.

5.16.4

Remove the lifting carriage CAUTION

Before you remove the mast from the truck, lower the forks and support the truck frame properly so that the load wheels are slightly lifted from the ground. Also remove the battery. For instructions, see Section 7.7.

Before you disconnect any hydraulic pipes or hoses, make sure that all pressure is released from the hydraulic system.

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1. Remove the locking screw.

2. Slide the forks to the middle of the lifting carriage.

3. Lift the fork latch to free the fork. 4. Remove the forks from the lifting carriage.

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5. Remove the hydraulic connectors from the tilt cylinder and the sideshift cylinders. 6. Plug the hydraulic connectors on the mast side to prevent oil leakage.

7. Remove the hose fastener.

8. Attach a lifting device on top of the first internal mast and tighten the lifting ropes/chains. NOTE: Make sure that you use applicable lifting devices and follow the safety instructions given by the lifting device manufacturer.

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9. Remove the locking pins from the chain anchors that are attached to the lifting carriage. 10. Remove the 2 nuts from the chain anchors. 11. Remove the chain anchors from the mounting holes.

12. Lift the mast up from the second internal mast. 13. Remove the lifting carriage.

5.16.5

Remove the mast

1. To support the mast, attach a lifting device on top of the mast and tighten the lifting ropes/chains. NOTE: Make sure that you use applicable lifting devices and follow the safety instructions given by the lifting device manufacturer.

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2. Disconnect the height reference sensor wires.

3. Remove the hydraulic oil hoses on the mast side. 4. Seal the hydraulic connectors on the mast side to prevent oil leakage.

5. From the reach carriage side, remove the hydraulic connectors that connect the mast to the hydraulic valve. 6. Seal the hydraulic connectors on the mast side to prevent oil leakage. 7. Disconnect the connectors.

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8. Remove the bolts that attach the mast mounting bracket to the truck frame. 9. Remove the mast mounting bracket.

10. Remove the locking pin from the shaft that connects the mast to the reach carriage. 11. Remove the shaft that connects the mast to the reach carriage.

12. Remove the bolts that attach the bearing housings to the truck frame.

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13. Use the lifting device to lighten the load on the bearing housing. Make sure that you do not lift the mast more than 5 mm. CAUTION: When you lift the mast, it can move forward!

14. Remove the bearing housing. NOTE: Be careful not to mix the shim plates between the left and right side of the mast. Do not change the number of the shim plates. Install the shim plates to their place after the mast is removed.

15. Remove the mast using the lifting device. NOTE: If it is necessary, lower the mast before you move it forward.

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5.16.6

Service Manual

Disassemble the mast

The steps provided in this section guide you through the disassembly of the mast. WARNING During the disassembly of the mast, mark down the direction of the different hydraulic connectors, the correct fastening points, direction of the rollers and the correct positioning of the hydraulic oil hoses and pipes. During the assembly of the mast, make sure that all the hydraulic connections, fastening points, roller directions and hose and pipe positions are the same as before disassembly.

Prepare a drip pan to catch any remaining oil in the pipes and hoses before disconnecting each pipe. Take appropriate actions to prevent dust and dirt from entering in the opening of the pipe and valve connections.

Remove the locking pins from the bottom chain anchors. 2. Remove the 2 nuts from the bottom chain anchors. 3. Remove the bottom chain anchors from the mounting holes.

4. Remove the chain guides from the chain wheels. 5. Slide the chains off the chain wheels.

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6. Remove the locking pins from the top chain anchors. 7. Remove the two nuts from the top chain anchors. 8. Remove the top chain anchors from the mounting holes.

9. Remove the hydraulic piping from the cylinders.

10. Remove the hose fasteners. 11. Remove the hydraulic oil hoses/pipes.

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12. Disconnect the wires of the lift pulse encoder in the height reference sensor. 13. Remove the cable ties and clips of the lift pulse encoder wires.

14. Loosen the screws that hold the belt of the lift pulse encoder in place. 15. Remove the belt of the lift pulse encoder.

16. Remove the screws from the mounting plate of the lift pulse encoder. 17. Remove the lift pulse encoder and its mounting plate.

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18. Remove the circlip that attaches the chain yoke to the free lift cylinder. NOTE: You can also remove the chain yoke and free lift cylinder as one unit. 19. Remove the chain yoke from the free lift cylinder.

20. Remove the free lift cylinder.

21. Lay the mast down onto a pallet or a strong table.

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22. Remove the screws of the slide stoppers. 23. Remove the slide stoppers.

24. Slide the first internal mast out, tilting it slightly upward at the end.

25. Remove the bolt that attaches the side cylinder on top of the mast. 26. Remove the curved washer.

27. Slide the second internal mast out, tilting it slightly upward at the end.

28. Remove the side cylinder, see Section 5.16.12.1.

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29. Remove the locking screws of the guidance rollers in the mast and internal mast. 30. Remove the guidance rollers from the mast and internal mast. 31. Remove the locking screws from the main rollers of the internal mast. 32. Remove the main rollers. NOTE: Count the shim plates and make sure you do not lose them! 33. Remove the circlips that attach the chain wheels and the hose wheel to the first internal mast. 34. Remove the chain wheels and the hose wheel.

35. Remove the main rollers from the lifting carriage. NOTE: Count the shim plates and measure their thickness. Make sure you do not lose the shim plates!

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5.16.7

Service Manual

Fork inspection

Inspect the forks carefully after each 300 hours of operation (or more frequently in severe or extreme environments). CAUTION Do any inspection, repair or exchange work of forks by pair. Very often, both forks are defective.

The fork inspection must be carried out carefully only by trained personnel.

NOTE: With an integral triplex mast, the support arms are welded to the truck frame.

Examine the forks for wear. If the forks have worn out more than 10% of the original fork thickness, the fork has to be taken out of service. 10% wear of the fork thickness already means a 20% reduction of fork capacity. The basis for wear measuring is the original nominal thickness of the fork (for example, if the original nominal thickness of the forks is 40 mm, the wear limit for the forks is 36 mm. Worn forks must not be welded.

Figure 66. Examining the forks for wear

Examine the forks for any cracks. Pay special attention to the inner heel section and all welded areas. If there are any cracks in the forks, remove the forks from service.

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Figure 67. Examining the forks for cracks

Examine the height difference of the forks. The height difference of the fork tips should not exceed 1.5% of the length of fork blade (L). Adjust or replace the fork if needed. The below formulas can be used to determine whether the height difference is acceptable or whether the forks need to be adjusted or replaced. •

Acceptable: h max = L in mm / 66

•

Adjust the fork: h max = L in mm / 66 to L in mm / 33

•

Replace the fork: h > L in mm / 33

Figure 68. Examining the height difference of the forks

Examine the forks for permanent deflection. The below formulas can be used to determine whether the deflection is acceptable or whether the forks need to be adjusted or replaced. •

Acceptable: k max = L in mm / 66

•

Adjust the fork: k max = L in mm / 66 to L in mm / 33

•

Replace the fork: k > L in mm / 33

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Figure 69. Examining the forks for permanent deflection

Examine the angularity of the forks. The forks are delivered with an angle of 90°. Forks with a differing angle must be replaced. CAUTION Do not try to bend the fork back in shape. The fork material can get weaker.

NOTE: Sometimes forks are used with deviant angular dimensions for special cases. Examine the correct angularity before inspection.

The below measurements can be used to determine whether the angularity of the forks is acceptable or whether the forks need to be adjusted or replaced. •

Ideal state 90°: d = 707 mm

•

Acceptable tolerance: d = 695-713 mm

•

Adjust the fork: d = 714-730 mm

•

Replace the fork: d = > 730 mm

Figure 70. Examining the angularity of the forks

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Examine the condition of the fork locking devices. The locking devices prevent loads from unintentionally slipping off the lifting carriage. Do not use forks with defective locking devices.

Figure 71. Examining the fork locking devices

Examine the fork tips for any signs of damage or wear. If the fork tip is worn or damaged, the fork needs to be shortened or replaced.

NOTE: Do not shorten the forks more than 5 mm!

Figure 72 Examining the condition of the fork tips

Examine the fork hook for lateral bending. Lateral forces and long-term use can cause lateral bending of the fork hook. In case of bending, the fork hooks or the forks need to be replaced.

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Figure 73 Examining the fork hook for lateral bending

5.16.8

Mast chains WARNING

Do not lengthen the mast chains. Do not shorten worn mast chains, but always replace worn chains with new ones.

Figure 74. Mast chains overview

1. 2. 3. 4.

Chain Chain anchor Tightening nut Locking nut

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5. 6. 7. 8.

Locking pin Mounting hole Chain wheel Chain yoke

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5.16.8.1 Inspect the mast chains Inspect and lubricate the chain masts after each 300 hours of operation (or more frequently in severe or extreme environments). During the inspection, examine the chains for the following: Elongation Always measure elongation when you do maintenance on the truck. To measure the elongation of the chains, you need a slide gauge and a chain gauge. Measure the mast chain from the section that moves over the chain wheel as that part of the chain flexes the most. If the chain is long, measure it at two different points.

Figure 75. Measure the elongation in the chain with a chain gauge

To measure the elongation:

1. Lift a load of approximately 300 kg up. 2. Use a slide gauge to measure the distance between two chain pins in millimeters.

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3. Find the correct measurement value in the chain gauge. 4. Record the value below the measurement value. You need the recorded value when you count the number of pins in step 6.

5. Set the slot of the chain gauge on one of the chain pins.

6. Count the same number of chain pins as you recorded in step 4. Begin counting at the first chain pin after the chain gauge. This gives you the length of the chain section under inspection. 7. See if the last chain pin you counted is approximately at the vertical line of the chain gauge. If the chain is approximately at that line, the length of the chain is right. 8. Make sure that the elongation is not more than 2%. If the elongation is more than 2%, you must replace the chain.

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You can also measure the elongation without a chain gauge. When a chain with the original length of 330.2 mm has elongated to the length of 336.8 mm, replace the chain (the elongation is approximately 2%).

Figure 76. Measure the elongation in the chain without a chain gauge

Edge wear Examine the chains for link plate edge wear by running your finger back and forth over the chain edge. See Figure 77 below. The wear of a link plate edge should not exceed 5%.

Figure 77. Edge wear in the chain

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Turning or protruding pins A highly loaded chain operated with inadequate lubrication can generate abnormal friction between the pins and the link plates. In extreme cases, the torque can surpass the press fit force between the pins and the outside plates, resulting in pin rotation. When a chain is operated in such a condition, a pin or a series of pins can begin to twist out of the chain, resulting in a failure. See Figure 78 below.

Figure 78. Turning or protruding chain pins

Examine the chain pin heads to make sure that all the flats are still correctly aligned. Replace chains with rotated or displaced heads or abnormal protrusion immediately. Do not attempt to repair the chain by welding or driving the pin(s) back into the chain. Any wear patterns on the pin heads or the sides of the link plates indicate misalignment. Such wearing damages the chain and increases frictional loading and should always be corrected. Cracked side plates Examine all the chains periodically for any cracked plates, see Figure 79 below.

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Figure 79. Cracked side plates

Examine the chains very carefully from all sides. If there is a cracked plate in a chain, the whole chain must be replaced. However, before you replace the chain, determine the cause of the crack to prevent the condition from repeating itself. Fatigue cracks Fatigue cracks are a result of repeated cyclic loading exceeding the endurance limit of the chain. Fatigue cracks nearly always start at the link plate pin hole (the point of the highest stress) and are perpendicular to the chain pitch line. In their early stages, fatigue cracks are microscopic. Unlike with stretching, there is no noticeable yielding or stretching of the material. Stress-corrosion cracks Stress corrosion is an environmentally assisted failure, caused by two conditions: corrosive agents and static stress. In the chain, the press fit pin causes static stress on the pin hole. No cycle motion is required, and the plates can crack even during idle periods. In addition, the reaction of several chemical agents (such as battery acid) with hardened steel can release hydrogen, which attacks and weakens the grain structure of the steel. The outside link plates of the chain, which are heavily press fitted to the pins, are particularly susceptible to stress-corrosion cracking. Like other cracks, stress-corrosion cracks also initiate at the highest stress point (pin hole), but tend to extend in an archlike pattern between the holes of the plate. A link plate often has more than one crack.

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Figure 80. Link plate with stress-corrosion cracks

Do not attempt to electroplate a leaf chain or its components. The plating process releases hydrogen, causing hydrogen embrittlement cracks, which look similar to stresscorrosion cracks. If a plated chain is required, contact the manufacturer. Plated chains are assembled from modified, individually plated components, which can reduce the rating of the chain. Corrosion fatigue Corrosion fatigue is caused by the combined action of an aggressive environment and cyclic stress (unlike in stress-corrosion cracking where static stress alone can be a cause). Appearance-wise, corrosion fatigue cracks are very similar (and in many cases identical) to normal fatigue cracks. They normally start at the pin hole and move perpendicularly to the chain pitch line. Ultimate strength failure This type of failure is caused by overloads that far exceed the maximum load of the mast.

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Figure 81. Ultimate strength failure

Tight joints All the joints in a leaf chain must flex freely. Tight joints resist flexing and increase internal friction, thus increasing the chain tension required to fit a given load. Increased tension accelerates wearing and causes more fatigue problems.

Figure 82. Tight joints

5.16.8.2 Examine the tension of the mast chains The tension of the mast chains must be examined every week. All chain pairs should have equal tension to ensure proper load distribution and mast operation.

Inspect the tension of the mast chains on level ground.

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2. Push the center of the chains in the chain pair. Both the chains should have equal give. If the chains do not give in equally, adjust the chains as instructed in Section 5.16.8.3.

5.16.8.3 Adjust the mast chains Adjust the tension of the mast chains by tightening or loosening the nuts of the chain anchors.

Figure 83. Adjust the mast chains overview

5.16.8.4 Replace the mast chains

NOTE: When replacing the mast chains, make sure that the new chains are of the correct length.

Mark down the correct fastening points of the chains. For instructions on removing the mast chains, see the mast chain related steps in Section 5.16.6.

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2. Remove the screws that attach the chain guide to the chain wheel. 3. Remove the chain guide. 4. Remove the hydraulic piping from the chain wheel.

5. Remove the mast chains, see Section 5.16.6. 6. Attach chain anchor(s) to both ends of the new chain(s).

7. Slide the free end of the chain onto the chain wheel.

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8. Install the top chain anchor to the mounting hole. The principle for correct chain routing is illustrated in Figure 84 below. 9. Install, but do not tighten, the two nuts to the top chain anchor. 10. Install the locking pin to the top chain anchor.

11. Install the bottom chain anchor to the mounting hole. The principle for correct chain routing is illustrated in Figure 84 below. 12. Install but do not tighten the two nuts to the chain anchor. 13. Install the locking pin to the chain anchor.

14. Adjust the chain tension according to the instructions provided in Section 5.16.8.3.

Figure 84. Principles of chain routing

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5.16.9

Service Manual

Guidance rollers

NOTE: The 2.0 and 2.5 ton truck models have the guidance rollers. Also, the 1.4 and 1.6 ton models have guidance rollers on top of the outer mast section.

Figure 85. Guidance rollers overview

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5.16.9.1 Adjust the guidance rollers

Figure 86. Adjust the guidance rollers overview

Guidance roller

Locking screw

In integral triplex masts, the guidance rollers are equipped with locking screws. To adjust the guidance rollers, you must first loosen the locking screws. Adjust the guidance rollers with a special adjustment tool (see Section 14.5) to make sure that the main roller has close connection with opposite side of the mast channel. After the adjustment, tighten the locking screws of the guidance rollers.

NOTE: Mast channel wear is not uniform throughout the length of the mast.

5.16.9.2 Replace the guidance rollers 1.

Disassemble the mast as instructed in Section 5.16.6. Note the correct placement of the guidance rollers for assembly.

2. Install the upper guidance rollers.

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3. In the second internal mast, install the shim plates of the bottom guidance rollers. If needed increase the number of the shim plates. 4. Install the bottom guidance rollers to the second internal mast.

5. Slide the internal masts in place. First slide the second internal mast into the mast and adjust it. Then slide the first internal mast into the second internal mast and adjust it.

6. Adjust the guidance rollers to position the internal masts correctly. For instructions, see Section 5.16.9.1 above. 7. Install the bottom guidance rollers to the second internal mast.

8. Grease all the guidance roller grooves with Vaseline.

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5.16.10 Main rollers

Figure 87. Main rollers overview

5.16.10.1 Replace the main rollers The main rollers need to be replaced if they jam.

Disassemble the mast as instructed in Section 5.16.6. Note the correct placement of the guidance rollers for reassembly.

2. Make sure that the main roller moves freely inside and out of the grooves. If the roller gets stuck inside the groove, hone the groove.

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3. Clean the grooves with pressurized air.

4. Install the shim plates of the main rollers. If needed, increase the number of the shim plates. Make sure that the play in the tightest point is no more than 0.5 mm. 5. Install the new main rollers. 6. Tighten the locking screws of the main rollers.

7. Grease all the groove surfaces with Vaseline.

8. Assemble the mast.

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5.16.11 Free lift cylinder

Figure 88. Free lift cylinder overview

1. 2. 3. 4.

Free lift cylinder Chain Chain yoke Hydraulic pipe/hose

5. 6. 7.

Hydraulic connector Sealing housing Bleed screw

5.16.11.1 Replace the free lift cylinder WARNING During the removal of the free lift cylinder, mark down the direction of the different hydraulic connectors, the correct fastening points and the correct positioning of the hydraulic oil hoses and pipes. During the installation of the new free lift cylinder, make sure that all the hydraulic connections, fastening points and hose and pipe positions are the same as before disassembly.

During the installation of the new free lift cylinder, make sure that the hose break valve is in the correct position. The hose break valve is located at the bottom of the free lift cylinder. This valve is a safety valve which regulates the oil flow to prevent the fork from moving down too quickly, if the piping between the free lift cylinder and lowering valve is broken or if the flow of return oil from the free lift cylinder becomes excessive due to an incorrectly adjusted proportional valve or a fault of another component.

1. Remove the free lift cylinder. For instructions, see the related steps in Section 5.16.6.

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Service Manual

2. Remove the cap from the new free lift cylinder.

3. Make sure that the hose break valve is in place.

4. Attach but do not tighten the 90˚ connector to the bottom of the free lift cylinder, making sure it points to the correct direction. 5. Install the new free lift cylinder, making sure the hydraulic connector point to the correct direction. 6. Install the screws that hold the free lift cylinder in place.

7. Install the chain yoke on top of the free lift cylinder.

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Service Manual

8. Insert protective grease to the chain yoke.

9. Install the free lift cylinder chain. For instructions, see steps 3-11 in Section 5.16.8.4. 10. Install the hose fasteners. 11. Attach and tighten the hydraulic pipes / hoses.

12. Tighten all hydraulic connections.

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Service Manual

5.16.11.2 Sealing housing of the free lift cylinder

Figure 89. Sealing housing of the free lift cylinder overview

1. 2. 3.

Sealing housing O-ring Ring

4. 5.

Wiper Teflon ring

If you notice an oil leakage, first make sure that the free lift cylinder piston is not damaged. Examine the outside surface of the piston on the whole length passing the housing (with the cylinder fully out) for any scratches. If there are any scratches on the piston surface, it is useless to replace the seals: the scratches would just destroy the new sealing and the leakage would continue. The correct way to repair the problem is to replace the whole cylinder with a new one. If the piston surface is undamaged, replace the seals. The recommended solution is to replace the whole sealing housing (includes factory-assembled seals). When replacing the whole sealing housing, the installation is simpler and you can avoid damaging the gaskets when performing the installation. However, if you prefer to replace just the seals, it is also possible to order only the gasket kit for each cylinder. The disassembly of the free lift cylinder sealing housing is described below. The assembly is performed by repeating the steps in reversed order.

1. Remove the free lift cylinder. For instructions, see the related steps in Section 5.16.6. 2. Install the free lift cylinder onto a work bench.

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Service Manual

3. Use the special hook tool (see Section 14.5) to unscrew the sealing housing.

5.16.11.3 Bleed out the air from the free lift cylinder

Figure 90. Bleed screw of the free lift cylinder

After replacing the free lift cylinder seals or sealing housings, bleed out the air from the free lift cylinder. Air inside the hydraulic system, lifting cylinders, valves or the piping can cause shimmy and abnormal noises together with jerky movement of the mast and forks.

1. Lift and lower the fork carriage 3-4 times within the free lift area.

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Service Manual

2. Lift the mast so that the lifting carriage is lifted by 1 meter.

3. Loosen the bleed screw and let the air bleed out.

4. When air bubbles cease to come out, tighten the bleed screw. 5. Repeat steps 2 and 3 until nothing but hydraulic oil flows out from the connection. 6. Fill up the hydraulic oil tank to the correct level, see Section 10.2. NOTE: Only use clean oil in the hydraulic system. Always fill the oil through the oil filter.

7. Bleed out the air from the side cylinders. For instructions, see Section 5.16.12.3. 8. Examine the air of the free lift cylinder once more after you have bled the air out of the side cylinders.

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Service Manual

5.16.12 Side cylinders

NOTE: With integral triplex masts, the side cylinders are integrated into the mast.

Figure 91. Side cylinders overview

1. 2.

Side cylinder piston Hydraulic connector

Sealing housing

5.16.12.1 Replace the side cylinders WARNING During the removal of the side cylinders, mark down the direction of the different hydraulic connectors, the correct fastening points and the correct positioning of the hydraulic oil hoses and pipes. During the installation of the new side cylinders, make sure that all the hydraulic connections, fastening points and hose and pipe positions are the same as before disassembly.

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Service Manual

During the installation of the new side cylinders, make sure that the hose break valve is in the correct position. The hose break valve is located at the bottom of the lifting cylinder. This valve is a safety valve which regulates the oil flow to prevent the fork from moving down too quickly, if the piping between the lifting cylinder and lowering valve is broken or if the flow of return oil from the lifting cylinder becomes excessive due to a incorrectly adjusted proportional valve or a fault of another component.

1. Remove the mast from the truck. For instructions, see Section 5.16.5. 2. Remove the hydraulic oil hoses.

3. Lay the mast down onto a pallet or a strong table.

4. Remove the bolt that attaches the side cylinder on top of the mast. 5. Remove the curved washer. 6. Remove the bleed screw of the side cylinder.

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Service Manual

7. Pull the internal masts out to extend the mast to its full height.

8. With the special extraction tool (see Section 14.5), unscrew the sealing housing.

9. Lift the top of the internal masts up. 10. Remove the side cylinder piston.

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Service Manual

5.16.12.2 Sealing housing of the side cylinder

Figure 92. Sealing housing of the side cylinder overview

1. 2. 3.

Sealing housing Teflon ring Seal

4. 5.

Wiper O-ring

If you notice an oil leakage, first make sure that the side cylinder piston is not damaged. Examine the outside surface of the piston on the whole length passing the housing (with the cylinder fully out) for any scratches. If there are any scratches on the piston surface, it is useless to replace the seals: the scratches would just destroy the new sealing and the leakage would continue. The correct way to repair the problem is to replace the whole cylinder with a new one. If the piston surface is undamaged, replace the seals. The recommended solution is to replace the whole sealing housing (includes factory-assembled seals). When replacing the whole sealing housing, the installation is simpler and you can avoid damaging the gaskets when performing the installation. However, if you prefer to replace just the seals, it is also possible to order only the gasket kit for each cylinder. The disassembly of the side cylinder sealing housing is described below. The assembly is performed by repeating the steps in reversed order.

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Service Manual

Unlock the piston mounting at the top of the internal mast. 2. Remove the curved washer.

3. Lift the internal mast out. NOTE: Make sure that you use applicable lifting devices and follow the safety instructions given by the lifting device manufacturer.

4. Remove the sealing housing locking screw.

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Service Manual

5. With the special extraction tool (see Section 14.5), unscrew the sealing housing. Be careful not to damage the threads!

6. Pull out the sealing housing (or the piston).

5.16.12.3 Bleed out the air from the side cylinders

Figure 93. Bleed screw of the side cylinder overview

After replacing the side cylinder seals or sealing housings, bleed out the air from the side cylinders. Air inside the hydraulic system, lifting cylinders, valves or the piping can Copyright © 2018 by MCFE. All rights reserved.

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Service Manual

cause shimmy and abnormal noises together with the jerky movement of the mast and forks.

1. Bleed out the air from the free lift cylinder. For instructions, see Section 5.16.11.3. 2. Lift the mast so that the first internal mast is lifted by 200 mm.

3. Loosen the bleed screw of one of the side cylinders and let the air bleed out.

4. When air bubbles cease to come out, tighten the bleed screw. 5. Repeat steps 2, 3 and 4 until nothing but hydraulic oil flows out from the connection. 6. Repeat the steps for the other side cylinder. 7. Fill up the hydraulic oil tank to the correct level, see Section 10.2. NOTE: Only use clean oil in the hydraulic system. Always fill the oil through the oil filter.

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Service Manual

5.16.13 Tilt cylinders

Figure 94. Tilt cylinders overview

5.16.13.1 Remove the tilt cylinders 1. Remove the forks. For instructions, see Section 5.16.4. 2. Remove the hoses from the fittings. 3. Remove the pipe from the tilt cylinders.

4. Remove the stopper from the lifting carriage.

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Service Manual

5. To remove the fork frame from the lifting carriage, roll the fork frame forward and lift it up.

6. Move the fork frame forward to remove it.

7. Remove the tilt cylinders from the lifting carriage. 8. Remove the spring pins that attach the tilt plate to the tilt cylinders. 9. Remove the tilt plate from the tilt cylinders.

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Service Manual

5.16.13.2 Sealing housing of the tilt cylinder

1. 2. 3.

Wiper seal (type A5) Sealing housing O-ring support ring

4. 5.

O-ring Twin lip seal

1. Remove the tilt cylinder. 2. Remove the locking nut. 3. Use the special hook tool (see Section 14.5) to unscrew the sealing housing.

4. Remove the tilt cylinder sealing housing.

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Service Manual

5. Remove the piston of the tilt cylinder.

5.16.14 Sideshift cylinder

Figure 95. Sideshift cylinder overview

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Service Manual

5.16.14.1 Remove the piston of the sideshift cylinder 1. Remove the forks, see Section 5.16.4. 2. Remove the stopper from the lifting carriage.

3. To remove the fork frame from the lifting carriage, roll the fork frame forward and lift it up.

4. Move the fork frame forward to remove it.

5. To remove the piston of the sideshift cylinder, see Section 5.16.14.2.

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Service Manual

5.16.14.2 Sealing housing of the sideshift cylinder

Figure 96. Sealing housing of the sideshift cylinder

1. 2. 3.

Sealing housing O-ring Twin lip seal

4. 5.

Teflon ring Wiper

To disassemble the sealing housing of the sideshift cylinder:

Use the special hook tool (see Section 14.5) to unscrew the sealing housing.

2. Remove the piston of the sideshift cylinder with the sealing housing. 3. Remove the piston of the sideshift cylinder from the sealing housing.

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5.17

Load backrest

5.17.1

Remove the load backrest

Service Manual

Remove the 4 screws that attach the load backrest to the truck.

2. Remove the load backrest.

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5.18

Operator’s seat

5.18.1

Replace the seat switch

Service Manual

NOTE: If you have the MSG20 seat in your truck see steps 1-2 for how to remove the seat padding and then move to step 5. If you have the MSG65 or MSG75 seat in your truck see steps 3-4 for how to remove the seat padding.

MSG20 seat: 1. Remove the screws that attach the seat padding to the seat. 2. Remove the seat padding.

MSG65 and MSG75 seats: 3. Tilt the backrest forward.

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Service Manual

4. Lift the seat padding and move it forward to remove it.

All seat models: 5. Lift the weight adjustment handle to release the backrest padding and push the seat backwards.

6. Lift the backrest padding up and tilt it forward.

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Service Manual

7. Remove the screws that attach the seat switch to the seat. 8. Remove the seat switch wiring.

To install the seat switch, repeat the steps in the reverse order.

Figure 97. Seat switch wiring overview

5.19

Arm rest

5.19.1

Remove the arm rest

1. Remove the instrument panel cover, see Section 5.7.7.

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Service Manual

2. Move the arm rest backwards so that you can see the locking bolt. 3. Remove the locking bolt.

4. Disconnect the arm rest connector. 5. Push and hold down the distance adjustment button of the arm rest. 6. Push the arm rest forward and remove it.

7. Lift the instrument panel up. 8. Remove the 4 locking nuts and 4 screws that hold the arm rest holder in place.

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Service Manual

9. Remove the arm rest holder from the instrument panel.

To install the armrest, do the steps in the opposite order.

5.19.2

Open the arm rest

1. Remove the arm rest from the truck. For instructions, see Section 5.19.1. 2. Remove the 5 screws that attach the top part of the arm rest to the arm rest. 3. Lift the top part of the arm rest up.

5.19.3

Remove the arm rest levers

After you have opened and closed the arm rest, you must calibrate it with TruckTool. For instructions, see the instructions of TruckTool.

1. Open the arm rest. For instructions, see Section 5.19.2.

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Service Manual

2. Remove the screw that attaches the lever to the arm rest. 3. Remove the lever.

If you want to remove a lever without the base under the lever, you do not need to open the arm rest:

1. Spread the sides of the lever and remove it.

NOTE: If you replace the lever without the base under the lever, it is not necessary to calibrate the levers.

5.19.4

Remove the arm rest buttons

1. Remove the screw that attaches the arm rest button panel to the arm rest. 2. Remove the arm rest button panel.

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5.20

Service Manual

Cabin

Figure 98. Cabin overview

5.20.1

Cabin covers

Figure 99. Cabin covers overview

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1. 2. 3. 4.

Instrument panel cover Ceiling cover Heater cover Front cabin cover

Service Manual

5. 6. 7. 8.

Left side cover with cabin control panel Right side cover Operator door cover Instrument panel cover

Window heater on/off button

Figure 100. Cabin control panel overview 1. 2.

Intercom on/off button (option) Push to talk button (option)

5.20.1.1 Remove the instrument panel cover 1. Remove the head of the air recirculation lever.

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Service Manual

2. Remove the 3 screws from the heater cover. 3. Disconnect the connectors. 4. Remove the heater cover.

5. Remove the front cabin cover.

6. Remove the 3 screws from the front part of the right side cabin cover. 7. Remove the side cabin cover.

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Service Manual

8. Remover the instrument panel cover.

5.20.1.2 Remove the ceiling cover 1. Remove the ceiling cover.

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5.20.1.3 Remove the left side cover 1. Remove the ceiling cover, see Section 5.20.1.2. 2. Remove the 6 screws from the left side cover.

3. Remove the left side cover.

5.20.1.4 Remove the right side cover 1. Remove the ceiling cover, see Section 5.20.1.2. 2. Remove the screws from the front part of the right side cover. 3. Remove the front part of the right side cover.

4. Remove the screws from the rear part of the right side cover. 5. Remove the rear part of the right side cover.

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Service Manual

5.20.1.5 Remove the operator door cover 1. Open the operator door. 2. Remove the screws from the handle of the operator door. 3. Remove the handle of the operator door. 4. Remove the screw that attaches the handle to the door opening lever.

5. Remove the handle of the door opening lever.

6. Remove the gas spring, see Section 5.20.2.1. 7. Remove the bolt from the stopper hinge. 8. Remove the stopper hinge.

9. Remove the operator door stoppers by turning them counterclockwise.

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Service Manual

10. Remove the door cover plate.

5.20.2

Operator door

Figure 101. Operator door

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5.20.2.1 Replace the gas spring of the operator door

Figure 102. Gas spring overview

To replace the gas spring:

1. Open the operator door all the way open. 2. Remove the pin from the truck side of the gas spring. 3. Release the truck side of the gas spring. 4. Remove the nut from the door side of the gas spring.

5. Remove the gas spring. To install the gas spring, do the steps in the opposite order.

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Service Manual

5.20.2.2 Remove the operator door WARNING The operator door is heavy. Make sure that you use applicable lifting devices and follow the safety instructions given by the lifting device manufacturer.

See the correct lifting points in Figure 103.

Figure 103. Lifting position of the operator door

To remove the operator door:

1. Remove the gas spring, see Section 5.20.2.1. 2. Remove the screw from the stopper hinge of the operator door. 3. Remove the rubber cover on top of the stopper hinge.

4. Lift the door with a lifting device. See the correct lifting points in Figure 103. NOTE: Make sure that you use applicable lifting devices and follow the safety instructions given by the lifting device manufacturer.

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Service Manual

5.20.2.3 Replace the lock of the operator door 1. Open the operator door. 2. Remove the 2 screws that attach the handle to the operator door 3. Remove the handle. 4. Remove the screw that attaches the handle to the opening lever.

5. Remove the opening lever handle.

6. Remove the gas spring, see Section 5.20.2.1. 7. Remove the bolt from the stopper hinge. 8. Remove the stopper hinge.

9. Turn the operator door stoppers counterclockwise to remove them.

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Service Manual

10. Remove the door cover plate.

11. Remove the lock.

12. Remove the lock handle.

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5.20.2.4 Adjust the operator door In a truck with the cabin, you can adjust the position of the operator door with the stoppers. Turn the stoppers until the door position is correct.

Figure 104. Operator door stoppers overview

You can also adjust the position of the operator door with the lock. To adjust the lock of the operator door, release the door latch and move it until it is in the correct position.

Figure 105. Adjustment of the lock of the operator door

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5.20.3

Service Manual

Roof window

Figure 106. Roof window

5.20.3.1 Open the roof window To open the roof window:

1. Push the lever to release the roof window.

2. Open the roof window.

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Service Manual

5.20.3.2 Remove the roof window 1. Remove the lock rings from the hinges of the roof window. 2. Remove the roof window.

5.20.3.3 Replace the sunroof wipers To replace the roof window wiper:

1. Remove the roof window wiper from the joint arm.

2. Install the new roof window wiper to the joint arm.

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Service Manual

5.20.3.4 Remove the motor of the roof window wipers 1. Open the operator door and leave it open. 2. Remove the ceiling cover, see Section 5.20.1.2. 3. Loosen the screw under the roof window wiper to remove the roof window wiper.

4. Remove the 2 nuts that keep the motor in position. 5. Remove the motor.

To install the motor of the windshield wipers, do the steps in the opposite order.

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Service Manual

5.20.3.5 Remove the roof window lock 1. Open the roof window.

2. Remove the screws from the cover of the roof window lock. 3. Remove the cover of the roof window lock.

4. Remove the 2 bolts. 5. Remove the roof window lock.

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5.20.4

Service Manual

Cabin seals

The cabin seals that you can replace are shown in Figure 107.

Figure 107. Cabin seals

Roof window seal

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Operator door seal

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5.20.5

Service Manual

Heater

Figure 108. Heater overview

1. 2.

Adjustment levers Air recirculation lever

Diffusers

5.20.5.1 Remove the heater 1. Remove the control panel, see Section 5.7.8. 2. Remove the left side cover, see Section 5.20.1.3. 3. Remove the front cabin cover, see the applicable steps in Section 5.20.1.1. 4. Remove the instrument panel cover, see Section 5.20.1.1. 5. Remove the heater panel cover, see the applicable steps in Section 5.20.1.1.

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Service Manual

6. Remove the contactor.

7. Disconnect and move aside the DC–DC converter supply fuse.

8. Remove the screws from the heater.

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Service Manual

9. Remove the heater.

10. Disconnect the heater wires.

5.20.5.2 Adjust the heater 1. Adjust the heating to OFF, LOW, or HIGH. See control locations in Figure 108.

2. Adjust the fresh air control. Pull the lever to increase fresh air circulation. Push the lever to increase cabin air circulation.

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Service Manual

3. Warm air diffusers.

5.20.6

Loudspeakers

Figure 109. Loudspeakers overview

5.20.6.1 Replace the loudspeakers 1. Push the loudspeaker from the sides. 2. Remove the loudspeaker from the panel

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Service Manual

3. Disconnect the connector.

To install the loudspeaker, do the steps in the opposite order.

5.20.7

Cabin windows CAUTION

Do not replace the cabin windows yourself. Contact a window repair service.

Before you take the truck to window repair service, remove the applicable covers and disconnect the heat resistors.

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Service Manual

Electrical operation This chapter describes the electrical operating principles of the reach truck. The standard model and its electrical schematic diagram are used as an example. CAUTION Always use the correct schematic diagram for the specific model you are servicing. The latest schematic diagrams are available from the Web site of the manufacturer. To troubleshoot a particular component, locate the component on the appropriate page of the schematic diagram and examine the circuitry associated with it. Keep the schematic diagram at hand for reference while reading the explanation. Make sure that you have the correct schematic diagram with regard to the truck model and its age.

6.1

How to use the schematic diagram CAUTION

The figures provided in this section are provided as examples only. Therefore the information in the actual schematic diagram of the truck model you are servicing can differ from the figures.

As an example, Figure 110 shows a part of a schematic diagram.

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Service Manual

Figure 110. Page 1/8, zone 13, wiring reference J14

Note the numbers above the wiring reference J14. These numbers (8/16) direct you to the page and zone where the wire is connected. This procedure is used to follow the circuits throughout the schematic diagram. If the numbers are given without the slash (/), the connection is on the same page of the schematic diagram. Table 5 below explains the different identifiers used in the schematic diagram. # stands for a number.

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Service Manual

Table 5. Schematic diagram identifiers IDENTIFIER

DESCRIPTION

Switches and other state changing devices (for example, most sensors).

#F#

Fuse

Reference. All references marked with an even ”J” (for example J2) are positive (+). All references marked with an odd “J” (for example J3) are negative (-).

Motor

Diode

Controllers and displays

Contactors and relays

Connector. Contact numbers are marked on individual wires.

XX#

Splice. Multiple wires are connected together at this point.

Figure 111 shows the reference to which Figure 110 referred.

Figure 111. Page 8, zone 16, wiring reference J14

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Service Manual

Once again, note the numbers below the wiring reference J14. These numbers (1/13) direct you back to the page (and zone) shown in Figure 110.

Figure 112. Page numbers (4/9), circuit diagram number (3-7109) and revision letter (H)

Page numbers, the circuit diagram number and the revision letter can be found in the bottom right corner of the page.

Figure 113. Page modification history

On the bottom left side of the circuit diagram, you can see the modification history of the page.

6.2

Power supply

This truck product family uses wet lead-acid batteries, which consist of 24 cells and supply a nominal voltage of 48 volts. The batteries have the maximum capacity of 930 Ah, depending on the truck model. The batteries reside in a separate compartment and are connected to the system via the X1 battery connector. In the electrical schematic diagram, the battery is presented as G1 in zone 11 on page 1.

6.3

Safety circuit (emergency stop button)

If the emergency stop button (S12) is in its normal closed position, B+ continues to flow to the key switch (S11). B+ also flows to the coil of the main contactor (K1). The operator can shut down the system power at any time by pushing the emergency stop button. When the button is pushed, the connection opens and removes B+ from the coil of the main contactor (K1).

6.4

Key switch

The main key switch S11 controls the electrical power supply to the entire system with the help of the main contactors K1 and K2. The coil that controls the main contactor (K1) contacts is presented in zone 12 on page 3. The coil that controls the emergency contactor (K2) contacts is presented in zone 22 on page 3. The key switch is activated by turning it to the ON position. When the key switch S11 closes, B+ flows to the coil of the main contactor K1, the negative is connected straight Copyright © 2018 by MCFE. All rights reserved.

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Service Manual

to the battery and the contactor K1 closes the contacts. Coil of the emergency contactor K2 is connected straight to the traction controller pins 17 (+) and 18 (-). Positive electrical power is supplied to the system through the main fuses 2F1, 3F1 and 4F1. The fuse 2F1 is rated at 300 A, 3F1 is rated at 300 A (or 350 A) and 4F1 is rated at 40 A. In the electrical schematic diagram, the location of the main fuses is illustrated in zones 17, 22 and 28 on page 2. After the main fuse 2F1, the B+ supply is fed to the contacts of the traction motor M1. The traction motor is controlled by the traction controller. In the schematic diagram, the M1 contacts are presented in zone 22 on page 2. The main voltage is supplied to the terminal +B on the traction controller. After the main fuse 3F1, B+ supply is fed to the contacts of the pump motor M2. The pump motor is controlled by the pump controller. In the schematic diagram, the M2 contacts are presented in zone 27 on page 2. The main voltage is supplied to the terminal +B on the pump controller´. After the main fuse 4F1, B+ supply is fed to the contacts of the steering motor M3. The steering motor is controlled by the steering controller. In the schematic diagram, the M3 contacts are presented in zone 16 on page 2. The main voltage is supplied to the terminal +B on the pump controller.

6.5

Traction

The movement of the truck is controlled by the traction controller. Before the truck can be operated, the battery must be connected, the main key switch must be closed and the system must have passed the self-test procedure. When the truck is powered on and in the standby mode, it can be operated by selecting the driving direction of the truck with the FNR control switch. Then the operator presence pedal must be pushed down. Then, when the operator pushes the accelerator pedal, the truck starts to move forward or backward, depending on the FNR switch. In the electrical schematic diagram, the FNR switch is presented in zone 17 to 18 on page 6. The operator presence pedal and accelerator pedal are presented in zones 15 to 18 and zone 24 on page 4. The accelerator pedal unit receives its positive 5 volt electrical supply from the traction controller XA1A/ pin 2. The negative connection is supplied from the traction controller XA1A/ pin 9. When the accelerator pedal is pushed down, it provides a varying voltage to the traction controller. The voltage varies between 0.5 and 4.5 volts, depending on the position of the accelerator pedal.

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Service Manual

Battery maintenance WARNING Always keep the battery of the truck clean and dry to prevent tracking currents. Follow the instructions of the manufacturer when you clean the battery.

Any liquid in the battery tray must be extracted and disposed of in the prescribed manner. After cleaning, repair all damages to the insulation of the tray to prevent tray corrosion and to ensure that the insulation value complies with the standard EN 62485-3.

If the battery is taken out of service for a longer period, make sure that the battery is fully charged and store it in a dry, frost-free room. The storage time should be taken into account when considering the lifetime of the battery.

In case of any malfunctions on the battery or in the charger, contact our service organization or your truck dealer without delay.

When using motive batteries and chargers, always make sure you follow the current standards, laws, rules and regulations in force in the country of use. For batteries according to the ATEX directive 94/9 EC, the instructions for maintaining the appropriate protection class during operation must be complied with (see the relevant certificate).

Batteries marked with this sign must be recycled. Batteries that are not marked with this sign are not returned for the recycling process and must be disposed of as hazardous waste.

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7.1

Service Manual

Safety regulations concerning the handling of lead-acid batteries

Pay attention to the operating instructions of the battery and fix them close to the battery. Work on batteries should be carried out by skilled personnel only!

Use protective glasses and clothes when working on batteries. Pay attention to the accident prevention rules as well as the standards EN 62485-3 and EN 50110-1

No smoking! Do not expose batteries to naked flames, glowing embers or sparks, as it can cause the battery to explode.

Acid splashes in the eyes or on the skin must be washed immediately with water. In case of an accident, consult a doctor immediately! Clothing contaminated by acid must be washed with water.

Risk of explosion and fire, avoid short circuits! Metal parts of the battery are always live. Do not place tools or other metal objects on the battery!

Electrolyte is highly corrosive.

Batteries and cells are heavy. Ensure secure installation. Use only suitable handling equipment, for example lifting gear in accordance with the standard VDI 3616.

Dangerous electrical voltage!

Pay attention to the hazards that can be caused by batteries.

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7.2

Battery maintenance

7.2.1

Daily maintenance

Service Manual

Charge the battery after every discharge. For batteries with electrolyte circulation, measure the electrolyte level towards the end of the charging and, if necessary, top it up to the specified level with deionized water according to the instructions of the manufacturer. The electrolyte level must not fall below the anti-surge baffle, the top of the separator or the electrolyte minimum level mark. For batteries with filling level sensors, look at the illuminated display daily. If the display is green, the level is OK. If the display shows a blinking red colour, the filling level is too low. For batteries with float indicator in the water filling plug, make sure that the white indicator is on the height of the window. For batteries with standard vent plugs, open the plug and visually examine the electrolyte level. When the watering level is low, top it up with demineralized water at the end of the charge.

7.2.2

Weekly maintenance

After charging, examine the battery visually for any signs of dirt or mechanical damages to the components of the battery. Pay special attention to the battery charging connectors and cables. In special cases when charging with an IU characteristic curve, also an equalizing charge must be carried out.

7.2.3

Monthly maintenance

At the end of the charge, switch the charger on and measure and record the voltages of all cells or bloc batteries. After the charging has been completed, measure and record the electrolyte density, electrolyte temperature and the filling level (when filling level sensors are used) of all cells. If there are any significant changes compared to earlier measurements or differences between the cells or bloc batteries, charge the battery fully and allow it to rest for the minimum of two hours. If the problem persists, contact our service organization or your truck dealer. Before contacting our service organization or your truck dealer, measure and record: •

Total voltage

•

Voltage per cell

•

If the voltage readings are irregular, also examine the specific gravity of each cell.

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7.2.4

Service Manual

Annual maintenance

The insulation resistance of the truck and the battery are measured in accordance with the standard EN 1175-1 at least once per year. The insulation resistance of the disconnected, filled and charged traction battery mounted on the truck must be at least 50 Ω multiplied by the nominal voltage of the truck system between the live parts and the frame of the truck. For batteries fitted with an electrolyte circulation system, examine the filter of the air pump and clean or replace it, if needed. It is possible that the filter needs to be replaced earlier than expected if there are no leaks in the air pipes, but for some reason the defect signal of the air mixing system on the charger or on the battery (on the DC air pump or remote signal) is illuminated. During annual maintenance, also make sure that the air pump operates correctly.

7.2.5

General maintenance

Keep the battery clean and dry to prevent tracking currents. Do the cleaning of the battery according to the ZVEI code of practice, see Section 7.2.8. If there is liquid in the battery tray, remove it and obey an approved procedure to discard it. Repair damage to the insulation of the tray after you have cleaned the tray. Thus you can make sure that the insulation value is in accordance with EN 62485-3and that you do not cause corrosion to the tray. If you must remove cells, contact the battery manufacturer.

7.2.6

Storage

If you remove a battery from service for a long period of time, make sure that: •

The battery is fully charged.

•

The storage is dry and frost-free.

To make sure that the battery is always prepared for operation, you can select one of these charging procedures: •

Do the equalizing charge monthly.

•

Do float charging at a charging voltage of 2.23 V × the number of cells.

Count the storage time, when you think about the life of the battery.

7.2.7

Malfunctions

If you find malfunctions in the battery or in the charger, contact the battery manufacturer immediately.

7.2.8

How to clean batteries

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Service Manual

It is important that you keep the battery clean. A clean battery: •

Can prevent accidents.

•

Is less likely to become damaged.

•

Is less likely to become damaged by corrosion or tracking currents.

•

Has a long life and operating time.

The insulation resistance of the disconnected, filled and charged traction battery mounted on the truck must be at least 50 Ω multiplied by the nominal voltage of the truck system between the live parts and the frame of the truck in accordance with EN 1175-1. Dust on batteries can cause tracking currents that can lead to self-discharge of the battery. If there is a flow of higher tracking currents, electrical sparking can occur and there is a risk of explosion of the charging gas. General instructions for battery maintenance: •

Use protective eyewear and protective clothing. Make sure that the surface resistance of your safety clothes, boots and gloves is ≤ 108 Ω to prevent a build-up of static electricity.

•

Do not use dry cleaning cloths to clean the battery.

Instructions for how to clean vehicle traction batteries: •

Before you clean the battery, remove the battery from the vehicle.

•

Make sure that you collect the rinsing water that contains electrolyte and discard it in a correct procedure. When you discard used electrolyte water or rinsing water, refer to the instructions for health and safety at work, accident prevention and how to discard water and waste.

•

Do not remove or open the cell plugs. See the instructions of the manufacturer.

•

Clean the plastic parts of the battery, especially the cell containers, with a cleaning cloth and clean water. Do not use cleaning agents.

•

After you have cleaned the battery, dry the battery with compressed air or damp antistatic cleaning cloth (cotton, for example). You can also use other applicable methods to dry the battery.

•

If there is liquid in the battery tray, remove it by suction and obey an approved procedure to discard it. For details, see EN 62485-3 and the ZVEI information leaflet Safety measures for the handling of electrolyte for lead-acid batteries.

•

You can also clean a vehicle traction battery with high pressure cleaning equipment. See the instructions of the high pressure cleaning equipment.

Instructions for how to avoid damage to the plastic parts of batteries: •

Make sure that you do not cause damage to the plastic parts of batteries, such as lids, the insulation of the intercell connectors and other connectors.

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Service Manual

•

Before you clean the battery, tighten the intercell connectors down or push them in tightly.

•

Make sure that the connectors are in their correct position and closed.

•

Do not use cleaning agents.

•

The maximum permitted temperature setting for the high pressure cleaning equipment is 140 ºC. Thus, you can make sure that 30 cm behind the jet nozzle, the temperature is no more than 60 ºC.

•

Make sure that the distance between the jet nozzle of the high pressure cleaning equipment and the battery is no less than 30 cm.

•

Make sure that the maximum working pressure is no more than 50 bar.

•

Clean large surface areas of the battery at a time to avoid heating the battery too much.

•

Do not leave the jet on one spot for a longer period of time than 3 seconds.

•

After you have cleaned the battery, dry the battery with compressed air or damp antistatic cleaning cloth (cotton, for example). You can also use other applicable methods to dry the battery.

•

Do not use air heaters with an open flame or with glow wires.

•

Make sure that the surface temperature of the battery is no more than 60 ºC.

•

7.3

Requirements for battery charging areas

The battery charging areas must be in compliance with the standard EN 62485-3. •

The battery charging area must be clearly defined by marking it permanently on the floor. The floor coating must be acid resistant and have a resistance to ground less than 100 MΩ to avoid sparks by electrostatic discharge.

•

The battery charging area must be adequately spaced from materials that can constitute a hazard, such as inflammable or explosive goods.

•

Except during essential maintenance or repair, the battery charging area must not be subjected to any sources of ignition, such as sparks or sources of high temperature. The exception is where high temperature equipment is required for work on the battery and this must be in the control of trained and authorized personnel who take all necessary precautions.

•

It is important to prevent electrostatic discharges when working with batteries. Make sure that you do not wear clothes and footwear that can build up electrostatic discharge. Absorbent cloth for battery cleaning must be antistatic and used moistened only with water without any cleaning agents.

•

When the battery is being charged or serviced, there must be a space 0.8 m wide on the sides of the truck that require access.

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Service Manual

•

When charging batteries on or off the truck, the ventilation requirements of EN 62485-3 clause 6 must be met.

•

The charger and other devices in the battery charging area, for example the battery changing equipment, must be installed so that they do not get damaged if the truck moves.

•

The battery charging area must not be vulnerable to falling objects, drip water or liquids that can leak from damaged pipes.

•

If you use battery replacement equipment, make sure that it is suitable for the battery trays and weights. Examine the battery replacement equipment regularly for damage. Battery replacement must be done by personnel trained to handle heavy weights. It is recommended that the batteries are replaced laterally with certified supporting devices to minimize the risk of batteries tipping over, crushing or damaging other equipment, etc.

•

The battery charging area must contain appropriate warning signs: -

Follow the instructions

Battery hazard

Dangerous voltage

Highly corrosive electrolyte

Use protective clothes and goggles

Prohibition of naked flame

Explosion hazard.

•

The battery charging area must contain fire extinguishing equipment.

•

The disassembly and disposal of batteries must be done according to the prevailing local regulation and by qualified personnel only.

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7.4

Service Manual

Charge the battery

Figure 114. Connectors overview

1. 2.

Charger connector Truck connector

Battery connector

CAUTION Make sure that the charger is the appropriate model (correct battery type and voltage) and that the battery has sufficient ventilation.

NOTE: Make sure that you guide the battery connector cables so that they do not get stuck between the battery and the instrument panel! See Section 7.7.1.

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Service Manual

1. Park the truck in a reserved battery charging area. 2. Switch the power of the truck off. 3. Make sure that the charger has been switched off.

4. Disconnect the battery connector from the truck connector.

5. Connect the battery connector to the charger connector.

6. Switch the charger on.

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Service Manual

After charging

1. Switch the charger off.

2. Disconnect the battery connector from the charger connector. Hold the connectors; do not pull the cables.

3. Examine the battery according to the battery maintenance instructions of the manufacturer. 4. Connect the battery connector to the truck connector. Make sure that the battery cables remain completely safe within the frame of the truck.

WARNING Do not leave the battery cables outside of the truck. The cables can get damaged and cause a serious burning hazard!

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7.5

Service Manual

Measure the specific gravity of the battery

Measure the specific gravity of the battery water according to the instructions of the manufacturer. The specific gravity of a fully charged battery is 1.28 to 1.30 at +30°C. The gravity is: •

1.24 when the battery is 3/4 charged.

•

1.20 when the battery is 1/2 charged.

•

1.16 when the battery is 1/4 charged.

•

1.15 when the battery is empty. Charge the battery immediately.

7.6

Acquire a new battery

When acquiring a battery for the truck, take the following sections of the standard EN 1175-1 into consideration: •

5.1 Traction batteries (includes the requirements for the protective cover of the battery case, ventilation and interior surface treatment)

•

7.4 Minimum markings (includes the requirements for the truck battery plate).

The battery plate should give at least the following information: •

Manufacturer

•

Type

•

Serial number

•

Nominal voltage

•

Capacity (Ah / 5h)

•

Service weight.

7.7

Replace the battery CAUTION

Always follow the instructions of the manufacturer when you replace the battery.

When you replace the battery, use a battery with equivalent dimensions and weight to maintain the stability and the braking properties of the truck. The minimum weight of the battery is indicated on the identification plate of the truck.

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Service Manual

When you install a battery, use the applicable tools to move, connect and attach the battery correctly. Do not keep tools or other metal objects on top of uncovered batteries.

Make sure that the capacity of the used lifting device is sufficient. When you use a lifting device to lift the battery, put a non-conductive plate on top of the battery to prevent the risk of a short circuit. This is not necessary, if the lifting device has sufficient insulation and is equipped with a distributor, or if the pole shoes and cell combinations are fully protected.

Figure 115. Replace the battery overview 1. 2.

Battery connector Battery locking mechanism

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Battery

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Service Manual

1. Disconnect the battery connector.

2. Open the instrument panel, see Section 5.7.5. 3. Push the locking pin in.

4. Attach the four lifting hooks to the empty battery. NOTE: Make sure that you use applicable lifting devices and follow the safety instructions given by the lifting device manufacturer.

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Service Manual

5. Loosen the bolts of the battery locking mechanism. 6. Lift the battery locking mechanism up to remove it.

7. Lift the discharged battery with a lifting device.

8. Insert a charged battery to the truck.

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Service Manual

9. Pull the locking pin out.

10. Push the instrument panel down.

11. Close the lock of the instrument panel.

NOTE: Make sure that you guide the battery connector cables so that they do not get stuck between the battery and the instrument panel! See Section 7.7.1.

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7.7.1

Service Manual

Guide the battery connector cables

1. Guide the battery connector cables through the opening in the instrument panel. Make sure that the cables do not get stuck between the battery and the instrument panel!

7.7.2

Quick battery replacement

As an alternative for the basic battery replacement, there is the quick battery replacement option, see Section 15.21.

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Service Manual

Electric system maintenance 8.1

Display panel

Figure 116. Display panel overview

1. 2. 3. 4.

Emergency stop button Start switch / key switch Display control buttons Truck display

Revision: C

5. 6. 7. 8.

Operator compartment fan switch (optional) Reading lamp switch (optional) Warning light switch (optional) Working lights switch (optional)

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8.1.1

Service Manual

Emergency stop button

Type

Complete emergency stop

Contact rating

24 Vdc / 4 A

Electrical wiring

Quick connect terminals 2.8 x 0.8 mm

Switching output

1 x NC

Figure 117. Emergency stop button overview

8.1.1.1 Emergency stop button functionality check 1. Measure at the resistance area that the contacts inside the emergency stop button are not stuck together. When the emergency stop button is released (the contacts are closed together), the resistance is ~0 Ω. When the emergency stop button is pushed down, the resistance is ~∞Ω. 2.

If the contacts are stuck together or broken, replace the emergency stop button.

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8.1.2

Service Manual

Key switch

Type

Key switch

Contact rating

24 Vdc / 5 A

Electrical wiring

Plug-in connector 6 poles

Switching output

3 x NO

Figure 118. Key switch overview

8.1.2.1 Key switch functionality check 1. Measure at the resistance area that the contacts inside the key switch are not stuck together. When the key switch is in the 0 position, the resistance is ~0 Ω between the pins 61 and 4-5. When the key switch is turned clockwise once, the resistance is ~0 Ω between the pins 6-1, 4-5, 6-4, 6-3, 1-4 and 1-3. When the key switch is turned clockwise for the second time, the resistance is ~0 Ω between the pins 6-1, 4-5, 6-5, 6-2, 1-5 and 1-2. 2. If the contacts are stuck together or broken, replace the key switch.

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8.2

Service Manual

Pedals

Figure 119. Pedals overview

1. 2.

Operator presence pedal Accelerator pedal

8.2.1

Brake pedal

Operator presence pedal

Type

Operator presence pedal

Contact rating

240 Vdc / 1.5 A

Electrical wiring

2-poles connector

Switching output

1 x NO, momentary action

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Service Manual

Figure 120. Operator presence pedal overview

8.2.1.1 Operator presence pedal functionality check 1. Measure at the resistance area that the contacts inside operator presence pedal are not stuck together. Connect the multimeter between pins X22/1 and X22/2. When the operator presence pedal is on neutral position, the contacts are open, and the resistance is ~∞Ω. When the pedal is pushed down, the resistance between pins is ~0 Ω. 2. If the contacts are stuck together or broken, replace the operator presence pedal.

8.2.1.2 Remove the operator presence pedal 1. Remove the screws that attach the pedal to the truck. 2. Remove the pedal. 3. Disconnect the connector.

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8.2.2

Service Manual

Accelerator pedal

Use the accelerator pedal with your right foot. The more you push the accelerator pedal, the higher the speed. The accelerator pedal returns automatically to the neutral position when it is released.

Figure 121. Accelerator pedal overview Table 6. Accelerator pedal wire details PIN LOCATION

COLOR

DESCRIPTION

Blue

Supply +5 V

White

GND

Yellow

Output signal 1, 0.5 – 4.5 Vdc

Grey

Supply +5 V

Brown

GND

Black

Output signal 2, 4.5 – 0.5 Vdc

The accelerator pedal has two analogue output signals that are crossed together. The output signal varies between 0.5 - 4.5 Vdc, depending on the pedal operating angle which is 15°. To calibrate the accelerator pedal, refer to the instructions of TruckTool.

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Service Manual

Figure 122. Accelerator pedal output signals

8.2.2.1 Accelerator pedal functionality check 1. Connect the supply voltage of +5 Vdc between pins B21/1-2 and B21/4-5. 2. Measure the output signal 1 on voltage area between the pins B21/2 and B21/3. When the accelerator pedal is in neutral position, the value should be 0.5 Vdc. When the accelerator pedal is pushed, the value should rise towards 4.5 Vdc. 3. Measure the output signal 2 on voltage area between pins B21/5 and B21/6. When the pedal is in neutral position, the value should be 4.5 Vdc. When the accelerator pedal is pushed, the value should decrease towards 0.5 Vdc. 4. If the values do not match the above, replace the accelerator pedal.

8.2.2.2 Remove the accelerator pedal 1. Remove the screws that attach the pedal to the truck. 2. Remove the pedal. 3. Disconnect the connector.

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8.2.3

Service Manual

Brake pedal

Use the brake pedal with your right foot. The more you push the brake pedal, the greater the braking is. The brake pedal returns automatically to the neutral position when it is released.

Figure 123. Brake pedal overview Table 7. Brake pedal wire details PIN LOCATION

COLOR

DESCRIPTION

Blue

Supply +5 V

White

GND

Yellow

Output signal 1, 0.5 – 4.5 Vdc

Grey

Supply +5 V

Brown

GND

Black

Output signal 2, 4.5 – 0.5 Vdc

The brake pedal has two analogue output signal that are crossed together. The output signal varies between 0.5 - 4.5 Vdc depending on the pedal operating angle which is 15°. To calibrate the brake pedal, see the instructions of TruckTool.

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Service Manual

Figure 124. Brake pedal output signals

8.2.3.1 Brake pedal functionality check 1. Connect the supply voltage of + 5 Vdc between the pins B22/1-2 and B22/4-5. 2. Measure the output signal 1 on voltage area between the pins B22/2 and B22/3. When the brake pedal is in neutral position, the value should be 0.5 Vdc. When the brake pedal is pushed, the value should rise towards 4.5 Vdc. 3. Measure the output signal 2 on voltage area between the pins B22/5 and B22/6. When the brake pedal is in neutral position, the value should be 4.5 Vdc. When the brake pedal is pushed, the value should decrease towards 0.5 Vdc. 4. If the values do not match the above, replace the brake pedal.

8.2.3.2 Remove the brake pedal 1. Remove the screws that attach the pedal to the truck. 2. Remove the pedal. 3. Disconnect the connector.

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8.3

Service Manual

Instrument panel WARNING

Before inspecting the controller, disconnect the battery connector.

Do not operate the truck with the electric panel uncovered.

CAUTION Before inspecting and replacing fuses, turn the key switch to the OFF position and disconnect the battery connector.

Figure 125. Instrument panel overview

1. 2. 3.

Vehicle controller Pump controller Traction controller

Revision: C

4. 5.

Steering controller Fuse box

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8.3.1

Service Manual

Discharge the controllers CAUTION

Before you start to do maintenance on the controllers, you must discharge them. Also, if you continue the maintenance work of the controllers after you have switched the power of the truck ON and OFF, you must discharge the controllers again. There is a risk of electric shock!

NOTE: It is not necessary to discharge each controller separately. If you discharge one controller, the other controllers are discharged at the same time.

To discharge the controllers: 1. Switch the power of the truck OFF. 2. Disconnect the battery connector. 3. Connect the red cable of the bleeder resistor to the B+ pole. See Figure 126. 4. Connect the black cable of the bleeder resistor to the B- pole. See Figure 126. Keep the bleeder resistor connected for at least 5 seconds. 5. Disconnect the cables of the bleeder resistor. 6. Measure the voltage between the terminals with a multimeter. The value must be under 5 V.

Figure 126. Positive and negative poles of the controller voltage feed

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8.3.2

Service Manual

Vehicle controller

This forklift truck has a VCM Vehicle Controller, which performs all the electric functions that are usually present in reach trucks, high level order pickers and counterweight lift trucks. The controller performs these functions: •

Drivers for several ON/OFF and proportional solenoid valves

•

CAN bus interface

•

Interface for two encoders

•

11 digital inputs

•

10 analog inputs

•

Flash memory

•

Double microcontroller

8.3.3

Vehicle controller connectors CAUTION

Before any inspection or repair work, turn the key switch to the OFF position, disconnect the battery connector, discharge all inverters and record the places of the harness connections before disassembly.

When disconnecting the connector, hold the connector housing and plug and unlock the connector. Holding the case can cause damage to the inside card, while holding the cable can cause wire breakage.

If the high-power cable terminals of the battery-operated vehicle are not tightened properly, the increased contact resistance causes excessive heat generation, and can even cause a fire. To prevent accidents and equipment problems, examine the tightening torque of the high-power cable terminals regularly. Do not pull the cables to examine connections or during adjustment. If the cable terminal sections are moved, retighten the connections.

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Service Manual

Figure 127. Vehicle controller connectors overview

The vehicle controller uses two connectors: •

CNA 35 poles connector

•

CNB 23 poles connector

Contact 0.5…1.25 mm 2 for CNA and CNB connectors.

8.3.3.1 CNA external connector CONNECTION

DESCRIPTION

A1 POWER IN 1 (XA4A/1) (Valves supply)

Power into PEVP 1-4. This input has to be supplied with positive taken after the main contactor and should be used to supply all solenoid valves.

A2 NEVP 3 (XA4A/2) (Reach forward valve XY43.1/1)

Coil of the reach forward valve.

A3 NEVP 4 (XA4A/3) (Reach backward valve XY43.2/1)

Coil of the reach backwards valve.

A4 NEVP 7 (XA4A/4) (Sideshift left valve XY45.2/1)

Coil of the sideshift left valve.

A5 NEVP 8 (XA4A/5) (Sideshift right valve XY45.1/1)

Coil of the sideshift right valve.

A6 NEV 2 (XA4A/6) (Aux hydraulic valve coil XY46.1/1)

Coil of the auxiliary hydraulic function valve A1.

A7 NEV 3 (XA4A/7) (Aux hydraulic valve coil XY46.2/1)

Coil of the auxiliary hydraulic function valve A2.

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Service Manual

CONNECTION

DESCRIPTION

A9 DI2 (XA4A/9) (Foot switch X22/5)

Operator presence pedal.

A10 DI11 (XA4A/10) (Reach limit switch XS42/2)

Reach end stop switch.

A11 CANL 1 (XA4A/11) (CAN bus low X45/17)

Low signal of CAN bus 1 (terminated).

A12 CANH 1 (XA4A/12) (CAN bus high X45/18)

High signal of CAN bus 1 (terminated).

A13 PEVP 1 (XA4A/13) (Positive to lift and lower valves XY41/2 & XY42/2)

Positive to proportional valves 1 and 2 (NEVP1 & NEVP2).

A14 PEVP 2 (XA4A/14) (Positive to reach forward and backward valves XY43.1/2 & XY43.2/2)

Positive to proportional valves 3 and 4 (NEVP3 & NEVP4).

A15 PEVP 3 (XA4A/15) (Positive to tilt forward and backward valves XY44.1/2 & XY44.2/2)

Positive to proportional valves 5 and 6 (NEVP5 & NEVP6).

A16 PEVP 4 (XA4A/16) (Positive to sideshift left and right valves XY45.1/2 & XY45.2/2)

Positive to proportional valves 7 and 8 (NEVP7 & NEVP8).

A17 PEV 2 (XA4A/17) (Positive to auxiliary function valves XY46.1/2 & XY46.2/2)

Positive to valves NEV 2 and NEV 3.

A18 DI3 (XA4A/18) (Height reference sensor XS43/2)

Height reference sensor.

A19 DI4 (XA4A/19) (LSS XFC4/12)

LSS switch from the arm rest.

A20 DI5 (XA4A/20) (Sideshift centering middle point XS52/2)

Sideshift centering midpoint sensor.

A21 DI0 (XA4A/21) (Sideshift centering direction XS51/2)

Sideshift centering direction sensor.

A22 NPOT (XA4A/22) (Pedal GND X3/2)

Accelerator pedal and brake pedal ground.

A24 NEVP 1 (XA4A/24) (Lift valve XY41/1)

Coil of the lifting valve.

A25 NEVP 2 (XA4A/25) (Lower valve XY42/1)

Coil of the lowering valve.

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Service Manual

CONNECTION

DESCRIPTION

A26 NEVP 5 (XA4A/26) (Tilt forward coil XY44.1/1)

Coil of tilt forward.

A27 NEVP 6 (XA4A/27) (Tilt backward coil XY44.2/1)

Coil of tilt backward.

A28 KEYLINE (XA4A/28) (Keyline X44/1)

Battery positive supply to microprocessors.

A29 -BATT (XA4A/29) (GND X44/6)

Battery negative supply.

A33 PENC (XA4A/33) (Encoder positive supply X48/1)

Positive +12 V supply to encoders.

8.3.3.2 CNB external connector CONNECTION

DESCRIPTION

B6 CPOT9 (XA4B/6) (Pressure sensor XB42/2)

Pressure sensor output signal.

B7 POWER IN 2 (XA4B/7) (Power in to PEV1 & PEV2)

Positive supply.

B8 PEV 1 (XA4B/8) (Supply in to NEV 1 & NEV 9 X44/3)

Positive supply to load wheel brakes.

B11 CPOT 7 (XA4B/11) (Throttle pedal X3/7)

Accelerator pedal output signal.

B12 CPOT 8 (XA4B/12) (Brake pedal X3/9)

Brake pedal output signal.

B13 DI6 (XA4B/13) (Tilt centering XS53/2)

Tilt centering sensor.

B14 DI7 (XA4B/14) (Load status X47/6)

Load status sensor.

B16 PPOT (XA4B/16) (Pedal assembly supply X3/1)

Positive +5 V supply to the accelerator pedal and brake pedal.

B17 CHA ENCA (XA4B/17) (Encoder A channel A XB41/2)

Lift encoder channel A.

B18 CHB ENCA (XA4B/18) (Encoder A channel B XB41/3)

Lift encoder channel B.

B19 NENC (XA4B/19) (GND to encoders XB41/4)

Negative supply to encoders A and B.

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Service Manual

CONNECTION

DESCRIPTION

B20 -BATT (XA4B/20) (GND X44/6)

Battery negative supply.

B21 DI8 (XA4B/21) (Reach backward end limit)

Reach backward end limit.

B22 DI9 (XA4B/22) (Lower stop XS44/2)

Lowering stop sensor.

B23 NEVP9 (XA4B/23) (NEVP load wheel brakes X44/4)

Load wheel brakes negative.

8.3.4

Traction controller

This forklift truck is equipped with the ACE-2 Controller, which controls 4.0 kW to 9.0 kW motors. It has been expressly designed for battery electric traction. It is suitable for material handling with electric trucks: order pickers, reach truck, CB 2.0 ton counterbalance trucks, tractors, boom lift and scissors lift. The controller performs these functions: •

Controller for AC asynchronous 3-phase motors

•

Regenerative braking functions

•

CAN bus interface

•

Flash memory (128 Kbytes on-chip program memory)

•

Digital control based upon a microcontroller

•

Voltage: 48 V

•

Maximum current ACE2 48 V / 350 A (RMS) for 3'

•

1 hour current rating ACE 48 V / 170 A (RMS)

•

Operating frequency: 8 kHz

•

External temperature range: -30°C - 40°C

•

Maximum inverter temperature (at full power): 85°C

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8.3.5

Service Manual

Traction controller connectors CAUTION

Before any inspection or repair work, turn the key switch to the OFF position, disconnect the battery connector, discharge all controllers and record the places of the harness connections before disassembly.

When disconnecting the connector, hold the connector housing and plug and unlock the connector. Holding the case can cause damage to the inside card, while holding the cable can cause wire breakage.

Figure 128. Traction controller CNA external connector

The traction controller uses one connector: •

CNA 23 poles connector

Contact 0.5 – 1.25 mm2 for the CNA connector.

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Service Manual

8.3.5.1 CNA external connector CONNECTION

DESCRIPTION

A1 KEY (XA1A/1) Keyline input

Connected to the battery positive through a 10 A fuse.

A2 PPOT (XA1A/2) (Pedals supply X3/7)

Positive supply of +5 V for the accelerator pedal and brake pedal.

A3 CPOT (XA1A/3) (Throttle pedal X3/4)

Accelerator pedal output signal.

A4 FORW (XA1A/4) (Seat switch X134/1)

Seat switch state.

A7 ENCA (XA1A/7) (Motor encoder channel A XM1/2)

Traction motor encoder channel A.

A8 PENC (XA1A/8) (Motor encoder supply XM1/1)

Positive supply of +12 V for the traction motor encoder.

A9 -BATT (XA1A/9) (Pedals GND X3/8)

Accelerator and brake pedal ground.

A10 CPOTBR (XA1A/10) (Brake pedal X3/10)

Brake pedal output signal.

A11 SAFETY IN (XA1A/11) (Safety chain XA2A/19)

Safety chain input.

A14 ENCB (XA1A/14) (Motor encoder channel B XM1/3)

Traction motor encoder channel B.

A15 ENC GND (XA1A/15) (Encoder GND XM1/4)

Traction motor encoder ground.

A16 NLC (XA1A/16) (Contactor driver K2/A2)

Coils output of the main contactor K2. The coil is driven to a negative reference.

A17 PLC/PB (XA1A/17) (Contactor coils positive supply K1/A1)

Positive supply of the main contactor K2.

A18 NEB (XA1A/18) (Brake coil control X34/2)

Coil of the electromechanical brake output. The coil is driven to a negative reference.

A20 CAN-L (XA1A/20) (CAN bus low)

Low signal of CAN bus.

A21 CAN-H (XA1A/21) (CAN bus high)

High signal of CAN bus.

A22 PTHERM (XA1A/22) (Motor temperature sensor supply XM1.1/2)

The positive supply of the traction motor temperature sensor.

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Service Manual

CONNECTION

DESCRIPTION

A23 NTHERM (XA1A/23) (Motor temperature sensor GND XM1.1/1)

Traction motor temperature sensor ground.

8.3.5.2 Description of the power connections CONNECTION

DESCRIPTION

-B

Negative of the battery.

Positive of the battery.

-P

Negative of the pump motor.

U; V; W

Connection bars of the three motor phases.

The correct tightening torque for the traction controller terminal bolts is 13 – 15 Nm (+/-1.4 Nm).

8.3.6

Pump controller

This forklift truck is equipped with the ACE-2 Controller, controls 10.0 kW to 14.0 kW motors. It has been expressly designed for battery electric traction. It is suitable for material handling with electric trucks: order pickers, reach truck, CB 2.0 tons, tractors, boom lift and scissors lift. The controller performs these functions: •

Controller for AC asynchronous 3-phase motors

•

CAN bus interface

•

Flash memory (128 Kbytes on-chip program memory)

•

Digital control based upon a microcontroller

•

Voltage: 48 V

•

Maximum current ACE2 48 V / 400 A (RMS) for 3'

•

Maximum current ACE2 48 V / 500 A (RMS) for 3'

•

1 hour current rating ACE 48 V / 200 A (RMS)

•

1 hour current rating ACE 48 V / 250 A (RMS)

•

Operating frequency: 8 kHz

•

External temperature range: -30°C - 40°C

•

Maximum inverter temperature (at full power): 85°C

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8.3.7

Service Manual

Pump controller connectors CAUTION

Before any inspection or repair work, turn the key switch to the OFF position, disconnect the battery connector, discharge all connectors and record the places of the harness connections before disassembly.

When disconnecting the connector, hold the connector housing and plug and unlock the connector. Holding the case can cause damage to the inside card, while holding the cable can cause wire breakage.

Figure 129. Pump controller CNA external connector

The pump controller uses one connector: •

CNA 23 poles connector

Contact 0.5 – 1.25 mm2 for the CNA connector.

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Service Manual

8.3.7.1 CNA external connector CONNECTION

DESCRIPTION

A1 KEY (XA2A/1) (Keyline input)

Connected to the battery positive through a 10 A fuse.

A3 CPOT (XA2A/3) (EMCY state X12/5)

Emergency state input.

A4 DI1 (XA2A/4) (Battery lock XS35/2)

Battery lock state.

A5 DI1 (XA2A/5) (Seat belt XS21/2)

Seat belt state.

A7 ENCA (XA2A/7) (Motor encoder channel A XM2/3)

Pump motor encoder channel A.

A8 PENC (XA2A/8) (Motor encoder supply XM2/1)

Positive supply of +12 V for the pump motor encoder.

A9 -BATT (XA2A/9) (GND XA2A/11)

Ground connection.

A10 CPOTBR (XA2A/10) (Eco mode X12/6)

Eco mode switch.

A11 SAFETY IN (XA2A/11) (Safety chain in XA2A/9)

Safety chain input.

A14 ENCB (XA2A/14) (Motor encoder channel B XM2/2)

Pump motor encoder channel B.

A15 ENC GND (XA2A/15) (Encoder GND XM2/4)

Pump motor encoder ground.

A16 NLC (XA2A/16) (Auxiliary output)

Operation warning buzzer and warning light output.

A17 PLC/PB (XA2A/17) (Positive supply)

Positive supply for the operation warning buzzer and warning light.

A18 NEB (XA2A/18) (Fan control)

PWM signal to the cooling fans.

A19 SAEFTY OUT (XA2A/19) (Safety output XA1A/11)

Safety output.

A20 CAN-L (XA2A/20) (CAN bus low)

Low signal of CAN bus.

A21 CAN-H (XA2A/21) (CAN bus high)

High signal of CAN bus.

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Service Manual

CONNECTION

DESCRIPTION

A22 PTHERM (XA2A/22) (Motor temperature sensor supply XM2.1/2)

The positive supply of the pump motor temperature sensor.

A23 NTHERM (XA2A/23) (Motor temperature sensor GND XM2.1/1)

Pump motor temperature sensor ground.

8.3.7.2 Description of the power connections CONNECTION

DESCRIPTION

-B

Negative of the battery.

Positive of the battery.

-P

Negative of the pump motor.

U; V; W

Connection bars of the three motor phases.

The correct tightening torque for the traction controller terminal bolts is 13 – 15 Nm (+/-1.4 Nm).

8.3.8

Steering controller

This forklift truck is equipped with the EPS AC-0 AMPSEAL Controller, which performs the steering functions that are usually present in walkie and ride-on pallet trucks, stackers and low level order pickers. The controller can perform the following functions: •

Steering controller for AC asynchronous 3-phase motors

•

Digital control using two microprocessors

•

CAN bus interface

•

Both microprocessors CAN bus connected

•

Encoder interface

•

Stepper motor or twin pot interface

•

Analogue feedback pot interface (1,024 steps resolution)

•

Analogue KTY84-130 temperature sensor input

•

Analogue input with 1,024 steps resolution (one input)

•

Analogue input with 4,096 steps resolution (one input)

•

Two digital inputs

•

Double safety relay inside

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8.3.9

Service Manual

Steering controller connectors CAUTION

When disconnecting the connector, hold the connector housing and plug and unlock the connector. Holding the case can cause damage to the inside card, while holding the cable can cause wire breakage.

Figure 130. Steering controller CNA external connector

The steering controller uses one connector: •

CNA 23 poles connector

Contact 0.5 – 1.25 mm2 for the CNA connector.

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Service Manual

8.3.9.1 CNA external connector CONNECTION

DESCRIPTION

A3 CHA (XA3A/3) (encoder channel A)

A channel of the steering motor encoder.

A4 CHB (XA3A/4) (encoder channel B)

B channel of the steering motor encoder.

A5 GND (XA3A/5) (encoder GND)

Ground for the steering motor encoder.

A6 PTHM (XA3A/6) (temperature sensor input)

Input for the motor temperature sensor.

A7 GND (XA3A/7) (temperature sensor GND)

Ground for the motor temperature sensor.

A8 GND (XA3A/8) (QL channel GND)

Ground for the steering wheel QL channel.

A9 PCOIL (XA3A/9) (brake supply)

Brake supply (single safety contact).

A11 SW1 (XA3A/11) (reference sensor 90 degrees)

Steering reference sensor 90 degree switch.

A12 SW2 (XA3A/12) (reference sensor 0 degrees)

Steering reference sensor 0 degree switch.

A15 KEY-IN (XA3A/15) (key)

Key line supply for EPS.

A16 VCC2 (XA3A/16) (encoder supply)

Supply for the motor encoder.

A17 QL (XA3A/17) (QL channel)

Steering wheel QL channel.

A19 GND (XA3A/19) (GND)

Ground for the steering wheel DL channel.

A20 DL (XA3A/20) (DL channel)

Steering wheel DL channel.

A22 CANH (XA3A/22) (CANH)

High signal of CAN bus.

A23 CANL (XA3A/23) (CANL)

Low signal of CAN bus.

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Service Manual

8.3.9.2 Description of the power connections CONNECTION

DESCRIPTION

-B

Negative of the battery.

Positive of the battery.

-P

Negative of the pump motor.

U; V; W

Connection bars of the three motor phases.

The correct tightening torque for the steering controller terminal bolts is 2.5 – 3 Nm (+/-1.4 Nm).

8.3.10

Fuses

Figure 131. Fuses of the basic truck (without cabin)

1. 2. 3. 4. 5. 6. 7.

Start circuit fuse Start circuit fuse Traction motor fuse Pump motor fuse Steering motor fuse Brake circuits fuse Valve circuits fuse

Revision: C

8. 9. 10. 11. 12. 13. 14.

Controller key circuits fuse Controller circuits fuse DC-DC converter supply fuse Horn circuits fuse Seat heating fuse (MSG75) 12 V supply fuse Service socket

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Service Manual

Table 8. Fuses of the basic truck (without cabin) LOCATION

RATING

DESCRIPTION

1F1

10 A

Start circuit fuse

1F2

10 A

Start circuit fuse (for the key switch)

2F1

300 A

Traction motor fuse

3F1

300 A 350 A

10kW Pump motor fuse 14kW Pump motor fuse

4F1

40 A

Steering motor fuse

5F1

10 A

Brake circuits fuse

6F1

10 A

Valve circuits fuse

7F1

10 A

Controller key circuits fuse

8F1

10 A

Controller circuits fuse

9F1

10 A

DC-DC converter supply fuse

10F1

12 A

Horn circuits fuse

11F1

10 A

Seat heating

12F1

10 A

12 V supply fuse

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8.3.11

Service Manual

Additional fuses with the cabin

Figure 132. Fuses of the cabin truck

1. 2. 3. 4. 5.

Cabin heater power circuit 1 Cabin heater power circuit 2 Cabin heater control circuit Front window heater Left side window heater

6. 7. 8. 9.

Right side window heater Door window heater Heater blower Roof window wiper

Table 9. Fuses of the cabin truck LOCATION

RATING

DESCRIPTION

21F1

30 A

Cabin heater power circuit 1

22F1

30 A

Cabin heater power circuit 2

23F1

10 A

Cabin heater control circuit

25F1

10 A

Front window heater

25F2

10 A

Left side window heater

25F3

10 A

Right side window heater

25F4

10 A

Door window heater

26F1

15 A

Heater blower

27F1

10 A

Roof window wiper

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8.4

Service Manual

Motor compartment

Figure 133. Motor compartment overview

1. 2. 3.

Magnetic brake Traction motor Steering motor

8.4.1

4. 5.

HALL sensor Steering motor HALL sensor

Traction motor

Type

3-phase AC

Voltage

30 V

Output power

7.5 kW

Electrical wiring

3 x M8 bolt terminals,1 x 2 and 4 poles connectors

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Service Manual

Figure 134. Traction motor overview

NOTE: The correct tightening torque for the traction motor power terminals is 8 Nm (±1.0 Nm).

8.4.1.1 Remove the traction motor 1. Remove the machinery cover. For instructions, see Section 5.7.1. 2. Open the machinery top cover. For instructions, see Section 5.7.4. 3. Remove the screws that hold the mounting bracket of the motor fan in place. 4. Remove the mounting bracket and the motor fan.

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Service Manual

5. Disconnect the motor connectors. 6. Disconnect the power cables of the motor.

7. Remove the screws that connect the traction motor to the transmission gear. 8. Remove the traction motor.

8.4.1.2 Lubricate the traction motor axle splines

NOTE: The correct lubricant is Molykote BR2 Plus.

NOTE: Do not mix different lubricants. It is possible that different brands of lubricants are not be compatible with each other. Only use lubricants recommended by the manufacturer.

1. Remove the traction motor, see Section 8.4.1.1.

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Service Manual

2. Apply Molykote BR2 Plus to the traction motor axle splines.

8.4.1.3 Temperature sensor check The temperature sensor is located inside the motor and cannot be changed. The condition of the temperature sensor can be verified with a multimeter. Measure the resistance between the traction motor connector pins XM1.1/1 and XM1.1/2. The value should be ~580 Ω.

Figure 135. Sensor resistance as a function of ambient temperature and operating current

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Service Manual

8.4.1.4 HALL sensor Type

HALL sensor

4.5 – 24 Vdc

Output signal

64 ppr

Electrical wiring

4-wire, Vs = RED wire, GND = BLK wire, signal output A = WHT & signal output B = BLU

Figure 136. HALL sensor overview

Replace the HALL sensor

1. Remove the socket screw. 2. Disconnect the connector.

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Service Manual

3. Disconnect the wires from the sensor connector. Note the pin location of each wire. 4. Remove the HALL sensor.

5. 6. 7. 8.

Install the new HALL sensor. Connect the wires to the sensor connector. Connect the sensor connector. Install and tighten the socket screw.

8.4.2

Steering motor

Type

3-phase AC

Voltage

30 V

Output power

0.4 kW

Electrical wiring

3 x M8 bolt terminals,1 x 2 and 4 poles connectors

Figure 137. Steering motor overview (0.4 kW)

NOTE: The correct tightening torque for the steering motor power terminals is 5.4 Nm (±10%).

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Service Manual

8.4.2.1 Remove the steering motor 1. Remove the machinery cover. For instructions, see Section 5.7.1. 2. Open the machinery top cover. For instructions, see Section 5.7.4. 3. Remove the steering motor power cables. 4. Disconnect the connectors of the steering motor.

5. Remove the screws holding the steering motor in place. 6. Remove the steering motor.

8.4.2.2 Temperature sensor check The temperature sensor is located inside the motor and cannot be changed. The condition of the temperature sensor can be verified with a multimeter. Measure the resistance between the traction motor connector pins XM3.1/1 and XM3.1/2. The value should be ~580 Ω.

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Service Manual

Figure 138. Sensor resistance as a function of ambient temperature and operating current

8.4.2.3 HALL sensor

Figure 139. HALL sensor overview

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Service Manual

Table 10. HALL sensor Type

HALL sensor

4.5 – 24 Vdc

Output signal

64 ppr

Electrical wiring

4-wire Pin 1, RED = Sensor supply Pin 2, BRN = Channel A Pin 3, BLK = Channel B Pin 4, ORA = Sensor GND

Table 11. HALL sensor wire details PIN

WIRE COLOR

DESCRIPTION

Red

Sensor supply

BRN

Channel A

BLK

Channel B

ORA

Sensor GND

Replace the HALL sensor

1. Remove the screws that hold the HALL sensor in place. 2. Remove connector from the connector holder.

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Service Manual

3. Disconnect pins from the connector. 4. Remove the HALL sensor.

To install the HALL sensor, repeat the steps in the reverse order.

8.4.3

Magnetic brake

Figure 140. Magnetic brake overview

1. 2. 3.

Inductor Friction disc Hub

4. 5. 6.

Flange Assembly screw Adjusting screw

Applying voltage to the brake coil generates a magnetic force that acts on the friction disk. The friction disc is pulled via the air gap against the pressure of the springs. The rotor is released and the brake torque is neutralized.

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Service Manual

8.4.3.1 Coil resistance measurement Use a multimeter to measure the brake coil resistance. The coil resistance has to be measured between the brake wires. The value must be ~31 Ω.

8.4.3.2 Install the magnetic brake

NOTE: The new magnetic brake is delivered completely assembled and adjusted.

1. Place a key into the brake shaft. 2. Slide the hub into the shaft and secure it axially. Make sure that the direction of the hub is correct.

3. Slide the rest of the brake parts onto the hub. Do not damage the splines of the disk. Also, make sure that the disk sits properly on the splines of the hub. 4. Install and tighten the fitting screws to 22 Nm. Secure the fitting screws using thermoplastic liquid (for example, Loctite 270).

5. Make sure that the brake disk rotates freely.

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Service Manual

6. Switch the truck on and drive forward and backward a few times. 7. Measure the air gap of the magnetic brake. Adjust the air gap, if needed. For instructions, see Section 8.4.3.3. CAUTION Do not apply grease on the guiding splines of the friction disc or the hub. It changes the performance of the brake.

8.4.3.3 Adjust the air gap of the magnetic brake 1. Jack up the truck so that the traction wheel is lifted off the ground. For the correct lifting points, see Section 5.1. 2. Use the electrical system of the truck to turn the drive unit and the magnetic brake. 3. Make sure that the brake disk rotates freely. 4. Measure the air gap of the magnetic brake. Make sure that the air gap is the same 0.3 mm throughout the magnetic brake. 5. If needed, tighten or loosen the adjustment screws to adjust the air gap of the magnetic brake to 0.3 mm.

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8.4.4

Service Manual

Release the magnetic brake manually

To release the magnetic brake:

Insert two M6x50 screws in to the holes.

2. Turn the screws until the brake disk is released.

To restore the magnetic brake:

1. Loosen the screws until the brake disc is engaged.

2. Remove the screws.

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8.5

Pump motor

8.5.1

Pump motor (Standard model)

Service Manual

Type

3-phase AC

Voltage

30 V

Output power

10 kW

Electrical wiring

3 x M8 bolt terminals,1 x 2 and 4 poles connectors

Figure 141. Pump motor, 10 kW

The correct tightening torque for the pump motor power terminals is 8 Nm (±10%).

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8.5.2

Service Manual

Pump motor (High performance model)

Type

3-phase AC

Voltage

30 V

Output power

14 kW

Electrical wiring

3 x M8 bolt terminals,1 x 2 and 4 poles connectors

Figure 142. Pump motor, 14 kW

The correct tightening torque for the pump motor power terminals is 8 Nm (±10%).

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8.5.3

Service Manual

Replace the pump motor

1. Remove the machinery cover, see Section 5.7.1. 2. Open the machinery top cover, see Section 5.7.4. 3. Disconnect the hydraulic hoses. Note that the oil tank drains through the hose, when you disconnect it from the pump motor. 4. Disconnect the power cables of the pump motor. 5. Disconnect the connectors of the pump motor.

6. Remove the 4 screws from the attachment plate. 7. Remove the pump motor.

To install the pump motor, do the steps in the opposite order.

8.5.4

Lubricate the pump axle splines

Lubricate the pump axle splines every two years. With regular lubrication, you can prevent corrosion and make sure that the pump axle splines are always correctly lubricated.

NOTE: The correct lubricant is Molykote BR2 Plus (NLGI. No. 2 grade).

NOTE: Do not mix different lubricants. It is possible that different brands of lubricants are not be compatible with each other. Only use lubricants recommended by the manufacturer.

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Service Manual

To lubricate, the pump axle splines:

1. Remove the pump motor from the truck, see Section 8.5.3. 2. Remove the 2 screws that attach the pump to the pump motor. 3. Remove the pump.

4. Apply Molykote BR2 Plus lubricant to the pump axle splines.

5. Install the pump to the pump motor with 2 screws. 6. Install the pump motor to the truck.

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8.5.5

Service Manual

Replace the HALL sensor

1. Remove the socket screw. 2. Disconnect the sensor connector.

3. Disconnect the wires from the sensor connector. Note the pin location of each wire. 4. Remove the HALL sensor.

5. 6. 7. 8.

Install the new HALL sensor. Connect the wires to the sensor connector. Connect the sensor connector. Install and tighten the socket screw.

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8.6

Sensors

8.6.1

Steering wheel sensor

Service Manual

Figure 143. Steering wheel sensor overview

Electrical steering helps the operator to steer the vehicle by augmenting the steering effort of the steering wheel. The electric motor adds controlled energy to the steering mechanism, so the operator needs only a modest effort to turn the truck. Electric steering helps considerably when the vehicle is stopped or moving slowly. The steering wheel has no direct mechanical connection to the traction wheel. The steering motor actuates the rotation of the traction wheel. When the steering is turned to the right or left, the steering wheel sensor informs the steering controller that the steering wheel is turned. The controller starts to turn the steering mechanism with the steering motor. There are two feedbacks devices; the HALL sensor bearing in the steering motor and two reference sensors, which provides feedback information to the controller. With this information, the controller knows the actual position of the turned wheel and can handle the steering movements carefully.

8.6.1.1 Steering wheel sensor functionality check Measure the coil resistance: measure the resistance between the connector X11/ 1–2 pins and X11/ 3-4 pins. The correct value is ~29Ω. Measure the ground leakage: measure the resistance between the X11/1 (or X11/3) and steering wheel frame. The correct value is ~∞Ω. If the values do not match the above, replace the steering wheel sensor.

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Service Manual

8.6.1.2 Steering control safety circuit check Test the operation of the steering control safety circuit every 1,000 h or once a year: Standard models 1. Jack the truck up so that the traction wheel is lifted off the ground. For the correct lifting points, see Section 5.1. 2. Open the instrument panel and lift it up, see Section 5.7.5. 3. Locate the steering wheel sensor connector X11 in the access hole under the instrument panel, see Figure 144. 4. Turn the start switch to the ON position. 5. Use the electrical system of the truck to release the magnetic brake and to run the drive unit at a low speed. 6. Disconnect the steering wheel sensor connector X11. This makes the magnetic brake to engage and the running of the truck stops immediately. If the magnetic brake does not engage, the safety circuit may be defected. Examine the steering controller and its wiring. 7. Replace the controller, if necessary. To return the truck to normal state: 1. Turn the start switch to the OFF position. 2. Connect the steering wheel sensor connector X11. 3. Push the instrument panel down and close the lock. Narrow models 1. Jack the truck up so that the traction wheel is lifted off the ground. For the correct lifting points, see Section 5.1. 2. Remove the control panel, see Section 5.7.8. 3. Locate the steering wheel sensor connector X11 in the access hole under the instrument panel, see Figure 144. 4. Turn the start switch to the ON position. 5. Use the electrical system of the truck to release the magnetic brake and to run the drive unit at low speed. 6. Disconnect the steering wheel sensor connector X11. This makes the magnetic brake to engage and the running of the truck stops immediately. If the magnetic brake does not engage, the safety circuit may be defected. Examine the steering controller and its wiring. 7. Replace the controller, if necessary.

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Service Manual

To return the truck to normal state: 1. Turn the start switch to the OFF position. 2. Connect the steering wheel sensor connector X11. 3. Assemble the control panel in reverse order.

Figure 144. Connector X11

8.6.2

Steering reference sensor

Type

Inductive proximity sensor

Size

M18x1 cylindrical, length 67 mm

10 - 60 Vdc

Switching output

NPN, NO

Electrical wiring

M12 connector / DC 3-wire, Vs = BRN, GND = BLU, signal output = BLK

Sensing range

6 mm

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Service Manual

Figure 145. Steering reference sensor overview

8.6.2.1 Steering reference sensor functionality check 1. Connect the supply voltage between the brown (+) and blue (-) wires. 2. Measure the supply voltage between the wires. The value should be +48 Vdc. 3. Measure the voltage between the blue (-) and black (output) wires. When a supply is connected and there are no metallic objects within the sensing range, the value is the same as the supply +48 Vdc. When a metallic object is moved within the sensing range, the value is approximately 0 Vdc. 4. If the values do not match the above, replace the sensor.

8.6.3

Reach end stop, retract limit, retract end stop and reach limit switch

Type

Inductive proximity sensor

Size

M12x1 cylindrical, length 46 mm

10 - 60 Vdc

Switching output

PNP, NO

Electrical wiring

M12 connector / DC 3-wire, Vs = BRN, GND = BLU, signal output = BLK

Sensing range

8 mm

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Service Manual

Figure 146. Reach end stop, retract limit, retract end stop and reach limit switch overview

8.6.3.1 Reach end stop, retract limit, retract end stop and reach limit switch functionality check 1. Connect the supply voltage between the brown (+) and blue (-) wires. 2. Measure the supply voltage between the wires. The value should be +48 Vdc. 3. Measure the voltage between the blue (-) and black (output) wires. When a supply is connected and there are no metallic objects within the sensing range, the value is approximately 0 V. When a metallic object is moved within the sensing range, the value is the same as the supply voltage, i.e. +48 Vdc. 4. If the values do not match the above, replace the sensor.

8.6.4

Battery lock sensor

Type

Inductive proximity sensor

Size

Rectangular, 6 mm x 10 mm x 27 mm

10 - 30 Vdc

Switching output

NPN, NO

Electrical wiring

DC 3-wire, Vs = BRN, GND = BLU, Signal output = BLK

Sensing range

0 – 4 mm

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Service Manual

Figure 147. Battery lock sensor overview

8.6.4.1 Battery lock sensor functionality check 1. Connect the supply voltage between the brown (+) and blue (-) wires. 2. Measure the supply voltage between the wires. The value should be +24 Vdc. 3. Measure the voltage between the blue (-) and black (output) wires. When a supply is connected and there are no metallic objects within the sensing range, the value is the same as the supply, +24 Vdc. When a metallic object is moved within the sensing range, the value is approximately 0 Vdc. 4. If the values do not match the above, replace the sensor.

8.6.5

Pressure sensor

The pressure sensor is used for monitoring the hydraulic pressure of the hydraulic system. With this sensor, the traction controller can adjust the driving speed according to the lifted load. The pressure sensor has an output signal of 1–5 Vdc in the range of 0250 bar oil pressure. Type

Pressure sensor

8 - 36 Vdc

Output signal

1 - 5 Vdc

Electrical wiring

1 = L+ (supply), 2 = OUT (output signal), 3 = M (GND)

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Service Manual

Figure 148. Pressure sensor overview

8.6.5.1 Pressure sensor functionality check 1. Lower the forks to their lowest position to minimize the oil pressure of the hydraulic system. 2. Measure the output signal voltage level with a multimeter between the signal output terminal (XB42/2) and the negative terminal (XB42/1). The nominal output signal level is ~1 Vdc when the hydraulic pressure is 0 bar. The output signal level rises relatively to the hydraulic oil pressure and with the maximum load (2,000 kg) the value is close to 4 Vdc. 3. If the pressure sensor values do not match the above, replace the sensor.

8.6.6

Height reference sensor

Type

Magnetic reed switch

Size

Rectangular, 9 mm x 13 mm x 44 mm

0 - 250 VAC

Switching output

1 bistable contact with S-actuating magnet

Electrical wiring

DC 2-wire, BRN and WHT

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Service Manual

Figure 149. Height reference sensor overview

8.6.6.1 Height reference sensor functionality check 1. Measure at the resistance area that the contacts inside the magnetic reed switch are not stuck together. Connect the multimeter between the brown and white wires. When an actuating magnet is moved into the sensor sensing range, the value on the multimeter should change from 0 to ~∞Ω or vice versa. 2. If the values do not match the above, replace the sensor.

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Service Manual

Electric system adjustments and measurements 9.1

Calibrate the arm rest levers

After you have replaced a sensor in the arm rest, you must calibrate the levers. For instructions on how to calibrate the levers, see the instructions of TruckTool.

NOTE: When you calibrate the arm rest, the arm rest connector must be connected to the truck.

9.2

Insulation resistance test

9.2.1

Test voltage

The insulation resistance of the truck and the traction battery is tested separately. The test voltage is greater than the nominal voltage but no more than 100 V or three times the nominal voltage: NOMINAL VOLTAGE

TEST VOLTAGE

Up to 24 V

50 V

Over 36 V

100 V

9.2.2

Insulation tester check

Connect the test probe to the frame of the truck (for example, to a non-painted bolt or bracket) and the other test probe to another bolt or bracket. The tester should show a zero value.

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Service Manual

Figure 150. Insulation tester check

9.2.3

Measure the insulation resistance

The test is performed with the battery disconnected from the truck. All the electrical components must be in place. 1. Release the emergency stop and turn the key switch to the ON position. 2. Connect the test probe to the frame of the truck (for example, to a non-painted bolt or bracket) and the other test probe to the positive terminal of the battery connector. 3. Read the resistance value. 4. Measure and read the negative terminal of the battery connector in the same way.

9.2.3.1 Insulation resistance of the truck

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Service Manual

The insulation resistance between the live parts of all the electric components and the frame of the industrial truck with the exception of the battery is at least 1000 Ω multiplied by the nominal voltage of the truck system. NOMINAL VOLTAGE

MINIMUM INSULATION RESISTANCE

24 V

24,000 Ω

36 V

36,000 Ω

48 V

48,000 Ω

80 V

80,000 Ω

9.2.3.2 Insulation resistance of the battery

Figure 152. Measure the insulation resistance of the battery

The insulation resistance of the disconnected, filled and charged traction battery mounted on the truck is at least 50 Ω multiplied by the nominal voltage of the truck system between the live parts and the frame of the truck. If the battery is fitted into more than one container, this test is carried out with the electrically-connected sections (including metal battery containers). NOMINAL VOLTAGE

MINIMUM INSULATION RESISTANCE

24 V

1,200 Ω

36 V

1,800 Ω

48 V

2,400 Ω

80 V

4,000 Ω

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Service Manual

Hydraulic operation This chapter presents the hydraulic operation of the truck. CAUTION Hydraulic oil is hazardous waste that must be disposed of accordingly.

Only use clean hydraulic oil. Dirt in the hydraulic system can cause problems in the functionality of the truck.

Always wear protective gloves when you handle hydraulic oil.

If the truck has been operated recently, the hydraulic oil can be hot. Be careful of the hot hydraulic oil.

Note that there can be pressure in the hydraulic system. Verify that hydraulic system is in rest, there is no load on the forks and hydraulic attachments are on their end-rest position or otherwise supported. Open the connections carefully!

Use a clean cloth or other applicable plug to seal open connections.

Only use clean oil in the hydraulic system. Always fill the oil through the oil filter.

Make sure that you have the appropriate version of the hydraulic schematic diagram for the truck model under maintenance. Contact your supplier or technical support for information on obtaining up to date documentation for your truck model.

The hydraulic schematic diagram shown in Figure 153 illustrates the operation of the hydraulic system.

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Service Manual

Figure 153. Hydraulic system overview

1. 2. 3. 4.

Lift/lower (Free lift) Lift/lower (Main lift) Reach function Tilt function

5. 6. 7. 8.

Sideshift Auxiliary Emergency lowering valve AV6288 without A4/B4-valve block section

Table 12. Hydraulic system in standard and high performance models STANDARD MODELS

HIGH PERFORMANCE MODELS

Electric motor

10 kW

14 kW

Motor type

3-ph AC

Pump size

16 cc/rev

19 cc/rev

Pump type

External gear pump

Tank V

Max. 38 l

Suction filter

• •

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Service Manual

STANDARD MODELS

HIGH PERFORMANCE MODELS

Return filter

• • •

Draining hose

10my Qmax: 165 lpm Built in breather

The principle of the hydraulic operation of the truck is as follows: Lifting: 1. The electrical motor operates the hydraulic gear pump. 2. The hydraulic oil is pressurized. 3. The maximum oil pressure is limited by relief valve. In case of overpressure, relief valve opens and returns the oil flow to the tank. The opening pressure of the relief valve is set by factory depending on the nominal lift capacity of the truck. 4. The pressurized hydraulic oil flows through the check valve to the lifting cylinder. When the lifting valve coil is energized the valve is opened. The pressurized oil flows through the check valve and opened lifting valve to the lifting cylinder. 5. The lifting cylinder piston lifts the forks.

Figure 154. Hydraulic oil flow during lifting

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Service Manual

Lowering 1. The solenoid valve is opened with the lowering switch. 2. Load on the cylinder pressurizes the oil. The oil flows through the lowering valve and pressure compensator to the return filter, and from there back to the tank. 3. As the hydraulic pressure reduces, the lifting cylinder piston retracts and the forks are lowered.

Figure 155. Hydraulic oil flow during lowering

NOTE: Different truck models can have different hydraulic system configurations.

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10.1

Service Manual

Hydraulic symbols

SYMBOL

DESCRIPTION Double acting cylinder

Plugged measuring point

Check valve

300 μ sieve

Solenoid valve

Hydraulic pump driven with electric motor

Adjustable relief valve

Hydraulic oil tank filling hole

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10.2

Service Manual

Hydraulic oil recommendations CAUTION

Make sure that you fill the hydraulic oil tank on level ground.

Clean the filler hole to make sure that no dirt falls into the hydraulic oil tank.

Make sure that you do not fill the hydraulic oil tank too much.

If you spill hydraulic oil, clean the spilled oil immediately.

Hydraulic oil is hazardous waste that must be disposed of accordingly.

Normal operating conditions

ISO VG 32

Cold storage

ISO VG 15

Hot temperatures

ISO VG 46

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Service Manual

Fill the hydraulic oil tank up to the volume according to Table 13 below. The filling hole for hydraulic oil is shown in Figure 156 below.

Figure 156. Hydraulic oil tank

1. 2.

Indicator line 1 (20 L) Indicator line 2 (25 L)

3. 4.

Indicator line 3 (30 L) Indicator line 4 (35 L)

Table 13. Hydraulic oil tank volume INDICATOR LINE

VOLUME

LIFTING HEIGHT

20 L

Reserved for an option

25 L

4,800 mm − 8,500 mm

30 L

8,501 − 11,500 mm

35 L

Over 11,501 mm

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10.3

Service Manual

Maintenance points of the hydraulic system

When you change the hydraulic oil, change the hydraulic oil return filter (sieve) at the same time. Clean the hydraulic oil suction filter (sieve) in the hydraulic oil tank when it is dirty. CAUTION Hydraulic oil is hazardous waste that must be disposed of accordingly.

Only use clean hydraulic oil. Dirt in the hydraulic system can cause problems in the functionality of the truck.

Always wear protective gloves when you handle hydraulic oil.

If the truck has been operated recently, the hydraulic oil can be hot. Be careful of the hot hydraulic oil.

Use a clean cloth or other applicable plug to seal open connections.

Only use clean oil in the hydraulic system. Always fill the oil through the oil filter.

10.3.1

Replace the hydraulic oil return filter (sieve) CAUTION

The used hydraulic oil return filter (sieve) is dangerous waste and must be discarded accordingly.

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Service Manual

1. Open the cap of the hydraulic oil tank. 2. Remove the hydraulic oil return filter (sieve).

3. Insert a new hydraulic oil return filter (sieve). 4. Close the cap of the hydraulic oil tank.

10.3.2

Clean the hydraulic oil suction filter

NOTE: Clean the hydraulic oil suction filter only when it is dirty.

1. Drain the hydraulic oil tank fully.

2. Disconnect the suction hose.

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Service Manual

3. Remove the hydraulic oil suction filter (sieve)

4. 5. 6. 7.

10.4

Clean the hydraulic oil suction filter (sieve). Insert the hydraulic oil suction filter back to the hydraulic oil tank. Connect the suction hose. Fill the hydraulic oil tank, see Table 13.

Hydraulic system CAUTION

Only use clean hydraulic oil. Dirt in the hydraulic system can cause problems in the functionality of the truck.

Always wear protective gloves when you handle hydraulic oil.

If the truck has been operated recently, the hydraulic oil can be hot. Be careful of the hot hydraulic oil.

CAUTION Use a clean cloth or other applicable plug to seal open connections.

Only use clean oil in the hydraulic system. Always fill the oil through the oil filter.

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Service Manual

Figure 157. Hydraulic system overview

1. 2. 3. 4.

Hydraulic oil tank Suction hose Pressure hose Oil returning hose

5. 6. 7. 8.

Oil filter (filling cap) Breather Pump Pump motor

The hydraulic system consists of an electric pump motor, hydraulic gear pump unit, hydraulic oil tank, suction filter, relief valve, solenoid valve, hydraulic oil hoses and connections for the hydraulic equipment. The hydraulic system is used to control the load handling device.

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10.4.1

Service Manual

Disassemble the hydraulic system WARNING

Prepare a drip pan to catch any remaining oil in the pipes and hoses before disconnecting each pipe. Take appropriate actions to prevent dust and dirt from entering the opening of the pipe and valve connections.

1. Remove the machinery cover. For instructions, see Section 5.7.1. 2. Open the machinery top cover. For instructions, see Section 5.7.4. 3. Remove the hydraulic oil hoses.

4. Disconnect the power cables of the hydraulic system. 5. Disconnect the connectors of the hydraulic system.

6. Remove the screws that attach the platform of the hydraulic system to the truck. 7. Remove the platform and the hydraulic system.

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10.5

Service Manual

Hydraulic valve unit CAUTION

When working on the hydraulic valves and connectors, avoid getting any dirt into the connectors or valves. Dirt in the hydraulic system often causes problems in the functionality of the truck.

Figure 158 shows the spare parts of the hydraulic valve unit. Note that during maintenance, you are only allowed to replace spare parts shown in the figure. Replacing other spare parts can break the hydraulic valve unit.

NOTE: The intermediate unit and the solenoid coils and the flange unit and the solenoid coils can also be replaced as single units.

Figure 158. Spare parts of the hydraulic valve unit

1. 2. 3.

Seal kit Lowering valve. Electric, hydraulically piloted valve (Proportional) Lifting valve. Electric, hydraulically piloted poppet valve (ON/OFF)

Revision: C

4. 5. 6. 7. 8.

Relief valve Intermediate unit Flange unit Solenoid coil 24 V, 24.6 Ω Solenoid coil 7.5 Ω, 0-1,800 mA

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Service Manual

Figure 159. Hydraulic valve unit overview

1. 2. 3. 4. 5. 6.

Lowering valve Lifting valve Reach backward valve Reach forward valve Tilt down valve Tilt up valve

Revision: C

7. 8. 9. 10. 11. 12.

Sideshift left valve Sideshift right valve Auxiliary hydraulics valve 1 Auxiliary hydraulics valve 2 Relief valve Emergency lowering valve

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Service Manual

Table 14. Valve connections in the hydraulic valve unit CONNECTION

DESCRIPTION

Lowering valve

Lifting valve

Reach backward valve

Reach forward valve

Tilt down valve

Tilt up valve

Sideshift left valve

Sideshift right valve

Auxiliary hydraulics valve 1

M10

Auxiliary hydraulics valve 2

10.5.1

Valve M1

Hydraulic solenoid valves control the flow of the hydraulic oil. The hydraulic system uses solenoids to control the flow of oil to the cylinders. Table 15. Valve M1 Type

Solenoid

Contact rating

0-750 mA

Electrical wiring

2-pole sealed connector

Valve functionality check: Measure the resistance between the solenoid terminals. The resistance should be ~25 Ω.

10.5.2

Valve M3, M4, M7 and M8

Hydraulic solenoid valves control the flow of hydraulic oil. The hydraulic system uses solenoids to control the flow of oil to the cylinders.

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Service Manual

Table 16. Valve M3, M4, M7 and M8 Type

Solenoid

Contact rating

0-1,800 mA

Electrical wiring

2-pole sealed connector

Valve functionality check: Measure the resistance between the solenoid terminals. The resistance should be ~7.5 Ω.

10.5.3

Valve M2, M5, M6, M9 and M10

Hydraulic solenoid valves control the flow of hydraulic oil. The hydraulic system uses solenoids to control the flow of oil to the cylinders. Table 17. Valve M2, M5, M6, M9 and M10 Type

Solenoid

Contact rating

24 Vdc

Electrical wiring

2-pole sealed connector

Valve functionality check: Measure the resistance between the solenoid terminals. The resistance should be ~25 Ω.

10.5.4

Emergency lowering valve

The emergency lowering valve is operated manually to bypass the M1-M6 valves and lower the mast in a controlled manner.

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10.5.5

Service Manual

Set the lifting pressure CAUTION

The pressure setting is set by the manufacturer and it should not be changed.

1. Loosen the locking nut of the pressure setting.

2. Start lifting the forks above the freelift area with nominal load.

3. Adjust the pressure setting so that the load rises easily.

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Service Manual

4. Tighten the locking nut of the pressure setting.

10.5.6

Disassemble the valves

1. Open the nut at the end of the valve. 2. Pull the coil of the valve out. 3. Use pliers or a similar tool to screw the valve stem out.

To assemble the valves, repeat the steps in reversed order.

NOTE: During reassembly, manually tighten the nut at the end of the valve. Do not tighten the nut too much!

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Service Manual

TruckTool Diagnostics Software maintenance can be performed with a diagnostics application called TruckTool. This program runs on a laptop PC and connects to the data bus of the truck (CAN) via a special adapter and wiring harness. TruckTool can be used to receive, display and modify settings, update (flash) controller firmware, reset settings to hardware defaults, review and clear alarms, perform calibrations, execute a quick truck setup and monitor digital and analogue inputs and outputs. Additional training is required to use the program.

Figure 160. TruckTool Diagnostics

For more information, see https://www.trucktool-online.com/

11.1

Location of the service socket

The location of the service socket for connecting TruckTool to the truck.

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Service Manual

Figure 161. Location of the service socket

11.1.1

Connect TruckTool to the service socket

The service socket is behind the fuse cover. You must open the cover before you can connect TruckTool to it.

1. Open the fuse cover.

2. Connect TruckTool to the service socket.

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Service Manual

Parameter descriptions CAUTION Always use the correct parameter list for the specific model you are servicing. See the latest TruckTool version for the latest parameter set.

12.1

VCM master

Table 18. VCM controller parameters PARAMETER

DESCRIPTION

Aux hydraulics, Pump, Ramp, Acceleration ramp ACC DELAY AUX

The pump acceleration ramp when using auxiliary hydraulics.

Aux hydraulics, Pump, Ramp, Deceleration ramp DEC DELAY AUX

The pump deceleration ramp when using auxiliary hydraulics.

Aux hydraulics, Speed, Maximum speed AUX MAX SPD

The maximum pump speed for an auxiliary hydraulic function.

Aux hydraulics, Speed, Minimum speed AUX MIN SPD

The minimum pump speed for an auxiliary hydraulic function.

Aux hydraulics, Valve, A2 PWM PWM ON EV2

The PWM value on the coil of the auxiliary hydraulics A1 valve.

ECO, Lift, Ramp, Acceleration ramp above freelift E ACCEL DLY LFT2

Eco mode parameter. The pump acceleration ramp on lift function, when the lifting carriage is above the free lift area.

•

• ECO, Lift, Ramp, Acceleration ramp on freelift area E ACC. DELAY LFT

Revision: C

Smaller value = faster deceleration

Smaller value = faster acceleration

Eco mode parameter. The pump acceleration ramp on lift function, when the lifting carriage is in the free lift area. •

ECO, Lift, Ramp, Deceleration ramp above freelift E DEC DELAY LFT2

Smaller value = faster acceleration

Eco mode parameter. The second part of the deceleration curve (a deceleration smoothening parameter).

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Service Manual

PARAMETER

DESCRIPTION

ECO, Lift, Ramp, Deceleration ramp on freelift area E DEC. DELAY LFT

Eco mode parameter. The pump deceleration ramp on the lift function.

ECO, Lift, Ramp, Slow down ramp E LIFT DECEL

Eco mode parameter. The deceleration ramp when the end value is a non-zero. This ramp is used when the lift is decelerated from one value to another nonzero value. This parameter is used on the free lift area.

•

Smaller value = faster acceleration

Smaller value = faster deceleration

ECO, Lift, Speed, Maximum speed E LIFT MAX SPEED

The pump maximum speed with the lift function when the truck is in the Eco mode. Applied when the full lift command is given, and no cutbacks are activated.

ECO, Traction, Ramp, Acceleration ramp E ACCELER. DELAY

Eco mode parameter. Acceleration ramp.

ECO, Traction, Ramp, Curve braking ramp E CURVE BREAKING

Eco mode parameter. The curve cutback activation ramp. When the curve cutback is activated, the truck is decelerated to the curve cutback speed via this ramp.

•

• ECO, Traction, Ramp, Inverse braking ramp E INVERS BRAKING

Smaller value = faster acceleration

Smaller value = faster deceleration

Eco mode parameter. The inverse braking ramp is applied when the operator changes the truck driving direction when travelling, and keeps pushing the accelerator pedal. •

Smaller value = faster deceleration

ECO, Traction, Ramp, Pedal braking ramp E PEDAL BRAKING

Eco mode parameter. The braking ramp when the brake pedal is pressed.

ECO, Traction, Ramp, Release braking ramp E RELEASE BRK

Eco mode parameter. The braking ramp when the accelerator pedal is released.

ECO, Traction, Ramp, Speed limit braking ramp E SPD LIMIT BRK

Eco mode parameter. The deceleration ramp when the driving speed reduction is activated or the accelerator pedal is partially released.

•

Revision: C

Smaller value = faster deceleration

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Service Manual

PARAMETER

DESCRIPTION

ECO, Traction, Speed, Cutback speed E CUTBACK SPEED

ECO mode parameter. This parameter sets traction speed in ECO mode when height is above "Traction, Speed, Cutback height 2". Given in percentage of maximum travel speed. •

100% = Full speed.

ECO, Traction, Speed, Maximum speed backwards E MAX SPEED BACK

Eco mode parameter. The maximum driving speed to the backward direction.

ECO, Traction, Speed, Maximum speed forwards E MAX SPEED FORW

Eco mode parameter. The maximum driving speed to the forward direction.

Lift, Ramp, Acceleration ramp ACCEL DELAY LIFT

The pump acceleration ramp on the lift function on the free lift area. •

Smaller value = faster acceleration

Lift, Ramp, Acceleration ramp above freelift ACCEL DELAY LFT2

The pump acceleration ramp on the lift function, when the lifting carriage is above the free lift area.

Lift, Ramp, Deceleration ramp DECEL DELAY LIFT

The pump deceleration ramp on the lift function.

Lift, Ramp, Deceleration smoothening level DECEL DELAY LFT2

The second part of the deceleration curve (a deceleration smoothening parameter).

Lift, Ramp, Slow down ramp at freelift LIFT DECEL

The deceleration ramp when the end value is a non-zero. This ramp is used when the lift is decelerated from one value to another non-zero value. This value is applied in the free lift area.

Lift, Speed, Maximum speed LIFT MAX SPD

The pump maximum speed with the lift function. Applied when the full lift command is given, and no cutbacks are activated.

Lift, Speed, Minimum speed LIFT MIN SPD

Pump absolute minimum speed with the lift function.

Lift, Valve, Maximum current I MAX EVP1

The maximum current of the lifting valve. NOTE: The lifting valve does not affect the lifting speed, so normally, you do not need to adjust this value.

Revision: C

•

Smaller value = faster acceleration

Document ID: 622075-EN

285 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

PARAMETER

DESCRIPTION

Lift, Valve, Minimum current I MIN EVP1

The minimum current of the lifting valve. NOTE: The lifting valve is an ON/OFF type valve. Thus, this parameter does not affect the lifting speed.

Lowering, Valve, Closed current I MIN EVP2 OFF

The current at which the lowering valve is considered closed when closing the valve. This parameter prevents the sharp stop caused by the dynamic friction of the valve.

Lowering, Valve, Maximum current I MAX EVP2

The maximum current of the lowering valve. Given in percentages of the maximum output of the hardware.

Lowering, Valve, Minimum current I MIN EVP2

The minimum current of the lowering valve. Given in percentages of the maximum output of the hardware.

Lowering, Valve, Ramp, Closing ramp end EVP2 CLOSE DELAY

The lowering valve closing ramp between the middle point current and the minimum current.

Lowering, Valve, Ramp, Closing ramp start EVP2 CLS DELAY 2

The lowering valve closing ramp between the maximum current and the middle point current.

Lowering, Valve, Ramp, Middlepoint current I MIDDLE EVP2

The middle point current value for the lowering valve. The current percentage value set by this parameter separates the beginning and the end of the opening and closing curves of the lowering valve.

Lowering, Valve, Ramp, Opening ramp end EVP2 OPN DELAY 2

The lowering valve opening ramp between the middle point current and the maximum current.

Lowering, Valve, Ramp, Opening ramp start EVP2 OPEN DELAY

The lowering valve opening ramp between the minimum current and the middle point current.

N/A, Output CNB:15 PWM value PWM ON EV3

The PWM value on the coil of the auxiliary hydraulics A2 valve.

Reach, Cutback, Height cutback REACH HEIGHT CTB

The reach cutback percentage when the lifting height is above the cutback height 2. The reach speed is linearly scaled between height 1 and height 2 from the full value to the value stated by this parameter.

Reach, Cutback, Load cutback REACH LOAD CTB

The reach speed cutback percentage when the load on the pressure sensor is above the reach cutback load 2.

Reach, Ramp, BW Acceleration ramp ACC DLY REACH IN

The pump acceleration ramp when retracting.

Revision: C

•

Smaller value = faster ramp

Smaller value = faster acceleration

Document ID: 622075-EN

286 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

PARAMETER

DESCRIPTION

Reach, Ramp, BW Acceleration ramp reducted ACC DLY RCH IN 2

The pump acceleration ramp when retracting. This value is applied proportionally to the reach speed between the reach cutback height 1 and 2.

Reach, Ramp, BW Deceleration ramp DEC DLY REACH IN

The pump deceleration ramp when retracting.

Reach, Ramp, BW Deceleration ramp reducted DEC DLY RCH IN 2

The pump deceleration ramp when retracting. This value is applied proportionally to the reach speed between the reach cutback height 1 and 2.

Reach, Ramp, FW Acceleration ramp ACC DLY RCH OUT

The pump acceleration ramp when reaching out.

Reach, Ramp, FW Acceleration ramp reducted ACC DLY RCH OUT2

The pump acceleration ramp when reaching. This value is applied proportionally to the reach speed between the reach cutback height 1 and 2.

Reach, Ramp, FW Deceleration ramp DEC DLY RCH OUT

The pump deceleration ramp when reaching out.

Reach, Ramp, FW Deceleration ramp reducted DEC DLY RCH OUT2

The pump deceleration ramp when reaching. This value is applied proportionally to the reach speed between the reach cutback height 1 and 2.

Reach, Speed, BW, Maximum speed REACH RV MAX SPD

The maximum pump speed when reaching backwards.

Reach, Speed, BW, Minimum speed REACH RV MIN SPD

The minimum pump speed when reaching backwards.

Reach, Speed, Cutback REACH CUTBACK

The reach maximum speed at the cutback area (at the both ends of the stroke of the reach function). Given in percentages of the full reach speed (depending on the reach direction).

Reach, Speed, FW, Maximum speed REACH FW MAX SPD

The absolute minimum pump speed with the reach forward function.

Reach, Speed, FW, Minimum speed REACH FW MIN SPD

The pump maximum speed with the reach forward function. Applied when the full reach forwards command is given, and no cutbacks are activated.

Reach, Valve, BW maximum current I MAX EVP4

The maximum current of the reach backward valve. Given in percentages of the maximum output of the hardware.

Revision: C

•

Smaller value = faster deceleration

Smaller value = faster acceleration

Document ID: 622075-EN

287 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

PARAMETER

DESCRIPTION

Reach, Valve, BW minimum current I MIN EVP4

The minimum current of the reach backward valve. Given in percentages of the maximum output of the hardware.

Reach, Valve, FW maximum current I MAX EVP3

The maximum current of the reach forward valve. Given in percentages of the maximum output of the hardware.

Reach, Valve, FW minimum current I MIN EVP3

The minimum current of reach forward valve. Given in percentages of the maximum output of the hardware.

Reach, Valve, Ramp, BW closing ramp EVP4 CLOSE DELAY

The closing ramp of the reach backward valve.

Reach, Valve, Ramp, BW opening ramp EVP4 OPEN DELAY

The opening ramp of the reach backward valve.

Reach, Valve, Ramp, FW closing ramp EVP3 CLOSE DELAY

The closing ramp of the reach forward valve.

Reach, Valve, Ramp, FW opening ramp EVP3 OPEN DELAY

The opening ramp of the reach forward valve.

Sshift, Pump, Ramp, Acceleration ramp ACC DELAY SSHIFT

The pump acceleration ramp when using the sideshift function.

Sshift, Pump, Ramp, Deceleration ramp DEC DELAY SSHIFT

The pump deceleration ramp when using the sideshift function.

Sshift, Speed, Maximum speed SSHIFT MAX SPD

The pump maximum speed with the sideshift function. Applied when the full sideshift command is given.

Sshift, Speed, Minimum speed SSHIFT MIN SPD

The pump absolute minimum speed with the sideshift function.

Sshift, Valve, Left maximum current I MAX EVP8

The maximum current of the sideshift left valve. Given in percentages of the maximum output of the hardware.

Sshift, Valve, Left minimum current I MIN EVP8

The minimum current of the sideshift left valve. Given in percentages of the maximum output of the hardware.

Sshift, Valve, Ramp, Closing ramp Left EVP8 CLOSE DELAY

The closing ramp of the sideshift left valve.

Revision: C

•

Smaller value = faster ramp

Smaller value = faster acceleration

Smaller value = faster deceleration

Smaller value = faster ramp

Document ID: 622075-EN

288 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

PARAMETER

DESCRIPTION

Sshift, Valve, Ramp, Closing ramp Right EVP7 CLOSE DELAY

The closing ramp of the sideshift right valve.

Sshift, Valve, Ramp, Opening ramp Left EVP8 OPEN DELAY

The opening ramp of the sideshift left valve.

Sshift, Valve, Ramp, Opening ramp Right EVP7 OPEN DELAY

The opening ramp of the sideshift right valve.

Sshift, Valve, Right maximum current I MAX EVP7

The maximum current of the sideshift right valve. Given in percentages of the maximum output of the hardware.

Sshift, Valve, Right minimum current I MIN EVP7

The minimum current of the sideshift right valve. Given in percentages of the maximum output of the hardware.

Tilt, Ramp, Acceleration ramp ACCEL DELAY TILT

The pump acceleration ramp when tilting.

Tilt, Ramp, Deceleration ramp DECEL DELAY TILT

The pump deceleration ramp when tilting.

Tilt, Speed, Down, Minimum speed TILTDOWN MIN SPD

The minimum pump speed when tilting down.

Tilt, Speed, Up, Maximum speed TILT UP MAX SPD

The pump maximum speed with the tilt up function. Applied when the full command is given.

Tilt, Speed, Up, Minimum speed TILT UP MIN SPD

The pump absolute minimum speed with the tilt up function.

Tilt, Valve, Down maximum current I MAX EVP6

The maximum current of the tilt down valve. Given in percentages of the maximum output of the hardware.

Tilt, Valve, Down minimum current I MIN EVP6

The minimum current of the tilt down valve. Given in percentages of the maximum output of the hardware.

Tilt, Valve, Ramp, Down closing ramp EVP6 CLOSE DELAY

The closing ramp of the tilt down valve.

Tilt, Valve, Ramp, Down opening ramp EVP6 OPEN DELAY

The opening ramp of the tilt down valve.

Tilt, Valve, Ramp, Up opening ramp EVP5 OPEN DELAY

The opening ramp of the tilt up valve.

Revision: C

•

Smaller value = faster ramp

Smaller value = faster acceleration

Smaller value = faster deceleration

Smaller value = faster ramp

Document ID: 622075-EN

289 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

PARAMETER

DESCRIPTION

Tilt, Valve, Ramp, Up opening ramp EVP5 CLOSE DELAY

The closing ramp of the tilt up valve.

Tilt, Valve, Up maximum current I MAX EVP5

The maximum current of the tilt up valve. Given in percentages of the maximum output of the hardware.

Tilt, Valve, Up minimum current I MIN EVP5

The minimum current of the tilt up valve. Given in percentages of the maximum output of the hardware.

PRO, Traction, Ramp, Acceleration ramp ACCELER. DELAY

The acceleration ramp.

Traction, Ramp, Brake smoothening level BRK SMOOTH

The braking smoothness ramp below the speed "Traction, braking smoothness fixed".

PRO, Traction, Ramp, Curve braking ramp CURVE BRAKING

The curve cutback activation ramp. When the curve cutback is activated, the truck is decelerated to the curve cutback speed via this ramp.

•

• PRO, Traction, Ramp, Inverse braking ramp INVERS. BRAKING

Smaller value = faster ramp

Smaller value = faster acceleration

0.1 = strongest

Smaller value = faster deceleration

The inverse braking ramp is applied when the operator changes the truck driving direction when travelling, and keeps pushing the accelerator pedal. •

Smaller value = faster deceleration

PRO, Traction, Ramp, Pedal braking ramp PEDAL BRAKING

The braking ramp when the brake pedal is pushed.

PRO, Traction, Ramp, Release braking ramp RELEASE BRAKING

The braking ramp when the accelerator pedal is released.

PRO, Traction, Ramp, Speed limit braking ramp SPEED LIMIT BRK

The deceleration ramp when the driving speed reduction is activated or the accelerator pedal partially released.

•

Smaller value = faster deceleration

Traction, Speed, Curve cutback speed CURVE CUTBACK

The maximum speed with the curve cutback fully activated. Given in percentage of the maximum driving speed.

Traction, Speed, Cutback speed CUTBACK SPEED

This parameter sets traction speed in PRO mode when height is above "Traction, Speed, Cutback height 2". Given in percentage of maximum travel speed. •

Revision: C

100% = Full speed

Document ID: 622075-EN

290 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

PARAMETER

DESCRIPTION

PRO, Traction, Speed, Maximum speed forwards MAX SPEED FORW

The maximum driving speed to the forward direction.

PRO, Traction, Speed, Maximum speed backwards MAX SPEED BACK

The maximum driving speed to the backward direction.

Aux hydraulics, Valve, A1 Enable EV1

This parameter enables and disables the Auxiliary A1 valve output.

Aux hydraulics, Valve, A2 Enable EV2

This parameter enables and disables the Auxiliary A2 valve output.

Brake, Output, Load wheel brake Enable EVP9

This parameter enables and disables the load wheel brakes driver output.

Maintenance check, Maintenance complete CHECK UP DONE

Maintenance check completed. Setting this parameter to ON, resets the maintenance check counter.

N/A, Output CNB:15 Enable EV3

This parameter enables and disables the XA2B/15 output. This output is currently not in use.

Option, Maintenance check CHECK UP TYPE

Maintenance interval reminder acknowledgement. If set to disabled, truck will not perform maintenance warnings. • •

0 Disabled 1 Enabled

Option, Height indicator HEIGHT INDICATOR

The height indicator shown on the truck display.

Option, Pre-height selector PRE HEIGHT FUNCT

Set the lifting height pre-selector functionality ON or OFF. Value range: • •

ON = the pre-height selector is ON OFF = the pre-height selector is OFF

Option, Battery lock BATTERY LOCK SW

This parameter sets the Battery lock monitoring ON and OFF. When this parameter is set to ON, the truck does not function if the Battery lock input (XA2A/:6) is inactive.

Option, Hour meter functionality HOUR COUNTER

Hour counter functionality.

Option, Load wheel brakes LOAD BRAKE

This parameter sets the load wheel brakes ON and OFF.

Revision: C

• •

0 = running 1 = key-on

Document ID: 622075-EN

291 (782)

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PARAMETER

Service Manual

DESCRIPTION

Option, Lowering stop LOWERING STOP

Enable lowering stop function. Option describes behavior when lowering stop signal is activated (i.e. forks are below sensor limit). Lowering is possible if reach is fully out. Lowering stop options:

• • •

•

0. Lowering stop function is disabled 1. Lowering is stopped to rising edge. Lowering is not allowed except when reach fully out. 2. Lowering is stopped to rising edge. Lowering is allowed with releasing and re-enabling lowering command. 3. Lowering is stopped to rising edge if sideshiftcentering has not been performed before or during lowering. Lowering is allowed after sideshift centering.

• 4. Same as point 3 + sideshift is not allowed when lower stop signal is active. Adjustment, BDI, Max voltage adjustment BAT. MAX ADJ.

This parameter sets the battery discharge level on which the full battery icon is shown on the truck display.

Adjustment, BDI, Min voltage adjustment BAT. MIN ADJ.

This parameter sets the battery discharge level on which the minimum battery icon is shown on the truck display.

Setup, Battery, Voltage reading adjustment ADJUST BATTERY

The battery voltage measurement calibration.

Setup, FC-lever, Curve 0-point JOY THROT 0 ZONE

This parameter sets the fingertip lever deadband value. This parameter sets the position of the lever, at which the command curve starts. From 0% to the 0zone, the creep speed is applied.

Setup, FC-lever, Curve X-point JOY THROT X ZONE

This parameter sets the fingertip lever response curve X point. X and Y points set a point on relation curve between the fingertip lever angle, and command given to the pump controller (or the valve opening). X point sets the angle of the lever correspondent to command signal set by the Y point.

Setup, FC-lever, Curve Y-point JOY THROT X ZONE

This parameter sets the fingertip lever response curve Y point. X and Y points set a point on relation curve between fingertip lever angle and the command given to the pump controller (or valve opening). Y point sets the command signal correspondent to the lever angle set by X point.

Setup, IMPC, distance setup RESET SW POS.

The Intelligent mast phase change (IMPC) setup parameter. The distance between the mast staging switch and the mechanical mast staging point in millimeters.

Revision: C

Document ID: 622075-EN

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Service Manual

PARAMETER

DESCRIPTION

Setup, IMPC, height per rotation scaling EST. HEIGHT FACT

The Intelligent mast phase change (IMPC) setup parameter. This parameter sets the scaling between the single pump rotation and the distance lifting carriage rises.

Setup, Lift limit, Block height meters LIFT LIMIT BLK M

The lift maximum height is set with this parameter and the block height millimeters parameter. This parameter sets the maximum height in full meters.

Setup, Lift limit, Block height millimetres LFT LIMIT BLK MM

The lift maximum height is set with this parameter and the block height meters parameter. This parameter sets the maximum height in millimeters, without the full meters given in the other parameter.

Setup, Lift limit, Block ramp length OFFSET FORK MM

This parameter sets the distance from the maximum lifting height (set by the lift limit, block height parameter) on which the reduction ramp is started. Function limits the maximum speed proportionally between these points.

Setup, Lift limit, Lift limit minimum speed CTB SPD LIFT LMT

The lifting speed at block height parameter. This is the minimum speed before a full stop.

Setup, Pedal, Accelerator, Curve 0point PED THROT 0 ZONE

The creep speed area. From command 0% (set by the accelerator pedal dead band parameter) to the 0 zone, the truck is driven with the creep speed. This adjustment sets the position to the pedal, at which the command curve starts.

Setup, Pedal, Accelerator, Curve X1-point PED THROT X ZONE

The accelerator pedal response curve X point. X and Y points set a point on the relation curve between the accelerator pedal position and the command given to the traction controller.

Setup, Pedal, Accelerator, Curve X2-point PED THROT2X ZONE

The accelerator pedal response curve X2 point. X2 and Y2 points set a point on the relation curve between the accelerator pedal position and the command given to the traction controller.

Setup, Pedal, Accelerator, Curve Y1-point PED THROT Y ZONE

The accelerator pedal response curve Y point. X and Y points set a point on the relation curve between the accelerator pedal position and the command given to the traction controller.

Setup, Pedal, Accelerator, Curve Y2-point PED THROT2Y ZONE

The accelerator pedal response curve Y2 point. X2 and Y2 points set a point on relation curve between the accelerator pedal position, and the command given to the traction controller.

Revision: C

Document ID: 622075-EN

293 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

PARAMETER

DESCRIPTION

Acquire, Calibration, Scale, Freeliftpressure at Load 1 LOAD1 POT FREEL.

Calibration parameter for Load weight measurement and speed reductions. This parameter contains the pressure sensor value at freelift when Freelift Calibration-load 1, defined at parameter "Calibration, Scale: Freelift-Load1", is at forks on freelift area.

Calibration, Scale, Freelift-Load 1 LOAD1 FREELIFT

Calibration parameter for Load weight measurement and speed reductions. This parameter contains the weight of the Freelift calibration-load 1. Usually calibration load 1 is 0kg, beeng equal to empty forks

Acquire, Calibration, Scale, Mainliftpressure at Load 1 LOAD1 POT MAINL.

DESCRIPTION Calibration parameter for Load weight measurement and speed reductions. This parameter contains the pressure sensor value at mainlift when Mainlift Calibration-load 1, defined at parameter "Calibration, Scale: mainlift-Load1", is at forks on mainlift area.

Calibration, Scale, Mainlift-Load 1 LOAD1 MAINLIFT

Calibration parameter for Load weight measurement and speed reductions. This parameter contains the weight of the Mainlift calibration-load 1. Usually calibration load 1 is 0 kg, being equal to empty forks.

Acquire, Calibration, Scale, Freeliftpressure at Load 2 LOAD2 POT FREEL.

Calibration parameter for Load weight measurement and speed reductions. This parameter contains the pressure sensor value at freelift when Freelift Calibration-load 2, defined at parameter "Calibration, Scale: Freelift-Load2", is at forks on freelift area.

Calibration, Scale, Freelift-Load 2 LOAD2 FREELIFT

Calibration parameter for Load weight measurement and speed reductions. This parameter contains the weight of the Freelift calibration-load 2. Usually calibration load 2 is 0 kg, being equal to empty forks.

Revision: C

Document ID: 622075-EN

294 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

PARAMETER

DESCRIPTION

Acquire, Calibration, Scale, Mainliftpressure at Load 2 LOAD2 POT MAINL.

Calibration parameter for Load weight measurement and speed reductions. This parameter contains the pressure sensor value at mainlift when Mainlift Calibration-load 1, defined at parameter "Calibration, Scale: mainlift-Load2", is at forks on mainlift area.

Calibration, Scale, Mainlift-Load 2 LOAD2 MAINLIFT

Calibration parameter for Load weight measurement and speed reductions. This parameter contains the weight of the Mainlift calibration-load 2. Usually calibration load 2 is 0kg, being equal to empty forks.

Options, Lift, Intermediate stop height INT STOP HEIGHT

DESCRIPTION Lift intermediate stopping height. Lifting will automatically stop on this height. Lifting can be reenabled by releasing and re-activating the lift command. This functionality can be set off by selecting intermediate stop height above maximum lift height.

Reach, ASC, ASC pump delay compensation COMPENSATION

Compensation for pump delay with ASC.

Reach, ASC, Laser Calibration Field Value 1 REACH LASER FV1

Raw analog laser sensor value. Corresponding position defined in "Laser Calibration Process Value 1". Used in calibration.

Reach, ASC, Laser Calibration Process Value 1 REACH LASER PV1.

Position of reach when laser output gives the value defined in "Laser Calibration Field Value 1". Used in calibration

Reach, ASC, Laser Calibration Field Value 2 REACH LASER FV2.

Raw analog laser sensor value. Corresponding position defined in "Laser Calibration Process Value 2". Used in calibration.

Reach, ASC, Laser Calibration Process Value 2 REACH LASER PV2

Position of reach when laser output gives the value defined in "Laser Calibration Field Value 2". Used in calibration.

Reach, ASC, Inner reach stop point REACH INNER STOP

Inner stopping point for reach carriage. Absolute position.

Revision: C

Document ID: 622075-EN

295 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

PARAMETER

DESCRIPTION

Reach, ASC, Outer reach stop point REACH OUTER STOP

Outer stopping point for reach carriage. Absolute position.

Reach, ASC, Inner reach slowdown point REACH SLWDWN OUT

DESCRIPTION Reach slows down to minimum speed after this point and continues to move until "Inner reach stop point". Defined as offset from "Inner reach stop point".

Reach, ASC, Outer reach slowdown point REACH SLWDWN OUT

Reach slows down to minimum speed after this point and continues to move until "Outer reach stop point". Defined as offset from "Outer reach stop point".

Reach, ASC, Reach ramp ASC ON ADJUSTMENT #02

Reach acceleration / deceleration ramp with ASC (Active Sway Control) function ON. Higher value means smoother ramp, but this adjustment cannot be used for making the stopping distance shorter. Stopping distance depends on the load on the forks and current fork height.

Reach, ASC, Reach ramp ASC ON below 5m ADJUSTMENT #03

Reach acceleration / deceleration ramp with ASC (Active Sway Control) function ON. This ramp is applied below 5m. Higher value means smoother ramp and slower reaction.

Reach, ASC, Reach ASC stopping point fine tuning ADJUSTMENT #04

Offset for reach ASC stopping point.

Reach, ASC, Pump displacement FW PUMP SIZE CM3

Displacement of the hydraulic pump which is used in ASC algorithm. FW direction.

Reach, ASC, Pump displacement BW PUMP SIZE CM3

Displacement of the hydraulic pump which is used in ASC algorithm. BW direction.

Setup, Multipurpose input, Multipurpose input lift cutback MIP LIFT CUTBACK

If lift cutback option is chosen for multipurpose input 1 or 2, this parameter sets the value of the cutback.

Setup, Multipurpose input, Multipurpose input lower cutback MIP LOWER CTB

If lift cutback option is chosen for multipurpose input 1 or 2, this parameter sets the value of the cutback.

Revision: C

Document ID: 622075-EN

296 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

PARAMETER

DESCRIPTION

Setup, Multipurpose output, Output 2 Functionality byte 1 MULTIP OUTPUT 1A

Multipurpose output XA4B/15 functionality. Parameter "Setup,Multipurpose output, Enable Multipurpose output 2” must be set accordingly. • • • • • • • •

Setup, Multipurpose output, Output 2 Functionality byte 2 MULTIP OUTPUT 1B

Multipurpose output XA4B/15 functionality. Parameter "Setup, Multipurpose output, Enable Multipurpose output 2” must be set accordingly. • • • • • • •

Setup, Multipurpose output, Output 2 Functionality byte 3 MULTIP OUTPUT 1C

Revision: C

0 Multipurpose input 1 active. 1 Multipurpose input 2 active. 3 Invert output. 4 Brake light.

Multipurpose output XA2A/16 functionality. "Setup, A16output, Functionality A16" must be set to correct state for the output to work. • • • • • • • •

0 Reach forward active. 1 Reach backward active. 2 Other hydraulic function active. 3 Controller temperature warning. 4 Motor temperature warning. 6 Warning active. 7 Error active.

Multipurpose output XA4B/15 functionality. Parameter "Setup, Multipurpose output, Enable Multipurpose output 2” must be set accordingly. • • • •

Setup, Multipurpose output, Output 1 Functionality byte 1 MULTIP OUTPUT 2A

0 Truck is powered on. 1 Seatswitch is active. 2 Traction is active. 3 Pump is active. 4 Drive backward active. 5 Drive forward active. 6 Lift active. 7 Lower active.

Document ID: 622075-EN

297 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

PARAMETER

DESCRIPTION

Setup, Multipurpose output, Output 1 Functionality byte 2 MULTIP OUTPUT 2B

Multipurpose output XA2A/16 functionality. "Setup, A16output, Functionality A16" must be set to correct state for the output to work. • • • • • • •

Setup, Multipurpose output, Output 1 Functionality byte 3 MULTIP OUTPUT 2C

0 Reach forward active. 1 Reach backward active. 2 Other hydraulic function active. 3 Controller temperature warning. 4 Motor temperature warning. 6 Warning active. 7 Error active.

Multipurpose output XA2A/16 functionality. "Setup, A16output, Functionality A16" must be set to correct state for the output to work. • • • •

0 Multipurpose input 1 active. 1 Multipurpose input 2 active. 3 Invert output. 4 Brake light.

Setup, Pedal, Alarm offset PEDAL FAILOFFSET

Sets the offset for the pedal out of range alarm. Area is defined from the teached pedal minimum and maximum area.

Sshift, Speed, Sideshift cutback speed SSHIFT CTB SPEED

Sideshift speed when full height cutback is added.

Traction, Speed, Cutback height 1 TRAC CTB HEIGHT1

Traction speed reduction according to lift height is linearly scaled between "Traction, Speed, Cutback height 1" (no cutback) and "Traction, Speed, Cutback height 2" (full cutback).

Traction, Speed, Cutback height 2 TRAC CTB HEIGHT2

Traction speed reduction according to lift height is linearly scaled between "Traction, Speed, Cutback height 1" (no cutback) and "Traction, Speed, Cutback height 2" (full cutback).

Traction, Speed, Fault cutback CUTBACK SPEED 3

Cutback speed applied when EPS high motor temperature, CANbus error: Armrest or Coil open EVP9 warning is active.

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Service Manual

PARAMETER

DESCRIPTION

Traction, Speed, Brake error cutback CUTBACK SPEED 4

Factory setup parameter. DO NOT ADJUST!

Traction, Speed, Limb mode cutback CUTBACK SPEED 5

Factory setup parameter. DO NOT ADJUST!

Traction, Cutback, Load cutback Backward LOAD SP RED BW

Truck has optional speed reduction in respect to load weight. For setting option OFF, reduction speed is set to 100%. Speed reduction is driven linearly between "Cutback load1" and "Cutback load2", from full speed to the speed described by this parameter.

Cutback speed applied when electromagnetic loadwheel brakes have failed.

Reducted speed when there is active alarm that causes limb mode to activate: MASTER: EEPROM KO, NO CAN MSG. 14 SLAVE : IN. MISM. D, IN. MISM. A/E, VALVE MISM. OUT, ANALOG INPUT, EEPROM KO, VALVE MISM. OUT

Cutback set by this parameter is applied to forward direction only. Traction, Cutback, Load cutback Forward LOAD SP RED FW

Traction, Cutback, Enable load cutback WEIGHT CUTBACK

This option enables traction speed cutback in respect to load weight. Cutback speed value can be adjusted with parameters: "Traction, Cutback, Load cutback backward" and "Traction, Cutback, Load cutback forward". Cutback weights can be set with the parameters "Cutback, Cutback load 1" and "Cutback, Cutback load 2".

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12.2

Service Manual

Traction controller

Table 19. Traction controller parameters PARAMETER

DESCRIPTION

Maximum current MAXIMUM CURRENT

Sets the maximum current for the controller. Usually set at 100%.

Voltage reading adjustment ADJUST BATTERY

The battery voltage measurement calibration. NOTE: This parameter changes the value in respect to the factory calibration. •

Change of 1 unit = 48V/512 = 0,094V.

Pull voltage MAIN CONT. VOLT

The pull voltage of the main contactor. Actuation of the main contactor is done with the PWM value set by this parameter. After the actuation, the voltage is reduced to "keep voltage", set by the "Setup, Main Contactor : Keep voltage" parameter.

Keep voltage MAIN CONT. V RID

Keep the voltage of the main contactor. The main contactor actuation is done with the PWM value set by the "Setup, Main Contacor : pull voltage" parameter. After the actuation, the voltage is reduced to "keep voltage", set by this parameter.

Keep voltage AUX OUTPUT V RID

Keep the voltage of the electromagnetic brake. The electromagnetic brake actuation is done with the PWM value set by the "Setup, Brake: pull voltage" parameter. After the actuation, the voltage is reduced to "keep voltage", set by this parameter.

Debug message type DEBUG MESSAGE

Factory setup parameter. DO NOT ADJUST. This parameter selects the debug message type. NOTE: There is no specification what these messages contain, so use is only when manufacturer requests to activate. There is a separate parameter for the activation.

Pull voltage AUX OUTPUT VOLT

The pull voltage of the electromagnetic brake. The actuation of the electromagnetic brake is done with the PWM value set by this parameter. After the actuation, the voltage is reduced to "keep voltage", set by the "Setup, Brake: Keep voltage" parameter.

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Service Manual

PARAMETER

DESCRIPTION

0-Voltage AUX OUTPUT V OFF

NOTE: USED WITH TRACTION CONTROLLER SOFTWARE v 0.37 OR GREATER ONLY. Off voltage of the traction motor brake. Set a non-zero value only at cold storage use, where a small current should be set to keep brake from sticking when the truck is not used for a long time. Electromagnetic brake actuation is done with the PWM value set by "Setup, Brake : pull voltage" - parameter. After actuation, voltage is reduced to "keep voltage", set by this parameter.

Debug message DEBUG FUNCTION

Factory setup parameter. DO NOT ADJUST. This parameter enables the debug messages. Use only when the manufacturer requests. • •

12.3

0 = OFF 1 = ON

Pump controller

Table 20. Pump controller parameters PARAMETER

DESCRIPTION

Debug message Enable DEBUG FUNCTION

This parameter enables the debug messages. Use only when the manufacturer requests. • •

Debug message type DEBUG MESSAGE

This parameter selects the debug message type. NOTE: There is no specification what these messages contain, so use this parameter only when the manufacturer requests to activate. There is a separate parameter for the activation. • •

Setup, A16output, Functionality A16 A16 FUNCTION

0 = OFF 1 = ON

0: OPTION #1 1: OPTION #2

Functionality of XA2A/:16 output. • •

Off = A16 is not used (Default) Output = A16 used like a generic output

Use the selection "Output" in this if multipurpose output is used. This means that the control comes via CAN bus. Otherwise set as "Off" to disable diagnostics of the output. Setup, A18output, Functionality A18 AUX OUT FUNCTION

Revision: C

Output XA2A/:18 functionality. Used for Fan control. Default for standard reach trucks is "Disabled", and for heavy models "Enabled".

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Service Manual

PARAMETER

DESCRIPTION

Hour counter functionality HOUR COUNTER

Factory setup parameter. DO NOT ADJUST. This parameter sets the time when the hour counter is increased. • •

Setup, Inverter type INVERTER TYPE

• •

RUNNING = Hour counter is increasing when traction is used. KEY-ON = Hour counter is increasing when controller is on. 0 and 1: traction 2 and 3: pump

With these parameters you can control 4 different parameter tables. All values are stored in flash, and also in the EEPROM. Setup, A16output, Keep voltage MAIN CONT. V RID

Keep voltage of the output A16. This parameter is used as an auxiliary output (to working lights, horn, etc.)

Setup, A18output, Keep voltage AUX OUTPUT V RID

Keep voltage of the FAN output. This parameter is not used, because fans are controlled actively in accordance with the temperature.

Pull voltage MAIN CONT. VOLT

The pull voltage of the A16 output. Enabling the output is done with the PWM value set by this parameter. After actuation, voltage is reduced to "keep voltage", set by the "Setup, A16output: Keep voltage" parameter.

Pull voltage AUX OUTPUT VOLT

Pull voltage of the A18 output. Enabling the output is done with PWM value set by this parameter. After actuation, voltage is reduced to "keep voltage", set by parameter "Setup, A18 output: Keep voltage".

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12.4

Service Manual

EPS controller

Table 21. EPS controller parameters PARAMETER

DESCRIPTION

Speed, Steering wheel maximum speed SPEED LIMIT

Speed limit of the steering wheel. This parameter sets the steering wheel speed on which maximum steering motor speed is applied. Higher value lowers the required steering wheel speed => Steering motor response gets quicker. The downside of the higher value is that response saturates quite quickly, that is, faster turning does not give faster response after speed set by this parameter.

Calibration, Steering 0-position STEER 0-POS DEG

The offset between the 0-point toggle switch and the actual mechanical 0-point of the steering. Acquired by the "Setup, Calibration: Start 0-pos calibration" parameter. There is a wizard for the calibration.

Option, Autocentering function AUTOCENTERING

Enable autocentering function on start-up. NOTE: This value is overwritten with an identical parameter from the VCM if it has a non-zero value (in the VCM).

Setup, Calibration, Start 0-pos calibration 0-POS TEACHING

Setting this parameter 1 starts the steering 0-position (steering straight) acquiring process. It corrects the angular difference with 0-position toggle switch and the real straight angle of the wheel. First you restart the truck, then set the wheel straight with SET 0-POS parameter.

DEBUG MODE DEBUG MODE

This parameter increases the number of the tests during running. This parameter is normally used only by the manufacturer for debugging the machine. Do not turn this parameter ON without a specific request from the manufacturer!

Speed, Sensitivity reduction SENSITIVI VS TRC

The dynamic steering sensitivity reduction parameter. Steering sensitivity is reduced in respect to the traction speed. This parameter sets the maximum reduction.

Speed, Steering wheel maximum speed reduction SPEED LIM VS TRC

The dynamic steering speed limit reduction parameter. Steering speed limit is reduced in respect to the traction speed. This parameter sets the maximum reduction.

Setup, Disable slave microcontroller MICRO CHECK

This parameter can disable slave microcontroller functionality (mainly diagnostics). This function is useful for debugging and troubleshooting the system. However, the system cannot be run with this parameter set to on. The safety contact will always stay open until the slave microcontroller is enabled.

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Service Manual

PARAMETER

DESCRIPTION

Setup, Decreasing angle limit 2ND ANGLE GAIN

This parameter sets the decreasing angle limit when using the 180° steering option. Counting starts from the straight ahead position.

Setup, Increasing angle limit 1ST ANGLE GAIN

This parameter sets the increasing angle limit when using the 180° steering option. Counting starts from the straight ahead position.

Adjustment, Maximum traction speed MAX SPEED TRAC.

The dynamic steering sensitivity and speed limit reduction parameter. This parameter sets the traction speed where full reduction to the steering parameters is applied.

Setup, Debug output DEBUG OUTPUT

This adjustment is used to temporary change the configuration or to inhibit some diagnosis to aid the troubleshooting. Take care to set DEBUG OUTPUT to "Normal operation" after finishing the troubleshooting. •

•

Stepper acquisition: Self-acquisition of the stepper motor offsets in open loop application. It switches automatically to the default Level 15 after the selfacquisition Disable alarms: Disables the alarms FB POT LOCKED, MOTOR LOCKED and POSITION ERROR (the latest only for FB ENC & TOGGLE SWs configuration). It switches automatically to the default Level 15 recycling the key. Normal operation: Default value (no special functions activated).

Option, Inverse steering REV STEER WHEEL

The reverse steering command.

Speed, Sensitivity SENSITIVITY

The steering sensitivity setting. This parameter sets the steering response when the steering wheel is turned slowly. In more detail: the steering motor response to the steering wheel speed of 1/6 of full speed.

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Service Manual

Alarm codes This chapter explains the meaning of the various alarms that the different controllers can produce. Refer to chapter 11 for information on the TruckTool diagnostics application. The truck is equipped with a state of the art failure analysis, which prevents that in normal usage, a single fault does not prevent the usage of the truck. For example, if the tilt lever is broken, only the tilt function is disabled, but otherwise, the truck remains functional. The faulty state of the truck is informed to the operator through the truck display. The system gives an alarm indication when there is an actual fault in the system, for example, if a broken sensor prevents the use of a certain functionality of the truck. A warning indication is given when the truck operator can solve the problem, for example, if the battery needs to be charged. Before you start to troubleshoot the truck: •

Make sure that all the power supplies, fuses and connections are not damaged.

•

Make sure that the battery is fully charged. Low battery voltage can cause error messages.

•

Restart the truck. Some error messages can be cleared after the restart.

•

Examine the status of the truck display (warning/alarm/info code).

•

Use the TruckTool Diagnostics application to troubleshoot the truck.

NOTE: Read the alarm code descriptions from the truck display to make sure that you always have the latest alarm code descriptions.

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13.1

VCM

13.1.1

VCM master alarms

Service Manual

Table 22. VCM master alarm codes CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A8

Watchdog

Internal alarm Call Service

MESSAGE TYPE Alarm

Watchdog circuit monitors the software operation. If a software gets jammed, watchdog circuit is triggered and an alarm occurs. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

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CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A19

Undervoltage detected

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Error in the battery voltage. This alarm occurs, when there is an undervoltage in the key input. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • • • • •

• • •

• •

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CODE

TRUCKTOOL DESCRIPTION

4A48

Main contractor open

DISPLAY DESCRIPTION

Service Manual

MESSAGE TYPE Alarm

VMC has opened main contactor. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

4A65

Motor temperature alarm Temperature of one motor exceeded the alarm threshold. Update the VMC software to have more detailed alarm description.

4W66

Low battery level

Battery voltage low Recharge battery

Warning

Battery level is low. Charge the battery.

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CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W78

Accelerator pedal calibration failed

Internal Warning Call Service

Service Manual

MESSAGE TYPE Warning

Wrong acquisition of the accelerator pedal calibration values. Minimum value is higher than the maximum value. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • • •

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CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A80

Simultaneous direction requests

Direction switch faulty, call service

Service Manual

MESSAGE TYPE Alarm

Forward and backward requests are active simultaneously. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

•

• • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Examine the sensor value(s) from the I/O menu. Make sure that all operator interface sensors are at rest position at key on. Make sure that the sensors and switches work correctly in the I/O menu. If there is an incorrect start, find the damaged switch. If the arm rest shows a faulty input state, calibrate the arm rest. If the sensor is stuck to a conductive state, disconnect the sensor. If the alarm goes out of view, the sensor is probably broken and must be replaced. Before you replace the sensor, make sure that there is power supply to the sensor. Disconnect the sensor connector, measure the resistance directly from the sensor. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. NOTE: Active sensors cannot be tested this way. If the problem is not in the sensor or in the wiring harness, set the truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

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CODE

TRUCKTOOL DESCRIPTION

4W95

Unverified steering angle

DISPLAY DESCRIPTION

Service Manual

MESSAGE TYPE Warning

Invalid angle from the EPS. Usually occurs after start-up, before the 0-position is reached. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • • •

• •

Turn the steering wheel. The warning disappears when the state of the steering feedback sensors changes. This is a normal truck operation. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

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311 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I157

Incorrect start: F2

F2 button Release to continue

Service Manual

MESSAGE TYPE Information

F2 button active during start-up. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • • • • • •

•

• •

Release the F2 button. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Examine the sensor value(s) from the I/O menu. Make sure that all operator interface sensors are at rest position at key on. Make sure that the truck model configuration is correct (from the I/O list, VCM numeric, advanced view). Make sure that the sensors and switches work correctly in the I/O menu. If there is an incorrect start, find the damaged switch. If the sensor is stuck to a conductive state, calibrate the arm rest. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the arm rest and run the calibrations again. If the calibration is not the solution and the arm rest signals function normally, replace the arm rest. NOTE: If the arm rest replacement does not help, install the original arm rest back. If the arm rest replacement does not help, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

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Document ID: 622075-EN

312 (782)

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CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I158

Incorrect start: AUXleft

Aux lever Release to continue

Service Manual

MESSAGE TYPE Information

Arm rest AUX-lever (Left) active during start-up. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • • • • •

• •

Release the Aux lever. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Examine the sensor value(s) from the I/O menu. Make sure that all operator interface sensors are at rest position at key on. Make sure that the sensors and switches work correctly in the I/O menu. If there is an incorrect start, find the damaged switch. If the sensor is stuck to a conductive state, calibrate the arm rest. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the arm rest and run the calibrations again. If the calibration is not the solution and the arm rest signals function normally, replace the arm rest. NOTE: If the arm rest replacement does not help, install the original arm rest back. If the arm rest replacement does not help, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

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Document ID: 622075-EN

313 (782)

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CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I159

Incorrect start: AUXright

Aux lever Release to continue

Service Manual

MESSAGE TYPE Information

Arm rest AUX-lever (Right) active during start-up. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • • • • •

• •

Release the Aux lever. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Examine the sensor value(s) from the I/O menu. Make sure that all operator interface sensors are at rest position at key on. Make sure that the sensors and switches work correctly in the I/O menu. If there is an incorrect start, find the damaged switch. If the sensor is stuck to a conductive state, calibrate the arm rest. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the arm rest and run the calibrations again. If the calibration is not the solution and the arm rest signals function normally, replace the arm rest. NOTE: If the arm rest replacement does not help, install the original arm rest back. If the arm rest replacement does not help, flash the controller and run the wizards again. If the flashing again does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

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314 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I160

Incorrect start: Sideshift left

Sideshift lever Release to continue

Service Manual

MESSAGE TYPE Information

Arm rest sideshift lever (left) active during start-up. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • • • • •

• •

Release the sideshift lever. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Examine the sensor value(s) from the I/O menu. Make sure that all operator interface sensors are at rest position at key on. Make sure that the sensors and switches work correctly in the I/O menu. If there is an incorrect start, find the damaged switch. If the sensor is stuck to a conductive state, calibrate the arm rest. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the arm rest and run the calibrations again. If the calibration is not the solution and the arm rest signals function normally, replace the arm rest. NOTE: If the arm rest replacement does not help, install the original arm rest back. If the arm rest replacement does not help, flash the controller and run the wizards again. If the flashing again does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

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315 (782)

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CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I161

Incorrect start: Sideshift right

Sideshift lever Release to continue

Service Manual

MESSAGE TYPE Information

Arm rest sideshift lever (right) active during start-up. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. For a solution to the problem: • • • • •

• • • • • •

• •

Release the sideshift lever. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Examine the sensor value(s) from the I/O menu. Make sure that all operator interface sensors are at rest position at key on. Make sure that the sensors and switches work correctly in the I/O menu. If there is an incorrect start, find the damaged switch. If the sensor is stuck to a conductive state, calibrate the arm rest. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the arm rest and run the calibrations again. If the calibration is not the solution and the arm rest signals function normally, replace the arm rest. NOTE: If the arm rest replacement does not help, install the original arm rest back. If the arm rest replacement does not help, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

316 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I162

Incorrect start: Reach-out

Reach lever Release to continue

Service Manual

MESSAGE TYPE Information

Arm rest reach lever (FW direction) active during start-up. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. For a solution to the problem: • • • • •

• • • • • •

• •

Release the reach lever. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Examine the sensor value(s) from the I/O menu. Make sure that all operator interface sensors are at rest position at key on. Make sure that the sensors and switches work correctly in the I/O menu. If there is an incorrect start, find the damaged switch. If the sensor is stuck to a conductive state, calibrate the arm rest. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the arm rest and run the calibrations again. If the calibration is not the solution and the arm rest signals function normally, replace the arm rest. NOTE: If the arm rest replacement does not help, install the original arm rest back. If the arm rest replacement does not help, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

317 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I163

Incorrect start: Reach-in

Reach lever Release to continue

Service Manual

MESSAGE TYPE Information

Arm rest reach lever (BW direction) active during start-up. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. For a solution to the problem: • • • • •

• • • • • •

• •

Revision: C

Document ID: 622075-EN

318 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I164

Incorrect start: Tilt down

Tilt lever Release to continue

Service Manual

MESSAGE TYPE Information

Arm rest tilt lever (down) active during start-up. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. For a solution to the problem: • • • • •

• • • • • •

• •

Release the tilt lever. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Examine the sensor value(s) from the I/O menu. Make sure that all operator interface sensors are at rest position at key on. Make sure that the sensors and switches work correctly in the I/O menu. If there is an incorrect start, find the damaged switch. If the sensor is stuck to a conductive state, calibrate the arm rest. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the arm rest and run the calibrations again. If the calibration is not the solution and the arm rest signals function normally, replace the arm rest. NOTE: If the arm rest replacement does not help, install the original arm rest back. If the arm rest replacement does not help, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

319 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I165

Incorrect start: Tilt up

Tilt lever Release to continue

Service Manual

MESSAGE TYPE Information

Arm rest tilt lever (up) active during start-up. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. For a solution to the problem: • • • • •

• • • • • •

• •

Revision: C

Document ID: 622075-EN

320 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I166

Incorrect start: Lowering

Lift lever Release to continue

Service Manual

MESSAGE TYPE Information

Arm rest lifting/lowering lever (lift) active during start-up. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. For a solution to the problem: • • • • •

• • • • • •

• •

Release the lift lever. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Examine the sensor value(s) from the I/O menu. Make sure that all operator interface sensors are at rest position at key on. Make sure that the sensors and switches work correctly in the I/O menu. If there is an incorrect start, find the damaged switch. If the sensor is stuck to a conductive state, calibrate the arm rest. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the arm rest and run the calibrations again. If the calibration is not the solution and the arm rest signals function normally, replace the arm rest. NOTE: If the arm rest replacement does not help, install the original arm rest back. If the arm rest replacement does not help, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

321 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I167

Incorrect start: Lifting

Lift lever Release to continue

Service Manual

MESSAGE TYPE Information

Arm rest lifting/lowering lever (lowering) active during start-up. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. For a solution to the problem: • • • • •

• • • • • •

• •

Revision: C

Document ID: 622075-EN

322 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I168

Incorrect start: Accelerator

Accelerator pedal Release to continue

Service Manual

MESSAGE TYPE Information

Accelerator pedal active during start-up. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. For a solution to the problem: • • • • •

• • • • • • •

• •

Release the accelerator pedal. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Examine the sensor value(s) from the I/O menu. Make sure that all operator interface sensors are at rest position at key on. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Calibrate the sensor with TruckTool. Calibrate with another sensor. NOTE: In case of the accelerator pedal, test with the brake pedal. Set the truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

323 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I169

Incorrect start: Brake

Brake pedal Release to continue

Service Manual

MESSAGE TYPE Information

Brake pedal active during start-up. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. For a solution to the problem: • • • • •

• • • • • • •

• •

Release the brake pedal. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Examine the sensor value(s) from the I/O menu. Make sure that all operator interface sensors are at rest position at key on. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Calibrate the sensor with TruckTool. Calibrate with another sensor. NOTE: In case of the brake pedal, test with the accelerator pedal. Set the truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

324 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I170

Incorrect start: FW direction switch

Direction switch Release to continue

Service Manual

MESSAGE TYPE Information

FW direction button active during start-up. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. For a solution to the problem: • • • • •

• • • • • •

• •

Release the forward function. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Examine the sensor value(s) from the I/O menu. Make sure that all operator interface sensors are at rest position at key on. Make sure that the sensors and switches work correctly in the I/O menu. If there is an incorrect start, find the damaged switch. If the sensor is stuck to a conductive state, calibrate the arm rest. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the arm rest and run the calibrations again. If the calibration is not the solution and the arm rest signals function normally, replace the arm rest. NOTE: If the arm rest replacement does not help, install the original arm rest back. If the arm rest replacement does not help, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

325 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I171

Incorrect start: BW direction switch

Direction switch Release to continue

Service Manual

MESSAGE TYPE Information

BW direction button active during start-up. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. For a solution to the problem: • • • • •

• • • • • •

• •

Release the backward function. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Examine the sensor value(s) from the I/O menu. Make sure that all operator interface sensors are at rest position at key on. Make sure that the sensors and switches work correctly in the I/O menu. If there is an incorrect start, find the damaged switch. If the sensor is stuck to a conductive state, calibrate the arm rest. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the arm rest and run the calibrations again. If the calibration is not the solution and the arm rest signals function normally, replace the arm rest. NOTE: If the arm rest replacement does not help, install the original arm rest back. If the arm rest replacement does not help, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

326 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I172

Incorrect start: OPP (Operator presence pedal)

Operator Presence Pedal Release to continue

Service Manual

MESSAGE TYPE Information

OPP (Operator presence pedal) active during start-up. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. For a solution to the problem: • • • • •

• • •

• •

•

• • •

• •

Release the backward function. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Examine the sensor value(s) from the I/O menu. Make sure that all operator interface sensors are at rest position at key on. Make sure that the sensors and switches work correctly in the I/O menu. If there is an incorrect start, find the damaged switch. If the sensor is stuck to a conductive state, disconnect the sensor. If the alarm goes out of view, the sensor is probably broken and must be replaced. Before you replace the sensor, make sure that there is power supply to the sensor. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Disconnect the controller connector, measure the resistance from the harness pins of the controller wire. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. If there are active sensors (inductive, capacitive, reed switches etc.), you must remove the sensor connector and manually short circuit pins of the switch (Examine the correct pins from the circuit diagram). Disconnect the sensor connector, measure the resistance directly from the sensor. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. NOTE: Active sensors cannot be tested this way. If the problem is not in the sensor or in the wiring harness, set the truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

327 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W173

Wrong encoder direction

Lift height measurement Sensor fault

Service Manual

MESSAGE TYPE Warning

Height encoder is running to wrong direction. Verify that encoder is correctly installed, and all connections are correct. Verify that encoder belt is running correctly through the wheel. 4W174

Height encoder locked

Lift height measurement Sensor fault

Warning

Height encoder is not sending pulses as predicted. Verify that encoder is correctly installed, and all connections are correct. Verify that encoder belt is running correctly through the wheel. 4A180

Scale is not calibrated

Weight measurement disabled, call service

Alarm

Pressure sensor is enabled in the parameters, but it has not been calibrated. Calibrate the pressure sensor using "Weight calibration wizard" or disable the pressure sensor. Note that functions like ASC and weight dependent speed reduction does not work without pressure sensor. 4W181

Internal ASC table fault, out of range

Active Sway Control disabled, call service

Warning

Internal Active Sway Control error in VMC. Active Sway Control is disabled due to error detected in ASC frequency table. Update VMC SW to the latest version and if it doesn't fix the fault, please contact manufacturer. 4A181

Alarm

Internal ASC table fault, out of range

Internal Active Sway Control error in the VMC. Active Sway Control is disabled due to an error in the ASC frequency table. Active Sway Control is disabled because an error was detected in the ASC frequency table. Update the VCM software to the latest version. If the update is not the solution to the problem, contact the manufacturer. 4W182

Reach carriage position measurement changed without moving reach carriage

Active Sway Control disabled, call service

Warning

Reach carriage position measurement changed more than +/-30mm without using the reach function. ASC is disabled and cutback speed is set for reach. • •

Examine that there's no obstructions in between laser beam and the surface against it. Examine wiring and connectors to laser sensor (B42). Restart the truck to continue.

Revision: C

Document ID: 622075-EN

328 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

4A183

Reach position laser sensor out of range

Service Manual

DISPLAY DESCRIPTION

MESSAGE TYPE

Alarm

Reach position laser sensor (B42) signal is out of the valid range, 4 mA...20 mA (4 mA correspond to 1,320 V on pin XA4B/1 and 20 mA correspond to 6.6 V on pin XA4B/1). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • • •

• •

4W183

Examine the wiring and connectors. Make sure that the laser sensor gives a signal to XA4B/1 and it changes as a function of reach carriage position. Clean the laser sensor lens. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Examine the sensor value(s) from the I/O menu. Make sure that all operator interface sensors are at rest position at key on. If the sensors are not the problem, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Reach position laser sensor out of range

Active Sway Control disabled, call service

Warning

Reach position laser sensor (B42) signal is out of valid range, 4mA...20mA (4mA correspond to 1,320V on pin XA4B/1 and 20mA correspond to 6,6V on pin XA4B/1). Examine wiring and connectors. Examine that laser sensor gives signal to XA4B/1 and it changes as a function of reach carriage position. 4A184

Internal ASC table fault, checksum

Alarm

Internal Active Sway Control error in the VMC. Active Sway Control is disabled due to an error in the ASC frequency table. Update the VCM software to the latest version. If the update is not the solution to the problem, contact the manufacturer.

Revision: C

Document ID: 622075-EN

329 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W184

Internal ASC table fault, checksum

Active Sway Control disabled, call service

Service Manual

MESSAGE TYPE Warning

Internal Active Sway Control error in VMC. Active Sway Control is disabled due to error detected in ASC frequency table. Update VMC SW to the latest version and perform MODEL CONFIGURATION WIZARD and ASC LASER CALIBRATION WIZARD. If problem persists, please contact manufacturer. 4W185

Lift lower valve disabled

Lift disabled, call service

Warning

VMC slave controller has disabled the lifting/lowering valve is disabled. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

330 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W186

Reach valve disabled

Reach disabled, call service

Service Manual

MESSAGE TYPE Warning

VMC slave controller has disabled the reach valve. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

331 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W187

Tilt valve disabled

Tilt disabled, call service

Service Manual

MESSAGE TYPE Warning

VMC slave controller has disabled the tilt valve. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

332 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W188

Sideshift valve disabled

Sideshift disabled, call service

Service Manual

MESSAGE TYPE Warning

VMC slave controller has disabled the sideshift valve. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

333 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

MESSAGE TYPE

4A189

VCM slave stopped

Alarm

VMC slave controller is stopped. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

334 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

4A190

VCM slave in alarm

DISPLAY DESCRIPTION

Service Manual

MESSAGE TYPE Alarm

There is an active alarm in the VMC slave controller. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

4I191

Disabled for maintenance

A mechanic has disabled the truck. The truck can be enabled with the Disable for maintenance parameter. 4A192

Main contactor open: ACE

All functions disabled, call service

Alarm

ACE has requested main contactor to be opened. In most occasions there is a warning or error code active in the ACE. Examine also the error history, because it is possible that the reason is not active anymore. Find the reason why the ACE requested the main contactor to be opened.

Revision: C

Document ID: 622075-EN

335 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A193

Main contactor open: Traction

All functions disabled, call service

Service Manual

MESSAGE TYPE Alarm

Traction controller has requested main contactor to be opened. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

336 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A194

Main contactor open: Pump

All functions disabled, call service

Service Manual

MESSAGE TYPE Alarm

Pump controller has requested main contactor to be opened. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

337 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A195

Main contactor open: EPS

All functions disabled, call service

Service Manual

MESSAGE TYPE Alarm

EPS controller has requested main contactor to be opened. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

338 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A198

Main contactor open: VCM slave

All functions disabled, call service

Service Manual

MESSAGE TYPE Alarm

VMC slave controller has requested main contactor to be opened. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

4W199

Maintenance required

Maintenance due Call Service

Warning

Maintenance must be done. After maintenance is done, reset the maintenance alarm. Do it with the Maintenance check, Maintenance complete parameter. 4A200

Battery voltage critical Charge battery

Battery empty

Alarm

Battery is empty. Charge the battery.

Revision: C

Document ID: 622075-EN

339 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I201

Traction incorrect start: Battery lock

Battery lock must be closed

Service Manual

MESSAGE TYPE Info

Incorrect traction start procedure. Battery lock must be closed to enable traction. Examine that battery lock is closed. If truck is not equipped with battery lock, this alarm can be set off by parameter "Battery lock". NOTE: During resistance measurements, check that battery cable is disconnected, and that voltage at the measured circuit is 0V. If the alarm is still raised: • • • •

•

• •

•

• • • • •

Read the alarm status from all controllers. Try to create overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure battery voltage when idle, and during full speed lift. Battery voltage should stay over 38V in all cases. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals).Examine sensor value(s) from I/O menu. All operator interface sensors must be at rest position simultaneously at key on. Verify that all sensors and switches work as expected in the I/O menu. Verify that they change state when they should. (In case of incorrect start you should find the switch that is stated in the alarm to be not working). If sensor is stuck to conductive state, try disconnecting the sensor. If alarm does not reappear (output changes state), sensor is most likely broken and needs to be replaced. Before replacing the sensor, verify power supply to the sensor. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Disconnect the controller connector and measure resistance from controller wire harness pins. Resistance must follow circuit diagram functionality when sensor is operated. In case of active sensors (inductive, capacitive, some reed switches etc.), you need to remove the sensor connector and manually short circuit pins of the switch (verify correct pins from the circuit diagram). Disconnect sensor connector, measure resistance directly from the sensor. Resistance must follow circuit diagram functionality when sensor is operated. (Note: Active sensors cannot be tested this way). If you have outruled possibility for sensor and wireharness fault do following. Reset truck back to default settings and run truck model configuration wizard. If resetting to default does not help, try to reflash the controller and re-run the wizards. If flashing does not help, replace the current controller with another controller. Note! If the controller replacement does not help, install the original controller back to the truck. If changing controller does not help, re-evaluate the possible root causes for the alarm. Also, see if there are another alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

340 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I202

Traction incorrect start: Multipurpose input

Auxiliary device # must be closed

Service Manual

MESSAGE TYPE Info

Incorrect traction start procedure. Multipurpose input must be active to enable traction. If there is no auxiliary equipment installed to the truck, and this alarm is raised, the truck can be enabled by adjusting “multipurpose input” parameters. If truck is installed with auxiliary equipment (connected to multipurpose inputs XA1A/5 or XA4A/8) that is supposed to disable truck (Note: Battery lock, seat switch and suchlike standard equipment of the truck cause different alarms), in this case verify correct wiring of the equipment. This alarm is related to non-standard equipment (for example human lifting equipment, special load clamps and so on). Troubleshoot according to information available of this equipment. 4I203

Traction incorrect start: Brake calibration active

Internal warning Please, restart

Information

Incorrect traction start procedure. Brake calibration is active. Finish the brake calibration procedure correctly. Restart the truck. If the alarm is still raised: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

341 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W203

Traction incorrect start: Brake calibration active

Internal warning Please, restart

Service Manual

MESSAGE TYPE Warning

Incorrect traction start procedure. Brake calibration is active. Finish the brake calibration procedure correctly. Restart the truck. If the alarm is still raised: • • • • •

• •

•

Read the alarm status from each controller. Try to create overall picture of the root cause for the event code(s). Note: during resistance measurements, check that battery cable is disconnected, and that voltage at the measured circuit is 0V. Make sure that the battery is not damaged. Measure battery voltage when idle, and during full speed lift. Battery voltage should stay over 38V in all cases. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up..

Revision: C

Document ID: 622075-EN

342 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

4I204

Incorrect traction start sequence

DISPLAY DESCRIPTION

Service Manual

MESSAGE TYPE Information

Start-up: Invalid start-up sequence. Accelerator or brake activated during start-up. Running: Traction request without the OPP (Operator presence pedal) and seat switch active. Also, if seat belt monitoring is active, this alarm occurs, if the seat belt is not closed when traction start command is given. If the direction is not chosen when the traction command is given, this alarm occurs. Release all traction controls. Pay attention to the correct order of the traction start. Activate the seat switch and operator presence pedal and select the driving direction before you activate the accelerator. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • • • •

• •

Finish the brake calibration procedure correctly. Restart the truck. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Make sure that the sensors and switches work correctly in the I/O menu. If there is an incorrect start, find the damaged switch. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

343 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I205

Traction incorrect start: Accelerator calibration active

Internal warning Please, restart

Service Manual

MESSAGE TYPE Information

Incorrect traction start procedure. Accelerator pedal calibration is active. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • •

• •

Finish the Accelerator pedal calibration procedure correctly. Restart the truck. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

344 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W205

Traction incorrect start: Accelerator calibration active

Internal warning Please, restart

Service Manual

MESSAGE TYPE Warning

Incorrect traction start procedure. Accelerator pedal calibration is active. Finish the accelerator calibration procedure correctly. Restart the truck. If the alarm is still raised: •

• • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). NOTE: During resistance measurements, check that battery cable is disconnected, and that voltage at the measured circuit is 0V. Make sure that the battery is not damaged. Measure battery voltage when idle, and during full speed lift. Battery voltage should stay over 38V in all cases. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals).Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

345 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

4I206

Traction incorrect start: OPP inactive

DISPLAY DESCRIPTION Incorrect operation Activate operator presence pedal

Service Manual

MESSAGE TYPE Info

Incorrect traction start procedure. Operator presence pedal is not active. Release all traction controls. Pay attention to the correct order of the traction start. Activate the seat switch and operator presence pedal and select the driving direction before you activate the accelerator. If the alarm is still raised: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

•

• •

•

• • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals).Examine sensor value(s) from I/O menu. All operator interface sensors must be at rest position simultaneously at key on. Verify that all sensors and switches work as expected in the I/O menu. Verify that they change state when they should. (In case of incorrect start you should find the switch that is stated in the alarm to be not working). If sensor is stuck to conductive state, try disconnecting the sensor. If alarm does not reappear (output changes state), sensor is most likely broken and needs to be replaced. Before replacing the sensor, verify power supply to the sensor. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Disconnect controller connector, measure resistance from controller wire harness pins. Resistance must follow circuit diagram functionality when sensor is operated. In case of active sensors (inductive, capacitive, some reed switches etc.), you need to remove the sensor connector and manually short circuit pins of the switch (verify correct pins from the circuit diagram). Disconnect sensor connector, measure resistance directly from the sensor. Resistance must follow circuit diagram functionality when sensor is operated. (NOTE: Active sensors cannot be tested this way.) If you have outruled the possibility for sensor and wireharness fault do the following. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

346 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I207

Traction incorrect start: Direction missing

Incorrect operation Choose direction

Service Manual

MESSAGE TYPE Info

Incorrect traction start procedure. Direction is not chosen. Release all traction controls. Pay attention to the correct order of the traction start. Activate the seat switch and operator presence pedal and select the driving direction before you activate the accelerator. If the alarm is still raised: •

• • •

• •

•

• • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Examine sensor value(s) from I/O menu. All operator interface sensors must be at rest position simultaneously at key on. Make sure that the sensors and switches work correctly in the I/O menu. If there is an incorrect start, find the damaged switch. If sensor is stuck to a conductive state, try disconnecting the sensor. If alarm does not reappear (output changes state), sensor is most likely broken and needs to be replaced. Before replacing the sensor, verify power supply to the sensor. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Disconnect controller connector and measure resistance from controller wire harness pins. Resistance must follow circuit diagram functionality when sensor is operated. In case of active sensors (inductive, capacitive, some reed switches etc.), remove the sensor connector and manually short circuit pins of the switch (verify correct pins from the circuit diagram). Disconnect sensor connector, measure resistance directly from the sensor. Resistance must follow circuit diagram functionality when sensor is operated. (Note: Active sensors cannot be tested this way) If you have outruled possibility for sensor and wireharness fault do following. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

347 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W208

Controller memory error (EEPROM)

Internal warning Call Service

Service Manual

MESSAGE TYPE Warning

Internal error inside VCM related to the EEPROM memory. General memory failure. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

4A209

Emergency mode activated

Alarm

Emergency mode is activated (By default this is set by pin 11111). Restart the truck. Enter the correct PIN code for another driving mode.

Revision: C

Document ID: 622075-EN

348 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A210

Controller memory error (RAM)

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Internal error in the VCM related to the RAM memory. Memory contents check failed. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

349 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

MESSAGE TYPE

4I211

Incorrect pump start sequence

Information

Start-up: Invalid start-up sequence of hydraulics. Hydraulic request active during start-up. Running: Hydraulics request without the seatswitch and seatbelt (option) active. Release all arm rest levers. Pay attention to the correct order of hydraulics command. You must activate the seat switch before the hydraulics command. If the alarm is still raised: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

350 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

MESSAGE TYPE

4A212

Pressure sensor out of range

Alarm

Weight measurement pressure sensor (B42) signal is out of range i.e. below 0.5 V or above 5.5 V. Active Sway Control is disabled and cutback speed is set for reach function. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • •

• •

Examine the wiring and connectors. Make sure that the pressure sensor signal changes proportionally to the weight in the pin XA4B/4. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

351 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

MESSAGE TYPE

4W213

EPS in alarm state

Please, restart

Warning

EPS is in alarm state. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • •

• •

4I214

Traction incorrect start: Seat switch open

Activate seat switch

Information

Incorrect traction start procedure. Seat switch is not activated. Seat switch must be active (=operator must sit on the seat) before the acceleration command. If the traction start procedure is correct, verify the correct operation of the seat switch from the I/O-menu. Verify wiring to the seat switch and operation of the switch with multimeter. 4A215

Internal Error Call Service

Output error

Alarm

An internal error at the output configuration. Turn the key switch OFF and ON. If the problem still occurs, replace the controller.

Revision: C

Document ID: 622075-EN

352 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I216

Traction incorrect start: Seatbelt not closed

Seat belt must be closed

Service Manual

MESSAGE TYPE Info

Incorrect traction start procedure. Seatbelt is not closed. Close the seatbelt before the acceleration command. Certain models are equipped with tamperproof seatbelt switch. In this case seat switch must be active prior to seatbelt switch. Release all traction controls. Pay attention to correct order of traction start. Activate the seat switch and the operator presence pedal and choose the direction before you activate the accelerator. In case of stuck alarm: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

•

• •

•

• • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals).If truck is not equipped with seatbelt (and seatbelt sensor), run truck options wizard. Examine sensor value(s) from I/O menu. All operator interface sensors must be at rest position simultaneously at key on. Verify that all sensors and switches work as expected in the I/O menu. Verify that they change state when they should. (In case of incorrect start you should find the switch that is stated in the alarm to be not working). If sensor is stuck to conductive state, try disconnecting the sensor. If alarm does not reappear (output changes state), sensor is most likely broken and needs to be replaced. Before replacing the sensor, verify power supply to the sensor. Examine wire harness condition, check all related connections for loose pins etc. Disconnect controller connector, measure resistance from controller wire harness pins. Resistance must follow circuit diagram functionality when sensor is operated. In case of active sensors (inductive, capacitive, some reed switches etc.), you need to remove the sensor connector and manually short circuit pins of the switch (verify correct pins from the circuit diagram). Disconnect sensor connector, measure resistance directly from the sensor. Resistance must follow circuit diagram functionality when sensor is operated. (Note: Active sensors cannot be tested this way) If you have outruled possibility for sensor and wireharness fault do following. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

353 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A217

Input A/D converter error

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

A/D conversion inside the controller shows frozen value. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • • •

• •

Examine the wiring and connectors. Make sure that the pressure sensor signal changes proportionally to the weight in the pin XA4B/4. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

354 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W218

Waiting VCM slave

Internal warning Call Service

Service Manual

MESSAGE TYPE Warning

VMC slave controller is in warning or error mode. This prevents the VMC master to enter the operational state. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

355 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W219

Waiting EPS

Internal warning Call Service

Service Manual

MESSAGE TYPE Warning

EPS controller is in warning or error mode. This prevents the VMC master to enter the operational state. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

356 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W220

Waiting Traction

Internal warning Call Service

Service Manual

MESSAGE TYPE Warning

Traction controller is in warning or error mode. This prevents the VMC master to enter the operational state. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

357 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W221

Waiting Pump

Internal warning Call Service

Service Manual

MESSAGE TYPE Warning

Pump controller is in warning or error mode. This prevents the VMC master to enter the operational state. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

358 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W222

Waiting Arm rest

Internal warning Call Service

Service Manual

MESSAGE TYPE Warning

Arm rest is in warning or error mode. This prevents the VMC master to enter the operational state. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

359 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I223

Pump incorrect start: Seat switch open

Incorrect operation Activate seat switch

Service Manual

MESSAGE TYPE Info

Incorrect pump start procedure. Seat switch is not activated. Release all arm rest levers. Pay attention to the correct order of hydraulics command. Activate the seat switch before the hydraulics command. If the alarm is still raised: • • • • •

• •

• • • • •

NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Check sensor value(s) from I/O menu. All operator interface sensors must be at rest position simultaneously at key on. Verify correct operation of all sensors. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc.Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

360 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W224

Waiting VCM slave controller

Internal Warning Call Service

Service Manual

MESSAGE TYPE Warning

Start-up check. Master-Slave communication is initialized. This warning can occur during start-up. It usually disappears without actions from the user. If the alarm is still raised: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

4A225

Non-genuine hardware

Internal alarm Call Service

Alarm

The software signature does not agree with the hardware. This indicates to a non-genuine hardware. The current software cannot be installed to this device. • • • • •

•

The original hardware has the letters RO in the controller type plate. The original software is downloaded by TruckTool. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If you cannot solve the problem, contact an authorized dealer.

Revision: C

Document ID: 622075-EN

361 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A226

Accelerator pedal signal out of range

Internal alarm Call Service

Service Manual

MESSAGE TYPE Warning

Accelerator pedal analog value is out of range. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • • •

Revision: C

Document ID: 622075-EN

362 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4I228

Pump incorrect start: Seatbelt not closed

Seat belt must be closed

Service Manual

MESSAGE TYPE Info

Incorrect pump start procedure. Seatbelt is not closed. Release all arm rest levers. Pay attention to the correct order of hydraulics command. You must activate the seat switch before the hydraulics command. If the alarm is still raised: • • • • •

• • • • • • •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). NOTE: during resistance measurements, check that battery cable is disconnected, and that voltage at the measured circuit is 0V. Check battery condition. Measure battery voltage when idle, and during full speed lift. Battery voltage should stay over 38V in all cases. Check fuses. Measure that truck frame is isolated from battery + and -. Verify this from both sides of drive contactor. Verify that there is no short-circuit or low resistance between + and – from terminals of any controller (B+ and B- terminals). If truck is not equipped with seatbelt, run truck options wizard. Check sensor value(s) from I/O menu. All operator interface sensors must be at rest position simultaneously at key on. Verify correct operation of all sensors. Check wire harness condition, check all related connections for loose pins etc. Reset truck back to default settings and run truck model configuration wizard. If resetting to default does not help, try to reflash the controller and re-run the wizards. If re-flashing does not help, try with another controller. Note! if controller replacement does not help, replace original controller back. If changing controller does not help, re-evaluate the possible root causes for the alarm. Especially if there are another alarm messages active in the system. Try also to clear online error codes from TruckTool, and restarting the truck. There might be some other codes during start-up that get run-down by the latest code.

Revision: C

Document ID: 622075-EN

363 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A229

Pump motor overtemperature

Pump motor Critical temperature

Service Manual

MESSAGE TYPE Alarm

Pump motor temperature is too high. Hydraulic functions not allowed. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • •

• • • •

•

• • • •

• •

Wait for the motor to cool down. It the problem occurs when the truck is cold, look at the motor temperature sensor measurement. If the temperature sensor indicates a too high temperature when the motor is cold, do the tests listed here: Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Verify the correct operation of the temperature sensor of the motor. The pump motor temperature sensor is of type KTY 84-130. The nominal resistance of the sensor at 20°C is 580 Ω. Measure the sensor disconnected to the system. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

364 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A230

Brake pedal calibration failed

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Minimum acquired value is higher than the maximum acquired value on the brake pedal. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • • • 4A231

Brake pedal signal out of range

Brake pedal faulty, call service

Alarm

Brake pedal analog value is out of range. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • • •

Revision: C

Document ID: 622075-EN

365 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A232

Accelerator pedal secondary signal failure

Accelerator pedal faulty, call service

Service Manual

MESSAGE TYPE Alarm

Mismatch between 2 analog channels of the accelerator pedal. Signals are crossed 0.5 - 4.5 V signals. Error limit for them is: •

abs(S1+S2-5V)>0.8V.

NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • • •

Revision: C

Document ID: 622075-EN

366 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A233

Brake pedal secondary signal failure

Brake pedal faulty, call service

Service Manual

MESSAGE TYPE Alarm

Mismatch between 2 analog channels of the brake pedal. Signals are crossed 0.5…4.5 V signals. Error limit for them is: •

abs(S1+S2-5V)>0.8V

NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • • • 4A234

Incorrect VCM slave controller software

Internal alarm Call Service

Alarm

Mismatch between master and slave software versions. • • • • • • •

Read the master and slave software versions from the Info view. The versions must be the same. The original hardware has the letters RO in the controller type plate. The original software is downloaded by TruckTool. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings do not help, flash the controller (master and slave) and run the wizards again. If flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the problem still occurs, contact an authorized dealer.

Revision: C

Document ID: 622075-EN

367 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A235

Steering motor overtemperature

Critical temperature Steering motor

Service Manual

MESSAGE TYPE Alarm

Steering motor temperature is too high. Driving is not allowed. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. Wait for the motor to cool down. • It the problem occurs when the truck is cold, look at the motor temperature sensor measurement. If the temperature sensor indicates a too high temperature when the motor is cold, do the tests listed here: • Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). • Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. • Make sure that the fuses are not damaged. • Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). • Measure thermal sensor ohmic value directly from the sensor output pins. The steering motor temperature sensor is of type KTY 83-122. The nominal resistance of the sensor at 20°C is 972 Ω. • Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. • Set the truck back to the default settings. Run the truck model configuration wizard. • If the default settings are not a solution to the problem, flash the controller and run the wizards again. • If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. • If changing controller does not help, re-evaluate the possible root causes for the alarm. Especially if there are another alarm messages active in the system. Try also to clear online error codes from TruckTool, and restart the truck. There might be some other codes during start-up that get run-down by the latest code.

Revision: C

Document ID: 622075-EN

368 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A237

Emergency stop request

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Emergency stop request to pump controller pin XA2A/3 is down (i.e. emergency stop switch has been pressed). Emergency braking is initiated. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

• • • •

• •

Revision: C

Document ID: 622075-EN

369 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

4W238

Staging sensor state change expected

DISPLAY DESCRIPTION Lift Height Measurement faulty, call service

Service Manual

MESSAGE TYPE Warning

This warning occurs if the lifting encoder starts to count, and the reset encoder switch is not detected. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • •

•

• • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Examine the sensor value(s) of the reset encoder switch from the I/O menu. The sensor should be set on when the lift carriage is on the free lift are and off on the main lift area. Examine the lift encoder counting from the I/O menu. No pulses should occur when the lift carriage is on the free lift area. The sensor is of state remembering reed switch type. To test the operation, move a magnet back and forth in front of the sensor. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Disconnect the controller connector, measure the resistance from the harness pins of the controller wire. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. If there are active sensors (inductive, capacitive, reed switches etc.), you must remove the sensor connector and manually short circuit pins of the switch (check the correct pins from the circuit diagram). Disconnect the sensor connector, measure the resistance directly from the sensor. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. NOTE: Active sensors cannot be tested this way. If the problem is not in the sensor or in the wiring harness, set the truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

370 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

MESSAGE TYPE

4A239

Battery lock not closed

Alarm

Battery lock input is not active (when option is set on). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • •

• •

•

• • •

• •

Make sure that the battery lock is closed. If there is no battery lock in the truck, select the Battery lock parameter or the truck option wizard to set off the alarm. Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Examine the sensor value(s) from the I/O menu. Make sure that all operator interface sensors are at rest position at key on. Make sure that the sensors and switches work correctly in the I/O menu. If there is an incorrect start, find the damaged switch. If the sensor is stuck to a conductive state, disconnect the sensor. If the alarm goes out of view, the sensor is probably broken and must be replaced. Before you replace the sensor, make sure that there is power supply to the sensor. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Disconnect the controller connector, measure the resistance from the harness pins of the controller wire. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. If there are active sensors (inductive, capacitive, reed switches etc.), you must remove the sensor connector and manually short circuit pins of the switch (check the correct pins from the circuit diagram). Disconnect the sensor connector, measure the resistance directly from the sensor. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. NOTE: Active sensors cannot be tested this way. If the problem is not in the sensor or in the wiring harness, set the truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

371 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W240

Pump motor high temperature

High Temperature Lighten Pump Use

Service Manual

MESSAGE TYPE Warning

Pump motor temperature is high. Performance reduction started. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • •

• • • •

•

• • • •

• •

Wait for the motor to cool down. It the problem occurs when the truck is cold, look at the motor temperature sensor measurement. If the temperature sensor indicates a too high temperature when the motor is cold, do the tests listed here. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Verify the correct operation of the temperature sensor of the motor. The steering motor temperature sensor is of type KTY 84-130. The nominal resistance of the sensor at 20°C is 580 Ω. Measure the sensor disconnected to the system. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

372 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W241

Parameter check failure

Internal alarm Call service

Service Manual

MESSAGE TYPE Warning

Master / slave CPU parameters do not match. This error is usually caused by adjusting the parameters, and using the truck at the same time. This causes the master and slave parameter check to fail. When you adjust the parameters, wait for a second after adjusting the parameter value before testing. • • • • • • 4A242

Turn the key switch off and on. If this does not solve the problem, change any parameter value from the settings and use the Save to truck function. Turn the key switch off and on again. If this does not solve the problem, export the default parameters to the truck and try again. If this does not solve the problem, clear the EEPROM and set the default values. If none of the previous actions solve the problem, replace the controller.

Parameter transfer

Internal alarm Call Service

Alarm

Master / slave parameter transfer failed. • • • • •

Revision: C

Document ID: 622075-EN

373 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W243

Display absent

Internal Warning Call Service

Service Manual

MESSAGE TYPE Warning

CAN PDO communication problem with the display. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that there are no additional devices on the CAN bus when this error occurs. NOTE: The controller debug messages increase the CAN bus load. Make sure that all debug messages from all nodes are disabled. See the settings or the advanced view for the DEBUG message. • • • • •

• • • •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that all nodes in the info view are active in the CAN bus. If there are offline-nodes (which are marked gray) examine their electrical connections. Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Measure the CAN bus resistance from the maintenance socket. The resistance must be approximately 60 Ω. Measure each CANH and CANL line resistance to the battery positive and negative. There should be no connection or extremely high resistance. Disconnect all controller signal connectors. Measure the CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Focus on the unit mentioned in the alarm. Make sure that there is voltage supply to the stated controller.

If there are offline nodes: • •

•

Flash the controller mentioned in the alarm. Replace the current controller mentioned in the alarm with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. Examine the electrical connections of the missing node.

If all nodes are online: • • •

• •

Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the VCM and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

374 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W244

Steering motor high temperature

High temperature Lighten truck use

Service Manual

MESSAGE TYPE Warning

Steering motor temperature is high. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • •

• • • •

• •

• • •

• •

4W245

Wait for the motor to cool down. It the problem occurs when the truck is cold, look at the motor temperature sensor measurement. If the temperature sensor indicates a too high temperature when the motor is cold, do the tests listed here. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Verify the correct operation of the temperature sensor of the motor. The steering motor temperature sensor is of type KTY 83-122. The nominal resistance of the sensor at 20°C is 972 Ω. Measure the sensor disconnected to the system. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Invalid display version

Internal Warning Call Service

Warning

Display hardware or software version is incorrect. • • • • • • •

The original software is downloaded by TruckTool. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings do not help, flash the display. If flashing the display does not help, flash the VMC master and slave. If the flashing does not help, replace the current display with another display. NOTE: If the display replacement does not help, install the original display back. If replacing the display does not help, replace the current VMC with another VMC. NOTE: If the controller replacement does not help, install the original controller back. If the problem still occurs, contact an authorized dealer.

Revision: C

Document ID: 622075-EN

375 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4W247

Traction motor high temperature

High Temperature Lighten Traction Use

Service Manual

MESSAGE TYPE Warning

Traction motor temperature is high. Performance reduction started. This alarm occurs, when the traction motor temperature is too high. No specific action is required. If overheating occurs constantly, consider better cooling. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • •

• • • •

• •

• • •

• •

Wait for the motor to cool down. It the problem occurs when the truck is cold, look at the motor temperature sensor measurement. If the temperature sensor indicates a too high temperature when the motor is cold, do the tests listed here. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Verify the correct operation of the temperature sensor of the motor. The steering motor temperature sensor is of type KTY 84-130. The nominal resistance of the sensor at 20°C is 580 Ω. Measure the sensor disconnected to the system. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

376 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A248

Traction motor overtemperature

Traction motor Critical temperature

Service Manual

MESSAGE TYPE Alarm

Traction motor temperature is too high. Driving is not allowed. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • •

• • • •

• •

• • •

• •

Wait for the motor to cool down. It the problem occurs when the truck is cold, look at the motor temperature sensor measurement. If the temperature sensor indicates a too high temperature when the motor is cold, do the tests listed here. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Verify the correct operation of the temperature sensor of the motor. The steering motor temperature sensor is of type KTY 84-130. The nominal resistance of the sensor at 20°C is 580 Ω. Measure the sensor disconnected to the system. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

377 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A249

CAN bus error: VCM slave

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

No CAN bus communication from the VMC slave controller (internal CAN bus of the VMC). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that there are no additional devices on the CAN bus when this error occurs. NOTE: The controller debug messages increase the CAN bus load. Make sure that all debug messages from all nodes are disabled. See the settings or the advanced view for the DEBUG message. • • • • •

• • • •

If there are offline nodes: •

•

If all nodes are online: • • • • •

Revision: C

Document ID: 622075-EN

378 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A250

CAN bus error: EPS

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

No CAN bus communication from the EPS. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that there are no additional devices on the CAN bus when this error occurs. NOTE: The controller debug messages increase the CAN bus load. Make sure that all debug messages from all nodes are disabled. See the settings or the advanced view for the DEBUG message. • • • • •

• • • •

If there are offline nodes: • •

•

If all nodes are online: • • •

• •

Revision: C

Document ID: 622075-EN

379 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A251

CAN bus error: Traction

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

No CAN bus communication from the traction. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that there are no additional devices on the CAN bus when this error occurs. NOTE: The controller debug messages increase the CAN bus load. Make sure that all debug messages from all nodes are disabled. See the settings or the advanced view for the DEBUG message. • • • • •

• • • •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that all nodes in the info view are active in the CAN bus. If there are offline-nodes (which are marked grey) examine their electrical connections. Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Measure the CAN bus resistance from the maintenance socket. The resistance must be approximately 60 Ω. Measure each CANH and CANL line resistance to the battery positive and negative. There should be no connection or extremely high resistance. Disconnect all controller signal connectors. Measure the CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Focus on the unit mentioned in the alarm. Make sure that there is voltage supply to the stated controller.

If there are offline nodes: • •

•

If all nodes are online: • • •

• •

Revision: C

Document ID: 622075-EN

380 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A252

CAN bus error pump

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

No CAN bus communication from the pump controller. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that there are no additional devices on the CAN bus when this error occurs. NOTE: The controller debug messages increase the CAN bus load. Make sure that all debug messages from all nodes are disabled. See the settings or the advanced view for the DEBUG message. • • • • •

• • • •

If there are offline nodes: • •

•

If all nodes are online: • • •

• •

Revision: C

Document ID: 622075-EN

381 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

4A253

CAN bus error: Arm rest

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

No CAN bus communication from the arm rest. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that there are no additional devices on the CAN bus when this error occurs. NOTE: The controller debug messages increase the CAN bus load. Make sure that all debug messages from all nodes are disabled. See the settings or the advanced view for the DEBUG message. • • • • •

• • • •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that all nodes in the info view are active in the CAN bus. If there are offline-nodes (which are marked grey) examine their electrical connections. Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and Bterminals). Measure the CAN bus resistance from the maintenance socket. The resistance must be approximately 60 Ω. Measure each CANH and CANL line resistance to the battery positive and negative. There should be no connection or extremely high resistance. Disconnect all controller signal connectors. Measure the CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Focus on the unit mentioned in the alarm. Make sure that there is voltage supply to the stated controller.

If there are offline nodes: • •

•

If all nodes are online: • • •

• •

Revision: C

Document ID: 622075-EN

382 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

13.1.2

Service Manual

VCM slave alarms

Table 23. VCM slave alarm codes CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A8

Watchdog

Internal alarm Call service

MESSAGE TYPE Alarm

The master-slave CAN communication is frozen. There is probably a software issue. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

383 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A19

Undervoltage detected

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Error at the battery voltage. This alarm occurs when an undervoltage at the key input is detected. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

384 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A185

Lift valve driver shorted

Lift faulty, call service

Service Manual

MESSAGE TYPE Alarm

Driving circuit of EVP1 (Lift valve) has a short circuit. This indicates the driving FET being burned to a close state. Error occurs when the voltage of the output is down while the output is not driven. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

• • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for possible short circuits from ground to EVP1 XA4A/24 (do the measuring while connector XA4A/ is disconnected). If the wiring harness is ok, verify that the short circuit is internal. Measure between controller pin XA4A/24 and ground XA4A/29 (without the wiring harness connected to the VMC). If there is an internal short circuit, replace the VMC. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for lift, lowering and auxiliary valves. For reach, tilt and sideshift values the correct value is 7.5 Ω. Measure the valve supply voltage. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

385 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A186

Lower valve driver shorted

Lift faulty, call service

Service Manual

MESSAGE TYPE Alarm

Driving circuit of EVP2 (Lowering valve) has a short circuit. This indicates that the driving FET is burned to a close state. Error occurs when the voltage of the output is down while the output is not driven. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for possible short-circuits from ground XA4A/29 to EVP2 XA4A/25 (do the measuring while connector XA4A/ is disconnected). If the harness is ok, verify that the short circuit is internal. Measure between controller pin XA4A/25 and XA4A/29 (without the harness connected to VMC). If there is an internal short circuit, replace the VMC. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for lift, lowering and auxiliary valves. For reach, tilt and sideshift values the correct value is 7.5 Ω. Measure the valve supply voltage. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Restart the truck: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

386 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A187

Reach FW valve driver shorted

Reach faulty, call service

Service Manual

MESSAGE TYPE Alarm

Driving circuit of EVP3 (Reach FW valve) has a short circuit. This indicates that the driving FET is burned to a close state. Error occurs when voltage of the output is down while the output is not driven. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for possible short-circuits from ground XA4A/29 to EVP3 XA4A/2 (do the measuring while connector XA4A/ is disconnected). If the harness is ok, verify that the short circuit is internal. Measure between controller pin XA4A/2 and XA4A/29 (without the harness connected to the VMC). If there is an internal short circuit, replace the VMC. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for lift, lowering and auxiliary valves. For reach, tilt and sideshift values the correct value is 7.5 Ω. Measure the valve supply voltage. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Restart the truck: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

387 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A188

Reach BW valve driver shorted

Reach faulty, call service

Service Manual

MESSAGE TYPE Alarm

Driving circuit of EVP4 (Reach BW valve) has a short circuit. This indicates that the driving FET is burned to a close state. Error occurs when voltage of the output is down while the output is not driven. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for possible short circuits from ground XA4A/29 to EVP4 XA4A/3 (do the measuring while connector XA4A/ is disconnected). If the harness is ok, verify that the short circuit is internal. Measure between controller pin XA4A/3 and XA4A/29 (without the harness connected to the VMC). If there is an internal short circuit, replace the VMC. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for lift, lowering and auxiliary valves. For reach, tilt and sideshift values the correct value is 7.5 Ω. Measure the valve supply voltage. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Restart the truck: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

388 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A189

Tilt Down valve driver shorted

Tilt faulty, call service

Service Manual

MESSAGE TYPE Alarm

Driving circuit of EVP5 (Tilt Down valve) has a short circuit. This indicates that the driving FET is burned to a close state. Error occurs when voltage of the output is down while the output is not driven. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for possible short circuits from ground XA4A/29 to EVP5 XA4A/26 (do the measuring while connector XA4A/ is disconnected). If the harness is ok, verify that the short circuit is internal. Measure between controller pin XA4A/26 and XA4A/29 (without the harness connected to the VMC). If there is an internal short circuit, replace the VMC. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for lift, lowering and auxiliary valves. For reach, tilt and sideshift values the correct value is 7.5 Ω. Measure the valve supply voltage. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Restart the truck: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

389 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A190

Tilt up valve driver shorted

Tilt faulty, call service

Service Manual

MESSAGE TYPE Alarm

Driving circuit of EVP6 (Tilt Up valve) has a short circuit. This indicates that the driving FET is burned to a close state. Error occurs when voltage of the output is down while the output is not driven. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for possible short circuits from ground XA4A/29 to EVP6 XA4A/27 (do the measuring while connector XA4A/ is disconnected). If the harness is ok, verify that the short circuit is internal. Measure between controller pin XA4A/27 and XA4A/29 (without the harness connected to VMC). If there is an internal short circuit, replace the VMC. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for lift, lowering and auxiliary valves. For reach, tilt and sideshift values the correct value is 7.5 Ω. Measure the valve supply voltage. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Restart the truck: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

390 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A191

Sideshift Left valve driver shorted

Sideshift faulty, call service

Service Manual

MESSAGE TYPE Alarm

Driving circuit of EVP7 (Sideshift Left valve) has a short circuit. This indicates that the driving FET is burned to close state. Error occurs when voltage of the output is down while the output is not driven. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for possible short-circuits from ground XA4A/29 to EVP8 XA4A/5 (do the measuring while connector XA4A/ is disconnected). If the harness is ok, verify that the short circuit is internal. Measure between controller pin XA4A/5 and XA4A/29 (without the harness connected to VMC). If there is an internal short circuit, replace the VMC. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for lift, lowering and auxiliary valves. For reach, tilt and sideshift values the correct value is 7.5 Ω. Measure the valve supply voltage. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Restart the truck: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

391 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A192

Sideshift right valve driver shorted

Sideshift faulty, call service

Service Manual

MESSAGE TYPE Alarm

Driving circuit of EVP8 (Sideshift Right valve) has a short circuit. This indicates that the driving FET is burned to a close state. Error occurs when voltage of the output is down while the output is not driven. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for possible short circuits from ground XA4A/29 to EVP8 XA4A/5 (do the measuring while connector XA4A/ is disconnected). If the harness is ok, verify that the short circuit is internal. Measure between controller pin XA4A/5 and XA4A/29 (without the harness connected to the VMC). If there is an internal short circuit, replace the VMC. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for lift, lowering and auxiliary valves. For reach, tilt and sideshift values the correct value is 7.5 Ω. Measure the valve supply voltage. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Restart the truck: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

392 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

5A197

Weight measurement error

DISPLAY DESCRIPTION

Service Manual

MESSAGE TYPE Alarm

There is an error in the weight measurement. Master and slave microcontrollers have inconsistent measurement data. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

393 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A199

Lift or lower valve coil shorted

Lift faulty, call service

Service Manual

MESSAGE TYPE Alarm

EVP1 or EVP2 coil has a short circuit. This alarm is generated by an overcurrent when driving output. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

•

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short-circuits from XA4A/13 to XA4A/24 and XA4A/25. Disconnect the controller connector. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for lift, lowering and auxiliary valves. For reach, tilt and sideshift values the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, replace the current coil with another coil. It the coil change does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

394 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A200

Reach valve coil shorted

Reach faulty, call service

Service Manual

MESSAGE TYPE Alarm

TEVP3 or EVP4 coil has a short circuit. This alarm is generated by an overcurrent when driving output. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

•

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short circuits from XA4A/14 to XA4A/2 and XA4A/3. Disconnect the controller connector. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for lift, lowering and auxiliary valves. For reach, tilt and sideshift values the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, replace the current coil with another coil. It the coil change does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

395 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A201

Tilt valve coil shorted

Tilt faulty, call service

Service Manual

MESSAGE TYPE Alarm

EVP5 or EVP6 coil has a short circuit. This alarm is generated by an overcurrent when driving output. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

•

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short circuits from XA4A/15 to XA4A/26 and XA4A/27. Disconnect the controller connector. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for lift, lowering and auxiliary valves. For reach, tilt and sideshift values the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, replace the current coil with another coil. It the coil change does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

396 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A202

Sideshift valve coil shorted

Sideshift faulty, call service

Service Manual

MESSAGE TYPE Alarm

EVP7 or EVP8 coil has a short circuit. This alarm is generated by an overcurrent when driving output. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

•

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short-circuits from XA4A/16 to XA4A/4 and XA4A/5. Disconnect the controller connector. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for lift, lowering and auxiliary valves. For reach, tilt and sideshift values the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, replace the current coil with another coil. It the coil change does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

397 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A203

Multipurpose output load shorted

Auxiliary device %d faulty, call service

Service Manual

MESSAGE TYPE Alarm

EV3 coil has a short circuit. This alarm is generated by an overcurrent when driving output. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

•

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short-circuits from XA4B/15 to XA4B/8. Disconnect the controller connector. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for lift, lowering and auxiliary valves. For reach, tilt and sideshift values the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, replace the current coil with another coil. It the coil change does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

398 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A204

Aux A1 valve coil shorted

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

EV1 coil has a short circuit. This alarm is generated by an overcurrent when driving output. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

•

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short-circuits from XA4A/6 to XA4A/17. Disconnect the controller connector. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for lift, lowering and auxiliary valves. For reach, tilt and sideshift values the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, replace the current coil with another coil. It the coil change does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

399 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A205

Load brake coil shorted

Load wheel brakes faulty, call service

Service Manual

MESSAGE TYPE Alarm

Load wheel brake (EBP9) coil has a short circuit. This alarm is generated by an overcurrent when driving output. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short-circuits from XA4B/8 to XA4B/23. Disconnect the controller connector. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for lift, lowering and auxiliary valves. For reach, tilt and sideshift values the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, replace the current coil with another coil. It the coil change does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

400 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A206

Aux A1 valve coil shorted

Auxiliary device %d faulty, call service

Service Manual

MESSAGE TYPE Alarm

EV2 coil has short circuit. This alarm is generated by overcurrent when driving output. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

•

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short-circuits from XA4A/17 to XA4A/7. Disconnect the controller connector. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for lift, lowering and auxiliary valves. For reach, tilt and sideshift values the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, replace the current coil with another coil. It the coil change does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

401 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A207

VCM master watchdog

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

VMC master watchdog has triggered. This indicates to a hardware or software fault. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

402 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5W208

Controller memory error (EEPROM)

Internal warning Call Service

Service Manual

MESSAGE TYPE Warning

• • •

• •

Revision: C

Document ID: 622075-EN

403 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

5A209

Parameters restored

DISPLAY DESCRIPTION

Service Manual

MESSAGE TYPE Alarm

Software parameters have been restored. If the clear EEPROM procedure was done before this message occurred, this indicates that the clear EEPROM procedure was successfully done. Turn the key switch OFF and ON. If the alarm is still raised: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

404 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A210

Controller memory error (RAM)

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Internal error in the VCM related to the RAM memory. Memory contents check failed. Turn the key switch OFF and ON. If the alarm is still raised: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

405 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A211

Lifting/lowering high side driver open

Lift faulty, call service

Service Manual

MESSAGE TYPE Alarm

Lifting and lowering valve high side driver (XA4A/13) is stuck open. The error is generated by a command to close the active contact, but the voltage does not rise on the output. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • •

• •

Revision: C

Document ID: 622075-EN

406 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A212

Lift/Lower high side driver shorted

Lift faulty, call service

Service Manual

MESSAGE TYPE Alarm

Lifting and lowering valve high side driver (XA4A/13) is stuck closed (short circuited). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • •

• •

Revision: C

Document ID: 622075-EN

407 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A213

Valve setpoint calculation mismatch

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Mismatch between the calculated operation point of the valve between master and slave controller. Turn the key switch OFF and ON. If the alarm is still raised: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

408 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A215

Output error

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Internal error at the output configuration. Turn the key switch OFF and ON. If the alarm is still raised: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

409 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A217

Input A/D converter error

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

A/D conversion inside the controller shows frozen value. Turn the key switch OFF and ON. If the alarm is still raised: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

410 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A218

Digital input mismatch

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

There is a mismatch between the master and slave microcontroller digital input states. Turn the key switch OFF and ON. If the alarm is still raised: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

411 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A219

Analog input mismatch

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

There is a mismatch between the master and slave microcontroller analog or encoder input states. Turn the key switch OFF and ON. If the alarm is still raised: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

412 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A223

CAN bus error

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

No CAN message from the VCM master microcontroller. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that there are no additional devices on the CAN bus when this error occurs. NOTE: The controller debug messages increase the CAN bus load. Make sure that all debug messages from all nodes are disabled. See the settings or the advanced view for the DEBUG message. • • • • •

• • • •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that all nodes in the info view are active in the CAN bus. If there are offlinenodes (which are marked gray) examine their electrical connections. Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Measure the CAN bus resistance from the maintenance socket. The resistance must be approximately 60 Ω. Measure each CANH and CANL line resistance to the battery positive and negative. There should be no connection or extremely high resistance. Disconnect all controller signal connectors. Measure the CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Focus on the unit mentioned in the alarm. Make sure that there is voltage supply to the stated controller.

If there are offline nodes: • •

•

If all nodes are online: • • •

• •

Revision: C

Document ID: 622075-EN

413 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A225

Non-genuine hardware

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

The software signature does not agree with the hardware. This indicates to a non-genuine hardware. The current software is prevented to be installed to this device. • • • • • •

The original hardware has the letters RO in the controller type plate. The original software is downloaded by TruckTool. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings do not help, flash the controller and run the wizards again. If flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the problem still occurs, contact an authorized dealer.

Revision: C

Document ID: 622075-EN

414 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

5A227

EV driver shorted

DISPLAY DESCRIPTION

Service Manual

MESSAGE TYPE Alarm

The driver shorted on EV1 or EVP9. Old message. For more accurate information, update the controller. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

• • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for possible short circuits from ground (XA4B/20) to EV1 and EVP9 (XA4B/15 & 23) (do the measuring while connector XA4A/ is disconnected). If the wiring harness is ok, verify that the short circuit is internal. Measure between controller pin XA4B/20 and XA4B15 and 23 (without the wiring harness connected to the VCM). If there is an internal short circuit, replace the VCM. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for lift, lowering and auxiliary valves. For reach, tilt and sideshift values the correct value is 7.5 Ω. Measure the valve supply voltage. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, replace the current coil with another coil. It the coil change does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

415 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

5A228

EV driver open

DISPLAY DESCRIPTION

Service Manual

MESSAGE TYPE Alarm

Driver open on EV1 or EVP9. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • •

• •

5A229

EV coil open

Coil open on EV1 or EVP9. Old message. For more accurate information, update the controller. If the truck does not have load wheel brakes, or additional equipment connected to output XA4B/15, this fault is caused by an incorrect parameter setup. Otherwise: Examine the wiring harness for possible short-circuits from EV1 or EVP9 (XA4B/15 & 23) outputs to ground (XA4B/20). Measure the EV1 and EVP9 coils that there is ohmic continuity. If there is no short circuit, and ohmic continuity can be measured from pin XA4B/8 to pins XA4B15&23 even with VMC connector connected, try reinstalling the VMC software.

Revision: C

Document ID: 622075-EN

416 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

5A231

EVP driver shorted

DISPLAY DESCRIPTION

Service Manual

MESSAGE TYPE Alarm

The proportional valve driver shorted. Old message. For more accurate information, update the controller. Examine the wiring harness for possible short-circuits from ground (XA4A/29) to one of the EVP valves (do the measuring while connector XA4A/ is disconnected). If the wiring harness is ok, verify that the short circuit is internal. Measure between controller pin XA4B/20 and all EVP and EV valves on the XA4A/ connector. If there is an internal short circuit, replace the VMC. If there is no short circuit even with VMC connector connected, try reinstalling the VMC software. 5A232

Alarm

EVP driver open One of the proportional valve drivers is stuck open.

NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • •

• •

Revision: C

Document ID: 622075-EN

417 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A235

AUX A1 driver shorted

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Driving circuit of EV1 (AUX A1) has a short circuit. This indicates that the driving FET is burned to a close state. Error occurs when voltage of the output is down while the output is not driven. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for possible short-circuits from ground to EV1 XA4A/6 (do the measuring while connector XA4B/ is disconnected). If the harness is OK, make sure that the short circuit is internal. Measure between controller pin XA4A/6 and ground XA4A/29 (without the harness connected to the VCM). If there is an internal short circuit, replace the VCM. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for Lift, Lowering and Auxiliary valves. For Reach, Tilt and Sideshift valves the correct value is 7.5 Ω. Measure the valve supply voltage. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller and run the wizards again. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

418 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A236

AUX A2 driver shorted

Auxiliary device # faulty, call service

Service Manual

MESSAGE TYPE Alarm

Driving circuit of EV2 (AUX A2 valve) has a short circuit. This indicates that the driving FET is burned to a close state. Error occurs when voltage of the output is down while the output is not driven. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for possible short-circuits from ground to EV2 XA4A/7 (do the measuring while connector XA4A/ is disconnected). If the harness is OK, make sure that the short circuit is internal. Measure between controller pin XA4A/7 and ground XA4A/29 (without the harness connected to the VMC). If there is an internal short circuit, replace the VMC. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for Lift, Lowering and Auxiliary valves. For Reach, Tilt and Sideshift valves the correct value is 7.5 Ω. Measure the valve supply voltage. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

419 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A237

Load wheel brake driver shorted

Load wheel brakes faulty, call service

Service Manual

MESSAGE TYPE Alarm

Driving circuit of EVP9 (Load wheel brakes) has a short circuit. This indicates that the driving FET is burned to a close state. Error occurs when voltage of the output is down while the output is not driven. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for possible short-circuits from ground to EVP9 XA4B/23 (do the measuring while connector XA4B/ is disconnected). If the harness is OK, make sure that the short circuit is internal. Measure between controller pin XA4B/23 and ground XA4B/20 (without the harness connected to the VMC). If there is an internal short circuit, replace the VMC. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for Lift, Lowering and Auxiliary valves. For Reach, Tilt and Sideshift valves the correct value is 7.5 Ω. Measure the valve supply voltage. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

420 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A238

Multipurpose output driver shorted

Auxiliary device # faulty, call service

Service Manual

MESSAGE TYPE Alarm

Driving circuit of EV3 (Multipurpose output) has a short circuit. This indicates the driving FET is burned to a close state. Error occurs when voltage of the output is down while the output is not driven. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for possible short-circuits from ground to EV3 XA4B/15 (do the measuring while connector XA4A/ is disconnected). If the harness is OK, make sure that the short circuit is internal. Measure between controller pin XA4B/15 and ground XA4B/20 (without the harness connected to the VMC). If there is an internal short circuit, replace the VMC. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for Lift, Lowering and Auxiliary valves. For Reach, Tilt and Sideshift valves the correct value is 7.5 Ω. Measure the valve supply voltage. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

421 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A239

AUX A1 coil open

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

The coil is open on the load connected to the EV1 valve output (XA4A/6). This alarm is generated by voltage on output that is shorted to the ground while no command is given, and there is no current on the output. If the truck does not have additional equipment connected to output XA4A/6, this fault is caused by an incorrect parameter setup. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The coil open alarm can occur, if there is no power at the VCM pin A1 (from the supplying fuse 6F1) during start-up. • • • •

• • • • • •

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the output status from the TruckTool I/O list. Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short-circuits from the EV1 XA4A/6 output to ground XA4A/29. Disconnect the controller connector. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for Lift, Lowering and Auxiliary valves. For Reach, Tilt and Sideshift valves the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

422 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A240

AUX A2 coil open

Auxiliary device # faulty, call service

Service Manual

MESSAGE TYPE Alarm

The coil is open on load connected to EV2 valve output (XA4A/7). This alarm is generated by voltage on output that is shorted to the ground while no command is given, and there is no current on the output. If the truck does not have additional equipment connected to output XA4A/7, this fault is caused by an incorrect parameter setup. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The coil open alarm can occur, if there is no power at the VCM pin A1 (from the supplying fuse 6F1) during start-up. • • • •

• • • • • •

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the output status from the TruckTool I/O list. Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short-circuits from the EV2 (XA4A/7) output to ground XA4A/29. Disconnect the controller connector. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for Lift, Lowering and Auxiliary valves. For Reach, Tilt and Sideshift valves the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

423 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A241

Load wheel brake coil open

Load wheel brakes faulty, call service

Service Manual

MESSAGE TYPE Alarm

The coil is open on load connected to EVP9 valve output (XA4B/23). This alarm is generated by voltage on output that is shorted to the ground while no command is given, and there is no current on the output. If the truck does not have additional equipment connected to output XA4A/7, this fault is caused by an incorrect parameter setup. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The coil open alarm can occur, if there is no power at the VCM pin A1 (from the supplying fuse 6F1) during start-up. • • • •

• • • • • •

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the output status from the TruckTool I/O list. Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short-circuits from the EVP9 (XA4B/23) output to ground XA4A/20. Disconnect the controller connector. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for Lift, Lowering and Auxiliary valves. For Reach, Tilt and Sideshift valves the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

424 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A242

Multipurpose output load open

Auxiliary device # faulty, call service

Service Manual

MESSAGE TYPE Alarm

The coil is open on load connected to EV3 valve output (XA4B/15). This alarm is generated by voltage on output that is shorted to the ground while no command is given, and there is no current on the output. If the truck does not have additional equipment connected to output XA4B/15, this fault is caused by an incorrect parameter setup. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The coil open alarm can occur, if there is no power at the VCM pin A1 (from the supplying fuse 6F1) during start-up. • • • •

• • • • • •

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the output status from the TruckTool I/O list. Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short-circuits from the EV3 (XA4B/15) output to ground XA4B/20. Disconnect the controller connector. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for Lift, Lowering and Auxiliary valves. For Reach, Tilt and Sideshift valves the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

425 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

5A243

EVP coil open

DISPLAY DESCRIPTION

Service Manual

MESSAGE TYPE Alarm

Proportional valve coil open. Old message. For more accurate information, update the controller. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The coil open alarm can occur, if there is no power at the VCM pin A1 (from the supplying fuse 6F1) during start-up. • • • •

• • • • • •

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the output status from the TruckTool I/O list. Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short-circuits from the EV1 XA4B/15 output to ground XA4B/20. Disconnect the controller connector. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 25 Ω for lift, lowering and auxiliary valves. For reach, tilt and sideshift values the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, replace the current coil with another coil. It the coil change does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

426 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A244

Lift valve coil open

Lift faulty, call service

Service Manual

MESSAGE TYPE Alarm

The coil is open on load connected to EVP1 valve output (XA4A/24). This alarm is generated by voltage on output that is shorted to the ground while no command is given, and there is no current on the output. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The coil open alarm can occur, if there is no power at the VCM pin A1 (from the supplying fuse 6F1) during start-up. • • • •

• • • • • •

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the output status from the TruckTool I/O list. Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short-circuits from the EVP1 (XA4A/24) output to ground (XA4A/29). Disconnect the controller connector. Measure the resistance from the wire harness pin XA4A/13 to pin XA4A/24. The correct value is approximately 25 Ω for Lift, Lowering and Auxiliary valves. For Reach, Tilt and Sideshift valves the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

427 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A245

Lowering valve coil open

Lift faulty, call service

Service Manual

MESSAGE TYPE Alarm

The coil is open on load connected to EVP2 valve output (XA4A/25). This alarm is generated by voltage on output that is shorted to the ground while no command is given, and there is no current on the output. NOTE: The coil open alarm can occur, if there is no power at the VCM pin A1 (from the supplying fuse 6F1) during start-up. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • • •

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the output status from the TruckTool I/O list. Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short-circuits from the EVP2 (XA4A/25) output to ground (XA4A/29). Disconnect the controller connector. Measure the resistance from the wire harness pin XA4A/13 to pin XA4A/25. The correct value is approximately 25 Ω for Lift, Lowering and Auxiliary valves. For Reach, Tilt and Sideshift valves the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

428 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A246

Reach FW valve coil open

Reach faulty, call service

Service Manual

MESSAGE TYPE Alarm

The coil is open on load connected to EVP3 valve output (XA4A/2). This alarm is generated by voltage on output that is shorted to the ground while no command is given, and there is no current on the output. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The coil open alarm can occur, if there is no power at the VCM pin A1 (from the supplying fuse 6F1) during start-up. • • • •

• • • • • •

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the output status from the TruckTool I/O list. Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short-circuits from the EVP3 (XA4A/2) output to ground (XA4A/29). Disconnect the controller connector. Measure the resistance from the wire harness pin XA4A/14 to pin XA4A/2. The correct value is approximately 25 Ω for Lift, Lowering and Auxiliary valves. For Reach, Tilt and Sideshift values the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

429 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A247

Reach BW valve coil open

Reach faulty, call service

Service Manual

MESSAGE TYPE Alarm

The coil is open on load connected to the EVP4 valve output (XA4A/3). This alarm is generated by voltage on output that is shorted to the ground while no command is given, and there is no current on the output. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The coil open alarm can occur, if there is no power at the VCM pin A1 (from the supplying fuse 6F1) during start-up. • • • •

• • • • • •

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the output status from the TruckTool I/O list. Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short-circuits from the EVP4 (XA4A/3) output to ground (XA4A/29). Disconnect the controller connector. Measure the resistance from the wire harness pin XA4A/14 to pin XA4A/3. The correct value is approximately 25 Ω for Lift, Lowering and Auxiliary valves. For Reach, Tilt and Sideshift valves the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

430 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A248

Tilt Down valve coil open

Tilt faulty, call service

Service Manual

MESSAGE TYPE Alarm

The coil is open on load connected to the EVP5 valve output (XA4A/26). This alarm is generated by voltage on output that is shorted to the ground while no command is given, and there is no current on the output. NOTE: The coil open alarm can occur, if there is no power at the VCM pin A1 (from the supplying fuse 6F1) during start-up. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • • •

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the output status from the TruckTool I/O list. Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short-circuits from the EVP5 (XA4A/26) output to ground (XA4A/29). Disconnect the controller connector. Measure the resistance from the wire harness pin XA4A/15 to pin XA4A/26. The correct value is approximately 25 Ω for Lift, Lowering and Auxiliary valves. For Reach, Tilt and Sideshift valves the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

431 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A249

Tilt Up valve coil open

Tilt faulty, call service

Service Manual

MESSAGE TYPE Alarm

The coil is open on load connected to EVP6 valve output (XA4A/27). This alarm is generated by voltage on output that is shorted to the ground while no command is given, and there is no current on the output. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The coil open alarm can occur, if there is no power at the VCM pin A1 (from the supplying fuse 6F1) during start-up. • • • •

• • • • • •

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the output status from the TruckTool I/O list. Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short-circuits from the EVP6 (XA4A/27) output to ground (XA4A/29). Disconnect the controller connector. Measure the resistance from the wire harness pin XA4A/15 to pin XA4A/27. The correct value is approximately 25 Ω for Lift, Lowering and Auxiliary valves. For Reach, Tilt and Sideshift valves the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

432 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A250

Side-Shift Left valve coil open

Sideshift faulty, call service

Service Manual

MESSAGE TYPE Alarm

The coil is open on load connected to EVP7 valve output (XA4A/4). This alarm is generated by voltage on output that is shorted to the ground while no command is given, and there is no current on the output. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The coil open alarm can occur, if there is no power at the VCM pin A1 (from the supplying fuse 6F1) during start-up. • • • •

• • • • • •

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the output status from the TruckTool I/O list. Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short-circuits from the EVP7 (XA4A/4) output to ground (XA4A/29). Disconnect the controller connector. Measure the resistance from the wire harness pin XA4A/16 to pin XA4A/4. The correct value is approximately 25 Ω for Lift, Lowering and Auxiliary valves. For Reach, Tilt and Sideshift valves the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

433 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

5A251

Side-Shift Right valve coil open

Sideshift faulty, call service

Service Manual

MESSAGE TYPE Alarm

The coil is open on load connected to EVP8 valve output (XA4A/5). This error is generated by voltage on output that is shorted to the ground while no command is given, and there is no current on the output. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The coil open alarm can occur, if there is no power at the VCM pin A1 (from the supplying fuse 6F1) during start-up. • • • •

• • • • • •

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the output status from the TruckTool I/O list. Examine the connection from the circuit diagram. Measure the valve supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short-circuits from the EVP8 (XA4A/5) output to ground (XA4A/29). Disconnect the controller connector. Measure the resistance from the wire harness pin XA4A/16 to pin XA4A/5. The correct value is approximately 25 Ω for Lift, Lowering and Auxiliary valves. For Reach, Tilt and Sideshift valves the correct value is 7.5 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. Swap the coil with another one in the system. See if the error moves accordingly. If testing with another coil does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

434 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

13.2

Service Manual

Traction controller

Table 24. Traction controller codes CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8W13

Controller memory error (EEPROM)

Internal warning Call service

MESSAGE TYPE Warning

Internal error in the controller related to the EEPROM memory. General memory failure. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

435 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A17

Internal error #2

Traction faulty, call service

Service Manual

MESSAGE TYPE Alarm

Hardware high current protection is damaged. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

436 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A18

Internal error #1

Traction faulty, call service

Service Manual

MESSAGE TYPE Alarm

Voltage feedback hardware failure. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

437 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A19

Input voltage failure

Traction faulty, call service

Service Manual

MESSAGE TYPE Alarm

Error at the battery voltage. This alarm occurs when there is overvoltage or undervoltage at the key input. The allowed input voltage range (for the logic) is 11 - 65 V. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

438 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A30

Phase voltage lower than expected

Traction faulty, call service

Service Manual

MESSAGE TYPE Alarm

Error at start-up: The motor control transistors are set to ON and OFF at start-up to make sure that they work correctly. This alarm occurs, if the motor phase voltage does not follow the command (the phase voltage is less than 66% of the battery voltage). Error while the motor is running: This alarm occurs if the feedback value of the motor voltage is considerably lower than the commanded value. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • • • • •

• •

Revision: C

Document ID: 622075-EN

439 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A31

Phase voltage higher than expected

Traction faulty, call service

Service Manual

MESSAGE TYPE Alarm

Error at start-up: The motor control transistors are set to ON and OFF at start-up to make sure that they work correctly. This alarm occurs, if the motor phase voltage does not follow the command (the phase voltage is above 110% of the battery voltage). Error while the truck stands still (Drive contactor K2 is closed): This alarm occurs if the phase voltage is more than 50% of the battery voltage. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • • • • •

• •

Revision: C

Document ID: 622075-EN

440 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A37

Contactor K2 stuck closed

Critical failure Call service

Service Manual

MESSAGE TYPE Alarm

Drive contactor is closed at start-up (before commanded). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • • • • •

• •

Revision: C

Document ID: 622075-EN

441 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A38

Contactor K2 stuck open

Critical failure Call service

Service Manual

MESSAGE TYPE Alarm

Drive contactor does not close the power contact. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • • • • •

• •

Revision: C

Document ID: 622075-EN

442 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A53

Current feedback circuit failure

Traction faulty, call service

Service Manual

MESSAGE TYPE Alarm

Current feedback section of the controller is damaged. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

443 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A60

Capacitor charge

Traction faulty, call service

Service Manual

MESSAGE TYPE Alarm

The controller internal capacitor bank is not charged in the desired time. NOTE: Capacitators are charged through a key line, and an internal charging resistor is installed to all controllers. The capacitators are connected to the controller B+ terminal. An additional load parallel to controllers B+ draws voltage through the charging circuit and causes the initialization test to fail. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the valve drive is not stuck to closed state on VCM. In this case, a corresponding alarm shows on VCM. Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). See if there are any additional devices connected to the controllers B+ line. NOTE: All controllers are in parallel. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

444 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8W62

Controller overtemperature

High Temperature Lighten Traction Use

Service Manual

MESSAGE TYPE Warning

Controller over temperature. The controllers are fan-cooled. This alarm occurs when the controller temperature is 85ºC and the maximum current is linearly decreased until the controller temperature is 105ºC. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • •

• • • •

• •

Wait for the controller to cool down. If the over-temperature occurs often, make sure that there are no obstructions to the airflow in the cooling system. If the problem occurs when the truck is cold, look at the controller temperature measurement. If it indicates an over-temperature (over 85 ºC) but the controller is cold, do the tests listed here: Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

445 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8W65

Motor overtemperature

High Temperature Lighten Traction Use

Service Manual

MESSAGE TYPE Warning

Motor overtemperature. Traction motor torque is reduced based on the curve adjusted by the parameters. This alarm indicates high temperature in the traction motor. No specific action is necessary. If the traction motor overheats constantly, consider better cooling. If the problem occurs when the truck is cold, look at the motor temperature sensor measurement. If it indicates an over-temperature but the motor is cold, do the tests listed here: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

• • •

• •

Revision: C

Document ID: 622075-EN

446 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A74

Contactor driver shorted

Critical failure Call service

Service Manual

MESSAGE TYPE Alarm

The driver circuit of the drive contactor (K2) is shorted. This alarm is generated by XA1A/16 output having low voltage while not controlled. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for possible short circuits from ground to XA1A/16 (do the measuring while connector XA1A/ is disconnected). If the wiring harness is ok, verify that the short circuit is internal. Measure between controller pin XA1A/16 and ground B- (without harness connected to the VCM). If there is an internal short circuit, replace the VCM. Measure the resistance of the load. Measure the valve supply voltage. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, replace the current coil with another coil. It the coil change does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

447 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A75

Contactor driver open

Critical failure Call service

Service Manual

MESSAGE TYPE Alarm

An error at the driver controlling the main contactor coil. The failure can be in the wiring / main contactor coil, or in the controller. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • •

• •

Revision: C

Document ID: 622075-EN

448 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8W80

Simultaneous direction commands

Internal alarm Call Service

Service Manual

MESSAGE TYPE Warning

This alarm occurs, when the forward and reverse direction requests are active at the same time. This alarm can indicate to problems in the VCM (this alarm occurs if both control bytes sent by the VCM are on at the same time). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

449 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A82

Motor feedback encoder error

Traction faulty, call service

Service Manual

MESSAGE TYPE Alarm

Error at the motor feedback sensor. The controller monitors the frequency from the encoder. If it changes too quickly, this alarm occurs. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

•

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the sensor value from the I/O menu. Turn the motor and verify that the actual speed (the encoder value) and the set speed (what the controller tries to drive) of the motor are relatively close to each other. Make sure that they both are either positive or negative. Examine the connection from the circuit diagram. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the wire harness connection directly from the encoder connector to the corresponding controller connector. Test the encoder functionality with another sensor. If you are sure that the problem is not in the wire harness and the sensor, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

450 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A216

Main contactor open

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Movement command is active while drive-contactor is reported open. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • •

•

Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

451 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A217

No brake power enabled

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Movement command is active while XA1A/18 power is reported not active. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • •

•

Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up. 8A218

Non-genuine hardware

Internal alarm Call Service

Alarm

The software signature is incorrect from hardware. This indicates non-genuine hardware. Installing current software to this device is prevented. NOTE: Original hardware has the letters RO on the controller type plate. Original software is downloaded by TruckTool. • • •

If the issue remains, contact an authorized dealer.

Revision: C

Document ID: 622075-EN

452 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A219

Controller in selftest mode

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Generic error (the node is in selftest mode). If the node is not able to finish the start-up self diagnostics test, or waiting for NMT command to enter operational mode. Usually, occurs when another node is in an error state, which prevents the finishing of the start-up check. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

453 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A223

Watchdog#1

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

• • •

• •

Revision: C

Document ID: 622075-EN

454 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8W224

Brake coil shorted

Parking brake faulty, call service

Service Manual

MESSAGE TYPE Warning

Brake coil is short circuited. Low impedance causes an overcurrent on the output (XA1A/18) that triggers the warning. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the connection from the circuit diagram. Measure the coil supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short circuits from XA3A/9 to XA1A/18. Disconnect the controller connector. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 35 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, replace the current coil with another coil. It the coil change does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

455 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A227

Watchdog#2

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

• • •

• •

Revision: C

Document ID: 622075-EN

456 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A229

Safety input not active

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Safety input XA1A/11 is open (=not connected to -Batt). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

457 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A230

Contactor coil shorted

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Short circuit at the main contactor (pin XA1A/16) valve coil. After the overload condition is removed, the control command is released and enabled and the alarm exits automatically. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • • • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the connection from the circuit diagram. Measure the coil supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for possible short circuits from XA1A/17 to XA1A/16. Disconnect the controller connector. Measure the resistance from the wire harness pins of the controller. The correct value is approximately 35 Ω. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, replace the current coil with another coil. It the coil change does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

458 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A231

Short circuit protection fault

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Short circuit protection hardware of the outputs has a fault. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

459 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A232

Key line interrupt

Internal alarm Please, restart

Service Manual

MESSAGE TYPE Alarm

Error at the key line voltage. Key line voltage dropped during the start-up sequence. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

460 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A233

Power MOSFET short-circuit

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Internal error in the traction controller. The controller verifies the condition of the power MOSFETs at start-up. If the voltage at the motor phases does not follow the command, this alarm occurs. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

•

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the additional devices connected to the B+ line of the controller are not damaged. NOTE: All controllers are in parallel. Make sure that the wiring harness is not damaged. Pay special attention to the power cables and motor phase cables. Make sure that the related connections do not have loose pins etc. Make sure that there is no leakage current from the motor connections to the battery or truck frame. If there is a leakage current from the motor connections to B+ or B-, disconnect the motor cables. Measure the leakage current from the controller motor terminals to B+ and B-. If there is a low resistance, replace the controller. Make sure that there is ohmic continuity through the motor. Make sure that the main contactor and drive contactor tips are not damaged. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

461 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8W236

Current gain setup not performed

Internal warning Call Service

Service Manual

MESSAGE TYPE Warning

This is an internal error, current gain setup procedure has not been done. This is a calibration procedure, and it can only be done by the manufacturer. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

462 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A237

A/D-converter failure

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

The analog to digital converter in the controller shows frozen values for more than 400 ms. There is always noise in the signals, and thus, this can be indicated as an A/D-converter fault. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

463 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A238

Motor voltage feedback error

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

This is an internal error of the controller. The voltage feedback circuit of the motor phases shows an incorrect value at the rest state. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

464 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A239

Safety output fault

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Safety output driver is shorted. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for short circuits from ground to XA1A/19 (do the measuring while connector XA1A/ is disconnected). If the wiring harness is not damaged, verify if the short circuit is internal. Measure between controller pin XA1A/19 and ground B- (without the wiring harness connected to controller). If there is an internal short circuit, replace the controller. Measure the resistance of the load. Measure the load supply voltage. Disconnect the coil connector, measure the resistance directly from the coil. If the resistance is incorrect, test functionality with another coil. If the test with another coil does not help, set truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

465 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A240

Hardware fault

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

An autocheck is done at start-up. The system examines the functionality of the safety input and the watchdog (the microcontroller examines if the generated fault causes a safety action or not). If this check cannot be done successfully, this alarm occurs. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

466 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A241

Incorrect FLASH checksum

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

After start-up the controller verifies that the program data is intact. If this check returns an incorrect value (the program data is corrupted), this alarm occurs. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

467 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

8A242

Motor locked

DISPLAY DESCRIPTION Traction motor jammed Call Service

Service Manual

MESSAGE TYPE Alarm

The controller drives the motor, but there is no feedback signal. After 4 seconds of this incorrect state, this alarm occurs. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

• • •

If you are sure that the problem is not in the sensor or in the wiring harness: • • •

• •

Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

468 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

8W243

Motor temperature sensor fault

DISPLAY DESCRIPTION Motor temperature sensor faulty, call service

Service Manual

MESSAGE TYPE Warning

Traction motor temperature sensor out of range. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

•

• • •

• •

Revision: C

Document ID: 622075-EN

469 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8W244

Software error

Internal warning Call Service

Service Manual

MESSAGE TYPE Warning

Alarm generated by DEBUG MODE parameter. Only for debugging. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

470 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A245

Controller memory error (RAM)

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Internal software fault in the state machine. The state is saved to 2 RAM locations. The locations are examined in each program cycle. If the values are different, the WRONG RAM MEMORY alarm occurs. Possible sources for the alarm: EMC, Software bug, Faulty RAM. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

471 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A246

Brake driver open

Parking brake faulty, call service

Service Manual

MESSAGE TYPE Alarm

There is a problem with the XA1A/18 output. The output is broken (stuck open). The voltage in the output is high and the current low, even when the logic tries to drive it. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • •

• •

Revision: C

Document ID: 622075-EN

472 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A248

CAN fault

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Periodic CAN bus messages are not received. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that there are no additional devices on the CAN bus when this error occurs. NOTE: The controller debug messages increase the CAN bus load. Make sure that all debug messages from all nodes are disabled. See the settings or the advanced view for the DEBUG message. • • • • •

• • • •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that all nodes in the info view are active in the CAN bus. If there are offlinenodes (which are marked gray) examine their electrical connections. Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Measure the CAN bus resistance from the maintenance socket. The resistance must be approximately 60 Ω. Measure each CANH and CANL line resistance to the battery positive and negative. There should be no connection or extremely high resistance. Disconnect all controller signal connectors. Measure the CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Focus on the unit mentioned in the alarm. Make sure that there is voltage supply to the stated controller.

If there are offline nodes: • •

•

If all nodes are online: • • •

• •

Revision: C

Document ID: 622075-EN

473 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8W250

Controller temperature sensor fault

Internal warning Call Service

Service Manual

MESSAGE TYPE Warning

Internal error in the traction controller. Controller temperature sensor faulty. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

474 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A251

Incorrect battery voltage

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Battery voltage does not match the controller voltage defined in the Nominal battery voltage parameter. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

475 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8W253

Faulty slip profile

Internal warning Call Service

Service Manual

MESSAGE TYPE Warning

Slip frequency parameters are not in ascendent order. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

476 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A254

Brake driver shorted

Parking brake faulty, call service

Service Manual

MESSAGE TYPE Alarm

XA1A/18 output problem. The output is shorted, the load short circuited to ground or load open circuit. The voltage on output stays low even when it is OFF (the output should be 48 V). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

• • • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for possible short circuits from ground to XA1A/18 (do the measuring while connector XA1A/ is disconnected). If the wiring harness is not damaged, verify that the short circuit is internal. Measure between controller pin XA2A/18 and ground B- (without the wiring harness connected to controller). If there is an internal short circuit, replace the controller. Measure the resistance of the load. Measure the load supply voltage. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. It the coil change does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

477 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

8A235

CNA4 open

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

The XA1A/4 input is open, and the emergency input parameter is set to Present (it must always be Absent). This alarm occurs when there are incorrect parameters in the controller. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

478 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

13.3

Service Manual

Display

Table 25. Display controller alarm codes CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

10A8100

Communication error

Internal warning Call Service

MESSAGE TYPE Warning

Error with the CAN bus related communication. Does not prevent usage of the operator panel, can be caused by diagnostics tool CAN dongle. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

479 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

10A8110

Communication error

Internal warning Call Service

Service Manual

MESSAGE TYPE Alarm

Error with the CAN bus related communication. Does not prevent usage of the operator panel, can be caused by diagnostics tool CAN dongle. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

480 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

10A8120

Communication error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Error with the CAN bus related communication. Does not prevent usage of the operator panel, can be caused by diagnostics tool CAN dongle. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

481 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

10A8130

Communication error

Internal warning Call Service

Service Manual

MESSAGE TYPE Alarm

Error with the CAN bus related communication. Does not prevent usage of the operator panel, can be caused by diagnostics tool CAN dongle. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

482 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

10A8140

Communication error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Error with the CAN bus related communication. Does not prevent usage of the operator panel, can be caused by diagnostics tool CAN dongle. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

483 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

10A8150

Communication error

Internal warning Call Service

Service Manual

MESSAGE TYPE Alarm

Error with the CAN bus related communication. Does not prevent usage of the operator panel, can be caused by diagnostics tool CAN dongle. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

484 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

10A8210

Communication error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Error with the CAN bus related communication. Does not prevent usage of the operator panel, can be caused by diagnostics tool CAN dongle. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

485 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

10A8240

Communication error

Internal warning Call Service

Service Manual

MESSAGE TYPE Alarm

Error with the CAN bus related communication. Does not prevent usage of the operator panel, can be caused by diagnostics tool CAN dongle. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

486 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

10AFF02

Wrong operator panel contents configuration

Internal warning Call Service

Service Manual

MESSAGE TYPE Alarm

Error related to the operator panel graphics. Master software trying to use an operator panel configuration which is not supported. Can be related to incorrect software version. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

487 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

10AFF03

Wrong operator panel contents configuration

Internal warning Call Service

Service Manual

MESSAGE TYPE Alarm

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

488 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

13.4

Service Manual

Pump controller

Table 26. Pump controller alarm codes CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20W13

Controller memory error (EEPROM)

Internal warning Call service

MESSAGE TYPE Warning

• • •

• •

Revision: C

Document ID: 622075-EN

489 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A17

Internal error #2

Pump faulty, call service

Service Manual

MESSAGE TYPE Alarm

• • •

• •

Revision: C

Document ID: 622075-EN

490 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A18

Internal error #1

Pump faulty, call service

Service Manual

MESSAGE TYPE Alarm

Voltage feedback hardware failure. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

491 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A19

Input voltage failure

Pump faulty, call service

Service Manual

MESSAGE TYPE Alarm

There is an error at the battery voltage. This alarm occurs when there is overvoltage or undervoltage at the key input. The allowed input voltage range (for the logic) is 11 - 65 V. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

492 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A30

Phase voltage lower than expected

Pump faulty, call service

Service Manual

MESSAGE TYPE Alarm

Error at start-up: The motor control transistors are set to ON and OFF at start-up to make sure that they work correctly. This alarm occurs, if the motor phase voltage does not follow the command (the phase voltage is less than 66% of the battery voltage). Error while the motor is running: This alarm occurs, if the motor voltage feedback value is considerably lower than the commanded value. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

• • • • •

• •

Revision: C

Document ID: 622075-EN

493 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A31

Phase voltage higher than expected

Pump faulty, call service

Service Manual

MESSAGE TYPE Alarm

Error at start-up: The motor control transistors are set to ON and OFF at start-up to make sure that they work correctly. This alarm occurs, if the motor phase voltage does not follow the command (the phase voltage is more than 110% of the battery voltage). Error while truck is standing still (drive contactor K2 is closed): The phase voltage must be less than 50% of the battery voltage. This alarm occurs, if the voltage is higher. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

•

• • • • •

• •

Revision: C

Document ID: 622075-EN

494 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A37

Contactor K2 stuck closed

Critical failure Call service

Service Manual

MESSAGE TYPE Alarm

• • • • • • • •

• •

Revision: C

Document ID: 622075-EN

495 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A38

Contactor K2 stuck open

Critical failure Call service

Service Manual

MESSAGE TYPE Alarm

Drive contactor does not close power contact. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • • • • •

• •

Revision: C

Document ID: 622075-EN

496 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A53

Current feedback circuit failure

Pump faulty, call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs when the current feedback section of the controller is damaged. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

497 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A60

Capacitor charge

Pump faulty, call service

Service Manual

MESSAGE TYPE Alarm

Controller internal capacitor bank is not charged in the desired time. NOTE: Capacitors are charged through keyline, and internal charging resistor is installed to all controllers. Capacitors are connected to B+ terminal. Additional load parallel to controllers B+ will draw voltage through the charging circuit and will cause this initialization test to fail. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • • •

•

• • • •

• •

Revision: C

Document ID: 622075-EN

498 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20W62

Controller overtemperature

High Temperature Lighten pump use

Service Manual

MESSAGE TYPE Warning

• • • •

• •

Wait for the motor to cool down. If the over-temperature occurs often, make sure that the cooling system functions correctly and that there are no obstruction to the airflow. If the problem occurs when the truck is cold, read the controller temperature measurement. If the controller temperature measurement indicates a temperature over 85 ºC, but the controller is cold, do the tests listed below. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

499 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20W65

Motor overtemperature

High Temperature Lighten pump use

Service Manual

MESSAGE TYPE Warning

Motor overtemperature. The pump motor torque is reduced based on the curve adjusted by the parameters. This alarm indicates high temperature on pump motor. No specific action is necessary. If pump motor is constantly overheating, better cooling could be considered. It the problem occurs when the truck is cold, look at the motor temperature sensor measurement. If the temperature sensor indicates a too high temperature but the motor is cold, do the tests listed here: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

• • •

• •

Revision: C

Document ID: 622075-EN

500 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A74

Multipurpose output driver shorted

Internal warning Call Service

Service Manual

MESSAGE TYPE Alarm

Driver circuit of the multipurpose output is shorted. This error occurs when the XA2A/16 output has a low voltage while it is not controlled. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

• • • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for short circuits from ground to XA2A/16 (do the measuring while connector XA2A/ is disconnected). If the wiring harness is not damaged, verify if the short circuit is internal. Measure between controller pin XA2A/16 and ground B- (without the wiring harness connected to the controller). If there is an internal short circuit, replace the controller. Measure the resistance of the load. Measure the load supply voltage. Disconnect the coil connector, measure the resistance directly from the load. If the resistance is incorrect, test the functionality with another load. If the test with another coil does not help, set truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

501 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A75

Multipurpose output driver open

Internal warning Call Service

Service Manual

MESSAGE TYPE Alarm

Error at the driver controlling the Multipurpose output coil. Failure can be in the wiring / Multipurpose output coil, or inside the controller. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • •

• •

Revision: C

Document ID: 622075-EN

502 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20W80

Simultaneous direction commands

Pump Choose direction

Service Manual

MESSAGE TYPE Warning

Forward and reverse direction requests are active at the same time. This alarm can indicate to problems in the VCM (this alarm occurs if both control bytes sent by the VCM are on at the same time). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

503 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A82

Motor feedback encoder error

Pump faulty, call service

Service Manual

MESSAGE TYPE Alarm

•

• • •

If you are sure that the problem is not in the sensor or in the wiring harness: • • •

• •

Revision: C

Document ID: 622075-EN

504 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A219

Controller in selftest mode

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Generic error (the node is in selftest mode). If the node is not able to finish the start-up self diagnostics test, or waiting for NMT command to enter operational mode. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

505 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A223

Watchdog#1

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

The watchdog circuit monitors the software operation. If the software freezes, the watchdog circuit is triggered, and this alarm occurs. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

506 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20W224

Fan output load shorted

Cooling system faulty, call service

Service Manual

MESSAGE TYPE Warning

Fan output load is short circuited. Low impedance causes overcurrent on the output (XA2A/18), that triggers the warning. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the connection from the circuit diagram. Measure the fan supply voltage. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Examine the wiring harness for short-circuits from B+ to XA2A/18. Measure also from the controller terminal. Disconnect the controller connector. Measure the resistance from the controller wiring harness pins. Disconnect the fan connectors. Measure the resistance directly from the fans. If the resistance is incorrect, test the functionality with only one fan connected. If testing with another fan does not help, set the truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

507 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A227

Watchdog#2

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

• • •

• •

Revision: C

Document ID: 622075-EN

508 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A229

Safety input not active

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Safety input XA2A/11 is open (it is not connected to -Batt). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

509 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A230

Multipurpose output load shorted

Internal warning Call Service

Service Manual

MESSAGE TYPE Alarm

Short circuit at the Multipurpose output (XA2A/16) load. After the overload condition is removed, the control command is released and enabled and the alarm exits automatically. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• • • • • •

• •

Revision: C

Document ID: 622075-EN

510 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A231

Short circuit protection fault

Internal warning Call Service

Service Manual

MESSAGE TYPE Alarm

• • • •

• •

Revision: C

Document ID: 622075-EN

511 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A232

Key line interrupt

Internal alarm Please, restart

Service Manual

MESSAGE TYPE Alarm

• • • •

• •

Revision: C

Document ID: 622075-EN

512 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A233

Power MOSFET short-circuit

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Internal error in the pump controller. The controller monitors the condition of the power MOSFETs at start-up. If the voltage at the motor phases does not follow the command, this alarm occurs. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

•

• • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the additional devices connected to the B+ line of the controller are not damaged. NOTE: All controllers are in parallel. Make sure that the wiring harness is not damaged. Focus on the power cables and motor phase cables. Make sure that the related connections do not have loose pins etc. Make sure that there is no leakage current from the motor connections to the battery or truck frame. If there is a leakage current from the motor connections to B+ or B-, disconnect the motor cables. Measure the leakage current from the controller motor terminals to B+ and B-. If there is a low resistance, replace the controller. Make sure that there is ohmic continuity through the motor. Make sure that the main contactor and drive contactor tips are not damaged. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

513 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20W236

Current gain setup not performed

Internal warning Call Service

Service Manual

MESSAGE TYPE Warning

Internal error, current gain setup procedure has not been done. This is a calibration procedure, and it can only be done by the manufacturer. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

514 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A237

A/D-converter failure

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

• • • •

• •

Revision: C

Document ID: 622075-EN

515 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A238

Motor voltage feedback error

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

• • • •

• •

Revision: C

Document ID: 622075-EN

516 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A239

Safety output fault

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Safety output driver is shorted. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

• • • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for short circuits from ground to XA2A/19 (do the measuring while connector XA2A/ is disconnected). If the wiring harness is not damaged, verify if the short circuit is internal. Measure between controller pin XA2A/19 and ground B- (without the wiring harness connected to the controller). If there is an internal short circuit, replace the controller. Measure the resistance of the load. Measure the load supply voltage. Disconnect the coil connector, measure the resistance directly from the coil. If the resistance is incorrect, test functionality with another coil. If the test with another coil does not help, set truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

517 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A240

Hardware fault

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Autocheck at start-up. The system checks the safety input functionality and watchdogs functionality (microcontroller checks if the generated fault causes safety action or not). If this check cannot be done successfully, "hardware fault" error occurs. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

518 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A241

Incorrect FLASH checksum

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

• • •

• •

Revision: C

Document ID: 622075-EN

519 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A242

Motor locked

Pump motor faulty, call service

Service Manual

MESSAGE TYPE Alarm

• •

• • •

If you are sure that the problem is not in the sensor or in the wiring harness: • • •

• •

Revision: C

Document ID: 622075-EN

520 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

20W243

Motor temperature sensor fault

DISPLAY DESCRIPTION Motor temperature sensor faulty, call service

Service Manual

MESSAGE TYPE Warning

Pump motor temperature sensor out of range. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

•

• • •

• •

Revision: C

Document ID: 622075-EN

521 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20W244

Software error

Internal warning Call Service

Service Manual

MESSAGE TYPE Warning

• • •

• •

Revision: C

Document ID: 622075-EN

522 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A245

Controller memory error (RAM)

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when there is an internal software fault in the state machine. The state is saved to 2 RAM locations. The locations are examined in each program cycle. If the values are different, the WRONG RAM MEMORY alarm occurs. Possible sources for the alarm: EMC, Software bug, Faulty RAM. If restarting the truck does not solve the problem the controller is faulty and must be replaced. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

523 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A246

Fan output driver open

Cooling system faulty, call service

Service Manual

MESSAGE TYPE Alarm

XA2A/18 output problem. The output is broken (stuck open). The voltage in the output is high and the current low, even when the logic tries to drive it. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • • •

• •

Revision: C

Document ID: 622075-EN

524 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A248

CAN fault

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

• • • •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that all nodes in the info view are active in the CAN bus. If there are offlinenodes (which are marked gray) examine their electrical connections. Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Measure the CAN bus resistance from the maintenance socket. The resistance must be approximately 60 Ω. Measure each CANH and CANL line resistance to the battery positive and negative. There should be no connection or extremely high resistance. Disconnect all controller signal connectors. Measure the CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Focus on the unit mentioned in the alarm. Make sure that there is voltage supply to the stated controller.

If there are offline nodes: • •

•

If all nodes are online: • • •

• •

Revision: C

Document ID: 622075-EN

525 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20W250

Controller temperature sensor fault

Internal warning Call Service

Service Manual

MESSAGE TYPE Warning

Internal error in the pump controller. Controller temperature sensor faulty. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

526 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A251

Incorrect battery voltage

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Battery voltage does not match the controller voltage defined by the parameter "Nominal battery voltage". NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

527 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20W253

Faulty slip profile

Internal warning Call Service

Service Manual

MESSAGE TYPE Warning

• • • •

• •

Revision: C

Document ID: 622075-EN

528 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A254

Cooling system fault

Cooling system faulty, call service

Service Manual

MESSAGE TYPE Alarm

XA2A/18 output problem. The output is shorted, the load short circuited to ground or the load open (disconnected). The voltage on output stays low even when it is OFF (the output should be 48 V). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

• • • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for possible short circuits from ground to XA2A/18 (do the measuring while connector XA2A/ is disconnected). If the wiring harness is not damaged, verify that the short circuit is internal. Measure between controller pin XA2A/18 and ground B- (without the wiring harness connected to the controller). If there is an internal short circuit, replace the controller. Measure the resistance of the load. Measure the load supply voltage. Disconnect the coil connector. Measure the resistance directly from the coil. If the resistance is wrong, test the functionality with another coil. It the coil change does not help, set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

529 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A216

Main contactor open

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

Movement command is active while drive contactor is reported open. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

530 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A217

No brake power enabled

Internal alarm Call Service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when the movement command is active while brake power is reported not active. This alarm being active in the pump controller indicates an incorrect parameter set. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • •

• •

20A218

Non-genuine hardware

Internal alarm Call Service

Alarm

•

Revision: C

Document ID: 622075-EN

531 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

20A235

CNA4 open

Internal warning Call Service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when the XA2A/4 input is open, and the emergency input parameter is set to Present (it must always be Absent). This alarm occurs when there are incorrect parameters in the controller. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

532 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

13.5

EPS

13.5.1

EPS master

Service Manual

Table 27. EPS master alarm codes CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A8

Watchdog

Internal alarm Call service

MESSAGE TYPE Alarm

• • •

• •

Revision: C

Document ID: 622075-EN

533 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A13

Controller memory error (EEPROM)

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Checksum error of both local parameter lists. Data in EEPROM memory is corrupted and it cannot be restored. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

534 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A16

Incorrect standstill voltage Vuw

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Error in the rest voltage of the power stage (Vuw). Voltage has been outside the allowed range for over 96ms. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

535 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A17

Incorrect standstill voltage Vvu

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when there is an error in the rest voltage of the power stage (Vvu). The voltage has been outside the allowed range for over 96 ms. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

536 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A32

Incorrect start-up voltage

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Error in the rest voltage of the power stage at start-up. Voltage has been outside the allowed range for over 50 ms. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

•

• • • • •

• •

Revision: C

Document ID: 622075-EN

537 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

MESSAGE TYPE

24W48

Main contactor open

Internal warning

Warning

Status of the main contactor on CAN bus is "open" (data sent by VMC). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). It is likely that this error is caused by another controller. Thus, you must do the error code fault diagnostics to other controllers. Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

538 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A53

Current measurement error

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Controller internal current amplifier (for measuring) problem. Output from the amplifier has too big offset from expected value. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

539 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A60

Capacitor charge

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Voltage of the controller internal capacitor bank does not rise quick enough. NOTE: The capacitors are charged through the keyline, and an internal charging resistor is installed to all controllers. The capacitors are connected to the B+ terminal. The additional load parallel to controller B+ draws a voltage through the charging circuit and causes the initialization test to fail. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

•

• • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). This alarm can be caused by the valve driver that is stuck closed on the VCM. In this case, there is a corresponding alarm in the VCM. Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the additional devices connected to the B+ line of the controller are not damaged. NOTE: All controllers are in parallel. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

540 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

24A61

Controller overtemperature

DISPLAY DESCRIPTION Steering over temperature Lighten truck use

Service Manual

MESSAGE TYPE Alarm

Controller temperature has exceeded 80°C limit. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • •

Wait for the controller to cool down. If the overtemperature occurs often, make sure that there are no obstructions to the airflow in the cooling system.

If problem exists with cold truck, verify from controller temperature measurement. If indicating over temperature (over 80°C) and in real life controller is cold, continue with following tests: • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

541 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

24A65

Steering motor overtemperature

DISPLAY DESCRIPTION Steering over temperature Lighten truck use

Service Manual

MESSAGE TYPE Alarm

Steering motor temperature has exceeded set limit in the system (default 120°C). This alarm indicates high temperature on steering motor. No specific action is necessary. If overheating occurs constantly, consider better cooling. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. If the problem occurs when the truck is cold, look at the motor temperature sensor measurement. If the temperature sensor indicates a too high temperature when the motor is cold, do the tests listed here: • • • •

• •

• • •

• •

Revision: C

Document ID: 622075-EN

542 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A70

Overcurrent at key-on

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Current limiter is active at key-on. This points to broken current limiter circuit. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

543 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A71

W phase current stuck to 0

Steering motor faulty, call service

Service Manual

MESSAGE TYPE Alarm

Current in the W phase is 0 (or close to 0) even when above 28% of maximum current is commanded. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

•

• • • • •

• •

Revision: C

Document ID: 622075-EN

544 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A72

V phase current stuck to 0

Steering motor faulty, call service

Service Manual

MESSAGE TYPE Alarm

Current in the V phase is 0 (or close to 0) even when above 28% of maximum current is commanded. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

•

• • • • •

• •

Revision: C

Document ID: 622075-EN

545 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A73

U phase current stuck to 0

Steering motor faulty, call service

Service Manual

MESSAGE TYPE Alarm

Current in the U phase is 0 (or close to 0) even when above 28% of maximum current is commanded. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

•

• • • • •

• •

Revision: C

Document ID: 622075-EN

546 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24W81

0-position teach active

Internal warning Call service

Service Manual

MESSAGE TYPE Warning

Steering 0-position teach mode is set active and the truck was restarted. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

547 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A84

Steering wheel broken

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Steering wheel channels have short circuited. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

If you are sure that the problem is not in the sensor or in the wiring harness do these tests: • • •

• •

Revision: C

Document ID: 622075-EN

548 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24W85

Steering angle limit

Steering limit active

Service Manual

MESSAGE TYPE Warning

Steered wheel has reached the maximum angle (warning should be present only in trucks with 180° steering option). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. If the 180º steering was not set on purposely: • • • • • •

• • •

• •

Run the truck options wizard. Set the 180º steering off. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Charge the battery or do the test with another, full battery. This alarm can occur, if the battery is completely empty. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

549 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

24A185

Inconsistent steering reference sensor state

Service Manual

DISPLAY DESCRIPTION

MESSAGE TYPE

Alarm

Steering wheel position is stored to EEPROM when the truck is turned OFF. When truck is restarted, the reference sensor states are compared to this value. If the sensor states do not match with the shutdown angle, this error occurs. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. •

Turn the steering wheel. Set the power of the truck OFF and ON again.

If the alarm is still raised: • • • •

• • •

• •

•

• • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the steering feedback sensor value(s) from the I/O menu. Make sure that the sensors and switches work correctly in the I/O menu. Make sure that the sensors and switches change state at the right time. If the sensor is stuck to a conductive state, disconnect the sensor. If the alarm goes out of view, the sensor is probably broken and must be replaced. Before you replace the sensor, make sure that there is power supply to the sensor. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Disconnect the controller connector. Measure the resistance from the controller wiring harness pins. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. If there are active sensors (inductive, capacitive, some reed switches etc.), you must remove the sensor connector and manually short circuit pins of the switch (verify correct pins from the circuit diagram). Disconnect the sensor connector, measure the resistance directly from the sensor. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. NOTE: Active sensors cannot be tested this way. If the problem is not in the sensor or in the wiring harness, set the truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

550 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A202

Steering autoteach has failed

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Steering autoteach function has failed. This is caused by too big variance in the automated measuring results. The most likely reason is faulty feedback sensors, or wrong parameter setup. •

Run the "EPS-autoteaching" wizard again.

If the alarm is still raised: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

•

• • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the steering feedback sensor value(s) from the I/O menu. Make sure that the sensors and switches work correctly in the I/O menu. Make sure that the sensors and switches change state at the right time. If the sensor is stuck to a conductive state, disconnect the sensor. If the output state changes, the sensor is probably broken and must be replaced. Before you replace the sensor, make sure that there is power supply to the sensor. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Disconnect the controller connector. Measure the resistance from the controller wiring harness pins. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. If there are active sensors (inductive, capacitive, some reed switches etc.), you must remove the sensor connector and manually short circuit pins of the switch (verify correct pins from the circuit diagram). Disconnect the sensor connector, measure the resistance directly from the sensor. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. NOTE: Active sensors cannot be tested this way. If the problem is not in the sensor or in the wiring harness, set the truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

551 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24W203

Steering autoteach active

Internal alarm Call service

Service Manual

MESSAGE TYPE Warning

Steering autoteach function is operating. Wait for autoteach function to finish and restart the truck. 24A207

Speed setpoint error

Alarm

Master and slave microcontrollers calculate speed setpoints independently. If setpoint calculation results vary above 10 Hz between the master and slave this alarm occurs. Turn the key switch OFF and ON. If the alarm is still raised: • • • • •

• • •

• •

NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

552 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

MESSAGE TYPE

24A208

Output mismatch

Alarm

Error in the motor output speed, current or torque. The master and slave microcontrollers verify the motor operation data independently from each other. If the difference between the measurement results is too big, this alarm occurs. Turn the key switch OFF and ON. If the alarm is still raised: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

553 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A209

Master-slave synchronization error

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Slave microcontroller detects falling edge sent by the master microcontroller on one of its inputs. It is expected every 4 ms. If over 90 ms passes without the falling edge, this alarm occurs. Turn the key switch OFF and ON. If the alarm is still raised: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

24A210

Incompatible master and slave software

Internal alarm Call service

Alarm

Master and slave software are incompatible. • • • • • •

•

Revision: C

Document ID: 622075-EN

554 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24W211

A10 output voltage mismatch

Internal warning Call service

Service Manual

MESSAGE TYPE Warning

This alarm should not be present in the reach truck application. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

555 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A212

Controller memory error (RAM)

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Internal software fault in the state machine. The state is saved to 2 RAM locations. The locations are examined in every program cycle. If the values are different, the WRONG RAM MEMORY alarm occurs. •

Possible sources for the alarm: EMC, Software bug, Faulty RAM.

NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

556 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A213

Parameters have been restored

Internal alarm Please, restart

Service Manual

MESSAGE TYPE Alarm

This alarm is shown after successful clearing of the EEPROM memory. Turn the key switch OFF and ON. If the alarm is still raised: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

557 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A215

Master-slave communication error

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Private CAN bus communication between EPS master and slave microcontrollers have frozen for over 100 ms. Turn the key switch OFF and ON. If the alarm is still raised: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

558 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24W216

A10 output resistance mismatch

Internal warning Call service

Service Manual

MESSAGE TYPE Warning

• • •

• •

24A218

Non-genuine hardware

Internal alarm Call service

Alarm

The software signature does not agree with the hardware. This indicates to a non-genuine hardware. The current software cannot be installed to this device. • • • • •

•

The original hardware has the letters RO in the controller type plate. The original software is downloaded by TruckTool. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings do not help, flash the controller and run the wizards again. If flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the problem still occurs, contact an authorized dealer.

Revision: C

Document ID: 622075-EN

559 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A219

Steering sensor output mismatch

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

There is a problem with the steering wheel sensor output signals: either the peak voltage and frequency do not match, or the difference between the channels is too big. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

If you are sure that the problem is not in the sensor or in the wiring harness do these tests: • • •

• •

Revision: C

Document ID: 622075-EN

560 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A220

Motor locked

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

Torque required to steer the wheel is too big. Make sure that the steered wheel is not mechanically locked by a problem in the steering mechanism or for example a hole in the ground. This error can also occur, if the operating surface has a very strong grip (for example, a very rough tarmac). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

•

• • •

If you are sure that the problem is not in the sensor or in the wiring harness: • • •

• •

Revision: C

Document ID: 622075-EN

561 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A221

Parameter check failure

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Turn the key switch OFF and ON. If the alarm is still raised, change any parameter value from the settings and use the Save to truck function. Set the power of the truck OFF and ON again. If this does not solve the problem, export the default parameters to the truck and try again. If this does not solve the problem, clear the EEPROM and set the default values. If none of the previous actions solve the problem, replace the controller.

Revision: C

Document ID: 622075-EN

562 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A222

Encoder locked 1

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

The controller is driving the motor, but there is no feedback signal. After 4 seconds of this incorrect state, this alarm occurs. Make sure that the steered wheel is not mechanically locked by a problem in the steering mechanism or for example a hole in the ground. This error can also occur, if the operating surface has a very strong grip (for example, a very rough tarmac). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • • •

• • •

If you are sure that the problem is not in the sensor or in the wiring harness: • • •

• •

Revision: C

Document ID: 622075-EN

563 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A223

Encoder error

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when the discontinuity in the feedback encoder output is too big. The cause of this alarm is usually a feedback encoder error. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • • •

• • • •

If you are sure that the problem is not in the sensor or in the wiring harness: • • •

• •

Revision: C

Document ID: 622075-EN

564 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A224

N/A 2

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

• •

Revision: C

Document ID: 622075-EN

565 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24W225

Current gain setup not performed

Internal warning Call service

Service Manual

MESSAGE TYPE Warning

This is an internal error: the current gain setup procedure has not been performed. This is a calibration procedure that only the manufacturer can do. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

566 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

24A227

N/A 3

DISPLAY DESCRIPTION

Service Manual

MESSAGE TYPE Alarm

• • •

• •

Revision: C

Document ID: 622075-EN

567 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A228

Angle measurement error

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

There is an inconsistency between the feedback signals. The operational data between the motor control, encoder and feedback sensors does not match. This is caused by incorrect parameter setup. Also, a problem in S31 or S32 can be the reason for this alarm. •

Turn the steering wheel. Set the power of the truck OFF and ON again.

If the alarm is still raised: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

•

• • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the steering feedback sensor value(s) from the I/O menu. Make sure that the sensors and switches work correctly in the I/O menu. Make sure that the sensors and switches change state at the right time. If the sensor is stuck to a conductive state, disconnect the sensor. If the alarm goes out of view, the sensor is probably broken and must be replaced. Before you replace the sensor, make sure that there is power supply to the sensor. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Disconnect the controller connector. Measure the resistance from the controller wiring harness pins. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. If there are active sensors (inductive, capacitive, some reed switches etc.), you must remove the sensor connector and manually short circuit pins of the switch (verify correct pins from the circuit diagram). Disconnect the sensor connector, measure the resistance directly from the sensor. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. NOTE: Active sensors cannot be tested this way. If the problem is not in the sensor or in the wiring harness, set the truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

568 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

24A229

N/A 4

DISPLAY DESCRIPTION

Service Manual

MESSAGE TYPE

• • •

• •

Revision: C

Document ID: 622075-EN

569 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

24A230

N/A 5

DISPLAY DESCRIPTION

Service Manual

MESSAGE TYPE

• • •

• •

Revision: C

Document ID: 622075-EN

570 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

24A231

N/A 6

DISPLAY DESCRIPTION

Service Manual

MESSAGE TYPE

• • •

• •

Revision: C

Document ID: 622075-EN

571 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

MESSAGE TYPE

24A233

Inconsistent eps start-up angle

Alarm

This alarm occurs, when the steered wheel angle at start-up is different than in the key-off situation. The angles are verified from the states of the feedback sensors S31 and S32. •

Turn the steering wheel. Set the power of the truck OFF and ON again.

NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. If the problem still occurs: • • • •

• • •

• •

•

• • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the steering feedback sensor value(s) from the I/O menu. Make sure that the sensors and switches work correctly in the I/O menu. Make sure that the sensors and switches change state at the right time. If the sensor is stuck to a conductive state, disconnect the sensor. If the alarm goes out of view, the sensor is probably broken and must be replaced. Before you replace the sensor, make sure that there is power supply to the sensor. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Disconnect the controller connector. Measure the resistance from the controller wiring harness pins. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. If there are active sensors (inductive, capacitive, some reed switches etc.), you must remove the sensor connector and manually short circuit pins of the switch (verify correct pins from the circuit diagram). Disconnect the sensor connector, measure the resistance directly from the sensor. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. NOTE: Active sensors cannot be tested this way. If the problem is not in the sensor or in the wiring harness, set the truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

572 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24W235

Brake supply error

Internal alarm Call service

Service Manual

MESSAGE TYPE Warning

This alarm occurs, when there is an error in the XA3A/9 output. The cause can be a short circuit of the load, or an error in the controller. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

• • • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for short circuits from ground to XA3A/9 (do the measuring while connector XA1A/ is disconnected). If the wiring harness is not damaged, verify if the short circuit is internal. Measure between controller pin XA2A/19 and ground B- (without the wiring harness connected to the controller). If there is an internal short circuit, replace the controller. Measure the resistance of the load. Measure the load supply voltage. Disconnect the coil connector, measure the resistance directly from the coil. If the resistance is incorrect, test functionality with another coil. If the test with another coil does not help, set truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

573 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24W236

A10 standby current high

Internal alarm Call service

Service Manual

MESSAGE TYPE Warning

• • •

• •

24W237

Slave microprocessor in alarm

Internal warning

Warning

This alarm occurs when the slave microcontroller is in the alarm mode. •

Look at the EPS slave error codes.

Revision: C

Document ID: 622075-EN

574 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A238

EPS alignment problem

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when there is no input state change from the feedback sensors when expected. The input state change is expected at start-up, when the auto-centering option is on. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. For a solution to this problem: •

Turn the steering wheel. Set the power of the truck OFF and ON again.

If the problem still occurs: • • • •

• • •

• •

•

• • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the steering feedback sensor value(s) from the I/O menu. Make sure that the sensors and switches work correctly in the I/O menu. Make sure that the sensors and switches change state at the right time. If the sensor is stuck to a conductive state, disconnect the sensor. If the alarm goes out of view, the sensor is probably broken and must be replaced. Before you replace the sensor, make sure that there is power supply to the sensor. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Disconnect the controller connector. Measure the resistance from the controller wiring harness pins. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. If there are active sensors (inductive, capacitive, some reed switches etc.), you must remove the sensor connector and manually short circuit pins of the switch (verify correct pins from the circuit diagram). Disconnect the sensor connector, measure the resistance directly from the sensor. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. NOTE: Active sensors cannot be tested this way. If the problem is not in the sensor or in the wiring harness, set the truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

575 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

MESSAGE TYPE

24A239

Waiting for traction controller

Internal alarm

Alarm

This alarm occurs when the EPS is waiting for the traction controller. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

576 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A240

Logic voltage supply error

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when the voltage supply for the power bridge logic controller has failed. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

577 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A241

Encoder locked 2

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when the steered wheel does not follow the command of the controller. Make sure that the steered wheel is not mechanically locked by a problem in the steering mechanism or for example a hole in the ground. This error can also occur, if the operating surface has a very strong grip (for example, a very rough tarmac). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

•

• • •

If you are sure that the problem is not in the sensor or in the wiring harness: • • •

• •

Revision: C

Document ID: 622075-EN

578 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A242

Steering wheel QL line error

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when the mean voltage on the steering wheel sensor QL-line (XA3A/17) is a non-zero. The output is a sinusoidal wave with null mean value. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

If you are sure that the problem is not in the sensor or in the wiring harness do these tests: • • •

• •

Revision: C

Document ID: 622075-EN

579 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A243

Steering wheel DL line error

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when the mean voltage on the steering wheel sensor DL-line (XA3A/20) is a non-zero. The output is a sinusoidal wave with null mean value. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

If you are sure that the problem is not in the sensor or in the wiring harness do these tests: • • •

• •

Revision: C

Document ID: 622075-EN

580 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A244

Parameter transfer failed

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

The master and slave microcontrollers have private parameter listings. When a parameter is changed, the master controller asks the slave to change its correspondent parameter. This alarm occurs when the transfer fails. • • • • • •

Set the power of the truck OFF and ON. If this does not solve the problem, change any parameter value from the settings and use the Save to truck function. Set the power of the truck OFF and ON again. If this does not solve the problem, export the default parameters to the truck and try again. If this does not solve the problem, clear the EEPROM and set the default values. If the problem still occurs, replace the controller.

Revision: C

Document ID: 622075-EN

581 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A247

CANbus error

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when there is no CAN messages from the traction controller to EPS for more than 200 ms. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that there are no additional devices on the CAN bus when this error occurs. NOTE: The controller debug messages increase the CAN bus load. Make sure that all debug messages from all nodes are disabled. See the settings or the advanced view for the DEBUG message. • • • • •

• • • •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that all nodes in the info view are active in the CAN bus. If there are offlinenodes (which are marked gray) examine their electrical connections. Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Measure the CAN bus resistance from the maintenance socket. The resistance must be approximately 60 Ω. Measure each CANH and CANL line resistance to the battery positive and negative. There should be no connection or extremely high resistance. Disconnect all controller signal connectors. Measure the CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Focus on the unit mentioned in the alarm. Make sure that there is voltage supply to the stated controller.

If there are offline nodes: •

•

If all nodes are online: • • •

• •

Revision: C

Document ID: 622075-EN

582 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

MESSAGE TYPE

24A250

Input mismatch

Alarm

This alarm occurs, when there is a mismatch between the master and the slave microcontroller input states. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. For a solution to the problem: •

Set the power of the truck OFF and ON.

If the problem still occurs: • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

583 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A251

Power bridge failure

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

At start-up, all motor-control MOSFETs are off. The motor phase voltages are expected to be half of the input voltage. If there is a large variance from this value, it indicates to a short circuited MOSFET. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. For a solution to the problem: • • • •

•

• • • • •

• •

Revision: C

Document ID: 622075-EN

584 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

24A253

A/D-converter failure

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when the analog to digital converter in the controller shows a frozen value for more than 400 ms. There is always noise in the signals, and thus, this can be indicated as an A/D-converter fault. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

585 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

24A254

A/D-converter failure (SP)

DISPLAY DESCRIPTION

Service Manual

MESSAGE TYPE Alarm

• • • •

• •

Revision: C

Document ID: 622075-EN

586 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

13.5.2

Service Manual

EPS slave

Table 28. EPS slave alarm codes CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A8

Watchdog

Internal alarm Call service

MESSAGE TYPE Alarm

This alarm occurs, when the master-slave CAN communication is frozen. There is probably a software issue. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

587 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A13

Controller memory error (EEPROM)

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when there is a checksum error of both local parameter lists. Data in the EEPROM memory is corrupted and it cannot be restored. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

588 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A16

Incorrect standstill voltage Vuw

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when there is an error in the rest voltage of the power stage (Vuw). The voltage has been outside the allowed range for over 96 ms. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

589 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A17

Incorrect standstill voltage Vvu

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

• • • •

• •

Revision: C

Document ID: 622075-EN

590 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A32

Incorrect start-up voltage

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when there is an error in the rest voltage of the power stage at start-up. The voltage has been outside the allowed range for over 50 ms. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

•

• • • • •

• •

Revision: C

Document ID: 622075-EN

591 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

MESSAGE TYPE

25W48

Main contactor open

Internal warning

Warning

This alarm occurs, when the status of the main contactor in the CAN bus is open (data sent by the VCM). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

592 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A53

Current measurement error

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when there is a problem in the controller internal current amplifier (for measuring). The output from the amplifier has too big offset from the expected value. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

593 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A60

Capacitor charge

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when the voltage of the controller internal capacitor bank does not rise quickly enough. This alarm often occurs because the valve driver is stuck closed on the VCM (there is the corresponding alarm on the VCM). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • • • •

• •

Revision: C

Document ID: 622075-EN

594 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

25A61

Controller overtemperature

DISPLAY DESCRIPTION Steering over temperature Lighten truck use

Service Manual

MESSAGE TYPE Alarm

This alarm occurs when the controller temperature has exceeded the 80°C limit. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • •

Wait for the motor to cool down. If the over-temperature occurs often, make sure that the cooling system functions correctly and that there are no obstruction to the airflow.

If the problem occurs when the truck is cold, read the controller temperature measurement. If the controller temperature measurement indicates a temperature over 80 ºC, but the controller is cold, do the tests listed below. • • • •

• • • •

• •

Revision: C

Document ID: 622075-EN

595 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

25A65

Steering motor overtemperature

DISPLAY DESCRIPTION Steering over temperature Lighten truck use

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when the steering motor temperature exceeds the set limit in the system (the default is 120 ºC). This alarm does not require a specific action. If the steering motor temperature is regularly too high, you must make the cooling of the motor better. If the problem occurs when the truck is cold, read the controller temperature measurement. If the controller temperature measurement indicates a temperature over 120 ºC, but the controller is cold, do the tests listed below. • • • •

• •

• • •

• •

Revision: C

Document ID: 622075-EN

596 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A70

Overcurrent at key-on

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when the current limiter is active at start-up. This points to a broken current limiter circuit. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

597 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A71

W phase current stuck to 0

Steering motor faulty, call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when the current in the W phase is 0 (or close to 0) even when above 28% of the maximum current is commanded. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

•

• • • • •

• •

Revision: C

Document ID: 622075-EN

598 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A72

V phase current stuck to 0

Steering motor faulty, call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs when the current in the V phase is 0 (or close to 0) even when above 28% of the maximum current is commanded. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

•

• • • • •

• •

Revision: C

Document ID: 622075-EN

599 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A73

U phase current stuck to 0

Steering motor faulty, call service

Service Manual

MESSAGE TYPE Alarm

•

• • • • •

• •

Revision: C

Document ID: 622075-EN

600 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25W81

0 position teach active

Internal warning Call service

Service Manual

MESSAGE TYPE Warning

This alarm occurs when the steering 0-position teach-mode is set active and the truck has been restarted. This alarm is a part of the steering wheel 0-position teaching process. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. If the steering wheel 0-position teaching process was not initiated: • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

601 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A84

Steering wheel broken

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when the steering wheel channels have short circuited. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

If you are sure that the problem is not in the sensor or in the wiring harness do these tests: • • •

• •

Revision: C

Document ID: 622075-EN

602 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25W85

Steering angle limit

Steering limit active

Service Manual

MESSAGE TYPE Warning

This alarm occurs, when the steered wheel has reached the maximum angle. This alarm should only occur in trucks with the 180º steering option. This alarm is a part of the normal operation when the 180º steering has been set to Present. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. If the 180º steering was not set on purposely: • • • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

603 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A185

Inconsistent steering reference-sensor state

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

The position of the steering wheel is stored to EEPROM when the power of the truck is set to OFF. When the power of the truck is set to ON again, the reference sensor states are compared to this value. If the sensor states do not match with the shutdown angle, this error occurs. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. •

Turn the steering wheel. Set the power of the truck OFF and ON again.

If the problem still occurs: • • • •

• • •

• •

•

• • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the steering feedback sensor value(s) from the I/O menu. Make sure that the sensors and switches work correctly in the I/O menu. Make sure that the sensors and switches change state at the right time. If the sensor is stuck to a conductive state, disconnect the sensor. If the alarm goes out of view, the sensor is probably broken and must be replaced. Before you replace the sensor, make sure that there is power supply to the sensor. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Disconnect the controller connector. Measure the resistance from the controller wiring harness pins. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. If there are active sensors (inductive, capacitive, some reed switches etc.), you must remove the sensor connector and manually short circuit pins of the switch (verify correct pins from the circuit diagram). Disconnect the sensor connector, measure the resistance directly from the sensor. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. NOTE: Active sensors cannot be tested this way. If the problem is not in the sensor or in the wiring harness, set the truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

604 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A202

Steering autoteach has failed

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs when the steering autoteach function has failed. This is caused by variance that is too big in the automated measuring results. •

Do the EPS-autoteaching wizard again.

If the EPS-autoteaching wizard does not solve the problem: NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• • •

• •

•

• • •

• •

25W203

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the steering feedback sensor value(s) from the I/O menu. Make sure that the sensors and switches work correctly in the I/O menu. Make sure that the sensors and switches change state at the right time. If the sensor is stuck to a conductive state, disconnect the sensor. If the output state changes, the sensor is probably broken and must be replaced. Before you replace the sensor, make sure that there is power supply to the sensor. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Disconnect the controller connector. Measure the resistance from the controller wiring harness pins. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. If there are active sensors (inductive, capacitive, some reed switches etc.), you must remove the sensor connector and manually short circuit pins of the switch (verify correct pins from the circuit diagram). Disconnect the sensor connector, measure the resistance directly from the sensor. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. NOTE: Active sensors cannot be tested this way. If the problem is not in the sensor or in the wiring harness, set the truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Steering autoteach active

Internal alarm Call service

Warning

This alarm occurs when the steering auto teach function is operating. Wait for the auto-teaching calibration to finish and restart the truck.

Revision: C

Document ID: 622075-EN

605 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A207

Speed setpoint error

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

The master and slave microcontrollers calculate the speed set points independently. This alarm occurs if the difference between the set point calculation results between the master and the slave is more than 10 Hz. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. •

Set the power of the truck OFF and ON.

If the problem still occurs: • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

606 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A208

Output mismatch

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when there is an error in the motor output speed, current or torque. The master and slave microcontrollers verify the motor operation data independently from each other. If the difference between the measurement results is too big, this alarm occurs. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. •

Set the power of the truck OFF and ON.

If the problem still occurs: • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

607 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A209

Master-slave synchronization error

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

The slave microcontroller detects a falling edge sent by the master microcontroller on one of its inputs. The falling edge is expected every 4 ms. If over 90 ms passes without the falling edge, this alarm occurs. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. •

Set the power of the truck OFF and ON.

If the problem still occurs: • • • •

• • •

• •

25A210

Incompatible master and slave SW

Internal alarm Call service

Alarm

This alarm occurs, when the master and slave software are incompatible. NOTE: The original hardware has the letters RO in the controller type plate and the original software is downloaded by TruckTool. • • • •

•

Read the master and slave software versions from the Info view. The versions must be the same. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the master and slave controllers and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If you cannot solve the problem, contact an authorized dealer.

Revision: C

Document ID: 622075-EN

608 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A212

Controller memory error (RAM)

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when there is an internal software fault in the state machine. The state is saved to 2 RAM locations. The locations are examined in every program cycle. If the values are different, the WRONG RAM MEMORY alarm occurs. • •

Possible sources: EMC, Software bug, Faulty RAM. If the error occurs after you have set the power of the truck OFF and ON again, the controller is damaged and must be replaced.

NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. For a solution to the problem: • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

609 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A213

Parameters have been restored

Internal alarm Please, restart

Service Manual

MESSAGE TYPE Alarm

This alarm occurs after a successful clearing of the EEPROM memory. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. •

Set the power of the truck OFF and ON.

If the problem still occurs: • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

610 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A215

Master-slave communication error

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when the private CAN bus communication between the EPS master and slave microcontrollers is frozen for over 100 ms. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. •

Set the power of the truck OFF and ON.

If the problem still occurs: • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

611 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25W216

A10 output resistance mismatch

Internal alarm Call service

Service Manual

MESSAGE TYPE Warning

• • •

• •

25A218

Non-genuine hardware

Internal alarm Call service

Alarm

This alarm occurs when the software signature does not agree with the hardware. This indicates to non-genuine hardware. The current software cannot be installed to this device. The original hardware has the letters RO in the controller type plate and the original software is downloaded by TruckTool. • • •

•

Revision: C

Document ID: 622075-EN

612 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A219

Steering sensor output mismatch

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when there is a problem with the steering wheel sensor output signals: either the peak voltage and frequency do not match, or the difference between the channels is too big. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

• •

If you are sure that the problem is not in the sensor or in the wiring harness do these tests: • • •

• •

Revision: C

Document ID: 622075-EN

613 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A220

Motor locked

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs when the torque required to steer the wheel is too big. Make sure that the steered wheel is not mechanically locked by a problem in the steering mechanism or for example a hole in the ground. This error can also occur, if the operating surface has a very strong grip (for example, a very rough tarmac). NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • •

•

• • •

If you are sure that the problem is not in the sensor or in the wiring harness: • • •

• •

Revision: C

Document ID: 622075-EN

614 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A221

Parameter check failure

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Master / slave CPU parameters do not match. This error is usually caused by adjusting the parameters, and using the truck at the same time. This will cause the master and slave parameter check to fail. When adjusting the parameters, operator should wait for a second after changing the parameter value before testing. • • • • • •

Set the power of the truck OFF and ON. If the alarm is still raised, change any parameter value from the settings and use the Save to truck function. Set the power of the truck OFF and ON again. If this does not solve the problem, export the default parameters to the truck and try again. If this does not solve the problem, clear the EEPROM and set the default values. If none of the previous actions solve the problem, replace the controller.

Revision: C

Document ID: 622075-EN

615 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A222

Encoder locked 1

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

•

• • •

If you are sure that the problem is not in the sensor or in the wiring harness: • • •

• •

Revision: C

Document ID: 622075-EN

616 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A223

Encoder error

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

•

• • •

If you are sure that the problem is not in the sensor or in the wiring harness: • • •

• •

Revision: C

Document ID: 622075-EN

617 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25W225

Current gain setup not performed

Internal warning Call service

Service Manual

MESSAGE TYPE Warning

• • •

• •

Revision: C

Document ID: 622075-EN

618 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A228

Angle measurement error

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when there is an inconsistency between the feedback signals. The operational data between the motor control, encoder and feedback sensors does not match. This is caused by incorrect parameter setup. Also, a problem in S31 or S32 can be the reason for this alarm. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. For a solution to this problem: •

Turn the steering wheel. Set the power of the truck OFF and ON again.

If the problem still occurs: • • • •

• • •

• •

•

• • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the steering feedback sensor value(s) from the I/O menu. Make sure that the sensors and switches work correctly in the I/O menu. Make sure that the sensors and switches change state at the right time. If the sensor is stuck to a conductive state, disconnect the sensor. If the alarm goes out of view, the sensor is probably broken and must be replaced. Before you replace the sensor, make sure that there is power supply to the sensor. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Disconnect the controller connector. Measure the resistance from the controller wiring harness pins. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. If there are active sensors (inductive, capacitive, some reed switches etc.), you must remove the sensor connector and manually short circuit pins of the switch (verify correct pins from the circuit diagram). Disconnect the sensor connector, measure the resistance directly from the sensor. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. NOTE: Active sensors cannot be tested this way. If the problem is not in the sensor or in the wiring harness, set the truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

619 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A233

Inconsistent eps start-up angle

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when the steered wheel angle at start-up is different than in the key-off situation. The angles are verified from the states of the feedback sensors S31 and S32. •

Turn the steering wheel. Set the power of the truck OFF and ON again.

NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. If the problem still occurs: • • • •

• • •

• •

•

• • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the steering feedback sensor value(s) from the I/O menu. Make sure that the sensors and switches work correctly in the I/O menu. Make sure that the sensors and switches change state at the right time. If the sensor is stuck to a conductive state, disconnect the sensor. If the alarm goes out of view, the sensor is probably broken and must be replaced. Before you replace the sensor, make sure that there is power supply to the sensor. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Disconnect the controller connector. Measure the resistance from the controller wiring harness pins. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. If there are active sensors (inductive, capacitive, some reed switches etc.), you must remove the sensor connector and manually short circuit pins of the switch (verify correct pins from the circuit diagram). Disconnect the sensor connector, measure the resistance directly from the sensor. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. NOTE: Active sensors cannot be tested this way. If the problem is not in the sensor or in the wiring harness, set the truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

620 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25W235

Brake supply error

Internal alarm Call service

Service Manual

MESSAGE TYPE Warning

• •

• • • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the wiring harness for short circuits from ground to XA3A/9 (do the measuring while connector XA1A/ is disconnected). If the wiring harness is not damaged, verify if the short circuit is internal. Measure between controller pin XA2A/19 and ground B- (without the wiring harness connected to the controller). If there is an internal short circuit, replace the controller. Measure the resistance of the load. Measure the load supply voltage. Disconnect the coil connector, measure the resistance directly from the coil. If the resistance is incorrect, test functionality with another coil. If the test with another coil does not help, set truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

621 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25W236

A10 standby current high

Internal alarm Call service

Service Manual

MESSAGE TYPE Warning

• • •

• •

25W237

Waiting EPS master

The EPS slave microcontroller is waiting for the ready to steer command from the EPS master microcontroller at start-up. If the message is not received within 4 seconds from the start-up, this alarm occurs. •

Examine the EPS master error codes.

Revision: C

Document ID: 622075-EN

622 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A238

EPS alignment problem

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

This alarm occurs, when there is no input state change from the feedback sensors when expected. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. For a solution to this problem: •

Turn the steering wheel. Set the power of the truck OFF and ON again.

If the problem still occurs: • • • •

• • •

• •

•

• • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Examine the steering feedback sensor value(s) from the I/O menu. Make sure that the sensors and switches work correctly in the I/O menu. Make sure that the sensors and switches change state at the right time. If the sensor is stuck to a conductive state, disconnect the sensor. If the alarm goes out of view, the sensor is probably broken and must be replaced. Before you replace the sensor, make sure that there is power supply to the sensor. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Disconnect the controller connector. Measure the resistance from the controller wiring harness pins. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. If there are active sensors (inductive, capacitive, some reed switches etc.), you must remove the sensor connector and manually short circuit pins of the switch (verify correct pins from the circuit diagram). Disconnect the sensor connector, measure the resistance directly from the sensor. The resistance must follow the functionality of the circuit diagram, when the sensor is operated. NOTE: Active sensors cannot be tested this way. If the problem is not in the sensor or in the wiring harness, set the truck back to the default settings and run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the controller and run the wizards again. If the flashing does not help, replace the current controller with another controller. NOTE: If the controller replacement does not help, install the original controller back to the truck. If the controller replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

623 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

MESSAGE TYPE

25A239

Waiting for traction controller

Internal alarm

Alarm

• • •

• •

Revision: C

Document ID: 622075-EN

624 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A240

Logic voltage supply error

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

• • • •

• •

Revision: C

Document ID: 622075-EN

625 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A241

Encoder locked 2

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

•

• • •

If you are sure that the problem is not in the sensor or in the wiring harness: • • •

• •

Revision: C

Document ID: 622075-EN

626 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A242

Steering wheel QL line error

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

• •

If you are sure that the problem is not in the sensor or in the wiring harness do these tests: • • •

• •

Revision: C

Document ID: 622075-EN

627 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A243

Steering wheel DL line error

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

• •

If you are sure that the problem is not in the sensor or in the wiring harness do these tests: • • •

• •

Revision: C

Document ID: 622075-EN

628 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A244

Parameter transfer failed

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Motor resistance acquiring

Steering disabled

Warning

This alarm occurs when the motor resistance is being acquired. This alarm should not occur in the reach truck application. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. • • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

629 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A247

CANbus error

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

• • • •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that all nodes in the info view are active in the CAN bus. If there are offlinenodes (which are marked gray) examine their electrical connections. Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Measure the CAN bus resistance from the maintenance socket. The resistance must be approximately 60 Ω. Measure each CANH and CANL line resistance to the battery positive and negative. There should be no connection or extremely high resistance. Disconnect all controller signal connectors. Measure the CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Focus on the unit mentioned in the alarm. Make sure that there is voltage supply to the stated controller.

If there are offline nodes: •

•

If all nodes are online: • • •

• •

Revision: C

Document ID: 622075-EN

630 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A250

Input mismatch

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

Set the power of the truck OFF and ON.

If the problem still occurs: • • • •

• • •

• •

Revision: C

Document ID: 622075-EN

631 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A251

Power bridge failure

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

•

• • • • •

• •

Revision: C

Document ID: 622075-EN

632 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A253

A/D-converter failure

Internal alarm Call service

Service Manual

MESSAGE TYPE Alarm

• • • •

• •

Revision: C

Document ID: 622075-EN

633 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

25A254

A/D-converter failure (SP)

Steering faulty, call service

Service Manual

MESSAGE TYPE Alarm

• • • •

• •

Revision: C

Document ID: 622075-EN

634 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

13.6

Service Manual

Arm rest controller

Table 29. Arm rest controller alarm codes CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5030

Lift minilever, sensor idle voltage invalid at startup

Internal warning Call service

MESSAGE TYPE Alarm

Lift minilever, channel A, sensor idle voltage invalid at startup. The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

635 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5031

Lift minilever, sensor idle voltage invalid at startup

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Lift minilever, channel B, sensor idle voltage invalid at startup. The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

636 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5032

Reach minilever, sensor idle voltage invalid at startup

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Reach minilever, channel A, sensor idle voltage invalid at startup. The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

637 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5033

Reach minilever, sensor idle voltage invalid at startup

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Reach minilever, channel B, sensor idle voltage invalid at startup. The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

638 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5034

Tilt minilever, sensor idle voltage invalid at startup

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Tilt minilever, channel A, sensor idle voltage invalid at startup. The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

639 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5035

Tilt minilever, sensor idle voltage invalid at startup

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Tilt minilever, channel B, sensor idle voltage invalid at startup. The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

640 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5036

Side-shift minilever, sensor idle voltage invalid at startup

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Side-shift minilever, channel A, sensor idle voltage invalid at startup. The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

641 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5037

Side-shift minilever, sensor idle voltage invalid at startup

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Side-shift minilever, channel B, sensor idle voltage invalid at startup. The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

642 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5038

AUX-hydraulics minilever, sensor idle voltage invalid at startup

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

AUX-hydraulics minilever, channel A, sensor idle voltage invalid at startup. The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

643 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5039

AUX-hydraulics minilever, sensor idle voltage invalid at startup

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

AUX-hydraulics minilever, channel B, sensor idle voltage invalid at startup. The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

644 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A503A

FNR switch, sensor idle voltage invalid at startup

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

FNR switch, channel A, sensor idle voltage invalid at startup. The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

645 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A503B

FNR switch, sensor idle voltage invalid at startup

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

FNR switch, channel B, sensor idle voltage invalid at startup. The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

646 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A503C

F2 button, sensor idle voltage invalid at startup

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

F2 button, channel A, sensor idle voltage invalid at startup. The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

647 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A503D

F2 button, sensor idle voltage invalid at startup

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

F2 button, channel B, sensor idle voltage invalid at startup. The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

648 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5040

Lift minilever, sensor output voltage out of reading range

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Lift minilever, channel A, sensor voltage outside allowed reading range (0.1 V ... 4.95 V). The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

649 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5041

Lift minilever, sensor output voltage out of reading range

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Lift minilever, channel B, sensor voltage outside allowed reading range (0.1 V ... 4.95 V). The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

650 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5042

Reach minilever, sensor output voltage out of reading range

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Reach minilever, channel A, sensor voltage outside allowed reading range (0.1 V ... 4.95 V). The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

651 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5043

Reach minilever, sensor output voltage out of reading range

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Reach minilever, channel B, sensor voltage outside allowed reading range (0.1 V ... 4.95 V). The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

652 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5044

Tilt minilever, sensor output voltage out of reading range

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Tilt minilever, channel A, sensor voltage outside allowed reading range (0.1 V ... 4.95 V). The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

653 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5045

Tilt minilever, sensor output voltage out of reading range

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Tilt minilever, channel B, sensor voltage outside allowed reading range (0.1 V ... 4.95 V). The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

654 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5046

Side-shift minilever, sensor output voltage out of reading range

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Side-shift minilever, channel A, sensor voltage outside allowed reading range (0.1 V ... 4.95 V). The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

655 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5047

Side-shift minilever, sensor output voltage out of reading range

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Side-shift minilever, channel B, sensor voltage outside allowed reading range (0.1 V ... 4.95 V). The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

656 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5048

AUX-hydraulics minilever, sensor output voltage out of reading range

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

AUX-hydraulics minilever, channel A, sensor voltage outside allowed reading range (0.1 V ... 4.95 V). The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

657 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5049

AUX-hydraulics minilever, sensor output voltage out of reading range

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

AUX-hydraulics minilever, channel B, sensor voltage outside allowed reading range (0.1 V ... 4.95 V). The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

658 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A504A

FNR switch, sensor output voltage out of reading range

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

FNR switch, channel A, sensor voltage outside allowed reading range (0.1 V ... 4.95 V). The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

659 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A504B

FNR switch, sensor output voltage out of reading range

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

FNR switch, channel B, sensor voltage outside allowed reading range (0.1 V ... 4.95 V). The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

660 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A504C

F2 button, sensor output voltage out of reading range

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

F2 button, channel A, sensor voltage outside allowed reading range (0.1 V ... 4.95 V). The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

661 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A504D

F2 button, sensor output voltage out of reading range

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

F2 button, channel B, sensor voltage outside allowed reading range (0.1 V ... 4.95 V). The warning disappears automatically when the conditions are correct. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

662 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5050

Lift minilever, comparison of the redundant sensors

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Lift minilever, sensor redundancy check failed. This alarm requires a restart to clear the conditions. During the failure, the sensor output = 0. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

663 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5051

Reach minilever, comparison of the redundant sensors

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Reach minilever, sensor redundancy check failed. This alarm requires a restart to clear the conditions. During the failure, the sensor output = 0. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

664 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5052

Tilt minilever, comparison of the redundant sensors

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Tilt minilever, sensor redundancy check failed. This alarm requires a restart to clear the conditions. During the failure, the sensor output = 0. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

665 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5053

Side-shift minilever, comparison of the redundant sensors

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

Side-shift minilever, sensor redundancy check failed. This alarm requires a restart to clear the conditions. During the failure, the sensor output = 0. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

666 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5054

AUX hydraulics minilever, comparison of the redundant sensors

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

AUX hydraulics minilever, sensor redundancy check failed. This alarm requires a restart to clear the conditions. During the failure, the sensor output = 0. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

667 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5055

FNR switch, comparison of the redundant sensors

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

FNR switch, sensor redundancy check failed. This alarm requires a restart to clear the conditions. During the failure, the sensor output = 0. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

668 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A5056

F2 button, comparison of the redundant sensors

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

F2 button, sensor redundancy check failed. This alarm requires a restart to clear the conditions. During the failure, the sensor output = 0. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

669 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A6100

Internal error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

An internal error related to the watchdog functionality. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

670 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A6102

Internal error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

671 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A6103

Internal error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

672 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A610A

Internal error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

673 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A6106

Internal error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

An internal error related to memory handling. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

674 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A6107

Internal error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

675 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A6108

Internal error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

676 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A6109

Internal error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

677 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A610B

Internal error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

An internal error related to EEPROM memory handling. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

678 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A610C

Internal error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

679 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A610D

Internal error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

680 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A610E

Internal error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

681 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A610F

Internal error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

682 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A8110

Communication error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

An error with CAN bus related communication. Does not prevent the use of the armrest, can be caused by the TruckTool (Peak) CAN dongle. NOTE: During resistance measurements, make sure that the battery connector is disconnected, and that the voltage at the measured circuit is 0 V. NOTE: The Peak dongle can cause CAN bus failures. Make sure that the error is present without any additional devices on the bus. NOTE: Controller debug messages increase the bus load. Make sure that the controller debug messages from all nodes are disabled. See settings / Advanced view for DEBUG message. • • • •

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

683 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A8120

Communication error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

684 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A8130

Communication error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

685 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A8140

Communication error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

686 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A8210

Communication error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

687 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A8220

Communication error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

• • • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the primary CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure the secondary CAN bus resistance from the debug socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

688 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

CODE

TRUCKTOOL DESCRIPTION

DISPLAY DESCRIPTION

32A8240

Communication error

Internal warning Call service

Service Manual

MESSAGE TYPE Alarm

• • •

• • • • • • •

• •

Read the alarm status from each controller. Try to make an overall picture of the root cause for the event code(s). Make sure that the battery is not damaged. Measure the battery voltage when idle, and during full speed lift. The battery voltage must stay over 38 V. Make sure that the fuses are not damaged. Make sure that the truck frame is isolated from the battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). Make sure that the truck model configuration is correct (from I/O list, VCM numeric, from advanced view). Measure the CAN bus resistance from the maintenance socket. The resistance must be about 60 Ω. Measure each CANH and CANL line resistance to battery positive and negative. Measure this from both sides of the drive contactor. Make sure that there is no short-circuit or low resistance between the positive and negative from the terminals of any controller (B+ and B- terminals). The resistance must be several kilo-ohms. Disconnect all signal connectors of the controllers and measure CAN bus shield conductivity. Make sure that the wiring harness is not damaged. Make sure that the related connections do not have loose pins etc. Measure the armrest supply voltage. It must be about 12 V. Calibrate the armrest with the TruckTool calibration wizard again. Set the truck back to the default settings. Run the truck model configuration wizard. If the default settings are not a solution to the problem, flash the armrest and run the wizards again. If the flashing does not help, replace the current armrest with another armrest. NOTE: If the armrest replacement does not help, install the original armrest back to the truck. If the armrest replacement does not help, evaluate the possible root causes for the alarm again. Also, see if there are other alarm messages active in the system. Clear the online error codes in TruckTool. Set the power of the truck OFF and ON again: other error codes can show up during start-up.

Revision: C

Document ID: 622075-EN

689 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

Service data 14.1

Special tightening torques

Traction wheel

80 Nm

Traction controller terminal bolts

7 Nm (±1.4 Nm)

Traction motor power terminals

6 Nm

Motor and transmission top section

23 Nm

14.2

Tightening torque for standard bolts and nuts

If no other tightening torque is given, you can use the tightening torques in the table below. The standard pitch is marked with grey color in the table. 8.8

10.9

12.9

Bolt size

Pitch [mm]

kg-m

0.70

2.8

0.3

4.1

0.4

4.8

0.5

0.80

5.5

0.6

8.1

0.8

9.5

1.0

1.00

9.5

1.0

1.4

16.5

1.7

1.00

1.5

2.3

2.9

1.25

2.3

3.5

4.1

1.00

2.4

3.7

4.4

1.50

4.7

6.9

8.1

1.00

5.3

7.7

9.1

1.25

5.0

7.3

8.6

1.75

8.1

115

11.7

135

13.8

1.25

8.9

125

12.7

150

15.3

1.50

8.5

120

12.2

145

14.8

1.75

125

12.7

185

18.9

215

21.9

1.50

135

13.8

200

20.4

235

24.0

2.00

195

19.9

280

28.6

330

33.7

1.50

205

20.9

300

30.6

360

36.7

M10

M12

M14

M16

Revision: C

Document ID: 622075-EN

690 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

8.8

10.9

Service Manual

12.9

Bolt size

Pitch [mm]

kg-m

M18

2.50

280

28.6

390

39.8

460

46.9

1.50

310

31.6

440

44.9

520

53.0

2.00

290

29.6

420

42.8

490

50.0

2.50

390

39.8

560

57.1

650

66.3

1.50

430

43.8

620

63.2

720

73.4

2.50

530

54.0

750

76.5

880

89.7

1.50

580

59.1

820

83.6

960

97.9

3.00

670

68.3

960

97.9

1,000

112.2

1.50

760

77.5

1,100

112.2

1,250

127.5

2.00

730

74.4

1,050

107.1

1,200

122.4

3.00

1,000

102.0

1,400

142.8

1,650

168.3

1.50

1,100

112.2

1,600

163.2

1,850

188.6

2.00

1,050

107.1

1,500

153.0

1,800

183.5

3.50

1,350

137.7

1,900

193.7

2,250

229.4

1.50

1,550

158.1

2,200

224.3

2,550

260.0

2.00

1,500

153.0

2,100

214.1

2,500

254.9

3.50

1,850

188.6

2,600

265.1

3,000

305.9

1.50

2,050

209.0

2,900

295.7

3,400

346.7

2.00

2,000

203.9

2,800

285.5

3,300

336.5

4.00

2,350

239.6

3,300

336.5

3,900

397.7

1.50

2,700

275.3

3,800

387.5

4,450

453.8

3.00

2,500

254.9

3,500

356.9

4,100

418.1

4.00

3,000

305.9

4,300

438.5

5,100

520.1

1.50

3,450

351.8

4,900

499.7

5,700

581.2

3.00

3,200

326.3

4,600

469.1

5,300

540.4

M20

M22

M24

M27

M30

M33

M36

M39

Revision: C

Document ID: 622075-EN

691 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

14.3

Service Manual

Maintenance check list

NOTE: In 500/1,000 h maintenance and 1,000/2,000 h maintenance, the longer maintenance period is for a basic truck and the shorter maintenance period is for a cold storage cabin truck.

Legend: C = Check, R = Repair, Clean or Change, G = Grease

BEFORE DAILY USE (USER)

MONTHLY (OWNER)

500/1000 h OR ONCE A YEAR (SERVICE)

1000/2000 h OR EVERY SECOND YEAR (SERVICE)

Drive unit C

Transmission leakage check

First change at 200 h, following changes 2,000 h

Transmission oil change Slewing bearing

Fastening of the transmission gear

Lubrication of the slewing bearing

2,000 h or every 2 years

Lubricate the traction motor axle splines Hydraulics C

Leakage check

C R

Replacement of the hydraulic oil return filter (sieve) 2,000 h or every 2 years

Hydraulic oil change

When necessary

Cleaning of the hydraulic oil suction filter Oil level

Hoses and cylinders

Adjustment of the rollers of the reach carriage

Lubrication of the rollers of the reach carriage

Operation of the hydraulics Relief valves

Every 2 years

Lubricate the pump axle splines Reach carriage lubrication

Revision: C

Document ID: 622075-EN

692 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

500/1000 h OR ONCE A YEAR (SERVICE)

1000/2000 h OR EVERY SECOND YEAR (SERVICE)

Lubrication of the contact surfaces

Reach end stop, retract limit, retract end stop and reach limit switch check

Installation of the mast

Visual inspection of the wear level of the mast rollers and contact surface

Chain lubrication (clean and lubricate)

Chain wear measurement and replacement if over the 2% limit

Chain anchors and locking pins check

Tightness of the cylinders and piston rods, possible leaks and damages

Lifting and lowering speed

Chain lubrication, clean and lubricate if necessary

Lubrication of the mast contact surfaces

Functionality of the lift sensors in the mast, possible damages

Test lift with rated load, and with a customer specific load if necessary

Examine the welding in the mast for cracks

Installation of any attachments and load carrying components

Examine the fork base for wear and cracking

BEFORE DAILY USE (USER)

MONTHLY (OWNER)

Tightness of the hydraulic connections, hoses and pipes, possible leaks and damages Tightness of the cylinders and piston rods, possible leaks and damages Mast

Chain setting, adjustment if needed

Tightness of the hydraulic connections, hoses and pipes, possible leaks and damages

Revision: C

Document ID: 622075-EN

693 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

500/1000 h OR ONCE A YEAR (SERVICE)

1000/2000 h OR EVERY SECOND YEAR (SERVICE)

Examine the cross for cracking

Examine the welding of the cylinder and masts for cracking

Examine the welding of the outer masts and cylinder support for cracking

Examine the lift bracket welds for cracking

Examine the rollers, roller pins and welds for cracking and damage

Examine the overhead guard for deformation, cracking and damage

Examine the fork carriage welding for cracking

Examine the installation, wear and damage of the forks and the load handling device

Fork thickness and locking

BEFORE DAILY USE (USER)

MONTHLY (OWNER)

Fork carriage

Load backrest

Wheels Damage and wear in the wheels C

Traction wheel

Traction wheel has to be replaced when its diameter reaches 350 mm Load wheels

Battery Battery water level Clean the battery if needed C

Battery cable and connector

Battery cell voltage and gravity C

Battery automatic watering system Charger

Revision: C

Document ID: 622075-EN

694 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

BEFORE DAILY USE (USER)

MONTHLY (OWNER)

Service Manual

500/1000 h OR ONCE A YEAR (SERVICE)

1000/2000 h OR EVERY SECOND YEAR (SERVICE)

Measure the insulation resistance of the battery Electrics Sensors (check the functionality of all sensors)

Steering wheel functions

Horn

Braking functions

Brake air gap and disc thickness

Controller power cable torque

Cable torque of the motor

Alarm history checking/clearance

Cables and wiring

Measure the insulation resistance of the truck

General C

Lubrication (check the correct lubrication points)

Check cracking and welding in the frame

Cleaning

Frame and the fork carriage

Gas springs

Type plate

Covers

Revision: C

Document ID: 622075-EN

695 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

500/1000 h OR ONCE A YEAR (SERVICE)

1000/2000 h OR EVERY SECOND YEAR (SERVICE)

Fastening of the steering wheel

Deformation, cracking and damage in the overhead guard

DC-DC converter

Abbot

BEFORE DAILY USE (USER)

Safety functions • • • • • • • • •

MONTHLY (OWNER)

Brake Operator presence pedal Battery lock Warning stickers Emergency stop Key switch Seat switch Seat belt (option) Fire extinguisher (option)

Options (CSM)

Accessory rack

Check the correct function of the options

14.4

Lubrication

NOTE: Do not mix different lubricants. It is possible that different brands of lubricants are not compatible with each other. Only use lubricants recommended by the manufacturer.

14.4.1

Hydraulic oil

Ambient temperatures -40...+0 °C

ISO VG 15

Ambient temperatures -10...+30 °C

ISO VG 32

Ambient temperatures +10...+50 °C

ISO VG 46

Revision: C

Document ID: 622075-EN

696 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

14.4.2

Transmission oil

SAE 80W/90, API

14.4.3

Spheerol LC 2

Pump axle splines Molykote BR2 Plus (NLGI. No. 2 grade)

Grease

14.4.5

Traction motor axle splines Molykote BR2 Plus

Grease

14.4.6

Lubrication points NLGI. No. 1 or 2 grade multipurpose type (lithium base)

Grease

14.4.7

GL-5

Heavy duty grease for slewing bearing

Castrol

14.4.4

Service Manual

Mast chains

For the best chain life, use graphite or molybdenum type lubricants (for example, sprays), which evaporate and leave the graphite or molybdenum on the chain. CAUTION If you use oil or grease to lubricate the chains in dusty or sandy operating conditions, dirt particles can stick to the chains and cause rapid wear from abrasion.

14.4.8

Mast channels

For the lubrication of the mast channels, use lubrication grease NLGI No. 2 that contains molybdenum disulphide.

14.5

Hazardous waste and disposal

Hydraulic and transmission oil and batteries are hazardous waste that must be disposed of accordingly. The truck itself is not hazardous waste, and can be recycled.

Revision: C

Document ID: 622075-EN

697 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

14.6 FIGURE

Service Manual

Special tools DESCRIPTION

PART NUMBER

Extraction tool for main connectors (SUPERSEAL)

RL622096

Extraction tool for main connectors (Junior Power Timer)

RL622350

Extraction tool for main connectors (HDSCS)

RL622094

Extraction tool for the key switch

RL360402

Crimp tool for main connectors (Junior Power Timer)

RL354737

Crimp tool for the key switch connector

RL360401

Extraction tools

Crimp tools

Revision: C

Document ID: 622075-EN

698 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

FIGURE

Service Manual

DESCRIPTION

PART NUMBER

Hand tool frame

RL622090 Die set for female pin (HDSCS)

RL622091

Die set for male pin (HDSCS)

RL622092

Complete tool (SUPERSEAL)

RL622095

Complete tool (AMPSEAL)

RL622097

Adjustment tool for reach carriage rollers

RL620755

Other tools

Revision: C

Document ID: 622075-EN

699 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

FIGURE

Service Manual

DESCRIPTION

PART NUMBER

Adjustment tool for mast clearance rollers

RL620761

Extraction tool for the side cylinder sealing housing (1.4 and 1.6 ton trucks)

RL614425

Extraction tool for the side cylinder sealing housing (2.0 and 2.5 ton trucks)

RL614369

Special hook tool

RL477394

Special hook tool

RL351262

Revision: C

Document ID: 622075-EN

700 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

14.7

Service Manual

Storage

If the truck is not used for a longer period of time, store it in a cool (above 0°C) and dry place on an even surface. Before storage, complete the following: •

Charge the battery, and charge it every 2 or 3 months to prevent damage during storage. At the same time, check the battery water level and, if needed, add more water.

•

If the truck is not used for more than a week, support the truck in such a way that the load placed on the traction wheel becomes lighter.

•

If the truck is not used for more than a year, change the hydraulic oil.

14.7.1

Return the truck to operation

If the truck has been stored for several months, it must undergo the scheduled maintenance actions that have not been carried out during the storage period. Otherwise, normal daily maintenance is sufficient.

14.8

Decommissioning

The correct decommissioning or disposal of the truck must be performed in accordance with the regulations of the country of use. In particular, regulations governing the disposal of batteries, fuels and electronic and electrical systems must be observed.

Revision: C

Document ID: 622075-EN

701 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

Options This chapter provides information about the optional features available for the truck. Figure 162 presents the available options.

NOTE: The hot and cold storage modification and reversed steering options are not presented in the following figure. WARNING The overhead guard is a safety device. Do not make modifications to the overhead guard that can make the structure weaker. Do not cut, bend, drill or weld the overhead guard. There is a risk of loss of the protection function.

Revision: C

Document ID: 622075-EN

702 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

Figure 162. Options overview

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Special color labels Customer design labels Accessory rack List bracket Computer rack Fork camera with 7” LCD color display Rear view mirror Reading lamp Audio system Warning light Working lights Operator compartment fan Drive alarm (programmable) Steel safety net for overhead guard Plexiglass safety cover for the overhead guard 16. Left shoulder protection plate 17. Fire extinguisher 18. DC-DC converter

Revision: C

19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.

Battery connector and cables Charger connector Fork carriage strengthening part Load weight indicator Lowering cut-off Operator’s seat options and accessories PIN code access to the start switch Abbot 2 Accessory rack on the roof Accessory rack under the truck floor Driving speed limiter Lifting height pre-selection Battery changing device for 2 batteries Fork positioner with sideshift Telescopic forks Mounting plate Working lights with an extension arm Blue spot rear light Active Sway Control (ASC)

Document ID: 622075-EN

703 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

15.1

Service Manual

Special color labels

Figure 163. Special color labels overview

As an option, the color of the truck can be modified according to customer needs. The special color is installed using side plate labels in the desired color.

15.2

Customer design labels

Figure 164. Customer design labels overview

The side of the truck can be decorated in any way the customer likes, for example with a logo or picture. The image is printed onto a strong plastic sheet that covers the metal side plates of the truck.

Revision: C

Document ID: 622075-EN

704 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

15.3

Service Manual

Truck display languages

The following truck display languages are available: •

Bulgarian – Bălgarski

•

Croatian - Hrvatski

•

Czech – Čeština

•

Danish – Dansk

•

Dutch – Nederlands

•

English

•

Estonian – Eesti

•

Finnish – Suomi

•

French – Français

•

German – Deutsch

•

Greek – Elinika

•

Hungarian –Magyar

•

Italian – Italiano

•

Latvian – Latviesu valoda

•

Lithuanian – Lietuviu kalba

•

Norwegian – Norsk

•

Polish – Polski

•

Portuguese – Português

•

Romanian – Română

•

Russian – Russkiy

•

Slovak – Slovenčina

•

Slovene – Slovenŝĉina

•

Spanish - Español

•

Swedish – Svenska

•

Turkish - Türkçe

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15.4

Service Manual

Accessory rack

Figure 165. Accessory rack overview

1. 2.

Accessory rack List bracket

3. 4.

Computer rack Rear view mirror

With the accessory rack, the truck can be equipped with accessories that make the work of the operator easier. The following accessories can be installed to the rack: •

List bracket With the list bracket, all work papers can be carried conveniently on the truck. The list bracket is equipped with a holder, which keeps the papers in place.

•

Computer rack With the computer rack, the truck can be equipped with a computer. The computer rack is suited for computers with a maximum width of 345 mm.

•

Rear view mirror The parabolic rear view mirror is placed on the accessory rack. It gives the operator visibility towards the right-hand side of the truck without having to turn his head. Includes also an extra equipment stand. WARNING The overhead guard is a safety device. Do not make modifications to the overhead guard that can make the structure weaker. Do not cut, bend, drill or weld the overhead guard. There is a risk of loss of the protection function.

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15.4.1

Service Manual

Install the accessory rack

1. Remove the control panel, see Section 5.7.8. 2. Attach the bottom part of the accessory rack to the truck frame below the control panel with a screw.

3. Attach the top part of the accessory rack to the overhead guard with a screw.

15.4.2

Install the list bracket

1. Install the mounting bracket holder to the accessory rack. 2. Install the mounting bracket of the list bracket to the mounting bracket holder. 3. Install the list bracket to the mounting bracket.

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15.4.3

Service Manual

Install the computer rack

1. Install the computer rack holder to the accessory rack. 2. Install and tighten the screws that hold the computer rack holder.

3. Install the adjustable arm to the computer rack holder. 4. Install the keyboard to the adjustable arm. 5. Install the computer to the adjustable arm.

15.4.4

Install the rear view mirror

1. Install the rear view mirror to the accessory rack with a screw.

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15.5

Accessory rack under the truck floor

15.5.1

Install the accessory rack under the floor

Service Manual

1. Remove the floor plate, see Section 5.7.3. 2. Install the rubber absorbers. 3. Install the accessory rack to the truck with screws.

15.6

Reading lamp

Figure 166. Reading lamp overview

NOTE: To install the reading lamp, you must have the DC-DC converter option installed, see Section 15.20.1.

The reading lamp can be used to get more light on the documents or terminal. The switch is located near the reading lamp in the overhead guard.

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15.6.1

Service Manual

Install the reading lamp

1. Install the reading lamp to the overhead guard. 2. Install and tighten the screws that hold the reading lamp in position.

Figure 167. Reading lamp wiring overview

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15.7

Service Manual

Audio system

Figure 168. Audio system overview

NOTE: To install the audio system, you must have the DC-DC converter option installed, see Section 15.20.1.

The audio system option includes speakers, an amplifier and an AUX 3.5 mm jack connector.

15.7.1

Install the audio system

1. Install the accessory rack under the truck floor, see Section 15.5.1. 2. Install the DC-DC converter. 3. Install the amplifier to the accessory rack under the truck floor with screws.

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Service Manual

4. Install the audio speakers to the overhead guard with screws.

5. Connect the audio system wires according to the truck model specific schematic diagram. See Figure 169 below.

Figure 169. Audio system wiring overview

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15.8

Service Manual

Warning light

Figure 170. Warning light overview

The warning light is a beacon that flashes when the operator has activated it using a switch.

NOTE: With this option, the height of the overhead guard increases by +95 mm.

15.8.1

Install the warning light

1. Install the accessory rack to the overhead guard with screws. 2. Install the warning light to the rack.

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Service Manual

3. Slide the wires of the warning light inside the support of the overhead guard.

4. Connect the warning light wires according to the truck model specific schematic diagram. See Figure 171.

Figure 171. Warning light wiring overview

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15.9

Service Manual

Warning light with an extension arm

Figure 172. Warning light with an extension arm overview

Warning lights can also be installed with an extension arm. The extension arm extends upwards and outwards from the truck's overhead guard and the warning light is built in at the end of the arm.

15.9.1

Install the warning light with an extension arm

1. Install the warning lights to the mounting plate. 2. Install the mounting plate to the overhead guard.

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Service Manual

3. Slide the wires of the warning light inside the support of the overhead guard.

Figure 173. Warning light with an extension arm wiring overview

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Service Manual

15.10 Working lights

Figure 174. Working lights overview

To improve visibility in dark environments, it is possible to fit 2 working lights to the side of the mast. The working lights are adjustable and shine up and down in the direction of the forks.

15.10.1 Install the working lights 1. Install the mounting plate of the working light to the mast.

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Service Manual

2. Install the mounting bracket to the mounting plate. 3. Install the working light to the mounting bracket.

4. Install the wires, see Figure 175.

Figure 175. Working lights wiring overview

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Service Manual

15.11 Blue spot rear light

Figure 176. Blue spot rear light overview

The blue spot rear light is used to help people notice a moving truck and decrease the risk of collisions between people and trucks. The blue spot rear light directs a focused beam of blue light to the ground behind the truck. The blue spot rear light is connected in parallel with the rear light. CAUTION Blue Light Radiance - Risk Group 2 Possibly hazardous optical radiation emitted from this product. Do not stare at operating lamp. May be harmful to the eye.

15.11.1 Install the blue spot rear light Install the blue spot rear light on top of the overhead guard:

1. Install the blue spot rear light to the mounting plate.

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Service Manual

2. Install the blue spot rear light and the mounting plate on top of the overhead guard.

3. Guide the wire through the hole in the overhead guard.

4. Connect the wiring, see the correct wiring in Figure 178.

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Service Manual

Figure 177. Blue spot rear light wiring overview

Figure 178. Connection of relay for blue spot rear light

15.12 Operator compartment fan

Figure 179. Operator compartment fan overview

The operator compartment fan option is meant for working in a warm environment. The cooling fan is integrated into the overhead guard cover and it blows air in the direction of the operator.

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Service Manual

15.12.1 Install the operator compartment fan 1. Remove the plastic cover under the overhead guard.

2. Install the fan cover to the plastic cover with screws. 3. Install the operator compartment fan to the plastic cover with screws.

4. Install the plastic cover back under the overhead guard.

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Service Manual

Figure 180. Operator compartment fan wiring overview

15.13 Drive alarm (programmable)

Figure 181. Drive alarm overview

The drive alarm is used to alert people of a truck in operation.

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Service Manual

15.13.1 Install the drive alarm 1. Remove the floor plate, see Section 5.7.3. 2. Install the drive alarm to the accessory rack on the floor plate. 3. Connect the drive alarm connector to the XH2/ connector.

15.14 Steel safety net for overhead guard

Figure 182. Steel safety net for overhead guard overview

Falling items can pass through the bars of the overhead guard. This can be prevented by placing a steel safety net on it. The size of the net is 37 x 69 mm.

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Service Manual

15.14.1 Install the steel safety net to the overhead guard 1. Remove the plastic cover under the overhead guard.

2. Install the two mounting brackets to the overhead guard with screws.

3. Install the steel safety net on top of the overhead guard. 4. Install and tighten the screws that attach the steel safety net to the mounting brackets. 5. Install the mounting plate on top of the steel safety net with screws.

6. Install the plastic cover back under the overhead guard.

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Service Manual

15.15 Plexiglass safety cover for the overhead guard

Figure 183. Plexiglass safety cover for the overhead guard overview

To prevent small falling objects or fluids from hurting the operator, it is possible to cover the overhead guard with a plexiglass.

NOTE: The plexiglass safety cover is not available in combination with the cold storage cabin option!

15.15.1 Install the plexiglass safety cover to the overhead guard 1.

Remove the plastic cover under the overhead guard.

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Service Manual

2. Install the two mounting brackets to the overhead guard with screws.

3. Install the plexiglass safety cover on top of the overhead guard. 4. Install and tighten the screws that attach the plexiglass safety cover to the mounting brackets. 5. Install the mounting plate on top of the plexiglass safety cover with screws.

6. Install the plastic cover back under the overhead guard.

15.16 Left shoulder protection plate

Figure 184. Left shoulder protection plate overview

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Service Manual

The plate protects the operator from impacts in narrow and tight areas.

15.16.1 Install the left shoulder protection plate 1. Install the left shoulder protection plate to the left side of the operator compartment with screws.

15.17 Fire extinguisher

Figure 185. Fire extinguisher overview

In case of a fire in the truck, the fire extinguisher can be used as a preliminary means of putting out the fire.

NOTE: With this option, the height of the overhead guard increases by 100 mm.

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Service Manual

15.17.1 Install the fire extinguisher 1. Remove the plastic cover under the overhead guard.

2. Install the accessory rack to the overhead guard with screws.

3. Install the fire extinguisher holder to the rack. 4. Attach the fire extinguisher to the fire extinguisher holder.

5. Install the plastic cover back under the overhead guard.

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Service Manual

15.18 Cold storage modification NOTE: The cold storage modification option is installed to the truck during manufacturing, so this option needs to be selected prior to purchasing the truck.

A standard truck can be continuously operated at a temperature of +5...+25°C and for short periods at a temperature of 0...+45°C. The recommended humidity is 30...95% (non-condensing). As an option, a truck specifically designed for cold conditions can be used in temperatures down to -35°C. A truck that is equipped with this option is always marked with a special cold storage modification sticker. Also the location of the type plate of the truck and warning stickers differs from a standard truck, see Figure 186. For more details on the plates and stickers of the truck, see the APPENDIX A.

Figure 186. Cold storage equipment sticker

1. 2.

Type plate Operation warning sticker

Cold storage equipment sticker

15.19 Hot storage modification NOTE: The hot storage modification option is installed to the truck during manufacturing, so this option needs to be selected prior to purchasing the truck.

A standard truck can be continuously operated at a temperature of +5...+25°C and for short periods at a temperature of 0...+45°C. The recommended humidity is 30...95%

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Service Manual

(non-condensing). As an option, a truck specifically designed for hot conditions can be used in temperatures up to +45°C.

15.20 DC-DC converter

Figure 187. DC-DC converter overview

The DC-DC converter (12 V, 12.5 A) option allows multiple peripherals, such as a computer, a barcode scanner or a sticker printer, to be connected to the electrical system of the truck. You need to have the DC-DC converter option installed for these options: •

Audio system, see Section 15.7.

•

Reading lamp, see Section 15.6.

•

Fork camera, see Section 15.27.

15.20.1 Install the DC-DC converter CAUTION Always use the correct schematic diagram for the specific model you are servicing. The latest schematic diagrams are available from the Web site of the manufacturer.

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Service Manual

1. Install the rubber absorbers to the truck frame. 2. Install the accessory rack to the truck frame.

3. Install the DC-DC converter onto the accessory rack with screws.

4. Install the USB connector to the truck.

5. Connect the DC-DC converter wires according to the truck model specific schematic diagram. See Figure 188.

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Service Manual

Figure 188. DC-DC converter wiring overview

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Service Manual

15.21 Battery changing device for 2 batteries CAUTION When you replace the battery, always follow the instructions of the manufacturer.

When you replace the battery, use one with similar dimensions and weight to maintain the stability and the braking properties of the truck. The minimum weight of the battery is indicated on the identification plate of the truck.

When you reinstall batteries, use the appropriate tools for moving, connecting and fastening the battery securely. Do not keep tools or other metal implements on top of uncovered batteries.

Before you install the charged battery, make sure that the battery type and voltage are correct.

The battery changing device enables changing the battery without the use of a lifting device. The device has two roller beds: 1 for rolling on the empty battery and 1 for rolling off the charged battery.

NOTE: You can also order the battery lock without the battery changing device for 2 batteries.

Figure 189. Battery changing device for 2 batteries overview

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Service Manual

15.21.1 Remove an empty battery with the battery changing device for 2 batteries

NOTE: Before you use the battery changing device for 2 batteries, make sure that you adjust its height so that you can move the batteries between the truck and the battery changing device.

1. Park the truck in the battery changing area. 2. Set the power of the truck to OFF. 3. Disconnect the battery connector.

4. Move the battery changing device so that the empty battery can be removed from the truck.

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Service Manual

5. Open the latch of the battery changing device.

6. To open the battery lock, push the pedal and remove the latch.

7. Pull or push the empty battery out onto the battery changing device. CAUTION: To prevent injury, do not put your foot between the rollers of the battery changing device when you pull the battery onto the battery changing device.

8. Close the latch of the battery changing device.

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Service Manual

15.21.2 Install a charged battery with the battery changing device for 2 batteries

NOTE: Make sure that you guide the battery connector cables so that they do not get stuck between the battery and the instrument panel! See Section 7.7.1. CAUTION Before you install the charged battery, verify the battery type and voltage.

WARNING When you move the battery into the truck, do not hold the battery box from the top edge or side. See Figure 190. Risk of trapping! Risk of crushing!

1. Move the battery changing device so that the charged battery can be inserted into the truck.

2. Open the latch of the battery changing device.

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Service Manual

Figure 190. Do not hold the battery box from the top edge or side!

3. Move the charged battery into the truck. NOTE: Make sure that the battery type and voltage are correct. WARNING: Do not hold the battery box from the top edge or side, when you move the battery into the truck, see Section 7.7. Risk of trapping! Risk of crushing! 4. Connect the battery connector. Make sure that the battery cables stay fully safe in the frame of the truck. NOTE: Make sure that you guide the battery connector cables so that they do not get stuck between the battery and the instrument panel! See Section 7.7.1.

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Service Manual

5. To close the battery lock, attach the latch and turn the pedal up. NOTE: The pedal must be turned to the upmost position!

6. Set the power of the truck to on. 7. Move the truck away from the battery changing area.

15.22 Battery connector + cables This option is a replacement for a defective battery connector + cables.

NOTE: Make sure that you set the mechanical voltage selector to the correct battery voltage (48 V)! Note also the polarity of the battery cables.

Figure 191. Battery connector overview

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Service Manual

15.22.1 Replace the battery connector Instructions for removing the battery connector are provided below. Install the battery connector by repeating the steps in reversed order. CAUTION Before you replace the battery connector, switch the power of the truck off.

NOTE: Make sure that you guide the battery connector cables so that they do not get stuck between the battery and the instrument panel! See Section 7.7.1.

1. Remove the cable clamp.

2. Use for example a pin punch to remove the encoding piece of the battery voltage.

3. Remove the cable holder. 4. Remove the cables.

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Service Manual

15.23 Charger connector This option is a replacement for a charger connector. The charger connector is compatible with the original battery connector

NOTE: Make sure that you set the mechanical voltage selector to the correct battery voltage (48 V)! Also note the polarity of the battery cables.

Figure 192. Charger connector overview

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Service Manual

15.23.1 Replace the charger connector Instructions for removing the charger connector are provided below. Install the charger connector by repeating the steps in reversed order.

1. Remove the cable clamp.

2. Use for example a pin punch to remove the encoding piece of the battery voltage.

3. Remove the cable holder. 4. Remove the cable.

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Service Manual

15.24 Extra valve with hosing to fork carriage

Figure 193. Extra valve with hosing to fork carriage

This option makes it possible to add attachments to the fork carriage, for instance, a set of telescopic forks.

15.25 Fork positioner with sideshift

Figure 194. Fork positioned with sideshift overview

Sideshift, opening 330…730 mm (includes an extra valve and hosing). This option enables the operator to adjust the fork spread without leaving the truck. Used for applications where many different load sizes are handled.

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Service Manual

15.26 Fork carriage strengthening part

Figure 195. Fork carriage strengthening part overview

Fork carriage strengthening part is required when the fork carriage of the truck is equipped with additional equipment.

15.27 Fork camera with 7” LCD color display

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Service Manual

A fork-mounted camera offers more visibility on the stacking spot in high lifting heights and results in higher productivity and less damage to the goods and racking. The camera and the display are connected by a wire for interference-free operation. To install the fork camera option, you must have the DC-DC converter option installed, see Section 15.20.

15.28 Telescopic forks

Figure 197. Telescopic forks overview

Pallets can be stacked in two depths in order to gain more storage capacity. To stack or retrieve the deepest pallet in or from the racking, special telescopic forks are necessary. The dimension of this attachment is basically designed for lengthwise storage of 2 pallets of 1,200 mm. The total length of this attachment is 1,350 mm and the stroke of the forks is 1,000 mm (includes an extra valve and hosing).

15.29 Sideshift and tilt centering The optional sideshift and tilt centering function is used to move the sideshift or the fork tilt to the neutral position with a push of a button on the arm rest. The sideshift and tilt centering icons are shown on the main view of the truck display.

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RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

Figure 198. Tilt centering and sideshift icons

15.29.1 Sideshift centering direction, sideshift centering midpoint and tilt centering sensor Type

Inductive proximity sensor

Size

Rectangular, 10 mm x 16 mm x 28 mm

10 - 30 Vdc

Switching output

PNP, NO

Electrical wiring

DC 3-wire, Vs = BRN, GND = BLU, Signal output = BLK

Sensing range

3 – 6 mm

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Service Manual

Figure 199. Sideshift centering direction, sideshift centering midpoint and tilt centering sensor overview

15.29.1.1 Sideshift centering direction, sideshift centering midpoint and tilt centering sensor functionality check 1. Connect the supply voltage between the brown (+) and blue (-) wires. 2. Measure the supply voltage between the wires. The value should be +24 Vdc. 3. Measure the voltage between the blue (-) and black (output) wires. When a supply is connected and there are no metallic objects within the sensing range, the value is approximately 0 V. When a metallic object is moved within the sensing range, the value is the same as the supply voltage, i.e. +24 Vdc. 4. If the values do not match the above, replace the sensor.

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Service Manual

15.30 Load weight indicator The load weight indicator option indicates the load weight on the truck display. The accuracy of the scale is +/-50 kg. The load weight indicator is shown in the middle of the center information area. WARNING Do not exceed the maximum loading capacity of the truck under any circumstances. Risk of overturning!

CAUTION The load weight indicator is only informative, always follow the maximum values for load weight and load center information on the capacity plate. Do not overload!

Figure 200. Load weight indicator

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Service Manual

15.31 Active Sway Control (ASC)

Figure 201. Active Sway Control

With Active Sway Control (ASC), the operator cannot move the reach carriage in sudden movements that can cause sway movement of the mast. ASC is fully automatic. It prevents the sway movement of the mast automatically and it also stops the forward movement of the reach carriage in time. With heavy loads and high lifting heights, the reach carriage takes a slightly longer time to stop with the ASC than without it. ASC is not activated in lifting heights below 5,000 mm, because there is no sway movement in low lifting heights. This option is recommended on lifting heights of 9,500 mm and above.

NOTE: ASC is as standard feature on the RB20N2X model.

15.31.1 Troubleshooting If Active Sway Control does not function correctly (there is sway movement of the mast): •

Make sure that the scale shows a correct value above the free lift area. Calibrate the scale, if necessary.

•

Make sure that the lifting height measurement functions correctly: compare the value given in the truck display to the height of the upper surface of the forks.

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Service Manual

15.32 Lowering cut-off

Figure 202. Lowering cut-off overview

With this option, the forks stop lowering at 500 mm above the ground level. This prevents the operator from putting a load on the support legs unintentionally. The forks start lowering again after the operator releases the fingertip control and restarts lowering.

1. Install the mounting plate of the lowering cut-off sensor to the mast with screws. 2. Install the lowering cut-off sensor to the mounting plate with a screw. 3. Connect the connector.

15.33 Operator’s seat options and accessories These accessories are available for the operator’s seats: •

Left arm rest (MSG20, MSG75)

•

Seat belt (MSG20)

•

Backrest extension (MSG65, MSG75)

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Service Manual

15.33.1 Arm rest

Figure 203. Arm rest overview

Left arm rest provides additional comfort during a long shuttle operation. You can fold the arm rest to any position and you can adjust the height and the angle of the arm rest. To adjust the height of the arm rest:

1. Remove the round cover from the side of the operator’s seat. NOTE: The round cover often breaks when you remove it, so you must have a new plastic rivet or a pop rivet to lock the arm rest in its correct position. 2. Remove the nut under the round cover.

3. Adjust the height of the arm rest.

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Service Manual

4. When the arm rest is on the correct height, insert and tighten the nut back to its correct position, or use a new plastic rivet or pop rivet. 5. Put the round cover back to its correct position. To adjust the angle of the arm rest: 1. Turn the adjustment knob towards the (+) sign to lift the front part of the arm rest or towards the (-) sign to lower the front part of the arm rest.

15.33.2 Backrest extension for MSG65/MSG75

Figure 204. Backrest extension overview

The integrated backrest prevents injuries caused by the poor posture of the truck operator. The height of the backrest can be adapted to the body height. It is adjustable in 13 steps from 475 mm to 645 mm.

15.33.2.1 Backrest extension adjustment To adjust the backrest extension, lift or lower the backrest extension and leave it in a locking position. To remove the backrest extension, lift it all the way up.

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Service Manual

15.33.3 Seat belt for MSG20 seat

Figure 205. Seat belt overview

The dual sensitive seat belt provides maximum freedom of manoeuvre, yet ensuring that the operator is safely restrained in the seat.

15.33.3.1 Install the seat belt 1. Install the seat belt buckle to the side of the operator’s seat with a nut.

2. Install the seat belt tongue to the opposite side of the operator’s seat.

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Service Manual

15.34 PIN code access to the Start switch

Figure 206. PIN code view

This option provides each operator with a personal access code for starting up the truck using the Start switch. After turning on the power of the truck, the operator must enter the personal PIN code to be able to start operating the truck.

15.35 Abbot 2

Figure 207. Abbot 2 overview

Abbot 2 is an Internet-based remote diagnostics system designed for forklifts and other similar local transport equipment. It relays use information from the forklifts to the computer of the operator for browsing and analysis.

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Service Manual

Abbot 2 measures, for example, driving forward and backward, lifting and lowering the forks, and records any collisions the forklift was involved in, the voltage of the battery, and the condition of the motor. If necessary, operator identification can be included with Abbot 2, which prevents unauthorised use of the forklift and records who operated it and when. With the gathered information, one can see precisely how much the forklifts are actually being used, how they are used, and what kind of forklift operating culture prevails in the work environment. The condition of the motor and battery provide information of a potential need for servicing or repairs. The equipment to be installed on the forklift consists of a central unit and a potential external collision sensor and iButton operator identification module. The information gathered of the forklifts is sent automatically to the Abbot 2 server using either the GPRS or WLAN network. The information on the Abbot 2 server is browsed in real-time using an Internet browser.

15.35.1 Install the Abbot 2 1. Install the rubber absorbers to the truck frame. 2. Install the accessory rack to the truck frame.

3. Install the Abbot 2 onto the accessory rack with screws.

4. Remove the control panel, see Section 5.7.8. 5. Connect the wires according to the truck model specific schematic diagram.

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Service Manual

6. Attach the WLAN antenna to the truck frame with a cable tie or bond the GPRS antenna with the adhesive surface. 7. Attach the cables to the truck frame with cable ties.

15.36 Lifting height pre-selection The optional lifting height pre-selection function is used when the truck is used repeatedly to lift loads to a certain height. The lifting height target levels are defined through the lifting height pre-selection view.

NOTE: Before you take the lifting height pre-selection function to use, read the instructions concerning its use carefully.

Figure 208. Lifting height pre-selection icons overview

1. 2.

Pre-height level Pre-height ready

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Pre-height area

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Service Manual

15.36.1 Define the lifting height target levels The lifting height target levels are defined through the lifting height pre-selection view.

Figure 209. Lifting height pre-selection view

NOTE: Teaching of the lifting height pre-selection is protected with a PIN code. If no PIN code is set, the lifting height pre-selection view does not allow modifications to the table. For instructions on how to set the PIN code, see the instructions of TruckTool.

To add a new value to the table: 1. Use the Browse up/down/left/right buttons to move the selection to the correct cell. 2. Push the Enter button to activate the cell. 3. Lift the forks to the correct height. The activated cell shows the current height in real time. 4. Push the Enter button on the truck display to set the value or push the Exit / Esc button to cancel. 5. Push the Exit / Esc button to return to the main view. To remove a value from the table: 1. Use the Browse up/down/left/right buttons to move the selection to the correct cell. 2. Push the Enter button to activate the cell. 3. Lower the forks all the way down.

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Service Manual

The activated cell shows the current height in real time. Below a certain threshold, the reading is ---. 4. Push the Enter button on the truck display to set the value or push the Exit / Esc button to cancel. 5. Push the Exit / Esc button to return to the main view.

15.36.2 How to unstack with the lifting height pre-selection 1. Lift the unloaded forks up. The system detects the unloaded forks automatically. 2. When you see the number of the target level on the truck display, push the F2 button down. When the target level is reached, the lifting stops automatically. Note that if you release the F2 button before the target level is reached, the lifting does not stop to that level. 3. When the lifting stops, release the F2 button. 4. Push the forks under the pallet. The system detects the pallet automatically. 5. Push the F2 button down and lift the pallet up from the shelf. CAUTION Before you lift the pallet up, make sure that there is enough space over the pallet. There is a risk that the pallet hits the shelf above.

The lifting stops automatically when the pallet is lifted to a height of 100 mm. 6. Release the F2 button. 7. Pull the pallet out from the shelf. 8. Before you drive the truck, lower the pallet down.

15.36.3 How to stack with the lifting height pre-selection 1. Lift the pallet up. The system detects the pallet automatically and adds 100 mm to the target level height. 2. When you see the number of the target level on the truck display, push the F2 button down. When the target level is reached, the lifting stops automatically. Note that if you release the F2 button before the target level is reached, the lifting does not stop to that level. 3. When the lifting stops, release the F2 button.

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Service Manual

4. Push the pallet to the shelf. CAUTION Before you push the pallet into the shelf, make sure that there is enough space over the pallet. There is a risk that the pallet hits the shelf above.

5. Push the F2 button down and lower the pallet to the shelf. The lowering stops automatically when the pallet is lowered by 100 mm. 6. Release the F2 button. 7. Pull the unloaded forks out from the shelf. The system detects the unloaded forks automatically. 8. Before you start to operate the truck, lower the forks down.

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Service Manual

Technical specification

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16.1

Service Manual

RB14N2S, RB14N2HS, RB16N2S, RB16N2HS and RB16N2

IDENTIFICATION

1.1

Manufacturer

Mitsubishi

1.2

Manufacturer's type designation

RB14N2S

RB14N2HS

RB16N2S

RB16N2HS

RB16N2

1.3

Drive

Electric

1.4

Operator type

Seated

1.5

Rated capacity / rated load

Q [t]

1.4

1.6

Load center distance

c [mm]

600

1.8

Load distance, axle to fork face

x [mm]

281

199

281

199

331

1.9

Wheel base

y [mm]

1,300

1,350

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Service Manual

WEIGHTS

2.1

Truck weight*

[kg]

4,770

5,497

4,991

5,697

5,245

2.3

Axle loading unladen, with battery, front / rear

[kg]

1,925 / 1,445

2,208 / 1,889

1,925 / 1,466

2,208 / 1,889

1,995 / 1,650

2.4

Axle loading laden, forks advanced, front / rear

[kg]

605 / 4,165

704 / 4,793

590 / 4,402

704 / 4,793

616 / 4,628

2.5

Axle loading laden, forks retracted, front / rear

[kg]

1,590 / 3,180

1,873 / 3,624

1,570 / 3,422

1,873 / 3,624

1,626 / 3,618

Vul

WHEELS

3.1

Wheels, material (R=rubber / U=Urethane / Vul=Vulkollan / P=Powerthane), drive / load side

3.2

Wheel size, front

[mm]

Ø360*140

3.3

Wheel size, rear

[mm]

Ø285x75

Ø285*130

3.5

Wheels, number front / rear (x = driven wheels)

2/1X

3.7

Track width, rear

b10 [mm]

1,195

1,140

DIMENSIONS

4.1

Tilt of fork carriage, forward / backward

[]

2/4

4.2

Height, mast lowered

h1 [mm]

2,710

3,785

2,710

3,785

2,710

4.3

Free lift

h2 [mm]

2,060

3,135

2,060

3,135

2,060

4.4

Lift

h3 [mm]

7,500

9,000

7,500

9,000

7,500

4.5

Height, mast extended

h4 [mm]

7,130

9,830

7,130

9,830

7,130

4.7

Height of overhead guard

h6 [mm]

2,200

4.8

Seat height relating to SIP**

h7 [mm]

1,030

4.10

Height of load legs

h8 [mm]

360

4.15

Fork height, lowered

h13 [mm]

4.19

Overall length

l1 [mm]

2,404

2,486

2,404

2,486

2,404

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Service Manual

4.20

Length to face of forks

l2 [mm]

1,254

1,336

1,254

1,336

1,254

4.21

Overall width

b1/b2 [mm]

1,270

4.22

Fork dimensions DIN ISO 2331

s/e/l [mm]

40 / 100 / 1,150

4.23

Fork carriage ISO 2328 class/type A, B

4.24

Fork carriage width

b3 [mm]

720

4.25

Distance between fork arms

b5 [mm]

315 - 710

4.26

Distance between load legs

b4 [mm]

1,070

900

4.28

Reach distance

l4 [mm]

463

381

463

381

513

4.32

Ground clearance, center of wheel base

m2 [mm]

4.33

Aisle width for pallets 1,000x1,200 mm, crossways

Ast [mm]

2,684

2,748

2,684

2,748

2,693

4.34

Aisle width for pallets 800x1,200mm, lengthwise

Ast [mm]

2,750

2,825

2,750

2,825

2,751

4.35

Turning radius

Wa [mm]

1,541

1,629

4.37

Length across load legs

l7 [mm]

1,693

1,793

PERFORMANCE

5.1

Operating speed, laden / unladen*****

[km/h]

12 / 12

5.2

Lifting speed, laden / unladen

[m/s]

0.4 / 0.65

0.4 /0.7

0.4 / 0.65

0.4 / 0.7

0.4 / 0.65

5.3

Lowering speed, laden / unladen

[m/s]

0.55 / 0.5

5.4

Reaching speed, laden /unladen

[m/s]

0.2 / 0.2

5.8

Maximum gradeability, laden / unladen

[%]

10 / 15

5.9

Acceleration time, laden / unladen

[s]

5.0 / 4.5

4.8 / 4.4

5.0 / 4.5

4.8 / 4.4

5.0 / 4.5

5.10

Service brake

Electric

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Service Manual

MOTORS

6.1

Traction motor rating S2 60%

[kW]

7.5

6.2

Pump motor rating S3 15%

[kW]

6.4

Battery voltage / nominal capacity (5 h)

[V/Ah]

48 / 465, 620, 775

48 / 620, 775

48 / 465, 620, 775

48 / 620,775

48 / 465, 620, 775

6.5

Battery weight

[kg]

700, 900, 1,100

900, 1,100

700, 900, 1,100

900, 1,100

700, 900, 1,100

8.1

Type of drive unit

Stepless

OTHER

10.7

Level of sound pressure at the ear level of the operator according to EN 12053:2001+A1:2008 and EN ISO 4871:2009 in work LpAZ***

[dB (A)]

10.7.1

Level of sound pressure at the ear level of the operator according to EN 12053:2001+A1:2008 and EN ISO 4871:2009, drive / lift / idle LpA***

[dB (A)]

58 / 73 / 50

61 / 69 48

58 / 73 / 50

61 / 69 48

58 / 73 / 50

Whole-body vibration according to EN 13 059:2002+A1:2008****

[m/s2]

0.31

Hand-arm vibration according to EN 13 059:2002+A1:2008****

[m/s2]

< 2.5

Manufacturer reserves the right to make technical changes. * Values of the table according to the smallest size of batteries. ** Measured with standard seat. *** Uncertainty of 4 dB (A). **** Whole-body vibration measured with air pressured seat. ***** Operating speed to the direction of the forks can be adjusted slower than announced.

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16.2

Service Manual

RB16N2H, RB16N2C, RB16N2HC, RB20N2H, RB20N2X and RB25N2X

IDENTIFICATION

1.1

Manufacturer

Mitsubishi

1.2

Manufacturer's type designation

RB16N2H

RB16N2C

RB16N2HC

RB20N2H

RB20N2X

RB25N2X

1.3

Drive

Electric

1.4

Operator type

Seated

1.5

Rated capacity / rated load

Q [t]

1.6

2.0

2.5

1.6

Load center distance

c [mm]

600

1.8

Load distance, axle to fork face

x [mm]

249

327

228

399

389

1.9

Wheel base

y [mm]

1,350

1,400

1,500

WEIGHTS

2.1

Truck weight*

[kg]

5,971

4,909

5,639

6,170

6,665

6,756

2.3

Axle loading unladen, with battery, fron / rear

[kg]

2,275 / 2,096

1,840 / 1,469

2,114 / 1,925

2,200 / 1,970

2,385 / 2,280

2,231 / 2,025

2.4

Axle loading laden, forks advanced, front / rear

[kg]

719 / 5,252

510 / 4,398

614 / 5,024

675 / 5,495

445 / 6,220

440 / 6,315

2.5

Axle loading laden, forks retracted, front / rear

[kg]

1,906 / 4,065

1,484 / 3,425

1,759 / 3,880

1,785 / 4,385

1,855 / 4,810

1,712 / 5,043

Vul

WHEELS

3.1

Wheels, material (R=rubber / U=Urethane / Vul=Vulkollan / P=Power thane), drive / load side

3.2

Wheel size, front

[mm]

Ø360*140

3.3

Wheel size, rear

[mm]

Ø285*130

Ø285x75

Ø285*130

3.5

Wheels, number front / rear (x = driven wheels)

2/1X

3.7

Track width, rear

1,140

1,025

1,140

1,310

b10 [mm]

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Service Manual

DIMENSIONS

4.1

Tilt of fork carriage, forward / backward

[]

2/4

4.2

Height, mast lowered

h1 [mm]

3,785

2,710

3,785

5,118

3,785

4.3

Free lift

h2 [mm]

3,135

2,060

3,135

4,468

3,135

4.4

Lift

h3 [mm]

11,500

7,500

9,000

11,500

13,000

11,500

4.5

Height, mast extended

h4 [mm]

9,830

7,130

9,830

13,830

9,830

4.7

Height of overhead guard

h6 [mm]

2,200

4.8

Seat height related to SIP**

h7 [mm]

1,030

4.10

Height of load legs

h8 [mm]

360

4.15

Fork height, lowered

h13 [mm]

4.19

Overall length

l1 [mm]

2,486

2,458

2,558

2,486

2,496

4.20

Length to face of forks

l2 [mm]

1,336

1,308

1,408

1,336

1,346

4.21

Overall width

b1/b2 [mm]

1,270

1,100

1,270

1,440

4.22

Fork dimensions DIN ISO 2331

s/e/l [mm]

40 / 100 / 1,150

50 / 100 / 1,150

4.23

Fork carriage ISO 2328 class/type A, B

4.24

Fork carriage width

b3 [mm]

720

4.25

Distance between fork arms

b5 [mm]

315 - 710

4.26

Distance between load legs

b4 [mm]

900

1,070

4.28

Reach distance

l4 [mm]

432

510

410

582

572

Revision: C

Document ID: 622075-EN

766 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

4.32

Ground clearance, center of wheel base

m2 [mm]

4.33

Aisle width for pallets 1,000x1,200 mm, crossways

Ast [mm]

2,755

2,730

2,807

2,784

2,805

4.34

Aisle width for pallets 800x1,200mm, lengthwise

Ast [mm]

2,826

2,789

2,881

2,830

2,853

4.35

Turning radius

Wa [mm]

1,629

1,735

1,749

4.37

Length across load legs

l7 [mm]

1,793

1,893

PERFORMANCE

5.1

Operating speed, laden / unladen*****

[km/h]

14 / 14

12 / 12

14 / 14

11 / 14

5.2

Lifting speed, laden / unladen

[m/s]

0.4 / 0.7

0.4 / 0.65

0.4 / 0.7

0.3 / 0.7

5.3

Lowering speed, laden / unladen

[m/s]

0.55 / 0.5

5.4

Reaching speed, laden /unladen

[m/s]

0.2 / 0.2

5.8

Maximum gradeability, laden / unladen

[%]

10 / 15

5.9

Acceleration time, laden / unladen

[s]

4.8 / 4.6

5.0 / 4.5

4.8 / 4.8

4.8 / 4.4

5.2 / 4.4

5.10

Service brake

[s]

Electric

MOTORS

6.1

Traction motor rating S2 60%

[kW]

7.5

6.2

Pump motor rating S3 15%

[kW]

6.4

Battery voltage / nominal capacity (5 h)

[V/Ah]

48 / 620, 775

48 / 465, 620

48 / 620

48 / 620, 775, 930

6.5

Battery weight

[kg]

900, 1,100

700, 900

900

900, 1,100, 1,300

8.1

Type of drive unit

Stepless

Revision: C

Document ID: 622075-EN

767 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

OTHER

10.7

Level of sound pressure at the ear level of the operator according to EN 12053:2001+A1:20 08 and EN ISO 4871:2009 in work LpAZ***

[dB (A)]

10.7.1

Level of sound pressure at the ear level of the operator according to EN 12053:2001+A1:20 08 and EN ISO 4871:2009, drive / lift / idle LpA***

[dB (A)]

61 / 69 / 48

58 / 73 / 50

61 / 69 / 48

Whole-body vibration according to EN 13 059:2002+A1:2008 ****

[m/s2]

0.31

Hand-arm vibration according to EN 13 059:2002+A1:2008 ****

[m/s2]

< 2.5

Revision: C

Document ID: 622075-EN

768 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

16.3

Service Manual

Mast heights

Legend: h3 = Lifting height, h4= Height with mast raised,

= Including load backrest

RB14N2S / RB16N2S / RB16N2 / RB16N2C LIFTING MAST

h3 (mm)

h1 (mm)

h2 (mm)

h4 1) (mm)

Triplex integral mast

4,800

2,210

1,560

5,630

5,400

2,410

1,790

6,230

5,700

2,510

1,860

6,530

5,900

2,577

1,927

6,730

6,300

2,710

2,060

7,130

7,000

2,943

2,293

7,830

7,500

3,110

2,460

8,330

RB14N2HS / RB16N2HS / RB16N2H / RB16N2HC LIFTING MAST

h3 (mm)

h1 (mm)

h2 (mm)

h4 1) (mm)

Triplex integral mast

8,000

3,297

2,647

8,830

8,500

3,436

2,813

9,330

9,000

3,785

3,135

9,830

Revision: C

Document ID: 622075-EN

769 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

RB20N2H / RB25N2X LIFTING MAST

h3 (mm)

h1 (mm)

h2 (mm)

h4 1) (mm)

Triplex integral mast

4,800

2,230

1,580

5,630

5,400

2,430

1,780

6,230

5,700

2,530

1,880

6,530

5,900

2,597

1,947

6,730

6,300

2,730

2,080

7,130

7,000

2,963

2,313

7,830

7,500

3,130

2,480

8,330

8,000

3,297

2,647

8,830

8,500

3,463

2,813

9,330

9,000

3,785

3,135

9,830

9,500

3,952

3,302

10,330

10,000

4,118

3,468

10,830

10,500

4,285

3,635

11,330

11,000

4,452

3,802

11,830

11,500

4,618

3,968

12,330

LIFTING MAST

h3 (mm)

h1 (mm)

h2 (mm)

h4 1) (mm)

Triplex integral mast

12,000

4,785

4,135

12,830

12,500

4,952

4,302

13,330

13,000

5,118

4,468

13,830

RB20N2X

Revision: C

Document ID: 622075-EN

770 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

Index

Adjust the load wheel brakes .................. 85

Free lift cylinder

Arm rest Calibrate the arm rest ........................ 260 Open the arm rest ............................. 162 Remove the arm rest ......................... 160 Remove the arm rest buttons ............ 163 Remove the arm rest levers .............. 162

Bleed out the air from the free lift cylinder ............................................. 142 Replace the free lift cylinder .............. 138 Sealing housing of the free lift cylinder ............................................. 141 Fuses See .............................. Instrument panel

B Battery

Battery maintenance ......................... 193 Charge the battery ............................ 198 Measure the battery's specific gravity ............................................... 201 Quick battery replacement ................ 206 Replace the battery ........................... 201 Safety regulations concerning the handling of lead-acid batteries........... 192 Battery roller frame

Guidance rollers Adjust the guidance rollers ................ 134 Replace the guidance rollers ............. 134

H HALL sensor See ............................. Sensors, Sensors Hydraulic operation

Remove the battery roller frame .......... 89

Hydraulic oil recommendations ......... 268 Maintenance points of the hydraulic system .............................................. 270

C Control panel .......................................... 27

Hydraulic system Disassemble the hydraulic system .... 274 Disassemble the valves ..................... 280 Hydraulic system ......................... 52, 272 Hydraulic valve unit ........................... 275 Set the lifting pressure....................... 279

Corner supports Replace the corner supports ............... 82

D Decommissioning ................................. 701

Display control buttons See .................................... Truck display Display panel

Instrument panel

Emergency stop button ..................... 208 Key switch ......................................... 209

Identification plates on the truck .............. 21

Revision: C

Fuses ................................................ 231 Instrument panel ......................... 51, 216 Pump controller ................................. 225 Pump controller connectors ............... 226 Steering controller ............................. 228 Document ID: 622075-EN

771 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Steering controller connectors ........... 229 Traction controller ............................. 222 Traction controller connectors ... 218, 223 Vehicle controller............................... 218

Service Manual

O Operating devices ................................... 26 Arm rest .............................................. 28 Pedals ................................................. 47 Order spare parts.................................... 66

Lifting points Hoist points ......................................... 58 Jack points .......................................... 57

P Pedals

Load backrest ....................................... 157

Accelerator pedal .............................. 212 Brake pedal ....................................... 214 Operator presence pedal................... 210

Load wheels Remove the load wheels ..................... 83 Lubrication ............................................ 696

Pump controller See .............................. Instrument panel Pump motor .......................................... 247

Lubricate the pump axle splines ........ 249 Remove the pump motor ................... 249 Replace the HALL sensor ................. 251

Magnetic brake See .......................... Motor compartment Main rollers Replace the main rollers.................... 136 Maintenance check list.......................... 692

R Reach carriage Adjust the guidance rollers of the reach carriage ..................................... 91 Lubricate the rollers of the reach carriage ............................................... 90 Remove the reach carriage ................. 94 Remove the reach cylinder .................. 95 Sensors of the reach carriage ............. 93

Mast Disassemble the mast ....................... 112 Fork inspection .................................. 118 Lubricant recommendations .............. 105 Mast maintenace ............................... 104 Mast chains Adjust the mast chains ...................... 130 Examine the tension of the mast chains ............................................... 129 Inspect the mast chains..................... 123 Replace the mast chains ................... 130 Motor compartment Adjust the air gap of the magnetic brake ................................................. 245 Coil resistance measurement ............ 244 Install the magnetic bracke ................ 244 Magnetic brake.................................. 243 Motor compartment ..................... 53, 234

S Sensors Battery lock sensor............................ 256 Height reference sensor .................... 258 Pressure sensor ................................ 257 Reach end stop, retract limit, retract end stop and reach limit switch ......... 255 Sensor locations.................................. 53 Sensors ............................................. 252 Steering reference sensor ................. 254 Steering wheel sensor ....................... 252 Side cylinders Bleed out air from the side cylinders .. 149

Revision: C

Document ID: 622075-EN

772 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Disassemble the side cylinder sealing housing ................................. 147 Replace the side cylinders ................ 144 Sealing housing of the side cylinder .. 147

Traction motor....................................... 234 HALL sensor ..................................... 238 Remove the traction motor ................ 235 Replace the HALL sensor ................. 238 Temperature sensor check ................ 237

Sideshift cylinder Disassemble the sealing housing of the sideshift cylinder .......................... 156 Remove the piston of the sideshift cylinder ............................................. 155 Sealing housing of the sideshift cylinder ............................................. 156

Service Manual

Traction wheel Assemble the traction wheel................ 81 Disassemble the traction wheel ........... 79 Replace the wheel shaft bolts.............. 79 Transmission gear Remove the transmission gear ............ 76

Slewing bearing Lubricate the slewing bearing .............. 77 Special tools ......................................... 698

Transportation......................................... 61 Truck covers Open the instrument panel .................. 70 Open the machinery top cover ............ 69 Remove the control panel ................... 73 Remove the cup holder ....................... 73 Remove the floor plate ........................ 68 Remove the front bumper .................... 68 Remove the instrument panel cover .... 72 Remove the machinery cover .............. 68 Remove the reach carriage cover ....... 73

Steering controller See .............................. Instrument panel Steering motor ...................................... 239 HALL sensor ..................................... 241 Remove the steering motor ............... 240 Replace the HALL sensor ................. 242 Temperature sensor check ................ 240 Storage ................................................. 701

Truck display Display control buttons ........................ 34 Selection view ..................................... 44 Truck display ....................................... 33

T Temperature sensor See .......................... Motor compartment

Truck operation modes ........................... 32

Tightening torques Special tightening torques ................. 690 Tightening torque for standard bolts and nuts ............................................ 690

Vehicle controller See .............................. Instrument panel

Tilt cylinders Remove the tilt cylinders ................... 151 Sealing housing of the tilt cylinder ..... 153 Traction controller See .............................. Instrument panel

Revision: C

W Windshield washer Remove the motor of the windshield wipers ............................................... 178

Document ID: 622075-EN

773 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

APPENDIX A: Stickers

Figure 210. Type plate

Revision: C

Document ID: 622075-EN

774 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

Figure 211. General warning sticker

Revision: C

Document ID: 622075-EN

775 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

Figure 212. Mast operation warning sticker

Figure 213. Serial number sticker

Figure 214. Battery maintenance warning sticker

Figure 215. Instrument panel cleanup warning sticker

Revision: C

Document ID: 622075-EN

776 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

Figure 216. Pinch warning sticker

Figure 217. Battery type plate example (can vary by battery manufacturer)

Figure 218. Hoist point indication sticker

Revision: C

Document ID: 622075-EN

777 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

Figure 219. Hydraulic oil tank filling cap sticker

Figure 220. Capacity plate for standard fork length (1,150 mm)

1. 2. 3.

Load center distance 400 mm Load center distance 600 mm Maximum lifting height (mm)

Revision: C

4. 5. 6.

Actual capacity (kg) at maximum. lifting height Lifting height (mm) for rated capacity Rated capacity (kg)

Document ID: 622075-EN

778 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Service Manual

Figure 221. Additional capacity plate for attachments

1. 2. 3.

Special load center distance Max. lifting height (mm) Actual capacity (kg) at maximum lifting height

4. 5.

Lifting height (mm) for rated capacity Rated capacity

NOTE: The capacity plate can include more actual capacities at other lifting heights and load centre distances, if applicable.

Figure 222. Emergency exit sticker (cabin truck)

Revision: C

Document ID: 622075-EN

779 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Revision: C

Document ID: 622075-EN

Service Manual

780 (782)

RB14N2S, RB14N2HS, RB16N2, RB16N2H, RB16N2S, RB16N2HS, RB16N2C, RB16N2HC, RB20N2H, RB20N2X, RB25N2X

Revision: C

Document ID: 622075-EN

Service Manual

781 (782)

MCFA 2121 W. Sam Houston Pkwy. N. Houston, TX 77043-2305 USA

MCFE B.V. Hefbrugweg 77 1332 AM Almere The Netherlands

Mitsubishi Logisnext Asia Pacific Pte. Ltd. No. 1, Tuas West Street Singapore 637444

Rev Q O Q I K N O J Q H P L K J I Q O

Description Update Dual Pedal option + CAN wiring impr Reach carriage wiring for HXM J29 added ELMO modifications Steer wheel plate grounding Dual Pedal option + CAN wiring impr Valve block Y46.1 and Y46.2 changed J27 and J30 added Orlaco -> Motec CAN-bus routing Low power fan added XAB2.1/ added Audio on/off switch, option switche Accessory rack grounding, Blue spot REACH CABLE WIRES Page added

Rev Date 2018-06-13 2017-03-28 2018-06-13 2015-02-24 2016-01-08 2017-01-12 2017-03-28 2015-06-05 2018-06-13 2014-10-13 2017-11-15 2016-08-22 2016-01-08 2015-06-05 2015-02-24 2018-06-13 2017-03-28

2018-06-13

Update

Title TABLE OF CONTENTS SUPPLY MOTOR CIRCUITS MAIN CIRCUITS DRIVE CIRCUIT STEERING CIRCUIT HYDRAULIC CONTROL CIRCUITS HYDRAULIC VALVES MAST AND REACH CARRIAGE SENSORS FORK CARRIAGE CAN-BUS FANS AND AUX DEVICES AUX DEVICES 2 AUX. DEVICES III AUX DEVICES IV AUX DEVICES V OPTION DUAL PEDAL

REV

DATE:

NAME:

CHANGE:

Pg 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

DATE: DESIGN. 2011-06-20 CHECK. APPROV.

NAME: JL

CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) TABLE OF CONTENTS

0 / 16

REV

3-7571

C1 +

XX86

K1 3-12

3-12

XX87

J29

220uF/100V 2

K2 3-21

+48V

J22 1

13-15

1F1

5F1

10A

6F1

10A

7F1

10A

8F1

10A

9F1

10A

10F1 2

11F1

10A

12F1

10A

13F1 2

10A

XX52

X1/ +

XX84 2

35mm

8L5

8L3

4-14

6-12

1L1

2L1

3L1

5L2

6L1

7L3

8L1

8L2

3-12

2-16

2-22

3-25

7-17

3-24

4-26

5-22

11L2

J21

13L1

11-19

14-20

13-14

15-13

2M1

3M1

8M1

9M1

10M1

11-12

2-16

2-22

5-23

13-12

6-27

1M1

8M2

3-12

6-26

12V OUTPUT

CONTROLLER CIRCUIT

1M2

11M1

13M1

11-19

15-13

8M3 10-26 2

B-

35mm

X1/

24V CONVERTER SUPPLY

11L1

6-27

COLD STORAGE OPTIONS

10L1

SEAT HEATER/-COMPRESSOR

9L1 13-12

12V CONVERTER SUPPLY

7L1 3-17

CONTROLLERS KEY

PUMPMOTOR

48V

DRIVEMOTOR

VALVES

8L4 14-13

BRAKES

7L2 10-15

MAIN CONTACTORS

1L2 12-20

HORN

35mm

B+

KEYSWITCH

Dual Pedal option + CAN wiring improvement EP 2017-03-28

NAME: REV

DATE:

CHANGE:

8M7

11-24

1F2 10A

8M5

14-14

A2 B0V

DATE: DESIGN. 2011-06-20 CHECK. APPROV.

NAME: JL

CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) SUPPLY

1 / 16

REV

3-7571

2L1

3L1

4L1

1-18

1-19

4L1

Reach carriage wiring for HXM

CHANGE:

+BF

2F1 B+

300A

B+

V W

3F1

425A

4F1 2

B+

V W

50A

V W V

U U

XA1A/ 7

BLU

XM1/ 3

XA1A/ 14

BLK

XM1/ 4

XA1A/ 15

XM1.1/ 2

XA1A/ 22

XM1.1/ 1

XA1A/ 23

WHT

XM2/ 3

BLU

XM2/ 2

BLK

TEMP. SENSOR 0V

R31 DRIVEMOTOR B-

4M1

XA2A/ 14 XA2A/ 7 J6

B31

XA2A/ 8 XX41

10-14

XM2/ 4

XA2A/ 15 XX42

B32 1

+12V

XM2.1/ 2

XA2A/ 22

XM2.1/ 1

XA2A/ 23

RED

XM3/ 1

XA3A/ 16

BRN

XM3/ 2

XA3A/ 3

BLK

XM3/ 3

XA3A/ 4

ORA

XM3/ 4

XA3A/ 5

XM3.1/ 2

XA3A/ 6

XM3.1/ 1

XA3A/ 7

SENSOR SUPPLY A

B32

TEMP. SENSOR 0V

R32 PUMPMOTOR

B-

TEMP. SENSOR 0V

R33 STEERINGMOTOR B-

STEERING CONTROLLER EPS AC-0

XM1/ 2

+12V

J26 J5 XM2/ 1

Speed sensor

WHT

RED

PUMP CONTROLLER ACE-2

XA1A/ 8

Speed sensor

XM1/ 1

TRACTION CONTROLLER ACE-2

Speed sensor

X70.1/ 1

J27

2M1 +12V

1-18

8-16

X70.1/ 2

XA4B/ 9

ENC2 chA

X70.1/ 3

XA4B/10

ENC2 chB

X70.1/ 4

J30

VMC

2018-06-13

RED

REV

DATE:

NAME:

11-21 10-12

3M1

4M1

1-19

8-19

DATE: DESIGN. 2011-06-20 CHECK. APPROV.

NAME: JL

CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) MOTOR CIRCUITS

2 / 16

REV

3-7571

7L1

7L3

5L2

1-14

1-23

1-21

X12/ 1

1L1

KEYSWITCH HARNESS 21

S12

EM.STOP 22

XX37

XX76

X33/ 1

LOAD WHEEL BRAKES

X32/ 1

X34/ 1

MAGN.BRAKE

S11 1

Y32

48V 2

XX2

X34/ 2

XX38

Y33

48V

48V 2

X32/ 2

Y31

X44/ 3

J29 added

CHANGE:

4 5

X33/ 2

X44/ 2

X44/ 1

KEY

NAME:

DATE:

2015-02-24

XX77

X44/ 4

X12/ 5

GRY

X12/ 6

12-23

XX25 A1

11-12

F101

J23 11-17

X45/ 4

XX1

X45/ 3

12-22 11-13

XX24

48V A2

XX78

J29

SAFETY IN

ECO EMCY -mode -state

KEY

SAFETY CONTACT

SAFETY KEY COIL MAIN CONT. BRAKE IN SUPPLY CONTROL CONTROL

PUMP CONTROLLER 1-14

STEER CTRL

KEY

+48V LOAD WHEEL (MAIN CONT. BRK. SUPPLY STATE) VEHICLE MASTER CONTROLLER

TRACTION CONTROLLER

XA4B/ 23

XA4B/ 8

14-17

XA4B/ 7

XA1A/ 18

XA1A/ 16

XA1A/ 17

1 XA1A/

XA1A/ 11

9 XA3A/

XA3A/ 15

KEY SAFETY OUT

J24

1-20

1M1

REACH CARRIAGE

8-25

XA2A/ 19

1 XA2A/

XA2A/ 3

XA2A/10

XA2A/

48V

XA4A/ 28

XA2A/ 11

REV

J10

XX45

X45/ 2

MAIN CONTACTOR

XX46

X45/ 1

X12/ 3

X12/ 2

XX3

BRAKE CONTROL

MAIN CONTACTOR

DATE: DESIGN. 2011-06-20 CHECK. APPROV.

NAME: JL

CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) MAIN CIRCUITS

3 / 16

REV

3-7571

A2 PUMP CONTROLLER

CHECK.

APPROV. DATE:

DESIGN. 2011-06-20

TRACTION CONTROLLER

CIRCUIT DIAGRAM

X44/ 11

3 4 5 6

X22/ 2

24 25

S25

X3/ 12

X22/ 1

X3/ 6

4,5...0,5V YEL

GND2

3903-00711-02

X45/ 11

X3/ 10

+UB2

3903-00710-02

BLU

ORA

BRAKE PEDAL SENSOR

0,5...4,5V GRN

GND1

THROTTLE PEDAL SENSOR

XA4A/ 9

X44/ 10

X3/ 9

BLK

SEAT SWITCH

XA4B/ 11

X45/ 10

X44/ 9

+UB1

XA4B/ 12

X45/ 9

WHT

X3/ 2

XA4A/ 22

XX6 XX7

X44/ 8

X3/ 1

4,5...0,5V YEL

B22

X135/ X44/ 7

BLU

X45/ 8

X45/ 7

X3/ 4

XA4B/ 16

XA1A/ 10

XA1A/

GND2

X3/ 8

XA1A/

+UB2

5V ORA

0,5...4,5V GRN

X3/ 7

XA1A/

GND1

B21 BLK

WHT

+48V

+UB1

X134/ 3

SEATBELT

X15/ V

S28

S21

X3/ 3

X136/

X134/ 1

X137/

BELT BUCKLE SWITCH

XA1A/

ELMO modifications

CHANGE:

SEAT GROUNDING

S W EA IT T C H

2016-01-08

X134/ 6

NAME:

DATE:

XA2A/ 5

REV

11 26

NAME:

RB14-25N2(S)(C)(H)(X) DRIVE CIRCUIT

27 28 29

4 / 16

CABIN FLOOR FOOT SWITCH

8L5

1-24

COM

XX8 XX9

COM

1-24

8L1

+48V

VEHICLE MASTER CONTROLLER

REACH CARRIAGE

REV

3-7571

STEERING FEEDBACK SENSOR

B11

STEERING WHEEL SENSOR

SENSOR A

S31

BLK

YEL

BLU

WHT

ORA

X11/ 2

X11/ 4

485304

NPN

X11/ 3

Steer wheel plate grounding

GND3

XX10

Top view

X14.1/ 3

8L2

8M1

1-24

X14/ 3

X14.1/ 4 X14/ 4

X14.1/ 2 X14/ 2

X14.1/ 1

SENSOR B

S32

XX11

X14/ 1

B-

RED

B+

X11/ 1

Steer wheel plate grounding IR 2017-01-12

CHANGE: NAME: DATE:

A-

STEERING FEEDBACK SENSOR

485304

NPN A+

S32

GND

+5V

STEERING STRAIGHT SWITCH

S31

XA3A/

12 XA3A/

XA3A/ 2

XA3A/ 1

XA3A/ 19

0 - 10VAC

8 XA3A/

XA3A/ 20

17 XA3A/

0 - 10VAC

REV

GND4 Truck frame

STEERING 90-DEG SWITCH

STEERING CONTROLLER

DATE: DESIGN. 2011-06-20 CHECK. APPROV.

NAME: JL

CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) STEERING CIRCUIT

5 / 16

REV

3-7571

Optional button LSS

HORN

S10

COM

S11

SSC

LIFT/LOWER

REACH

TILT

SIDESIFT

AUX

ALS

N R

COM

+ A B -

CPU, INTEGRATED CONTROL ELECTRONICS

FNR (LOW ACTIVE)

CAN

SUPPLY

HORN

2017-03-28

FNR - F

XFC4/ 11

ALS

FNR - N

XFC4/ 2

HORN (2W)

FNR - R

XFC4/ 10

XFC4/ 3 CONNECTED TO CAN-BUS

10L1

GRY

1-26

X44/ 13

X44/ 12

8L3 1-24

XFC4/ 13

CANL

XFC4/ 9

CONNECTED TO CAN-BUS

XA8B/

XX51

0 ... 96VDC

CANH

XFC4/ 1

XFC4/ 5

XFC4/ 6

XFC4/ 14

LSS

XFC4/ 12

+5 ... +20V

SUPPLY

XFC4/ 4

120R

K32

REACH CARRIAGE

X45/ 13 LSS

XA4A/ 33

J13

48V

X45/ 12

48V

XA4A/ 19

DATE:

RL-5CG63616CW Dual Pedal option + CAN wiring improvement

CHANGE:

FNR CONTROL

XX106

REV

APACHE ARMREST

NAME:

8-16

+12V VEHICLE MASTER CONTROLLER

J15

10-12

DATE: DESIGN. 2011-06-20 CHECK. APPROV.

10-13 10-13

8M2

10M1

1-24

1-26

NAME: JL

CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) HYDRAULIC CONTROL CIRCUITS

6 / 16

REV

3-7571

6L1

V10

Y41.1

Y41.2

Y43.2

Y44.1

Y45.2

Y46.1

X44/ 5

BUCHHOLZ Y43.1

Y44.2

Y45.1

Y46.2

J11

X45/ 5

REACH CARRIAGE

10-30

XA4A/ 29

XA4A/ 1

XA4B/ 20

XX12

J16

J25

13-28

8-26

14-17

To work lights

To reach sensors

A4 VEHICLE MASTER CONTROLLER

2 E

XA4A/ 17

XA4A/ 7

XA4A/ 6

XX16

XX17

0-1,9A

20-24V

0-1,9A

V E N

E P

XA4A/ 16

XA4A/ 5

P V

V E N

E N

XA4A/ 4

XX15

0-1,9A

8 P

7 P V

P V E P

XA4A/ 15

XA4A/ 27

XA4A/ 26

XX14

0-1,9A

6 V E N

E N

XA4A/ 14

XA4A/ 3

XX13

5 P V

P V

V E

V E N

XA4A/ 2

3 P

P V E N

XA4A/ 25

XA4A/ 24

+48

XA4A/ 13

IR 2015-06-05

Valve block Y46.1 and Y46.2 changed cross-wis

NAME:

LIFT

LOWER

REACH

DATE: DESIGN. 2011-06-20 CHECK. APPROV.

TILT

LEFT

Y46.1

XY46.2/ 1

XY46.1/ 1

Y45.2

Y46.2

(V8)

SIDESHIFT

RIGHT

XY46.2/ 2

(V7)

XY45.2/ 1

XY45.1/ 1

(V6)

Y45.1

Y46

XY46.1/ 2

(V5)

XY44.2/ 2

(V4)

Y44.2

Y45

XY45.2/ 2

Y44.1

XY44.1/ 2

(V3)

Y44

20-24V

XY45.1/ 2

Y43.2

0-1,9A

XY44.2/ 1

XY44.1/ 1

XY43.2/ 1

XY43.1/ 1 Y43.1

0-1,9A

XY43.2/ 2

XY42/ 2

(V1)

(V2)

Y41.1

Y43

XY43.1/ 2

Y41.2

Y41

XY42/ 1

0-1,9A

XY41/ 1

20-24V

XY41/

REV

DATE:

CHANGE:

1-22

AUX DEVICE

NAME: JL

CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) HYDRAULIC VALVES

7 / 16

REV

3-7571

OPTION

REACH CARRIAGE

MAST

LIFTING HEIGHT REF. /SLOW SPEED SENSOR

REACH DISTANCE SENSOR (ASC) PRESSURE SENSOR

OFF

LOWER STOP

LIFT PULSE ENCODER

Reach

Schmersal BN-80 rz

L+ (+12v)

OUT A

S45

S46

+48V S41

+48V

A10

OFF RETRACT LIMIT SWITCH

618307

XX54

XX55

PNP

1 XX53

S42

618307

PNP

X43/ 2

X43/ 1

X48/ 6

X48/ 5

X48/ 4

X48/ 3

S46

REACH LIMIT SWITCH

S41

618307

RETRACT END STOP

XS44/ 2

XS44/ 1

XS43/ 2

XS43/ 1

XB41/ 4

XB41/ 3

XB41/ 1

4...20mA

XX81

XX56

XX19

XX18

ASC -SENSOR

J17

9-13

9-14

3-24

7-21

to fork carriage

+48V

GND

+12V

HEIGHT REFERENCE

LOWER STOP

XA4A/ 10

J18

XA4B/ 22

2-15

XA4A/ 18

6-16

RETRACT CTB

XA4B/ 21

XX21

J30

XA4B/ 19

XA4B/ 4 PRESSURE SENSOR

XX20

J13

XA4A/ 33

to fork carriage

to Speed sensor

XA4B/ 17

to armrest

J27 2-15

XA4B/ 18

to Speed sensor

XA4B/ 1

REV

PNP

X48/ 2

IR 2018-06-13

BLK

S45

X48/ 1

NAME:

BLU

S42

Retract

J27 and J30 added

+12V

WHT

B21

OUT B

REACH END STOP

XX82

DATE:

CHANGE:

RED

OUT A

L+

S44

489564

BLK

S43

486929

BRN

B41

XB41/ 2

L+

618309

BLK

B42

BRN

B43

REACH CTB

VEHICLE MASTER CONTROLLER

DATE: DESIGN. 2011-06-20 CHECK. APPROV.

NAME: JL

CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) MAST AND REACH CARRIAGE SENSORS

8 / 16

REV

3-7571

OPTION

SIDESHIFT CENTERING DIRECTION

SIDESHIFT CENTERING MIDPOINT

OPTION

FORK CARRIAGE

LOAD STATUS SENSOR

S53

600300

PNP

600300

PNP

B51

618308

PNP L+

BLK

BLU

BRN

XS51/ Orlaco -> Motec

BRN

BLK

BLU

XS53/ 2

OUT Q

GND

X47/ 1

X47/ 2

X47/ 6

X47/ 3

X47/ 4

X47/ 5

X47/ 7

X47/ 8

X46/ 2

X46/ 6

X46/ 3

X46/ 4

X46/ 5

X46/ 7

X46/ 8

XX23

X46/ 1

2014-10-13

XX22

J17 8-19

S-SHIFT DIRECTION

S-SHIFT MIDP.

XA4B/ 14

8-16

XA4B/ 13

J18

XA4A/ 20

SPARE XA4A/ 21

CHANGE: NAME: DATE:

BLU

XS52/

REV

BLK

BRN

OUT _Q

BLK

S52

600300

BLU

S51

TILT CENTERING

LOAD STATUS

VEHICLE MASTER CONTROLLER

REACH CARRIAGE

DATE: DESIGN. 2011-06-20 CHECK. APPROV.

NAME: JL

CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) FORK CARRIAGE

9 / 16

REV

3-7571

X56/

CAN OUTPUT CANL

GND

CANH = WHT CANL = BRN

J6 2-22

GND

XX90

+12 V

XX39

CANH

2-21

DB9

+12V

XX40

CANH

CANL

6-19

6-20

J15

ARMREST

CANH

CANL

-B

CANH

CANL

CANH

CANL

X44/ 16

X44/ 17 X45/16

XX31

X45/ 17

XX30

XA4A/ 11

XA3A/ 22

-B

XX29

XA2A/ 21

XA5A/ 3

XX28

XA2A/ 20

XA5A/ 2

CANL

XX33

XA1A/ 21

XA5A/ 4

CANH

+B GND

XX32

XA1A/ 20

XX26

XA3A/ 23

XX57

XA5A/ 1

XX27

XA4A/ 12

XX88

X45/ 18

XX89

X44/ 18

7L2 1-23 XX44

IR 2017-11-15

CAN-bus routing

1-24

NAME: REV

DATE:

CHANGE:

8M3

120R

J11 7-18

CANH

DISPLAY

STEER CONTROLLER

DATE: DESIGN. 2012-06-19 CHECK. APPROV.

TRACTION CTRL

PUMP CONTROLLER

NAME: JL

CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) CAN-BUS

VMC

10 / 16

REV

3-7571

VIOL

S34

NPN

BLK

BRN

BLU

147144 A

J26

(618667)

48V

PWM

48V

M9.1

11M1

48V

M8.1

J19

1-27

XK31/ 3

24V A2

619779

K31

Multip. output

1-24

+12V

GND

BAT.LOCK

1M2

K A

E4 2

XX4

XX5 1

XA2A/ 16

XA2A/ 17 +48V SUPPLY

AUX.OUTPUT

+48V

PULL

E5 2

XK31/ 4

XX35

8M7

2-21

XA2A/ 6

XA4B/ 15

XM9.1/ 2

XM8/ 2

XM8.1/ 2

48V

GND -

DK31

1N4005

XK31/1 1

XK31/2

XS35.3/ 3 XS35.2/ 3

XH2/ 1

XS35.3/ 2 XS35.2/ 2 XS35/ 2

XS35.3/ 1 XS35.2/ 1 XS35/ 1

XS34.3/ 3 XS34.2/ 3

XS34/ 1

XE1/ 2

+ (618643)

PWM

XM9/ 2

REV

RUBBER BASE LIGHTS

XX43 VIOL

BEEPER

619476

BLK

XS35.1/

NPN

XS34/ 3

R134

X134/ 5

XM9.1/ 1

XM8/ 3

XM8/ 1

XM9/ 1

XM9/ 3

XM8.1/ 1

LOW POWER FANS FOR HS-MODEL

X42/ 2

(450441)

2016-08-22

X134/ 2

NAME:

+50°C

619476

XX36

DATE:

S34

13-30

t K

BATTERY LOCK

XS34.1/

SM2

XS34.3/ 2

J4 3-16

+48V

48V

X42/ 1

XA2A/ 18

Low power fan added

CHANGE:

XX34

3-13

XS34.2/ 2

FAN

1-27

XS34/ 2

PUMP CONTROLLER

11L1

BRN

3-26

MULTIPURPOSE OUTPUT

J23

+48V

Jumper XS31.1/ and/or XS32.1 is removed, if truck is equipped with corresponding battery lock sensor.

PWM CONTROLLED FANS FOR HX-MODEL

XE1/ 1

XH2/ 2

BLU

XS35/ 3

XS34.3/ 1

XS34.2/ 1

SEAT COMPRESSOR/ SEAT HEATER

1-14

PULL

+48V

PUMP CONTROLLER

VMC

DATE: DESIGN. 2012-06-15 CHECK. APPROV.

J20 13-30

NAME: JL

CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) FANS AND AUX DEVICES

11 / 16

REV

3-7571

FORK CAMERA iButton

ABBOT II

Red

13-22

3-16

3-13

2 XAB1/ ENABLE RELAY OUT

X49/

ENABLE RELAY IN

XX49

0 V

XX48

XAB2.1/ XAB2.1/ XAB2.1/ XAB2.1/

1 XAB1/

XAB2/ 1 XAB2/ 2 XAB2/ 3 XAB2/ 4

XX71

XX72

XX50

CANL

CANH

X44.2/16

X44.1/16

XAB1/ 3

X47/

CAMERA

X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

iButton LED1

iButton LED2

XJ1/ 5 XJ1/ 4 XJ1/ 11 XJ1/ 12

XJ1/ 19

XJ1/ 3

XJ1/ 7

XJ1/ 1

XJ1/ 9

XJ1/ 20 CANL

iButton 1-wire

iButton GND

+12V

ENABLE OUT

VIDEO

KEY SWITCH

MONITOR

ENABLE IN

POWER +12V

SAFETY CHAIN

X10.2/

PWR IN

BLK

XA10.1/ 1

10.8V - 56V

RED

XJ1/ 16

XJ1/ 15

FA10/

CANH

IR 2016-01-08

XAB2.1/ added

NAME: REV

DATE:

CHANGE:

1 2 3 4

X44.2/ 17 X44.2/ 18

1 2 3 4

J10

1-14

X44.1/ 17 X44.1/ 18

1L2

X1D1/ X1D1/ X1D1/ X1D1/

13-22

Green

CAMERA

A11 J14

J12

ABBOT2 TERMINAL

A10

DATE: DESIGN. 2013-09-05 CHECK. APPROV.

NAME: EP

CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) AUX DEVICES 2

12 / 16

REV

3-7571

Reading light

9L1

X27/ 1

Operator fan

Alarm light

Working lights OHG

Working lights mast

J22

1-29

SA1/

SE41/

J19

RCA INPUT

Speaker Amplifier

6dB 0dB 12dB BASS EQ

XB/ CH1+ XB/ CH1-

X-OVER

X31/ 1 2

X31.1/ 1 2

S29

X23/ 2 XE3/ 1

XM6/ 1

XH3/ 1 X44/ 6

X1 LED LIGHT 10-30V

X45/ 6

XX68

XE3/ 2

XM6/ 2

XH3/ 2

XE42/ 1 1

12-14

E40

E41

E42 2

XX80

XE42/ 2

E44 2

E43 2

XE43/ 2

X29/ -

X28/ -

XE43/ 1

XX79

J14

X26/ 2

XX67

B23

XX64

Haarukkakamera Fork camera supply

XRCA2/

X29/ +

X28/ +

GAIN

2 2

XB/ CH2+ XB/ CH2-

GND

XPS/

12-13

LPF FULL HPF

GND out

J12

RCA SIGNAL2 RCA SIGNAL1

+12V out

12 V / 25A DC

XX70

12V/5V Converter (fused) USB socket out

XG2/ 2

POWER SUPPLY

48 V DC

XG2/ 3

X27/ 5

XX85

XPS/ REMOTE

XG2/ 1

SH3/

3.5mm AUDIO JACK

SPEAKERS

2015-06-05

SM6/

X26/ 1

RCA SH

X31.1/6

X31.1/ 5 X31/ 5

XPS/ BATT+

XX65

A20

GND in

12V Virran ulosotto 12V Power output

XRCA1/

SE3/

11-29

XX63

+48V in

X27/ 3

X25/ 1 X25/ 2

X23/ 4

X31/ 6

X23/ 1

J21

X24/ 1

XG2/ 4

Audio on/off switch, option switches pins cha

X23/ 5

XX58

B24

XX59

J28 14-20

X23/ 3

REV

DATE:

NAME:

CHANGE:

1-25

+48V

X24/ 2

XX61

XX69

X25/ 3

X27/ 4

J16

J20

7-20

11-29

X27/2

XX83

XX62

9M1 1-25

GND

DATE: DESIGN. 2013-09-18 CHECK. APPROV.

NAME: EP

CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) AUX. DEVICES III

13 / 16

REV

3-7571

Multipurpose input: EL-panel

Multipurpose input: Reach carriage

Cold storage option

8L4

J24

11L2

1-24

3-24

1-28

Accessory rack grounding, Blue spot from page

BLUE SPOT

t 2

220R

K33

7-22

48V

XK31/2

XA4A/ 8

J25

1-24

XA1A/ 5

8M5

STEERING WHEEL

X41/ 2

X41/3

GND

X13/ 3

GND

XK31/ 3

GROUND1

SR54 +10°C

X13/ 2

IR 2015-02-24

E2 2

XR54/ 2

GROUND2

XK31/ 4

X41/ 1

X13/ 1

XR54/ 1

NAME:

Blue Spot: Further connection on page 11.

R54

DATE:

Accessory rack grounding

REV

XK31/1 1

CHANGE:

A4 J28 13-11

Traction controller

Vehicle master controller

DATE: DESIGN. 2014-05-22 CHECK. APPROV.

NAME: EP

CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) AUX DEVICES IV

14 / 16

REV

3-7571

13L1 1-30

X20/ 1

+48V

14F1 2

SPARE WIRES

X45/ 14

X45/ 15 X44/ 15

+24V out

48 V DC

X44/ 14

XG3/ 2

XG3/ 4

REACH CABLE WIRES

+48V in

24 V / 12.5A DC GND out

X21/ 2

XG3/ 1

XG3/ 3

2018-06-13

GND in

X20/ 2

REV

DATE:

NAME:

CHANGE:

X21/ 1

15A

13M1 1-30

GND

DATE: DESIGN. 2016-12-20 CHECK. APPROV.

NAME: IR

CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) AUX DEVICES V

15 / 16

REV

3-7571

CHECK.

APPROV. DATE:

DESIGN. 2017-03-28 IR

CIRCUIT DIAGRAM

BRAKE PEDAL SENSOR

24 26

COM

NAME:

RB14-25N2(S)(C)(H)(X) OPTION DUAL PEDAL

X4.1/ 2

X4.1/ 1

X4/ 2

X4/ 1

YEL

XB22/ 6

GND2

+UB2

X13.1/ 3

TC (XA1A/10) brake input

X3/10

BLU

XB22/ 5

ORA

XB22/ 4

GRN

XB22/ 3

TC (XA1A/5) Multipurpose input

VCM (XA4B/12) brake input

X3/ 9

GND1

BLK

XB22/ 2

+UB1

B25

WHT

OUT2

GND2

DUAL PEDAL ANGLE SENSOR (Connected instead of original Throttle pedal)

XB22/ 1

XB25/ 6

XB25/ 4

+UB2

X13.1/ 2

TC (XA1A/3) throttle input

X3/ 4

XX103

XB25/ 5

+48V

X3/ 8

XX102

X13.1/ 1

+5V

OUT1

GND1

X3/ 7

XB25/ 3

NO +UB1

VCM (XA4B/11) Throttle input

COM

X3/ 3

XB25/ 1

XB25/ 2

ENABLE MICRO SWITCH LEFT RIGHT

XX101

XX100

+5V

X3/ 1

X3/ 2

OPP (VCM XA4A/9) input

Page added

CHANGE:

X3/ 6

NAME:

COM

+48

2017-03-28

DATE:

X3/ 12

REV

11 27 28 29

16 / 16

GATE / DOOR MICRO SWITCH

B22

S8 NO

REV

3-7571

ERROR TABLE Brand: Mitsubishi Models: RB14N-25NH Date: 13.6.2014 Error:

Fault:

Description: No CAN messages received from the traction controller (A1) to logic

Traction Fault

board (A5), CAN bus wiring should be checked if fault persists replace traction controller. Stop mode active. No CAN messages received from the pump controller (A2) to logic board

Hydraulic Fault

(A5), CAN bus wiring should be checked if fault persists replace pump controller. Stop mode active.

Input Unit Fault

No CAN messages received from the input unit (A6) to logic board (A5), CAN bus wiring must be checked if fault persists replace input unit. Stop mode active. No CAN messages received from the steering controller (A3) to logic

Steer Fault

board (A5), CAN bus wiring must be checked, if fault persists replace steering controller. (Old SW). Stop mode active. Steering controller failed to be activated via the CAN communication

Steer Fault

problems. CAN bus wiring must be checked, if fault persists replace steering controller. (Old SW) Stop mode active.

Service Request

Truck's scheduled maintenance period is exceeded. Truck service is to be carried out immediately. To reset alarm confirm next maintenance. (In service mode: Service -> Set Maintenance Interval). Slow Mode active.

Confirm –

You have changed some parameter, truck needs to be restarted.

Restart

Stop mode active.

Logic Fault

Real-Time-Clock battery is exhausted. Logic board should be replaced. Normal mode active.

logic, cpu ram

Software checksum check failed.

check failed

Program should be reloaded or unit replaced.

logic, cpu rom

Software checksum check failed.

check failed

Program should be reloaded or unit replaced.

logic

CN1_44 over current over 2s

logic,

CN1_64 over current over 2s

logic

CN1_62 over current over 2s

logic,

CN1_61 over current over 2s

logic,

CN1_60 over current over 2s

logic,

Logic Fault

logic,

CN1_59 over current over 2s 2nd pump control valve (Y34) output over current. Measure the valve coil resistance (~39 ohms) and check wiring. Normal Mode active. CN1_57 over current over 2s Traction controller W output current has exceeded its maximum limit.

Traction Fault

Check motor cables if fault persists replace traction controller. Stop mode active. Traction controller V output current has exceeded its maximum limit.

Traction Fault

Check motor cables if fault persists replace traction controller. Stop mode active. Traction controller U output current has exceeded its maximum limit.

Traction Fault

Check motor cables if fault persists replace traction controller. Stop mode active.

Traction Fault

Traction controller V current sensor fault. Replace traction controller. Stop mode active. Traction controller U current sensor fault. Replace traction controller. Stop mode active. Traction controller W circuit break. Connections between phases are not

Traction Fault

detected. Check motor cables if fault persists replace traction controller. Stop mode active. Traction controller V circuit break. Connections between phases are not

Traction Fault

detected. Check motor cables if fault persists replace traction controller. Stop mode active. Traction controller U circuit break. Connections between phases are not

Traction Fault

detected. Check motor cables if fault persists replace traction controller. Stop mode active.

Traction Fault

Traction, no motor movement (Old SW). Stop mode active. Motor speed has been detected to be above 5800rpm. Stop mode active. No CAN messages received from the traction controller (A1) to logic

Traction Fault

board (A5), CAN bus wiring should be checked if fault persists replace traction controller. Stop mode active.

Traction Fault

Traction software checksum check failure. Traction controller should be replaced. Stop mode active. Traction controller connector wiring incorrect. Check mode bridges. Stop mode active. Speed remains zero for more than 5 seconds even there is speed order

Traction Fault

above minimum speed. Check free rotation of wheel and motor and measure feedback sensor signals. Stop mode active.

Hydraulic Fault

Pump controller W output current has exceeded its maximum limit. Check motor cables if fault persists replace pump controller. Stop mode active. Pump controller V output current has exceeded its maximum limit. Check motor cables if fault persists replace pump controller. Stop mode active. Pump controller U output current has exceeded its maximum limit. Check motor cables if fault persists replace pump controller. Stop mode active. Pump controller V current sensor fault. Replace pump controller. Stop mode active. Pump controller W circuit break. Connections between phases are not

Hydraulic Fault

detected. Check motor cables if fault persists replace pump controller. Stop mode active. Pump controller V circuit break. Connections between phases are not

Hydraulic Fault

detected. Check motor cables if fault persists replace pump controller. Stop mode active. Pump controller U circuit break. Connections between phases are not

Hydraulic Fault

detected. Check motor cables if fault persists replace pump controller. Stop mode active. Motor feedback sensor signals missing. Check free rotation of the motor.

Hydraulic Fault

If fault persists measure feedback sensor signals A and B if missing replace feedback sensor. Stop mode active.

Hydraulic Fault

Motor speed has detected to be above maximum speed level. Stop mode active.

Pump controller has not received messages from logic board within 50 70

Hydraulic Fault

msec or invalid CAN message was received. Check wiring if persists replace pump controller. Stop mode active.

Hydraulic Fault

Pump software checksum check failure. Pump controller should be replaced. Stop mode active. Pump mode bridges (X46:1 and X46:2) are in incorrect position. Wiring should be checked to be according to schematics. Stop mode active. Feedback sensor channels are reporting reversed direction. Wiring should be corrected. Stop mode active. Unidentified error. Restart and if problem persists, pump controller (A2) should be replaced. Stop mode active.

Output Module

CAN communication between output module (A6) and logics board (A5)

Fault

is disturbed. Check CAN bus. Stop mode active.

Output Module

Supply voltage (XA4_1/20) of output module (A6) is less than 7V.

Fault

Check wiring. Stop mode active.

Output Module

Output module memory fault. Restart and if problem persists, replace the

Fault

output module. Stop mode active.

Output Module

Reach backward over current XA4_1/25.

Fault

Check wiring. Normal mode active.

Output Module

Reach forward over current XA4_1/24. Check wiring. ‘

Fault

Normal mode active.

Output Module

Lift (XA4_1/21) of lower output (XA4_1/22) short circuit.

Fault

Check wiring. Normal mode active.

Output Module

Lowering output over current XA4_1/22.

Fault

Check wiring. Normal mode active.

rio11, lift output fault rio11, side shift left output fault

Output current below 0,16A or above 1,9A more than 180ms

rio11, 99

current leak of side shift

Output feedback is measured above 0,18A even the output is set off.

output(s)

100

101

rio11, tilt down output fault rio11, tilt up output fault

Output current below 0,16A or above 1,9A more than 180ms

rio11, current 102

leak of tilt

Output feedback is measured above 0,18A even the output is set off.

output(s) 103

104

rio11, aux b output fault rio11, aux a output fault

Output current below 0,16A or above 1,9A more than 180ms

rio11, 105

current leak of side shift

Output feedback is measured above 0,18A even the output is set off.

output(s) rio11, 106

side shift right

Output current below 0,16A or above 1,9A more than 180ms

output fault rio11, 107

current leak of

Output feedback is measured above 0,18A even the output is set off.

aux output(s) 108

120

121

122

Output Unit

Unidentified error. Restart and if problem persists, output unit (A4) should

Fault

be replaced. Stop mode active.

Input Unit

No CAN messages received from logics within 100ms. Check wiring. If

Fault

fault persists replace input unit (A6) board. Stop mode active.

Input Unit

Software memory checksum check failed. Input unit (A6) should be

Fault

replaced. Stop mode active.

Input Unit

Unidentified error. Input unit (A6) should be replaced.

Fault

Stop mode active.

140

Steering Fault

141

Steering Fault

Motor short circuit. Check motor and cables if fault persists replace steering controller. Stop mode active. Continuous over current. Check free rotation of steering motor. If ok, replace steering controller. Stop mode active.

Charging timeout. Key input (XA3_1/1) is not reaching battery positive 142

Steering Fault

voltage within 10 sec from the start up. Check wiring from fuse (8F1). Stop mode active. Key input (XA3_1/1) voltage above defined (68,74V) high voltage level.

143

Steering Fault

Measure voltage from fuse 8F1. (Software limit) Stop mode active. Key input (XA3_1/1) voltage above defined (68,74V) high voltage level.

144

Steering Fault

Measure voltage from fuse 8F1. (Hardware limit) Stop mode active.

145

Steering Fault

146

Steering Fault

Key input (XA3_1/1) voltage below defined (15,6V) low voltage level. Measure from fuse 8F1. Stop mode active. Steering controller temperature is above defined alarm level. Stop mode active. Motor temperature is too high. Let the motor cool down. If fault still

147

Steering Fault

persists check also the resistance of thermal sensor from connector (XA3_1) between pins 16 and 4. The resistance of the sensor is 580 ohms at 20 °C. Stop mode active.

148

Steering Fault

149

Steering Fault

150

Steering Fault

Steering controller temperature is above defined alarm level. Stop mode active. Steering controller (A3) internal 15V supply voltage is too low. Cannot be measured, replace the steering controller. Stop mode active. Steering controller (A3) internal 5V supply voltage is too low. Cannot be measured, replace the steering controller. Stop mode active. Offset for the current measurement is too high. Offset is adjusted

151

Steering Fault

automatically on truck power on (steering is powered on after K2 main contactor). Steering controller current sensor fault. Replace steering controller. Stop mode active. Steering controller (A3) open drain output (XA3:1/21) current is too high.

152

Steering Fault

Open drain is used for as magnetic brake output. Check wiring and magnetic brake coil for short/broken circuit, if ok, replace steering controller. Stop mode active.

155

Steering Fault

Can Open communication timeout. Check CAN bus wiring. Restart truck. If fault still persist, replace steering controller (A3). Stop mode active.

156

Steering Fault

157

Steering Fault

158

Steering Fault

159

Steering Fault

Steering reference sensor (S31, S34) was not detected within 100 degrees rotate. Check sensors and wirings. Stop mode active. Steering reference sensors (S31, S34) do not match steering angle. Check sensors and wiring. Stop mode active. Sensor bearing (B32) feedback error, not connected or short circuit. Stop mode active. Steering calibration (Cam Calibration, Par 253) did not complete within certain time period (2 sec.) Stop mode active. During calibration an error happens, mostly when the steering reference

160

Steering Fault

sensors (S31, S34) gets loose and never finds the cam within certain angle. Stop mode active.

161

Steering Fault

162

Steering Fault

Steering reference sensor (S31,S34) error, not connected or short circuit. Stop mode active. Steering wheel sensor (B11) error, not connected or short circuit. Stop mode active. Difference between set and actual value for motor output current are

163

Steering Fault

outside the limit. Check free rotation of steering motor. If ok, replace steering controller. Stop mode active. Difference between set and actual value for the position are outside the

164

Steering Fault

limit. Check free rotation of steering motor. If ok, replace steering controller. Stop mode active. Motor sensor bearing signals (B32) missing. Check motor cables and

165

Steering Fault

free rotation of the motor, If fault persists measure sensor bearing signals A and B, if missing, replace sensor bearing. Stop mode active. Difference between set and actual value for the steering speed are

166

Steering Fault

outside the limit. Check free rotation of steering motor. If ok, replace steering controller. Stop mode active. No CAN messages received from the steering controller (A3) to logic

167

Steering Fault

board (A5), CAN bus wiring must be checked if fault persists replace steering controller. Stop mode active.

168

Steering Fault

169

Steering Fault

Steering controller must be replaced. Stop mode active. Unidentified error from a steering controller. Restart and try to replicate the fault. Check pulse bearing, motor cables, free rotation of motor etc.

170

Steering Fault

171

Steering Fault

Steering controller voltage too low (B+). Stop mode active. Sensor bearing (B32) feedback error, only one channel is giving signal. Check wiring. Stop mode active. Throttle input (XA5_1/20) out of defined range (0.3V-4.7V). Measure

180

Logic Fault

throttle input voltage, if out of range check wiring and throttle pedal (B21). Stop mode active. Brake input (XA5_1/22) out of defined range (0.3V-4.7V). Measure

181

Logic Fault

throttle input voltage, if out of range check wiring and brake pedal (B22). Stop mode active. Lift input (XA5_1/27) out of defined range (0.3V-4.7V). Measure lift input

183

Logic Fault

voltage, if out of range check wiring and lift/lower lever (B43). Stop mode active. Reach input (XA5_1/28) out of defined range (0.3V-4.7V). Measure reach

184

Logic Fault

input voltage, if out of range check wiring and lift/lower lever (B44). Stop mode active. Tilt input (XA5_1/29) out of defined range (0.3V-4.7V). Measure tilt input

185

Logic Fault

voltage, if out of range check wiring and lift/lower lever (B45). Stop mode active. Side shift input (XA5_1/47 and XA5_1/48) is out of the defined range (0.3

186

Logic Fault

V - 4.7 V). Measure the side shift input voltage. If it is out of range, check the wiring and the side shift fingertip (S14). (only in case of analog lever) Stop mode active. Aux input (XA5_1/40 and XA5_1/41) is out of the defined range (0.3 V -

187

Logic Fault

4.7 V). Measure the aux input voltage. If out of range, check the wiring and the fingertip (S21 and S22). (only in case of analog lever) Stop mode active. Lifting height pulse encoder (B41) feedback signal missing. Check

188

Logic Fault

encoder belt and free rotation. If fault persists measure encoder feedback signals A and B. If missing, replace height encoder. Low Mode active.

189

Input Unit Fault

Pressure sensor input (XA6_1/29) out defined range (0.3V-4.7V). Measure pressure sensor input voltage, if out of range check wiring and pressure sensor (B42). Low Mode active.

Height encoder pulses were detected before the reference state change 190

Logic Fault

of mast height was detected. Check the height reference sensor (S43) and its wiring. Measure the gap between the sensor and the magnet (5 mm). Low Mode active.

Left Load 195

Wheel Brake Fault Right Load

196

Wheel Brake Fault

205

206

207

Battery Low

wiring and fuse 11F1. Stop mode active

No voltage detected at XA5_1/39 when load wheel brakes are off. Check wiring and fuse 11F1. Stop mode active Battery discharged. Battery should be charged immediately. Low Mode active.

Battery

Battery voltage too low. Check voltage of the battery.

Voltage

Low Mode active.

Battery

Battery voltage too high. Check voltage of the battery.

Voltage

Stop mode active.

210

Traction Fault

211

Hydraulic Fault

212

Traction Fault

213

Hydraulic Fault

223

No voltage detected at XA5_1/42 when load wheel brakes are off. Check

Traction controller temperature is above defined alarm level (95°C). Stop mode active. Pump controller temperature is above defined alarm level (95°C). Stop mode active. Traction motor temperature is above defined alarm level (130°C). Stop mode active. Pump motor temperature is above defined alarm level (130°C). Stop mode active.

Main

Pump and traction controller voltage (terminals P - N) is below 12V.

Contactor

Check main contactor (K12) and fuses 3F1/4F1. Stop mode active.

WARNINGS TABLE Brand: Models: Date: Warning:

Mitsubishi RB14N-25NH 23.6.2014 Fault: Truck is

shutting down

Service Request

Description: Voltage has dropped below 7V at XA5:19 and because of that the truck is shutting down.

Truck maintenance warning time has elapsed. Normal Mode active.

Steering

Steering motor temperature is below -50°C (Low mode active) or above

Fault

145°C (Stop mode active). Normal Mode active.

Steering

Steering motor temperature sensor not connected or short circuit.

Fault

Stop mode active.

Steering

Steering controllers DC bus voltage is either too low or too high.

Fault

Check B+ and B- to steering controller.

Steering Fault

One of the steering system temperatures is in a warning state and truck is in slow mode. Check for unrestricted and proper operation cooling system of steering controller and steering motor. Low Mode active.

Steering

Current output to magnetic brake coil (Y31) is above the warning limit 2,5A.

Fault

Normal Mode active.

Steering Fault

Current output to magnetic brake coil (Y31) is above 4A and output is set off. Normal Mode active.

Steering

The steering controller temperature is below -20°C or above 85°C.

Fault

Low Mode active.

Steering

Steering controller (A3) internal temperature sensor not connected or short

Fault

circuit. Stop mode active.

Steering Fault

New Application SW has been programmed into the drive. Steering controller default parameters restored. Please restart the truck. Stop mode active.

Steering

Sensor bearing not connected or short circuit. Check wiring and sensor

Fault

bearing (B32). Stop mode active.

Aisle

Aisle sensor has been detected to be active. Truck is in "aisle mode".

detection

Slow Mode active.

Logic fault

Reach position has been lost (Front). Check sensor (S41), cam adjustment and wiring. Normal Mode active.

101

102

190

Logic fault

Incorrect operating sequence. Throttle activated before deadman pedal.

Operation

Normal Mode active.

No Direction

Battery lock switch is open, check that battery is correctly in-place and the

Lock

lock is properly closed. Stop mode active.

Incorrect

Seat switch has been de-activated for more than 5 seconds.

Operation

Stop mode active.

202

Logic fault

205

Alarm has caused truck to go into low performance mode. (See alarm list.) Normal Mode active. Alarm has caused truck to go into stop mode. All functions are disabled. (See alarm list.) Normal Mode active.

Slow

Alarm has caused truck to go into slow performance mode.

Mode

(See alarm list.) Normal Mode active.

Normal

Truck idle timeout has elapsed and the truck has entered the sleep mode.

State

Normal Mode active.

Battery

Battery level close to minimum. Battery should be charged soon.

Low

Slow Mode active.

Max. 206

Drive direction not selected. Normal Mode active.

Battery

Logic fault

204

and wiring. Normal Mode active.

Incorrect

201

203

Reach position has been lost (Rear). Check sensor (S41), cam adjustment

Lifting

Mast is at its defined electrical top position, further lifting is disabled. Normal Mode active.

Height 208

210

211

212

213

Incorrect

No lifting allowed, because defined maximum weight is exceeded. (Option)

Operation

Normal Mode active.

Traction

Traction controller temperature is above defined warning level (80°C).

Fault

Power reduction active. Normal Mode active.

Hydraulic

Pump controller temperature is above defined warning level (80°C). Power

Fault

reduction active. Normal Mode active.

Traction

Traction motor temperature is above defined alarm level (110°C).

Fault

Power reduction active. Normal Mode active.

Hydraulic

Pump motor temperature is above defined alarm level (110°C).

Fault

Power reduction active. Normal Mode active.

FWD/BW 230

D Switch Active

231

232 233 234 235 236

239

250

Throttle Active Brake Active Lift Active Reach Active Tilt Active Side Shift Active OPP Active Battery Voltage

FWD/BWD switch has been active during start-up check. All controls must be in neutral position before the truck can be activated. Stop mode active.

Throttle pedal has been activated at start-up. Stop mode active.

Brake pedal has been activated at start-up. Stop mode active. Lift/lower lever activated at start-up Stop mode active. Reach lever has been activated at start-up. Stop mode active. Tilt lever has been activated at start-up. Stop mode active. Side shift has been activated at start-up. Stop mode active.

Foot switch has been activated at start-up. Stop mode active.

Battery voltage too high. Check voltage of the battery. Slow mode active.

NEW DRAWING

A G1/4

G1/4

A2 G1/4

Aux.

G1/4 HS 3/16" HX 1/4"

Sideshift

G1/4

3/8" G3/8

1/4"

B1 G1/2

Tilt

B3 G1/4

G1/4

A4 G1/4

75bar

Y41.2 Qmax = 70 lpm

2012-12-21

Y41.1 Qmax = 60 lpm

Qmax = 15 lpm

Y43.1

Y43.2

Qmax = 15 lpm

Y44.1

Y44.2

Qmax = 20 lpm

Y45.1

Y45.2

Qmax = 20 lpm

Y46.1

Y46.2

Emergency lowering -valve

G1/2

Tank: V = 38 l Suction Filter: 125my Qmax = 70 lpm

P 5/8"

T 5/8"

DATE: REV

G1/2

5/8"

AV6288 AV6289

NAME:

CHANGE:

G1/2

G3/8

Main lift

Reach

G1/4 HS 3/16" HX 1/4"

Freelift

Lift/Lower

Return Filter: 10my Qmax = 165 lpm Built in breather

S-models: Electric motor: Motor type: Pump Size: Pump type:

10 kW 3-ph AC 14 cc/rev External gear pump

X-models: Electric motor: Motor type: Pump Size: Pump type:

14 kW 3-ph AC 19 cc/rev External gear pump

AV6288 without A4/B4-block section

Draining hose

DATE: DESIGN. 2012-12-21 CHECK. APPROV.

NAME: EP

HYDRAULIKAAVIO HYDRAULIC CIRCUIT DIAGRAM

RB14/16/20/25/N2S/C/HS/H/X/HC Main Hydraulic Circuit

1/1

REV

3-7535_HS

Rev D B A A A A A A A A A A A A A B D A

Description update Production revision Initial revision Initial revision Initial revision Initial revision Initial revision Valve block Y46.2 & Y46.2 Initial revision Initial revision Initial revision Initial revision Initial revision SA1/ added Initial revision Production revision Intercom switches changed. Initial revision

Rev Date 2015-12-07 2015-06-17 2015-04-13 2015-04-13 2015-04-13 2015-04-13 2015-04-13 2015-04-13 2015-04-13 2015-04-13 2015-04-13 2015-04-13 2015-04-13 2015-04-13 2015-04-13 2015-06-17 2015-12-07 2015-04-13

update

Pg 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

2015-12-07 D

REV

DATE:

NAME:

CHANGE:

DATE: DESIGN. 2011-06-20 CHECK. APPROV.

NAME: JL

PIIRIKAAVIO CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) COLD CABIN SISÄLLYS TABLE OF CONTENTS

0 / 17

REV

3-7689

3-12

+48V 1

J22 2

13-15

3-21

1 1

1F1

1 2

5F1

16-13

10A

2 1

6F1 2

7F1

10A

10F1 2

10A

A2.2

25F4 10A

35mm

10A

8L5

8L3

4-14

6-12

2L1

3L1

5L2

6L1

7L3

8L1

8L2

2-15

2-21

3-25

7-17

3-24

4-26

5-22

7L1

9L1

10L1

11L1

13L1

J21

3-17

13-12

6-27

11-17

14-20

13-14

CONTROLLER CIRCUIT

CONTROLLERS KEY

VALVES

PUMPMOTOR

DRIVEMOTOR

CABIN HEATER POWER CIRCUIT

BRAKES

16-16

25L4

16-16

25L3

15-11

16-16

23L1

15-12

CABIN HEATER CONTROL CIRCUIT

21L2

15-12

MAIN CONTACTORS

48V

21L1

25L2

8L4 14-13

16-16

7L2 10-15

25L1

1L2 12-20

1M2

21M1

23M1

25M1

2M1

3M1

11-12

15-12

15-11

16-11

2-15

2-21

1M1

21M2

8M2

3-12

15-12

6-26

8M1

9M1

5-23

13-12

10M1 11M1 6-27

11-17

8M3 2

21M3

7M1

12V OUTPUT

COLD STORAGE OPTIONS

10A

SEAT HEATER/-COMPRESSOR

3-12

A1.2

23F1 2

HORN

30A

12V CONVERTER SUPPLY

1L1

22F1 2

35mm

30A

25F3

21F1

25F2

25F1

15-12

10-28

35mm

B-

12F1

XX84 1

B+

X1/

11F1

X1/ +

KEYSWITCH

Production revision IR

10A

2015-06-17

CHANGE: NAME: DATE:

9F1

XX52

REV

8F1

8M4 10-26

8M7

11-23

1F2 10A

8M5

A2 B-

14-14

DATE: DESIGN. 2011-06-20 CHECK. APPROV.

NAME: JL

PIIRIKAAVIO CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) COLD CABIN JÄNNITESYÖTÖT SUPPLY

1 / 17

REV

3-7689

2L1

3L1

4L1

1-21

1-22

4L1 27

ENCODER AND MOTOR CHANNELS / PHASES SWAPPED TO GET CORRECT STEERING DIRECTION

ENCODER AND MOTOR CHANNELS / PHASES SWAPPED TO GET CORRECT PUMP DIRECTION

+BF

2F1

Initial revision

CHANGE:

B+

300A

B+

V W

3F1

425A

4F1 2

B+

V W

50A

V W V

U U

11-19 10-17

XA1A/ 7

BLU

XM1/ 3

XA1A/ 14

BLK

XM1/ 4

XA1A/ 15

XM1.1/ 2

XA1A/ 22

XM1.1/ 1

XA1A/ 23

WHT

BLU

BLK

B31

TEMP. SENSOR 0V

R31 B-

XA2A/ 8

+12V

XX41

XM2/ 3

XA2A/ 14

XM2/ 2 J6 10-19 XM2/ 4

XA2A/ 7

XA2A/ 15

XX42

B32 1

XM3/ 1

XA3A/ 16

BRN

XM3/ 2

XA3A/ 3

BLK

XM3/ 3

XA3A/ 4

ORA

XM3/ 4

XA3A/ 5

XM3.1/ 2

XA3A/ 6

XM3.1/ 1

XA3A/ 7

SENSOR SUPPLY A

B32

XM2.1/ 2

XA2A/ 22

XM2.1/ 1

XA2A/ 23

TEMP. SENSOR 0V

R32

B-

RED

TEMP. SENSOR 0V

R33 B-

STEERING CONTROLLER EPS AC-0

XM1/ 2

+12V

J26 J5 XM2/ 1

Speed sensor

WHT

RED

PUMP CONTROLLER ACE-2

XA1A/ 8

Speed sensor

XM1/ 1

TRACTION CONTROLLER ACE-2

Speed sensor

2015-04-13 A

REV

DATE:

NAME:

RED

4M1 27

2M1

3M1

4M1

1-21

1-22

DRIVEMOTOR

PUMPMOTOR

DATE: DESIGN. 2011-06-20 CHECK. APPROV.

NAME: JL

PIIRIKAAVIO CIRCUIT DIAGRAM

STEERINGMOTOR

RB14-25N2(S)(C)(H)(X) COLD CABIN MOOTTORIKYTKENNÄT MOTOR CIRCUITS

2 / 17

REV

3-7689

7L1

7L3

5L2

1-13

1-25

1-23

X12/ 1

1L1

KEYSWITCH HARNESS 21

S12 HÄTÄSEIS EM.STOP

XX37

XX76

X33/ 1

LOAD WHEEL BRAKES

X32/ 1

X34/ 1

MAGN.BRAKE

Y32

48V 2

XX2

X34/ 2

XX38

Y33

48V

48V 2

X32/ 2

Y31

X44/ 3

4 5

X33/ 2

X44/ 2

X44/ 1

KEY

Initial revision

CHANGE:

S11

X44/ 4

X12/ 5

GRY

X12/ 6

12-23

XX25 A1.1

11-12

F101

J23 11-15

X45/ 4

XX1

X45/ 3

12-22 11-13

XX24

48V A2.1

XX78

SAFETY IN

ECO EMCY -mode -state

1-13

KEY

SAFETY CONTACT

STEER CTRL

SAFETY KEY COIL MAIN CONT. BRAKE IN SUPPLY CONTROL CONTROL

KEY

+48V LOAD WHEEL (MAIN CONT. BRK. SUPPLY STATE) VEHICLE MASTER CONTROLLER

TRACTION CONTROLLER

XA4B/ 23

14-17

XA4B/ 8

J24

XA4B/ 7

XA1A/ 18

XA1A/ 16

XA1A/ 17

1 XA1A/

XA1A/ 11

9 XA3A/

XA3A/ 15

KEY SAFETY OUT

PUMP CONTROLLER

1M1

REACH CARRIAGE

8-25

XA2A/ 19

1 XA2A/

XA2A/ 3

XA2A/10

XA2A/

48V

XA4A/ 28

XA2A/ 11

REV

J10

XX45

X45/ 2

MAIN CONTACTOR

XX46

X45/ 1

X12/ 3

X12/ 2

XX3

2015-04-13

DATE:

NAME:

XX77

BRAKE CONTROL

MAIN CONTACTOR

DATE: DESIGN. 2011-06-20 CHECK. APPROV.

NAME: JL

PIIRIKAAVIO CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) COLD CABIN PÄÄPIIRIT MAIN CIRCUITS

3 / 17

REV

3-7689

CABIN FLOOR PENKIN MAADOITUS SEAT GROUNDING

TURVAVYÖKYTKIN BELT BUCKLE SWITCH

ISTUINKYTKIN SEAT SWITCH

+48V

JALKAKYTKIN FOOT SWITCH

KAASUPOLJINANTURI

JARRUPOLJINANTURI

THROTTLE PEDAL SENSOR

BRAKE PEDAL SENSOR

3903-00710-02

3903-00711-02

8L5

X22/ 2

GND2

BLU

ORA 5V

BLK

X22/ 1

+UB2

6 4,5...0,5V YEL

0,5...4,5V GRN

GND1

4,5...0,5V YEL

+UB1

BLU 0V

XX8 XX9

X44/ 10

X3/ 12

X44/ 11

X3/ 6

X3/ 10

X3/ 9

X3/ 2

X44/ 9

X44/ 7

X135/

X44/ 8

X3/ 1

X3/ 4

X3/ 8

X134/ 1

X134/ 6

COM

S25

COM

S28

X3/ 7

S21

B22

WHT

GND2

+UB2

0,5...4,5V GRN

ORA

BLK 0V

X134/ 3

GND1

X3/ 3

Initial revision

X136/

2015-04-13

DATE:

XX6 XX7

NAME:

CHANGE:

X137/

1 WHT

B21

+UB1

1-25

X44/

X44/ 14

8L1

X45/ 11

X45/

TRACTION CONTROLLER

P P O

TT O R TH

XA4A/ 9

XA4B/ 11

X45/ 10

XA4B/ 12

X45/ 9

XA4A/ 22

X45/ 8

XA4B/ 16 V +5

E K A R B

PUMP CONTROLLER

XA1A/ 10

9 XA1A/

XA1A/

2 XA1A/

4 XA1A/ S

SEATBELT

X15/

S W EA IT T C H

XA2A/ 5

X45/ 7

REV

1-25

+48V

VEHICLE MASTER CONTROLLER

REACH CARRIAGE

DATE: DESIGN. 2011-06-20 CHECK. APPROV.

NAME: JL

PIIRIKAAVIO CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) COLD CABIN AJOPIIRIT DRIVE CIRCUIT

4 / 17

REV

3-7689

STEERING WHEEL SENSOR

RED

BLK

YEL

BLU

WHT

ORA

X11/ 2

X11/ 4

SENSOR B

S32

485304

NPN

X11/ 3

XX10

Top view

X14.1/ 3

8L2

8M1

1-26

1-25

X14/ 3

X14.1/ 4 X14/ 4

X14.1/ 2 X14/ 2

X14.1/ 1 X14/ 1

2015-04-13

B-

X11/ 1

Initial revision

GND

STEERING STRAIGHT SWITCH

S31

XA3A/

XA3A/ 19

0 - 10VAC

8 XA3A/

XA3A/ 20

0 - 10VAC

S32

XA3A/

CHANGE:

B+

XX11

NAME: DATE: REV

A-

STEERING FEEDBACK SENSOR

SENSOR A

S31 NPN

A+

STEERING FEEDBACK SENSOR

RATTIANTURI

B11

STEERING 90-DEG SWITCH

STEERING CONTROLLER

DATE: DESIGN. 2011-06-20 CHECK. APPROV.

NAME: JL

PIIRIKAAVIO CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) COLD CABIN OHJAUSPIIRIT STEERING CIRCUIT

5 / 17

REV

3-7689

Optional button LSS

HORN

FNR CONTROL

S10

S11

COM

SSC

LIFT/LOWER

REACH

TILT

SIDESIFT

AUX

N R

COM

+ A B -

Initial revision

FNR (LOW ACTIVE)

CAN

SUPPLY

HORN

ALS

XFC4/ 3

FNR - F

XFC4/ 11

HORN (2W)

FNR - N

XFC4/ 2

XFC4/ 13

FNR - R

XFC4/ 10

0 ... 96VDC

CANL

XFC4/ 9

XFC4/ 5

CANH

XFC4/ 1

+5 ... +20V

XFC4/ 6

LSS

XFC4/ 12

XFC4/ 14

SUPPLY

XFC4/ 4

120R

NAME: A

8L3 1-26

X44/ 13

GRY

XX51

CONNECTED TO CAN-BUS

10L1 1-27

2015-04-13

CONNECTED TO CAN-BUS

X44/ 12

J15 10-12

K32

REACH CARRIAGE

LSS

XA4A/ 33

XA4A/ 19

X45/ 12

48V

X45/ 13

CHANGE:

ALS

CPU, INTEGRATED CONTROL ELECTRONICS

DATE:

APACHE ARMREST

REV

A1 48V

J13

8-16

+12V VEHICLE MASTER CONTROLLER

10-13 10-13

DATE: DESIGN. 2011-06-20 CHECK. APPROV.

NAME: JL

PIIRIKAAVIO CIRCUIT DIAGRAM

8M2

10M1

1-25

1-27

RB14-25N2(S)(C)(H)(X) COLD CABIN HYDRAULIIKAN OHJAUSPIIRIT HYDRAULIC CONTROL CIRCUITS

6 / 17

REV

3-7689

6L1

V10

Y41.1

Y41.2

Y43.2

Y44.1

Y45.2

Y46.1

1-24

X44/ 5

BUCHHOLZ Y45.1

Y46.2

X45/ 5

J11 10-30

XA4A/ 29

XA4A/ 1

XA4B/ 20

XX12

J16

J25

13-28

8-26

14-17

To work lights

To reach sensors

A4 VEHICLE MASTER CONTROLLER

2 E

XA4A/ 17

XA4A/ 7

XA4A/ 6

XX16

0-1,9A

V E N

E P

XA4A/ 16

XA4A/ 5

P V

V E N

E N

XA4A/ 4

XX15

0-1,9A

8 P

7 P V

P V E P

XA4A/ 15

XA4A/ 27

XA4A/ 26

XX14

0-1,9A

6 V E N

E N

XA4A/ 14

XA4A/ 3

XX13

5 P V

P V

V E

V E N

XA4A/ 2

3 P

P V E N

XA4A/ 25

XA4A/ 24

+48

XA4A/ 13

Valve block Y46.2 & Y46.2 2015-04-13

Y44.2

XX17

0-1,9A

20-24V

NOSTO LIFT

LASKU LOWER

TYÖNTÖ REACH

DATE: DESIGN. 2011-06-20 CHECK. APPROV.

LEFT

NAME: JL

PIIRIKAAVIO CIRCUIT DIAGRAM

Y46

Y46.1

XY46.2/ 1

XY46.1/ 1

Y45.2

Y46.2

SIVUSIIRTO SIDESHIFT

RIGHT

XY46.2/ 2

(V8)

XY46.1/ 2

(V7)

KALLISTUS TILT BW

XY45.2/ 1

XY45.1/ 1

(V6)

Y45.1

XY45.2/ 2

(V5)

Y44.2

Y45

20-24V

XY45.1/ 2

(V4)

XY44.1/ 2

(V3)

Y44.1

Y44

XY44.2/ 2

Y43.2

0-1,9A

XY44.2/ 1

XY44.1/ 1

XY43.2/ 1

XY43.1/ 1 Y43.1

0-1,9A

XY43.2/ 2

(V1)

Y43

XY43.1/ 2

(V2)

Y41.1

XY42/ 2

Y41.2

Y41

XY42/ 1

0-1,9A

XY41/ 1

20-24V

XY41/

REV

DATE:

NAME:

CHANGE:

REACH CARRIAGE

Y43.1

LISÄTOIMINTO AUX DEVICE A2

RB14-25N2(S)(C)(H)(X) COLD CABIN HYDRAULIVENTTIILIT HYDRAULIC VALVES

7 / 17

REV

3-7689

OPTION

REACH CARRIAGE

MAST PAINEANTURI PRESSURE SENSOR

REACH DISTANCE SENSOR (ASC) TYÖNNÖN ETÄISYYSANTURI

LASKUN PYSÄYTYS

KORKEUSREFERENSSI/AJOHIDASTUSANTURI LIFTING HEIGHT REF. /SLOW SPEED SENSOR

NOSTON PULSSINANTURI LIFT PULSE ENCODER

OFF

LOWER STOP

Reach

Schmersal BN-80 rz

L+ (+12v)

OUT A

BLK

S46

+48V S41

+48V

A10

RETRACT LIMIT SWITCH

618307

XX53

S42

618307

XX54

XX55

PNP

X43/ 2

X43/ 1

X48/ 6

X48/ 5

X48/ 4

X48/ 3

618307

XX56

2015-04-13

XX81

X48/ 2

X48/ 1

PNP

S46

REACH LIMIT SWITCH

S41

618307

RETRACT END STOP

XS44/ 2

XS44/ 1

XS43/ 2

XS43/ 1

XB41/ 4

XB41/ 3

XB41/ 1

OFF

S45

XX19

XX18

XX20 to armrest

XX21

J13

ASC -SENSOR

XA4B/ 4 PRESSURE SENSOR

+12V

HEIGHT REFERENCE

LOWER STOP

XA4A/ 10

GND

XA4B/ 22

+48V

to fork carriage

XA4A/ 18

7-21

XA4B/ 19

3-24

XA4B/ 17

9-14

XA4B/ 18

J17

9-13

XA4A/ 33

J18

RETRACT CTB

XA4B/ 21

6-16

to fork carriage

XA4B/ 1

REV

S45

4...20mA

+12V

BLU

S42

Retract

Initial revision

CHANGE:

WHT

B21

OUT B

REACH END STOP

XX82

NAME: DATE:

RED

OUT A

L+

S44

489564

BLK

S43

486929

BRN

B41

XB41/ 2

L+

618309

BLK

B42

BRN

B43

REACH CTB

VEHICLE MASTER CONTROLLER

DATE: DESIGN. 2011-06-20 CHECK. APPROV.

NAME: JL

PIIRIKAAVIO CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) COLD CABIN MASTON JA TYÖNTÖKELKAN ANTURIT MAST AND REACH CARRIAGE SENSORS

8 / 17

REV

3-7689

OPTION

SIVUSIIRRON KESKITYS SUUNTA

SIVUSIIRRON KESKITYS KESKIPISTE

TILTIN KESKITYS

SIDESHIFT CENTERING DIRECTION

SIDESHIFT CENTERING MIDPOINT

S51

S52

600300

S53

600300

PNP

BLU

BRN

B51

Initial revision

BLU

XS53/ 2

OUT Q

GND

X47/ 2

X47/ 6

X47/ 3

X47/ 4

X47/ 5

X47/ 7

X47/ 8

X46/ 2

X46/ 6

X46/ 3

X46/ 4

X46/ 5

X46/ 7

X46/ 8

XX23

X47/ 1 2015-04-13

BLK

OUT _Q

X46/ 1

XX22

J17 8-19

S-SHIFT DIRECTION

S-SHIFT MIDP.

TILT CENTERING

XA4B/ 14

8-16

XA4B/ 13

J18

XA4A/ 20

SPARE XA4A/ 21

DATE: REV

BRN

618308

PNP

BLU

XS52/

NAME:

CHANGE:

XS51/

BLK

LOAD STATUS SENSOR

BRN

BLK

LASTIN STATUSANTURI

L+

BRN

OPTION

FORK CARRIAGE

TILT CENTERING

600300

PNP

BLK

BLU

LOAD STATUS

VEHICLE MASTER CONTROLLER

REACH CARRIAGE

DATE: DESIGN. 2011-06-20 CHECK. APPROV.

NAME: JL

PIIRIKAAVIO CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) COLD CABIN HAARUKKAKELKKA FORK CARRIAGE

9 / 17

REV

3-7689

X56/

GND

XX40

CANL

XX39

CANH

+12 V

J6 2-20

GND

CANH = YEL CANL = GRN

8M4

8M3

1-25

X44/ 17

CANH

CANL

6-17

6-20

J15

ARMREST

XA3A/ 22

XA3A/ 23

XA1A/ 20

XA1A/ 21

XA2A/ 20

XA2A/ 21

XA4A/ 11

XX29

XX30

XX31

CANH

CANL

CANH

CANL

CANH

CANL

X45/ 17

XA5A/ 3

CANL

XX28

XA4A/ 12

XA5A/ 2

CANH

CANL

XX33

X45/16

XX26

XA5A/ 1

XX57

XA5A/ 4

XX27

+B GND

XX32

X44/ 18

2015-04-13

7L2 1-25

X44/ 16

XX44

NAME: DATE: REV

DB9

Initial revision

CAN OUTPUT

+12V

2-20

CHANGE:

X45/ 18

120R

J11 7-18

CANH

DISPLAY

STEER CONTROLLER

DATE: DESIGN. 2012-06-19 CHECK. APPROV.

NAME: JL

PIIRIKAAVIO CIRCUIT DIAGRAM

TRACTION CTRL

PUMP CONTROLLER

VMC

RB14-25N2(S)(C)(H)(X) COLD CABIN CAN-VÄYLÄ CAN BUS

10 / 17

REV

3-7689

X42/ 1

PWM

48V

BLK

BRN

BLU

BLK

147144 A

J19

J26

PWM

11M1

1-28

XK31/ 3

24V A2

619779

K31

Multip. output

1-25

+12V

GND

BAT.LOCK

1M2

48V

K A

E4 2

8M7

2-20

XX4

XX5 1

XA2A/ 16

XA2A/ 17

XA2A/ 6

+48V SUPPLY

AUX.OUTPUT

+48V

PULL

E5 2

XK31/ 4

XX35

XM8/ 2

DK31

1N4005

XK31/1 1

XS35.3/ 3 XS35.2/ 3

XK31/2

XS35.3/ 2 XS35.2/ 2 XS35/ 2

XS35.3/ 1 XS35.2/ 1 XS35/ 1

XS34.3/ 3

XS34/ 1

VIOL

XA4B/ 15

NPN

619476

GND -

XM9/ 2

REV

RUBBER BASE LIGHTS

BEEPER

XX43 VIOL

XE1/ 2

XM8/ 3

XM8/ 1

XM9/ 1

XM9/ 3

2015-04-13

X42/ 2

(450441)

S34

NPN

XS34.2/ 3

X134/ 5

NAME:

R134

+50°C

XX36

DATE:

X134/ 2 +

t K

13-30

SM2

XS35.1/

619476

XS34/ 3

J4 3-16

S34

XS34.3/ 2

XS34.1/

+48V

3-13

XS34.2/ 2

+48V

XS34/ 2

XA2A/ 18 Initial revision

CHANGE:

XX34

48V

BRN

FAN

1-28

XS34.3/ 1

PUMP CONTROLLER

11L1

BATTERY LOCK

XS34.2/ 1

3-26

MULTIPURPOSE OUTPUT

J23

SEAT COMPRESSOR/ SEAT HEATER

Jumper XS31.1/ and/or XS32.1 is removed, if truck is equipped with corresponding battery lock sensor.

XE1/ 1

XH2/ 1

XH2/ 2

BLU

XS35/ 3

1-13

PULL

PUMP CONTROLLER

+48V

VMC

J20 13-30

DATE: DESIGN. 2012-06-15 CHECK. APPROV.

NAME: JL

PIIRIKAAVIO CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) COLD CABIN TUULETTIMET JA LISÄLAITTEET FANS AND AUX DEVICES

11 / 17

REV

3-7689

OPTION HAARUKKAKAMERA FORK CAMERA

J10

1-13

3-16

3-13

2 XAB1/

XX72

CAMERA

X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/ X44.1/

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/ X44.2/

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

iButton LED1

XJ1/ 5 XJ1/ 4 XJ1/ 11 XJ1/ 12

XJ1/ 20 CANL

XJ1/ 3

XJ1/ 7

XJ1/ 1

XJ1/ 15

XJ1/ 19 CANH

iButton LED2

iButton 1-wire

+12V

ENABLE OUT

VIDEO

KEY SWITCH

MONITOR

ENABLE IN

POWER +12V

SAFETY CHAIN

X10.2/

PWR IN

BLK 2

10.8V - 56V

RED

XJ1/ 9

XJ1/ 16

FA10/

XA10.1/ 1

1 2 3 4 XX71

XX50

CANL

ENABLE RELAY OUT

0 V

X49/

XX49

ENABLE RELAY IN

2015-04-13

XX48

X44.2/ 17 X44.2/ 18

XAB2/ XAB2/ XAB2/ XAB2/

CANH

X44.2/16

XAB1/

X44.1/16

XAB1/ 3

Initial revision

CHANGE:

X47/ 11

NAME: DATE:

Red

1L2

X44.1/ 17 X44.1/ 18

REV

26 iButton

ABBOT II

13-22

CAMERA

A11

J14

J12

Green

1 2 3 4

X1D1/ X1D1/ X1D1/ X1D1/

iButton GND

ABBOT2 TERMINAL

A10

DATE: DESIGN. 2013-09-05 CHECK. APPROV.

NAME: EP

PIIRIKAAVIO CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) COLD CABIN LISÄLAITTEET 2 AUX DEVICES 2

12 / 17

REV

3-7689

Reading light

9L1

X27/ 1

Operator fan

Alarm light

Working lights OHG

Working lights mast

1-26

X23/ 5

J21

J22

1-29

SA1/

SE41/

J19

6dB 0dB 12dB BASS EQ

XB/ CH1+ XB/ CH1-

XB/ CH2+ XB/ CH2-

GND

XPS/

X-OVER

X31/ 1 2

X31.1/ 1 2

12V Virran ulosotto 12V Power output

RCA INPUT

S29

X23/ 2 XE3/ 1

XM6/ 1

XH3/ 1 X44/ 6

X1 LED LIGHT 10-30V

XX67

XE3/ 2

XM6/ 2

XH3/ 2

XE42/ 1

XE43/ 1

XX79

J14

12-14

E40

E41

E42 2

E44 2

E43 2

XX80

XE42/ 2

XE43/ 2

X29/ -

X28/ -

XX68

X26/ 2

X45/ 6

B23

XX64

Haarukkakamera Fork camera supply

X29/ +

XRCA2/

2 2

LPF FULL HPF

XG2/ 1

12-13

GAIN

+12V out

GND out

J12

RCA SIGNAL2 RCA SIGNAL1

Speaker Amplifier

12 V / 25A DC

XX70

12V/5V Converter (fused) USB socket out

POWER SUPPLY

XG2/ 2

XG2/ 4

X27/ 5

XX85

XPS/ REMOTE

XRCA1/

48 V DC

XG2/ 3

SH3/

3.5mm AUDIO JACK

2015-04-13

SM6/

X26/ 1

RCA SH

X31.1/6

X31.1/ 5 X31/ 5

XPS/ BATT+

SA1/ added

A20

B24

XX59

J28 14-20

X23/ 3

DATE: REV

XX65

SPEAKERS

NAME:

CHANGE:

XX63

GND in

X28/ +

XX58

SE3/

11-29

X24/ 1

+48V in

X27/ 3

X25/ 1 X25/ 2

X23/ 4

X31/ 6

X23/ 1

+48V

X24/ 2

XX61

XX69

X25/ 3

X27/ 4

J16

J20

7-20

11-29

X27/2

XX83

XX62

9M1 1-26

GND

DATE: DESIGN. 2013-09-18 CHECK. APPROV.

NAME: EP

PIIRIKAAVIO CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) COLD CABIN LISÄLAITTEET III AUX. DEVICES III

13 / 17

REV

3-7689

Multipurpose input: EL-panel

Multipurpose input: Reach carriage

Cold storage option

8L4

J24

13L1

1-26

3-24

1-29

Accessory rack grounding

BLUE SPOT

Blue Spot: Further connection on page 11.

SR54 t +10°C

XK31/2

E2 2

XR54/ 2

GROUND2

XK31/ 4

7-22

XA4A/ 8

J25

1-25

XA1A/ 5

8M5

48V

STEERING WHEEL

X41/ 2

X13/ 3

X13/ 2

2015-04-13

220R

X41/3

NAME: DATE: REV

K33

R54 GND

1 GND

XK31/ 3

GROUND1

XK31/1 1

X41/ 1

X13/ 1

Initial revision

CHANGE:

XR54/ 1

A4 J28 13-11

Traction controller

Vehicle master controller

DATE: DESIGN. 2014-05-22 CHECK. APPROV.

NAME: EP

PIIRIKAAVIO CIRCUIT DIAGRAM

RB14-25N2(S)(C)(H)(X) COLD CABIN LISÄLAITTEET IV AUX DEVICES IV

14 / 17

REV

3-7689

J30 16-11

J32 16-12

J33

BOSAL COLD CABIN PACKAGE

12V supply to Intercom

SIROCO 3-speed blower

16-12

Production revision

CHANGE:

Electrical power 100W

J34

J35

16-11

48V supply to glass heater J31 control 16-11

48 VDC 4

23L1

Vin

Vout

26F1

XX88

1 XX86

GND in

XX89

XM11/ 3 XM11/ 1

M11

XM11/ 4

M10

Thermal Fuse 216°C 2

1.6A

X61/ 1

2 15A

M L

X61/ 2

1 XX90

12V/25A DC

1-18

2015-06-17

GNDout

3 XX91

RD +

2 10A

XM11/ 2

27F1 1

23M1 NAME:

S63

1-18

DATE:

Wipers

R61

K61 7

X62/ 6

21M1

S61

80°C

REV

1-16

X62/ 5

21M2

M L

1-16

X62/ 4

21M3

K62

2 1

1-16

S62

PTC-heater element 1800W@+20°C 2150W@-20°C

X62/ 1

21L1 1-16

X62/ 2

21L2 1-17

DATE: DESIGN. 2015-04-13 CHECK. APPROV.

NAME: EP

RB14-25N2(S)(C)(H)(X) COLD CABIN KYLMÄKABIINI COLD CABIN

15 / 17

REV

3-7689

WINDOW HEATER

S64 J31

+48Vdc

15-13

+12Vdc

15-16

J35

BOSAL COLD CABIN PACKAGE Heater elements

J30

GND

15-17

25L1

8 12V

1-19

K4 25L2

Intercom switches changed.

25L3

J34

1-20

XR63/ 1 XR63/ 2

R63

XR64/ 1 XR64/ 2

R64

25L4 XX87

25M1 GND

Front Window

Left-side Window

Right-side Window

1-21

XDH/ 1 XDH/ 2

XDS/3 XDS/4

XES/ 2 XES/ 1

XDS/ 2 XDS/ 1

R65

XR65/ 1 XR65/ 2

Door Window

1-19

Door speaker wiring along with wiring to door glass heater

BOSAL INTERCOM PACKAGE INTERCOM 2015-12-07

19 XPI/ 1

J33 +12V

XX92

+12V KL15

+12V KL31

23 8

XPI/ 2

J32 GND

15-17

GND KL30

XIS/ 2 J36 12

15-17

DATE: REV

R62

15-13

NAME:

CHANGE:

1-20

XR62/ 1 XR62/ 2

J37

Interior speaker (Overhead)

XIS/ 1

3 12

XIM/ 2 XIM/ 1

XES/ 2

XDS/ 2

XES/ 1

XDS/ 1

1 10

XEM/ 2 XEM/ 1

1 2

(12V)

Interior microphone (sidecolumn)

SRE NO1

NO2

Rear - exterior ON/OFF

REAR / EXTERIOR GND

SP PTT (Press to talk)

4 NO1

NO2

NC1

NC2

J36 19

ES 1

Exterior speaker (Door) 2

EM 1 2

Exterior microphone (Sidecolumn)

PTT

J37 20

DATE: DESIGN. 2015-04-17 CHECK. APPROV.

NAME: EP

RB14-25N2(S)(C)(H)(X) COLD CABIN KYLMÄKABIINI II COLD CABIN II

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REV

3-7689

XES/ XIS/ Interior Speaker

Initial revision

XEM/

XDS/

XIM/

Door windor heater XR65/

XDH/

Mics XPI/

2015-04-13

XSP/

Intercom

REV

DATE:

NAME:

CHANGE:

XSRE/

Switches

Door speaker

DATE: DESIGN. 2015-05-25 CHECK. APPROV.

NAME: IR

RB14-25N2(S)(C)(H)(X) COLD CABIN KABIININ LIITINKARTTA CABIN CONNECTOR LAYOUT

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REV

3-7689

ELECTRONIC • OLEODYNAMIC • INDUSTRIAL EQUIPMENTS CONSTRUCTION Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY Tel +39 0522 960050 (r.a.) – Fax +39 0522 960259 e-mail: zapi@zapispa.it – web: www.zapispa.it

EN User Manual

ACE2 INVERTER

The contents of this publication is a ZAPI S.p.A. property; all related authorizations are covered by Copyright. Any partial or total reproduction is prohibited. Under no circumstances will Zapi S.p.A. be held responsible to third parties for damage caused by the improper use of the present publication and of the device/devices described in it. Zapi spa reserves the right to make changes or improvements to its products at any time and without notice. The present publication reflects the characteristics of the product described at the moment of distribution. The publication therefore does not reflect any changes in the characteristics of the product as a result of updating.

is a registered trademark property of Zapi S.p.A.

NOTES LEGEND

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The symbol aboard is used inside this publication to indicate an annotation or a suggestion you should pay attention.

The symbol aboard is used inside this publication to indicate an action or a characteristic very important as for security. Pay special attention to the annotations pointed out with this symbol.

AF2ZP0CL - ACE2 - User Manual

Contents 1 2

5 6

INTRODUCTION ...................................................................................................................5 SPECIFICATION ...................................................................................................................6 2.1 Technical specifications ACE2 ...................................................................................6 2.2 Technical specifications ACE2 Power ........................................................................6 2.3 Block diagram .............................................................................................................7 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT.......8 3.1 Microswitches .............................................................................................................8 3.2 Accelerator unit...........................................................................................................8 3.3 Other analog control unit ............................................................................................9 3.4 Speed feedback........................................................................................................10 INSTALLATION HINTS.......................................................................................................11 4.1 Material overview......................................................................................................11 4.1.1 Connection cables ......................................................................................11 4.1.2 Contactors...................................................................................................11 4.1.3 Fuses ..........................................................................................................11 4.2 Installation of the hardware.......................................................................................12 4.2.1 Positioning and cooling of the controller .....................................................12 4.2.2 Wirings: power cables.................................................................................12 4.2.3 Wirings: CAN connections and possible interferences ...............................13 4.2.4 Wirings: I/O connections .............................................................................15 4.2.5 Connection of the encoder..........................................................................15 4.2.6 Main contactor and key connection ............................................................16 4.2.7 Insulation of truck frame..............................................................................16 4.3 Protection and safety features ..................................................................................17 4.3.1 Protection features......................................................................................17 4.3.2 Safety Features...........................................................................................17 4.4 EMC..........................................................................................................................18 4.5 Various suggestions .................................................................................................20 OPERATIONAL FEATURES ..............................................................................................21 5.1 Diagnosis ..................................................................................................................22 DESCRIPTION OF THE CONNECTORS............................................................................23 6.1 Connectors of the logic - Traction configuration .....................................................23 6.2 Connectors of the logic - Pump configuration...........................................................24 6.3 Description of power connections.............................................................................25 DRAWING ...........................................................................................................................26 7.1 Mechanical drawing ACE2........................................................................................26 7.2 Mechanical drawing ACE2 Power ............................................................................27 7.3 Connection drawing - Traction configuration ............................................................28 7.4 Connection drawing - Pump configuration................................................................29 7.5 Connection drawing - Combi configuration ...............................................................30 PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE...................................31 8.1 Adjustments via Console ..........................................................................................31 8.2 Description of Console & Connection .......................................................................31 8.3 Description of Standard Console Menu ....................................................................32 8.3.1 Traction configuration .................................................................................32 8.3.2 Pump configuration .....................................................................................33 8.4 Function configuration ..............................................................................................34

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8.4.1 Traction....................................................................................................... 34 8.4.2 Pump .......................................................................................................... 39 8.5 Parameter regulation................................................................................................ 49 8.5.1 Traction....................................................................................................... 49 8.5.2 Pump .......................................................................................................... 52 8.6 Programming console functions ............................................................................... 56 8.7 Sequence for Ac Inverter Traction setting ................................................................ 57 8.8 Sequence for Ac Inverter Pump setting.................................................................... 58 8.9 Tester: description of the function ............................................................................ 59 8.9.1 Traction....................................................................................................... 59 8.9.2 Pump .......................................................................................................... 60 8.10 Description of the Console “SAVE” function............................................................. 63 8.11 Description of Console “RESTORE” function ........................................................... 64 8.12 Description of Console “PROGRAM VACC” function............................................... 65 8.13 Description of the battery charge detection setting .................................................. 67 8.14 Description of “ALARMS” menu ............................................................................... 68 8.15 Faults diagnostic system .......................................................................................... 69 8.16 Microcontroller alarms overview ............................................................................... 70 8.17 Analysis and troubleshooting of alarms displayed on console ................................. 73 8.18 Microcontroller warning overview ............................................................................. 80 8.19 Analysis and troubleshooting of warnings displayed on console.............................. 81 9 RECOMMENDED SPARE PARTS FOR INVERTER ......................................................... 84 10 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED......................... 85

APPROVAL SIGNS

COMPANY FUNCTION

INIZIALS

PROJECT MANAGER

TECHNICAL ELECTRONIC MANAGER VISA

SALES MANAGER VISA

SIGN

Publication N°: AF2ZP0CL Edition: July 2009

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1 INTRODUCTION Within the ZAPIMOS family, the ACE-2 inverter (E stands for evolution) is the model suitable for control of 4.0 kW to 9.0 kW motors. It has been expressly designed for battery electric traction. It is fit for electric truck, material handling: order pickers, reach truck, CB 2,0 tons, tractors, boom lift and scissors lift. The ACE-2 can be supplied in three versions: 1) Sensored version: using an Encoder (Sensor Bearing) in the Motor axle is realised an extremely precise and reliable motor speed and torque control 2) SenseCoils version: using special auxiliary windings inside the motor instead of an encoder is realised the motor speed and torque control. 3) Sensorless version: using only the phase voltage feedback is implemented the motor speed and torque control with the Zapi patented sensor-less control software. Here the Sensored Version is descripted: it adopts an Encoder integrated in the Ball Bearing (Sensor Bearing). The Encoder fills up the truck performance, respect to the Sensorless and Sense Coils versions, with lower minimum speed, the “stop on the ramp” service and a smoother inversion; on the other hand the reliability gets penalized by the fragile mechanics and inaccessible position of the Sensor Bearing.

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2 SPECIFICATION 2.1 Technical specifications ACE2 Inverter for AC asynchronous 3-phase motors Regenerative braking functions Can-bus interface Flash memory (128 Kbytes On-Chip Program Memory) Digital control based upon a microcontroller Voltage:.............................................................................................. 24 - 36 - 48 V Maximum current ACE2 24V/400: ............................................. 400 A (RMS) for 3' Maximum current ACE2 36-48V/350: ........................................ 350 A (RMS) for 3' 1 hour current rating ACE2 24V/400:................................................. 200 A (RMS) 1 hour current rating ACE2 36-48V/350: ........................................... 170 A (RMS) Operating frequency: ......................................................................................8 kHz External temperature range: .............................................................-30 °C ÷ 40 °C Maximum inverter temperature (at full power): ............................................... 85 °C

2.2 Technical specifications ACE2 Power Inverter for AC asynchronous 3-phase motors Regenerative braking functions Can-bus interface Flash memory (128 Kbytes On-Chip Program Memory) Digital control based upon a microcontroller Voltage:....................................................................................... 24 - 36 – 48- 80 V Maximum current ACE2 24V/500: ............................................. 500 A (RMS) for 3' Maximum current ACE2 36-48V/450: ........................................ 450 A (RMS) for 3' Maximum current ACE2 80V/300: ............................................. 300 A (RMS) for 3' 1 hour current rating ACE2 24V/500:................................................. 250 A (RMS) 1 hour current rating ACE2 36-48V/450: ........................................... 225 A (RMS) 1 hour current rating ACE2 80V/300:................................................. 125 A (RMS) Operating frequency: ......................................................................................8 kHz External temperature range: .............................................................-30 °C ÷ 40 °C Maximum inverter temperature (at full power): ............................................... 85 °C

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2.3 Block diagram

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3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT The ACE2 inverter needs some external parts in order to work. The following devices complete the kit for the ACE2 installation.

3.1 Microswitches -

The microswitches must have a contact resistance lower than 0.1 Ω and a leakage current lower than 100 µA. When full load connected, the voltage drop between the key switch contacts must be lower than 0.1 V. The microswitches send a voltage signal to the microprocessor when a function request (for ex.: running request) is made.

3.2 Accelerator unit The accelerator unit can consist of a potentiometer or an Hall effect device. It should be in a 3-wire configuration. The potentiometer is supplied through CNA#2. Potentiometer output signal must be input to CPOT (CNA#3), signal range is from 0 to 10 V. The negative supply of the potentiometer has to be taken from CNA#9 (GND), or from CNA-5 (REV/ 1ST SPEED) if the diagnosis PEDAL WIRE KO is done. In this case the hardware must be configured closing a jumper on the logic card. Potentiometer value should be in the 0.5 – 10 kΩ range; generally, the load should be in the 1.5 mA to 30 mA range. Faults can occur if it is outside this range. The standard connection for the potentiometer is the one in the Left side of next figure (potentiometer on one end at rest) in combination with a couple of Travel demand switches. On request it is also possible the handling in the Right side of next figure (potentiometer in the middle at rest) still in combination with a couple of Travel demand switches.

The Procedure for automatic potentiometer signal acquisition is carried out using the Console. This enables adjustment of the minimum and maximum useful signal level (PROGRAM VACC function), in either direction. This function is unique when it is necessary to compensate for asymmetry with the mechanical Page - 8/85

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elements associated with the potentiometer, especially relating to the minimum level. The sequence of procedure is described in the programming console manual.

The two graphs show the output voltage from a non-calibrated potentiometer with respect to the mechanical “zero” of the control lever. MI and MA indicate the point where the direction switches close. 0 represents the mechanical zero of the rotation. The Left Hand graph shows the relationship of the motor voltage without signal acquisition being made. The Right Hand Graph shows the same relationship after signal acquisition of the potentiometer.

3.3 Other analog control unit 1) Input A10 is an analog input, whose typical application is for proportional braking. It should be in a 3 wire configuration. Potentiometer value should be in the 0.5-10 kΩ range. Generally, the load should be in the 1.5 mA to 30 mA range. The CPOTB (A10) signal range is from 0 to 10 V. 2) Connections A22 (PTHERM) and A23 (NTHERM) are used for a motor thermal sensor. It can be digital (on/off sensor, normally closed) or analog. See also chapter 8.4 for more explanation.

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3.4 Speed feedback The motor control is based upon the motor speed feedback. The speed transducer is an incremental encoder, with two phases shifted at 90°. The encoder can be of different types: - power supply: +5 V or +12 V. - electric output: open collector ( NPN), push-pull - standard (A and B) output. For more details about encoder installation see also chapter 4.2.5.

Note: The encoder resolution and the motor poles pair (the controller can handle), is specified in the home page display of the handset showing following headline: AE2T2B ZP1.13 That means: AE2T= ACE-2 traction controller (AE2P= ACE-2 pump controller) 2 = motor’s poles pair number B = 64 pulses/rev encoder The encoder resolution is given by the last letter in the following list: A = 32 pulses/rev B = 64 pulses/rev C = 80 pulses/rev D = 128 pulses/rev

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4 INSTALLATION HINTS In the description of these installation suggestions you will find some boxes of different colors, they mean:

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These are information useful for anyone is working on the installation, or a deeper examination of the content

These are Warning boxes, they describe: - operations that can lead to a failure of the electronic device or can be dangerous or harmful for the operator; - items which are important to guarantee system performance and safety

4.1 Material overview Before to start it is necessary to have the required material for a correct installation. Otherwise a wrong choice of cables or other parts could lead to failures/ misbehaviour/ bad performances.

4.1.1 Connection cables For the auxiliary circuits, use cables of 0.5 mm² section. For power connections to the motor and to the battery, use cables having section of at least 50 mm². The screwing torque for the controller power connection must be comprised in the range 13 Nm÷15Nm. For the optimum inverter performance, the cables to the battery should be run side by side and be as short as possible.

4.1.2 Contactors The main contactor must be installed. Depending on the setting two parameters in the controller (MAIN CONT VOLT [V%] and MAIN CONT V RID [%] ; see chapter 8.4.1, 8.4.2): - the output which drives the main contactor coil is modulated with a PWM at high frequency (1 kHz). After an initial delay of about 1 sec in which the coil is driven with a percentage of Vbatt set by MAIN CONT. VOLT. parameter, the PWM reduces the voltage down to a percentage which is set by the MAIN CONT V RID parameter. This feature is useful to decrease the power dissipation of the contactor coil.

4.1.3 Fuses -

Use a 10 A Fuse for protection of the auxiliary circuits. For protection of the power unit, refer to chapter 9 (Recommended spare parts for inverter). The Fuse value shown is the maximum allowable. For special applications or requirements these values can be reduced. For Safety reasons, we recommend the use of protected fuses in order to prevent the spread of fused particles should the fuse blow.

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4.2 Installation of the hardware

Before doing any operation, ensure that the battery is disconnected and when all the installation is completed start the machine with the drive wheels raised from the floor to ensure that any installation error do not compromise safety. After operation, even with the Key Switch open, the internal capacitors may remain charged for some time. For safe operation, we recommend that the battery is disconnected, and a short circuit is made between Battery Positive and Battery Negative power terminals of the inverter using a Resistor between 10 ohm and 100 ohm.

4.2.1 Positioning and cooling of the controller Install the inverter with the base-plate on a flat metallic surface that is clean and unpainted. - Apply a light layer of thermo-conductive grease between the two surfaces to permit better heat dissipation. - Ensure that the wiring of the cable terminals and connectors is carried out correctly. - Fit transient suppression devices to the horn, solenoid valves, and contactors not connected to the controller. - The heat generated by the power block must be dissipated. For this to be possible, the compartment must be ventilated and the heat sink materials ample. - The heat sink material and system should be sized on the performance requirement of the machine. Abnormal ambient air temperatures should be considered. In situations where either ventilation is poor, or heat exchange is difficult, forced air ventilation should be used. - The thermal energy dissipated by the power block module varies and is dependent on the current drawn and the duty cycle.

4.2.2 Wirings: power cables -

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The power cables length must be as short as possible to minimize power losses. They must be tightened on controller power posts with a Torque of 13-15 Nm. The ACE2 module should only be connected to a traction battery. Do not use converters outputs or power supplies. For special applications please contact the nearest Zapi Service Centre.

Do not connect the controller to a battery with a nominal voltage different than the value indicated on the controller label. A higher battery voltage may cause power section failure. A lower voltage may prevent the logic operating.

AF2ZP0CL - ACE2 - User Manual

4.2.3 Wirings: CAN connections and possible interferences

CAN stands for Controller Area Network. It is a communication protocol for real time control applications. CAN operates at data rate of up to 1 Megabits per second. It was invented by the German company Bosch to be used in the car industry to permit communication among the various electronic modules of a vehicle, connected as illustrated in this image:

The best cable for can connections is the twisted pair; if it is necessary to increase the immunity of the system to disturbances, a good choice would be to use a cable with a shield connected to the frame of the truck. Sometimes it is sufficient a simple double wire cable or a duplex cable not shielded. In a system like an industrial truck, where power cables carry hundreds of Ampere, there are voltage drops due to the impedance of the cables, and that could cause errors on the data transmitted through the can wires. In the following figures there is an overview of wrong and right layouts of the cables routing.

Wrong Layout: R Can Bus Power cables

Module 1

Module 2

Module 3 R

The red lines are can wires. The black boxes are different modules, for example traction controller, pump controller and display connected by canbus. AF2ZP0CL - ACE2 - User Manual

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The black lines are the power cables. This is apparently a good layout, but can bring to errors in the can line. The best solution depends on the type of nodes (modules) connected in the network. If the modules are very different in terms of power, then the preferable connection is the daisy chain.

Correct Layout: R Can Bus Power cables

Module 1

Module 2

Module 3 R

Note: Module 1 power > Module 2 power > Module 3 power

The chain starts from the –BATT post of the controller that works with the highest current, and the others are connected in a decreasing order of power. Otherwise, if two controllers are similar in power (for example a traction and a pump motor controller) and a third module works with less current, the best way to deal this configuration is to create a common ground point (star configuration).

Correct Layout: R Can Bus Power cables

Module 1

Module 2 Center of the Ground connection

Module 3 R

Note: Module 1 power ≈ Module 2 power > Module 3 power

In this case the power cables starting from the two similar controllers must be as short as possible. Of course also the diameter of the cable concurs in the voltage drops described before (higher diameter means lower impedance), so in this last example the cable between the minus of the Battery and the common ground point (pointed by the arrow in the image) must be dimensioned taking into Page - 14/85

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account thermal and voltage drop problems.

Can advantages: The complexity of today systems needs more and more data, signal and information must flow from a node to another. CAN is the solution to different problems that arise from this complexity - simplified design (readily available, multi sourced components and tools) - lower costs (less and smaller cables ) - improved reliability (fewer connections) - analysis of problems improved (easy connection with a pc to read the data flowing through the cable).

4.2.4 Wirings: I/O connections -

After crimping the cable, verify that all strands are entrapped in the wire barrel. Verify that all the crimped contacts are completely inserted on the connector cavities.

A cable connected to the wrong pin can lead to short circuits and failure; so, before turning on the truck for the first time, verify with a multimeter the continuity between the starting point and the end of a signal wire.

For information about the mating connector pin assignment see the paragraph “description of the connectors”.

4.2.5 Connection of the encoder 1) ACE2 card is fit for different types of encoder. To control AC motor with Zapi inverter, it is necessary to install an incremental encoder with 2 phases shifted of 90°. The encoder power supply can be +5 or +12 V. It can have different electronic output. A8 +5V/+12V A15 GND A7 ENC A A14 ENC B

positive of encoder power supply. negative of encoder power supply. phase A of encoder. phase B of encoder.

2) Connection of encoder with +5 V power supply.

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Connection of encoder with +12 V power supply.

VERY IMPORTANT It is necessary to specify in the order the type of encoder used, in terms of power supply, electronic output and n° of pulses for revolution, because the logic unit must be set in the correct way by Zapi.

4.2.6 Main contactor and key connection -

The connection of the main contactor can be carried out following the drawing in the figure

The connection of the battery line switches must be carried out following ZAPI instructions. If a mechanical battery line switch is installed, it is necessary that the key supply to the inverter is open together with power battery line; if not, the inverter may be damaged if the switch is opened during a regenerative braking. An intrinsic protection is present inside the logic when the voltage on the battery power connection overtakes 40% more than the battery nominal voltage or if the key is switched off before the battery power line is disconnected.

4.2.7 Insulation of truck frame

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As stated by EN-1175 “Safety of machinery – Industrial truck”, chapter 5.7, “there shall be no electrical connection to the truck frame”. So the truck frame has to be isolated from any electrical potential of the truck power line.

AF2ZP0CL - ACE2 - User Manual

4.3 Protection and safety features 4.3.1 Protection features The ACE-2 is protected against some controller injuries and malfunctions: - Battery polarity inversion It is necessary to fit a MAIN CONTACTOR to protect the inverter against reverse battery polarity and for safety reasons. - Connection Errors All inputs are protected against connection errors. - Thermal protection If the controller temperature exceeds 85 °C, the maximum current is reduced in proportion to the thermal increase. The temperature can never exceed 105 °C. - External agents The inverter is protected against dust and the spray of liquid to a degree of protection meeting IP65. - Protection against uncontrolled movements The main contactor will not close if: - The Power unit is not functioning. - The Logic is not functioning perfectly. - The output voltage of the accelerator does not fall below the minimum voltage value stored, with 1 V added. - Running microswitch in closed position. - Low battery charge When the battery charge is low, the maximum current is reduced to the half of the maximum current programmed. - Protection against accidental Start up A precise sequence of operations are necessary before the machine will start. Operation cannot begin if these operations are not carried out correctly. Requests for drive, must be made after closing the key switch.

4.3.2 Safety Features

ZAPI controllers are designed according to the prEN954-1 specifications for safety related parts of control system and to UNI EN1175-1 norm. The safety of the machine is strongly related to installation; length, layout and screening of electrical connections have to be carefully designed. ZAPI is always available to cooperate with the customer in order to evaluate installation and connection solutions. Furthermore, ZAPI is available to develop new SW or HW solutions to improve the safety of the machine, according to customer requirements. Machine manufacturer holds the responsibility for the truck safety features and related approval.

ACE-2 inverter electronic implements an hardware safety circuit, which is able to open the Line Contactor (LC) and the Electric Brake (EB) - and therefore to cut the power line stopping the machine via HARDWARE, that is bypassing the software control of the LC and EB. This safety circuit is driven by "SAFETY" input. If safety input is connected to -BATT, the "SAFETY" circuit is inactive; if the input is open, the "SAFETY" circuit becomes active and, within a timeout, it is able to open the drivers of LC coil and EB coil. The safety circuit is also periodically checked by the ACE-2 microcontroller; if the microcontroller detects a AF2ZP0CL - ACE2 - User Manual

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failure in the "SAFETY" circuit, the microcontroller itself will bring the machine in a safe status. Suggested connection of "SAFETY" circuit: - STANDALONE CONFIGURATION: it is suggested to connect safety input to the "SEAT" microswitch or to the "DEADMAN" microswitch (it depends on the application); in this way the machine will be brought to a safe status as soon as the operator leaves the machine. - COMBI CONFIGURATION: in this case the pump controller acts as supervisor, checking the traction controller functionality by the CANBUS. So it is suggested to connect the "SAFETY" input of traction controller to a dedicated output of pump controller "SAFETY OUT", so that the pump controller can drive the traction safety input and open the power line in case of malfunctioning of traction controller.

4.4 EMC

EMC and ESD performances of an electronic system are strongly influenced by the installation. Special attention must be given to the lengths and the paths of the electric connections and the shields. This situation is beyond ZAPI's control. Zapi can offer assistance and suggestions, based on its years experience, on EMC related items. However, ZAPI declines any responsibility for non-compliance, malfunctions and failures, if correct testing is not made. The machine manufacturer holds the responsibility to carry out machine validation, based on existing norms (EN12895 for industrial truck; EN50081-2 for other applications).

EMC stands for Electromagnetic Compatibility, and it represents the studies and the tests on the electromagnetic energy generated or received by an electrical device. So the analysis works in two directions: 1) The study of the emission problems, the disturbances generated by the device and the possible countermeasure to prevent the propagation of that energy; we talk about “conduction” issues when guiding structures such as wires and cables are involved, “radiated emissions” issues when it is studied the propagation of electromagnetic energy through the open space. In our case the origin of the disturbances can be found inside the controller with the switching of the mosfets which are working at high frequency and generate RF energy, but wires and cables have the key role to propagate the disturbs because they works as antennas, so a good layout of the cables and their shielding can solve the majority of the emission problems. 2) The study of the immunity can be divided in two main branches: protection from electromagnetic fields and from electrostatic discharge. The electromagnetic immunity concern the susceptibility of the controller with regard to electromagnetic fields and their influence on the correct work made by the electronic device. There are well defined tests which the machine has to be exposed to. These tests are carried out at determined levels of electromagnetic fields, to Page - 18/85

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simulate external undesired disturbances and verify the electronic devices response. 3) The second type of immunity, ESD, concerns the prevention of the effects of electric current due to excessive electric charge stored in an object. In fact, when a charge is created on a material and it remains there, it becomes an “electrostatic charge”; ESD happens when there is a rapid transfer from a charged object to another. This rapid transfer has, in turn, two important effects: - this rapid charge transfer can determine, by induction, disturbs on the signal wiring and thus create malfunctions; this effect is particularly critical in modern machines, with serial communications (canbus) which are spread everywhere on the truck and which carry critical information. - in the worst case and when the amount of charge is very high, the discharge process can determine failures in the electronic devices; the type of failure can vary from an intermittently malfunction to a completely failure of the electronic device.

IMPORTANT NOTE: it is always much easier and cheaper to avoid ESD from being generated, than to increase the level of immunity of the electronic devices. There are different solutions for EMC issues, depending on level of emissions/ immunity required, the type of controller, materials and position of the wires and electronic components. 1) EMISSIONS. Three ways can be followed to reduce the emissions: -

SOURCE OF EMISSIONS: finding the main source of disturb and work on it. SHIELDING: enclosing contactor and controller in a shielded box; using shielded cables; LAYOUT: a good layout of the cables can minimize the antenna effect; cables running nearby the truck frame or in iron channels connected to truck frames is generally a suggested not expensive solution to reduce the emission level.

2) ELECTROMAGNETIC IMMUNITY. The considerations made for emissions are valid also for immunity. Additionally, further protection can be achieved with ferrite beads and bypass capacitors. 3) ELECTROSTATIC IMMUNITY. Three ways can be followed to prevent damages from ESD: -

PREVENTION: when handling ESD-sensitive electronic parts, ensure the operator is grounded; test grounding devices on a daily basis for correct functioning; this precaution is particularly important during controller handling in the storing and installation phase. ISOLATION: use anti-static containers when transferring ESD-sensitive material. GROUNDING: when a complete isolation cannot be achieved, a good grounding can divert the discharge current trough a “safe” path; the frame of a truck can works like a “local earth ground”, absorbing excess charge. So it is strongly suggested to connect to truck frame all the parts of the truck which can be touched by the operator, who is most of the

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time the source of ESD.

4.5 Various suggestions -

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Never connect SCR low frequency chopper with ASYNCHRONOUS INVERTER because the ASYNCHRONOUS filter capacitors alter the SCR choppers' work. If it is necessary to use two or more control units (traction + lift. for ex.), they must belong to the ZAPIMOS family. During battery charge, disconnect ASYNCHRONOUS from the battery.

AF2ZP0CL - ACE2 - User Manual

5 OPERATIONAL FEATURES -

Speed control (three versions available: sensored, sense coil and sensorless as explained in the introduction section) . Optimum behaviour on a slope due to the speed feedback: the motor speed follows the accelerator, starting a regenerative braking if the speed overtakes the speed set-point. the system can perform an electrical stop on a ramp (the machine is electrically hold on a slope) for a programmable time (see also chapter 8.4). Stable speed in every position of the accelerator. Regenerative release braking based upon deceleration ramps. Regenerative braking when the accelerator pedal is partially released (deceleration). Direction inversion with regenerative braking based upon deceleration ramp. Regenerative braking and direction inversion without contactors: only the main contactor is present. The release braking ramp can be modulated by an analog input, so that a proportional brake feature is obtained. Optimum sensitivity at low speeds. Voltage boost at the start and with overload to obtain more torque (with current control). The inverter can drive an electromechanical brake. Hydraulic steering function: - traction inverter - the traction inverter sends a "hydraulic steering function" request to the pump inverter on the can-bus line (see also OPTIONS chapter 8.4). - moreover, if the pump inverter is not present (for ex: tractor application), the traction inverter can manage an "hydraulic steering function" by driving a hydro contactor which drive an hydraulic steering motor (output A18), see also OPTIONS chapter. - pump inverter the pump inverter manage an "hydraulic steering function". That is, it drives the pump motor at the programmed speed for the programmed time. High efficiency of motor and battery due to high frequency commutations. Self diagnosis, the faults can be displayed through the console or Zapi’s MDI/Display. Modification of parameters through the programming console. Internal hour-meter with values that can be displayed on the console. Memory of the last five alarms with relative hour-meter and temperature displayed on the console. Test function within console for checking main parameters.

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5.1 Diagnosis The microcontroller continually monitors the inverter and carries out a diagnostic procedure on the main functions. The diagnosis is made in 4 points: 1) Diagnosis on key switch closing that checks: watchdog circuit, current sensor, capacitor charging, phase's voltages, contactor drives, can-bus interface, if the switch sequence for operation is correct and if the output of accelerator unit is correct. 2) Standby diagnosis in standby that checks: watchdog circuit, phase's voltages, contactor driver, current sensor, can-bus interface. 3) Diagnosis during operation that checks: watchdog circuits, contactor driver, current sensors, can-bus interface. 4) Continuous diagnosis that check: temperature of the inverter, motor temperature. Diagnosis is provided in two ways. The digital console can be used, which gives a detailed information about the failure; the failure code is also sent on the CanBus.

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AF2ZP0CL - ACE2 - User Manual

6 DESCRIPTION OF THE CONNECTORS 6.1 Connectors of the logic - Traction configuration A1

KEY

Connected to the power supply through a microswitch (CH) with a 10 A fuse in series.

PPOT

Potentiometer positive: 12 V / 5 V output; keep load > 1 kohm / 0.5 kohm.

CPOT

Accelerator potentiometer wiper.

FORW

Forward direction request input. It must be connected to the forward direction microswitch, active high.

REV

Backward direction request input. It must be connected to the backward direction microswitch, active high. It can also be used as NPOT (potentiometer negative reference) with the PEDAL WIRE KO diagnosis implemented.

SEAT

SEAT input; it must be connected to the SEAT microswitch; it is active when connected to -BATT.

ENCA

Incremental encoder phase A input.

PENC

Incremental encoder positive supply 12 V / 5 V

-BATT

Negative power supply. It is used as NPOT, without PEDAL WIRE KO diagnosis, for acceleration potentiometer and brake potentiometer

A10

CPOTBR

Brake potentiometer wiper.

A11

SAFETY IN

If not connected to -Batt the MC and EB coil power output will be disabled. In the COMBI configuration it is connected to SAFETY OUT (CNA#19) of pump controller. This input can also be used as a general purpose digital input.

A12

CAN-T

If it is connected with A21 (CAN H) it introduces the 120 Ohm termination resistance between CAN-L and CAN-H.

A13

SR/HB

Speed reduction (handbrake) input. Active with switch opened. Not active with switch closed to -Batt.

A14

ENCB

Incremental encoder phase B input.

A15

ENC GND

Encoder negative power supply.

A16

NLC

Main contactor coil output. The coil is driven to negative reference.

A17

PLC/PB

Positive of the main contactor and electromechanical brake coil.

A18

NEB

Electro mechanic brake coil output. The coil is driven to negative reference.

A19

SAFETY OUT

It drives the external load to negative reference when the REV input is active. It can be used for a flashing light or acoustic indicator. The maximum current load is 1 A. In case of inductive load it is suggested to use a free-wheeling diode across the load (with cathode

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connected to +Batt) A20

CAN-L

Low level CAN-BUS voltage I/O.

A21

CAN-H

High level CAN-BUS voltage I/O.

A22

PTHERM

Input for motor temperature sensor. It is possible to use a digital or analogue (PTC) sensor.

A23

NTHERM

-Batt.

PCLRXD

Positive serial reception (Not used: it can be disconnected).

NCLRXD

Negative serial reception.

PCLTXD

Positive serial transmission.

NCLTXD

Negative serial transmission.

GND

Negative console power supply.

+12

Positive console power supply.

FLASH

It must be connected to B8 for the Flash memory programming.

FLASH

It must be connected to B7 for the Flash memory programming.

6.2 Connectors of the logic - Pump configuration

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KEY

Connected to the power supply through a microswitch (CH) with a 10 A fuse in series.

PPOT

Potentiometer positive: 12 V / 5 V output; keep load > 1 kohm / 0.5 kohm.

CPOT

Lifting potentiometer wiper.

LIFT ENABLE

Input for potentiometer lifting enable input; it is active HIGH.

SPEED1

Input for first speed request; it is active HIGH. It can also be used as NPOT (potentiometer negative reference) with the PEDAL WIRE KO diagnosis implemented.

SEAT

SEAT input; it must be connected to the SEAT microswitch; it is active when connected to -BATT.

ENCA

Incremental encoder phase A input.

PENC

Incremental encoder positive supply 12 V / 5 V

-BATT

Negative power supply. It is used as NPOT, without PEDAL WIRE KO diagnosis, for lifting potentiometer

A10

SPEED2

Input for second speed request; it is active HIGH.

A11

SAFETY IN

If not connected to -Batt the AUX1 and AUX2 coil power output will be disabled. It can also be used as a general purpose digital input.

A12

CAN-T

If it is connected with A21 (CAN H) it introduces the 120 Ohm termination resistance between CAN-L and CAN-H.

A13

SPEED3

Input for third speed request; it is active when AF2ZP0CL - ACE2 - User Manual

connected to -Batt. A14

ENCB

Incremental encoder phase B input.

A15

ENC GND

Encoder negative power supply.

A16

NLC

Main contactor coil output. The coil is driven to negative reference.

A17

PLC/PAUX

Positive of the LC and Auxiliary coil.

A18

NAUX

Auxiliary coil output. The coil is driven to negative reference.

A19

SAFETY OUT

In the COMBI configuration it is connected to SAFETY IN (CNA#11) of traction controller. It can also be used to drive an external load to negative reference when the pump motor is driven. The maximum current load is 1 A. In case of inductive load it is suggested to use a free-wheeling diode across the load (with cathode connected to +Batt)

A20

CAN-L

Low level CAN-BUS voltage I/O.

A21

CAN-H

High level CAN-BUS voltage I/O.

A22

PTHERM

Input for motor temperature sensor. It is possible to use a digital or analogue (PTC) sensor.

A23

NTHERM

-Batt.

PCLRXD

Positive serial reception (Not used: it can be disconnected).

NCLRXD

Negative serial reception.

PCLTXD

Positive serial transmission.

NCLTXD

Negative serial transmission.

GND

Negative console power supply.

+12

Positive console power supply.

FLASH

It must be connected to B8 for the Flash memory programming.

FLASH

It must be connected to B7 for the Flash memory programming.

6.3 Description of power connections View of the power bars: -BATT

Negative of the battery.

+BATT

Positive of the battery.

U; V; W

Connection bars of the three motor phases; follow this sequence and the indication on the motor.

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7 DRAWING 7.1 Mechanical drawing ACE2

Existing others versions (with or without power fuse): - With heat sink 200x40x150mm (longitudinal / transversal)

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AF2ZP0CL - ACE2 - User Manual

7.2 Mechanical drawing ACE2 Power

Existing others versions (with or without power fuse): - With heat sink 200x40x185mm (transversal) - With heat sink 200x40x200mm (transversal / longitudinal)

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7.3 Connection drawing - Traction configuration

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7.4 Connection drawing - Pump configuration

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7.5 Connection drawing - Combi configuration

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8 PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE 8.1 Adjustments via Console Adjustment of Parameters and changes to the inverter’s configuration are made using the Digital Console. The Console is connected to the “B” connector of the inverter.

8.2 Description of Console & Connection

Digital consoles used to communicate with AC inverter controllers must be fitted with EPROM CK ULTRA, minimum "Release Number 3.02". AF2ZP0CL - ACE2 - User Manual

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8.3 Description of Standard Console Menu 8.3.1 Traction configuration

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8.3.2 Pump configuration

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8.4 Function configuration 8.4.1 Traction Using the CONFIG MENU of the programming console, the user can configure the following functions (see "OPERATIONAL FEATURE" chapter for an explanation of "hydraulic steering function"): SUBMENU "SET OPTIONS" 1) DISPLAY TYPE This parameter decides wich display is connected to the inverter. 0: No Display 1: MDI PRC connected 2: ECO DISPLAY connected 3: SMART DISPLAY connected 4: MDI CAN connected 2) TILLER SWITCH This option handles the input CNA#6 . This input opens when the operator leaves the truck. It is connected to a key voltage when the operator is present. There are two levels: - HANDLE: CNA#6 is managed as tiller input (no delay when released). - SEAT: CNA#6 is managed as seat input (with a delay when released debouncing function) 3) HOUR COUNTER - RUNNING: the counter registers travel time only. - KEY ON: the counter registers when the "key" switch is closed. 4) CUTBACK MODE OPTION#1, PRESENT or OPTION#2. - If option 2.5 POT is ON: OPTION#1: A13 is a handbrake. PRESENT: A13 is a speed reduction request. OPTION#2: no function for A13. - If option 2.5 POT is OFF: OPTION#1: A13 is a handbrake. PRESENT: A13 is a speed reduction request. OPTION#2: A13 is enable input. 5) BATTERY CHECK - ON: the battery discharge level check is carried out; when the battery level reaches 10%, an alarm is signalled and the maximum current is reduced to the half of the programmed value. - OFF: the battery discharge level check is carried out but no alarm is signalled. 6) STOP ON RAMP - ON: the stop on ramp feature (truck electrically hold on a ramp) is managed for a time established by "auxiliary time" parameter. After this time, the behaviour depends on the "aux output #1" option programming (see also the following table). Page - 34/85

AF2ZP0CL - ACE2 - User Manual

OFF: the stop on ramp feature is not performed.

7) AUX OUTPUT #1 - BRAKE: output A18 drives an electromagnetic brake coil which is activated every time the traction motor is driven. - FREE: No function. - OPTION#1: Reverse Alarm. A18 is active when input REVERSE is active or when motor is drived in reverse direction. 8) SET MOT. TEMPERATURE - DIGITAL: a digital (ON/OFF) motor thermal sensor is connected between A22 and A23 inputs. - ANALOG: an analogue motor thermal sensor is connected between A22 and A23 (the curve can be customized on a customer request). - NONE: no motor thermal sensor switch is connected. 9) AUX INPUT#1 This parameter decide if input A10 is used for brake or for quick inversion. BRAKE: A10 is used like brake pedal. BELLY: A10 is used like quick inversion input. There’s inversion until A10 is closed. TIMED: A10 is used for quick inversion request and inversion is timed. 10) 2.5 POT ON: when the potentiometer is under the half range level, is backward. When is over is forward. Forward and backward microswitches are not present. Enable is A4. 11) BACKING: ON: Inching function is available. Enable input on A19, Forward direction request input on A4, reverse direction request input on A5. 12) EPS ON: EPS is present. SUBMENU "ADJUSTMENTS" 1) SET POT BRK MIN It records the minimum value of braking pedal potentiometer when the braking switch is closed; the procedure is similar to the "Program Vacc" function (see chapter 9.4). This procedure must be carried out only if the "Pedal braking" option is programmed as "Analog". 2) SET POT BRK MAX It records the maximum value of braking pedal potentiometer when the braking pedal is fully pressed; the procedure is similar to the "Program Vacc" function (see chapter 9.4). This procedure must be carried out only if the "Pedal braking" option is programmed as "Analog". 3) SET BATTERY TYPE It selects the nominal battery voltage. 4) ADJUST BATTERY Fine adjustment of the battery voltage measured by the controller.

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5) THROTTLE 0 ZONE It establishes a deadband in the accelerator input curve (see also curve below). 6) THROTTLE X POINT This parameter changes the characteristic of the accelerator input curve. 7) THROTTLE Y POINT This parameter changes the characteristic of the accelerator input curve.

VACC MIN and VACC MAX are values programmable by the "Program Vacc" function. 8) BATT. MIN. ADJ. It adjusts the lower level of the battery discharge table. It is used to calibrate the discharge algorithm with the battery of the application. See chapter 9.5 for more information. 9) BATT. MAX. ADJ. It adjusts the upper level of the battery discharge table. It is used to calibrate the discharge algorithm with the battery of the application. See chapter 9.5 for more information. 10) ADJUSTMENT #03 This parameter adjusts the updating of battery charge after Key-On. Decreasing this parameter the difference between the battery voltage measured after Key-On and the last stored value necessary to update the charge with the new value measured decrease. It is used to calibrate the discharge algorithm with the battery of the application. See chapter 9.5 for more information. 11) LOAD HM FROM MDI When set On, the HourMeter of the Controller is transferred and recorded on the HourMeter of the Standard MDI (connected on the Serial Link).

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12) CHECK UP DONE Turn it On when the required Maintenance service has been executed to cancel the CHECK UP NEEDED warning. 13) CHECK UP TYPE It specifies the handling of the CHECK UP NEEDED warning: - NONE: No CHECK UP NEENED warning - OPTION#1: CHECK UP NEENED warning shown on the hand set and - MDI after 300 hours - OPTION#2: Equal to OPTION#1 but Speed reduction after 340 hours - OPTION#3: Equal to OPTION#2 but the truck definitively stops after 380 hours 14) MAIN CONT VOLT It specifies the percentage of battery voltage supplied to MC coil to close the contactor. 15) AUX OUT VOLT It specifies the percentage of battery voltage supplied to EB coil to apply the electro mechanic brake. 16) MAIN CONT. V RID It specifies the percentage of MAIN CONT VOLT parameter, supplied to MC coil to keep the contactor closed. Example 1 MAIN CONT VOLTAGE = 100% MAIN CONT V RID = 70% The contactor will be closed with full battery voltage applied to the coil and then the voltage will be reduced to 70% of battery voltage. Example 2 MAIN CONT VOLTAGE = 70% MAIN CONT V RID = 100% The contactor will be closed with 70% of battery voltage applied to the coil and then the voltage will be kept at the same value. Example 3 MAIN CONT VOLTAGE = 70% MAIN CONT V RID = 70% The contactor will be closed with 70% of battery voltage applied to the coil and then the voltage will be reduced to 49% of battery voltage. 17) AUX OUTPUT V RID It specifies the percentage of AUX OUT VOLT parameter, supplied to EB coil to keep the electro mechanic brake applied. Example 1 MAIN CONT VOLTAGE = 100% MAIN CONT V RID = 70% The Ebrake will be closed with full battery voltage applied to the coil and then the voltage will be reduced to 70% of battery voltage. Example 2 MAIN CONT VOLTAGE = 70% MAIN CONT V RID = 100% The Ebrake will be closed with 70% of battery voltage applied to the coil and then the voltage will be kept at the same value. Example 3 MAIN CONT VOLTAGE = 70% AF2ZP0CL - ACE2 - User Manual

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MAIN CONT V RID = 70% The Ebrake will be closed with 70% of battery voltage applied to the coil and then the voltage will be reduced to 49% of battery voltage.

AUX OUTPUT

BRAKE

HYDRO CONT.

STOP ON RAMP

OFF

HYDRO CONT.

OFF

EXCL. HYDRO

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OFF

A18 OUTPUT

-It drives the coil of a electromagnetic brake. -The hydraulic steering function request is sent to the pump inverter by the can-bus link.

-It drives the coil of a electromagnetic brake. -The hydraulic steering function request is sent to the pump inverter by the can-bus link. -It drives the coil of a hydraulic steering contactor when the direction input or brake pedal input are active or a movement of the truck is detected.-The hydraulic steering function request is also sent to the pump inverter by the can-bus link. -It drives the coil of a hydraulic steering contactor when the direction input or brake pedal input are active or a movement of the truck is detected. -The hydraulic steering function request is also sent to the pump inverter by the can-bus link. -It drives the coil of a hydraulic steering contactor when the exclusive hydro input is active. -The hydraulic steering function request is also sent to the pump inverter by the can-bus link. -It drives the coil of a hydraulic steering contactor when the exclusive hydro input is active. -The hydraulic steering function request is also sent to the pump inverter by the can-bus link.

BEHAVIOUR ON A SLOPE The truck is electrically hold on a slope; when the time set by "auxiliary time" parameter is elapsed the brake is applied and the 3-phase bridge is released. Do not use this combination if the negative brake is not installed. The truck is not electrically hold on a slope, but comes down very slowly; when the time set by "auxiliary time" parameter is elapsed, the brake is applied and the 3-phase bridge is opened. Do not use this combination if the negative brake is not installed. The truck is electrically hold on a slope; when the time set by "auxiliary time" parameter is elapsed, the truck comes down very slowly, till the flat is reached.

The truck is not electrically hold on a slope, but comes down very slowly till the flat is reached.

The truck is electrically hold on a slope; when the time set by "auxiliary time" parameter is elapsed, the truck comes down very slowly, till the flat is reached.

The truck is not electrically hold on a slope, but comes down very slowly till the flat is reached.

AF2ZP0CL - ACE2 - User Manual

SUBMENU "SPECIAL ADJUST" 1) ADJUSTMENT#01 Reserved. 2) ADJUSTMENT#02 Reserved. 3) SET CURRENT It adjusts the regolation of maximum current. It shouldn’t be changed. 4) HIGH ADRESS Reserved. 5) DEBUG MODE Reserved. 6) INVERTER TYPE It decides what kind of inverter is used. 0 and 1: traction. 2 and 3: pump. The change of this parameter changes the other parameters at the next keyoff. 7) SAFETY IN 0: input allways closed (bridged) 1: safety_in_drived: safety came from a different controller, need a can handshake. 2: general purpose input (not jet defined. Need hardware change) 8) SAFETY OUT 0: none : fa comunque la diag all'init per verificare il funzionamento. 1: driver: is for drive a safety in. 2: general purpose: standard function: reverse direction indicator. 9) MAIN CONTACTOR OFF No main contactor (directly connect to +Battery) ON Main contactor in stand alone config OPTION#1 Traction +pump 1 only MC OPTION#2 Traction +pump 2 MC 10) AUX OUT FUNCTION ON/OFF. If OFF, A18 is not drived and there is no diagnosis on it.

8.4.2 Pump Using the config menu of the programming console, the user can configure the following functions. SUBMENU "SET OPTIONS" 1) DISPLAY TYPE This parameter decides wich display is connected to the inverter. 0: No Display 1: MDI PRC connected 2: ECO DISPLAY connected AF2ZP0CL - ACE2 - User Manual

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3: SMART DISPLAY connected 4: MDI CAN connected 2) TILLER SWITCH This option handles the input CNA#6 . This input opens when the operator leaves the truck. It is connected to a key voltage when the operator is present. There are two levels: - HANDLE: CNA#6 is managed as tiller input (no delay when released). - SEAT: CNA#6 is managed as seat input (with a delay when released debouncing function) 3) HOUR COUNTER - RUNNING: the counter registers travel time only. - KEY ON: the counter registers when the "key" switch is closed. 4) CUTBACK MODE OPTION#1: A13 is third speed request PRESENT: A13 is speed reduction request OPTION#2: A13 has no function. 5) BATTERY CHECK - ON: the battery discharge level check is carried out; when the battery level reaches 10%, an alarm is signalled and the maximum current is reduced to the half of the programmed value. - OFF: the battery discharge level check is carried out but no alarm is signalled.

Very important: In the combi system (pump + traction), the battery discharge calculation for the complete system is carried out by the traction inverter; the information about the pump inverter consumption is sent on the can-bus line from the pump inverter to the traction inverter. So the correct programming for the "Battery check" option is: traction inverter: ON pump inverter: OFF.

6) STOP ON RAMP - ON: the stop on ramp feature (truck pump electrically hold on with load) is managed for a time established by "auxiliary time" parameter. - OFF: the stop on ramp feature is not performed. 7) AUX OUTPUT #1 Not used. 8) SET MOT TEMPERATURE - ANALOG: an analogue motor thermal sensor is connected between A22 and A23 inputs (the curve can be customized on a customer request). - DIGITAL: a digital (ON/OFF) motor thermal sensor is connected between A22 and A23 inputs. - NONE: no motor thermal sensor switch is connected.

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SUBMENU "ADJUSTMENTS" 1) SET BATTERY TYPE It selects the nominal battery voltage. 2) ADJUST BATTERY Fine adjustment of the battery voltage measured by the controller. 3) THROTTLE 0 ZONE It establishes a dead band in the lift potentiometer input curve (see also curve below). 4) THROTTLE X POINT This parameter, together with the THROTTLE Y POINT, changes the characteristic of the lift potentiometer input curve : when the potentiometer is depressed to X point per cent, the corresponding pump speed is Y point per cent of the Maximum pump speed. The relationship between the lift potentiometer position and the pump speed is linear between the THROTTLE 0 ZONE and the X point and also between the X point and the maximum potentiometer position but with two different slopes. 5) THROTTLE Y POINT This parameter, together with the THROTTLE X POINT, changes the characteristic of the lift potentiometer input curve (see also paragraph 13.5): when the potentiometer is de-pressed to X point per cent, the corresponding pump speed is Y point per cent of the Maximum pump speed. The relationship between the potentiometer position and the pump speed is linear between the THROTTLE 0 ZONE and the X point and also between the X point and the maximum accelerator position but with two different slope. VACC MIN and VACC MAX are values programmable by the "Program Vacc" function.

6) BATT. MIN. ADJ. It adjusts the lower level of the battery discharge table. It is used to calibrate the discharge algorithm with the battery of the application. See chapter 9.5 for more information. AF2ZP0CL - ACE2 - User Manual

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7) BATT. MAX. ADJ. It adjusts the upper level of the battery discharge table. It is used to calibrate the discharge algorithm with the battery of the application. See chapter 9.5 for more information. 8) ADJUSTMENT #03 This parameter adjusts the updating of battery charge after Key-On. Decreasing this parameter the minimum difference between the battery voltage measured after Key-On and the last stored value, necessary to update the charge with the new value measured, decrease. It is used to calibrate the discharge algorithm with the battery of the application. See chapter 9.5 for more information. 9) LOAD HM FROM MDI When set On, the HourMeter of the Controller is transferred and recorded on the HourMeter of the Standard MDI (connected on the Serial Link). 10) CHECK UP DONE Turn it On when the required Maintenance service has been executed to cancel the CHECK UP NEEDED warning. 11) CHECK UP TYPE It specifies the handling of the CHECK UP NEEDED warning: - NONE: No CHECK UP NEENED warning - OPTION#1: CHECK UP NEENED warning shown on the hand set and MDI after 300 hours - OPTION#2: Equal to OPTION#1 but Speed reduction after 340 hours - OPTION#3: Equal to OPTION#2 but the truck definitively stops after 380 hours 12) MAIN CONT VOLT It specifies the percentage of battery voltage supplied to MC coil to close the contactor. 13) AUX OUT VOLT It specifies the percentage of battery voltage supplied to AUX coil to close the AUXILIARY electro valve. 14) MAIN CONT. V RID It specifies the percentage of MAIN CONT VOLT parameter, supplied to MC coil to keep the contactor closed. Example 1 MAIN CONT VOLTAGE = 100% MAIN CONT V RID = 70% The contactor will be closed with full battery voltage applied to the coil and then the voltage will be reduced to 70% of battery voltage. Example 2 MAIN CONT VOLTAGE = 70% MAIN CONT V RID = 100% The contactor will be closed with 70% of battery voltage applied to the coil and then the voltage will be kept at the same value. Example 3 MAIN CONT VOLTAGE = 70% MAIN CONT V RID = 70% Page - 42/85

AF2ZP0CL - ACE2 - User Manual

The contactor will be closed with 70% of battery voltage applied to the coil and then the voltage will be reduced to 49% of battery voltage. 15) AUX OUTPUT V RID It specifies the percentage of AUX OUT VOLT parameter, supplied to EB coil to keep the electro mechanic brake applied. Example 1 MAIN CONT VOLTAGE = 100% MAIN CONT V RID = 70% The load will be closed with full battery voltage applied to the coil and then the voltage will be reduced to 70% of battery voltage. Example 2 MAIN CONT VOLTAGE = 70% MAIN CONT V RID = 100% The load will be closed with 70% of battery voltage applied to the coil and then the voltage will be kept at the same value. Example 3 MAIN CONT VOLTAGE = 70% MAIN CONT V RID = 70% The load will be closed with 70% of battery voltage applied to the coil and then the voltage will be reduced to 49% of battery voltage.

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SUBMENU "SPECIAL ADJUST" 1) ADJUSTMENT#01 Reserved. 2) ADJUSTMENT#02 Reserved. 3) SET CURRENT It adjust the regolation of maximum current. It shouldn’t be changed. 4) HIGH ADRESS Reserved. 5) DEBUG MODE Reserved. 6) INVERTER TYPE It decides what kind of inverter is used. 0 and 1: traction. 2 and 3: pump. The change of this parameter changes the other parameters at the next keyoff. 7) SAFETY IN 0: input allways closed (bridged) 1: safety_in_drived: safety came from a different controller, need a can handshake. 2: general purpose input (not jet defined. Need hardware change). 8) SAFETY OUT 0: none : fa comunque la diag all'init per verificare il funzionamento. 1: driver: is for drive a safety in. 2: general purpose: standard function: reverse direction indicator. 9) MAIN CONTACTOR OFF No main contactor (directly connect to +Battery) ON Main contactor in stand alone config OPTION#1 Traction +pump 1 only MC OPTION#2 Traction +pump 2 MC 10) AUX OUT FUNCTION ON/OFF. If OFF, A18 is not drived and without diagnosis.

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AF2ZP0CL - ACE2 - User Manual

Flow chart showing how to make changes to OPTION Menu. 1) Opening Zapi Menu.

AE2T2B ZP0.12 24V 400A 00000

2) Press Top Left & Right Buttons to enter SET Menu. 3) The Display will show: SET MODEL.

% ' % ' ' ' CONFIG MENU SET MODEL

4) Press ROLL UP or ROLL DOWN button until SET MODEL Menu appears. 5) SET OPTIONS appears on the display.

% ' ' ' ' ' CONFIG MENU SET OPTIONS ' % ' ' ' '

6) Press ENTER to go into the SET MODEL Menu. 7) The display will shows the first OPTION.

HOUR COUNTER RUNNING

8) Press ROLL UP or ROLL DOWN button until desired OPTION appears. 9) Desired OPTION appears.

% ' ' % ' '

BATTERY CHECK OFF

10) Press SET UP or SET DOWN button in order to modify the changes. 11) New OPTION appears.

' ' % ' ' % BATTERY CHECK ON ' ' ' ' % '

12) Press OUT to exit the Menu. 13) Confirmation request appears.

ARE YOU SURE? YES=ENTER NO=OUT

14) Press ENTER to accept the changes, or press OUT if you do not accept the changes.

' % ' ' ' '

15) SET OPTIONS Menu appears. 16) Press OUT again. Display now show the Opening Zapi Menu.

AF2ZP0CL - ACE2 - User Manual

' ' ' ' % '

CONFIG MENU SET OPTIONS ' ' ' ' % '

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Flow chart showing how to make changes to ADJUSTMENTS Menu. 1) Opening Zapi Menu. 2) Press Top Left & Right Buttons to enter CONFIG Menu. 3) The display will show: SET MODEL. 4) Press ROLL UP or ROLL DOWN button until ADJUSTMENTS Menu appears. 5) ADJUSTMENTS appears on the display.

AE2T2B ZP0.12 24V 400A 00000 % ' % ' ' ' CONFIG MENU SET MODEL % ' ' ' ' ' CONFIG MENU ADJUSTMENTS

6) Press ENTER to go into the ADJUSTMENTS Menu.

' % ' ' ' '

7) The display will shows SET BATTERY TYPE.

BATTERY TYPE 48V

8) Press ROLL UP or ROLL DOWN button until the desired parameter is reached. 9) The desired parameter appears. 10) Press SET UP or SET DOWN button to modify the adjustment.

% ' ' % ' ' TROTTLE 0 ZONE 3% ' ' % ' ' % TROTTLE 0 ZONE 7%

11) Press OUT.

' ' ' ' % '

12) Press ENTER to confirm.

' % ' ' ' '

13) Repeat the same from 5 to 12 points for the other adjustments.

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AF2ZP0CL - ACE2 - User Manual

Flow chart showing how to use the SET BATTERY TYPE adjustment. 1) Opening Zapi Menu.

AE2T2B ZP0.12 24V 400A 00000

2) Press Top Left & Right Buttons to enter CONFIG Menu. 3) The Display will show: SET MODEL.

% ' % ' ' ' CONFIG MENU SET MODEL

4) Press ROLL UP button until ADJUSTMENTS Menu appears. 5) ADJUSTMENTS appears on the display.

% ' ' ' ' ' CONFIG MENU ADJUSTMENTS

6) Press ENTER to go into the ADJUSTMENTS Menu.

' % ' ' ' '

7) The display will show: SET BATTERY TYPE.

SET BATTERY TYPE 80V

8) Press SET UP to choose nominal value of the battery.

' ' % ' ' '

9) New battery value appears.

SET BATTERY TYPE 48V ' ' ' ' % '

10) Press OUT. 11) Confirmation request appears.

ARE YOU SURE? YES=ENTER NO=OUT

12) Press ENTER to accept the changes, or press OUT if you do not accept the changes.

' % ' ' ' '

13) Press OUT. Display now shows the Opening Zapi Menu.

AF2ZP0CL - ACE2 - User Manual

' ' ' ' % '

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Flow chart showing how to carry out ADJUSTMENT BATTERY operation by console. 1) Opening Zapi Menu.

AE2T2B ZP0.12 24V 400A 00000

2) Press Top Left & Right Buttons to enter CONFIG Menu. 3) The Display will show: SET MODEL.

% ' % ' ' ' CONFIG MENU SET MODEL

4) Press ROLL UP button until ADJUSTMENTS Menu appears. 5) ADJUSTMENTS appears on the display.

% ' ' ' ' ' CONFIG MENU ADJUSTMENTS

6) Press ENTER to go into the ADJUSTMENTS Menu. 7) The display will show the first OPTION.

' % ' ' ' '

SET BATTERY TYPE 48V

8) Press ROLL UP or ROLL DOWN button until desired OPTION appears. 9) ADJUST BATTERY appears.

% ' ' % ' ' ADJUSTMENT BATTERY

50.2V

10) Press SET UP or SET DOWN button in order to increase or decrease respectively. Set the value read by an external meter. 11) Battery value appears on the display.

' ' % ' ' % ADJUSTMENT BATTERY

50.6V ' ' ' ' % '

12) Press OUT to exit the Menu. 13) Confirmation request appears.

ARE YOU SURE? YES=ENTER NO=OUT

14) Press ENTER to accept the changes, or press OUT if you do not accept the changes.

' % ' ' ' '

15) ADJUSTMENTS Menu appears. 16) Press OUT. Display now show the Opening Zapi Menu.

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' ' ' ' % '

CONFIG MENU ADJUSTMENT ' ' ' ' % '

AF2ZP0CL - ACE2 - User Manual

8.5 Parameter regulation In addition to the input configuration, parameter modification is made directly by ZAPI on customer specifications, or by the customer, making the adjustments using the programming console.

8.5.1 Traction The following parameters can be modified: 1) ACCELERATION 0 It specifies the motor acceleration at 0 Hz. At level 0 the acceleration is maximum. Increasing the parameter’s level the acceleration decreases. 2) INV. ACCEL 0 It specifies the motor acceleration at 0 Hz after an inversion of direction. At level 0 the acceleration is maximum. Increasing the parameter’s level the acceleration decreases. 3) ACCELERATION 1 It specifies the motor acceleration at ACC PROF. FREQ 1 [Hz]. At level 0 the acceleration is maximum. Increasing the parameter’s level the acceleration decreases. 4) ACCELERATION 2 It specifies the motor acceleration at ACC PROF. FREQ 2 [Hz]. At level 0 the acceleration is maximum. Increasing the parameter’s level the acceleration decreases. 5) ACCELERATION 3 It specifies the motor acceleration at ACC PROF. FREQ 3 [Hz]. At level 0 the acceleration is maximum. Increasing the parameter’s level the acceleration decreases. 6) ACC PROF. FREQ 1 In correspondence to this frequency in [Hz] the acceleration is defined by the ACCELERATION 1 parameter. 7) ACC PROF. FREQ 2 In correspondence to this frequency in [Hz] the acceleration is defined by the ACCELERATION 2 parameter. 8) ACC PROF. FREQ 3 In correspondence to this frequency in [Hz] the acceleration is defined by the ACCELERATION 3 parameter.

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9) RELEASE BRAKING Seconds. It controls the deceleration ramp when the travel request is released. The parameter sets the time needed to decelerate the traction motor from 100Hz to 0Hz. 10) INVERSION BRAKING Seconds. It controls the deceleration ramp when the direction switch is inverted during travel. The parameter sets the time needed to decelerate the traction motor from 100Hz to 0Hz. 11) DECELERATION BRAKING Seconds. It controls the deceleration ramp when the accelerator has turned down but not completely released. The parameter sets the time needed to decelerate the traction motor from 100Hz to 0Hz. 12) PEDAL BRAKING Seconds. It controls the deceleration ramp when the pedal position is changed but not completely released. The parameter sets the time needed to decelerate the traction motor from 100Hz to 0Hz. 13) SPEED LIMIT BRK Seconds. It controls the deceleration ramp when a speed reduction has been activated. The parameter sets the time needed to decelerate the traction motor from 100Hz to 0Hz. 14) TIL. REL. BRAKING Seconds. It controls the deceleration ramp when the tiller is released. The parameter sets the time needed to decelerate the traction motor from 100Hz to 0Hz. 15) MAX SPEED FORW It determines the maximum speed in forward direction. 16) MAX SPEED BACK It determines the maximum speed in backward direction.

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AF2ZP0CL - ACE2 - User Manual

17) CUTBACK SPEED 1 Speed reduction when the cutback input is active. 18) BACKING SPEED It determines the speed in inching function. 19) BACKING TIME It determines the time of the inching function. 20) FREQUENCY CREEP Minimum speed when the forward or reverse switch is closed, but the accelerator is on a minimum position. 21) MAXIMUM CURRENT This parameter changes the maximum current of the inverter. 22) BRK SMOOTH It gives a parabolic form to the deceleration ramp. 23) STOP BRK SMOOTH Hz. It sets the level of frequency where the smooth effect of the deceleration parabolic form ends. 24) CURVE CUTBACK Determines the speed reduction in curve (only if the EPS is present). 25) STEER DEAD ANGLE Under this angle the curve cutback is not applied (only if the EPS is present). 26) AUXILIARY TIME Time units value (seconds). For the encoder version, it determines the time duration the truck is hold on the ramp if the STOP ON RAMP option is ON. The following table shows the minimum / maximum programmable value for each parameter. In the table is also present the parameters resolution. PARAMETER

UNIT

MIN VALUE

MAX VALUE

RESOLUTION

ACCELERATION 0 (*)

Sec.

0,3

0,1

INV. ACCEL 0 (*)

Sec.

0,3

0,1

ACCELERATION 1 (*)

Sec.

0,3

0,1

ACCELERATION 2 (*)

Sec.

0,3

0,1

ACCELERATION 3 (*)

Sec.

0,3

0,1

ACC PROF. FREQ 1

200

ACC PROF. FREQ 2

200

ACC PROF. FREQ 3

200

RELEASE BRAKING (**)

Sec.

0,3

0,1

INVERS BRAKING (**)

Sec.

0,3

0,1

DECELERATION BRAKING (**)

Sec.

0,3

0,1

PEDAL BRAKING (**)

Sec.

0,3

0,1

SPEED LIMIT BRAKING (**)

Sec.

0,3

0,1

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MAX SPEED FW

200

MAX SPEED BW

200

CUTBACK SPEED 1

%Max Sp

100

FREQUENCY CREEP

0,6

0,1

MAXIMUM CURRENT

% IMAX

100

BRK SMOOTH

Num

0,1

STOP BRK SMOOTH

Hz.

AUXILIARY TIME

Sec.

0,1

4 4

(*) The acceleration time shown is the time from 0 Hz to 100 Hz. This is the ideal ramp calculated by the software; the real ramp could change as a function of motor control parameter setting and, obviously, as a function of the load. (**) The braking feature is based upon deceleration ramps. The value shown in the table is the time to decrease the speed from 100 Hz to 0 Hz. This is the ideal ramps calculated by the software; the real ramp could change as a function of motor control parameter setting and, obviously, as a function of the load.

After changing a parameter, press ENTER to confirm data when requested by the message on the console. Parameters modified and optimized on one unit can be stored by the console (SAVE) and then released (RESTORE) on another inverter, thus allowing fast and standardized settings (see console manual for details).

8.5.2 Pump The following parameters can be modified: 1) ACCELERATION 0 It specifies the motor acceleration at 0 Hz. At level 0 the acceleration is maximum. Increasing the parameter’s level the acceleration decreases. 2) ACCELERATION 1 It specifies the motor acceleration at ACC PROF. FREQ 1 [Hz]. At level 0 the acceleration is maximum. Increasing the parameter’s level the acceleration decreases. 3) ACCELERATION 2 It specifies the motor acceleration at ACC PROF. FREQ 2 [Hz]. At level 0 the acceleration is maximum. Increasing the parameter’s level the acceleration decreases. 4) ACCELERATION 3 It specifies the motor acceleration at ACC PROF. FREQ 3 [Hz]. At level 0 the acceleration is maximum. Increasing the parameter’s level the acceleration decreases. 5) ACC PROF. FREQ 1 In correspondence to this frequency in [Hz] the acceleration is defined by the Page - 52/85

AF2ZP0CL - ACE2 - User Manual

ACCELERATION 1 parameter. 6) ACC PROF. FREQ 2 In correspondence to this frequency in [Hz] the acceleration is defined by the ACCELERATION 2 parameter. 7) ACC PROF. FREQ 3 In correspondence to this frequency in [Hz] the acceleration is defined by the ACCELERATION 3 parameter.

8) RELEASE BRAKING Seconds. It controls the deceleration ramp when the pump request is released. The parameter sets the time needed to decelerate the traction motor from 100Hz to 0Hz. 9) MAX SPEED LIFT It determines the pump maximum speed when LIFT ENABLE switch is closed . 10) 1ST SPEED COARSE It determines the pump maximum speed when SPEED1 switch is closed . 11) 2ND SPEED COARSE It determines the pump maximum speed when SPEED2 switch is closed . 12) 3RD SPEED COARSE It determines the pump maximum speed when SPEED3 switch is closed. 13) HYD SPEED FINE It determines the pump maximum speed when an hydraulic steering function request is received via CAN BUS. 14) CUTBACK SPEED 1 Speed reduction when the cutback input is active. 15) FREQUENCY CREEP AF2ZP0CL - ACE2 - User Manual

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Minimum speed when the LIFT ENABLE switch is closed, but the accelerator is on a minimum position. 16) MAXIMUM CURRENT This parameter changes the maximum current of the inverter. 17) AUXILIARY TIME Time units value (seconds). For the encoder version, is the delay when an hydraulic steering function request is switched off. The following table shows the minimum / maximum programmable value for each parameter. In the table is also present the parameters resolution. PARAMETER

UNIT

MIN VALUE

MAX VALUE

RESOLUTION

ACCELERATION 0 (*)

Sec.

0,3

0,1

ACCELERATION 1 (*)

Sec.

0,3

0,1

ACCELERATION 2 (*)

Sec.

0,3

0,1

ACCELERATION 3 (*)

Sec.

0,3

0,1

ACC PROF. FREQ 1

200

ACC PROF. FREQ 2

200

ACC PROF. FREQ 3

200

RELEASE BRAKING (**)

Sec.

0,3

0,1

MAX SPEED LIFT

200

1ST SPEED COARSE

200

SPEED COARSE

200

3RD SPEED COARSE

200

HYD SPEED FINE

200

CUTBACK SPEED 1

%Max Sp

100

FREQUENCY CREEP

0,3

0,1

MAXIMUM CURRENT

% IMAX

100

AUXILIARY TIME

Sec.

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AF2ZP0CL - ACE2 - User Manual

Flow Chart showing how to make Programme changes using Digital Console fitted with Eprom CK ULTRA. 1) Opening Zapi Display.

AE2T2B ZP0.12 24V 400A 00000 ' % ' ' ' '

2) Press ENTER to go into the General Menu. 3) The Display will show:

MAIN MENU PARAMETER CHANGE

4) Press ENTER to go into the Parameter Change facility. 5) The Display will show the first parameter.

' % ' ' ' ' ACCELERATION 0

6) Press either ROLL UP and ROLL DOWN to display the next parameter.

% ' ' % ' '

7) The names of the Parameters appear on the Display.

INV. ACCEL 0 1

8) When the desired Parameter appears, the Display will show the parameter value. Press either SET UP (Top Right) or SET DOWN (Bottom Right) buttons to increase/decrease the value. 9) The Display will show the New Level.

' ' % ' ' %

INV. ACCEL 0 2

10) When you are satisfied with the results of the changes you have made, Press OUT.

' ' ' ' % '

11) The Display asks “ ARE YOU SURE?”.

ARE YOU SURE? YES=ENTER NO=OUT

12) Press ENTER to accept the changes, or press OUT if you do not wish to accept the changes and wish to make further modifications to the parameters.

' % ' ' ' '

13) The Display will show:

MAIN MENU PARAMETER CHANGE

AF2ZP0CL - ACE2 - User Manual

' ' ' ' % '

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8.6 Programming console functions -

Functional configuration (see 8.1, 8.2, 8.3, 8.4). Parameter programming (see 8.5.1, 8.5.2). Tester: the user can verify the state of the following parameters: TRACTION

PUMP

battery voltage (V)

motor voltage (%)

voltage booster (%)

frequency (Hz)

encoder (Hz)

slip value (Hz)

current rms (A)

motor power (W)

battery charge (%)

temperature (°C)

motor temperat. (°C)

motor temperature (°C)

accelerator (V)

handle/seat switch (ON/OFF)

lifting control (V)

forward switch (ON/OFF) backward switch (ON/OFF)

1 speed switch (ON/OFF)

cutback switch (ON/OFF)

2nd speed switch (ON/OFF)

hand brake (ON/OFF)

3rd speed switch (ON/OFF)

Brakepedal pot. (%)

hydro speed req. (ON/OFF)

2 -

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lifting enable (ON/OFF) st

hourmeters

2nd hourmeters

Save function (for storing data). Restore function (for loading parameters on another inverter). Display of the last 5 alarms including hour-meter value and temperature at the moment of the alarm. Accelerator range programming: records the minimum and maximum useful accelerator stroke values for both direction of running. See the console manual for a detailed description of function and parameters.

AF2ZP0CL - ACE2 - User Manual

8.7 Sequence for Ac Inverter Traction setting When the "Key Switch" is closed, if no alarms or errors are present, the Console Display will be showing the Standard Zapi Opening Display. If the controller is not configured to your requirements, follow the sequence detailed on Chapter 9.2. Remember to re-cycle the Key Switch if you make any changes to the controller’s configuration. Otherwise follow the sequence detailed below: 1) Select the Options required. See Chapter 8.4.1. 2) Select and set the Battery Voltage. See Chapter 8.4.1. 3) Confirm correct installation of all wires. Use the Console’s TESTER function to assist. 4) Perform the accelerator signal acquisition procedure using the Console “PROGRAM VACC”. Procedure is detailed on Chapter 9.4. 5) Set the "MAXIMUM CURRENT” Current, using the table on Chapter 8.5.1. 6) Set the Acceleration Delay requirements for the machine. Test the parameters in both directions. 7) Set the FREQUENCY CREEP level starting from level 0.3 Hz. The machine should just move when the accelerator microswitch is closed. Increase the Level accordingly. 8) Set the Speed Reductions as required. Make adjustments to “CUTBACK SPEED” Check the performance with the accelerator pedal totally depressed. If the machine is a forklift, check the performance with and without load. 9) RELEASE BRAKING. Operate the machine at full speed. Release the accelerator pedal. Adjust the level to your requirements. If the machine is a forklift, check the performance with and without load. 10) INVERSION BRAKING. Operate the machine at 25% full speed. Whilst travelling INVERT the Direction Switch. Set a soft Level of Inversion Braking. When satisfactory, operate the machine at Full Speed and repeat. If the machine is a Forklift, repeat the tests and make adjustments with and without load. The unloaded full speed condition should be the most representative condition. 11) DECELERATION BRAKING. Operate the machine at full speed. Release the accelerator pedal until 50% of its range is reached. Adjust the level to your requirements. If the machine is a forklift, check the performance with and without load. 12) PEDAL BRAKING (If used). Operate the machine at full Speed. Release the accelerator pedal and press the Pedal Brake. Set braking level to your requirements. If the machine is a forklift, check the performance with and without load. 13) SPEED LIMIT BRAKING (If used). Operate the machine at full Speed. Close the speed reduction switch. Set braking level to your requirements. If the machine is a forklift, check the performance with and without load. 14) Set “MAX SPEED FORW”. 15) Set “MAX SPEED BACK” (Reverse). 16) Make the choice for the truck behaviour on a slope (see chapter 8.4). If the "Stop on ramp" option is ON, set the desired value of "auxiliary time" parameter. 17) Set “SET TEMPERATURE”, setting the motor thermal sensor type used.

AF2ZP0CL - ACE2 - User Manual

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8.8 Sequence for Ac Inverter Pump setting When the "Key Switch" is closed, if no alarms or errors are present, the Console Display will be showing the Standard Zapi Opening Display. If the controller is not configured to your requirements, follow the sequence detailed on Chapter 9.2. Remember to re-cycle the Key Switch if you make any changes to the controller’s configuration. Otherwise follow the sequence detailed below: 1) Select the Options required. See Chapter 8.4.2. 2) Select and set the Battery Voltage. See Chapter 8.4.2. 3) Confirm correct installation of all wires. Use the Console’s TESTER function to assist. 4) Perform the lift signal acquisition procedure using the Console “PROGRAM VACC”. Procedure is detailed on Chapter 9.4. 5) Set the "MAXIMUM CURRENT” Current, using the table on Chapter 8.5.2. 6) Set the Acceleration and Deceleration Delay requirements for the pump. 7) Set the “FREQUENCY CREEP” level starting from 0 Hz. The pump should just turn when the request microswitch is closed. Increase the level accordingly. 8) Set the Speed Reductions as required. Make adjustments to “CUTBACK SPEED 1”. Check the performance with the full request. Check the performance with and without load. 9) Set “MAX SPEED LIFT” , max speed of pump motor when Lift enable switch is closed. 10) Set “1ST SPEED COARSE”, speed of pump motor when SPEED1 switch is closed. 11) Set “2ND SPEED COARSE”, speed of pump motor when SPEED2 switch is closed. 12) Set “3RD SPEED COARSE”, speed of pump motor when SPEED3 switch is closed. 13) Set “HYD SPEED FINE” to adjust the hydraulic steering speed (pump motor speed when HYDRO function is requested). 14) Set “AUXILIARY TIME” (time delay before pump stops when an hydraulic steering function request is switched off). 15) Set “SET TEMPERATURE”, setting the motor thermal sensor type used.

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AF2ZP0CL - ACE2 - User Manual

8.9 Tester: description of the function The most important input or output signals can be measured in real time using the TESTER function of the console. The Console acts as a multimeter able to read voltage, current and temperature. The following definition listing shows the relative measurements.

8.9.1 Traction 1) BATTERY VOLTAGE Level of battery voltage measured at the input to the key switch. 2) MOTOR VOLTAGE This is the RMS voltage supplied to the motor by the inverter; it is expressed as a percentage of the full voltage (which depends of the battery voltage). 3) VOLTAGE BOOSTER This is the booster of the voltage supplied to the motor in load condition; it is expressed in a percentage of the full voltage. 4) FREQUENCY This is the frequency of the voltage and current supplied to the motor. 5) ENCODER This is the speed of the motor, expressed in the same unit of the frequency; this information comes from the speed sensor. 6) SLIP VALUE This is the difference of speed between the rotating field and the shaft of the motor, expressed in the same unit of the frequency. 7) CURRENT RMS Root Mean Square value of the motor current. 8) MOTOR POWER It is the power provided to the motor. 9) BATTERY CHARGE The percentage Charge level of the battery. 10) TEMPERATURE The temperature measured on the aluminium heat sink holding the MOSFET devices. 11) MOTOR TEMPERAT. This is the temperature of the motor; if the option is programmed "None" (see chapter 8.4.1) it shows 0°. 12) ACCELERATOR The voltage of the accelerator potentiometer's wiper (CPOT). The voltage level is shown on the Left Hand Side of the Console Display and the value in percentage is shown on the Right Hand Side. 13) HANDLE/SEAT switch The level of the Handle/Seat digital entry - ON / GND = active entry of closed switch. - OFF / GND = non active entry of open switch. 14) FORWARD SWITCH The level of the Forward direction digital entry FW. - ON / +VB = active entry of closed switch. - OFF / GND = non active entry of open switch. 15) BACKWARD SWITCH The level of the Reverse direction digital entry BW. - ON / +VB = active entry of closed switch. - OFF / GND = non active entry of open switch. AF2ZP0CL - ACE2 - User Manual

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16) CUTBACK SWITCH The level of the Speed Reduction Microswitch. - ON / GND = active entry of speed reduction microswitch. - OFF / +VB = non active entry of microswitch. 17) HAND BRAKE The level of the Hand Brake Microswitch. - ON / GND = active entry of Brake pedal Microswitch. - OFF / +VB = non active entry of microswitch. 18) BRAKEPEDAL POT. The percentage of the pressure on the brake pedal (100% if the pedal is totally pressed, 0% if the pedal is released). 19) 2ND HOURMETERS This parameter displays the working hour of traction controller. 20) STEER ANGLE It shows the steering angle.

8.9.2 Pump 1) BATTERY VOLTAGE Level of battery voltage measured at the input to the key switch. 2) MOTOR VOLTAGE This is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full voltage (which depends of the battery voltage). 3) VOLTAGE BOOSTER This is the booster of the voltage supplied to the motor in load condition; it is expressed in a percentage of the full voltage. 4) FREQUENCY This is the frequency of the voltage and current supplied to the motor. 5) ENCODER This is the speed of the motor, expressed in the same unit of the frequency; this information comes from the speed sensor. 6) SLIP VALUE This is the difference of speed between the rotating field and the shaft of the motor, expressed in the same unit of the frequency. 7) CURRENT RMS Root Mean Square value of the motor current. 8) MOTOR POWER It is the power provided to the motor. 9) BATTERY CHARGE The percentage Charge level of the battery. 10) TEMPERATURE The temperature measured on the aluminium heat sink holding the MOSFET devices. 11) MOTOR TEMPERATURE This is the temperature of the motor; if the option is programmed "None" (see chapter 8.4.2) it shows 0°. 12) HANDLE/SEAT switch The level of the Handle/Seat digital entry - ON / GND = active entry of closed switch. - OFF / +VB = non active entry of open switch. 13) LIFTING CONTROL The voltage of the lift potentiometer's wiper (CPOT). The voltage level is shown on the Left Hand Side of the Console Display and the value in percentage is shown on the Right Hand Side. 14) LIFT ENABLE Status of the lifting switch. Page - 60/85

AF2ZP0CL - ACE2 - User Manual

15)

16)

17)

18)

19)

20)

- ON / +VB = active entry of closed switch. - OFF / GND = non active entry of open switch. 1ST SPEED SWITCH Status of the first speed switch of the pump. - ON / +VB = active entry of closed switch. - OFF / GND = non active entry of open switch. 2ND SPEED SWITCH Status of the second speed switch of the pump. - ON / +VB = active entry of closed switch. - OFF / GND = non active entry of open switch. 3RD SPEED SWITCH Status of the third speed switch of the pump. - ON / GND = active entry of closed switch. - OFF / +VB = non active entry of open switch. HYDRO SPEED REQ. Status of the hydro speed request of the pump. - ON = an hydro speed request is received via Can Bus. - OFF = no hydro speed request active. CUTBACK SWITCH The level of the Speed Reduction Microswitch. - ON / GND = active entry of speed reduction microswitch. - OFF / +VB = non active entry of microswitch. 2ND HOURMETERS This parameter displays the working hour of pump controller.

AF2ZP0CL - ACE2 - User Manual

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Flow Chart showing how to use the TESTER function of the Digital Console. 1) Opening Zapi Display. 2) Press ENTER to go into the General menu. 3) The Display will show: 4) Press ROLL UP or ROLL DOWN button until TESTER MENU appear on the display. 5) The Display shows:

AE2T2B ZP0.12 24V 400A 00000 ' % ' ' ' ' MAIN MENU PARAMETER CHANGE % ' ' % ' ' MAIN MENU TESTER

6) Press ENTER to go into the TESTER function.

' % ' ' ' '

7) The first variable to be tested is shown on the Display.

BATTERY VOLTAGE %

8) Press either ROLL UP or ROLL DOWN buttons until your desired variable for measurement appears on the Display.

% ' ' % ' '

9) When you have finished, Press OUT.

' ' ' ' % '

10) The Display shows: 11) Press OUT again and return to Opening Zapi Display.

FREQUENCY Hz ' ' ' ' % ' MAIN MENU TESTER

Remember it is not possible to make any changes using TESTER. All you can do is measure as if you were using a pre-connected multimeter. 21) Other functions

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AF2ZP0CL - ACE2 - User Manual

8.10 Description of the Console “SAVE” function The SAVE function allows the operator to transmit the Parameter values and Configuration data of the inverter into the Console memory. It is possible to load 64 different programmes. The information saved in the Console memory can then be reloaded into another inverter using the RESTORE function. The data that is available via the SAVE function is as follows: - All Parameter Values (PARAMETER CHANGE). - Options (SET. OPTIONS). - The Level of the Battery (ADJUST BATTERY). Flow Chart showing how to use the SAVE function of the Digital Console. 1) Opening Zapi Display. 2) Press ENTER to go into the General menu. 3) The Display will show: 4) Press ROLL UP or ROLL DOWN button until SAVE PARAM. appears on the display. 5) The Display will show: 6) Press ENTER to go into the SAVE function.

AE2T2B ZP0.12 24V 400A 00000 ' % ' ' ' ' MAIN MENU PARAMETER CHANGE % ' ' % ' ' MAIN MENU SAVE PARAM. ' % ' ' ' '

7) If this facility has been used before the type of inverter data stored appears on the top Main with a 2 digit reference.

SELECT: MOD. 00 FREE

8) Keep pressing either ROLL UP or ROLL DOWN keys until the second Main indicates a FREE storage facility.

% ' ' % ' ' SELECT: MOD. 01 FREE

9) Press ENTER to commence SAVE routine. 10) You can see the items that are being stored whilst the SAVE routine is happening. 11) When finished, the Console shows: 12) Press OUT to return to the Opening Zapi Display. AF2ZP0CL - ACE2 - User Manual

' % ' ' ' ' READING … ACCEL. DELAY (ECC.) MAIN MENU SAVE PARAM ' ' ' ' % '

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8.11 Description of Console “RESTORE” function The RESTORE PARAM function allows transfer of the Console’s stored data into the memory of the inverter. This is achieved in a fast and easy way using the method previously used with the SAVE PARAM. function. The data that is available via the RESTORE PARAM. function is as follows: - All Parameter Values (PARAMETER CHANGE). - Options (SET OPTIONS). - The level of the Battery (ADJUST BATTERY).

ATTENTION: When the RESTORE operation is made, all data in the inverter memory will be written over and replace with data being restored.

Flow Chart showing how to use the RESTORE function of the Digital Console. 1) Opening Zapi Display.

AE2T2B ZP0.12 24V 400A 00000 ' % ' ' ' '

2) Press ENTER to go into the General menu. 3) The Display will show:

MAIN MENU PARAMETER CHANGE

4) Press ROLL UP or ROLL DOWN button until RESTORE PARAM. appears on the Display. 5) The Display will show:

% ' ' % ' ' MAIN MENU RESTORE PARAM.

6) Press ENTER to go into the RESTORE PARAM. Function. 7) The Display shows the type of Model stored, with a Code Number.

' % ' ' ' ' SELECT : MOD. 00 AE2T ZAPI V1

8) Keep pressing either ROLL UP and ROLL DOWN buttons until the desired model appears on the Display.

% ' ' % ' ' SELECT : MOD. 01 AE2T ZAPI V1

9) Press ENTER to commence the Restore operation. 10) The Display will ask “ARE YOU SURE?”.

11) Press ENTER for YES, or OUT for No.

Page - 64/85

' % ' ' ' ' ARE YOU SURE? YES=ENTER NO=OUT ' % ' ' ' '

' ' ' ' % '

AF2ZP0CL - ACE2 - User Manual

12) You can see the items that are being stored in the inverter memory whilst the RESTORE routine is happening.

STORING ACCELER. DELAY

13) When finished the Console displays:

MAIN MENU RESTORE PARAM.

14) Press OUT to return to the Opening Zapi Display.

' ' ' ' % '

8.12 Description of Console “PROGRAM VACC” function This enables adjustment of the minimum and maximum useful signal level, in either direction. This function is unique when it is necessary to compensate for asymmetry with the mechanical elements associated with the potentiometer, especially relating to the minimum level. The two graphs show the output voltage from a non-calibrated potentiometer with respect to the mechanical “zero” of the control lever. MI and MA indicate the point where the direction switches close. 0 represents the mechanical zero of the rotation. The Left Hand graph shows the relationship of the motor voltage without signal acquisition being made. The Right Hand Graph shows the same relationship after signal acquisition of the potentiometer.

This function looks for and remembers the minimum and maximum potentiometer wiper voltage over the full mechanical range of the pedal. It enables compensation for non symmetry of the mechanical system between directions. The operation is performed by operating the pedal after entering the PROGRAM VACC function.

AF2ZP0CL - ACE2 - User Manual

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Flow Chart showing how to use the PROGRAM VACC function of the Digital Console. 1) Opening Zapi Display.

AC2 ZAPI V0.0 48V 350A 00000 ' % ' ' ' '

2) Press ENTER to go into the General Menu. 3) The Display will show:

MAIN MENU PARAMETER CHANGE

4) Press ROLL UP or ROLL DOWN button until PROGRAM VACC appears on the display. 5) The Display will show:

% ' ' % ' ' MAIN MENU PROGRAM VACC

6) Press ENTER to go into the PROGRAM VACC routine. 7) The Display will show the minimum and maximum values of potentiometer wiper output. Both directions can be shown.

' % ' ' ' ' VACC SETTING 4.8 4.8

8) Press ENTER to clear these values. Display will show 0.0. 9) Select Forward Direction, close any interlock switches that may be in the system.

' % ' ' ' ' MIN 0.0

VACC -

MAX 0.0

MIN 0.6

VACC ↑

MAX 4.4

10) Slowly depress the accelerator pedal (or tiller butterfly) to its maximum value. The new minimum and maximum voltages will be displayed on the Console plus an arrow indicating the direction. 11) Select the Reverse Direction and repeat Item 10. 12) When finished, press OUT. 13) The Display will ask: “ARE YOU SURE?”. 14) Press ENTER for yes, or OUT for NO.

15) When finished, the Console shows: 16) Press OUT again to return to the Opening Zapi Menu.

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' ' ' ' % ' ARE YOU SURE YES=ENTER NO=OUT ' % ' ' % '

MAIN MENU PROGRAM VACC ' ' ' ' % '

AF2ZP0CL - ACE2 - User Manual

8.13 Description of the battery charge detection setting The Battery Charge detection uses two setting that specify the Full Charge Voltage Level (100%) and the Discharge Voltage Level (10%). These two settings are the Bat.Max.Adj and the Bat.Min.Adj. It is possible to adapt the Battery Charge Detection to your specific battery, by changing the above two settings (e.g. if the Battery Discharged Detection occurs when the battery is not totally discharged, it is necessary to reduce the Bat.Min.Adj setting as indicated in the figure below). 48V NOMINAL BATTERY VOLTAGE

24V NOMINAL BATTERY VOLTAGE

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8.14 Description of “ALARMS” menu The ALARMS logbook in the MAIN MENU’ records the alarms of the controller. It has a FIFO (First Input First Output) structure that means the oldest alarm is lost when the database is full and a new alarm occurs. The logbook is composed of five locations getting possible to stack five different type of alarms with the following information: 1) 2) 3) 4)

The alarm code The times that each alarm occurs consecutively The Hour Meter value when the first event of every alarm occurred And the inverter temperature when the first event of every alarm occurred.

This function permits a deeper diagnosis of problems as the recent history can be revised.

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NOTE: if the same alarm is continuously happening, the controller does not use new memory of the logbook, but only updates the last memory cell increasing the related counter (point 2) of previous list). Nevertheless, the hourmeter indicated in this memory refers to the first time the alarm occurred. In this way, comparing this hourmeter with the controller hourmeter, it is possible to determine: - When this alarm occurred the first time. - How many hours are elapsed from the first occurrence to now. - How many times it has occurred in said period.

AF2ZP0CL - ACE2 - User Manual

Flow Chart showing how to use the ALARMS function via the Digital Console. 1) Opening Zapi Display.

AE2T2B ZP0.12 24V 400A 00000 ' % ' ' ' '

2) Press ENTER to go into the General menu. 3) The Display will show:

MAIN MENU PARAMETER CHANGE

4) Press ROLL UP or ROLL DOWN button until PARAMETER CHANGE appears on the display. 5) The Display will show:

% ' ' % ' ' MAIN MENU ALARMS ' % ' ' ' '

6) Press ENTER to go into the ALARMS function. 7) The Display will show the most recent Alarm.

CODE 00005 #02 20°C

8) Each press of the ROLL UP button brings up following Alarms. Pressing ROLL DOWN returns to the most recent. 9) If an Alarm has not occurred, the Display will show: ALARM NULL.

% ' ' % ' '

CODE

00007 #03 18°C

10) When you have finished looking at the Alarms, press OUT to exit the ALARMS menu.

' ' ' ' % '

11) The Display will ask “CLEAR LOGBOOK?”.

CLEAR LOGBOOK? YES=ENTER NO=OUT

12) Press ENTER for yes, or OUT for NO.

' % ' ' ' '

13) Press OUT to return to the Opening Zapi Display.

' ' ' ' % '

8.15 Faults diagnostic system The fault diagnostic system of ACE-2 controller is divided into 2 main groups of faults: ALARMS: these are the faults which open the power section, which means the power bridge is opened and, when possible, the LC is opened and EB is applied. These are faults related to: - failures in the motor/controller that the power system is not anymore able to drive the truck - safety related failures AF2ZP0CL - ACE2 - User Manual

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WARNINGS: these are faults which do not stop the truck or stop it by a controlled regenerative braking. In other words, the controller is working well, but it has detected conditions to reduce the performances or to stop the truck without opening the power devices. These warnings are related to: - wrong operator sequences - conditions which require performance reduction (like high temperatures, ….)

8.16 Microcontroller alarms overview Error Code

Description

Effect

Flash checksum MDI code allarm 71

The program verify is not OK

MC is not closed, EB is applied, traction/pump stopped

Start-up

Key re-cycle

Analog MDI code allarm 96

The analogue channel Reading is not updated

MC is opened, EB is applied, traction/pump stopped

Start-up, running

Traction/Pump request

Wrong set battery

The absolute difference between the Key voltage and the nominal battery voltage is greater than 20% of Vbatt nom.

MC is not closed, EB is applied, traction/pump stopped

Start-up

Traction/Pump Request

Capacitor charge MDI code allarm 60

Power capacitors voltage does not increase

MC is not closed, EB is applied, Traction/Pump stopped

Start-up

Traction/Pump request

Coil shorted hw ko MDI code allarm 76

The harware to check a MC or EB/AUX coil shorted is damaged

MC is not closed, EB is applied, Traction/Pump stopped

Start-up

Traction/Pump Request

Driver shorted MDI code allarm 74

The MC driver is shorted so it is not able to open the contactor

MC is opened (the command is released), EB is applied, Traction/Pump stopped

Start-up, stand-by, running

Traction/Pump Request

Aux driver shorted

The EB/AUX driver is shorted so it is not able to open the contactor

MC is opened (the command is released), EB is applied, Traction/Pump stopped

Start-up, stand-by, running

Traction/Pump Request

Safety in MDI code allarm 86

The safety input is open (it is not connected to –Batt)

MC is opened, EB is applied, Traction/Pump stopped

Start-up, stand-by, running

Key re-cycle

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Machine status When the test is done

Restart procedure

AF2ZP0CL - ACE2 - User Manual

Safety out

The Safety-out driver is damaged (shorted or open)

MC is not closed, EB is applied, Traction/Pump stopped

Start-up

Traction/Pump request

Watchdog#1 MDI code allarm 8

The watchdog signal #1 is not in the correct status

MC is opened, EB is applied, Traction/Pump stopped

Start-up, stand-by, running

Key re-cycle

Watchdog#2 MDI code allarm 8

The watchdog signal #2 is not in the correct status

Start-up, stand-by, running

Key re-cycle

Keyoff shorted MDI code allarm 76

At Start-up the Keyoff logic signal is low

Start-up

Key re-cycle

Logic Failure#1 MDI code allarm 54

An undervoltage / overvoltage condition has been detected

MC is opened, EB is applied, Traction/Pump stopped MC is not closed, EB is applied, Traction/Pump stopped MC is not closed, EB is applied, Traction/Pump stopped

Start-up, stand-by, running

Traction/Pump request

Logic failure #3 MDI code allarm 17

High current HW protection circuit is damaged

MC is not closed, EB is applied, Traction/Pump stopped

Start-up

Traction/Pump request

Power mos shorted MDI code allarm 89

Short circuit on the power Mosfets

MC is not closed, EB is applied, Traction/Pump stopped

Start-up

Traction/Pump request

Vmn high

Motor output voltage higher than expected

MC is not closed, EB is applied, Traction/Pump stopped

Start-up, Stand-by

Traction/Pump request

Vmn low MDI code allarm 72

Motor output voltage lower than expected

MC is opened, EB is applied, Traction/Pump stopped

Start-up, running

Traction/Pump request

Stby I high MDI code allarm 53

In stby condition (no current applied to the motor) the current feedbacks are out of permitted stby range

MC is not closed, EB is applied, Traction/Pump stopped

Start-up

Traction/Pump request

Wrong 0 voltage MDI code allarm 53

The motor phases voltage feedback are out of permitted range

MC is not closed, EB is applied, Traction/Pump stopped

Start-up

Traction/Pump Request

Contactor closed MDI code allarm 75

LC contact is stuck

MC is not closed (command is not activated), EB is applied, Traction/Pump stopped

Start-up

Traction/Pump Request

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Hardware fault 20

The Mosfets driver are not switched off with Watch-dog signal in alarm status

MC is not closed , EB is applied, Traction/Pump stopped

Start-up

Key re-cycle

Hardware fault 21

The EB/AUX driver is not switched off with Watch-dog signal in alarm status

MC is not closed , EB is applied, Traction/Pump stopped

Start-up

Key re-cycle

Hardware fault A1

The MC driver is not switched off with Watch-dog signal in alarm status

MC is not closed , EB is applied, Traction/Pump stopped

Start-up

Key re-cycle

Coil shorted MC MDI code allarm 76

Shortcircuit on MC coil

MC is opened, EB is applied, Traction/Pump stopped

Start-up (immediately after MC closing), stand-by, running

Traction/Pump Request

Coil shorted EF MDI code allarm 68

Shortcircuit on EB/AUX coil

MC is opened, EB is applied, Traction/Pump stopped

Start-up (immediately after MC closing), standby, running

Traction/Pump Request

Contactor open MDI code allarm 77

The MC coil has been driven but MC does not close

MC is opened , EB is applied, Traction/Pump stopped

Start-up (immediately after MC closing), Stand-by, running

Traction/Pump Request

Logic failure #2 MDI code allarm 55

Motor phases voltage feedback circuits are damaged

MC is opened , EB is applied, Traction/Pump stopped

Start-up (immediately after MC closing)

Traction/Pump Request

Contactor driver MDI code allarm 75

Driver of MC coil is damaged (not able to close)

MC is opened (the command is released), EB is applied, Traction/Pump stopped

Stand-by, running

Traction/Pump Request

Aux Driver Open

Driver of EB/AUX coil is damaged (not able to apply the brake)

MC is opened, EB is applied, Traction/Pump stopped

Stand-by, running

Traction/Pump Request

Encoder Error MDI code allarm 82

Problem on the encoder reading

MC is opened, EB is Running applied, Traction/Pump stopped

Traction/Pump Request

Wrong Ram Memory MDI code allarm 71

The program checks the contents of main RAM registers and find a “dirty value”

MC is opened, EB is Continuous applied, Traction/Pump stopped

Key re-cycle

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AF2ZP0CL - ACE2 - User Manual

8.17 Analysis and troubleshooting of alarms displayed on console 1) FLASH CHECKSUM Cause: After Key-on the software verifies the integrity of program stored in the flash memory, if the verify has a negative result this alarm is generated. Troubleshooting: The problem is in the microcontroller flash memory, which could be damaged, or in the program stored inside, which could be corrupted. Try to program the logic again, if the alarms is still signalled the problem is in the microcontroller. Replace the ACE logic board. 2) ANALOG Cause: This alarm occurs when the A/D conversion of the analog inputs gives frozen value, on all of the converted signals, for more than 400msec. The goal of this diagnosis is to detect a failure of the A/D converter or a problem in the code flow that omits the refreshing of the analog signal conversion. Troubleshooting: If the problem occurs permanently it is necessary to substitute ACE logic board. 3) WRONG SET BATTERY Cause: At start-up, the controller checks the battery voltage and verify it is within a window around the nominal value. Troubleshooting: - Check that the controller SET BATTERY parameter value matches the battery nominal voltage. - Check that TESTER MENU / BATTERY VOLTAGE parameter shows same value as the battery voltage measured with a voltmeter. If it does not match, then do an “ADJUST BATTERY” function. - Replace the battery. 4) CAPACITOR CHARGE Follows the charging capacitor system:

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Cause: When the key is switched ON, the inverter tries to charge the power capacitors through a series of a PTC and a power resistance, and check if the capacitor are charged within a timeout. If the capacitor voltage measured is less than 20% of the nominal battery voltage, an alarm is signalled; the main contactor is not closed. Troubleshooting: - There is an external load in parallel to capacitor bank, which sinks current from the controller capacitors pre-charging circuit, thus preventing the caps from charging. Check if a lamp or a dc/dc converter or an auxiliary load is placed in parallel to capacitor bank. - The charging resistance or PTC is opened; insert a power resistance across line contactor power terminals; if the alarm disappears, it means the controller internal charging resistance is damaged. - The charging circuit has a failure, inside the controller. - There is a problem in the controller power section. 5) COIL SHORT HW KO Cause: The hardware circuits which manages short circuits protection of LC and EB/AUX coils has a problem. Troubleshooting: This type of fault is not related to external components; replace the ACE logic board. 6) DRIVER SHORTED Cause: The driver of the main contactor coil is shorted. Troubleshooting: - Check if there is a short or a low impedance pull-down between NMC (CNA#16) and –BATT. - The driver circuit is damaged in the logic board, which has to be replaced. 7) AUX DRIVER SHORTED Cause: The driver of the electro mechanic brake/ auxiliary electro valve coil is shorted. Troubleshooting: - Check if there is a short or a low impedance pull-down between NEB/NAUX (CNA#18) and –BATT. - The driver circuit is damaged in the logic board, which has to be replaced. 8) SAFETY IN Cause: The safety input is opened and accordingly the MC is opened an EB/AUX OUT coil is driven. Troubleshooting: Check the CAN#11 input, if it is connected to –Batt and the alarm is generated then there is a fault in the SAFETY IN hardware circuit. Replace the logic board. 9) SAFETY OUT Cause: Page - 74/85

AF2ZP0CL - ACE2 - User Manual

The safety out driver is shorted. Troubleshooting: - Check if there is a short or a low impedance pull-down between SAFETY OUT (CAN#19) and –BATT. - The driver circuit is damaged in the logic board, which has to be replaced. 10) WATCHDOG#1 Cause: At start-up the watch dog signal is already active before the software has generated it. At stby or running condition the watch dog signal is not active (in alarm status). Troubleshooting: The WD hardware circuit or microcontroller output port are damaged. In both cases no external component are involved. Replace the logic board. 11) WATCHDOG#2 Cause: At start-up the watch dog signal is already active before the software has generated it. At stby or running condition the watch dog signal is not active (in alarm status). Troubleshooting: The WD hardware circuit or microcontroller output port are damaged. In both cases no external component are involved. Replace the logic board. 12) KEYOFF SHORTED Cause: This fault is displayed when the controller detects a low logic level of Key-Off signal during Start-Up diagnosis. Troubleshooting: It is very likely the fault is due to an under voltage, so it is suggested to check: - Key input signal down-going pulses (below under voltage threshold) due to external loads, like DC/DC converters starting-up, relays or contactor switching, solenoids energizing / de-energizing. - Check the connection of power cables to the battery terminal, positive and negative, to MC and to controller +Batt and –Batt, which must be screwed with a torque comprised in the range 13Nm÷15Nm. - If no voltage transient is detected on the supply line and the alarm is present every time the key is switched ON, the failure is probably in the controller hardware, so it is necessary to replace the logic board. 13) LOGIC FAILURE#1 Cause: This fault is displayed when the controller detects an over voltage or under voltage condition. Over voltage threshold is 45V, under voltage threshold is 9V in the 24V controller. In 48V controller over voltage threshold is 65V, under voltage threshold is 11V. Troubleshooting: Troubleshooting of fault displayed at start-up or in standby; in these cases it is very likely the fault is due to an under voltage, so it is suggested to check: - Key input signal down-going pulses (below under voltage threshold) due to external loads, like DC/DC converters starting-up, relays or contactor switching, solenoids energizing / de-energizing. - Check the connection of power cables to the battery terminal, positive AF2ZP0CL - ACE2 - User Manual

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and negative, to MC and to controller +Batt and –Batt, which must be screwed with a torque comprised in the range 13Nm÷15Nm. If no voltage transient is detected on the supply line and the alarm is present every time the key is switched ON, the failure is probably in the controller hardware, so it is necessary to replace the logic board. Troubleshooting of fault displayed during motor driving; in this case it can be an under voltage or an over voltage condition. If the alarm happens during traction acceleration or driving hydraulic functions, it is very likely it is an under voltage condition; check battery charge condition, power cable connection. If the alarm happens during release braking, it is very likely it is due to over voltage condition; check line contactor contact, battery power cable connection.

14) LOGIC FAILURE #3 Cause: Hardware problem in the logic card circuit for high current (overload) protection. Troubleshooting: This type of fault is not related to external components, so, when it is present it is necessary to replace the ACE logic board. 15) POWER MOS SHORTED Cause: Before switching the MC on, the software checks the power bridge: it turns on alternatingly the Low side and High side Power Mosfets and expects the phases voltage to decrease down to –BATT (increase up to +Batt). If the phases voltage do not follow the commands, this alarm occurs. Troubleshooting: This type of fault is not related to external components; replace the controller. 16) VMN HIGH Cause 1: Before switching the LC on, the software checks the power bridge: it turns on alternatingly the Low side Power Mosfets and expects the phases voltage to decrease down to -BATT. If the phases voltage is higher than 10% of nominal battery voltage, this alarm occurs. Cause 2: This alarm may occur also when the start up diagnosis is overcome, and so the LC is closed. In this condition, the phases’ voltages are expected to be lower than 1/2 Vbatt. If it is higher than that value, fault status is entered. Troubleshooting: - If the problem occurs at start up (the LC does not close at all), check: - Motor internal connections (ohmic continuity) - Motor power cables connections - If the motor connection are OK, the problem is inside the controller, replace it. - If the problem occurs after closing the LC (the LC closed and then opens back again), check: - Motor connections - If motor phases windings/cables have leakages towards truck frame - If no problem are found on the motors, the problem is inside the controller, replace it.

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AF2ZP0CL - ACE2 - User Manual

17) VMN LOW Cause 1: Start-up test. Before switching the LC on, the software checks the power bridge: it turns on alternatingly the High side Power Mosfets and expects the phases voltage to increase toward the rail capacitor value. If the phases voltage is less than 66% of the rail capacitor voltage, this alarm occurs. Cause 2: Motor running test. When the motor is running, power bridge is ON, the motor voltage feedback is tested; if it is lower than commanded value (a window of values are considered) fault status is entered. Troubleshooting: - If the problem occurs at start up (the LC does not close at all), check: - Motor internal connections (ohmic continuity) - Motor power cables connections - Motor leakage to truck frame - If the motor connections are OK, the problem is inside the controller, replace it. - If the alarm occurs during motor running, check: - Motor connections - If motor phases windings/cables have leakages towards truck frame - That the LC power contact closer properly, with a good contact - If no problem are found on the motors, the problem is inside the controller, replace it. 18) STBY I HIGH Cause: The current transducer or the current feedback circuit is damaged in the controller. Troubleshooting: This type of fault is not related to external components so, when it is present, it is necessary to replace the controller. 19) WRONG 0 VOLTAGE Cause: At start-up the high resolution VMN feedback is not comprised in a permitted window of values centred around 2,5V. The circuit is damaged in the controller. Troubleshooting: It is suggested to check: - Motor internal connections (ohmic continuity) - Motor power cables connections - Motor leakage to truck frame - If the motor connections are OK, the problem is inside the controller, replace the logic board 20) CONTACTOR CLOSED Cause: Before driving the MC coil, the controller checks if the contactor is stuck. The controller drives the bridge for some tens milliseconds, trying to discharge the capacitors bank. If the capacitor voltage does decrease by 20% of the key voltage the alarm is generated. Troubleshooting: It is suggested to verify the power contacts of LC; to replace the LC is necessary.

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21) HARDWARE FAULT 20 Cause: Before driving the MC coil, the controller checks if the Mosfets drivers are turned of by a not active (alarm status) Watch-dog signal. If they are not turned of then the alarm is generated. Troubleshooting: The problem is inside the controller, no external component are involved, replace the logic board. 22) HARDWARE FAULT 21 Cause: Before driving the MC coil, the controller checks if the EB/AUX driver is turned of by a not active (alarm status) Watch-dog signal. If it is not turned of then the alarm is generated. Troubleshooting: The problem is inside the controller, no external component are involved, replace the logic board. 23) HARDWARE FAULT A1 Cause: Before driving the MC coil, the controller checks if the MC/AUX driver is turned of by a not active (alarm status) Watch-dog signal. If it is not turned of then the alarm is generated. Troubleshooting: The problem is inside the controller, no external component are involved, replace the logic board. 24) COIL SHORTED MC Cause: This alarm occurs when there is a short circuit of the MC coils connected to CNA#16 output. After the overload condition has been removed, the alarm exits automatically by releasing and then enabling a travel demand. Troubleshooting: - The typical root cause for this error code to be displayed is in the harness or in the load coil. So the very first check to carry out concerns connections between controller outputs and loads. - In case no failures/problems have been found externally, the problem is in the controller, which has to be replaced. 25) COIL SHORTED EF Cause: This alarm occurs when there is a short circuit of the EB/AUX coils connected to CNA#18 output. After the overload condition has been removed, the alarm exits automatically by releasing and then enabling a travel demand. Troubleshooting: - The typical root cause for this error code to be displayed is in the harness or in the load coil. So the very first check to carry out concerns connections between controller outputs and loads. - In case no failures/problems have been found externally, the problem is in the controller, which has to be replaced. 26) CONTACTOR OPEN Cause: The main contactor coil has been driven by the controller, but the contactor does not close. Page - 78/85

AF2ZP0CL - ACE2 - User Manual

Troubleshooting: - It could be a problem of the contacts in the MC that are not working (does not pull-in), try replacing the MC. - If the contactors of MC are working correctly than the problem is in the controller, replace it. 27) LOGIC FAILURE #2 Cause: Fault is in the hardware section of the logic board which manages the phase’s voltage feedback. Troubleshooting: This type of fault is not related to external components, so when it happens it is necessary to replace the ACE2 logic board. 28) CONTACTOR DRIVER Cause: The MC coil driver is not able to drive the load. The device itself or its driving circuit is damaged. Troubleshooting: This type of fault is not related to external components; replace the ACE2 logic board. 29) AUX DRIVER OPEN Cause: The EB/AUX coil driver is not able to drive the load. The device itself or its driving circuit is damaged. Troubleshooting: This type of fault is not related to external components; replace the ACE2 logic board. 30) ENCODER ERROR Cause: This fault is signalled in following conditions: the frequency supplied to the motor is higher than 40 Hz and the signal feedback from the encoder has a jump higher than 40 Hz in few tens mSec. This condition is related to a malfunctioning of the encoder. Troubleshooting: - Check both the electric and the mechanical encoder functionality, the wires crimping. - Check the encoder mechanical installation, if the encoder slips inside its compartment raising this alarm condition. - Also the electromagnetic noise on the sensor bearing can be a cause for the alarm. In these cases try to replace the encoder. - If the problem is still present after replacing the encoder, the failure is in the controller. 31) WRONG RAM MEMORY Cause: The algorithm implemented to check the main RAM registers finds a wrong contents: the register is “dirty”. This alarm inhibit the machine operations. Troubleshooting: Try to switch the key off and then on, if the alarm is still present replace the ACE2 logic board.

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8.18 Microcontroller warning overview Error code

Description

Effect

Machine status when the test is done

Restart procedure

Vacc not OK

The accelerator/ lift potentiometer value is higher than the minimum value recorded, and the direction/enable switches are opened. Incorrect starting sequences

Traction/ Pump motor is stopped

Start-up, standby, running

Traction/Pump request

Traction/ Pump motor is stopped

Start-up, standby

Traction/Pump request

Traction/ Pump motor is stopped

Start-up, standby, running

Traction/Pump request

Traction controller reduces the max current linearly from Imax (85°C) down to 0A (105°C) The maximum current is reduced to half and speed is reduced

Continuous

MDI code allarm 78

Incorrect start

MDI code allarm 79 Vacc out of range

MDI code allarm 85 Temperature

MDI code allarm 62 Motor temperature

MDI code allarm 65 Brake run out

The accelerator input is out of the range Vacc_min ÷ Vacc_max, which has been acquired with “PROGRAMM VACC” function. The controller has reached the thermal cutback temperature of 85°C when the current is IMAX Motor temperature sensor is opened (if digital) or has overtaken the threshold of 150°C (if analogue) The Brake potentiometer input is at the maximum value without the HB request

Continuous

No effect, the warning is only displayed through the console

Continuous

Traction/Pump request Traction/ Pump request

Handbrake

A traction request is done with the Handbrake input active

Traction motor is stopped

Stand-by, running

Current Gain

The Maximum current gain parameters are the default values, which means the maximum current adjustment procedure has not been carried out yet The output of the motor thermal sensor is out of range.

Controller works, but with low maximum current

Start-up, standby

The maximum current is reduced to half and speed is reduced

Continuous

The output of the controller thermal sensor is out of range.

The maximum current is reduced to half and speed is reduced

Continuous

Error on the parameters of the slip profile setting.

Traction/Pump motor is stopped

Start-up, standby, running

Error is detected in Eeprom or in Eeprom management

Controller works using default parameters

continuous

The travel demands are active in both directions at the same time

Traction is stopped

Start-up, standby, running

MDI code allarm 92

Sens mot temp Ko

MDI code allarm 65 Thermic sens Ko

MDI code allarm 61 Slip profile

MDI code allarm 99 EEPROM KO

MDI code allarm 71 Forward + Backward

MDI code allarm 80 Page - 80/85

Traction/ Pump request

Traction request

AF2ZP0CL - ACE2 - User Manual

8.19 Analysis and troubleshooting of warnings displayed on console 1) VACC NOT OK Cause: The test is made at key-on and immediately after that both the travel demands have been turned off. This alarm occurs if the ACCELERATOR reading in the TESTER menu’ is 1,0V higher than PROGRAM VACC min acquisition when the accelerator is released. Troubleshooting: Acquire the maximum and minimum potentiometer value through the PROGRAM VACC function. If the alarm is still present, check the mechanical calibration and the functionality of the potentiometer. If the alarm is not disappeared the failure is in the ACE logic board, replace it. 2) INCORRECT START Cause: This is a warning for an incorrect starting sequence. Troubleshooting: The possible reasons for this alarm are (use the readings in the TESTER to facilitate the troubleshooting): - A travel demand active at key on - Presence man sensor active at key on Check the wirings. Check the micro switches. It could be also an error sequence made by the operator. A failure in the logic is possible too; so when all of the above conditions were checked and nothing was found, replace the ACE logic board. 3) VACC OUT OF RANGE Cause: The CPOT input red by the microcontroller is not comprised in the range Vacc_min ÷ Vacc_max, programmed through the “PROGRAMM VACC” function. Troubleshooting: Acquire the maximum and minimum potentiometer value through the PROGRAM VACC function. If the alarm is still present, check the mechanical calibration and the functionality of the potentiometer. If the alarm is not disappeared the failure is in the ACE logic board, replace it. 4) TEMPERATURE Cause: This alarm occurs when the temperature of the base plate is higher than 85°. Then the maximum current decreases proportionally with the temperature increases from 85° up to 105°. At 105° the Current is limited to 0 Amps. Troubleshooting: It is necessary to improve the controller cooling. For realise an adequately cooling in case of finned heat sink are important factor the flux [m3/h] and temperature [°C] of cooling air. In case of thermal dissipation realised with the controller base plate installed on truck frame it is important the thickness of frame and the planarity and roughness of its surface. If the alarm is signalled when the controller is cold, the possible reasons are a thermal sensor failure or a failure in the logic card. In this case, it is necessary to replace the controller.

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5) MOTOR TEMPERATURE Cause: This warning occurs when the temperature sensor is opened (if digital) or has overtaken the threshold of 150° (if analogue). Troubleshooting: Check the thermal sensor inside the motor (use the MOTOR TEMPERATURE reading in the TESTER menu); check the sensor ohmic value and the sensor wiring. If the sensor is OK, improve the cooling of the motor. If the warning is present when the motor is cool, then the problem is inside the controller. 6) BRAKE RUN OUT Cause: The CPOTBRAKE input red by the microcontroller is at the maximum value without the hand brake request. Troubleshooting: Check the mechanical calibration and the functionality of the brake potentiometer. If the alarm is not disappeared the failure is in the ACE logic board, replace it. 7) HAND BRAKE Cause: The hand brake input is active when a traction request is done. Troubleshooting: The possible reasons for this alarm are (use the readings in the TESTER to facilitate the troubleshooting): - The HB switch is damaged so it does not close the input CNA#13 to – Batt. Replace it. - The HB switch work correctly but in the tester menu the HB input is always ON. In this case the failure is in the logic board, replace it. 8) CURRENT GAIN Cause: The Maximum current gain parameters are at the default values, which means the maximum current adjustment procedure has not been carried out yet. Troubleshooting: Ask the assistance of a Zapi technician to do the correct adjustment procedure of the current gain parameters 9) SENS MOT TEMP KO Cause: The output of the motor thermal sensor is out of range. Troubleshooting: Check the sensor ohmic value and the sensor wiring. If the sensor is OK, then the problem is inside the ACE logic board, replace it. 10) THERMIC SENS KO Cause: The output of the controller thermal sensor is out of range. Troubleshooting: This type of fault is not related to external components; replace the controller.

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11) SLIP PROFILE Cause: There is an error on the choice of the parameters of the slip profile. Troubleshooting: Check in the hardware setting menu the value of those parameter 12) EEPROM KO Cause: It’s due to a HW or SW defect of the non-volatile embedded memory supporting the controller parameters. This alarm does not inhibit the machine operations, but the truck will work with the default values. Troubleshooting: Try to execute a CLEAR EEPROM operation (refer to Console manual). Switch the key off and on to check the result. If the alarm occurs permanently, it is necessary to replace the controller. If the alarm disappears, the previously stored parameters will have been replaced by the default parameters. 13) FORW+BACK Cause: This alarm occurs when both the travel demands (Fwd and Bwd) are active at the same time. Troubleshooting: Check the wiring of the Fwd and Rev travel demand inputs (use the readings in the TESTER to facilitate the troubleshooting). Check the microswitches for failures. A failure in the logic is possible too. So, when you have verified the travel demand switches are fine working and the wiring is right, it is necessary to replace the ACE-2 logic board.

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9 RECOMMENDED SPARE PARTS FOR INVERTER Part number

Description

ACE Version

C16588

Protected 350 A strip UL Fuse.

24V/400 & 36-48V/450

C16588

Protected 350 A strip UL Fuse.

24V/500

C16586

Protected 250 A strip UL Fuse.

36-48V/350

C16603

Protected 200 A strip UL Fuse.

80V/300

C16520

10 A 20 mm Control Circuit Fuse

All

C29523

SW 180 80 V

All

Single Pole Contactor C29522

SW 180 48 V

All

Single Pole Contactor C29508

SW 180 24 V

All

Single Pole Contactor C12531

Connector Ampseal 23 pins Female

All

C12372

Connector Molex 8 pins Female

All

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AF2ZP0CL - ACE2 - User Manual

10 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED Check the wear and condition of the Contactors’ moving and fixed contacts. Electrical Contacts should be checked every 3 months. Check the Foot pedal or Tiller microswitch. Using a suitable test meter, confirm that there is no electrical resistance between the contacts by measuring the volt drop between the terminals. Switches should operate with a firm click sound. Microswitches should be checked every 3 months. Check the Battery cables, cables to the inverter, and cables to the motor. Ensure the insulation is sound and the connections are tight. Cables should be checked every 3 months. Check the mechanical operation of the pedal or tiller. Are the return springs ok ? Do the potentiometers wind up to their full or programmed level ? Check every 3 months. Check the mechanical operation of the Contactor(s). Moving contacts should be free to move without restriction. Check every 3 months. Checks should be carried out by qualified personnel and any replacement parts used should be original. Beware of NON ORIGINAL PARTS. The installation of this electronic controller should be made according to the diagrams included in this Manual. Any variations or special requirements should be made after consulting a Zapi Agent. The supplier is not responsible for any problem that arises from wiring methods that differ from information included in this Manual. During periodic checks, if a technician finds any situation that could cause damage or compromise safety, the matter should be bought to the attention of a Zapi Agent immediately. The Agent will then take the decision regarding operational safety of the machine. Remember that Battery Powered Machines feel no pain. NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER.

IMPORTANT NOTE ABOUT WASTE MANAGEMENT: This controller has both mechanical parts and high-density electronic parts (printed circuit boards and integrated circuits). If not properly handled during waste processing, this material may become a relevant source of pollution. The disposal and recycling of this controller has to follow the local laws for these types of waste materials. Zapi commits itself to update its technology in order to reduce the presence of polluting substances in its product.

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EN User Manual

EPS-AC0

is a registered trademark property of Zapi S.p.A.

NOTES LEGEND

4 U

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The symbol aboard is used inside this publication to indicate an annotation or a suggestion you should pay attention.

The symbol aboard is used inside this publication to indicate an action or a characteristic very important as for security. Pay special attention to the annotations pointed out with this symbol.

AEMZP0BA - EPS-AC0 - User Manual

Contents 1 2

5 6

INTRODUCTION ...................................................................................................................6 SPECIFICATION................................................................................................................... 7 2.1 Technical specifications ............................................................................................. 7 2.2 Block diagram............................................................................................................. 7 2.3 Electrical specifications .............................................................................................. 7 2.4 Mechanical specifications........................................................................................... 8 2.4.1 Basic release ................................................................................................ 8 FUNCTIONS OF THE EPS-AC0........................................................................................... 9 3.1 Manual Mode Steering ............................................................................................... 9 3.2 Automatic Centering ................................................................................................. 10 3.3 Operational features ................................................................................................. 11 3.4 Diagnosis.................................................................................................................. 11 SYSTEM COMPONENTS ................................................................................................... 12 4.1 Steering Motor .......................................................................................................... 12 4.2 Gear Box and total reduction ratio............................................................................ 12 4.3 Eps-ac0 controller .................................................................................................... 12 4.3.1 Eps-ac0 PCB .............................................................................................. 13 4.4 Sensor in the steering handle................................................................................... 14 4.4.1 Stepper motor............................................................................................. 14 4.4.2 Twin pot ...................................................................................................... 14 4.5 Feedback sensors .................................................................................................... 15 4.5.1 Encoder in the motor shaft and a Feedback Potentiometer ....................... 15 4.5.2 Encoder in the motor shaft and one (two) toggle switch(es) ...................... 17 4.5.3 Feedback Encoder ..................................................................................... 18 AUTC MODE....................................................................................................................... 21 CONNECTING DIAGRAMS................................................................................................ 22 6.1 Power Connecting Diagram ..................................................................................... 22 6.2 EPS-AC0 Stepper Motor diagram ............................................................................ 23 6.3 EPS-AC0 Twin pot diagram...................................................................................... 24 CONNECTIONS: SUGGESTIONS AND CAUTIONS ......................................................... 25 7.1 Stepper Motor connections ...................................................................................... 25 7.2 Twin pot connections................................................................................................ 25 7.3 Encoder connections ................................................................................................ 25 7.4 Feedback pot connections ....................................................................................... 25 7.5 Digital Inputs connections ........................................................................................ 26 7.6 Safety contacts ......................................................................................................... 27 7.7 Motor thermal sensor connections ........................................................................... 27 INSTALLATION: SUGGESTIONS AND CAUTIONS ......................................................... 28 8.1 Thermal consideration.............................................................................................. 28 8.1.1 Controller with Base Plate .......................................................................... 28 8.1.2 Controller with finned Heatsink................................................................... 28 8.2 General suggestion .................................................................................................. 29 8.3 Connection cables .................................................................................................... 29 8.4 Fuses........................................................................................................................ 30 8.5 Contactors ................................................................................................................ 30 8.6 Installation of a CAN Communication System.......................................................... 31 8.7 Wiring: I/O connections ............................................................................................ 33

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8.8 8.9

Safety features ......................................................................................................... 34 EMC ......................................................................................................................... 34 8.9.1 Emission ..................................................................................................... 35 8.9.2 Electromagnetic Immunity .......................................................................... 35 8.9.3 ESD ............................................................................................................ 35 8.10 Fighting the dither..................................................................................................... 36 DESCRIPTION OF THE CONNECTORS ........................................................................... 38 9.1 Connectors of the logic............................................................................................. 39 9.1.1 CNA connector ........................................................................................... 39 9.1.2 CNB connector ........................................................................................... 39 9.1.3 CNC connector ........................................................................................... 40 9.2 Description of power connections ............................................................................ 41 INSTALLATION PROCEDURE .......................................................................................... 42 10.1 Twin Pot with Encoder and Feedback pot: one shot installation procedure ............. 42 10.2 Twin Pot with Encoder, Straight Ahead Switch and Feedback pot: one shot installation procedure ................................................................................................................. 43 10.3 Stepper Motor with Encoder and Feedback pot: one shot installation procedure .... 45 10.4 Stepper Motor with Encoder and Toggle Switch(es): one shot installation procedure46 SETTING THE EPS-AC0 .................................................................................................... 49 11.1 Complete set-up description..................................................................................... 49 11.1.1 Stepper Motor only ..................................................................................... 49 11.1.2 Stepper Motor & AUTC............................................................................... 49 11.1.3 RTC (Twin Pot) only ................................................................................... 49 11.1.4 RTC & AUTC .............................................................................................. 50 11.2 Quick set-up ............................................................................................................. 50 11.2.1 Stepper Motor only ..................................................................................... 50 11.2.2 Stepper Motor & AUTC............................................................................... 51 11.2.3 RTC only or RTC & AUTC.......................................................................... 51 PROGRAMMAING & ADJUSTMENTS USING DIGITAL CONSOLE................................ 52 12.1 Adjustments via console........................................................................................... 52 12.2 Description of console (hand set) & connection ....................................................... 52 12.3 Description of standard console menu ..................................................................... 53 12.3.1 Stepper motor with Encoder and Feedback pot ......................................... 54 12.3.2 RTC with Encoder and Feedback pot......................................................... 55 12.3.3 Stepper motor with Encoder and Toggle switch(es)................................... 56 12.4 Function configuration .............................................................................................. 57 12.4.1 Config menu “SET OPTIONS” functions list............................................... 58 12.4.2 Config menu “ADJUSTMENTS” functions list ............................................ 62 12.4.3 Config menu “SET MODEL” functions list .................................................. 65 12.4.4 Main menu “PARAMETER CHANGE” functions list................................... 68 12.4.5 Zapi menu “HARDWARE SETTINGS” functions list .................................. 75 12.4.6 Zapi menu “SPECIAL ADJUSTMENT” functions list .................................. 76 12.4.7 Main menu “TESTER” functions list ........................................................... 78 OTHER FUNCTIONS .......................................................................................................... 82 13.1 Acquiring the Motor resistance ................................................................................. 82 13.2 Alignment at the rest position ................................................................................... 82 13.3 Straight ahead steering numbness........................................................................... 82 13.4 Special Debugging and Troubleshooting system ..................................................... 83 EPS-AC0 ALARMS LIST.................................................................................................... 84

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14.1

Main menu “ALARMS” list ........................................................................................ 84 14.1.1 One Blink Alarms........................................................................................ 84 14.1.2 Two Blinks Alarms ...................................................................................... 86 14.1.3 Three Blinks Alarms ................................................................................... 87 14.1.4 Four Blinks Alarms ..................................................................................... 90 14.1.5 Five Blinks Alarms ...................................................................................... 91 14.1.6 Six Blinks Alarms........................................................................................ 91 14.1.7 Thirty-two Blinks Alarms ............................................................................. 92 14.1.8 No Blink Alarms (Warning) ......................................................................... 92 14.2 CAN BUS “ALARMS” List......................................................................................... 93 15 RECOMMENDED SPARE PARTS ..................................................................................... 94 16 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED......................... 95 16.1 Testing the faulty detection circuitry ......................................................................... 95

APPROVAL SIGNS

COMPANY FUNCTION

INIZIALS

PROJECT MANAGER

TECHNICAL ELECTRONIC MANAGER VISA

SALES MANAGER VISA

SIGNS

Publication N°: AEMZP0BA Edition: May 2006

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1 INTRODUCTION This equipment (Eps-ac0: AC0 Electrical Power Steering) may perform two steer by wire functions on a truck: 1) manually controlled power steering 2) automatic centering (AUTC). Manually controlled steering may use either a stepper motor (used as a tachogenerator) or a twin pot fixed to the steering wheel. Feedback sensors are mandatory to close the loop when an automatic function is required (Automatic Centering). Feedback sensors are mandatory to close the loop in manual mode if a twin pot is mounted on the steering wheel. Feedback sensors are strongly suggested (to improve safety) in manual mode if a stepper motor is mounted on the steering wheel (open loop). The feedback sensor may be an incremental encoder on the steering motor shaft in combination with one straight-ahead switch. A second switch may be adopted, together with the first one, in the 90 degrees position to improve safety. Besides a feedback potentiometer may be chosen in alternative to the straight-ahead switch. The eps-ac0 runs an inexpensive, robust and maintenance free three phases AC induction motor. Also, our patented system makes possible to use a very lowresolution encoder (4 pulses/rev are more than enough) mounted on the steering motor shaft. The on board CAN interface makes the communication exchange between our eps-ac0 and other units in the truck rapid and simple. Via CAN it is possible to enhance the steering performances with additional functions like: steer sensitivity changes with the traction speed, traction speed modulation vs. the steered angle, via CAN automatic centering request and so on. Configuration options, steering adjustment, measurement functions, and troubleshooting operations are integrally supported by the ZAPI hand held controller equipped with Eprom release number CKULTRA ZP3.01 or subsequent. Having two microprocessors provides improved safety and operation. The first microprocessor performs operations and a second one executes supervisor functions. Both the aboard microprocessors are CAN BUS connected, as consequence the eps-ac0 may receive a remote steering command directly via CAN fulfilling the norm (the redundant check of the steering command complies with the Category #3 requirement). The microprocessors combined with the ZAPI hand held controller make servicing easy and direct, reducing adjustment and troubleshooting time. Increased steering motor performance and reduced noise levels are achieved by using MOSFET technology. The reference SW release for this manual is ZP0.70.

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2 SPECIFICATION 2.1 Technical specifications Steering controller for AC asynchronous 3-phase motors Digital Control using Two Microprocessors Can-Bus interface Both microprocessors Can Bus connected Encoder Interface Stepper Motor or Twin Pot Interface Analog Feedback pot interface (1024 steps resolution) Analog KTY84-130 thermal sensor input Analog input with 1024 steps resolution (one input) Analog input with 4096 steps resolution (one input) Two digital inputs Double Safety Relay inside Operating frequency: ............................................. 8 kHz with center aligned PWM External temperature range: .............................................................-30 °C ÷ 40 °C Maximum inverter temperature:...................................................................... 75 °C Environment protection:....................................................................................IP54

2.2 Block diagram

Figure 2-1

2.3 Electrical specifications Battery Voltage: ....................................................................................... 24 V-36 V Maximum current (24 V-36 V):..................................................... 50 A (RMS) for 2' Logic Supply current: ..............................................................max 200 mA @ 24 V AEMZP0BA - EPS-AC0 - User Manual

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Minimum Input (key) Supply Voltage after start-up:..........................................12 V

2.4 Mechanical specifications 2.4.1 Basic release It has Molex Minifit connector with international protection IP54.

EPS-AC0

Figure 2–2

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3 FUNCTIONS OF THE EPS-AC0 The eps-ac0 controls a steer system for warehouse trucks. It executes the following functions: 1) Manual mode steering 2) Automatic Centering.

3.1 Manual Mode Steering Manual mode steering requires a command sensor in the hand wheel. The hand wheel may be of two types: 1) Multiturn steering wheel without end-strokes. 2) Handlebar, tiller or joy-stick with end-strokes to limit the angle. With a Multiturn steering wheel, the sensor in the hand-wheel shall be a stepper motor used as a tacho-generator (see Figure 3-1). Then the control will turn the steering motor moving at a speed proportional to the stepper motor speed (Open loop Mode).

Stepper Motor Figure 3-1

With a Handlebar (tiller or joy-stick), the sensor in the hand-wheel will be a twin pot (see Figure 3-2 below). Then the system works as a position control loop with a rigid correspondence between the angle of the handlebar and the angle of the steered wheel (Closed Loop Mode). In this case a feedback sensor on the steered wheel is mandatory.

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Twin Pot

Figure 3–2

The same controller may work either with the stepper motor or the twin pot without hardware modification. It is just enough to set the SYSTEM CONFIG to the correct value (see 12.4.3.1).

3.2 Automatic Centering Automatic Centering turns the steered wheel straight ahead to keep the steer aligned meanwhile travelling inside an aisle between rails (see Figure 3-3).

Figure 3–3 Page - 10/95

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3.3 Operational features A list of eps-ac0 operational features follows below: 1) Static sensitivity boost in open loop (steering sensitivity increases for a slow moving steering wheel). 2) Static numbness in closed loop (steering sensitivity decreases for handle steer close to the straight-ahead direction). 3) Dynamic Numbness in open loop (steering sensitivity reduces when the truck speed increases). 4) Dynamic Numbness on request in closed loop (steering sensitivity reduces when the truck speed increases). 5) Truck speed reduces when the steering angle increases. 6) Alignment at the rest position in open loop application (to avoid the drift of the steered wheel when travelling with released steering wheel). 7) Embedded PID algorithm for closed loop application (Twin Pot). 8) Embedded PID algorithm for automatic functions (AUTC). 9) Special Debugging & Troubleshooting system makes easier the fault catching. 10) Possibility to run in a stand-alone (not CAN Bus supported) configuration. 11) Motor control may be performed with or without encoder. Default choice is without encoder. The adoption of a cheap and low-resolution encoder is possible. 12) Redundant processing (two microprocessors aboard) fulfils the Category #3 requirement including the set-point comes via CAN Bus from a remote unit. 13) Redundant set point and feedback sensors fulfil the Category #3 requirement. 14) Redundant safety-contact fulfils the Category #3 requirement in a stand-alone configuration.

3.4 Diagnosis According to EN1175, most of the diagnoses deenergize steer and traction in less then 100 msec. Few secondary alarm conditions require longer time for detection. They too deenergize steer and traction: it is better to have delayed alarm than no alarm at all. Diagnosis is provided in two ways. The digital console can be used, which gives a detailed information about the failure; the failure code is also sent on the Can-Bus.

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4 SYSTEM COMPONENTS The eps-ac0 controller needs some external parts in order to work. The following list describes the complete equipment.

4.1 Steering Motor The steering system includes a three phase AC induction motor. The motor rated power (S2-1h) changes with the truck type. As a thumb rule: 1) A low level OP asks a motor with rated power higher than 250 W @ 3000 rpm. 2) A reach truck asks a motor with rated power higher than 400 W @ 3000 rpm. Obviously the above list is only a rough information: the motor should be chosen from time to time according the rated torque and speed customer’s specifications.

4.2 Gear Box and total reduction ratio Normally, the total reduction ratio between steered wheel and motor shaft should be close to 1:200. Normally it is split into: 1) Gear box ratio close to 1:50. 2) External gears ratio close to 1:4. The maximum continuous output torque requirement changes with the truck type. As a thumb rule and in the worst case (stalled steer): 1) A low level OP asks a maximum torque of about 250 Nm on the wheel to steer. 2) A reach truck asks a maximum torque of about 600 Nm on the wheel to steer. Obviously the above list is only a rough information: the reduction ratio together with the gear-box should be chosen from time to time according the customer’s specifications.

4.3 Eps-ac0 controller It consists of a control unit on a PCB marked AEMZPA0B (see Figure 4.1) which operates the AC asynchronous motor for manual and centering mode. Eps-ac0 works with 24 to 36 V battery and a maximum current up to 50 Aac. It has flash memory aboard and it is possible to boot the SW in the Master microprocessor through both, Serial hand set connector (CNC) and via CAN Bus. For the Slave microprocessor, only via CAN Bus booting is admitted. A Zapi own program (Flasher) is needed to boot-on the SW.

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4.3.1 Eps-ac0 PCB It has Molex Minifit connector with international protection IP54.

Figure 4–1

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4.4 Sensor in the steering handle Two configurations are foreseen: 1) No limit, multiturn steering wheel. 2) Tiller, handlebar or joystick arrangement with a limited angle. Depending by the above choice, there are two different handling: 1) In case of multiturn steering wheel, a stepper motor is used. 2) In case of a handlebar with limited angle, a twin pot is used.

4.4.1 Stepper motor The stepper motor is used as a tachogenerator. The following part numbers resulted suited to work with eps-ac0: 1) MINEBEA Type code AA23KM-K227-T20V. 2) JAPAN SERVO Type Code KH56JM2X 1269 DC12V 30 ohm. They have the same mechanical dimensions (see Figure 4.2 below). Obviously, the above information states only these parts are suited for the eps-ac0; no reliability evaluation is given here. Other sources are possible on request, but must be tested for approval.

Figure 4–2

4.4.2 Twin pot The Twin pot is a double potentiometer in the same frame. The two potentiometers inside must have complementary action (i.e. one wiper grows up from zero to Vcc meanwhile the second wiper reduces from Vcc to zero - see Figure 4-3 below).

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AEMZP0BA - EPS-AC0 - User Manual

Figure 4–3

The following part numbers resulted suited to work with eps-ac0: 1) CONTELEC twin hall sensors 170° Type code VERT-X 2841 417 225. 2) BOURNS twin potentiometers 180° Type Code 6657S-466-502. 3) MCB twin potentiometers 85° Type Code PMR 410 or PMR426. The CONTELEC is without brushes but drains a high level of current (about 15 mA). The MCB has the advantage of a spring in the shaft. This spring neutralizes the dead zone in the tiller side getting a strongly accurate straight-ahead matching; unfortunately MCB has a limited angle (85°). Obviously, the above information states only these parts are suited for the eps-ac0; no reliability evaluation is given here. Other sources are possible on request, but must be tested for approval.

4.5 Feedback sensors Feedback sensors are mandatory to close the loop in manual mode if a twin pot is mounted on the steering wheel. Feedback sensors are strongly suggested (to improve safety) in manual mode if a stepper motor is mounted on the steering wheel (open loop). Eps-ac0 may handle two different configurations for the feedback sensors: 1) Incremental encoder in the motor shaft together with a feedback potentiometer on the steered wheel. 2) Incremental encoder in the motor shaft together with one (or two) toggle switch(es) in the straight ahead (and 90 degrees) position of the steered wheel. On request, in the closed loop application only, eps-ac0 may work also with two encoders in the motor shaft together with a straight ahead toggle switch.

4.5.1 Encoder in the motor shaft and a Feedback Potentiometer One possible arrangement for the feedback sensor consists of (see Figure 4-4): 1) Feedback encoder in the motor shaft. 2) Feedback potentiometer on shaft of the steering motor gear box.

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Figure 4–4

4.5.1.1 Feedback potentiometer The feedback potentiometer is used for both, encoder initialisation and redundancy on the steered wheel angle measurement. Normally the feedback potentiometer is multiturn (5 or 10 turns) 5K hybrid technology mounted on the output shaft of the steering gearbox (see Figure 4-4).

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4.5.2 Encoder in the motor shaft and one (two) toggle switch(es) It consists of (see Figure 4-5): 1) Straight ahead toggle switch on the input CNA#3 and GND. 2) 90 degrees toggle switch on the input CNA#2 and GND. 3) Feedback encoder on the steering motor shaft.

Figure 4–5

4.5.2.1 Straight ahead toggle switch The straight ahead toggle switch must be of NPN type (i.e. it must connect a minus battery to CNA#3). A possible arrangement for the straight-ahead switch (proximity switch) is shown in Figure 4-6 below. The proximity switch is connected to the truck frame; the Iron plate rotates together with the steered wheel.

Figure 4-6 AEMZP0BA - EPS-AC0 - User Manual

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It is handled this way: 1) At key-on, the eps-ac0 turns the steering motor moving in either CW or CCW side, according to whether the output level from the straight ahead switch is high or low (in the above sketch a proximity sensor is used as a straight ahead switch). 2) When the falling edge on the prox switch is detected, the encoder counting is initialized to 0 and the steered wheel is centered. 3) Then the encoder counting is continuously updated to measure the steered wheel angle. At key on, the Iron plate (with the shape shown in Figure 4-6), provides the correct direction in which the eps-ac0 must turn the steering motor in order the falling edge on the proximity switch is detected. An option POT UP SW1 EDGE (see 12.4.1.12) determines the direction where the steered wheel rotates to seek the straight ahead switch (i.e. it specifies if the steered wheel at the initial alignment is oriented with the iron plate in its right or left side). Together with the straight-ahead switch, a second toggle switch could be adopted to detect when the steered wheel is in the 90 degrees limiting position. This second toggle switch must be connected to CNA#2 and GND (minus battery).

S te e re d w h e e l P ro x s w itc h

Iro n P la te

9 0 ° Pro x s w itc h

Figure 4-7

4.5.3 Feedback Encoder One big advantage of our eps-ac0 controller is that it can work with a cost-effective very low-resolution encoder. Our competitors normally need a sensor bearing with 32 or higher pulses/rev; our eps-ac0 works also with a cheap encoder having 4 pulses/rev. That is more than enough for the angle measurement: in fact, with a total reduction of 1:200 and a 4 pulses/revs resolution, we have 1600 events (encoder transitions) within 180° of the steered angle. So the angle measurement is determined with quanta of 180/1600=0.112 degrees. This is possible because our patent system does not use the encoder for the AC motor control; it works completely sensorless. Following this statement, we have developed, together with a Zapi’s partner ACmotor-brand, a 4 pulses/rev discrete encoder. It is an external device (not integrated in the ball bearing) mounted in the backside of the motor (see Figure 4.8 below showing a 300 W AC Motor by “Best Motor” brand). The advantages of this solution are both, money saving and effective time saving in case of encoder replacement.

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AEMZP0BA - EPS-AC0 - User Manual

Figure 4-8

Note: On request, it is possible to use the encoder for the motor control. In this case, the SW must know the encoder resolution together with the poles-pair number. The encoder resolution and the motor poles pair (the controller can handle), will be specified in the headline of the handset showing something like: EPSAC0S2A ZP0.70 That means: EPSAC0=Eps-ac0 steering controller S= 2= A=

Stepper motor poles pair number 32 pulses/rev encoder

ZP= SW release type Zapi 0.70= SW release number 0.70 The command configuration is specified through the first letter after EPSAC0 in the following list: S= Stepper Motor P= Twin Pot C= via CAN Bus Position D= via CAN Bus Speed The encoder resolution is given by the last letter before of the SW release in the following list:

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Q= S= W= A= K= B=

4 pulses/rev 6 pulses/rev 16 pulses/rev 32 pulses/rev 48 pulses/rev 64 pulses/rev

The letters to specify the poles pair number and the Encoder resolution are present only if the SW includes the function for controlling the motor with the encoder.

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5 AUTC MODE Eps-ac0 may perform an automatic centering operation (AUTC). AUTC means the steered wheel shall be aligned straight-ahead following a centering request. The centering request can be provided via CAN Bus. As alternative, it is possible to use wired requests. For example: 1) in a configuration with feedback pot and feedback encoder, it is possible to use inputs CNA#3 and CNA#2 for the centering request (redundancy is recommended). 2) in a configuration with toggle switches and feedback encoder, when input CNA#1 is not used, it is possible to use inputs CNB#6 and CNA#1 for the centering request (redundancy is recommended). In case of AUTC a customized software must be developed.

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6 CONNECTING DIAGRAMS Below we have a collection of suggested connecting diagrams. They correspond to the main configurations. On request it is possible to choose also customized proposals or wiring modifications.

6.1 Power Connecting Diagram

EPS-AC0

Figure 6-1

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6.2 EPS-AC0 Stepper Motor diagram

Figure 6-2 AEMZP0BA - EPS-AC0 - User Manual

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6.3 EPS-AC0 Twin pot diagram

Figure 6-3

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7 CONNECTIONS: SUGGESTIONS AND CAUTIONS Read the following suggestions to get a correct connection of the steering equipment.

7.1 Stepper Motor connections The stepper motor has 4 connections: two are the stepper motor channels (CNA#9 and CNA#8) and two are the common (negative) references (CNA#10 and CNA#11). In the past we had 6 wires connected between stepper motor and eps-ac. We consider this 4-wire connection fulfils the norm because it is still possible to detect all of the single stepper motor electrical fault.

Note: The stepper motor should be connected with two distinct common (negative) references (CNA#10 and CNA#11). We advice against using just one common wire. That is because it takes long delay to detect when a single common wire is broken.

7.2 Twin pot connections The twin pot is connected, in alternative to the stepper motor, between CNB#5 (PPOC: 5 V positive supply), CNA#10 (negative supply), CNA#9 (CPOC1: 1st wiper), CNA#8 (CPOC2: 2nd wiper). CNB#5 is connected to a 5 Vdc supply source through a 22 ohms resistance. Take care the supply current of the Twin pot stays lower than 5 mA.

7.3 Encoder connections The encoder may be supplied either with 5 Vdc or 13 Vdc (factory set jumper J8) on CNB#4 (default set is 5 Vdc on CNB#4). A 10 ohms resistance is connected between the internal supply source and the pin CNB#4. The encoder outputs may be either open collector NPN type or Push-Pull type.

7.4 Feedback pot connections When a feedback pot is adopted it will be connected between CNB#2 (PPOT: positive supply), CNB#1(NPOT: negative supply), CNB#6 (CPOT: wiper). Pay attention, inside the eps-ac0, a 470 ohms resistance is connected between PPOT and 5 V supply and also between NPOT and the minus battery. That is done

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in order it will be possible to detect if a feedback pot connection breaks (see Figure 7-1 below): when Vout overtakes 4.7 V or is lower than 0.3 V an alarm occurs.

Figure 7-1

7.5 Digital Inputs connections There are three digital inputs available. Two of them must be GND connected to work properly. Their function primarily is: CNA#3: Input for the straight-ahead toggle switch CNA#2: Input for a 90° toggle switch When the application adopts the feedback pot instead of the straight-ahead toggle switch, CNA#3 and CNA#2 have the function to limit the maximum steered angle in CW and CCW side (in alternative, it is possible to use them as centering request). CNA#3 and CNA#2 are detected low if they are lower than 1.3 V. CNA#3 and CNA#2 are detected high if they are higher than 6.6 V or open. Besides there is a third digital input (CNA#1). Default choice wants CNA#1 connected to a plus battery (default choice) to work properly. CNA#1 is detected low if it is open or lower than 5.17 V. CNA#1 is detected high if it is higher than 11 V. By changing jumper J12 it is possible to reverse CNA#1 logic. Then CNA#1 must be connected to a minus battery to work properly. CAN#1 is detected low if it is lower than 1.3 V. CNA#1 is detected high if it is open or higher than 3.3 V.

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7.6 Safety contacts The Eps-ac0 provides an internal safety contact accessible through connector pins CNA#5 and CNA#4. It should be used to stop the traction and to enable an electromechanical brake when a steering alarm occurs. This safety contact is closed when the key switch is turned on. The contact opens where there is a steering alarm. This safety contact is floating, that means it's possible to connect it either to the plus battery or to the minus battery. Ensure that the pin #5 is connected to an equal or higher voltage than pin #4. For safety two cascaded switches are internally connected between CNA#5 and CNA#4. The Main microprocessor manages the first contact; the Supervisor microprocessor manages the second contact.

Note: If the safety switch is connected in series with external switches (deadman switch, tiller switch or similar) it's recommended that the steering safety switch should be directly connected to the supply source (plus battery or minus battery) with no interposed switches (it should be the first the chain: see Figure below).

7.7 Motor thermal sensor connections Eps-ac0 handles a motor thermal sensor: it should be KTY184-130 type. Through this sensor, the eps-ac0 measures the motor temperature: when DIAG MOTOR TEMP is set ON, and the motor temperature overtakes 150 degrees, an alarm occurs. Input CNB#3 is configured with a aboard 1K Pull-up resistor suited to receive the analog thermal sensor between this input and a negative (CNA#13).

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8 INSTALLATION: SUGGESTIONS AND CAUTIONS Read and respect the following suggestions to avoid problem during installation and in the definitive releasing.

8.1 Thermal consideration 1) The heat generated by the power block must be dissipated. For this to be possible the compartment must be ventilated and the heat sink materials ample. 2) Normally eps-ac0 does not ask for a forced ventilation: if the cooling is poor, a possible solution could be to redirect a part of the forced air flow of the traction controller toward the eps-ac0. 3) Abnormal ambient air temperatures should be considered. In situations where either ventilation is poor, or heat exchange is difficult, forced air ventilation should be used. 4) The thermal energy dissipated by the power block module varies and is dependent on the current drawn and the duty cycle.

8.1.1 Controller with Base Plate Installs the controller with the base-plate on a flat metallic surface that is clean and unpainted; suggested characteristics are: planarity 0.05 mm and roughness 1.6 µm Apply a light layer of thermo-conductive grease between the two surfaces to permit better heat dissipation.

8.1.2 Controller with finned Heatsink Sometimes the base plate installation cannot be adopted. Due to positioning problems or to a low thickness truck frame, it is necessary to adopt a finned dissipation combined with one or more fans. 1) The air flux should hit the fins directly, to maximize the cooling effect. 2) In addition to fans, also air-ducting systems can be used to maintain low the temperature of the controller. 3) It is necessary to ensure that cold air is taken from outside the controller compartment and hot air is easily pushed away from the controller compartment. 4) It is mandatory to avoid that the cooling air is re-circulated inside the controller compartment.

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8.2 General suggestion For a proper installation take care of the following recommendations:

U U

Never connect SCR low frequency chopper with AC Motor Inverter because the Rail capacitors alter the SCR choppers' work. If it is necessary to use two or more control units (e.g. traction + lift. + steering controller), they must belong to the ZAPIMOS family.

Do not connect the inverter to a battery with a nominal value different from the value indicated on the controller plate. If the battery value is greater, the MOS may fail; if it is lower, the control unit does not "power up".

During battery charge, disconnect the controller from the battery.

Supply the controller only with battery for traction; do not use a power supply.

U U U

When the inverter is installed, simulate a steering alarm and verify that both traction and electromechanical brake shall be de-energized in a very short time.

After the battery is disconnected, the Rail capacitor remains charged for some minutes; if you need to work on the inverter, discharge them using a 10 Ω ÷ 100 Ω resistance connected from the +Batt to the –Batt terminals in the controller side.

Take care all the inductive devices in the truck (horn, solenoid valves, coils, contactors) have a proper transient suppression device.

8.3 Connection cables 1) For the auxiliary circuits, use cables at least 0.5 mm² section. 2) For power connections to the motor and to the battery, use cables having section of 4-6 mm² (as a minimum). 3) The power cables length must be as short as possible to minimize power losses.

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4) For the optimum inverter performance, the cables to the battery should be run side by side and be as short as possible. 5) They must be tightened on controller power posts with a Torque of 2.5-3 Nm.

8.4 Fuses 1) Use a 6.3-10 A fuse for protection of the auxiliary circuits. 2) Use a 32 A fuse for protection of the power stage.

8.5 Contactors According to EN1175 5.9.6, a contactor to cut the line to the eps-ac0 is not strictly required. In fact in an AC system, the steer is automatically de-energized when a power failure occurs. In a DC system with permanent magnet motor instead, a short circuit in a power device, gets the steering motor rotates at maximum speed (and so it is necessary to cut off the line from the controller).

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A power contactor is still useful to remove the battery from controller when a power failure occurs. This is useful in order to limit the time in which a damaged controller remains battery connected. When a power contactor is used, the contactor coil shall be connected to a power supply through the eps-ac0 safety contact.

AEMZP0BA - EPS-AC0 - User Manual

8.6 Installation of a CAN Communication System

CAN stands for Controller Area Network. It is a communication protocol for real time control application. CAN operates at data rate of up to 1 Megabits per second. It was invented by the German company Bosch to be used in the car industry to permit communication among the various electronic modules of a vehicle, connected as illustrated in the figure below:

The eps-ac0 drains low level of current and so low section cables (4 mm2) are adopted for the power connections. This could be a drawback: in fact, a low section cable has higher reactance (impedance) than a wide section cable. As a consequence the noise generated on the minus battery cable, by the CAN lines switching, will be a wide amplitude spike. So, when it is possible, we suggest to use a (as short as possible) cable of a wide section for the minus battery connection, even for the eps-ac0 and the other low current units in the system.

VERY IMPORTANT: The eps-ac0 has the 120 ohms termination resistance aboard.

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In the following figures there is an overview of wrong and right layouts of the cables routing.

Wrong Layout: R Can Bus

Node 1

Power cables

Node 2

Traction Control

Lift Control

Node 3 eps-ac0 R

The red lines are can wires. The black boxes are different modules, for example traction controller, pump controller and eps-ac0 connected by can bus. The black lines are the power cables. This is apparently a good layout, but can bring to errors in the can line. The best solution depends on the type of nodes (modules) connected in the network. If the modules are very different in terms of power, then the preferable connection is the daisy chain.

Correct Layout: R Can Bus

Node 1

Power cables

Node 2

Traction Control

Lift Control

Node 3 eps-ac0 R

The chain starts from the –BATT post of the controller that works with the highest current, and the others are connected in a decreasing order of power.

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Otherwise, if two controllers are similar in power (for example a traction and a pump motor controller) and a third module works with less current, the best way to deal this configuration is to create a common ground point (star configuration)

Correct Layout: R Can Bus

Node 1

Power cables

Node 2

Traction Control

Lift Control

Center of the Ground Connections

Node 3 eps-ac0 R

In this case the power cables starting from the two similar controllers must be as short as possible. Of course also the diameter of the cable concurs in the voltage drops described before (higher diameter means lower impedance). So, in this last example, the cable between the minus of the Battery and the common ground point (pointed by the arrow in the image) must dimensioned taking into account thermal and voltage drop problems.

Can advantages The complexity of today systems needs more and more data, signal and information must flow from a node to another. CAN is the solution to different problems that arise from this complexity - simplified design (readily available, multi sourced components and tools) - lower costs (less and smaller cables ) - improved reliability (fewer connections) - analysis of problems improved (easy connection with a pc to read the data flowing through the cable).

8.7 Wiring: I/O connections After crimping the cable, verify that all strands are entrapped in the wire barrel. Verify that all the crimped contacts are completely inserted on the connector cavities. For information about the mating connector pin assignment see the description of the connectors in topic 9.

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8.8 Safety features

Eps-ac0 implements a double µC structure to comply with the Category#3 specification. The second µC main task is to check correct functionality of the first µC, whose main task is to control the steering motor. Basically, the two microcontrollers implement a double check control of the main functions. The two µCs are both CAN Bus connected. This characteristic makes possible the eps-ac0 receives the steering command (wished steered wheel position) via CAN Bus fulfilling the norm.

8.9 EMC

EMC stands for Electromagnetic Compatibility, and it represents the studies and the tests on the electromagnetic energy generated or received by an electrical device. Emission refers to the energy radiated from the controller and the harness. Immunity can be divided in two main branches: rejection from external electromagnetic fields and from electrostatic discharges (ESD). So the analysis works in three directions: Page - 34/95

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1) Emission 2) Electromagnetic Immunity 3) ESD rejection.

When possible it is strongly recommended preventing Emission and Immunity problems by locating the controllers inside a metallic enclosure. In most cases, a truck with a metallic enclosure will avoid EMC problem.

8.9.1 Emission Emission refers to the electromagnetic disturbances that the device generates in the surrounding space. Countermeasure should be adopted to prevent the propagation of those disturbances. We talk about “conduction” issues when guiding structures such wires and cables are involved; “radiated emissions” issues when it is studied the propagation of electromagnetic energy through the open space. In our case the origin of the disturbances can be found inside the controller with the switching of the mosfets which are working at high frequency and generate RF energy. Wires and cables are responsible for the spreading of this RF disturbance because they works as antennas, so a good layout of the cables and their shielding can solve the majority of the emission problems. Three ways can be followed to reduce the emissions: 1) SOURCE OF EMISSIONS: finding the main source of disturbs and works on it. 2) SHIELDING: enclosing contactor and controller in a shielded box; using shielded cables. 3) LAYOUT: a good layout of the cables can minimize the antenna effect; cables running nearby the truck frame or in iron channels connected to truck frame is generally a suggested not expensive solution to reduce the emission level.

8.9.2 Electromagnetic Immunity The electromagnetic immunity concerns the susceptibility of the controller to external electromagnetic fields and their influence on its correct work made. These tests are carried out at determined levels of electromagnetic fields, to simulate external undesired disturbances and verify the electronic device response. Here are some suggestions to improve the electromagnetic immunity: 1) SHIELDING: enclosing controller and wiring when possible on a shielded box; using shielded cables. 2) LAYOUT: hide the exposed wires, which are connected to the controller, behind metallic part working like natural barriers. 3) FERRITES: embrace the exposed wires, connected to the controller, with a split or solid ferrite. 4) BY-PASS CAPACITOR: connect an interference suppression capacitor (Y type) between the minus battery and the truck frame, as close as possible to the controller.

8.9.3 ESD When an accumulation of charge occurs in a part insulated from the ground, it may discharging in a shot when turning in contact with a part having different potential. This phenomenon is called Electrostatic Discharge (ESD). In forklift trucks applications, special attention should be adopted for avoiding ESD. The main rule is that it is always much easier and cheaper to avoid ESD from being generated, than to increase the level of immunity of the electronic devices. AEMZP0BA - EPS-AC0 - User Manual

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ESD happens when there is a rapid transfer from a charged part to another. This rapid transfer has, in turn, two important effects: 1) It can determine, by induction, disturbs on the signal wiring and thus create malfunctions. This effect is particularly critical in modern machines, with CAN Bus communications, which are spread everywhere on the truck and which carry critical information. 2) In the worst case and when the amount of charge is very high, the discharge process can determine failures in the electronic devices; the type of failure can vary from an intermittently malfunction to a completely failure of the electronic device. Three ways can be followed to prevent damages from ESD: 1) INSULATION: To prevent the controller from ESD, it is necessary to consider that the operator is most of the time the source of ESD. When it gets in touch with a device on the dashboard having metallic head terminal, the accumulated charge will be directed from the head terminal to the wires of the device towards the other units in the truck (e.g. the CAN Bus wires or the wires of the stepper motor on the dashboard could be the transmission mean). As consequence a huge inrush current will be generated getting the controller cut off or damaged.

To prevent ESD risk it is necessary to avoid that the devices connected to the CAN communication system have exposed metallic head terminals. The operator shall not get in touch with any metallic part of the devices CAN Bus connected.

2) GROUNDING: when a complete isolation cannot be achieved, a good grounding can divert the discharge current trough a “safe” path; the frame of a truck can work like a “local earth ground”, absorbing excess charge.

It is strongly suggested to connect to the truck frame all the parts of the truck that can get in touch with the operator (who is most of the time the source of ESD). For example, we strongly suggest to connect the stepper motor frame to the truck frame.

3) PREVENTION: Another important issue is the storing and handling of ESDsensitive electronic parts. Then, ensure the operator is grounded; test grounding devices on a daily basis for correct functioning. This precaution is particularly important during controller handling in the storing and installation phase. Use anti-static containers when transferring ESD-sensitive material.

8.10 Fighting the dither In Closed Loop application with potentiometers, the quantum nature of the Analog to Digital conversion, generates dither on the steered wheel. This is a continuous rolling of the steered wheel from a little bit right to a little bit left around the commanded position. Obviously, both the potentiometers (SP POT and FB POT) have noise and contribute to the problem. There are some countermeasures to reduce or neutralize the dither.

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1) Use shielded cable for the connections of the potentiometers (especially for the SP POT). The shielded cable reduces the noise in the wiper voltage. Connect the shield to a GND pin of the eps-ac0 connectors. 2) Use the FB ENC instead of the FB POT as feedback sensor. The Encoder has not noise. When the Encoder is stopped in a position, the Encoder counting is absolutely constant. 3) Reduce the gain of the Closed Loop. It means KP and POS. ACCURACY parameters must be decreased. When the gain reduces, the modification of the position error due to noise, are less amplified giving less dither; but less accuracy is got in the final pursuing at the wished position.

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9 DESCRIPTION OF THE CONNECTORS

W V

-B

CNC

EPS-AC0

CNB

CNA

7 14

Figure 9–1

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9.1 Connectors of the logic

CNC

CNB

CNA

7 14

Figure 9–2

9.1.1 CNA connector A1

DRIVE SWITCH Traction Travel Demand Input.

SW2

2nd Toggle Switch or Left Limit Switch (LLS).

SW1

1st Toggle Switch or Right Limit Switch (RLS).

NK1

Safety Switch Lower Voltage Point.

Safety Switch Higher Voltage Point.

CANL

Can Bus Low.

KEY

Key in (24-36 Vbatt).

CPOC2 / QL

2nd SP POT Wiper or Stepper Motor Q line.

CPOC1 / DL

1st SP POT Wiper or Stepper Motor D line.

A10

NPOC

Twin SP POT Negative Supply (GND).

A11

GND

GND. Encoder Negative Supply

A12

GND

GND. SW1 & SW2 Negative.

A13

GND

GND. Motor Thermal Sensor Negative.

A14

CANH

Can Bus High.

9.1.2 CNB connector B1

NPOT

FB POT Negative Supply.

PPOT

FB POT Positive Supply.

THMOT

Motor Thermal Sensor (KTY84-130) Input.

+5VDC

Encoder Positive Supply.

PPOC

Twin SP POT Positive Supply (5 Vdc).

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CPOT

FB POT Wiper.

CHB

Encoder Channel B.

CHA

Encoder Channel A.

9.1.3 CNC connector

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PCLRXD

Positive serial reception.

NCLRXD

Negative serial reception.

PCLTXD

Positive serial transmission.

NCLTXD

Negative serial transmission.

GND

Negative console power supply.

+12

Positive console power supply.

FLASH

Must be connected to C8 for the Flash memory programming (if used).

FLASH

Must be connected to C7 for the Flash memory programming (if used).

AEMZP0BA - EPS-AC0 - User Manual

9.2 Description of power connections View of the power bars:

W V

-B

CNC

EPS-AC0

CNB

CNA

7 14

Figure 9–3

-B

Negative of the battery.

Positive of the battery.

U; V; W

Connection bars of the three motor phases; follow this sequence and the indication on the motor.

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10 INSTALLATION PROCEDURE As stated in the topic 4.5 there are two equipments that it is possible to adopt for the feedback sensor: 1) Encoder and Feedback pot. 2) Encoder and toggle switches. The standard handling in both cases consists in performing an automatic centering at key-on. The automatic centering at key-on is used to initialize the incremental encoder. When a straight-ahead switch is used to initialize the encoder, the steered wheel rotates automatically until an edge is detected on the straight ahead switch. When a Feedback pot is used to initialize the encoder, the steered wheel rotates automatically until the potentiometer reaches the straight-ahead position. On request, it is possible to avoid the automatic centering at key-on. In case of feedback pot, the feedback encoder counting will be initialized at key-on with the angle measured on the feedback pot; in case of the toggle switches, the truck speed will be limited until the driver rotates the steered wheel and an edge on the straight ahead switch is detected. Several feedback sensors and command sensor combinations are not described below. That is because they are not handled yet.

10.1 Twin Pot with Encoder and Feedback pot: one shot installation procedure This procedure is relative to the connecting drawings Figure 6-3. It describes the step by step installation procedure to get the prototype working in manual mode: to raise the AUTC function it is necessary to make the complete set-up procedure (see topic 11). For every truck released on the field, the default set-up shall reply the prototype settings and so no installation procedure is required except for the acquisition of the limiting position (see the quick set-up 11.2). Carry out the procedure in the following order. Step1 Connect the AC motor phases in such a way the phase references U, V, W on the steering motor correspond to the terminals references (U, V, W) on the eps-ac0. Step2 In the SET MODEL menu set the SYSTEM CONFIG setting to LEVEL 1 to steer in closed loop with a twin pot in manual mode (RTC). Turn off and on the key in order the setting is acquired. Step3 Set the FEEDBACK DEVICE to OPTION #1 to specify your feedback solution is the sole FEEDBACK POT. Switch off the key after the change. (It is necessary to start with the sole feedback pot to avoid a POSITION ERROR due to the unknown scaling between the encoder counting and the feedback pot value before of an encoder learning operation - Step 9 and 11 below). Step4 Set option ENCODER CONTROL to OFF. Step5 Connect the feedback pot in such a way the FEEDBACK POT reading in the tester menu assumes higher voltage when the FREQUENCY in the tester menu is positive. When a FB POT LOCKED alarm occurs immediately after switching on the key, it means the motor is turning away from the wished position (i.e. FEEDBACK POT decreases when the FREQUENCY is

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Step6 Step7

Step8 Step9 Step10 Step11 Step12

Step13

Step14

Step15

Step16 Step17

positive). Then it is necessary to swap the PPOT with NPOT (CNB#2 with CNB#1). Connect the encoder. The encoder supply is between CNB#4 (5Vdc) and CNA#11 (GND): the two channels are CNB#8 (CHA) and CNB#7 (CHB). Verify the reading ENC SPEED in the tester menu is consistent with the reading FREQUENCY in the tester menu. Consistent means that ENC SPEED and FREQUENCY must have the same sign and a close value. If ENC SPEED has a wrong sign, swap CHA (CNB#8) with CHB (CNB#7). If ENC SPEED is not close to FREQUENCY, the encoder resolution is wrong and a different SW is needed (see 12.4.7.12 and 12.4.7.8). If the motor runs well without glitches, it is possible to stays with ENCODER CONTROL to OFF; otherwise, turn ENCODER CONTROL to ON. Verify the steered wheel rotates in the correct direction according to the hand wheel. If it isn’t, swap CPOC1 (CNA#9) with CPOC2 (CNA#8). Set the LIMIT DEVICE option to OFF to avoid the maximum angle limitations. Set NUMBNESS parameters to Level 0. Move the hand wheel until the maximum (plus 90 degrees) steered wheel angle is achieved (Increase 1ST ANGLE COARSE - and FINE - if necessary). This position (plus 90 degrees) corresponds to the maximum value of the FEEDBACK POT reading in the TESTER menu. With the steered wheel in the maximum angle (plus 90 degrees), enter and save the adjustment SET MAX FB POT on the hand set to memorize the steer angle feedback pot voltage for the maximum (plus 90 degrees) limit position. If present, the maximum of the FB ENC is recorded too (although it is not shown in the hand set). Move the steering wheel until the minimum (minus 90 degrees) steered wheel angle is achieved (Increase 2ND ANGLE COARSE - and FINE - if necessary). This position (minus 90 degrees) corresponds to the minimum value of the FEEDBACK POT reading in the TESTER menu. With the steered wheel in the minimum angle (minus 90 degrees), enter and save the adjustment SET MIN FB POT on the hand set to memorize the steer angle feedback pot voltage for the minimum (minus 90 degrees) limit position. If present, the minimum of the FB ENC is recorded too (although it is not shown in the hand set). Set FEEDBACK DEVICE to OPTION#2 (feedback pot plus feedback encoder) and recycle the key to enable the steering by encoder. Carry out the complete set-up procedure (see 11.1).

10.2 Twin Pot with Encoder, Straight Ahead Switch and Feedback pot: one shot installation procedure This procedure is relative to a feedback sensor arrangement consisting of a straight ahead switch, together with the feedback potentiometer and the encoder. This configuration is not much spread. It is useful to have a redundancy in the initialization of the encoder (without straight ahead switch, the feedback encoder is initialized by using the feedback pot only) and a better precision in the straight ahead matching (the feedback pot mounting normally has a dead zone). It describes the step by step installation procedure to get the prototype working in manual mode: to raise the AUTC function it is necessary to make the complete set-up procedure (see topic 11).

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For every truck released on the field, the default set-up shall reply the prototype settings and so no installation procedure is required except for the acquisition of the limiting position (see the quick set-up 11.2). Carry out the procedure in the following order. Step1 Connect the AC motor phases in such a way the phase references U, V, W on the steering motor correspond to the terminals references (U, V, W) on the eps-ac0. Step2 In the SET MODEL menu set the SYSTEM CONFIG setting to LEVEL 1 to steer in closed loop with a twin pot in manual mode (RTC). Turn off and on the key in order the setting is acquired. Step3 Set the FEEDBACK DEVICE to OPTION #1 to specify your feedback solution is the sole FEEDBACK POT. Switch off the key after the change. (It is necessary to start with the sole feedback pot to avoid a POSITION ERROR due to the unknown scaling between the encoder counting and the feedback pot value before of an encoder learning operation - Step 13 and 15 below). Step4 Set option ENCODER CONTROL to OFF. Step5 Connect the feedback pot in such a way the FEEDBACK POT reading in the tester menu assumes higher voltage when the FREQUENCY in the tester menu is positive. When a FB POT LOCKED alarm occurs immediately after switching on the key, it means the motor is turning away from the wished position (i.e. FEEDBACK POT decreases when the FREQUENCY is positive). Then it is necessary to swap the PPOT with NPOT (CNB#2 with CNB#1). Step6 Connect the encoder. The encoder supply is between CNB#4 (5 Vdc) and CNA#11 (GND): the two channels are CNB#8 (CHA) and CNB#7 (CHB). Step7 Verify the reading ENC SPEED in the tester menu is consistent with the reading FREQUENCY in the tester menu. Consistent means that ENC SPEED and FREQUENCY must have the same sign and a close value. If ENC SPEED has a wrong sign, swap CHA (CNB#8) with CHB (CNB#7). If ENC SPEED is not close to FREQUENCY, the encoder resolution is wrong and a different SW is needed (see 12.4.7.12 and 12.4.7.8). Step8 If the motor runs well without glitches, it is possible to stays with ENCODER CONTROL to OFF; otherwise, turn ENCODER CONTROL to ON. Step9 Verify the steered wheel rotates in the correct direction according to the hand wheel. If it isn’t, swap CPOC1 (CNA#9) with CPOC2 (CNA#8). Step10 Set the LIMIT DEVICE option to OFF to avoid the maximum angle limitations. Step11 Set NUMBNESS parameters to Level 0. Step12 Move the hand wheel until the maximum (plus 90 degrees) steered wheel angle is achieved (Increase 1ST ANGLE COARSE - and FINE - if necessary). This position (plus 90 degrees) corresponds to the maximum value of the FEEDBACK POT reading in the TESTER menu. Step13 With the steered wheel in the maximum angle (plus 90 degrees), enter and save the adjustment SET MAX FB POT on the hand set to memorize the steer angle feedback pot voltage for the maximum (plus 90 degrees) limit position. If present, the maximum of the FB ENC is recorded too (although it is not shown in the hand set). Step14 Move the steering wheel until the minimum (minus 90 degrees) steered wheel angle is achieved (Increase 2ND ANGLE COARSE - and FINE - if necessary). This position (minus 90 degrees) corresponds to the minimum value of the FEEDBACK POT reading in the TESTER menu. Step15 With the steered wheel in the minimum angle (minus 90 degrees), enter and save the adjustment SET MIN FB POT on the hand set to memorize the steer angle feedback pot voltage for the minimum (minus 90 degrees) limit Page - 44/95

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Step16

Step17

Step18

Step19

position. If present, the minimum of the FB ENC is recorded too (although it is not shown in the hand set). Set FEEDBACK DEVICE to OPTION#3 (feedback pot, feedback encoder and straight ahead toggle switch) and recycle the key to enable the steering by encoder. When FEEDBACK DEVICE is OPTION #3, it is necessary to seek a falling edge on the SW1 (CNA#3) corresponding at the straight ahead position. This is done by moving the steered wheel toward a falling edge of the straight ahead switch. Depending by the shape of the iron plate to act the straight ahead sensor, the falling edge may occur either in a CW or in a CCW rotation. If the iron plate in your arrangement generates a sole rising edge in present steering direction, it is possible to reverse the turning direction of the steered wheel during the initial alignment. To do that an OPTIONS called POT UP SW1 EDGE is supplied. When it is ON, the steered wheel seeks the falling edge during an initial automatic rotation in the direction of an increasing FB POT. When it is OFF, the steered wheel seeks the falling edge during an initial automatic rotation in the direction of a decreasing FB POT. (A properly setting of POT UP SW1 EDGE is required to avoid EPS NOT ALIGN alarm). When FEEDBACK DEVICE is OPTION #3, it is necessary to autoacquire the FB POT value at the matching with the falling edge on the straight ahead switch (SW1). To do that, enter the SET FBPOT AT SW1 setting in the adjustments menu. Save and recycle the key. After the acquisition, the SET FBPOT AT SW1 value should be close to the 2.5 V value; otherwise it is necessary to re-make the FB POT mounting in such a way its wiper is close to 2.5 V at the matching with the falling edge on SW1. Carry out the complete set-up procedure (see 11.1).

10.3 Stepper Motor with Encoder and Feedback pot: one shot installation procedure This procedure is relative to the connecting drawings Figure 6-2. It describes the step by step installation procedure to get the prototype working in manual mode: to raise the AUTC function it is necessary to make the complete set-up procedure (see topic 11). For every truck released on the field, the default set-up shall reply the prototype settings and so no installation procedure is required except for the acquisition of the limiting position (see the quick set-up 11.2). Carry out the procedure in the following order. Step1 Connect the AC motor phases in such a way the phase references U, V, W on the steering motor correspond to the terminals references (U, V, W) on the eps-ac0. Step2 In the SET MODEL menu set the SYSTEM CONFIG setting to LEVEL 0 to steer in open loop with a stepper motor in manual mode. Turn off and on the key in order the setting is acquired. Step3 Set the FEEDBACK DEVICE to OPTION #1 to specify your feedback solution is the sole FEEDBACK POT. Switch off the key after the change. (It is necessary to start with the sole feedback pot to avoid a POSITION ERROR due to the unknown scaling between the encoder counting and the feedback pot value before of an encoder learning operation - Step 12 and 14 below). Step4 Set option ENCODER CONTROL to OFF.

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Step5 Connect the feedback pot in such a way the FEEDBACK POT reading in the tester menu assumes higher voltage when the FREQUENCY in the tester menu is positive. When a FB POT LOCKED alarm occurs immediately after switching on the key, it means the motor is turning away from the wished position (i.e. FEEDBACK POT decreases when the FREQUENCY is positive). Then it is necessary to swap the PPOT with NPOT (CNB#2 with CNB#1). Step6 Connect the encoder. The encoder supply is between CNB#4 (5 Vdc) and CNA#11 (GND): the two channels are CNB#8 (CHA) and CNB#7 (CHB). Step7 Verify the reading ENC SPEED in the tester menu is consistent with the reading FREQUENCY in the tester menu. Consistent means that ENC SPEED and FREQUENCY must have the same sign and a close value. If ENC SPEED has a wrong sign, swap CHA (CNB#8) with CHB (CNB#7). If ENC SPEED is not close to FREQUENCY, the encoder resolution is wrong and a different SW is needed (see 12.4.7.12 and 12.4.7.8). Step8 If the motor runs well without glitches, it is possible to stays with ENCODER CONTROL to OFF; otherwise, turn ENCODER CONTROL to ON. Step9 Verify the steered wheel rotates in the correct direction according to the hand wheel. If it isn’t, swap DL (CNA#9) with QL (CNA#8). Step10 Set the LIMIT DEVICE option to OFF to avoid the maximum angle limitations. Step11 Turn the steering wheel until the maximum (plus 90 degrees) steered wheel angle is achieved. This position (plus 90 degrees) corresponds to the maximum value of the FEEDBACK POT reading in the TESTER menu. Step12 With the steered wheel in the maximum angle (plus 90 degrees), enter and save the adjustment SET MAX FB POT on the hand set to memorize the steer angle feedback pot voltage for the maximum (plus 90 degrees) limit position. If present, the maximum of the FB ENC is recorded too (although it is not shown in the hand set). Step13 Turn the steering wheel until the minimum (minus 90 degrees) steered wheel angle is achieved. This position (minus 90 degrees) corresponds to the minimum value of the FEEDBACK POT reading in the TESTER menu. Step14 With the steered wheel in the minimum angle (minus 90 degrees), enter and save the adjustment SET MIN FB POT on the hand set to memorize the steer angle feedback pot voltage for the minimum (minus 90 degrees) limit position. If present, the minimum of the FB ENC is recorded too (although it is not shown in the hand set). Step15 Set FEEDBACK DEVICE to OPTION#2 (feedback pot plus feedback encoder) and recycle the key to enable the steering by encoder. Step16 Carry out the complete set-up procedure (see 11.1).

10.4 Stepper Motor with Encoder and Toggle Switch(es): one shot installation procedure This procedure is relative to the connecting drawings Figure 6-2. It describes the step by step installation procedure to get the prototype working in manual mode: to raise the AUTC function it is necessary to make the complete set-up procedure (see topic 11). For every truck released on the field, the default set-up and wiring shall reply the prototype settings and so no installation procedure is required except for the acquisition of the limiting position (see the quick set-up 11.2). Carry out the procedure in the following order.

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Step1 Connect the AC motor phases in such a way the phase references U, V, W on the steering motor correspond to the terminals references (U, V, W) on the eps-ac0. Step2 In the SET MODEL menu set the SYSTEM CONFIG setting to LEVEL 0 to steer in open loop with a stepper motor in manual mode. Turn off and on the key in order the setting is acquired. Step3 Set the FEEDBACK DEVICE to OPTION #4 to specify your feedback solution is the encoder with one or two toggle switches. Switch off the key after the change. Step4 Turn the special adjustment DEBUG OUTPUT to Level 11 to inhibit the alarm POSITION ERROR and recycle the key. Step4 Set option ENCODER CONTROL to OFF. Step5 Connect the encoder. The encoder supply is between CNB#4 (5 Vdc) and CNA#11 (GND): the two channels are CNB#8 (CHA) and CNB#7 (CHB). Step6 Verify the reading ENC SPEED in the tester menu is consistent with the reading FREQUENCY in the tester menu. Consistent means that ENC SPEED and FREQUENCY must have the same sign and a close value. If ENC SPEED has a wrong sign, swap CHA (CNB#8 with CHB (CNB#7). If ENC SPEED is not close to FREQUENCY, the encoder resolution is wrong and a different SW is needed (see 12.4.7.12 and 12.4.7.8). Step7 If the motor runs well without glitches, it is possible to stays with ENCODER CONTROL to OFF; otherwise, turn ENCODER CONTROL to ON. Step8 Verify the steered wheel rotates in the correct direction according to the hand wheel. If it isn’t, swap DL (CNA#9) with QL (CNA#8). Step9 Set the LIMIT DEVICE option to OFF to avoid the maximum angle limitations. Step10 Detect the encoder counting corresponding to a steered wheel revolution. To do that, turn the steered wheel some revolutions in CW direction and read the ENC COUNT AT 360 in the tester menu. At every falling edge of the CNA#3 toggle switch (SW1), this reading is updated. It corresponds to the encoder counting for a complete revolution of the steered wheel. ENC COUNT AT 360 shows real time the encoder counting between two consecutive falling edges on the straight ahead toggle switch. The reading is scaled in the range 0 to ±5 V. 5 V corresponds to an encoder counting of 215 events. -5 V corresponds to an encoder counting of -215 events. To be sure the shown value is correct, turn the steered wheel some revolutions in the opposite direction. I expect the reading ENC COUNT AT 360 gets the same value but with opposite sign. Step11 Enter and save the adjustment SET ENC AT 360. The absolute value in the reading ENC COUNT AT 360 will be recorded on SET ENC AT 360. Step12 Recycle the key and turn the steered wheel to get the WHEEL ANGLE reading in the tester menu close to 0 degrees. Step13 Check the orientation of the steered wheel in the position having WHEEL ANGLE close to 0. If the steered wheel has not the wished orientation change AUX FUNCTION 11. If AUX FUNCTION 11 is set to Level 5, it is necessary to change to Level 4 or vice versa. If AUX FUNCTION 11 is set to Level 2, it is necessary to change to Level 3 or vice versa. Step14 Recycle the key. Now, when WHEEL ANGLE is null, the steered wheel must be oriented in the wished direction. Step15 Turn the steered wheel to have the reading WHEEL ANGLE close to +45 degrees (first sector). Read the ENDSTROKE CW and ENDSTROKE ACW in the tester menu. Set AUX FUNCTION 11 to the proper level as specified below: ENDSTROKE CW=OFF and ENDSTROKE ACW=OFF: Level 2 AEMZP0BA - EPS-AC0 - User Manual

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ENDSTROKE CW=OFF and ENDSTROKE ACW=ON: Level 3 ENDSTROKE CW=ON and ENDSTROKE ACW=OFF: Level 4 ENDSTROKE CW=ON and ENDSTROKE ACW=ON: Level 5 This setting is necessary to match the WHEEL ANGLE measurement (calculated through the encoder counting) with the sector determined with the toggle switches configuration (POSITION ERROR alarm in case of mismatching). Table 10-1 below shows the correct setting for AUX FUNCTION 11 vs. the toggle switches configuration in the first sector (WHEEL ANGLE inside the range 0 to 90 degrees). AUX FUNCTION 11

Toggle sw number

Level 0 Level 1 Level 2 Level 3 Level 4 Level 5

1 1 2 2 2 2

SW1 to CNA#3 H L H H L L

SW2 to CNA#2 NC NC H L H L

Table 10-1

Step16 Option AUTOCENTERING enables the automatic alignment at key-on together with the automatic centering operations. Step17 Option ORIENT THE WHEEL is used only when AUTOCENTERING is ON to specify the steered wheel orientation at the initial automatic alignment. It gets the steered wheel oriented at the straight ahead position (null WHEEL ANGLE) or to the 180 degrees position (depending by this setting). Step18 Parameters 1ST ANGLE COARSE and 2ND ANGLE COARSE set the maximum steered wheel angle respectively in the positive and negative WHEEL ANGLE. Set both of them to level 9 to avoid angle limitation. Lower setting limits the maximum angle in the range 80 degrees + Level*4degrees (e.g. Level 0 means limitation to 80 deg; Level 1 means limitation to 84 deg and so on). Step19 If there is not angle limitation, a refreshing of the steered wheel position is made on every edge of the CNA#3 straight ahead toggle switch provided that the absolute value of WHEEL ANGLE is less than 30 degrees. That mean the refreshing is performed for every edge of the straight ahead switch but only once per steered wheel revolution. If the angle is limited, a refreshing of the steered wheel position is made on every falling edge of the CNA#3. In the worst case a refresh is performed every 360 degrees. Step20 Don’t forget to turn the special adjustment DEBUG OUTPUT to level 15 after finished the setting procedure to enable the POSITION ERROR test between encoder counting and toggle switches sector. Recycle the key. Step21 Carry out the complete set-up procedure (see 11.1).

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11 SETTING THE EPS-AC0 11.1 Complete set-up description This procedure shall be executed on the prototype after the installation procedure is completed (see topic 10). The complete set-up changes vs. the truck configuration. Seek your own configuration below:

11.1.1 Stepper Motor only Step1 Set the SET SAT FREQ adjustment to the corner frequency of the steering motor (see 12.4.2.7). Step2 Set OVERSAT FREQ adjustment in order the sum between SET SAT FREQ and OVERSAT FREQ gives the wished maximum steering motor speed (see 12.4.2.8). Step3 Set the NO LOAD CURRENT adjustments to the current the motor drains when lightened at the maximum flux (see 12.4.2.10). Step4 Set the steer sensitivity with the SPEED LIMIT and SENSITIVITY parameters (see 12.4.4.1-2). Step5 Set AUTO REQ TYPE in the set model menu to level 0 (no automatic function). (See 12.4.3.2). Step6 (CAN Bused system only). Set the Dynamic Numbness in open loop (steering sensitivity reduces when the truck speed increases). Use parameters AUX FUNCTION#2 and AUX FUNCTION #3 (see 12.4.4.5-4). Step7 (No CAN Bused system only). Connect a traction travel demand to CNA#1. It can be a tiller switch (or a dead-man or a seat switch). This operation supplies the information the truck is moving or not to stand-by the steer when the truck is standing.

11.1.2 Stepper Motor & AUTC When the AUTC is required, it is necessary to carry out all the Steps in paragraph 11.1.1 together with the following: Step1 When the autocentering (AUTC) is required, it is necessary to contact a Zapi technician to decide the physical and the superior protocol layers for the AUTC demanding. (AUTC is a customized function that the eps-ac0 does not execute in its standard version). One possible arrangement for the AUTC request could be a via CAN bus demanded centering. Step2 Turn the truck in the automatic centering mode, drive the truck and roll up and down the adjustment SET STEER 0-POS until the truck is straight travelling. Step3 Set the parameters KP, POS. ACCURACY, LEAD FB REGULAT and LAG FB REGULAT to avoid overshoot or damping during the centering operation (see paragraph 12.4.4).

11.1.3 RTC (Twin Pot) only Step1 Set the SET SAT FREQ adjustment to the corner frequency of the steering motor (see 12.4.2.7). Step2 Set OVERSAT FREQ adjustment in order the sum between SET SAT FREQ and OVERSAT FREQ gives the wished maximum steering motor speed (see 12.4.2.8).

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Step3 Set the NO LOAD CURRENT adjustments to the current the motor drains when lightened at the maximum flux (see 12.4.2.10). Step4 Leave the handle steer in its straight position. Enter and Save the adjustment ZERO SP POT (see 12.4.2.16). This operation is used to automatically learn the twin pot voltage. Step5 Set AUTO REQ TYPE in the set model menu to level 0 (no automatic function). Step6 Leave the handle steer in its straight position. Drive the truck and roll up and down the adjustment SET STEER 0-POS until the truck is straight travelling. Step7 Set 1ST ANGLE COARSE (and FINE) to get the steered wheel position limited at +90 degrees when the SET POINT POT reading is maximum. This is the direction where the FEEDBACK ENC reading is higher than 2.5 Vdc. Step8 Set 2ND ANGLE COARSE (and FINE) to get the steered wheel position limited at -90 degrees when the SET POINT POT reading is minimum. This is the direction where the FEEDBACK ENC reading is lower than 2.5 Vdc. Step9 Try to adjust the NUMBNESS parameter to get the steer less sensitive when close to the straight ahead direction (see 12.4.4.17). (For every new NUMBNESS value, repeat the above Step7 and Step8). Step10 Try different settings for KP, POS. ACCURACY, LEAD FB REGULAT and LAG FB REGULAT to avoid overshoot or damping during the pursuing operation (see paragraph 12.4.4). Step11 (CAN Bused system only). Set the Dynamic Numbness in closed loop (steering sensitivity reduces when the truck speed increases). The parameters to handle this function are AUX FUNCTION#2 and AUX FUNCTION #3 (see 12.4.4.5-4). Step12 (No CAN Bused system only). Connect a traction travel demand to CNA#1. It can be a tiller switch (or a dead-man or a seat switch). This operation supplies the information the truck is moving or not to stand-by the steer when the truck is standing.

11.1.4 RTC & AUTC When the AUTC is required, it is necessary to carry out all the Steps in paragraph 11.1.3 together with the following: Step1 When the autocentering (AUTC) is required, it is necessary to contact a Zapi technician to decide the physical and the superior protocol layers for the AUTC demanding. (AUTC is a customized function that the eps-ac0 does not execute in its standard version). One possible arrangement for the AUTC request could be a via CAN bus demanded centering.

11.2 Quick set-up This procedure shall be executed on every manufactured truck. It changes with the configuration. We assume the default setting includes the correct value for SET ENC AT 360 in a configuration with feedback enc and toggle switches. When a configuration with the feedback pot is adopted, step 11 to step 15 in paragraph 10.3 are required too (acquisition of the limits).

11.2.1 Stepper Motor only No set-up required on a truck working open loop (stepper motor) in manual mode only.

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11.2.2 Stepper Motor & AUTC When the Automatic Centering (AUTC) is required on a truck working open loop in manual mode (stepper motor), it is necessary to guide the truck in automatic mode and to perform the following steps: Step1

Roll-up or down the adjustments SET STEER 0-POS to get the truck straight travelling when automatic centered.

11.2.3 RTC only or RTC & AUTC In a truck working closed loop in manual mode (with a Twin Pot connected on the Return To Center handlebar) with or without the AUTC function, it is necessary to perform the following steps: Step1 Step2

Release the handlebar in its straight-ahead rest position and acquire the adjustments ZERO SP POT (to record the rest twin pot voltage). Roll-up or down the adjustments SET STEER 0-POS to get the truck straight travelling when the handlebar is straight ahead.

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12 PROGRAMMAING & ADJUSTMENTS USING DIGITAL CONSOLE 12.1 Adjustments via console Adjustment of Parameters and changes to the inverter’s configuration are made using the Digital Console. The Console is connected to the CNC connector of the inverter.

12.2 Description of console (hand set) & connection

Figure 12–1

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12.3 Description of standard console menu Digital consoles used to communicate with AC inverter controllers must be fitted with EPROM CK ULTRA, minimum "Release Number 3.02". The section describes the Zapi hand set functions. Numbers inside the triangles correspond to the same number on the hand set keyboard buttons shown in the Figure 12-1. The orientation of the triangle indicates the way to the next function.

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12.3.1 Stepper motor with Encoder and Feedback pot

Figure 12–2

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12.3.2 RTC with Encoder and Feedback pot

Figure 12–3

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12.3.3 Stepper motor with Encoder and Toggle switch(es)

Figure 12-4

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12.4 Function configuration The functions list change with the settings SYSTEM CONFIG and FEEDBACK DEVICE (see 12.4.3.1 and 12.4.1.3). In particular, we will distinguish between the configuration with stepper motor against the one with RTC in the hand wheel: besides we distinguish between the configuration with the encoder plus toggle switches against the one with the encoder plus potentiometer as feedback sensor. In the next we refer to a complete list that is the union of the settings in the above configurations. When the setting refers to only one configuration, it will be specified in the description.

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12.4.1 Config menu “SET OPTIONS” functions list To enter the CONFIG MENU it is necessary to push in the same time the right side top and left side top buttons. Then roll until the SET OPTION item appears on the hand set display. Push the ENTER button (see Figure 12-5). EPSAC0 S ZP0.70 24V 50A 00000

Opening Zapi Display Push ROLL UP + SET UP simultaneously to enter CONFIG MENU

% ' % ' ' ' CONFIG MENU SET MODEL

The Display will show : SET MODEL Press ROLL UP or ROLL DOWN button until SET OPTIONS menu appear The Display will show : SET OPTIONS

% ' ' ' ' ' CONFIG MENU SET OPTIONS ' % ' ' ' '

Press ENTER to go in the SET OPTIONS MENU The Display will show the first OPTION

HOURCOUNTER RUNNING

Press SET UP or SET DOWN button in order to modify the OPTION The Display will show the new option

' ' % ' ' % HOURCOUNTER KEYON ' ' ' ' % '

Press OUT to exit the menu The Display will ask “ARE YOU SURE?”

ARE YOU SURE? YES=ENTER NO=OUT

Press ENTER for YES, or OUT for No

' % ' ' ' '

The Display will show : SET OPTIONS Press OUT again. Display now will show the opening Zapi menu

' ' ' ' % '

CONFIG MENU SET OPTIONS ' ' ' ' % '

Figure 12–5

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1) HOUR COUNTER This option specifies the hour counter mode. It can be set one of two: - RUNNING: The counter registers travel time only. - KEY ON: The counter registers when the "key" switch is closed. 2) MICRO CHECK This option is useful to support debug and troubleshooting. It makes possible to inhibit the supervisor (Slave uC) operations and allows the system to run with just the Main uC. When entering this operating mode the safety contacts stay open. Therefore, traction shall be disabled. It can be set one of two: - PRESENT: Default setting: enable the operations of the supervisor (Slave uC). - ABSENT: Disable the operations of the supervisor (Slave uC). The safety contacts stay opened. 3) FEEDBACK DEVICE This option specifies which kind of Feedback Sensor is adopted. Here is the feedback sensor list: - OPTION #1: FB POT only. The only feedback sensor is the potentiometer at the steered wheel. This setting must be temporary chosen for the set-up of the FB ENC & FB POT configuration (see below). After the set-up is ended, it is necessary to turn FEEDBACK DEVICE to OPTION #2 to get the steer working with FB ENC & FB POT. - OPTION #2: FB POT & FB ENC. This is the right setting when the encoder is chosen together with the FB POT. Pay attention, the set-up must be done with the FEEDBACK DEVICE to OPTION #1. When the setup is finished, turn to OPTION #2. When the FEEDBACK DEVICE is OPTION #2 an automatic centering is always carried out at key-on. - OPTION #3: FB POT & FB ENC & ONE TOGGLE SWITCH This is the right setting when the encoder is chosen together with the FB POT and a straight ahead toggle switch (SW1). Pay attention, the set-up must be done with the FEEDBACK DEVICE to OPTION #1. When the set-up is finished, turn to OPTION #3. When the FEEDBACK DEVICE is OPTION #3 an automatic centering is always carried out at key-on. - OPTION #4: FB ENC & ONE (or TWO) TOGGLE SWITCHES This is the right setting when the FB POT is not present and two toggle switches are adopted (normally in the straight and 90 degrees angled positions of the steered wheel). At key on, an Automatic Centering operation is executed seeking the Toggle Switch signal (SW1 on CNA#3). When the Toggle Switch edge is met the Encoder counter is zeroed. The 2nd Switch (SW2 on CNA#2) is used to verify the encoder counter at 90° is matched with the SW2 transition. 4) LIMIT DEVICE (Versions with FEEDBACK DEVICE to OPTION #1, 2, 3 only). When this option is set ON, the steered wheel angle will be limited using the feedback sensor value. It can be set one of two: - ON: When the feedback sensor overtakes either the CW or the CCW limit (see 12.4.2.13-14, SET MAX FB POT, SET MIN AEMZP0BA - EPS-AC0 - User Manual

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OFF:

FB POT), the steered wheel angle shall be automatically limited. No steered wheel angle limitation, based on the feedback sensor value, occurs.

Note: the configurations without toggle switches (FB POT only and FB POT & FB ENC) may use the switches connected to CNA#3 and CNA#2 as CW and CCW limiting requests. Then, the limitation through the feedback device and the limitation through the limiting switches are processed with an OR Logic. 5) AUTOCENTERING (Versions with FEEDBACK DEVICE to OPTION #4 only). When this option is set ON, the controller performs an automatic centering at key-on and enables the function to operate an automatic centering on demand. Set AUTOCENTERING to OFF if the automatic centering function is not required. 6) DIRECTION GAUGE Not used. 7) AUX FUNCTION 1 This option sets the steering mode after the feedback sensor has reached the commanded position (it is used only in closed loop configurations (i.e. RTC and automatic centering)). It can be set one of three: - LEVEL 0: The steering control is always active when a travel demand is active. The steer control is turned off when the travel demands are deactivated (after a 3 sec delay). - LEVEL 1: The steering control is alternatively turned off (15 secs long plus the AUXILIARY TIME) and on (3 secs long). - LEVEL 2: The steering control is alternatively turned off (15 secs long plus the AUXILIARY TIME) and on (3 secs long) but only when a travel demand is active. AUXILIARY TIME is the delay (in secs) the DC standing current takes to arrive to 0 (see 12.4.4.11). 8) DIAG MOTOR TEMP This option enables the diagnosis of the motor temperature. When it is set On and the motor temperature overtakes 150°, a MOTOR TEMPERAT alarm occurs. The KTY84-130 motor thermal sensor must be connected between CNB#3 and a minus battery (CNA#13). 9) AUX FUNCTION 11 (only when FEEDBACK DEVICE is OPTION #4). Option AUX FUNCTION 11 specifies the number of toggle switches (one or two) and defines the correspondence between the levels of the toggle switches and the steer sector (quadrant). Set AUX FUNCTION 11 to the proper Level following table 10-1 (see 10.4). The proper level must be meant as the one meeting the configuration of the toggle switches in the first sector (WHEEL ANGLE between 0 and 90 degrees). 10) ENCODER CONTROL This option specifies if the motor is controlled via encoder or completely sensorless. Normally it is set OFF. When glitches are heard from the motor, it is necessary to turn to a sensored control. In this case set ENCODER CONTROL to On. Then, take care the encoder resolution used in the software (see 4.5.3) is Page - 60/95

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matched with the actual encoder resolution. 11) ORIENT THE WHEEL (only when FEEDBACK DEVICE is OPTION #4). Option ORIENT THE WHEEL is used only when AUTOCENTERING is ON to specify the steered wheel orientation at the initial automatic alignment. It gets the steered wheel oriented at the straight ahead position (null WHEEL ANGLE) or to the 180 degrees position (depending by this setting). 12) POT UP SW1 EDGE (only when FEEDBACK DEVICE is OPTION #3). It is possible to reverse the turning direction of the steered wheel during the initial alignment. To do that an OPTIONS called POT UP SW1 EDGE is supplied. When it is ON, the steered wheel seeks the falling edge during an initial automatic rotation in the direction of an increasing FB POT. When it is OFF, the steered wheel seeks the falling edge during an initial automatic rotation in the direction of a decreasing FB POT. (A properly setting of POT UP SW1 EDGE is required to avoid EPS NOT ALIGN alarm).

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12.4.2 Config menu “ADJUSTMENTS” functions list To enter the CONFIG MENU it is necessary to push in the same time the right side top and left side top buttons. Then roll until the ADJUSTMENTS item appears on the hand set display. Push the ENTER button (see the Figure 12-6 below). EPSAC0 S ZP0.70 24V 50A 00000

Opening Zapi Menu

Press Top Left & Right Buttons to enter CONFIG MENU

The Display will show: SET MODEL

Press ROLL UP button until ADJUSTMENTS MENU appears

ADJUSTMENTS appears on the display

Press ENTER to go into the ADJUSTMENTS MENU

The display will show:

Press ROLL UP or ROLL DOWN button until the desired parameter is reached

The desired parameter appears

% ' % ' ' ' CONFIG MENU SET MODEL % ' ' ' ' ' CONFIG MENU ADJUSTMENTS ' % ' ' ' ' ADJUSTMENT #01 LEVEL= 0 % ' ' % ' ' SET SAT. FREQ. 100HZ

10) Press SET UP or SET DOWN button to modify the adjustment

' ' % ' ' % SET SAT. FREQ. 110HZ

11) Press OUT

' ' ' ' % '

12) Press ENTER to confirm

' % ' ' ' '

13) Repeat the same from 5 to 12 points for the other adjustments Figure 12–6

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1) ADJUSTMENT #01 This setting is used to acquire the motor resistance (see 13.1). 2) SET CURRENT This setting is factory adjusted to calibrate the ADJUSTMENT #03 and #04 below. 3) ADJUSTMENT #02 Motor resistance in milliohms. This is the resistance of the motor measured between two motor terminals. The motor resistance may be either self-acquired with the procedure 13.1 or may be set by rolling up or down this adjustment. 4) ADJUSTMENT #03 (Factory adjusted). Parameter to compensate for the gain of the current amplifier in phase W. 5) ADJUSTMENT #04 (Factory adjusted). Parameter to compensate for the gain of the current amplifier in phase V. 6) SET BATTERY TYPE Set this adjustment to the nominal battery voltage. Pay attention, never set SET BATTERY TYPE higher than 36 V for a 24/36 V controller. 7) SET SAT. FREQ. Set this adjustment to the corner frequency of the motor. SET SAT FREQ is to be meant as the maximum frequency at which the motor supplies the maximum torque (it is the superior limit of the constant torque characteristic). Frequency higher than SET SAT FREQUENCY gets the motor weakened. 8) OVERSAT FREQ The maximum motor frequency is set with the sum between SET SAT FREQ and OVERSAT FREQ. OVERSAT FREQ is the increment, over the SET SAT FREQUENCY, in which the steering motor works with degraded flux (weakening area). Default choice is 1 Hz (i.e. the steering motor never works in the weakening region). 9) MAXIMUM SLIP (Factory adjusted). MAXIMUM SLIP modifies the acceleration and deceleration ramp for the frequency in the motor. Higher MAXIMUM SLIP gets faster acceleration and deceleration ramp. If the encoder is used for the motor control (ENCODER CONTROL is On), MAXIMUM SLIP has another meaning: it is the slip to be applied when the control is sourcing the maximum current. 10) NO LOAD CURRENT In order it shall be possible to weaken the steering motor when lightened (reducing power loss in the motor), it is necessary to specify the current the motor drains when working full flux and without load (NO LOAD CURRENT). To find this value it is necessary to set the DEBUG OUTPUT to level 10 (see 12.4.6.4) and to measure the current in the motor when running without load and a frequency close to SET SAT FREQ/2. 11) AUX VOLTAGE #1 (Factory adjusted). This is the self-acquired offset value of the stepper motor line connected to CNA#9. The default value is 2.500 mV and can be re-acquired AEMZP0BA - EPS-AC0 - User Manual

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by rolling the DEBUG OUTPUT to 0 (see 12.4.6.4). 12) AUX VOLTAGE #2 (Factory adjusted). This is the self-acquired offset value of the stepper motor line connected to CNA#8. The default value is 2.500 mV and can be re-acquired by rolling the DEBUG OUTPUT to 0 (see 12.4.6.4). 13) SET MIN FB POT (Versions with FB POT only). This adjustment is used to self-acquire (see 10.3 and 10.4) the feedback pot value and the encoder counting corresponds to the limiting position having the FEEDBACK POT reading lower than 2.5V (typically 90 degrees). If the option LIMIT DEVICE is set On, the steered wheel angle will be limited when the FEEDBACK POT reading is lower than SET MIN FB POT value. 14) SET MAX FB POT (Versions with FB POT only). This adjustment is used to self-acquire (see 10.3 and 10.4) the feedback pot value and the encoder counting corresponds to the limiting position having the FEEDBACK POT reading higher than 2.5 V (typically +90 degrees). If the option LIMIT DEVICE is set On, the steered wheel angle will be limited when the FEEDBACK POT reading is higher than SET MAX FB POT value. 15) SET ENC AT 360 (Versions with FEEDBACK DEVICE to OPTION #4 only). This adjustment is used to self-acquire (see 10.4) the encoder counting corresponding to a complete steered wheel revolution. It is used in the arrangements using the FB ENC and Toggle switches to properly scale the encoder counting with the steered wheel angle (WHEEL ANGLE). 16) ZERO SP POT (RTC version only). This adjustment is used to self-acquire (see 11.1.3 and 11.2.3) the voltages on the twin potentiometers when the steer handle is released in its straight ahead position. Just push the enter button with a released steer handle to record the new ZERO SP POT value. 17) SET STEER 0-POS Although ZERO SP POT was acquired, it is possible the steer handle is released but the steered wheel is not straight-ahead yet. This offset can be compensated through this adjustment. It must be set to the FEEDBACK ENC value corresponding to a perfectly straight-ahead steered wheel. This setting is used for manual mode RTC and AUTC. SET STEER 0-POS may be rolled up or down in 5 mV steps. 18) SET FBPOT AT SW1 (Versions with FEEDBACK DEVICE to OPTION #3 only). Reading READ FBPT AT SW1 provides the FB POT value at the initial matching with the falling edge on the straight ahead switch (SW1). By entering adjustment SET FBPOT AT SW1, its value changes to the value of reading READ FBPOT AT SW1 (i.e. the READ FBPO AT SW1 is recorded on SET FBPOT AT SW1). In normal condition, reading READ FBPT AT SW1 is expected to reply the SET FBPOT AT SW1 value. When a displacement exists between these two values, a POSITION ERROR alarm may occur (see 14.1.3.5).

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12.4.3 Config menu “SET MODEL” functions list To enter the CONFIG MENU it is necessary to push in the same time the right side top and left side top buttons. Then roll until the SET MODEL item appears on the hand set display. Push the ENTER button (see the Figure 12-7 below). EPSAC0 S ZP0.70 24V 50A 00000

Opening Zapi Menu

Press Top Left & Right Buttons to enter CONFIG MENU

The Display will show: SET MODEL

Press ENTER to go into the SET MODEL MENU

The display will show:

Press ROLL UP or ROLL DOWN button until the desired parameter is reached

The desired parameter appears

Press SET UP or SET DOWN button to modify the adjustment

% ' % ' ' ' CONFIG MENU SET MODEL ' % ' ' ' ' SYSTEM CONFIG LEVEL= 0 % ' ' % ' ' MODEL TYPE. 0 ' ' % ' ' % MODEL TYPE. 1

' ' ' ' % '

Press OUT

' % ' ' ' '

10) Press ENTER to confirm 11) Repeat the same from 5 to 10 points for the other adjustments Figure 12–7

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1) SYSTEM CONFIG Level 0 to 6. This setting is used to select the steer configuration (i.e. the open or closed loop mode and the type of command sensors) in the following combination list.

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LEVEL 0:

LEVEL1:

LEVEL 2:

LEVEL 3:

LEVEL 4:

Stepper motor with feedback sensor. This is an open loop configuration. The stepper motor is used as a tachogenerator to supply the wished steering motor speed. The feedback sensor is not strictly necessary in open loop configuration; in spite of that, this setting specifies the feedback sensor is present and it will be used for the automatic function (AUTC), maximum angle limitation, detection of the locked motor and to perform the alignment at the rest position. The FEEDBACK DEVICE option (see 12.4.1.3) specifies which kind of feedback sensor is adopted. Twin pot with feedback sensor. This is a closed loop configuration. The twin pot supplies the commanded position for the steered wheel. The feedback sensor is mandatory to close the loop with the commanded position. The twin pot is a double potentiometer with complementary action (see 4.4.2). The FEEDBACK DEVICE option (see 12.4.1.3) specifies which kind of feedback sensor is adopted. Via CAN demanded-speed with feedback sensor. This is an open loop configuration. A remote unit provides the wished steering motor speed via CAN Bus. The feedback sensor is not strictly necessary in open loop configuration; in spite of that, this setting specifies the feedback sensor is present and it will be used for the automatic function (AUTC), maximum angle limitation, detection of the locked motor and to perform the alignment at the rest position. The FEEDBACK DEVICE option (see 12.4.1.3) specifies which kind of feedback sensor is adopted. Via CAN demanded-position with feedback sensor. This is a closed loop configuration. A remote unit provides the commanded position for the steered wheel via CAN Bus. The feedback sensor is mandatory to close the loop with the commanded position. The FEEDBACK DEVICE option (see 12.4.1.3) specifies which kind of feedback sensor is adopted. Stepper motor without feedback sensor. This is an open loop configuration. The stepper motor is used as a tachogenerator to supply the wished steering motor speed. As the feedback sensor is not strictly necessary in open loop mode, it is possible to work without feedback sensor at all. In spite of that, when the maximum angle limitation via feedback sensors is enabled (option LIMIT DEVICE to ON when FEEDBACK DEVICE is OPTION #1,2,3; 1ST ANGLE COARSE and 2ND ANGLE COARSE less than level 9 when FEEDBACK DEVICE is OPTION #4), the feedback sensor is expected to perform the secondary functions of maximum angle limitation, detection of the locked motor and to perform the alignment at the rest position. When these conditions are met, the FEEDBACK DEVICE option (see 12.4.1.3) specifies which kind of feedback sensor is adopted for the secondary AEMZP0BA - EPS-AC0 - User Manual

functions. With this choice, the automatic functions are inhibited (the AUTC function isn’t possible). - LEVEL 5: Single pot with feedback sensor. This is a closed loop configuration. The single pot supplies the commanded position for the steered wheel. The feedback sensor is mandatory to close the loop with the commanded position. This choice is just for testing a prototype before to gather a twin pot; we strongly advice against using this configuration for the field production. The FEEDBACK DEVICE option (see 12.4.1.3) specifies which kind of feedback sensor is adopted. - LEVEL 6: Via CAN demanded speed without feedback sensor. This is an open loop configuration. A remote unit provides the wished steering motor speed via CAN Bus. As the feedback sensor is not strictly necessary in open loop mode, it is possible to work without feedback sensor at all. In spite of that, when the maximum angle limitation via feedback sensors is enabled (option LIMIT DEVICE to ON when FEEDBACK DEVICE is OPTION #1-2-3; 1ST ANGLE COARSE and 2ND ANGLE COARSE less than level 9 when FEEDBACK DEVICE is OPTION #4), the feedback sensor is expected to perform the secondary functions of maximum angle limitation, detection of the locked motor and to perform the alignment at the rest position. When these conditions are met, the FEEDBACK DEVICE option (see 12.4.1.3) specifies which kind of feedback sensor is adopted for the secondary functions. With this choice, the automatic functions are inhibited (the AUTC function isn’t possible). In the above list, the configurations with the command via CAN Bus may be developed only if the communication protocol between eps-ac0 and remote unit is known. 2) AUTO REQ TYPE Level 0 to 9. This setting specifies the type of the automatic request. The standard version foresees no automatic function so this setting is ineffective. The only exception is the configuration FEEDBACK DEVICE to OPTION #4 (encoder and toggle switches). Then the automatic centering is regulated with the option AUTOCENTERING (see 12.4.1.5). AUT REQ TYPE will be handled time to time according the automatic function customer’s specification. 3) CONNECTED TO It assumes a number between 0 to 255. This setting is used to (virtually) connect the hand-set to a remote unit CAN Bus connected. With the hand-set connected to the eps-ac0 it is possible to communicate with a remote Zapi unit. Every Zapi unit has its own identification number (e.g. eps-ac0 is 6; traction controller is 2; pump controller is 1). By setting CONNECTED TO to 2, the hand set will be virtually connected to the traction controller. 4) MODEL TYPE It assumes a number between 0 to 3. This setting is used to specify which one local elaboration unit must be virtually connected to the hand-set. In fact eps-ac0 has two uCs aboard. When MODEL TYPE is set to 0, the hand set is communicating with the main uC; when MODEL TYPE is set to 1, the hand set is communicating with the slave uC. AEMZP0BA - EPS-AC0 - User Manual

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12.4.4 Main menu “PARAMETER CHANGE” functions list To enter the MAIN MENU it is just necessary to push the ENTER button from the home display in the hand set. EPSAC0 S ZP1.93 24V 50A 00000

Opening Zapi Menu

Press ENTER to go into the General Menu

The Display will show: PARAMETER CHANGE

Press ENTER to go into the Parameter Change facility

The Display will show the first parameter

Press either ROLL UP and ROLL DOWN to display the next parameter

% ' ' % ' '

The names of the Parameters appear on the Display

SENSITIVITY LEVEL = 0

When desired Parameter appear, it’s possible to change the Level by pressing either SET UP or SET DOWN buttons.

The Display will show the new level

' % ' ' ' ' MAIN MENU PARAMETER CHANGE ' % ' ' ' ' SPEED LIMIT LEVEL = 7

' ' % ' ' % SENSITIVITY LEVEL = 1

10) When you are satisfied with the result of the changes you have made, press OUT

' ' ' ' % ' ARE YOU SURE? YES=ENTER NO=OUT

11) The Display asks: “ARE YOU SURE?” 12) Press ENTER to accept the changes, or press OUT to discard them

' ' ' ' % ' MAIN MENU PARAMETER CHANGE

13) The Display will show Figure 12–8

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1) SPEED LIMIT (Stepper Motor version only). Level 0 to 9. It determines the scaling factor between the speed of the steering wheel and the speed of the steering motor but only when the steering wheel is fast turning. By increasing the SPEED LIMIT value, the steering motor speed increases too. In practice, it sets the maximum motor speed when the steering wheel is fast turning. 2) SENSITIVITY (Stepper Motor version only). Level 0 to 9. It determines the scaling factor between the speed of the steering wheel and the speed of the steering motor but only when the steering wheel is slow turning. By increasing the SENSITIVITY value, the steering motor speed increases too. In practice, it changes the sensitivity of the steering wheel when it is slow turning. 3) CREEP SPEED Level 0 to 9. It sets a minimum amount of motor torque when the steering motor is slow turning. It is useful (together with the ANTIROLLBACK parameter, see 12.4.4.12) to neutralize the recall torque generated by the elastic tyre on the steered wheel. 4) AUX FUNCTION #3 Depending on the configuration, this parameter has different meaning. RTC version: Level 0 to 9. This setting performs the Dynamic Numbness compensation: it consists of a reduction in the steer sensitivity when the truck is driving at high speed. To get this goal, this setting adjusts the maximum angle at full truck speed. When the truck speed increases, the maximum steered wheel angle reduces proportionally. When the truck is full speed the steered wheel angle is limited to a percentage of the absolute maximum steered wheel angle (i.e. 90 degrees) specified with this setting. -

LEVEL 0:

Maximum steered angle at full truck speed is 73% (i.e. 66 degrees). - LEVEL 1: Maximum steered angle at full truck speed is 66% (i.e. 59 degrees). - LEVEL 2: Maximum steered angle at full truck speed is 59% (i.e. 53 degrees). - LEVEL 9: Maximum steered angle at full truck speed is 10% (i.e. 9 degrees). Each step has a weight of 7%. Stepper Motor version: Level 0 to 9. This setting performs the Dynamic Numbness compensation: it consists of a reduction in the steer sensitivity when the truck is driving at high speed. To get this goal, it is necessary to attenuate the scaling factor between the speed of the steering wheel and the speed of the steering motor. AUX FUNCTION #3 does that but only when the steering wheel is fast turning. This attenuation must be proportional to the drive speed. At full drive speed the attenuation of the scaling factor is maximum. AUX FUNCTION #3 to Level 0 means no attenuation of the scaling factor with the truck speed. AUX FUNCTION #3 to Level 9 means maximum attenuation of the scaling factor with the truck speed. Obviously, to perform the Dynamic Numbness compensation, it is necessary to know the drive speed and so the eps-ac0 must be CAN Bus connected. AEMZP0BA - EPS-AC0 - User Manual

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5) AUX FUNCTION #2 Depending on the configuration, this parameter has different meaning. RTC version: Level 0 to 9. This setting performs the Dynamic Numbness compensation: it consists of a reduction in the steer sensitivity when the truck is driving at high speed. To get this goal, this setting adjusts the percentage of the maximum truck speed, at which the steered angle reduction will start. Then for higher speed the steered angle reduction increases proportionally up to the above specified limit. -

LEVEL 0:

LEVEL 1:

LEVEL 2:

LEVEL 9:

max angle starts to reduce when the truck speed is 1% of the maximum speed. max angle starts to reduce when the truck speed is 12% of the maximum speed. max angle starts to reduce when the truck speed is 23% of the maximum speed. max angle starts to reduce when the truck speed is 100% of the maximum speed (No max angle reduction).

Each step has a weight of 11%. Stepper Motor version: Level 0 to 9. This setting performs the Dynamic Numbness compensation: it consists of a reduction in the steer sensitivity when the truck is driving at high speed. To get this goal, it is necessary to attenuate the scaling factor between the speed of the steering wheel and the speed of the steering motor. AUX FUNCTION #2 does that but only when the steering wheel is slow turning. This attenuation must be proportional to the drive speed. At full drive speed the attenuation of the scaling factor is maximum. AUX FUNCTION #2 to Level 0 means no attenuation of the scaling factor with the truck speed. AUX FUNCTION #2 to Level 9 means maximum attenuation of the scaling factor with the truck speed. Obviously, to perform the Dynamic Numbness compensation, it is necessary to know the drive speed and so the eps-ac0 must be CAN Bus connected. 6) KP Level 0 to 9. It is used to set the proportional contribution to a PID algorithm for RTC and AUTC functions. The proportional contribution is applied to the difference between the commanded position and the real position (steered wheel angle). The accuracy of the pursuing between commanded and real position increases if KP increases. It is used in closed loop applications. 7) POS. ACCURACY Level 0 to 9. It is used to set the proportional contribution to a PID algorithm for RTC and AUTC functions. The proportional contribution is applied to the difference between the commanded position and the real position (steered wheel angle). The accuracy of the pursuing between commanded and real position increases if POS. ACCURACY increases. POS. ACCURACY is used only for closed loop applications. KP and POS. ACCURACY are a coarse and a fine contribution to the same setting. 8) DYNAM NUMB ANG Level 0 to 9. This parameter handles the Dynamic Numbness vs. the Steering Error for RTC and AUTC functions. This functions applies a linear Page - 70/95

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correspondence between the steering motor speed and the angle error between the actual commanded position and the latest steady state position of the steered wheel: when this angle error is wider than the angle specified with this setting, there will be no clamp on the steering motor speed (full speed steering motor is SET SAT FREQ plus OVERSAT FREQ); when this angle error is smaller than 40% of the angle specified with this setting, the maximum Numbness will be applied. This parameter sets the angle, between the commanded position and the latest steady state position, at which the steering motor speed gets its maximum value (SET SAT FREQ plus OVERSAT FREQ). -

LEVEL 0:

No Numbness if the angle between tiller and latest steady state is higher than 5°. - LEVEL 1: No Numbness if the angle between tiller and latest steady state is higher than 11°. - LEVEL 2: No Numbness if the angle between tiller and latest steady state is higher than 17°. - LEVEL 9: No Numbness if the angle between tiller and latest steady state is higher than 60°. Each step has a weight of 6 degrees. 9) DYNAM NUMB SPEED Level 0 to 9. This parameter handles the Dynamic Numbness vs. the Steering Error for RTC and AUTC functions. This functions applies a linear correspondence between the steering motor speed and the angle error between the actual commanded position and the latest steady state position of the steered wheel. This parameter sets the percentage of the full steering motor speed is applied when in the full Dynamic Numbness. The full steering motor speed is the sum of the SET SAT FREQ and OVERSAT FREQ settings. When the angle between the actual commanded position and the latest steady state position is less than 40% of the DINAM NUMB ANG setting, the Full Dynamic Numbness vs. the Steering Error is applied and the steering speed is clamped to the DYNAM NUMB SPEED percentage below. -

LEVEL 0:

At full Dynamic Numbness, the steering motor frequency is clamped to 40% (maximum Numbness). - LEVEL 1: At full Dynamic Numbness, the steering motor frequency is clamped to 46%. - LEVEL 2: At full Dynamic Numbness, the steering motor frequency is clamped to 53%. - LEVEL 9: At full Dynamic Numbness, the steering motor frequency is clamped to 100% (no Numbness). Each step more has a weight of 6.6 %. 10) COMPENSATION Level 0 to 2. This parameter applies a compensation for the drops in the motor connections to have a real Emf/f control law. -

LEVEL 0: LEVEL 1: LEVEL 2:

No compensation. Compensate the drop on power mosfets and cables. Compensate the drop on power mosfet, cables and motor resistance. COMPENSATION to LEVEL 2 is strongly suggested (the correct setting of the motor resistance is required when COMPENSATION is set to LEVEL 2-see 13.1).

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11) AUXILIARY TIME This parameter defines the time, after the steer handle is released and the travel demand deactivated, for which the stand still torque is applied. -

LEVEL 0: LEVEL 1: LEVEL 9:

No stand still torque. Brief application of the stand still torque (about 6 secs). Long application of the stand still torque (about 90 secs).

Intermediate levels are for proportionally increasing auxiliary time. The stand still torque reduces with a ramp from the ANTIROLLBACK value down to zero with a delay specified with this setting. 12) ANTIROLLBACK This parameter adjusts the standstill torque after the steer handle is released and the travel demand deactivated. It is in percentage of the maximum current. Injecting a continuous current in the motor generates the stand still torque. It is useful (together with the CREEP SPEED parameter, see 12.4.4.3) to neutralize the recall torque generated by the elastic tyre on the steered wheel. 13) 1ST ANGLE COARSE Depending on the configuration, this parameter has different meaning. RTC version with feedback pot: This parameter regulates in coarse steps the maximum steered wheel angle in the direction where FEEDBACK ENC is higher than 2.5 V. It is a scaling factor between the SET POINT POT reading and the FEEDBACK ENC reading. By increasing this parameter, the maximum steered wheel angle increases too. The maximum angle in RTC should be regulated in feedforward way by properly adjusting the angle settings. Stepper Motor version with toggle switches: This parameter regulates in coarse steps the maximum steered wheel angle in the direction where FEEDBACK ENC is higher than 2.5 V. It limits the angle measured with the reading WHEEL ANGLE in the following range: - LEVEL 0: Angle is limited to a WHEEL ANGLE is +80 degrees. - LEVEL 1: Angle is limited to a WHEEL ANGLE is +84 degrees. - LEVEL 9: Angle is limited to a WHELL ANGLE is +118 degrees. Each step has a weight of 3.8 degrees. When 1ST ANGLE COARSE and 2ND ANGLE COARSE are both to Level 9, the angle limitation is inhibited. 14) 1ST ANGLE FINE (RTC version only). This parameter regulates in fine steps the maximum steered wheel angle in the direction where FEEDBACK ENC is higher than 2.5 V. It is used in closed loop application only (RTC) and it is a scaling factor between the SET POINT POT reading and the FEEDBACK ENC reading. By increasing this parameter, the maximum steered wheel angle increases too. 15) 2ND ANGLE COARSE Depending on the configuration, this parameter has different meaning. RTC version with feedback pot: This parameter regulates in coarse steps the maximum steered wheel angle in the direction where FEEDBACK ENC is lower than 2.5 V. It is a scaling factor between the SET POINT POT reading and the FEEDBACK ENC reading. Page - 72/95

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By increasing this parameter, the maximum steered wheel angle increases too. The maximum angle in RTC should be regulated in feedforward way by properly adjusting the angle settings. Stepper Motor version with toggle switches: This parameter regulates in coarse steps the maximum steered wheel angle in the direction where FEEDBACK ENC is lower than 2.5 V. It limits the angle measured with the reading WHEEL ANGLE in the following range: - LEVEL 0: Angle is limited to a WHEEL ANGLE is -80 degrees. - LEVEL 1: Angle is limited to a WHEEL ANGLE is -84 degrees. - LEVEL 9: Angle is limited to a WHELL ANGLE is -118 degrees. Each step has a weight of 3.8 degrees. When 1ST ANGLE COARSE and 2ND ANGLE COARSE are both to Level 9, the angle limitation is inhibited. 16) 2ND ANGLE FINE (RTC version only). This parameter regulates in fine steps the maximum steered wheel angle in the direction where FEEDBACK ENC is lower than 2.5 V. It is used in closed loop application only (RTC) and it is a scaling factor between the SET POINT POT reading and the FEEDBACK ENC reading. By increasing this parameter, the maximum steered wheel angle increases too. 17) NUMBNESS (RTC version only). This parameter reduces the steering sensitivity close to the straight-ahead direction. -

LEVEL 0: LEVEL 9:

No reduction in the steer sensitivity with the steering angle. Steering 4.5 less sensitive in the straight ahead direction.

Intermediate reductions of sensitivity are applied for intermediate settings. The steering sensitivity increases in a proportional relationship with the increased steering wheel angle. To be more precise, by increasing the NUMBNESS setting, no sensitivity modification is applied when the steering wheel is close to be straight, but higher sensitivity is applied when the steering wheel is angled. As consequence, when changing the NUMBNESS value, it is necessary to readjust the maximum angle limitations with the settings 1ST ANGLE COARSE (and FINE) and 2ND ANGLE COARSE (and FINE). 18) LAG FB REGULAT Level 0 to 9. It is used to set the integral (lag) contribution to a PID algorithm for RTC and AUTC functions. The integral contribution is applied to the FEEDBACK ENC value only. It works like a low pass filter to get smooth the pursuing next to the commanded position. The derivative (lead) contribution generates dither that is possible to reduce by increasing this adjustment. Obviously lag and lead regulations influence the stability of the closed loop and so different setting must be empirically tried to avoid oscillations. -

LEVEL 0: LEVEL 9:

lowest lag contribution (high cut off frequency low pass filter). highest lag contribution (low cut off frequency low pass filter).

19) LEAD FB REGULAT Level 0 to 9. It is used to set the derivative (lead) contribution to a PID algorithm for RTC and AUTC functions. The derivative contribution is applied to the FEEDBACK ENC value only. High LEAD FB REGULAT value brakes the steering motor in advance respect to the commanded position so avoiding the AEMZP0BA - EPS-AC0 - User Manual

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overshooting of the commanded position. On the other side generates damping and dither, close to the commanded position. Obviously lag and lead regulations influence the stability of the closed loop and so different setting must be empirically tried to avoid oscillations. -

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LEVEL 0: LEVEL 9:

lowest lead contribution (overshooting is favourite). highest lead contribution (damping is favourite).

AEMZP0BA - EPS-AC0 - User Manual

12.4.5 Zapi menu “HARDWARE SETTINGS” functions list To enter this Zapi hidden menu a special procedure is required. Ask this procedure directly to a Zapi technician. 1) MAXIMUM CURRENT MAXIMUM CURENT sets the limit for the current in the controller. 2) CAN BUS ABSENT or PRESENT. This setting specifies whether the eps-ac0 is CAN Bus connected or not. When CAN BUS is ABSENT, the CAN BUS KO alarm is inhibited together with any starting sequence used to synchronize via CAN Bus the eps-ac0 with the other controllers. 3) SET HI RESOL AD When it is set to Level 1, enables an analog to digital conversion with high resolution applied to the command pot CPOC1. Level 0 means the high resolution AD conversion is inhibited. Level 2 is not used.

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12.4.6 Zapi menu “SPECIAL ADJUSTMENT” functions list To enter this Zapi hidden menu a special procedure is required. Ask this procedure directly to a Zapi technician. 1) HIGH ADDRESS Zapi reserved. 2) SET TEMPERATURE Factory adjusted. 3) MAX SP SLOPE (RTC version only). This setting is used to adjust the slope threshold for the STEER SENSOR KO alarm (see 14.1.3.6). This alarm occurs when the slope of one of the set point potentiometers (CPOC1 or CPOC2) is detected larger than the MAX admitted slope. The MAX admitted slope is specified with this setting: -

LEVEL 0:

the max admitted slope is 61 corresponding to 0.3 V in 16 msec. (i.e. STEER SENSOR KO alarm occurs when either CPOC1 or CPOC2 changes more than ±0.3 V in 16 msec. This means that the SLOPE PEAK reading in the tester menu assumes larger than ±61 value. See 12.4.7.23). - LEVEL 1: the max admitted slope is 79 corresponding to 0.39 V in 16 msec. - LEVEL 2: the max admitted slope is 97 corresponding to 0.47 V in 16 msec. - LEVEL 3: the max admitted slope is 115 corresponding to 0.56 V in 16 msec. - LEVEL 4: the max admitted slope is 133 corresponding to 0.65 V in 16 msec. - LEVEL 5: the max admitted slope is 151 corresponding to 0.74 V in 16 msec. - LEVEL 6: the max admitted slope is 169 corresponding to 0.83 V in 16 msec. - LEVEL 7: the max admitted slope is 187 corresponding to 0.91 V in 16 msec. - LEVEL 8: the max admitted slope is 205 corresponding to 1.00 V in 16 msec. - LEVEL 9: the max admitted slope is 410 corresponding to 2.00 V in 16 msec. Default value is LEVEL 9. Pay attention the LEVEL 9 gets the alarm strongly insensitive and it is the right setting only when the twin pot redundancy is adopted for the set point potentiometer; when just one single set point potentiometer is adopted, we advice against using LEVEL 9. 4) DEBUG OUTPUT This adjustment is used to temporary change the configuration or inhibit some diagnosis to aid the troubleshooting. Take care to set DEBUG OUTPUT to Level 15 after finishing the troubleshooting. -

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LEVEL 0:

Self-acquisition of the stepper motor offsets (see 12.4.2.1112) in open loop application. It switches automatically to the default Level 15 after the self-acquisition. AEMZP0BA - EPS-AC0 - User Manual

LEVEL 1-9 LEVEL 10:

LEVEL 11:

LEVEL 12:

LEVEL 13:

LEVEL 14:

LEVEL 15:

AEMZP0BA - EPS-AC0 - User Manual

Zapi reserved. Enables the NO LOAD CURRENT test (see 12.4.2.10). Roll from level 10 to level 15 and save the new setting to exit this testing condition. Disables the alarms FB SENS LOCKED, MOTOR LOCKED and POSITION ERROR (the latest only for FB ENC & Toggle Switches configuration) till a new DEBUG OUTPUT hand setting. The SET POINT POT of the Tester menu is connected at the high resolution AD input (it is in the range 0 to 5Vdc when the command potentiometer (CPOC1) is close to ZERO SP POT). Reading SET POINT POT in the tester menu is connected to the 2nd wiper of the twin (command) pot (CPOC2 on CNA#8). Disables the alarms FB POT LOCKED, MOTOR LOCKED and POSITION ERROR (the latest only for FB ENC & TOGGLE SWs configuration). It switches automatically to the default Level 15 recycling the key. Default value (no special functions activated).

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12.4.7 Main menu “TESTER” functions list The TESTER functions are real time feedback measurements of the state of the controller. It is possible to know the state (active disactive) of the digital I/Os, the voltage value of the analog inputs and the state of the main variables used in the motor. Enter the headline in the hand-set display and roll for the TESTER item. 1) STEPPER MOTOR Voltage value with 2 decimal digit. Measurement of the stepper motor speed with sign in the range 0 to ±5 Vdc. 2) SET POINT POT Voltage value with 2 decimal digit. Measurement of the potentiometer connected to CNA#9 (CPOC1). Switch DEBUG OUTPUT to level 13 to get CNA#8 (CPOC2) on this reading (see 12.4.6.4). 3) FEEDBACK POT (feedback pot version only). Voltage value with 2 decimal digits. Measurement of the feedback potentiometer connected to CNB#6 (CPOT). 4) FEEDBACK SECTOR (toggle switches version only). Voltage value with 2 decimal digits. It supplies real time the information of the sector (quadrant) detected through the toggle switches. It assume the following value: 3.13 V in the sector from 0 to +90 degrees. 4.39 V in the sector from +90 to +180 degrees. 0.62 V in the sector from -180 to -90 degrees. 1.88 V in the sector from -90 to 0 degrees. 5) FEEDBACK ENC Voltage value with 2 decimal digit. Measurement (scaled in the range 0 to 5 Vdc) of the position of the feedback encoder connected to CNB#7 and CNB#8. 6) TEMPERATURE Degrees. Temperature of the controller base plate. 7) MOTOR TEMPERATURE Degrees. Temperature of the motor windings measured with the thermal sensor inside the motor and connected to CNB#3. 8) FREQUENCY Hertz value with 2 decimal digit. This is the frequency applied to the steering motor. 9) SAT. FREQ HZ Hertz value with 2 decimal digit. This is a real time magnetic flux measurement: Vbattery/ SAT. FREQ HZ provides real time the linked flux in the motor. The flux in the motor is modulated from 75% to 100% of the maximum flux. The maximum flux is Vbattery/SET SAT FREQ. The minimum flux is Vbattery/(1.33*SET SAT FREQ). When the motor is loaded, SAT. FREQ HZ is equal to SET SAT FREQ; when the motor is lightened the flux reduces and SAT. FREQ HZ increases up to 1.33*SET SAT FREQ.

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10) MOTOR VOLTAGE It is a percentage. 100% means the sine waves in the motor have the maximum PWM amplitude. 11) MOTOR CURRENT Ampere value. Root Mean Square value of the line current in the motor. 12) ENC SPEED Hertz value with 2 decimal digit. This is the speed of the motor measured with the encoder on the motor shaft. 13) ENDSTROKE CW Provides real time the active state (ON) or not of the CW toggle switch (connected to CNA#3). It is On when CNA#3 is low (see 7.5). 14) ENDSTROKE ACW Provides real time the active state (ON) or not of the CCW toggle switch (connected to CNA#2). It is On when CNA#2 is low (see 7.5). 15) CW LIMIT LEVEL When the maximum angle limitation via feedback sensors is enabled (option LIMIT DEVICE to ON when FEEDBACK DEVICE is OPTION #1,2,3; 1ST ANGLE COARSE and 2ND ANGLE COARSE less than level 9 when FEEDBACK DEVICE is OPTION #4) and the FEEDBACK ENC overtakes the superior limit for the steered wheel angle limitation, the steered wheel angle will be limited and CW LIMIT LEVEL turns ON (active). 16) ACW LIMIT LEVEL When the maximum angle limitation via feedback sensors is enabled (option LIMIT DEVICE to ON when FEEDBACK DEVICE is OPTION #1,2,3; 1ST ANGLE COARSE and 2ND ANGLE COARSE less than level 9 when FEEDBACK DEVICE is OPTION #4) and the FEEDBACK ENC is lower than the inferior limit for the steered wheel angle limitation, the steered wheel angle will be limited and ACW LIMIT LEVEL turns ON (active). 17) AUTO IN PROGRESS Provides real time the information the eps-ac0 follows the manual command (AUTO IN PROGRESS is OFF) or is executing an automatic centering (AUTO IN PROGRESS is ON). 18) MM ALARM SWITCH It is On when the safety contact belonging to the main uC is closed. 19) SM ALARM SWITCH It is On when the safety contact belonging to the slave uC (supervisor) is closed. 20) TRUCK MOVING It provides the state of the travel demand for driving the truck. This information is obtained either with the travel demands directly connected to CNA#1 or via CAN Bus (depending by the state of the CAN BUS setting see 12.4.5.2). 21) HIGH RESOL AD It turns ON when the set point potentiometer is processed with a high resolution AD.

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22) WHEEL ANGLE Angle measurement degrees. For the configuration with toggle switches only, it is the steered wheel angle in the range 0 ±180 degrees. WHEEL ANGLE is zero in the position where an edge is detected in the straight ahead toggle switch. 23) SLOPE PEAK This reading is just for debugging the maximum slope of the potentiometers connected to the eps-ac0. Especially when a reduced sensor equipment is chosen (just a single command potentiometer or just a single feedback potentiometer without encoder), a concern regarding the safety raises: if a single potentiometer fails a sudden movement of the steered wheel may occur with danger. To avoid this problem it is necessary to detect any failure in a single potentiometer. This is hard to do because the failure mode can be quite different. Anyway, the best countermeasure we can take, is to seek for the wiper voltage changes faster than its physical limit. In fact, for the limited speed of the steering motor (or of the steering wheel), the slope in the wiper voltage must be limited under a certain threshold. When this slope threshold is overtook, the potentiometer may be assumed broken. So, it is useful to measure the maximum slope occurring in your application when right working, in order a right slope threshold can be chosen to avoid an alarm occurs when the potentiometer is not failed (see 12.4.6.3). The SLOPE PEAK reading in the tester menu is a real time measurement of the slope peak of the potentiometers. In particular: When the special adjustments DEBUG OUTPUT is other than Level 12 or 13, SLOPE PEAK supplies the slope peak of the CPOC1 set point potentiometer (CNA#9). When the special adjustments DEBUG OUTPUT is Level 13, SLOPE PEAK supplies the slope peak of the CPOT feedback potentiometer (CNB#6). When the special adjustments DEBUG OUTPUT is Level 12, SLOPE PEAK supplies the slope peak of the CPOC2 set point potentiometer (CNA#8). The SLOPE PEAK measurement is the difference between two AD conversions of the selected potentiometer picked up with 16 msec long interval. The SLOPE PEAK reading can be converted in a Voltage change (∆V in volts) of the wiper voltage in an interval 16 msec long, with the formula: ∆V = SLOPE PEAK*5/1024 = Voltage change in Volts in 16 msec (e.g. When SLOPE PEAK is 61 it means the selected potentiometer, in the worst case, changes 61*5/1024=0.3 V in 16 msec.). Obviously the SLOPE PEAK reading must be compared with the threshold for the STEER SENSOR KO and JERKING FB POT alarms (see 14.1.3.6-7). The STEER SENSOR KO alarm may be adjusted (see MAX SP SLOPE 12.4.6.3); the JERKING FB POT occurs when the CPOT slope, overtakes a constant threshold is ± 0.3 V in 16 msec (i.e. SLOPE PEAK=± 61). 24) READ FBPT AT SW1 This reading is used only when the FEEDBACK DEVICE is OPTION #3 (FBENC, FBPOT, SW1). It gives the FB POT value at the initial matching with the falling edge on the straight ahead switch (SW1). This reading is expected to reply the SET FBPOT AT SW1 value (see 12.4.2.18 in the adjustments menu). When a displacement exists between these two readings, a POSITION ERROR alarm may occur (see 14.1.3.5). 25) TRUCK SPEED Percentage value. It represents the truck speed represented in percentage of Page - 80/95

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the full drive speed. It is used for the dynamic numbness (i.e. the steering sensitivity reduces when the truck speed increases). 26) ENC COUNT AT 360 (only when FEEDBACK DEVICE is OPTION #4).This reading shows the encoder counting between two falling edges on the straight ahead switch. It must be meant as the encoder counting corresponding to a steered wheel revolution. It is scaled in the range 0 to ±5 V with the meaning that 5 V corresponds to an encoder counting of 215 events. The ENC COUNT AT 360 absolute value can be recorded on the adjustment SET ENC AT 360.

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13 OTHER FUNCTIONS Here is a list of special functions hand set assisted, that are not documented yet.

13.1 Acquiring the Motor resistance When it is possible, the steering motor is controlled sensorless. To get the best performance in terms of the max torque generated, it is necessary to compensate for the drop in the motor resistance. So the correct value of the motor resistance must be known. Eps-ac0 provides a self-acquisition procedure to acquire the motor resistance. It is just enough to connect the eps-ac0 to the battery, to the motor and to the wiring in order no alarm occurs. Then: 1) Enter the ADJUSTMENTS menu searching for ADJUSTMENT #01 setting. 2) Turn ADJUSTMENT #01 to Level 1. (A DATA ACQUISITION alarm occurs and a half Imax DC current is automatically injected in the motor). 3) Wait about 2 secs. 4) Roll ADJUSTMENT #01 back to Level 0. 5) Save the new setting. With this procedure the resistance between two motor terminals is automatically measured and recorded (in milliohms) on the ADJUSTMENT #02 (see 12.4.2.3). It is also possible to adjust the motor resistance value without self-acquisition by rolling the ADJUSTMENT #02. The acquisition of the motor resistance should be performed to find the correct value when developing a new truck prototype; the correct value will be the default setting for the mass production of that truck.

13.2 Alignment at the rest position In the open loop applications (i.e. when the stepper motor is used in the steering wheel or the steer command is a speed information coming via CAN bus) an alignment at the rest position is automatically performed when the steered wheel has a drift with a released steering wheel. This alignment at the rest position is handled closed loop and so a feedback sensor is required. So this function is performed only either with SYSTEM CONFIG to level 0 or with SYSTEM CONFIG to level 4. When the feedback sensor uses a feedback potentiometer, the alignment at rest position is performed for both cases (SYSTEM CONFIG to level 0 and 4) provided that option LIMIT DEVICE is ON. When the feedback sensor uses toggle switches, the alignment at the rest position is performed only when SYSTEM CONFIG is level 0.

13.3 Straight ahead steering numbness It is possible to reduce the steering sensitivity while the steered wheel is close to be straight ahead by using the NUMBNESS setting in the PARAMETERS CHANGE menu. Increasing the NUMBNESS parameter gets the steering less responsive when the truck is driving next to the straight ahead direction (i.e. a certain increment of the steering wheel angle gets a smaller increment of the steered wheel angle when the truck is driving straight ahead than when it is angled). Page - 82/95

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Higher NUMBNESS setting results in higher numbness of the steering at low steered wheel angle. NUMBNESS to Level 0 results in a linear relationship between the command and the steered wheel angle (no sensitivity reduction in straight ahead).

13.4 Special Debugging and Troubleshooting system Eps-ac0 provides a special adjustment (DEBUG OUTPUT) to facilitate the troubleshooting. Some alarms may be due to many different causes that are difficult to catch. In particular, the alarms in which the steered wheel does not pursuit the commanded positions (FB POT LOCKED, FB SENSOR LOCK, MOTOR LOCKED, POSITION ERROR) may be due to a mechanical fault or to a failed sensor or to a problem in the motor. It is difficult to find the root for the problem in the short time before the alarm occurs. For this reason the eps-ac0 provides a method to temporary inhibit these alarms. It is just enough to set the special adjustment DEBUG OUTPUT to Level 11. Then the steering system works without these alarms and the service can take longer time to analyze the system and to catch the fault. Together with this possibility DEBUG OUTPUT provides many other special functions (that are described in paragraph 12.4.6.4). For example it is possible to use the hand set to read the voltage from the second twin pot wiper (CPOC2 on CNA#8) on the reading SET POINT POT of the hand set. It is just enough to turn DEBUG OUTPUT to level 13.

Don’t forget to turn DEBUG OUTPUT to Level 15 after finished the test.

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14 EPS-AC0 ALARMS LIST The ALARMS logbook in the MAIN MENU records the alarms of the controller. It has a FIFO (First Input First Output) structure that means the oldest alarm is lost when the database is full and a new alarm occurs. The logbook is composed of five locations getting possible to stack five different types of alarms with the following information: 1) The alarm code 2) The times that each alarm occurs consecutively 3) The Hour Meter value when the latest event of every alarm occurred 4) The inverter temperature when the latest event of every alarm occurred. This function permits a deeper diagnosis of problems as the recent history can be revisited. The CAN Bus code is the corresponding number with which the alarm is signalled on the CAN Bus (ID 0x298h).

14.1 Main menu “ALARMS” list To Enter the MAIN MENU push the Enter button at the Home Page of the hand set display and Roll for the ALARMS item. Here is the ALARMS list:

14.1.1 One Blink Alarms 1) MICRO SLAVE KO CAN Bus Code = 246 - Cause: In stepper motor application, this alarm occurs if the main uC is detecting a direction of the stepper motor not matched with the one that the slave uC is detecting. In closed loop application, this alarm occurs if the main uC is detecting a direction of the steering error not matched with the one that the slave uC is detecting. Furthermore, this alarm occurs also if the main uC is detecting no steering limitation meanwhile the slave uC is detecting e steering limitation. - Remedy: It is necessary to replace the controller. 2) MICRO SLAVE #4 CAN Bus Code = 221 - Cause: It occurs in one of the following conditions: (Open loop application only) If the slave uC detects the stator voltage phasor rotates in the opposite direction respect to the sign of the stepper motor speed, this alarm occurs. (Closed loop application only) If the slave uC detects the stator voltage phasor rotates in the opposite direction respect to the commanded position, this alarm occurs. - Remedy: It is necessary to replace the controller. 3) MICRO SLAVE CAN Bus Code = 250 - Cause: It occurs when the information on the status bus between the main uC and the slave uC is frozen to the 0xFF value (the slave uC does not update the status bus configuration). - Remedy: It is necessary to replace the controller. Page - 84/95

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4) MICRO SLAVE #8 CAN Bus Code = 212 - Cause: It occurs when the encoder counting of the main uC is not matched with the encoder counting of the slave uC. - Remedy: It is necessary to replace the controller. 5) INPUT ERROR #1 CAN Bus Code = 99 - Cause: It occurs when the voltage on CNA#4 (NK1: Lower Potential Terminal of the Safety Contacts (see 7.6) is higher than 12 V before to turn the safety contacts closed. - Remedy: When the safety contacts are open, the voltage on CNA#4 is expected to be close to 0 Vdc and this is independent from whether the safety contacts are connected to a plus battery or to a minus battery (see 7.6). In the first case (safety contacts connected to a plus battery), when the safety contacts are open, CNA#4 is connected to a minus battery through a load. Only a harness mistake may connect NK1 to a higher than 12 V voltage. 6) SERIAL ERR #1 CAN Bus Code = 6 - Cause: Main uC and Slave uC communicate via a local serial interface. This alarm occurs when the slave uC does not receive the communication from the main uC through this serial interface. - Remedy: It is necessary to replace the controller. 7) SLAVE COM. ERROR CAN Bus Code = 227 - Cause: Main uC and Slave uC communicate via a local serial interface. This alarm occurs when the main uC does not receive the communication from the slave uC through this serial interface. - Remedy: It is necessary to replace the controller. 8) NO SYNC - Cause:

- Remedy:

CAN Bus Code = 226 Every 16msec, inside the code cycle, the main uC rises and then lowers an input for the slave uC (SYNC). When the slave uC detects no edge for more than 100 msec on this input, this alarm occurs. This is just a watch dog function: when the main uC does not execute the code cycle it does not update the SYNC signal and the slave uC cuts off the steer and traction. It is necessary to replace the controller.

9) KM CLOSED CAN Bus Code = 253 - Cause: This alarm occurs at key on if the slave uC detects the safety contact, of the main uC, closed prior to be commanded. - Remedy: This alarm occurs if the connection CNA#5 (K1) is around a voltage of 12 Vdc when switching on the key. In fact, when the safety contacts are open, K1 is expected being connected to a battery voltage (not 12 V). Search for a harness problem or replace the controller. 10) KM OPEN CAN Bus Code = 251 AEMZP0BA - EPS-AC0 - User Manual

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- Cause: - Remedy:

This alarm occurs if the slave uC detects the safety contact, of the main uC, open when expected being closed. It is necessary to replace the controller.

11) KS CLOSED - Cause: - Remedy:

CAN Bus Code = 254 This alarm occurs if the main uC detects the safety contact, of the slave uC, closed prior to be commanded. This alarm occurs if the connection CNA#4 (NK1) is around a voltage of 12 Vdc when switching on the key. In fact, when the safety contacts are open, NK1 is expected being connected to a minus battery voltage (not 12 V). Search for a harness problem or replace the controller.

12) KS OPEN - Cause: - Remedy:

CAN Bus Code = 252 This alarm occurs if the main uC detects the safety contact, of the slave uC, open when expected being closed. It is necessary to replace the controller.

13) CLOCK PAL NOT OK CAN Bus Code = 218 - Cause: The main uC sends an analog signal towards the slave uC to reset the slave uC on demand. When the slave uC detects this analog signal external to a window from 2.2 to 2.8 and not in the range to generate the reset on demand, the slave uC raises this alarm. - Remedy: It is necessary to replace the controller.

14.1.2 Two Blinks Alarms 1) HIGH CURRENT CAN Bus Code = 70 - Cause: This alarm occurs if the circuit to limit via hardware the current in the motor is either always active at key-on or repeatedly active when the motor is turning. - Remedy: Check the motor is suited to work with the eps-ac0 (not oversized). Otherwise it is necessary to replace the controller. 2) POWER FAILURE #1 CAN Bus Code = 73 - Cause: This alarm occurs when the current in the phase W of the motor is zero and the motor is commanded for moving. - Remedy: Check the power fuse is OK. Check the battery positive arrives to the controller. Check the continuity of the wire in the phase W of the motor. Otherwise it is necessary to replace the controller. 3) POWER FAILURE #2 CAN Bus Code = 72 - Cause: This alarm occurs when the current in the phase U of the motor is zero and the motor is commanded for moving. - Remedy: Check the power fuse is OK. Check the battery positive arrives to the controller. Check the continuity of the wire in the phase U of the motor. Otherwise it is necessary to replace the controller.

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4) POWER FAILURE #3 CAN Bus Code = 71 - Cause: This alarm occurs when the current in the phase V of the motor is zero and the motor is commanded for moving. - Remedy: Check the power fuse is OK. Check the battery positive arrives to the controller. Check the continuity of the wire in the phase V of the motor. Otherwise it is necessary to replace the controller. 5) LOGIC FAILURE #1 CAN Bus Code = 19 - Cause: This alarm occurs when the real voltage between phases W and U of the motor is different from the desired. - Remedy: It is necessary to replace the controller. 6) LOGIC FAILURE #2 CAN Bus Code = 18 - Cause: This alarm occurs when the real voltage between phases W and V of the motor is different from the desired. - Remedy: It is necessary to replace the controller. 7) MAIN CONT. OPEN CAN Bus Code = 48 - Cause: This alarm occurs only when the setting CAN BUS is PRESENT. Then the eps-ac0 waits for a via CAN information that the traction controller has closed the main contactor. If this information lacks more than about 1.5 secs, this alarm occurs. - Remedy: Find, on the traction controller, the reason for keeping the main contactor open. 8) CAN BUS KO CAN Bus Code = 247 - Cause: This alarm occurs only when the setting CAN BUS is PRESENT. Then the eps-ac0 must receive the event messages from the traction controller. If these messages lack more than about 1 sec, this alarm occurs. - Remedy: Check the CAN Bus communication system and analyse the frames from the traction controller to the steer controllers. 9) MOTOR LOCKED CAN Bus Code = 220 - Cause: This alarm occurs if the current in the steering motor stays close to the maximum current longer than 1 sec. - Remedy: Search for a mechanical problem locking the motor. To make easier the fault catching, set DEBUG OUTPUT to level 11 (see 12.4.6.4).

14.1.3 Three Blinks Alarms 1) D LINE SENSOR KO CAN Bus Code = 243 - Cause: This alarm occurs when the mean voltage on the Direct line of the stepper motor (connection CNA#9) is not null: the voltage on every stepper motor line is a sine wave with null mean voltage. - Remedy: Check the continuity of the stepper motor connections. In particular the resistance between CNA#9 and the minus battery (with the AEMZP0BA - EPS-AC0 - User Manual

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stepper motor at rest) is expected being very low (close to 30 ohms). 2) Q LINE SENSOR KO CAN Bus Code = 242 - Cause: This alarm occurs when the mean voltage on the Quadrature line of the stepper motor (connection CNA#8) is not null: the voltage on every stepper motor line is a sine wave with null mean voltage. - Remedy: Check the continuity of the stepper motor connections. In particular the resistance between CNA#8 and the minus battery (with the stepper motor at rest) is expected being very low (close to 30 ohms). 3) S.P OUT OF RANGE CAN Bus Code =248 - Cause: This alarm occurs for a fault on the command potentiometer (CPOC1 on CNA#9, CPOC2 on CNA#8). When a single command pot is chosen, the alarm occurs if its wiper (CPOC1) exits the range from 0.8 Vdc to 4.2 Vdc. When the twin pot is chosen, the alarm occurs if the sum of the two wiper voltages (CPOC1+CPOC2) exits the range from 4.5 Vdc to 5.5 Vdc. - Remedy: Check the connections of the potentiometer. This alarm occurs when one connection of the command potentiometer is broken. 4) F.B OUT OF RANGE CAN Bus Code =249 - Cause: This alarm occurs for a fault on the feedback potentiometer (CPOT on CNB#6). This alarm occurs if CPOT exits the range from 0.3 Vdc to 4.7 Vdc. - Remedy: Check the connections of the feedback potentiometer. This alarm occurs when one connection of the feedback potentiometer is broken. 5) POSITION ERROR CAN Bus Code =228 - Cause: This alarm occurs for an error in the redundant test of the feedback sensors. 1) When the feedback potentiometer is used together with the feedback encoder, the angle of the steered wheel is measured with both of them: FEEDBACK ENC and FEEDBACK POT in the tester menu are expected to be equal. When they are different more than 20 degrees this alarm occurs (SET MAX FB POT–SET MIN FB POT corresponds to 180 degrees). 2) When the feedback encoder is used together with toggle switches, this alarm occurs if the sector (toggles switches configuration) and the encoder counting are not matched. The sector is provided via the FEEDBACK SECTOR reading in the tester menu; the encoder counting is provided via the WHEEL ANGLE reading in the tester menu. In particular (in case of two toggle switches):

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- Remedy:

WHEEL ANGLE [degrees]

Admitted sector

-22 to +22 +23 to +67 +68 to +112 +113 to +157 +158 to -158 -157 to -113 -112 to -68 -67 to -23

1st or 4th 1st 1st or 2nd 2nd 2nd or 3rd 3rd 3rd or 4th 4th

Admitted FEEDBACK SECTOR

3.13 V or 1.88 V 3.13 V 3.13 V or 4.39 V 4.39 V 4.39 V or 0.62 V 0.62 V 0.62 V or 1.88 V 1.88 V

Check the potentiometer connected to CNB#6 is right working. If toggle switches are connected to CNA#2 and CNA#3, verify they are right working and the setting AUX FUNCTION 11 (see 12.4.1.9) is correct. Verify also the sensor bearing in the motor (encoder) has not a slip (the sensor bearing has two rings: one is connected to the rotor shaft; the other is connected to the motor frame. Check these two rings are strictly connected to their structure without slip.

6) STEER SENSOR KO CAN Bus Code =84 - Cause: This alarm occurs if the command potentiometer (CPOC1 on CNA#9 or CPOC2 on CNA#8) changes with a jerk larger than MAX SP SLOPE (see 12.4.6.3). This alarm is used to catch a discontinuity in the voltages of the command potentiometer. - Remedy: Change the twin pot. 7) JERKING FB POT CAN Bus Code =223 - Cause: This alarm occurs if the feedback potentiometer (CPOT on CNB#6) changes with a jerk larger than 0.3 V in 16 msec. This alarm is used to catch a discontinuity in the voltages of the feedback potentiometer. - Remedy: Change the feedback potentiometer. 8) FB POT LOCKED or FB SENS LOCKED CAN Bus Code =222 - Cause: In application with a feedback potentiometer, this alarm occurs if the feedback potentiometer (CPOT on CNB#6) does not change (or changes in the opposite direction) its value even if commanded to change. In application with toggle switches with ENCODER CONTROL to off, this alarm occurs if the feedback encoder counting does not change its value even if commanded to change. - Remedy: In application with the feedback potentiometer, verify the feedback potentiometer is not mechanically loosened. Check there is not a mechanical block of the steered wheel. Be sure the wiper has not reached its own electrical limit because of too much angle of the steered wheel. Besides, this alarm may occur at the installation when the motor rotates in the wrong direction turning away from the wished AEMZP0BA - EPS-AC0 - User Manual

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position. In application with toggle switches, verify the encoder is not mechanically loosened. Check there is not a mechanical block of the steered wheel. To make easier the fault catching, set DEBUG OUTPUT to level 11 (see 12.4.6.4). 9) STEPPER MOTOR MISM CAN Bus Code =219 - Cause: This alarm occurs if the frequency and the amplitude of the voltages from the stepper motor lines are mismatched in between (i.e. the voltage from the D and Q line of the stepper motor have high amplitude but with very low frequency). In normal condition when the amplitude of the stepper motor lines increases, the frequency of the stepper motor lines must increase too. - Remedy: It is necessary to replace the controller. 10) ENCODER ERROR CAN Bus Code =241 - Cause: It occurs when ENCODER CONTROL is set ON and the real frequency does not pursuit the commanded frequency - Remedy: This condition is several times due to either, a mismatching between the Encoder resolution used in the SW and the real encoder resolution, or a wrong connection between the two encoder channels. In this latest case exchange in between the two encoder channels. 11) BAD ENCODER SIGN CAN Bus Code =83 - Cause: It occurs in applications with toggle switches when the applied frequency (FREQUENCY) and the motor speed (ENC SPEED) have opposite sign. - Remedy: Swap in between the two encoder channels (CNB#7 with CNB#8).

14.1.4 Four Blinks Alarms 1) EEPROM KO CAN Bus Code = 13 - Cause: It occurs if a test to write and read one location in EEPROM fails. The SW expects to read the written value. It occurs also when the hour counter gives different values between the three redundant locations in which it is recorded. It occurs also when the busy bit of the EEPROM does not rise within 12 msec. - Remedy: It is necessary to replace the controller. 2) GAIN EEPROM KO CAN Bus Code = 244 - Cause: The parameters to compensate for the gain of the current amplifiers (ADJUSTMENT #03 and ADJUSTMENT #04) are recorded in a not volatile memory (eeprom) with a redundant handling. In fact every adjustment is recorded in three eeprom locations. If the values in these three locations are different in between this alarm occurs. - Remedy: It is necessary to send the controller to Zapi to execute the maximum current regulation. Page - 90/95

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3) CURRENT GAIN CAN Bus Code = 225 - Cause: This alarm occurs when the parameters to compensate for the gain of the current amplifiers (ADJUSTMENT #03 and ADJUSTMENT #04) have the default values (i.e. the maximum current was not regulated). - Remedy: It is necessary to send the controller to Zapi to perform the maximum current regulation.

14.1.5 Five Blinks Alarms 1) HIGH TEMPERATURE CAN Bus Code = 61 - Cause: This alarm occurs if the temperature of the controller base plate overtakes 75 degrees. - Remedy: Improve the cooling of the controller; otherwise it is necessary to replace the controller. 2) MOTOR TEMPERAT. CAN Bus Code = 65 - Cause: This alarm occurs only when DIAG MOTOR TEMP is on and the thermal sensor inside the motor measures a temperature higher than 150 degrees. It occurs also when trying to acquire the motor resistance with a temperature in the motor higher than 150 degree (still with DIAG MOTOR TEMP to ON). - Remedy: Check the thermal sensor in the motor is right working. If it is, improve the cooling of the motor.

14.1.6 Six Blinks Alarms 1) STBY I HIGH CAN Bus Code = 53 - Cause: This alarm occurs two ways: 1) In the initial rest state after key on, if the outputs of the current amplifiers are not comprised in the window 2.2 to 2.8 Vdc. 2) After the initial diagnosis this alarm occurs when the outputs of the current amplifiers at rest have a drift larger than ±0.15 V. - Remedy: It is necessary to replace the controller. 2) VMN NOT OK CAN Bus Code = 32 - Cause: This alarm occurs in the initial rest state after key on if the outputs of the motor voltage amplifiers are not in the window from 2.2 to 2.8 Vdc. - Remedy: It is necessary to replace the controller. 3) LOGIC FAILURE #3 CAN Bus Code = 17 - Cause: This alarm occurs in the rest state if the output of the voltage amplifier of the phase Vu-Vw have a drift larger than ±0.25 V. - Remedy: It is necessary to replace the controller. 4) LOGIC FAILURE #4 CAN Bus Code = 16 AEMZP0BA - EPS-AC0 - User Manual

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- Cause: - Remedy:

This alarm occurs in the rest state if the output of the voltage amplifier of the phase Vw-Vv have a drift larger than ±0.25 V. It is necessary to replace the controller.

14.1.7 Thirty-two Blinks Alarms 1) DATA ACQUISITION MDI-PRC Code = 245 - Cause: This alarm occurs when the acquiring the motor resistance or when adjusting the parameters to compensate for the gain of the current amplifiers (maximum current factory adjusted). - Remedy: Recycle the key.

14.1.8 No Blink Alarms (Warning) These alarms do not cut the truck off; they only reduce the truck speed. So they warns the operator of a particular state in the truck. 1) STEER HAZARD CAN Bus Code = 85 - Cause: This is just a warning to inform that the steering controller is limiting the angle in the steering direction. No speed reduction occurs on the traction. 2) WAITING DATA CAN Bus Code = 237 - Cause: This warning occurs only if CAN BUS is PRESENT. At key-on the eps-ac0 asks to the traction controller to send a list of parameters via CAN Bus. From the request until the parameters are correctly relieved, this warning occurs. The steer is not activated yet, and the safety relays remain open when this warning is present. 3) WAITING FOR TRAC CAN Bus Code = 239 - Cause: At key-on the eps-ac0 needs an assent from the traction controller to close the safety contacts and to turn onto operational mode. Until this assent is not relieved, this warning occurs. The steer is not activated yet and the safety relays remain open when this warning is present. 4) EPS NOT ALIGNED CAN Bus Code = 238 - Cause: This is a real alarm that cut off the traction. It occurs at the initial alignment if the straight-ahead condition is not matched within 6sec. Throughout this 6 secs delay, the steer is not activated yet, the safety relays are open and the traction is stopped.

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AEMZP0BA - EPS-AC0 - User Manual

14.2 CAN BUS “ALARMS” List The Alarm Code List supplied by the eps-ac0 (Source Device Code 06) is the following: 6: 13: 16: 17: 18: 19: 32: 48: 53: 61: 65: 70: 71: 72: 73: 83: 84: 85: 99: 212: 218: 219: 220: 221: 222: 223: 225: 226: 227: 228: 237: 238: 239: 241: 242: 243: 244: 245: 246: 247: 248: 249: 250: 251: 252: 253: 254:

SERIAL ERR #1 EEPROM KO LOGIC FAILURE #4 LOGIC FAILURE #3 LOGIC FAILURE #2 LOGIC FAILURE #1 VMN NOT OK MAIN CONT. OPEN STBY I HIGH HIGH TEMPERATURE MOTOR TEMPERAT. HIGH CURRENT POWER FAILURE #3 POWER FAILURE #2 POWER FAILURE #1 BAD ENCODER SIGN STEER SENSOR KO STEER HAZARD INPUT ERROR #1 MICRO SLAVE #8 CLOCK PAL NOT OK STEPPER MOTOR MISM MOTOR LOCKED MICRO SLAVE #4 FB POT LOCKED JERKING FB POT CURRENT GAIN NO SYNC SLAVE COM. ERROR POSITION ERROR WAITING DATA EPS NOT ALIGNED WAITING FOR TRAC ENCODER ERROR Q LINE SENSOR KO D LINE SENSOR KO GAIN EEPROM KO DATA ACQUISITION MICRO SLAVE KO CAN BUS KO S.P OUT OF RANGE F.B OUT OF RANGE MICRO SLAVE KM OPEN KS OPEN KM CLOSED KS CLOSED

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15 RECOMMENDED SPARE PARTS

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Part number

Description

C36090 E07161 C38207

Stepper motor minebea Twin pot Best motor 300 W AC motor and P62 DMS gear box 1:51

AEMZP0BA - EPS-AC0 - User Manual

16 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED Check the wear and condition of the Contactors’ moving and fixed contacts. Electrical Contacts should be checked every 3 months. Check the Battery cables, cables to the controller, and cables to the motor. Ensure the insulation is sound and the connections are tight. Cables should be checked every 3 months. Check the mechanical operation of the Contactor(s). Moving contacts should be free to move without restriction. Check every 3 months. Checks should be carried out by qualified personnel and any replacement parts used should be original. Beware of NON ORIGINAL PARTS. The installation of this electronic controller should be made according to the diagrams included in this Manual. Any variations or special requirements should be made after consulting a Zapi Agent. The supplier is not responsible for any problem that arises from wiring methods that differ from information included in this Manual. During periodic checks, if a technician finds any situation that could cause damage or compromise safety, the matter should be bought to the attention of a Zapi Agent immediately. The Agent will then take the decision regarding operational safety of the machine. Remember that Battery Powered Machines feel no pain. NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER.

16.1 Testing the faulty detection circuitry The material handling directive EN1175 requires periodic testing of the controller’s fault detection circuitry to be checked in one of the following modes (choose the one you prefer): 1) Switch on the key and try to disconnect the stepper motor or the twin pot. An alarm, stopping the traction should immediately occur. 2) Try to disconnect the steering motor. After switching on the key an alarm stopping the traction should immediately occur as soon as the steering (or handle) wheel rotates.

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Mitsubishi Forklift RB14N2S RB14N2HS RB16N2 RB16N2H RB16N2S RB16N2HS RB16N2C RB16N2HC Service Manual

Articles inside

3 Safety instructions

1 Foreword