Maintenance Manual
ESR4500 Series Printed in Germany ● Status 2, Revision Level A Order Number: 812549-006
This master manual is subject to continual updates. It is meant exclusively for businesses authorized by CROWN. It is not permitted to pass on the contents or copies thereof to third parties.
CROWN Gabelstapler GmbH & Co. KG - European Headquarter Moosacher Str. 52 80809 Munich Germany Phone +49 (0) 89 93 00 2 - 0 Fax +49 (0) 89 93 00 2 - 133
All rights reserved under international and Pan-American Copyright Agreement. Copyright 2004 CROWN Equipment Corporation
TABLE OF CONTENT
Printed in Germany
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Printed in Germany
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TABLE OF CONTENT Table of Content MA – SAFETY
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Safety Symbols used in the Manual ...................................... 3 General Maintenance and Repair Safety Notes ................... 3 Maintenance and Repair ................................................ 3 Before Leaving the Truck ................................................ 4 Before Carrying out Work on the Truck .......................... 4 Before Operating the Truck............................................. 4 Warnings and Labels on the Truck ........................................ 4
ITD – INTRODUCTION
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SER-N0. CUT
REV.
General ..................................................................................... 7 Operating Instructions .................................................... 7 Service Training .............................................................. 7 Ordering Spare Parts ...................................................... 7 Using the Manual ............................................................ 7
M1 – LUBRICATION AND ADJUSTMENT
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Lifting the Truck ....................................................................... 11 Towing the Truck ..................................................................... 11 Jacking up the Truck ............................................................... 12 Component Access ................................................................ 13 Access to the Motor Compartment ................................ 14 Removing the Floorboard ............................................... 14 Plastic Panel Disassembly / Assembly .......................... 14 Maintenance ............................................................................ 16 Recommended Lubricants and Oils .............................. 16 Lubricants ................................................................... 16 Cold Store Trucks ........................................................ 16 Truck Decommissioning .................................................. 16 Restoring the Truck to Service ....................................... 16 Battery Maintenance ....................................................... 16 Daily Safety Check .................................................................. 18 Inspection and Maintenance Schedule ................................. 20 Cold Store Trucks ........................................................ 20 Torques .................................................................................... 26
M2 – HYDRAULICS
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Hydraulic Symbols .................................................................. 29 Functional Description ........................................................... 33 Abbreviations .................................................................. 33 Lifting ............................................................................... 35 Lowering .......................................................................... 35 Mast Reach Carriage Retraction ................................... 37 Mast Reach Carriage Extension .................................... 37 Tilt Back Circuit ............................................................... 39 Tilt Down Circuit .............................................................. 39 Sideshift Left ................................................................... 41 Sideshift Right ................................................................. 41 Hydraulic Components ........................................................... 42 Hydraulic Lines ............................................................... 42 Valve Block ...................................................................... 43 Relief Valve RV1 ......................................................... 43 Lowering Speed Adjustment Valve AVL ...................... 44 Pressure Load Switch PLS ............................................. 44 Hydraulic Reservoir ........................................................ 45
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TABLE OF CONTENT M2 – HYDRAULICS
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Discharging the Hydraulic Reservoir .......................... 45 Filling the Hydraulic Tank ............................................ 45 Filter ................................................................................. 46 Replacing the Return Filter ......................................... 46 Replacing the Aeration Filter ...................................... 47 Replacing the Suction Filter ........................................ 47 Pump Motor ..................................................................... 48 Hydraulic Pump ............................................................... 48 Disassembly ............................................................... 48 Commissioning ........................................................... 48 Bleeding the Hydraulic System ............................................. 50 Bleeding the Free Lift Cylinder ....................................... 50 Bleeding the Lift Cylinders ............................................. 50 Bleeding the Reach Cylinder ......................................... 51 Bleeding the Sideshift Cylinder ...................................... 51 Bleeding the Tilt Cylinders ............................................. 51 Bleeding the 5th Function Cylinder ................................ 51 Flushing the Cylinders .................................................... 51 Drift Tests ................................................................................. 52 Lift cylinder drift test ....................................................... 52 Tilt cylinder drift test ....................................................... 52 Causes of Drift ................................................................ 52
M3 – DRIVE UNIT
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Gear unit .................................................................................. 55 Preparation .............................................................................. 55 Tools required: ............................................................ 55 Removal .......................................................................... 55 Servicing ......................................................................... 55 General ....................................................................... 57 Gear Unit Disassembly / Assembly ............................... 57 Disassembly ............................................................... 57 Assembly .................................................................... 57 .................................................................................. 57 Preparing the gear unit ............................................. 57 Inserting the bevel pinion shaft ................................. 58 Assembling the flange shaft ...................................... 58 Adjusting the Bevel Wheel Set .................................. 58 Checking the flank tooth bearing .............................. 59 Final Assembly ......................................................... 59 Re-Assembly ................................................................... 60 Traction motor ................................................................. 60
M4 – ELEKTRICS
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Electrical Components ........................................................... 63 SPS (Safety Switch) .................................................... 63 KYS (Key Switch) ........................................................ 63 HNS (Horn Switch) ..................................................... 63 HN (Horn) ................................................................... 63 FS (Forward Switch) ................................................... 63 RS (Reverse Switch) ................................................... 63 ACS (Accelerator Switch) ........................................... 63 BFS (Brake Fluid Switch) ............................................ 63 BLS (Battery Lock Switch) .......................................... 63 ................................................................................................................... BS (Flashing Beacon Switch) 63 FKS (Fork Tilt Switch) ................................................. 63 LS (Load Sensor) ........................................................ 63 POT1 (Traction potentiometer) .................................... 63 MS-IDX-2140
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TABLE OF CONTENT M4 – ELEKTRICS
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POT2 (Raise potentiometer) ....................................... 63 POT3 (Reach potentiometer) ...................................... 64 POT4 (Tilt potentiometer) ........................................... 64 POT5 (Sideshift potentiometer) .................................. 64 POT6 (5th hydraulic function potentiometer) .............. 64 PLS (Pressure load switch) ........................................ 64 SES (Seat switch) ....................................................... 64 SFS 1SA (Forward travel steering feedback sensor) .. 64 SFS 2 (Steering feedback sensor 2) ........................... 64 BRS (Parking brake switch) ........................................ 64 BPS (Brake pressure switch) ...................................... 64 ORS (Override switch) ................................................ 64 ECR1 (Travel encoder) ............................................... 64 ECR2 (Lift encoder) .................................................... 64 ECR3 (Steering feedback encoder) ............................ 65 ECR4 (Steering encoder) ........................................... 65 ECR5 (Height encoder) .............................................. 65 THS1 (Temperature sensor 1) .................................... 65 THS2 (Temperature sensor 2) .................................... 65 THS3 (Temperature switch 3) ..................................... 65 RES1 (Reach sensor 1) .............................................. 65 RES2 (Reach sensor 2) .............................................. 65 SVH (Lift valve) ........................................................... 65 PVL (Proportional valve lower) ................................... 65 PVRT (Proportional valve retract) ............................... 66 PVRE (Proportional valve extend) .............................. 66 PVAR (Proportional valve accessories right) .............. 66 PVAL (Proportional valve accessories left) ................. 66 RV (Relief valve) ......................................................... 66 MVL (Manual lowering valve) ...................................... 66 AVL (Lowering speed adjustment valve) .................... 66 FU1 (TDM / Display control fuse) ............................... 66 FU2 (VCM / HDM control fuse) ................................... 66 FU3 (Brake control fuse) ............................................. 66 FU4 (SDM power fuse) ............................................... 66 FU5 / FU6 (Options control fuses) ............................. 66 FU7 (Main fuse) .......................................................... 66 FAN1 (Electric compartment fan) .............................. 66 FAN2 (traction and hydraulic module fan) ................... 66 FAN3, FAN4 (Motor compartment fans) ..................... 66 K1(R1-R10 Heating resistor relays) ............................ 66 K2 (Heating fan relay) ................................................. 67 K3 / K4 (Brake light relay) ........................................... 67 K5 (Travel lights relay) ................................................ 67 K6 (Work lights relay) ................................................. 67 K7 / K8 (Travel alarm relay) ........................................ 67 K9 / K10 (Flashing beacon relay) ............................... 67 K12 / K13 (Options relay) ........................................... 67 SW (Work lights switch) .............................................. 67 SD (Travel lights switch) .............................................. 67 SI (Indicator switch) .................................................... 67 ESR4500 Status Codes ........................................................... 69 Status Codes ................................................................... 69 When a Service Code Occurs .................................... 69 Truck does not operate and there is no Status Code . 69 1. Fault during power-up ........................................... 69 2. The fault is not electrical ....................................... 69
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TABLE OF CONTENT M4 – ELEKTRICS
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3. Malfunction in one of a group of unmonitored inputs ........................................................................ 69 Statuscode 100 - 102 ..................................................... 71 Statuscode 110 - 120 ..................................................... 72 Statuscode 121 - 130 ..................................................... 73 Statuscode 131 - 160 ..................................................... 74 Statuscode 180 - 181 ..................................................... 75 Statuscode 182 - 183 ..................................................... 76 Statuscode 184 - 200 ..................................................... 77 Statuscode 201 - 210 ..................................................... 78 Statuscode 211 - 213 ..................................................... 79 Statuscode 214 - 220 ..................................................... 80 Statuscode 221 - 222 ..................................................... 81 Statuscode 223 - 224 ..................................................... 82 Statuscode 225 - 230 ..................................................... 83 Statuscode 240 ............................................................... 84 Statuscode 241 ............................................................... 85 Statuscode 243 ............................................................... 86 Statuscode 244 ............................................................... 87 Statuscode 246 ............................................................... 88 Statuscode 247 ............................................................... 89 Statuscode 249 ............................................................... 90 Statuscode 250 ............................................................... 91 Statuscode 252 ............................................................... 92 Statuscode 253 ............................................................... 93 Statuscode 260 ............................................................... 94 Statuscode 261 ............................................................... 95 Statuscode 262 ............................................................... 96 Statuscode 263 ............................................................... 97 Statuscode 264 ............................................................... 98 Statuscode 265 ............................................................... 99 Statuscode 266 ............................................................... 100 Statuscode 267 ............................................................... 101 Statuscode 268 ............................................................... 102 Statuscode 280 - 282 ..................................................... 103 Statuscode 283 - 284 ..................................................... 104 Statuscode 285 - 300 ..................................................... 105 Statuscode 301 - 310 ..................................................... 106 Statuscode 311 - 313 ..................................................... 107 Statuscode 314 - 320 ..................................................... 108 Statuscode 321 - 322 ..................................................... 109 Statuscode 323 - 324 ..................................................... 110 Statuscode 325 - 330 ..................................................... 111 Statuscode 340 ............................................................... 112 Statuscode 341 ............................................................... 113 Statuscode 343 - 381 ..................................................... 114 Statuscode 382 - 383 ..................................................... 115 Statuscode 384 - 385 ..................................................... 116 Statuscode 430 - 431 ..................................................... 117 Statuscode 460 - 462 ..................................................... 118 Statuscode 463 - 465 ..................................................... 119 Statuscode 840 - 841 ..................................................... 120 Statuscode 880 ............................................................... 121 Statuscode 881 ............................................................... 122 Statuscode 883 ............................................................... 123 Statuscode 884 ............................................................... 124 Statuscode 885 ............................................................... 125 Statuscode 886 ............................................................... 126 MS-IDX-2140
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TABLE OF CONTENT M4 – ELEKTRICS
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APPENDIX ...................................................................... 127 Display not active ........................................................ 127 Main contactor switches continuously ON/OFF ...................................................................... 127 Only battery discharge indicator and message display active ............................................... 127 Main contactor briefly activated after power up .......... 127 Service Level ........................................................................... 129 Display ............................................................................. 129 Design and Functions ................................................. 129 Steer Angle Display .................................................. 129 Travel Direction Display ............................................ 129 Battery Charge Status Display ................................. 129 Operator error display ............................................... 129 Service Display ......................................................... 130 Function Keys ........................................................... 130 Message Display ...................................................... 130 Capacity Data Monitor ................................................ 130 Brake Fluid Level Indicator ....................................... 130 Steer Fault Display .................................................... 130 Parking Brake Display ............................................... 130 Performance Setting Display .................................... 130 Operator Menu ........................................................................ 131 Tilt Position - Assist On / Off ....................................... 132 Rack Height Select On / Off ........................................ 133 Programming Rack Height Select ............................... 133 Programming Rack Height Select ... ........................... 134 Service Level ........................................................................... 135 Chapter structure : .......................................................... 135 ANALYZER ................................................................. 135 A1 STATUS ............................................................... 135 A2 INPUTS ................................................................. 135 A3 OUTPUTS ............................................................. 135 CALIBRATION ............................................................ 135 C1 Accelerator Pedal ................................................ 135 C2 Raise Lower Handle ............................................ 135 C3 Reach Handle ..................................................... 135 C4 Tilt Handle ........................................................... 135 C5 Sideshift Handle .................................................. 136 C6 5th Function Handle ............................................ 136 C7 Height .................................................................. 136 C8 Weight ................................................................. 136 C9 Fork Positioning ................................................... 136 C10 Reach retract slow down ................................... 136 C11 Save? ................................................................ 136 FEATURE .................................................................... 136 F1 Truck size ............................................................. 136 F2 FLS Switch .......................................................... 136 F3 Height Encoder .................................................... 136 F4 Lower Cut out ...................................................... 136 F5 Fifth Function ....................................................... 136 F6 Max Load ............................................................. 136 F7 Capacity Data Monitor CDM ................................ 136 F8 Alarm 2 ................................................................ 136 F9 Beacon ................................................................ 137 F10 User Performance .............................................. 137 F11 User Codes ........................................................ 137 F12 Language ........................................................... 137 ESR4500 06/2004 • Printed in Germany
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TABLE OF CONTENT M4 – ELEKTRICS
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F13 Truck lockout ...................................................... 137 F14 Rack select ........................................................ 137 F15 Height & weight on/off ....................................... 137 F16 Timer on/off ........................................................ 137 F17 Error log on/off ................................................... 137 F18 Operator Alarm1 on/off ...................................... 137 F19 Battery low level alarm ...................................... 137 F20 Fork positioning ................................................. 137 F21 Change value Euro/US ...................................... 137 F22 Save ................................................................... 137 HOUR METER ............................................................ 137 H1 Run ...................................................................... 137 H2 TDM Traction Drive Module ................................. 137 H3 HDM Pump Drive Module ................................... 137 H4 VCM Vehicle Controll Module .............................. 137 H5 SDM Steer Drive Module .................................... 137 H6 Display ................................................................. 137 H7 Set Service Timer ................................................ 137 H8 Escape ................................................................ 137 LOG EVENTS ............................................................. 137 L1 History .................................................................. 137 L2 Totals .................................................................... 137 L3 Erase ................................................................... 137 L4 Escape ................................................................. 137 PERFORMANCE ........................................................ 138 P1 Setup P1 .............................................................. 138 P2 Setup P2 .............................................................. 138 P3 Setup P3 .............................................................. 138 P4 BDI setting ........................................................... 138 P5 Travel > LCS ........................................................ 138 P6 Travel > FLS ......................................................... 138 P7 Travel > Custom ................................................... 138 P8 Lower > Custom .................................................. 138 P9 Reach > Custom ................................................. 138 P10 5th Function left ................................................. 138 P11 5th Function right .............................................. 138 P12 Steer low speed ................................................. 138 P13 Steer high speed ............................................... 138 P14 Brake at ramp .................................................... 138 P15 Save .................................................................. 138 UTILITIES ................................................................... 138 U1 Software Version ................................................. 138 U2 Hour Set .............................................................. 138 U3 Accy Override ...................................................... 138 U4 Escape ................................................................ 138 Overview of Performance Default Settings .......................... 139 Service Menu ........................................................................... 140 Access to Service Level ................................................. 140 Overview of menu items ............................................. 140 Analyzer .................................................................... 140 Calibration ................................................................. 140 Feature ...................................................................... 140 Hour Meter ................................................................ 140 Log Events ................................................................ 140 Performance ............................................................. 140 Utilities ...................................................................... 140 Analyzer ........................................................................... 142 A1.1 - A1.12 Status ..................................................... 142 MS-IDX-2140
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TABLE OF CONTENT M4 – ELEKTRICS
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A2.1 - A2.6 Inputs ....................................................... 143 A2.7 - A2.13 Inputs ..................................................... 144 A2.14 - A2.20 Inputs ................................................... 145 A2.21 - A2.25 Inputs .................................................. 146 A2.26 - A2.32 Inputs ................................................... 147 A2.33 - A2.37 Inputs ................................................... 148 A3.1 - A3.9 Outputs .................................................... 149 A3.10 - A3.16 Outputs ................................................ 150 A3.17 - A3.18 Outputs ................................................ 151 Calibration ....................................................................... 152 C1 - C3 Calibration ..................................................... 152 C4 - C5 Calibration ..................................................... 153 C6 - C7.1 Calibration .................................................. 154 C7.1.3 Calibration ....................................................... 155 C7.2 Calibration .......................................................... 156 C7.3 Calibration .......................................................... 157 C7.3.4 - C7.5 Calibration ............................................ 158 C8 Calibration ............................................................. 159 C9 Calibration ............................................................. 160 C10 - 11.2 Calibration ................................................. 161 Feature ............................................................................ 162 F1 - F3 Features ......................................................... 162 F4 - F6 Features ......................................................... 163 F7 - F7.7 Features ...................................................... 164 F8 Features ................................................................. 165 F9 - F10 Features ....................................................... 166 F11 Features ............................................................... 167 F12 - F14 Features ..................................................... 168 F15 - F19 Features ..................................................... 169 F20 - F22 Features ..................................................... 170 H1 - H3 Hourmeter ..................................................... 171 H4 - H8 Hourmeter ..................................................... 172 Log Events ...................................................................... 173 L1 - L3.2 Features ...................................................... 173 L3.2.1 - L4 Features ................................................... 174 Performance .................................................................... 175 P1 - P1.5.1 Performance ............................................ 175 P1.6 - P1.10.1 Performance ....................................... 176 P1.11 - P1.15 Performance ........................................ 177 P2 - P6 Performance .................................................. 178 P7 - P10 Performance ................................................ 179 P11 - P15.2 Performance ........................................... 180 Utilities ............................................................................. 181 U1 - U2 Utilities ........................................................... 181 U3 - U4 Utilities ........................................................... 182 Control Module Safety Test .................................................... 183 General ............................................................................ 183 Steer Module Safety Test ............................................... 183 Preparatory measures ................................................ 183 Procedure ................................................................... 183 Drive Module Safety Test ................................................ 184 Tools required ............................................................. 184 Preparatory measures ................................................ 184 Procedure ................................................................... 184 Final procedure ........................................................... 185
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TABLE OF CONTENT M5 – BRAKE
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Load Wheel Brake ................................................................... 189 General ............................................................................ 189 Brake Lining .................................................................... 189 Disassembly ............................................................... 189 Assembly .................................................................... 189 Wheel Brake Cylinder ..................................................... 190 General ....................................................................... 190 Disassembly ............................................................... 190 Assembly .................................................................... 190 Bleeding the load wheel brake and replacing the brake fluid ........................................................... 190 Operating Brake ...................................................................... 192 Disassembly .................................................................... 192 Test and Inspection ..................................................... 192 Assembly ......................................................................... 192 Air gap setting ................................................................. 192 Setting the brake pedal clearance ................................. 194
M6 – STEERING
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Steering .................................................................................... 197 General ............................................................................ 197 Functional Description ................................................ 197 Quadrant - Definition ................................................... 198 Error routine .................................................................... 198 When the error routine starts … ................................. 198 Ending the error routine .............................................. 198 Causes of error routine activation .................................. 198 Other error causes .......................................................... 198 Examples of steer faults ................................................. 199 Example 1: Manual wheel change, drive wheel turned 160° to the right .......................................................... 199 Ending the error routine ............................................ 199 Example 2: Manual wheel change, drive wheel turned 70° to the right ............................................................ 200 Setting the SFS … proximity switches ........................... 202 Replacing the steer motor .............................................. 202 Disassembly ............................................................... 202 Assembly .................................................................... 202 Steering wheel ................................................................ 204 Disassembly ............................................................... 204 Assembly .................................................................... 204 Steering Sensor (ECR4) ................................................. 206 Disassembly ............................................................... 206 Assembly .................................................................... 206
M7 – MAST
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Mast .......................................................................................... 211 General ............................................................................ 211 Torque Requirements ................................................. 211 Lifting Gear Minimum Capacity ................................... 211 Mast Testing (Assembled) .............................................. 212 Flaking ........................................................................ 212 Mast Shock Absorbers ................................................ 212 Mast end stops ........................................................... 212 Fork Adjustment .......................................................... 212 Mast Removal and Assembly ................................................. 213
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TABLE OF CONTENT M7 – MAST
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General ............................................................................ 213 Disassembly .................................................................... 213 Assembly ......................................................................... 215 Dismantling and Assembling the Mast ................................. 216 General ............................................................................ 216 Dismantling ..................................................................... 216 Fork Carriage Removal ............................................... 216 2nd Mast Stage Removal ........................................... 216 1st Mast Stage Removal ............................................. 216 Replacing the Mast Rollers .................................................... 218 General ............................................................................ 218 Mast Roller Assembly ..................................................... 218 Calculating the Roller Diameter .................................. 218 Calculating the Required Number of Shims ............... 218 Outer Mast / 1st Mast Stage ..................................... 218 1st Mast Stage / 2nd Mast Stage ............................. 220 Fork Carriage ............................................................ 222 Final Work and Settings ................................................. 223 Free lift cylinder removal / installation with mast attached 224 General ............................................................................ 224 Torque Requirements ................................................. 224 Lifting Gear Minimum Capacity ................................... 224 Disassembly .................................................................... 224 Assembly ......................................................................... 225 Lift cylinder removal / assembly ............................................ 228 General ............................................................................ 228 Lifting Gear Minimum Capacity ................................... 228 Disassembly .................................................................... 228 Assembly ......................................................................... 230 Lift Chains ............................................................................... 232 General ............................................................................ 232 Inspection ........................................................................ 232 Cleaning ...................................................................... 232 Wear ........................................................................... 232 Freedom of Movement of Chain Links ........................ 233 Chain Tension ............................................................. 233 Chain Anchor and Pulleys .......................................... 234 Worn Connection Plates ............................................. 234 Protruding or Turned Chain Pins ................................. 234 Corrosion .................................................................... 234 Chain Lateral Wear ..................................................... 235 Uneven Chain Tension .............................................. 235 Misalignment of Lift Components ............................. 235 Lift Chain Lubrication ...................................................... 236 Detaching Lift Chains ..................................................... 237 Tools and Equipment Required ...................................... 237 Detachment ..................................................................... 237 Fork Tines ................................................................................ 238 General ............................................................................ 238 Terms .......................................................................... 238 Fork Identification ....................................................... 238 Repairs ............................................................................ 238 Checking the Fork ........................................................... 238 Crack Inspection ......................................................... 238 Verticality Test ............................................................. 239 Fork Blade Warping .................................................... 239 Measuring the Fork Tip Width ........................................ 239 Fork Tine Height Difference ........................................... 239 ESR4500 06/2004 • Printed in Germany
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TABLE OF CONTENT M7 – MAST
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Stop Mechanism ............................................................. 240 Fork Blade Wear ............................................................. 240 Reach ....................................................................................... 242 Disassembly .................................................................... 242 Assembly ......................................................................... 242 Side Roller Adjustment ............................................... 242 Backing Roller Adjustment .......................................... 243 Reach Cylinder ........................................................................ 244 Disassembly .................................................................... 244 Assembly ......................................................................... 244 Integrated Sideshifter ............................................................. 245 Disassembly .................................................................... 245 Assembly ......................................................................... 245
M8 – CYLINDERS
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Cylinders .................................................................................. 249 General ............................................................................ 249 Safety when working on hydraulic systems ................ 249 General Instructions for Repairing Hydraulic Components ............................................................... 249 Rod Seal Assembly ................................................................. 250 General ............................................................................ 250 Large Rod Seal Assembly .............................................. 250 Small Seal Rod Assembly .............................................. 251 Rod Seal Assembly, Sealing Lip First ............................ 252 Lift cylinder .............................................................................. 255 General ............................................................................ 255 Removal and Assembly .................................................. 255 Dismantling ..................................................................... 255 Rod Seal Removal ...................................................... 255 Piston Rod Removal ................................................... 255 Assembly ......................................................................... 255 Piston Rod Assembly .................................................. 255 Installing the Rod Seal ................................................ 255 Free-Lift Cylinder .................................................................... 259 General ............................................................................ 259 Removal and Assembly .................................................. 259 Dismantling ..................................................................... 259 Rod Seal Removal ...................................................... 259 Piston Rod Removal ................................................... 259 Cushion Removal ........................................................ 259 Assembly ......................................................................... 259 Cushion Installation .................................................... 259 Piston Rod Assembly .................................................. 259 Installing the Rod Seal ................................................ 259 Reach Cylinder ........................................................................ 263 General ............................................................................ 263 Removal and Assembly .................................................. 263 Dismantling ..................................................................... 263 Rod Seal Removal ...................................................... 263 Piston Rod Removal ................................................... 263 Assembly ......................................................................... 263 Piston Rod Assembly .................................................. 263 Installing the Rod Seal ................................................ 263 Sideshift, Cylinder ................................................................... 266 Dismantling ..................................................................... 266 Assembly ......................................................................... 266
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TABLE OF CONTENT DIA – ELECTRICAL DIAGRAMS
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Wiring Diagram - AC System ................................................. 273 Wiring Diagram - AC System ................................................. 274 Wiring Diagram Option ........................................................... 275 Wiring Diagram Coldstore Cabin ........................................... 276 Main Harness ........................................................................... 279 Main Harness ........................................................................... 280 PARTS_TABLE .......................................................... 281 Connector Table ...................................................................... 281 PARTS_TABLE .......................................................... 281 WIRE_TABLE ............................................................ 281 Connector Table ...................................................................... 282 WIRE_TABLE ............................................................ 282 WIRE_TABLE ............................................................ 282 Harness: Connector Panel to Reach Carriage ..................... 283 Harness: Reach Carriage ....................................................... 284 Harness Options ..................................................................... 285 Harness Beacon ...................................................................... 286 Harness Beacon Switch ......................................................... 287 Harness Coldstore .................................................................. 288 Harness Working Light12 V .................................................... 289 Harness Working Light 24 V ................................................... 290 Harness Driving Light ............................................................. 291 Harness Travel Alarm .............................................................. 292 Harness DC/DC Converter with Harness Options 813445 ................................................ 293 Harness DC/DC Converter without Harness Options 813445 .......................................... 294 Harness Heated Seat .............................................................. 295 Harness 12V / 24V Supply to B/W Screen ............................. 296 Harness Monitor B/W or Connection Box to Connector Panel ................................................................. 297 Harness (Camera) Connector Panel to Reach Carriage ...... 298 Harness (Camera) Reach Carriage to Mast .......................... 299 Harness (Camera) Mast to Camera ....................................... 300 Harness (Camera) TFT Display to Connection Box ............. 301 Harness 12 V Supply to Connection Box .............................. 302 Harness and Installation Drawing 6th Function ................... 303 Harness Davis Derby System ................................................ 304 Davis Derby EV 16 Circuit Program ...................................... 305 Davis Derby S 16 Circuit Program ......................................... 306 Harness 1 Coldstore Cabin .................................................... 307 Harness 2 Coldstore Cabin .................................................... 308
HYD – HYDRAULIC SCHEMATICS
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Hydraulic Schematic ............................................................... 311 Hydraulic Lines to the Valve Block ........................................ 312
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TABLE OF CONTENT
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SAFETY
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SAFETY Safety Symbols used in the Manual To help guide you through the manual and to highlight particular danger areas, we have used graphic illustrations:
General Maintenance and Repair Safety Notes DANGER
DANGER This symbol indicates life-threatening risks ●
●
Failure to comply with this notice may result in fatal injuries to yourself or other people.
WARNING This symbol indicates the risk of serious injury and/or serious material damage. ●
Read the safety notices in the truck Maintenance and Operator's Manuals.
Failure to comply with this notice may result in severe injuries to yourself or other people and/or serious material damage.
CAUTION
Motorised vehicles can be dangerous if maintenance and service are neglected. For this reason maintenance and inspections must be carried out at regular short intervals by trained personnel working to approved company guidelines.
DANGER Follow all national/local safety regulations applicable for maintenance work, e.g. for work on higher levels. ●
This symbol indicates the risk of minor injury and/or minor material damage. ●
Failure to comply with this notice may result in minor injuries to yourself or other people and/or minor material damage.
1.
Maintenance work must only be carried out in accordance with the test and maintenance program contained in the present Maintenance Manual and any applicable service notices.
2.
Only qualified and authorised personnel may carry out work on the truck.
3.
Always keep fire extinguishers in good working condition. Do not approach fluid levels or leaks with a naked flame.
4.
To clean, use a non flammable, non combustible cleaning solution which is groundwater-neutral. Only carry out cleaning with an oil separator. Protect the electrical system from dampness.
5.
Keep the service area clean, dry and wellventilated.
6.
Do not allow oil to penetrate the ground or enter the draining system. Used oil must be recycled. Oil filters and desiccants must be treated as special waste products. Relevant applicable regulations must be followed.
7.
Neutralise and thoroughly rinse any spilled battery fluid immediately.
8.
Keep the truck clean. This will facilitate the location of loose or faulty components.
OPTION These items relate to optional features not supplied with the standard version.
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Failure to do so could result in severe or fatal injuries to maintenance personnel and/or other persons.
Maintenance and Repair
INFORMATION Contains additional information with supplementary notes and hints.
Failure to do so could result in severe or fatal injuries to maintenance personnel and/or other persons.
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SAFETY 9.
Make sure that capacity and data plates, warnings and labels are legible at all times.
10. Alterations or modifications by the owner or operator are not permitted without the express written authorisation from Crown. 11. Only use original Crown spare parts to ensure the reliability, safety and suitability of the Crown truck.
Before Leaving the Truck ●
Stop the truck.
●
Lower the fork carriage fully.
●
Apply the parking brake.
●
Turn off the truck and remove the key.
●
Block all wheels when parking on an uneven surface.
Warnings and Labels on the Truck During regular maintenance check that the warnings and labels on the truck are complete and legible. ●
Clean any illegible labels.
●
Replace any faulty or missing labels.
The order and meaning of the warnings and labels on the truck are described in section 10.9 of the parts manual.
Before Carrying out Work on the Truck ●
Raise the truck to free the drive wheel. Press the emergency Stop button and disconnect the battery.
●
Prevent the truck from rolling away.
●
Before carrying out work on the hoist frame, the lift mast or on the fork carriage: Block these parts according to maintenance instructions in order to prevent them from dropping.
●
Only carry out operational testing when there is sufficient room to manoeuvre, to avoid the risk of injury to yourself and others.
Before Operating the Truck ●
Check the safety devices.
●
Get into the driver's seat.
●
Check the operation of the lifting device, travel direction switch, speed control, steering, warning devices and brakes.
MS-MA-0000
4
SC3200 03/2004 • Printed in Germany
INTRODUCTION
Printed in Germany
5
Blank page
Printed in Germany
6
INTRODUCTION General The present manual is designed for Customer Service engineers who wish to familiarise themselves with the maintenance work required for the various truck components. It also contains troubleshooting sections which can be used to identify and remedy truck faults.
INFORMATION This book is not an operating manual. It is designed solely for specialist personnel who have been trained and authorised to carry out the work described in the manual.
This manual therefore contains fewer and less detailed warnings than the Operator’s Manual, as the latter is aimed at persons who have very little or no prior experience at all.
Operating Instructions This manual contains no operating instructions. An operating instructions manual is supplied with the vehicle. Additional copies can be ordered as required. With the help of this manual you and your personnel will be able to ensure the long service life, operational safety and error free functioning of your CROWN vehicle.
Service Training CROWN offers the appropriate vehicle related training for service personnel. Details on this training can be obtained from CROWN on request.
Ordering Spare Parts The maintenance manual does not cover spare parts. These are listed in a separate manual. Spare parts can be ordered by quoting: ●
The truck specification number
●
The truck model number
●
The truck serial number
This information can be found on the truck’s data plate. Only if this information is provided can the order be processed quickly, correctly and reliably.
Please refer to the Technical Specifications Sheet for the utilisable loads, technical data and dimensions for thisseries. Brochures can be obtained from your CROWN dealer or from the following address: CROWN Gabelstapler GmbH & Co.KG Moosacher Str. 52 80809 Munich GERMANY Tel.: +49 (0)89 / 93 002 -0 Fax: +49 (0)89 / 93 002 -175 oder 133
Using the Manual The manual is divided into sections. The following table shows how the manual is structured.
Sections Maintenance Section
Description
IDX
Table of Content
MA
Safety
ITD
Introduction
M1
Lubrication and Adjustment
M2
Hydraulics
M3
Drive Unit
M4
Electrical
M5
Brake
M6
Steering
M7
Mast / Lifting Mechanism
M8
Cylinder
DIA
Electrical Diagrams
HYD
Hydraulic Schematic A01M-gb
SC3200 03/2004 • Printed in Germany
MS-ITD-2232
7
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0Printed in Germany
8
LUBRIFICATION AND ADJUSTMENT
Printed in Germany
9
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Printed in Germany
10
LUBRIFICATION AND ADJUSTMENT Lifting the Truck
Towing the Truck
CAUTION Scalding hazard! Spilled battery acid can cause injuries and damage the truck. You must remove the battery before transporting the truck.
If the truck has been switched off and is idle, it can be towed over short distances without having to release the drive wheel brake. A brokendown truck can be removed from its operating aisle using a fork lift truck with a minimum 2500 kg capacity. ●
Tilt the forks down and position them under the chassis as illustrated in the diagram.
●
Raise the truck approximately 20 mm off the ground. The drive wheel should not be in contact with the ground. Otherwise the truck will be damaged!
●
Slowly tow the truck in a forward direction only (black arrow).
DANGER Falling loads are hazardous! Accidents can result from lifting gear with insufficient capacity and unsecured loads. Always use lifting gear with sufficient capacity and prevent the load slings from sliding. Calculate the minimum capacity requirement based on the weight of the truck. This information can be found on the truck data plate. Attach the 4 straps to the hitch points as shown.
Support points
MO-2140-020
MO-2140-019 ESR4500 06/2004 • PRINTED IN GERMANY
MS-M1-2140
11
LUBRIFICATION AND ADJUSTMENT Jacking up the Truck DANGER Risk of injuries! A non-supported or insufficiently supported truck or truck part can suddenly drop and seriously injure you if you leave your hands or other body parts underneath it. Always support the raised truck on square blocks or other appropriate material to relieve the jack. ●
Fully lower the forks.
●
Place wedges in front of both load wheels.
●
Apply a jack with sufficient capacity as centrally as possible on the skirting rail and lift the truck.
●
Slide hard wooden blocks underneath the left and right-hand sides and lower the truck onto them.
●
Apply the jack underneath the load wheel arm and raise until the load wheel is max. 10 mm off the ground (risk of tipping!).
●
Slide a hard wooden block underneath and lower the truck onto it.
●
Raise the other load wheel arm and lower it onto a hard wooden block.
MO-2140-021
MS-M1-2140
12
ESR4500 06/2004 • Printed in Germany
LUBRIFICATION AND ADJUSTMENT Component Access In the course of regular maintenance the components inside the truck chassis can be reached by unscrewing the panels or simply by flipping up and lifting out the driver seat. Detailled descriptions are contained on the next page.
DANGER Danger of death! When servicing or adjusting the drive motor, hydraulic system or truck drive module, accidentally starting the drive motor or a hydraulic function can fatally injure people standing in front, beside or behind the truck. Lower the forks and retract the mast reach. Jack up the truck so that the drive wheel is clear of the ground.
Underneath the panel ● VCM, TDM, HDM, SDM ● Line contactor ● Fuses ● Emergency Disconnect ● Fan
Underneath the steering column panel ● Steer sensor
Underneath the floorboard ● Main brake cylinder ● Pedal mechanism of ● Accelerator pedal ● Brake pedal ● Safety pedal ● Horn
Underneath the driver’s seat ● Drive unit ● Brake ● Hydraulic motor, pump and reservoir ● Steer motor
MS-2140-013
● Connector panel
ESR4500 06/2004 • PRINTED IN GERMANY
MS-M1-2140
13
LUBRIFICATION AND ADJUSTMENT Access to the Motor Compartment ●
Push the seat forward.
●
Open the quick release mechanism (see Fig. MO-2140-023).
●
Push the seat backward.
●
Flip the seat forward (Fig. MS-2140-015).
●
Disconnect the cable to the seat switch on the connector panel (see double arrow Fig. MS2140-015).
●
Lift out the seat from the top.
●
Installation is the reverse of disassembly. Do not forget the cable to the seat switch!
Removing the Floorboard Remove one screw (see Fig. MS-2140-014). Lift the floorboard backwards and up to remove it (seat must be removed first).
MS-2140-014
Plastic Panel Disassembly / Assembly
MO-2140-023
●
Remove screw (1, see Fig. MS-2140-016).
●
Raise the cover (2) and disconnect the electrical connections. Remove the cover (2).
●
Remove screws (3).
●
Remove panel (4).
●
Installation is the reverse order.
1 3 3 2
4
3 MS-2140-016
MS-2140-015
MS-M1-2140
14
ESR4500 06/2004 • Printed in Germany
LUBRIFICATION AND ADJUSTMENT
Emergency Disconnect Switch
Display Main Fuse FU7 Vehicle Control Module VCM
Steer Drive Module SDM
Travel Direction Switch
Fuses
Main Contactor
Traction Drive Module TDM
Hydraulic Drive Module HDM
Start Up Module
Optional Switches
Steer Sensor Hydraulic Tank
MS-2140-017
Brake Pedal
Steer Motor
Pump Motor
Safety Pedal Brake Fluid Reservoir + Main Brake Cylinder
Brake
Connector panel
Drive Motor
ESR4500 06/2004 • PRINTED IN GERMANY
MS-M1-2140
15
LUBRIFICATION AND ADJUSTMENT Maintenance
●
Jack up the truck. Lower the chassis onto suitable wooden blocks in order to clear the wheels from the ground (this prevents the wheels from flattening under constant pressure).
●
Every 3 months connect the battery, carry out a daily check and test the truck functions. Then disconnect the battery again.
Recommended Lubricants and Oils Lubricants The following page lists typical lubricants which are also used by Crown in the factory. However, any lubricants with the same technical specifications can be used.
Cold Store Trucks
Restoring the Truck to Service When restoring the truck to service, proceed as follows:
Special hydraulic oil, lubricant oils and grease for low temperature applications must be used for cold store trucks (see table on following page). All screws, washers, nuts, pins, retaining rings etc. must be treated regularly with an anti-corrosion solution CROWN no. 805236004. Electrical connections and components must be carefully protected against corrosion.
●
Remove any addition corrosion protection applied (except for cold store protection)*.
●
Jack up the truck, remove the wooden blocks and lower the truck.
●
Charge the battery or install a charged battery.
Maintenance intervals must be adapted to the conditions of use. They should be as frequent as possible to prevent excess wear. Please contact CROWN who will draw up an appropriate maintenance schedule for your conditions.
●
Connect the battery.
●
Carry out the daily check.
Truck Decommissioning When taking the truck out of service for more than 3 months, proceed as follows: ●
Disconnect the battery.
●
Decommission the battery in accordance with the manufacturer's instructions.
●
Clean the truck*. Grease the truck in accordance with the maintenance manual.
●
If the truck is to be stored in hostile ambient conditions (e.g. saline atmosphere) treat the surfaces of the truck with a suitable solution to prevent corrosion.
●
Do not park the truck in the open air or in a humid environment. The ideal location is a dry room with as constant a temperature and air humidity as possible. If the truck has to be covered, use material through which air can permeate rather than plastic sheets. Otherwise condensation water may form.
MS-M1-2140
16
* Do not use high pressure cleaners and/or solvents on the truck. Do not use metal brushes. Do not wet-clean the electrical system and do not use flammable cleaning solutions.
Battery Maintenance The condition of the battery will affect the performance and driving characteristics of the truck. Optimal maintenance (regular specific gravity and electrolyte level checks, keeping the cell tops clean) is key to maintaining the performance and useful life of the battery. Service the battery in accordance with the battery manufacturer‘s instructions only.
ESR4500 06/2004 • Printed in Germany
LUBRIFICATION AND ADJUSTMENT Lubricant Type
Product Description
Manufacturer
CROWN Part No.
Type
Grease (multi purpose)
Aralube HLP-2 LM-Grease Regulus A2 Beacon EP2 EP2 Mobiluxe E2 Retinax LX LGWM1
Aral Castrol Century Esso Maxol Mobil Shell SKF
053002-001
B
Low temperature grease
Aralube SKL2 Unirex Lotemp EP
Aral Mobil
053002-005
BB
Lubrication oil (chain)
Kowal 40 Essolube HDX + 40 Delvac 1240
Aral Esso Mobil
053002-007
G
Low temperature lubrication oil
SHC 626
Mobil
053002-008
GG
Hydraulic oil
Vitam GF 32 Hyspin AWS-32 Nuto H32 DTE 24 Tellus 32 B110
Aral Castrol Esso Mobil Shell Fuchs Mineralölwerke GmbH
053001-003
D
Low temperature hydraulic oil
Univis J 13 Aero HFA
Esso Mobil
053001-008
DD
Transmission oil
Castrol EPX-80W-90 Spirax HD 80W-90
Burmah Castrol Shell
053002-002
A
Low temperature transmission oil
Mobilube SHC-LS75W-90
Mobil
053002-006
AA
Brake fluid
DOT 4
053059-001
J
Rubber and vinyl dressing
H
Special grease
MOS2 Lithium
Universal lubrication oil
SEA40
Anti-corrosion agent
Tectyl
Dow Corning
063002-022
M
C Corrosion agent for cold store trucks
805236-004
L01-gb
ESR4500 06/2004 • PRINTED IN GERMANY
MS-M1-2140
17
LUBRIFICATION AND ADJUSTMENT Daily Safety Check 8, 21 7 8, 21
MS-2140-020
Above the Battery
4
11
3
11
8
MS-2140-018
MS-2140-019
Daily or every 8 service hours Item Component
Action
1
S eat
Make sure that the seat is in a fixed position. Check for damage.
2
Steering Column
Make sure that the steering column's position is fixed.
3
Covers / Panels
All covers / panels present, undamaged and secure?
4
Safety Shield
Check if it is properly secured. Check for damage. Good visibility through shield?
L a b e l s, D e ca l s
Check that they are all present, clean and legible (see operator manual, page 210).
6
Forks, Fork Carriage
Check for deformation, fissures and excess wear. Make sure the fork tines are in a fixed position, with the latch pin located in the carriage slot.
7
Load Backrest, Accessories (if applicable)
Check if properly secured. Check for damage.
8
Lift Chain, Chain Anchor
Check for corrosion, fissures, deformation and any signs of damage.
9
Wheels
Check tyres for wear and for any foreign bodies. Remove any foreign bodies found.
5
Any signs of leakage on the ground under the truck? 10
- Gear Unit
- by the drive wheels (brown oil)
- Hydraulic System
over the entire area below the chassis and mast (light oil)
- Braking System
below the chassis between the brake pedal and drive wheel, below the outriggers (light fluid) L02-gb
MS-M1-2140
18
ESR4500 06/2004 • Printed in Germany
LUBRIFICATION AND ADJUSTMENT DANGER Risk of accidents! If you carry out the test run (test items 12 to 26) in your normal working environment, you risk endangering yourself and
your colleagues, as you will have to concentrate on the truck. Carry out the test drive in an open area free of obstacles.
Daily or every 8 service hours (contd.) Pos. Component
Action
11
Battery
- Check that the battery cable is secured. Check for any damage. - Check battery compar tment for battery acid leakage. - Check that the clamps on both sides of the battery are tight. - Check/maintain battery in accordance with battery maintenance manual.
12
Key Switch
Turn key switch ON (green dot) and check the operation of the indicators in the display panel ( see operator manual, page 3-3).
13
Parking Brake
Check operation. Travel should be inhibited when the parking brake is applied.
14
Emergency Disconnect Switch, Seat Switch, Safety Pedal
Test operation (separately): Press the emergency disconnect switch; take your weight off the seat; release the safety pedal while the forks are moving.
15
Horn
Check operation.
16
Steering
Check operation and absence of play.
17
Travel Functions
Move the truck in both directions, slowly at first and then at full speed. The truck movement should not be jerky. The travel direction switch should remain in a fixed position.
18
Braking
Check braking in both directions: - release accelerator pedal: braking depending on settings - change travel direction: braking depending on settings - apply brake pedal: brake distance longer than during previous check?
19
Fans
Check operation / air flow (➔ see illustration). The fans operate when the hydraulic control unit exceeds an operating temperature of 35 °C.
20
Battery Latch
The battery must not move when you extend the mast.
21
Hydraulic Functions
Check all functions (lifting/lowering, mast reach, fork tilt, sideshift, additional function). Raise and lower the forks with maximum speed: ➔ The forks must automatically slow down when approaching the limit positions Extend and retract the mast reach carriage with maximum speed: ➔ The mast must automatically slow down when approaching the reach limit positions. Check the control levers for excessive play. Check the movement of mast, chains, hoses and pulleys during fork lifting and lowering.
22
if fitted: Height Indicator + Speed Reduction
Check that the speed of truck, mast and fork is reduced as corresponding lift height is exceeded.
23
if fitted: Lift Cutout + Override
Check that fork automatically stops at the programmed height. Check function of lift/lower cutout override switch.
24
if fitted: Lower Cutout + Override
Check that fork automatically stops at the height of the outriggers. Check function of lift/lower cutout override switch.
25
if fitted: Tilt Position Assist
Tilt fork downward and upward. Check that fork automatically stops in horizontal position.
26
if fitted: Lights
Check operation. L03-gb
ESR4500 06/2004 • PRINTED IN GERMANY
MS-M1-2140
19
LUBRIFICATION AND ADJUSTMENT Inspection and Maintenance Schedule The standard service intervals are based on single shift operation under normal conditions. They should be reduced accordingly if the truck is to be operated in dusty or extreme conditions. Exact details should be discussed with a Crown service engineer. Clean the respective components prior to inspection or maintenance: apply compressed air to them. When carrying out maintenance routinely check for wear, corrosion, damage, component operation and safety. If in doubt, always replace a questionable part. The inspection/maintenance work for longer service intervals must also include the items covered under the shorter intervals.
Cold Store Trucks CAUTION Before performing any maintenance work, the truck must be allowed to thaw out for at least 2 hours. This will ensure all truck parts are equally warmed up. Do not open any covers before the warming up phase is complete. This will avoid brittle fracturing of cables etc.
MS-M1-2140
20
ESR4500 06/2004 • Printed in Germany
LUBRICATION AND ADJUSTMENT
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ESR4500 06/2004 • Printed in Germany
MS-M1-2140
21
LUBRICATION AND ADJUSTMENT I-65 I-39
I-44
I-66
I-51 I-47
I-46
I-63 L-15
I-66 I-64 L-16
I-41
I-48
I-1
I-39
I-43
I-46
I-50
I-36
I-40 I-42 I-23
I-45
I-53
I-47
I-11 I-21
I-46
MO-2140-004
I-46 L-13 I-37
L-4 I-61
I-34 I-37
I-49 I-21 I-69 L-7
I-68
I-10
I-29
I-28
L-11
I-54 I-3
I-52 I-50 I-26 I-27
I-29
MS-2140-073
I-53 I-53
MS-2140-017
I-52
I-54 I-55
I-64
L-5
I-22
I-14
L-3 L-14 I-20
I-58
MS-2140-085
L-12
I-52
L-9 L-10
I-9 I-5
L-14
I-2
I-33
L-6 I-13
I-18 L-1
I-31
I-24
I-29
MS-2140-075
I-4
I-24 I-25
I-15 I-7
I-4
I-34
I-36
MS-2140-079
I-30
MS-2140-064
MS-2140-063
L-15 MS-2140-080
L-2 I-6
L-5
MS-2140-078
I-16
I-19 I-12
MS-2140-074
I-57 I-62
I-17
I-38
I-64
I-16 L-8
I-14 I-32
I-13 I-35 MS-2140-071 ESR4500 06/2004 • Printed in Germany
MS-2140-077
L-5
MS-2140-081
I-34
MS-2140-024
I-58 I-59 I-60
L-18
L-17
MS-2140-084
MS-2140-086 MS-M1-2140
22
LUBRIFICATION AND ADJUSTMENT Inspection and Maintenance Schedule (X = Standard, C = Cold Store) I = Inspection, L = Lubricate / A, M, ... = Lubricant
Years / Service Hours
Item
Action
1/4 500
I-1
Check the overhead guard for damage.
X/C
I-2
Check chassis structure for damage
X/C
I-3
Check skids for wear and attachment
X/C
I-4
Check transmission for noise and leakage
C
X
I-5
Make sure the mounting bolts on the drive plate are secure
C
X
C
X
L-1
A
Check transmission oil, replenish if necessary
L-2
A
Change transmission oil
1/2 1 2.5 1000 2000 5000
C
I-6
Check drive wheel for wear
I-7
Check drive wheel attachment (+ after 50 - 100 hours for a new truck)
C
X
I-9
Check transmission attachment
C
X
I-10
Check steer motor attachment
X/C
X/C
L-3
M
Grease steering toothing
L-4
B
Clean seat rails, lubricate and check for freedom of movement
X/C
I-11
Test reach mechanism operation, initial and final speed reduction
X/C
I-12
Check reach carriage for damage
X/C
Check and lubricate rollers
X/C
I-13
Check suppor t rollers, adjust if necessary
X/C
I-14
Check and adjust lateral suppor t rollers
X/C
I-15
Check reach cylinder attachment on mast
X/C
I-16
Check mast cable connectors are secure, strain relief present?
X/C
I-17
Check rubber buffer for wear, replace if necessary
X/C
I-18
Hydraulic block cover present and secure?
C
X
I-19
Check slide rails for damage and wear, make sure they are secure
C
X
I-20
Check operation and condition of battery container terminals
I-21
Check battery container seat in locked condition
C
X
I-22
Check slide piece lateral clearance, adjust if necessary
C
X
L-5
B
C
X
X/C
L-6
B
Check the outrigger contact surface
C
X
L-7
B
Check battery rollers (optional) for wear, test operation and apply grease
C
X
L-8
B
Grease battery locking mechanism
C
X
Test battery lock operation
C
X
I-23
X
L04-gb
ESR4500 06/2004 • PRINTED IN GERMANY
MS-M1-2140
23
LUBRIFICATION AND ADJUSTMENT Inspection and Maintenance Schedule (X = Standard, C = Cold Store) I = Inspection, L = Lubricate / A, M, ... = Lubricant
Years / Service Hours
Item
1/4 500
Action
L-9
J
Check brake fluid, replenish if necessary
L-10
J
Replace brake fluid
1/2 1 2.5 1000 2000 5000 X/C C
I-24
Check brake lining wear on load wheel brakes, clean brake linings (apply dry compressed air), replace if necessary
I-25
Replace brake linings irrespective of wear
I-26
Check air gap and brake lining wear on the motor brake; Clean brake linings X/C (apply dry compressed air), replace if necessary
I-27
Replace brake lining irrespective of wear
I-28
Check snifting clearance on main brake cylinder, adjust if necessary
X/C
I-29
Check brake connections and por ts for leaks and damage
X/C
L-11
B
Check the load wheels for damage / wear
I-31
Check the load wheel suppor ts for clearance and wear
X/C C
C
X X/C
C
X
L-12 D/DD Check hydraulic oil (fully lower the mast) and replenish as necessary
X/C
I-32
Check hydraulic block in reach frame for leaks
X/C
I-33
Check aux. hydraulic block in fork carriage for leaks
X/C
I-34
Check all hoses, lines and connections for leaks and damage
X/C
I-35
Check hose attachments in reach carriage for wear and make sure they are secure
X/C
I-36
Check all cylinders are secure, check for leaks and damage
X/C
L-13 D/DD Replace hydraulic oil (requires 30 litres)
C1
X 2
C
X
I-37
Replace return filter and aeration filter (+ after 50 - 100 hours for a new truck)
I-38
Check emergency lowering valve
X/C
I-39
Test operation of all displays
X/C
I-40
Test EMERGENCY DISCONNECT switch.
X/C
I-41
Test safety pedal operation.
X/C
I-42
Test horn operation.
X/C
I-43
Test parking brake switch and parking brake operation
X/C
I-44
Test travel direction switch operation, the switch should engage
X/C
I-45
Test seat switch operation.
X/C
C 1 = every 1000 h or annually
MS-M1-2140
24
X 2 = every 2000 h or every two years
X
X/C
Grease the pedal mechanism (brake pedal + accelerator + safety pedal)
I-30
X2
L05-GB
ESR4500 06/2004 • Printed in Germany
LUBRIFICATION AND ADJUSTMENT Inspection and Maintenance Schedule (X = Standard, C = Cold Store) I = Inspection, L = Lubricate / A, M, ... = Lubricant
Years / Service Hours
Item
Action
1/4 500
I-46
Check the controllers are fixed.
X/C
I-47
Make sure line connections to traction and lift drive modules, EMERGENCY DISCONNECT switch and main fuse FU7 are secure
X/C
I-48
Make sure potentiometer connections are secure
X/C
I-49
Make sure plugs on the connector panel are secure
X/C
I-50
Test fan operation (drive module operating temperature must exceed 35°C)
X/C
I-51
Check contactor, replace worn par ts as necessary
X/C
I-52
Make sure all line connections from drive and lift motors are secure
X/C
I-53
Check power cables from drive and lift motors for damage
X/C
I-54
Check drive and lift motor attachments
X/C
L-14
M
1/2 1 2.5 1000 2000 5000
Check and grease motor shaft toothing
X/C
I-55
Check rubber buffer on hydraulic motor
X/C
I-56
Check sensor and temperature gauge connections
X/C
I-57
Check battery cables and connectors for damage
C
X
I-58
Check battery terminals
C
X
I-59
Check battery condition
C
X
I-60
Check acid density and acid level
C
X
I-61
Check mast attachment
X/C
Check, adjust and lubricate lift chains and chain anchors
X/C
I-62
Check mast cables and tension jacks for damage and position
X/C
I-63
Check diver ter rollers
X/C
Check mast sections for wear and apply grease
X/C
I-64
Check mast rollers and stops
X/C
I-65
Check height sensor and height sensor cable
X/C
I-66
Check height reset switch or mast switch for lift speed reduction
X/C
I-67
Check fork carriage for damage
X/C
I-68
Check forks for damage and wear
X/C
L-15
L-16
L-17
G
B
B
Sideshift: check rollers and slide blocks for wear, clean, grease and test operation
L-18 B/BB Lubricate the fork carriage slide rail via grease nipple I-69
Check if load backrest is secure, check for damage
C 1 = every 1000 h or annually
ESR4500 06/2004 • PRINTED IN GERMANY
X 2 = every 2000 h or twice
C
X
C
X X/C L06-gb
MS-M1-2140
25
LUBRIFICATION AND ADJUSTMENT Torques The screw and nut strengths shown below are used in the manufacture of Crown trucks. The information on this page is designed to help determine the correct torque.
SScrew crew Marking GGrade rade M arking
NOTE
NNut ut GGrade rade MMarking arking
8.8 8.8
8
The torques listed in the maintenance section always supersede those shown here.
12.9 12.9
graphics: m0340_1...5
T01-gb
Standard Srews and Nuts Grade
8 and 8.8
10 and 10.9
Thread Size
12 and 12.9
Torque (Nm)
M5 x 0,8
5-6
7-8
8 - 10
M6 x 1
8 - 10
12 - 14
14 - 16
M8 x 1,25
20 - 25
30 - 35
34 - 40
M10 x 1,5
40 - 45
60 - 65
70 - 75
M12 x 1,75
7 0 - 80
100 - 110
115 - 130
M16 x 2
170 - 190
240 - 270
280 - 320
M20 x 2,5
340 - 380
450 - 500
550 - 600
M24 x 3
580 - 650
800 - 900
900 - 1050
M30 x 3,5
1150 - 1300
1600 - 1800
1850 - 2100 T02-gb
Umbrako Screws and Nuts Grade
10 and 10.8
Thread Size
12 and 12.9 Torque (Nm)
M5 x 0,8
8
11
M6 x 1
14
19
M8 x 1,25
33
45
M10 x 1,5
63
86
M12 x 1,75
111
152
M16 x 2
270
372
M20 x 2,5
521
717 T03-gb
MS-M1-2140
26
ESR4500 06/2004 • Printed in Germany
HYDRAULICS
Printed in Germany
27
Blank page
Printed in Germany
28
HYDRAULICS Hydraulic Symbols
Vented reservoir with lines above the fluid level
M
Electric motor with unidirectional turn and speed
M
Electric motor with unidirectional turn and variable speed
Vented reservoir with lines below the fluid level
Filter or strainer
Hydraulic line with full flow (tubing or hose)
Pilot or drain line or drainage with limited flow
Hydraulic pump with fixed displacement and single direction of turn
Hydraulic motor, bi-directional
Lines not connected Pressure gauge
Lines connected Thermometer
Plugged port (test port)
Accumulator gas charged diaphragm type Flow meter
M3559a M3559 ESR4500 06/2004 • Printed in Germany
MS-2.0-0000
29
HYDRAULICS
Pressure switch
Manual actuator
Double-acting cylinder;unequal area
Spring, (bias to normal deenergised position)
Double-acting cylinder;equal area Solenoid single coil or winding
Single-acting cylinderwith spring returned (rod end vented) Hydraulic pilot operated
Single-acting cylinder ram type Solenoid valve, pilot operated
Single-acting cylinder, with cushion Dual solenoid
Assembly housing, manifold block Proportional solenoid
Manual lever actuator
Pilot check valve (pilot to open)
M3560 MS-2.0-0000
30
ESR4500 06/2004 • Printed in Germany
HYDRAULICS
Throttle, fixed
Shuttle valve
Throttle, adjustable
Single counterbalance valve assembly in manifold Pressure-compensated flow control, fixed
Pressure-compensated flow control with reverse flow bypass; fixed. Flow divider/combiner
Velocity fuse Bypass flow control with controlled flow, pressure-regulated
Relief valve, fixed setting
Relief valve, adjustable
Check valve
Shut-off valve, manual
Torque generator
P T
T P
L R
Hydraulic steer unit
M3561 ESR4500 06/2004 • Printed in Germany
MS-2.0-0000
31
HYDRAULICS
2/2 way valve (two way, two switch positions)
Valve block with 3 operating units
3/2 way valve (three way, two switch positions)
4/2 way valve (four way, two switch positions)
4/3 way valve (four way, three switch positions)
4/3 way valve (four way, three switch positions); spring centered, manual activation
3/2 way valve (three way, two switch positions); spring bias solenoid control
M3562 MS-2.0-0000
32
ESR4500 06/2004 • Printed in Germany
HYDRAULICS Functional Description
RV1
RV is used to restrict the maximum operating pressure and is set to 210 bar. RV must be reset when replaced.
The hydraulic system consists essentially of three parts: ●
Tank and pump
●
Valve block
●
Cylinders
Relief Valve
PVL
Proportional Valve Lower
PVRT Proportional Valve Retract* PVRE Proportional Valve Reach* The various hydraulic functions are generally controlled in the valve block.
PVAL Proportional Valve Accessories Left* PVAL governs the upward tilt speed of the forks when TILT is selected, and the sideshift left speed when SIDESHIFT is selected.
Abbreviations POT2 Hydraulic function potentiometers to The potentiometers are connected to their POT6 respective control levers and transmit an analog, proportional control signal to the truck control module. DCVH Directional Control Valve Hoist DCVH is located inside the valve block. Depending on the command, it releases the path for the hydraulic oil - from the pump to the lift cylinders (raise) - from the lift cylinders back to the tank (lower) SVH
Solenoid Valve Hoist SVH is a black and white valve and opens when lifting is selected. The lift speed is governed by the pump speed.
SVT
Solenoid Valve Tilt
SVS
Solenoid Valve Sideshift
SV5
Solenoid Valve 5th function
AVL
Adjustment Valve Lowering Speed
PVAR Proportional Valve Accessories Right* PVAR governs the downward tilt speed of the forks when TILT is selected, and the sideshift right speed when SIDESHIFT is selected. PCL
Pressure Compensation Lowering
PCR Pressure Compensation Reach PCA
Pressure Compensation Accessories For fork tilt, sideshift and optional 5th function
CV
Check Valve
CBV
Counterbalanced Valve
PLS
Pressure Load Switch When a load in excess of 400 kg is being lowered, PLS prevents the fork carriage from stopping abruptly. This prevents the mast from swaying. PLS must be reset when replaced (to 400 kg).
The AVL allows you to set the maximum lowering speed when PVL is fully opened (see “Valve Block” section). MVL
Manual Valve Lower In an emergency, MVL can be used to manually lower the fork carriage. Attention: Close the valve again after lowering the fork carriage (turn anti-clockwise).
* If PVRT, PVRE, PVAL or PVAR fail, the complete valve block must be replaced. The magnetic coils can be individually replaced. ESR4500 06/2004 • PRINTED IN GERMANY
MS-MA-2140
33
HYDRAULICS Lifting
Pilot Pressure Pressure Suction Return MS-2140-027
Lowering
MS-2140-028 MS-M2.0-2140
34
ESR4500 06/2004 • Printed in Germany
HYDRAULICS Lifting “Lifting” is requested by pulling the raise/lower control lever. This changes the voltage on the loop of the raise potentiometer POT2. As a result, the main control module VCM switches on the pump and the magnet of the SVH raise pilot valve. The SVH valve drives the DCVH raise/lower spool. The spool opens. The lift speed is controlled by the pump motor speed in proportion to the movement of the control lever. The oil flows from input P of the valve block through the DCVH spool via output A to the hydraulic cylinders. The hydraulic cylinders extend.
counter-pressure from building up (which would affect the movement of the spool). If the raise/lower control lever is released, the main control module VCM switches off the pump and the current to the SVH solenoid. SVH changes through bias spring force so that the “raise” control pressure side of the spool is connected to the tank return line. The drop in pressure causes the spool to return to its home position and breaks the connection to the cylinders. The cylinders remain in their current position. Note: If the MVL manual lowering valve is open, i.e. turned in, raising is inhibited.
During raising, the “lower” control pressure side of the DCVH spool is connected to the tank return line via the lowering valve PVL. This is necessary to prevent any
Lowering “Lowering” is requested by pushing the raise/lower control lever forward. This changes the voltage on the loop of the raise potentiometer POT2. As a result, the main control module VCM switches on the magnet of the lowering proportional valve PVL. The PVL valve drives the DCVH raise/lower spool. The spool opens. The oil then flows from the hydraulic cylinders, via port A of the valve block through the flow control valve PCL and the spool to output T, and from there via the return line back to the tank. The hydraulic cylinders retract. In proportion to the movement of the control lever, the lowering proportional valve PVL controls the oil pressure on the spool, and hence the amount of opening of the spool and ultimately the lowering speed. The flow control valve PCL installed before the spool ensures that the lowering speed is kept constant for each control lever position. During lowering, the “raise” control pressure side of the DCVH spool is connected to the tank return line via the raise valve PVL. This is necessary to prevent any counter-pressure from building up (which would affect the movement of the spool).
ESR4500 06/2004 • PRINTED IN GERMANY
If the raise/lower control lever is released, the main control module VCM switches off the current to the PVL solenoid. PVL changes through bias spring force so that the “lower” control pressure side of the spool is connected to the tank return line. The drop in pressure causes the spool to return to its home position and breaks the connection to the cylinders. The cylinders remain in their current position. Pressure switch PLS is fitted on the hydraulic line to the lift cylinders. If more than 400 kg is placed on the forks, the pressure switch converts the switch limit of PVL. This prevents the load from stopping abruptly when being lowered. This prevents the mast from swaying. The valve block contains the AVL valve which is used to set the maximum lowering speed when PVL is fully opened. The maximum lowering speed for 1.4 t and 1.6 t trucks is 0.58 m/s, and for 2.0 t trucks 0.51 m/s. Replacement AVLs are preset to 0.58 m/s and must be set to 0.51 m/s for 2.0 t trucks (see description in the “Valve Block” section). The MVL emergency lowering valve allows the mast to be lowered manually in the event of hydraulic failure. To lower, turn the emergency lowering valve clockwise.
MS-MA-2140
35
HYDRAULICS Mast Reach Carriage Retraction
Pilot Pressure Pressure Suction Return MS-2140-029
Mast Reach Carriage Extension
MS-2140-030 MS-M2.0-2140
36
ESR4500 06/2004 • Printed in Germany
HYDRAULICS Mast Reach Carriage Retraction The “retract” function is requested by pulling the corresponding control lever. The voltage on the loop of reach potentiometer POT3 changes. As a result, the main control module VCM switches on the pump and the magnet of the PVRT proportional valve.
pressure on PCR. The two pilot lines on the flow control valve PCR regulate this in such a way that the flow of oil and hence the speed of the reach carriage are kept constant depending on the oil pressure and the potentiometer setting.
The speed of the reach carriage is determined by the movement of the control lever. It is governed by the pump motor speed and the position of the PVRT proportional valve.
The backward moving reach cylinder forces the oil out of the rear section of the cylinder and thereby creates a pressure on CBV (3 bar). CBV (3 bar) now opens via a pilot line and the oil can flow via port A1 of the valve block and the PVRT valve back into the tank.
PVRT opens in proportion to the movement of the control lever. The oil then flows from input P of the valve block through the flow control valve PCR and valve PVRT to output B1, and further via the bypass line of the counterbalance valve CBV (8 bar) to the piston rod side of the reach cylinder. The reach carriage retracts. The oil pressure created displaces the ball of the twin check valve from right to left and releases the control
If the control lever is released, the main control module VCM switches off the pump and the current to the PVRT solenoid. PVRT is closed through bias spring force and the flow of oil to the reach cylinder is interrupted. The pressure on the pilot line to CBV (3 bar) also drops and CBV moves back to its original position. The cylinder remains in its current position.
Mast Reach Carriage Extension The “extend” function is requested by pushing the corresponding control lever forward. The voltage on the loop of reach potentiometer POT3 changes. As a result, the main control module VCM switches on the pump and the magnet of the PVRE proportional valve.
pressure on PCR. The two pilot lines on the flow control valve PCR regulate this so that the flow of oil and hence the speed of the reach carriage are kept constant depending on the oil pressure and the potentiometer setting.
The speed of the reach carriage is determined by the movement of the control lever. It is governed by the pump motor speed and the position of the PVRE proportional valve.
The forward moving reach cylinder forces the oil out of the front section of the cylinder and thereby creates a pressure on CBV (8 bar). CBV (8 bar) now opens via a pilot line and the oil can flow via port B1 of the valve block and the PVRE valve back into the tank.
PVRE opens in proportion to the movement of the control lever. The oil then flows from input P of the valve block through the flow control valve PCR and valve PVRE to output A1, and further via the bypass line of the counterbalance valve CBV (3 bar) to the piston rod side of the reach cylinder. The reach carriage extends. The oil pressure created displaces the ball of the twin check valve from left to right and releases the control
ESR4500 06/2004 • PRINTED IN GERMANY
If the control lever is released, the main control module VCM switches off the pump and the current to the PVRE solenoid. PVRE is closed through bias spring force and the flow of oil to the reach cylinder is interrupted. The pressure on the pilot line to CBV (8 bar) also drops and CBV moves back to its original position. The cylinder remains in its current position.
MS-MA-2140
37
HYDRAULICS Tilt Back Circuit “Tilt/Sideshift” valve block Main valve block
Pilot Pressure Pressure Suction Return
MS-2140-031
Tilt Down Circuit “Tilt/Sideshift” valve block Main valve block
MS-2140-032 MS-M2.0-2140
38
ESR4500 06/2004 • Printed in Germany
HYDRAULICS Tilt Back Circuit The “fork tilt back” function is requested by pulling the corresponding control lever. This changes the voltage on the loop of the tilt potentiometer POT4. As a result, the main control module VCM switches on the pump and the magnets of the SVT valve and the PVAL proportional valve.
The oil pressure created displaces the ball of the twin check valve (behind PVAL) from left to right and releases the control pressure on PCA. The two pilot lines on the flow control valve PCA regulate this in such a way that the flow of oil is kept constant depending on the oil pressure and the potentiometer setting.
The tilt speed is determined by the movement of the control lever. It is governed by the pump motor speed and the position of the PVAL proportional valve.
The forward moving piston of the tilt cylinder forces the oil out of the front section of the tilt cylinder. The oil flows via port T2 of the “tilt/sideshift” valve block, through valve SVT to port A1, and further through the mast hose to port A2 of the main valve block, from there through valve PVAL to output T and finally back into the tank.
PVAL opens in proportion to the movement of the control lever. The oil flows through port P of the main valve block, the flow control valve PCA and the proportional valve PVAL to output B2, and further through the mast hose to port B of the “tilt/sideshift” valve block, through the open valve SVT and the check valve CV2 to port T1 and finally to the piston side of the tilt cylinder. The piston extends, and the forks tilt up (back).
If the control lever is released, the main control module VCM switches off the pump and the current to the SVT and PVAL solenoids. Both valves are set to the home position through bias spring force. The oil flow through SVT is interrupted. The tilt cylinder remains in its current position.
Tilt Down Circuit The “fork tilt down” function is requested by pushing the corresponding control lever forward. This changes the voltage on the loop of the tilt potentiometer POT4. As a result, the main control module VCM switches on the pump and the magnets of the SVT valve and the PVAR proportional valve. The tilt speed is determined by the movement of the control lever. It is governed by the pump motor speed and the position of the PVAR proportional valve. PVAR opens in proportion to the movement of the control lever. The oil flows through port P of the main valve block, the flow control valve PCA and the proportional valve PVAR to output A2, and further through the mast hose to port A1 of the “tilt/sideshift” valve block, through the open valve SVT to port T2 and finally to the piston side of the tilt cylinder. The piston retracts, and the forks tilt down. The oil pressure created displaces the ball of the twin check valve (behind PVAR) from right to left and releases the control pressure on PCA. The two pilot lines on the flow control valve PCA regulate this in such a way that the flow of oil is kept constant depending on the oil pressure and the potentiometer setting.
ESR4500 06/2004 • PRINTED IN GERMANY
A pilot line of the counterbalance valve CBV (90 bar) is connected to the pressure circuit after SVT. When pressure is applied, CBV opens and release the line for the returning oil. CBV requires a pressure of 90 bar on the pilot line in order to open. Otherwise CBV will block, which will prevent any load on the forks from automatically tilting down. The piston moving backward forces the oil out of the rear section of the tilt cylinder. The oil flows via port T1 of the “tilt/sideshift” valve block, through CBV (90 bar) and the SVT valve to port B, and further through the mast hose to port B2 of the main valve block, from there through valve PVAR to output T and finally back into the tank. If the control lever is released, the main control module VCM switches off the pump and the current to the SVT and PVAR solenoids. Both valves are set to the home position through bias spring force. The oil flow through SVT is interrupted. The drop in oil pressure in the pilot line causes CBV to close. The tilt cylinder remains in its current position.
MS-MA-2140
39
HYDRAULICS Sideshift Right
Pilot Pressure Pressure MS-2140-033
Suction Return
Sideshift Left
MS-2140-034 MS-M2.0-2140
40
ESR4500 06/2004 • Printed in Germany
HYDRAULICS Sideshift Right The “sideshift right” function (seen from the operator’s position) is requested by pulling the corresponding control lever. The voltage on the loop of sideshift potentiometer POT5 changes. As a result, the main control module VCM switches on the pump and the magnets of the SVS valve and the PVAR proportional valve.
The oil pressure created displaces the ball of the twin check valve (behind PVAR) from right to left and releases the control pressure on PCA. The two pilot lines on the flow control valve PCA regulate this in such a way that the flow of oil is kept constant depending on the oil pressure and the potentiometer setting.
The sideshift speed is determined by the movement of the control lever. It is governed by the pump motor speed and the position of the PVAR proportional valve.
The oil emerges from the left port of the sideshift twin cylinder via port SS1 of the “tilt/sideshift” valve block, through the SVS valve to port B, and further through the mast hose to port B2 of the main valve block, from there through valve PVAR to output T and finally back into the tank.
PVAR opens in proportion to the movement of the control lever. The oil flows through port P of the main valve block, the flow control valve PCA and the proportional valve PVAR to output A2 of the manifold, and further through the mast hose to port A1 of the “tilt/sideshift” valve block, through the open valve SVS to port SS2 and finally to the right hand port of the sideshift twin cylinder. The fork carriage moves to the right.
If the control lever is released, the main control module VCM switches off the pump and the current to the SVS and PVAR solenoids. Both valves are set to the home position through bias spring force. The oil flow through SVS is interrupted. The sideshift remains in its current position.
Sideshift Left The “sideshift left” function (seen from the operator’s position) is requested by pushing the corresponding control lever forward. The voltage on the loop of sideshift potentiometer POT5 changes. As a result, the main control module VCM switches on the pump and the magnets of the SVS valve and the PVAL proportional valve.
The oil pressure created displaces the ball of the twin check valve (behind PVAL) from left to right and releases the control pressure on PCA. The two pilot lines on the flow control valve PCA regulate this in such a way that the flow of oil is kept constant depending on the oil pressure and the potentiometer setting.
The sideshift speed is determined by the movement of the control lever. It is governed by the pump motor speed and the position of the PVAL proportional valve.
The oil emerges from the right port of the sideshift twin cylinder via port SS2 of the “tilt/sideshift” valve block, through the SVS valve to port A1, and further through the mast hose to port A2 of the main valve block, from there through valve PVAL to output T and finally back into the tank.
PVAL opens in proportion to the movement of the control lever. The oil flows through port P of the main valve block, the flow control valve PCA and the proportional valve PVAL to output B2 of the manifold, and further through the mast hose to port B of the “tilt/sideshift” valve block, through the open valve SVS to port SS1 and finally to the left hand port of the sideshift twin cylinder. The fork carriage moves to the left.
If the control lever is released, the main control module VCM switches off the pump and the current to the SVS and PVAL solenoids. Both valves are set to the home position through bias spring force. The oil flow through SVS is interrupted. The sideshift remains in its current position.
ESR4500 06/2004 • PRINTED IN GERMANY
MS-MA-2140
Rev. 01/03
41
HYDRAULICS Hydraulic Components DANGER
Hydraulic Lines 1.
Air blast all hoses and pipes to remove any loose dirt prior to installation. Any rubber hoses with interior wiring, thermoplastic hoses and steel tubes which are squashed together or bent are non-serviceable and must be replaced, even if no external damage is visible.
2.
Flexible thermoplastic hoses must be replaced if they distort in their normal operating position. Rubber hoses must always be replaced if they leak.
3.
Hoses and pipes must not rest loosely against other components. This could result in chafing or cuts. Route lines so that they do not get jammed.
4.
All connections must be completely sealed.
5.
The elbows on suction connections must be positioned so that the suction hose has the full flow and does not collapse.
Pressurised hydraulic systems can cause serious injury when the system is opened. High pressure hydraulic oil can cause serious injuries. Whenever a high pressure fluid enters the skin it must be treated as an emergency, even if the skin initially shows no reaction. Physical effects may take time to set in. Tighten all ports before pressurising the system again. Keep hands and body away from any holes as high pressure hydraulic oil can emerge. Wear protective clothing, safety glasses and safety gloves when tracing leaks or bleeding the system. Use a piece of absorbent paper to trace leaks, never use your hands. Follow the hydraulic oil manufacturer’s safety instructions when handling these oils.
●
Depressurise the hydraulic system before removing any components. Fully lower the forks and tilt them down until they are resting on the ground.
●
Place a flat tray underneath to collect any spilled hydraulic oil.
●
Only use dry, compressed air and a clean, lintfree cloth for cleaning purposes.
●
Apply a thin layer of hydraulic oil to new components and seals to facilitate the bleeding of the system.
MS-M2.0-2140
42
ESR4500 06/2004 • Printed in Germany
HYDRAULICS MVL
AVL
2
1 RV1
MS-2140-024
MS-2140-023
Valve Block The valve block is located in the mast reach carriage below a cover, see Fig. MS-2140-023. It contains the solenoids for controlling the various hydraulic functions, the lowering speed setting valve AVL, the manual lowering valve MVL and the relief valve RV1.
Adjusting the setting: ●
Undo the counternut (1, Fig. MS-2140-024).
●
Turn the adjusting screw (2) as required. Clockwise = Increase threshold value of pressure
●
Tighten the counter nut (1) again.
●
Check the setting.
Relief Valve RV1 The relief valve RV1 is preset to the correct pressure (210+5 bar). Replace the valve in the event of operational failure. Checking the setting ●
Raise a load which is 10% more than the rated load.
●
Raise the weight above the free lift height. It should just be possible to raise this load. At 100 kg more, the relief valve should apply.
ESR4500 06/2004 • PRINTED IN GERMANY
MS-MA-2140
43
HYDRAULICS
PLS
1
3
2
MS-2140-048 MS-2140-035
DANGER
Lowering Speed Adjustment Valve AVL
Risk of trapping and severing limbs!
The AVL valve is factory set to the maximum lowering speed of 0.58 m/s for 1.4 t and 1.6 t trucks. If a new valve block is fitted on a 2.0 t truck, AVL must be set to 0.51 m/s.
When carrying out work on the mast and the attachments: always block the mast stages and attachments to prevent them from accidentally lowering.
●
Undo the counternut (1, Fig. MS-2140-035).
Make sure the wooden blocks and lifting gear used have sufficient capacity.
●
Turn the adjusting screw (2) out by approx. 200° (just over half a turn).
●
Call up menu item A2.22 in the ANALYZER menu.
●
Tighten the counter nut (1) again (torque 6+2 Nm).
●
Raise a 400 kg load.
●
Raise the load so that the pressure load switch is freely accessible.
●
Secure the fork carriage: Attach a load sling around the fork carriage and hold it with the crane.
●
Additionally secure the mast stages with square wooden blocks to prevent them from accidentally lowering. The square wooden blocks must be secured to prevent them from falling.
●
Raise the load slightly so that it is supported by the hydraulic system.
●
Set the switch point by turning the adjusting screw (3) on the pressure load switch.
CAUTION Risk of leakage. The counternut acts as a seal. When loosened, oil will escape under load. Remember to re-tighten the counternut after adjusting the valve.
Pressure Load Switch PLS The pressure load switch is fitted in the pipeline leading to the left hand main lift cylinder (seen from the forks), see Fig. MS-2140-048. When lowering a load in excess of 400 kg it prevents the fork carriage from stopping abruptly. This prevents the mast from swaying. PLS must be checked and if necessary reset after being replaced (to 400 kg).
MS-M2.0-2140
44
ESR4500 06/2004 • Printed in Germany
HYDRAULICS Hydraulic Reservoir 5 The hydraulic reservoir has a capacity of approx. 36 litres.
Discharging the Hydraulic Reservoir ●
Unscrew the filter lid (5).
●
Suction off the hydraulic oil via the filler port.
●
Fully discharge the reservoir into a suitable collection tray by opening the drain plug (4) (Fig. MS-2140-054).
Filling the Hydraulic Tank
MAX
All hydraulic systems are extremely sensitive to contamination.
MIN
Therefore, the oil must be filtered through a 10 micron filter or strainer 100 before entering the system. Note: The return filter filters the return flow, i.e. from outside to inside. It does not filter the oil you add to the reservoir via the filler port. ●
Bleed the entire hydraulic system and then fill the reservoir.
●
All cylinders must be fuly retracted (mast carriage on chassis, mast lowered, fork carriage tilted forward).
●
Keep filling until the oil is at the “Max” level (Fig. MS-2140-026).
MS-2140-026
4
MS-2140-054
ESR4500 06/2004 • PRINTED IN GERMANY
MS-MA-2140
45
HYDRAULICS
3 1 5 6
MS-2140-049 MS-2140-053
MS-2140-050
●
Ensure no foreign bodies fall into the open reservoir. Do not replace the filter cartridge in the filter container when it is installed. Sediment from the filter container could enter the hydraulic oil reservoir.
●
Pull the filter cartridge (1) up out of the filter container (Fig. MS-2140-053) and dispose of it in accordance with local regulations.
●
Clean the filter container and the ascending tube.
●
Fit a new filter cartridge in the filter container, by gently turning it down.
●
Insert the new filter container and the ascending tube into the hydraulic reservoir.
●
Screw the lid back onto the reservoir.
3
7 7
MS-2140-062
Filter There are two large filters in the system: The return filter (1, Fig. MS-2140-053) and the suction filter (12, Fig. MS2140-069).
Replacing the Return Filter ●
Turn the filter lid (5) to the left and remove it (Fig. MS-2140-049).
●
Lift up the filter clip and remove the filter container (3) and the ascending tube (6), see Figs. MS-2140-062 and MS-2140-050.
MS-M2.0-2140
46
ESR4500 06/2004 • Printed in Germany
HYDRAULICS 2 14 14 (7x)
4 (2x)
4
4
10
8 MS-2140-051
Replacing the Aeration Filter ●
Unscrew the insert from the reservoir (nuts (4), Fig. MS-2140-051).
●
Pull the insert (8) slightly to the left, see arrow.
●
Pull off the aeration cap and the aeration filter (2).
●
Replace the aeration cap and the aeration filter (= 1 component).
●
Installation is the reverse of removal.
11
12
9
Replacing the Suction Filter ●
Undo the hydraulic hoses (hose clamps (7), Fig. MS-2140-062).
●
Seal all ports to prevent foreign bodies from entering.
●
Undo the screws (14, Figs. MS-2140-051 and MS-2140-069).
●
Remove the insert (10).
●
Unscrew the filter cartridge (12).
●
Replace the seal (11), if necessary.
●
Installation of the new suction filter is the reverse of removal.
MS-2140-069
ESR4500 06/2004 • PRINTED IN GERMANY
MS-MA-2140
47
HYDRAULICS ●
Undo the mounting screw (25) from the connector panel (19) (Figs. MS-2140-060 and -061).
●
Pull the electronics cable off the pump motor (2, Fig. MS-2140-061).
●
Undo the 2 mounting screws (26) from the carrier plate (1) (Figs. MS-2140-060 and -061).
●
Raise the motor and the pump until you can disassemble the pump.
●
Undo the 2 mounting screws (9) from the pump (Fig. MS-2140-060).
●
Pull off the pump with it exactly in line to avoid damaging the pump shaft toothing.
●
Discharge the pressure line (16) connected to the pump as well as the suction line (14).
●
Remove the lines from the pump.
●
Fit the new pump.
●
Do not yet attach the suction hose to the reservoir.
2
27
19
1
25 26 MS-2140-061
Pump Motor Refer to Chapter 4 for pump motor maintenance and repair instructions.
Commissioning ●
Check that the assembly is clean and correctly assembled.
●
Add hydraulic oil only via a 10 micron filter through the suction hose.
Hydraulic Pump INFORMATION The hydraulic pump should not be repaired on site.
●
Attach the suction hose to the reservoir.
For this reason it is supplied only as a complete assembly.
●
Keep the sideshift control lever in its limit position.
When commissioning a new or repaired hydraulic pump proceed as follows:
●
Start the pump unladen and leave it to operate for a few seconds without pressure to allow for sufficient lubrication. Never run the pump without oil.
●
If after 20 seconds the oil is still not free of bubbles, check the unit again.
●
After reaching operating temperature check the pipe connections for leaks.
Disassembly ●
●
Undo the union (27) from the pressure line (16) on the pump. Seal the pressure line ports.
●
Undo the clamp (13) from the suction hose port of the reservoir.
●
Pull the suction hose (14) off the reservoir.
●
Seal the reservoir port and the suction hose to prevent foreign bodies from entering.
MS-M2.0-2140
48
ESR4500 06/2004 • Printed in Germany
HYDRAULICS
2 17
27
18 1
16
26 13
19
7 14
8
15 25
10 11
9
13 12
MS-2140-060
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HYDRAULICS Bleeding the Free Lift Cylinder ●
Prepare the work area to collect spilled oil.
●
Extend the free lift cylinder fully.
●
Wear protective clothing, safety glasses and gloves before carrying out the next step.
●
Slowly open the vent screw (SW10, 1, Fig. MS2140-052) on the free lift cylinder.
●
Tighten the vent screw as soon as bubble-free oil emerges.
●
Clean any oily components on the truck.
2
Bleeding the Lift Cylinders ●
Prepare the work area to collect spilled oil.
●
Extend the cylinders as far as possible.
●
Wear protective clothing, safety glasses and gloves before carrying out the next step.
●
Slowly open the vent screw (SW10, 2, Fig. MS2140-052) on one of the lift cylinders.
●
Tighten the vent screw as soon as bubble-free oil emerges.
●
Repeat the previous stages on the other lift cylinder.
●
Clean any oily components on the truck.
1
MS-2140-052
Bleeding the Hydraulic System Whenever the hydraulic system has been opened for repairs, e.g. repairs to free lift, lift and tilt cylinders, replacing pumps or valves, you will need to bleed the system.
CAUTION Possible damage! On hydraulic connections with O ring seals the O rings will be damaged if opened under pressure. Do not open connections with O ring seals for ventilation. Use only the vent screws provided on the assemblies.
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ESR4500 06/2004 • Printed in Germany
HYDRAULICS Bleeding the Reach Cylinder ●
Extend and retract the mast reach several times until it moves without a jolt or delay.
●
Hold the control lever each time at the limit position for 5 seconds.
Sealed air can flow to the other side of the cylinder piston and therefore be conducted to the reservoir.
Flushing the Cylinders After bleeding the cylinders: ●
Extend the mast fully.
●
Check the cylinders for leaks.
●
Fully extend and retract the mast at least 10 times at max. speed up to the maximum lift height to flush the system.
Bleeding the Sideshift Cylinder ●
Extend and retract the sideshift several times until it moves without a jolt or delay.
●
Hold the control lever each time at the limit position for 5 seconds.
When the sideshift is extended as far as the stop, a connection to the “passive” cylinder chamber opens. The sealed air can be routed along here back to the reservoir. “Bleeding the sideshift” bleeds all the hydraulic lines to the fork carriage.
Bleeding the Tilt Cylinders Attention: The sideshift cylinders must be bled beforehand. ●
Tilt the fork carriage back fully and hold the control lever at the limit position for approx. 5 seconds.
●
At the same time, keep the sideshift control lever in its limit position.
●
Tilt the fork carriage forward fully and hold the control lever at the limit position for approx. 5 seconds.
●
At the same time, keep the sideshift control lever in its limit position.
●
Repeat this process 10 times.
Bleeding the 5th Function Cylinder See “Bleeding the tilt cylinders”
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HYDRAULICS Drift Tests After carrying out repairs to the hydraulic system perform a drift test. This is the only way of identifying internal leakage.
INFORMATION Whenever you carry out a drift test the hydraulic oil temperature must be 30 40 °C. Increase the temperature, if required, by raising below the free lift height several times.
●
Record the height of the plumb again.
●
The load should lower max. 100 mm.
Tilt cylinder drift test ●
Fully extend and retract the fork carriage several times from one end to the other to flush the hydraulic system.
●
Raise the test load and secure it.
●
Attach a lowering plumb with a 3 m long string to the fork tip. The distance from the fork shank should be 1150 mm. If not, you must convert the rated drift value accordingly.
●
With the fork carriage tilted back, raise the test load above the free lift height until you can comfortably measure the plumb height above the ground.
●
Record the height of the plumb.
●
Switch off the truck and disconnect the battery.
●
Wait for 5 minutes.
●
Record the height of the plumb again.
●
The difference should be max. 50 mm.
Measure the temperature in the hydraulic reservoir before carrying out the tests. The test load should be the same as the maximum capacity (see truck capacity plate). The test load must be evenly distributed. The load centre of gravity must be centrally located, 600 mm in front of the fork shanks, and must not exceed the capacity plate specification. DANGER Falling loads are hazardous! You could be fatally injured by a falling load. Never stand underneath a raised load. Secure the test load to prevent it from slipping and falling. Set the maximum possible fork spread.
Lift cylinder drift test
The following reasons may apply if the rated values are exceeded: ●
Cylinder leaking
Fully extend and retract the mast several times to flush the hydraulic system.
●
Union leaking
●
Raise the test load and secure it.
●
Foreign body in a valve seat
●
Tilt the forks fully down.
●
Attach a lowering plumb with a 3 m long string to the fork tip.
●
Raise the test load above the free lift height until you can comfortably measure the plumb height above the ground.
●
Record the height of the plumb.
●
Switch off the truck and disconnect the battery.
●
Wait for 10 minutes.
●
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Causes of Drift
Repeated flushing (lifting/lowering or forward/ backward tilting at least 10 times) may remove foreign bodies from the valve seat. Now carry out the test again.
ESR4500 06/2004 • Printed in Germany
DRIVE UNIT
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DRIVE UNIT Gear unit Preparation Raise the truck approx. 500 mm to remove the gear unit. See Chapter 1, Raising and Jacking up the Truck
Tools required: ●
Forklift truck with sufficient capacity, lift height and fork length for the truck to be raised.
●
Safety mechanism for the forks of the lifting truck, required to hold the raised truck.
●
Sufficient number of wooden blocks (surface area of at least 250 x 250 mm) or suitable supports to secure the raised truck.
●
Device to carry the gear unit onto a jack or pallet truck.
MS-2140-082
●
Undo the six gear unit mounting screws (A) and the six motor mounting screws (B) in Fig. MS2140-082.
●
Lower the device together with the gear unit and pull it out from under the truck.
Removal ●
Disconnect the battery and remove the key.
●
Secure the truck to prevent it from being switched on again.
●
Secure the truck with a second forklift and prevent it from sliding away.
Servicing WARNING
DANGER Never work underneath a suspended load. Fatal injuries could result if the truck is suddenly lowered. ●
Raise the truck until you can push a jack / pallet truck underneath the truck to support it.
●
Raise the truck again by approx. 50 mm in order to be able to loosen the gear unit from the toothing at a later time.
●
Lower the truck onto the wooden blocks/supports.
●
Raise the device on the jack/pallet truck until it contacts the gear unit.
●
Remove the electrical connections from the motor.
ESR4500 06/2004 • Printed in Germany
The gear unit must only be serviced by trained and authorised Crown personnel. Failure to comply will invalidate the warranty. Correcting the flank tooth bearing and pre-tensioning the shaft support requires years of experience with gear units. Incorrect adjustments and settings will result in premature failure of the gear unit. It is therefore generally preferable to replace the whole gear unit. New gear units are always supplied without oil. Before using the gear unit for the first time, fill oil in accordance with the “Lubricant Table”.
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DRIVE UNIT 1 2
3
4 7 2
6
5
8
15 12
9
16
13
10 11
14
17 37 18
13
24 23 25 44 38 36 18
42
27
2
30 35 29
26
27 28 34
19 43
22
30 41 20
40 39
31
21 33 32 22 MP-2140-089
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ESR4500 06/2004 • Printed in Germany
DRIVE UNIT General ●
All bearings and seals must be replaced.
●
Prior to dismantling, thoroughly clean the gear unit with a cold cleaning solution and dry with low-pressure pressurised air.
●
●
Take the bevel gear (22), spacer ring (36) and adjusting shim(s) (18, 35) where applicable out of the housing.
●
Extract the inner ring of the conical roller bearing (34) from the bevel gear (22).
●
Extract the outer rings of the conical roller bearings (34, 38) from their seats in the transmission housing.
●
Remove the thread shield ring (41), radial shaft seal (40) and retaining ring (39) from the housing seat.
●
Press the bevel pinion shaft (22) down from out of the spur wheel (16) and the conical roller bearing (17).
●
Remove the conical roller bearing (17) and shim(s) (18) where applicable.
●
Extract the outer ring of the conical roller bearing (21).
●
Remove the spacer bushing (19) from the bevel pinion shaft and extract the inner ring of the conical roller bearing (21) from the bevel pinion shaft.
●
Thoroughly clean all components and remove the remains of the sealant and adhesive.
Use assembly equipment and a clean work area.
Gear Unit Disassembly / Assembly All item numbers refer to Figure MP-2140-089 unless otherwise stated.
Disassembly ●
Drain the oil.
●
Insert the gear unit with the wheel nuts (43) into a secure device to prevent it from twisting.
●
Remove the hex. socket screws (26) and the lock washers (2), take off the gear unit cover (25) and loosen the O ring (24).
●
Remove the hex. socket screws (1) and the lock washers (2).
●
Take off the live ring bearing (3).
●
Remove the O ring (5) from the recess of the ring gear (8).
●
Remove the hex. socket screws (29, 31) and the lock washers (30).
●
Take off the ring gear (8).
●
Remove the Allen screws (32) and the washer (33).
●
Undo the hex. nut (15) of the bevel pinion shaft.
●
Take the gear unit out of the device.
Assembly NOTE All bearings and seals must be replaced.
Preparing the gear unit ●
Press the outer rings of the conical roller bearings (17, 21, 34 and 38) into their respective notches in the cleaned housing. Make sure they are positioned level in the housing.
●
Insert the inner ring of the conical roller bearing (38) in the pre-assembled outer ring of the conical roller bearing (blade wheel side).
●
Insert the retaining ring (39) in its corresponding groove.
NOTE When disassembling, mark the assembly location of the shims (18, 20, 35). They will have to be put back temporarily in the same position at a later stage. ●
Push out the flange shaft (42) using a suitable device.
●
Extract the inner ring of the conical roller bearing (38) from the flange shaft (42).
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DRIVE UNIT ●
Press the radial shaft seal (40) into the housing using a suitable tool.
●
Place the thread shield ring (41) onto its space in the housing and caulk it.
●
Press the inner ring of the conical roller bearing (34) onto the bevel gear (22) using a suitable tool.
●
Press the wheel nuts (43) into the flange shaft holes (42) using a suitable tool.
NOTE The flange shaft assembly must be tensioned with a torque wrench. ●
Guide the hex. bolts (32) through the washer (33) and torque the flange shaft assembly to max. 77 Nm.
●
Check the shaft for freedom of movement and make sure there is no clearance. If necessary, reduce the torque. Note the final reading. It will be required for adjustment purposes.
Inserting the bevel pinion shaft ●
Press the inner ring of the conical roller bearing (21) onto the conical pinion shaft (22).
●
Place the shim(s) (20) and spacer bushing (19) on the conical pinion (22).
●
Insert the pre-assembled bevel pinion shaft (22) into the housing (23) from below.
●
Push the inner ring of the conical roller bearing (17) over the shaft of the bevel pinion shaft into the outer ring of the conical roller bearing (17).
Adjusting the Bevel Wheel Set
NOTE Adjust with care. Pre-tensioning the bearings and shims will affect the tooth pattern. Do not set the pre-tension too low. it will automatically reduce during normal operation. The correct setting can be calculated via the tooth profile pattern. Basic Rules:
NOTE The spur wheel nut must be tightened with a torque wrench.
●
Always adjust the bevel wheel set according to the correct flank position. The tooth ends should not form a straight line.
●
Assemble the spur wheel (16) and torque the new hex. nut (15) to max. 100 Nm.
●
The tooth pattern must always align with the inner tooth end.
●
Check the bevel pinion shaft for freedom of movement and make sure there is no clearance. If necessary, reduce the torque. Note the final reading. It will be required later for adjustment purposes.
●
The tooth pattern must range from high (top edge of the tooth) to low (bottom edge of the tooth).
●
To adjust, add and/or remove shims (18, 20, 35) or change the pre-tension of the bearings.
Assembling the flange shaft ●
Bring the housing into its later assembly position.
●
Insert the spacer ring (36) and the pre-assembled bevel gear (22) in the respective order through the housing opening.
●
Apply a thin layer of oil to the flange shaft (42) and carefully push it through the previously inserted unit parts in the housing.
●
Insert the housing with the wheel nuts into a secure device to prevent it from twisting.
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ESR4500 06/2004 • Printed in Germany
DRIVE UNIT Final Assembly
Correct tooth patterns of bevel pinion inside tooth end
●
Re-assemble the bevel pinion shaft and flange shaft.
●
Clean all the components.
●
Apply a thin layer of Loctite 307 to the inside of the conical roller bearing inner rings.
●
Apply medium strength Loctite 242 (CROWN part no. 053050-006) to the threads of the hex. nuts (15) and the hex. bolts (32).
●
Re-assemble as described previously.
●
Manually turn the gear unit through, while checking for freedom of movement and ensure it operates without any clearance.
●
Apply a thin layer of Loctite 307 to the contact surfaces of the housing cover.
●
Screw the drain plug (28) with the copper ring (27) underneath it into the transmission lid (25).
●
Insert the O ring (24) into the groove intended for it in the transmission lid.
●
Using the hex. socket screws (26) and the lock washers (2) connect the transmission lid (25) to the housing (23). Tighten the hex. socket screws (26) and the lock washers (2) evenly and crosswise. When assembly, make sure that the oil drain opening is at the lowest point when the gear unit is subsequently installed.
●
Apply a thin layer of Loctite 307 to the contact surfaces of the transmission housing to the ring gear. Fit the ring gear.
●
Insert the O ring (5) into the recess of the ring gear (8).
●
Fit the live ring bearing.
High
Low
High
Low
Correct tooth patterns of bevel gear inside tooth end M1565-1
Fig. M1565-1 shows the limits of the permissible tooth patterns on the bevel pinion and bevel gear. Checking the flank tooth bearing ●
Colour the tooth profiles of the bevel gear (22) with touch-up past (striking colour) or a light oil colour.
●
Take the gear unit out of the device.
●
Turn the bevel gear several times in one direction. The tooth bearing will appear as a bright point (marked black in Fig. M1565-1) on the tooth flanks.
●
Check the tooth bearing. Remove and/or add shims (18, 20, 35) to restore the tooth bearing to the tolerance limits (Fig. M1565-1). Attention: Torque the hex. bolts (32) and hex. nuts (15) to the previously recorded values. Repeat the process until the tooth bearing is within the tolerance limits.
NOTE Leave the surface and thread sealants to dry for at least 2 hours at room temperature before filling with oil.
ESR4500 06/2004 • Printed in Germany
●
Set the gear unit in the assembly position.
●
Replenish with oil up to the bottom marker of the refill plug – (for the correct oil for the application temperature see the Lubrication and Adjustment chapter).
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DRIVE UNIT Re-Assembly ●
Assembly is the reverse of disassembly. Take care not to damage the toothing of the spur pinion (14) or the spur wheel (16).
Traction motor Maintenance and servicing requirements for the traction motor are described in Chapter 4.
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ESR4500 06/2004 • Printed in Germany
ELECTRICS
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ELECTRICS BLS (Battery Lock Switch)
Electrical Components SPS (Safety Switch) The safety switch is located underneath the floor board. It is connected mechanically to the safety pedal. The operator’s foot must be on the pedal when travelling, otherwise travel and hydraulic functions will be deactivated. The “safety switch” message is displayed if:
The BLS is fitted on the battery locking mechanism in the motor compartment. It monitors the locking of the battery tray when the reach is retracted. If the battery tray is not locked correctly, the truck can only be operated in creep mode.
BS (Flashing Beacon Switch) Installed in the control panel (overhead guard column, left of the steering wheel).
FKS (Fork Tilt Switch)
●
the safety pedal is activated when the truck is started up
●
you apply the travel switch without first applying the safety pedal
●
you activate a hydraulic function without first applying the safety pedal
The FKS is fitted to the fork carriage. It is activated via a trip cam. It cuts out the weight display if the forks are not positioned horizontally. (The weight can only be displayed correctly if the forks are horizontal).
LS (Load Sensor)
KYS (Key Switch) The key switch switches on the power supply to the VCM (main truck controller).
The load sensor is fitted to the top of the tilt cylinder. It senses the weight when a load is placed on the forks. The load sensor is wired in series with the fork tilt switch.
POT1 (Traction potentiometer) HNS (Horn Switch) Pressing the horn switch (horn symbol) activates the horn.
HN (Horn) FS (Forward Switch) This is installed in the travel direction toggle switch. It activates travel in the direction of the driver.
The traction potentiometer is mechanically connected to the accelerator pedal. It supplies an analog control signal to the main controller (VCM) in proportion to the position of the pedal (see A2.3). The VCM controls the travel speed via the TDM (traction module) in proportion to this control signal. POT 1 must be recalibrated if replaced (see C1 in the Service Level menu).
POT2 (Raise potentiometer)
RS (Reverse Switch) This is installed in the travel direction toggle switch. It activates travel in the direction of the forks.
ACS (Accelerator Switch) Located below the accelerator pedal and activates travel.
The raise potentiometer is mechanically connected to the Raise/Lower lever. It supplies an analog control signal to the main controller (VCM) in proportion to the position of the lever (see A2.4 in the Service Level menu). The VCM controls the lift speed via the HDM (hydraulic module) in proportion to this control signal. POT2 must be recalibrated if replaced (see C2 in the Service Level menu).
BFS (Brake Fluid Switch) The brake fluid switch is located in the cover of the brake fluid container. A warning is displayed when the brake fluid falls below the minimum level required.
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ELECTRICS POT3 (Reach potentiometer) The reach potentiometer is connected to the reach lever. It supplies an analog, proportional control signal to the truck controller (VCM). This governs the reach speed (see A2.5 in the Service Level menu). POT3 must be recalibrated if replaced (see C3 in the Service Level menu).
The seat switch is located in the driver’s seat. When the driver leaves the seat, all functions are deactivated except for steering.
SFS 1SA (Forward travel steering feedback sensor) This switch is located in the motor compartment behind the drive motor. SFS 1SA monitors the forward position of the drive wheel.
POT4 (Tilt potentiometer) SFS 2 (Steering feedback sensor 2) The tilt potentiometer is connected to the tilt lever. It supplies an analog, proportional control signal to the truck controller (VCM). This governs the tilt speed (see A2.6 in the Service Level menu). POT4 must be recalibrated if replaced (see C4 in the Service Level menu).
POT5 (Sideshift potentiometer) The sideshift potentiometer is connected to the sideshift lever. It supplies an analog, proportional control signal to the truck controller (VCM). This governs the sideshift speed (see A2.7 in the Service Level menu). POT5 must be recalibrated if replaced (see C5 in the Service Level menu).
POT6 (5th hydraulic function potentiometer) The potentiometer for the 5th hydraulic function is connected to the “5th hydraulic function” lever. It supplies an analog, proportional control signal to the truck controller (VCM). This governs the speed of the 5th hydraulic function (see A2.8 in the Service Level menu). POT6 must be recalibrated if replaced (see C6 in the Service Level menu).
PLS (Pressure load switch) The pressure load switch (seen in the fork direction) is located in the pipeline leading to the right-hand main lift cylinder. When a load in excess of 500 kg is being lowered, it prevents the fork carriage from stopping abruptly. This prevents the mast from swaying. The pressure load switch must be reset when replaced (to 500 kg).
SES (Seat switch)
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Located in the motor compartment to the right of the drive motor. SFS2 monitors the quadrant (See Chapter 6 for an explanation of the quadrant control principle).
BRS (Parking brake switch) The parking brake switch (next to the key switch) activates and deactivates the parking brake. When “ON” the parking brake symbol in the display lights up. When the parking brake is released the truck remains braked until you apply the accelerator pedal. This prevents the truck from rolling away.
BPS (Brake pressure switch) The brake pressure switch is located on the brake cylinder. It is applied when a preset brake pressure is exceeded. When this pressure is exceeded, in addition to the mechanical brake an electrical braking process (with regenerative feed) is activated via the drive motor.
ORS (Override switch) The override switch is Installed in the control panel (overhead guard column, left of the steering wheel). When you approach a programmed lift stop, you can apply the override switch to continue raising to the limit position, or to the next programmed lift stop.
ECR1 (Travel encoder) The travel encoder consists of a sensor ball bearing in the top bearing plate of the drive motor. The travel encoder monitors the current motor speed and relays this to the TDM.
ECR2 (Lift encoder)
ESR4500 06/2004 • Printed in Germany
ELECTRICS The lift encoder is a sensor ball bearing in the top bearing plate of the pump motor. The lift encoder monitors the current motor speed and relays this to the HDM.
THS3 (Temperature switch 3) Switch THS3 is used only with cold store trucks. It is attached near to the accelerator pedal. The thresholds are:
ECR3 (Steering feedback encoder) The steering feedback encoder is installed in the steer motor. It feeds back a signal in proportion to the steering direction and the steering speed.
ON:
+2°C
OFF:
+12°C
RES1 (Reach sensor 1) ECR4 (Steering encoder) SLOW Down range identified for forward/reverse reach, The steering encoder is located in the steering column below the steering wheel. When the steering wheel is turned it transmits a signal to the steer module which is based on the direction of turn and the speed of turn.
ECR5 (Height encoder) The height encoder is located on the top cross member of the outer mast. It monitors the lift height when the free lift has been exceeded. It must be re-calibrated when replaced (see Calibration in the Service menu). Lifting is inhibited if the height encoder is faulty or if there are no height encoder signals to the VCM after 30 seconds.
THS1 (Temperature sensor 1) THS 1 is located in the drive motor and monitors the current motor temperature. When the motor temperature reaches 145 °C, the maximum current is restricted to 250 A. If the motor temperature continues to rise, the current is reduced in proportion up to 0 A for a temperature of 165°C. At a motor temperature of 165°C and 0 A current, the motor cuts out.
THS2 (Temperature sensor 2) THS2 is located in the hydraulic pump motor and monitors the current motor temperature. When the motor temperature reaches 145 °C, the maximum current is restricted to 250 A. If the motor temperature continues to rise, the current is reduced in proportion up to 0 A for a temperature of 165°C. At a motor temperature of 165°C and 0 A current, the motor cuts out.
ESR4500 06/2004 • Printed in GermanyMANY
”OFF“ = Reduced fwd./rev. reach (OFF = in slow down range, ON in “normal” range) RES1 generally activates reach speed reduction
RES2 (Reach sensor 2) Slow Down range identified. (ON = Slow Down rear, OFF = Slow Down front) RES2 identifies the position of the mast in order to set off again at the appropriate speed. (If the mast is in the Slow Down range, the speed must be reduced for Fwd. reach activation). For Rev. reach activation start again at normal reverse speed.
SVH (Lift valve) SVR is incorporated with PVL in a single valve. SVR is a black and white valve and opens when lifting is selected. The lift speed is governed by the pump speed.
PVL (Proportional valve lower) PVL is incorporated with SVR in a single valve. The lowering speed is governed proportionally by PVL.
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ELECTRICS PVRT (Proportional valve retract) The retract speed is governed proportionally by PVRT. If PVRT fails, the entire hydraulic manifold block must be replaced.
FU2 (15A) protects the control circuits for the VCM (main controller) and the HDM (hydraulic module).
FU3 (Brake control fuse) FU3 (15A) protects the brakes from overcurrents.
PVRE (Proportional valve extend) FU4 (SDM power fuse) The extend speed is governed proportionally by PVRE. If PVRE fails, the entire hydraulic manifold block must be replaced.
FU4 (30A) protects the power circuit of the steer module.
FU5 / FU6 (Options control fuses) PVAR (Proportional valve accessories right) PVAR governs the downward tilt speed of the forks when TILT is selected, and the sideshift right speed with SIDESHIFT is selected. If PVAR fails, the entire hydraulic manifold block must be replaced.
PVAL (Proportional valve accessories left) PVAL governs the upward tilt speed of the forks when TILT is selected, and the sideshift left speed with SIDESHIFT is selected. If PVAL fails, the entire hydraulic manifold block must be replaced.
FU5 (15A) and FU6 (15A) protect the auxiliary options control circuits.
FU7 (Main fuse) FU7 (425A) protects the power and control circuits for the entire truck.
FAN1 (Electric compartment fan) This fan is optional. It can fitted subsequently if required. The fan connector (PC401) is fitted in the truck as standard.
RV (Relief valve) FAN2 (traction and hydraulic module fan) RV is used to restrict the maximum operating pressure. It is set to 210 bar. RV must be reset when replaced.
MVL (Manual lowering valve) In an emergency, MVL can be used to manually lower the fork carriage. Close the valve again after lowering the fork carriage (turn anti-clockwise).
AVL (Lowering speed adjustment valve) The AVL allows you to set the maximum lowering speed when PVL is fully opened.
FU1 (TDM / Display control fuse)
FAN2 is installed in the electric compartment below the control lever unit. This fan is temperature controlled. It switches on when the hydraulic module temperature > 35°C.
FAN3, FAN4 (Motor compartment fans) FAN3 and FAN4 are attached to the chassis behind the hydraulic reservoir. These fans are temperature controlled. They switch on when the hydraulic module temperature > 35°C.
K1(R1-R10 Heating resistor relays) K1 is located on the options panel. It is only used for cold store trucks. If K1 is active, heating resistors R1 to R10 are energised.
FU1 (15A) protects the control circuits for the traction module and the display.
FU2 (VCM / HDM control fuse)
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ELECTRICS K2 (Heating fan relay) K2 is located on the options panel. It is only used for cold store trucks. A heating fan (optional) can be connected to K2.
K3 / K4 (Brake light relay) K3 and K4 are located on the option panel. They activate the brake lights. Both relays are activated when the brake pedal is applied, as well as during inversion braking and release braking. K3 and K4 are controlled via the VCM, output CA26, pin 7.
SD (Travel lights switch) The SD switch is located in the control panel, to the right of the steering wheel. Switch position 1 governs the dipped lights. Switch position 2 governs relay K5. Relay K5 activates the dipped lights, reverse lights and parking lights.
SI (Indicator switch) The SI switch is located in the control panel, to the right of the steering wheel. SI activates the indicators in the reverse lights and the dipped lights.
K5 (Travel lights relay) K5 is located on the options panel. K5 is set to position 2 via the SD switch. This activates the dipped lights, reverse lights and parking lights.
K6 (Work lights relay) K6 is located on the options panel. K6 is activated via the SW switch. The work lights are activated via a normally open interrupteur of K6.
K7 / K8 (Travel alarm relay) K7 and K8 are installed in the steering column. The travel alarm is only activated if one of the available functions has been activated in Service Menu Features F8. It is controlled by the VCM, output CA205, pin 11.
K9 / K10 (Flashing beacon relay) K9 and K10 are installed in the steering column. The flashing beacon is only activated if one of the functions has been activated in Service Menu F9. It is controlled by the VCM, output CA205, pin 10.
K12 / K13 (Options relay) K12 and K13 are assembled in the electric compartment on the start up module. Both relays are only fitted for the “light package and cold store” options.
SW (Work lights switch) The SW switch is located in the control panel, to the left of the steering wheel. Relay K6 is controlled via the SW switch.
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ELECTRICS ESR4500 Status Codes The ESR4500 is fitted with an electronic control system for the key operating functions. For certain faults the system automatically generates a service code which can be viewed on the operator display.
HNS:
Horn switch
FKS:
Fork tilt switch
HGT(R)S: Height switch, height reset switch
This maintenance section helps identify the problem when a code is encountered and provides corrective actions to help resolve the cause of the code.
Status Codes Each of the status codes described on the following pages has a number as well as a brief description of the affected assembly and hints as to the possible causes.
When a Service Code Occurs Generally speaking, the majority of malfunctions occur in or at output components such as solenoid valves, contactors and motors. The next most error prone components are connectors, wiring and input devices such as switches, potentiometers or encoders. The least likely to fail are the VCM (main module), TDM (traction module), HDM (hydraulic module) and SDM (steer module) control modules. In all cases, begin troubleshooting with the consumer component.
Truck does not operate and there is no Status Code Status codes are the result of tests performed on the inputs and outputs of control signals. The malfunctions that can occur without providing a service code can fall into one of four categories. 1. Fault during power-up Malfunctions in the power-up circuit can keep the truck from powering up. Refer to the power up circuit on the following page and the detailed description attached. 2. The fault is not electrical The fault occurs after the truck has powered up correctly, but with no status code. The fault is probably mechanical or hydraulic. Refer to the relevant section in the maintenance chapter of the manual. 3. Malfunction in one of a group of unmonitored inputs One of the unmonitored inputs is causing the malfunction. These include:
ESR4500 06/2004 • Printed in GermanyMANY
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ELECTRICS
FU 7 = 425 A
EDS ED1 FU 1 = 15 A ED1
EDS (mechanical)
A
CA 420
9
KYS
+
K11 C
R2
K11
CA 420
48 V
FU 2 = 15 A
F1
V5
10
2
4 12
C5 V1
C1,2 Charge-R1
1
CA402
START UP CARD
HORN
V2
HNS
3 11
B-
-
14 B+ 17 KYS
1
24
ED1
CA 205
28 B-
KYS
CA202
B+
1
KYS
CAP
VCM
TDM
B+
19
KYS
18
B-
CAP
HDM
B-
B+ CA204
CA203
DISPLAY
B+
CA201
20
8
FU 4 = 30 A
1
BB-
7
2
SDM
MS-2140-022
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ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 100 - 102 Status Code 100
Überstrom in der Lenksteuerung Over Current on Steer Drive Module
LOG BOOK display:
1
0
0
O
V
E
Explanation:
Motor
X R
X
X
X
X
h
C
U
R
R
E
X N
T
X
X
C
S
D
M
current > 49A
Effect on truck:
- Parking brake applied - Traction drive module deactivated - Main contactor ED1 deactivated
Possible Causes:
- Error in module power circuit. - If the truck is operating, this could be a nuisance code. Monitor code frequency. If necessary, inform Crown Service.
Status Code 101
Erhöhter Strom in der Lenksteuerung High Current Steer Drive Module
LOG BOOK display:
Explanation:
1
0
X
X
X
X
X
h
H
I G H current > 27A
C
U
R
R
E
Motor
1
X N
T
X
X
C
S
D
M
Effect on truck:
- Parking brake applied - Traction drive module deactivated - Main contactor ED1 deactivated
Possible Causes:
- Error in module power circuit. - If the truck is operating, this could be a nuisance code. Monitor code frequency. If necessary, inform Crown Service.
Status Code 102
Fehler im Lenkmotor-Stromkreis Error Steer Motor Circuit
LOG BOOK display:
1
0
2
E
R
R
X O
R
X
X
X
X
h
S
T
E
E
X R
X
X
C
M O
T
.
Explanation:
Open or shorted steer motor power circuit
Effect on truck:
- Parking brake applied - Traction drive module deactivated - Main contactor ED1 deactivated
Possible Causes:
- Line interruption in phase R, S or T. Check power cable and motor connections, replace motor if necessary.
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ELECTRICS Statuscode 110 - 120 Status Code 110 LOG BOOK display:
Überspannung an der Lenksteuerung High Voltage Steer Drive Module 1
1
0
H
I
G
X
H
X
X
X
X
h
V
O
L
T
A
X G
E
X
X
C
S
D
M
Explanation:
Excess voltage in power circuit, exceeds 63 volts.
Effect on truck:
- Hydraulic and traction drive modules deactivated - Main contactor ED1 deactivated - Parking brake applied
Possible Causes:
- Emergency Disconnect pressed during plugging - Internal error in steer drive module - If the truck is operating, this could be a nuisance code. Monitor code frequency. If necessary, inform Crown Service.
Status Code 120
Übertemperatur in der Lenksteuerung Over Temperature Steer Drive Module
LOG BOOK display:
1
2
0
O
V
E
X R
X
X
X
X
h
T
E
M
P
.
X
X
X
C
S
D
M
Explanation:
Temperature in steer drive module exceeds 85°C
Effect on truck:
Truck brakes electrically, then the main contactor is deactivated.
Possible Causes:
- Check the conditions of use and total service hours of the truck. If the conditions of use are arduous, check the SDM for dirt. - - Error in control module power circuit. - Power up the truck and press the key at the same time, enter password. Check steer motor current in menu A2.32. If the motor current exceeds 18A when the truck is idle or travelling slowly, take the following measurement. Jack up the truck and measure current in menu A2.32. If the current is less than 5A there is no technical problem with the transmission and the toothing. If the current remains high, replace the steer motor or the steer drive
module.
- If the error persists, monitor the code frequency. If necessary, inform Crown Service.
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ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 121 - 130 Status Code 121 LOG BOOK display:
Erhöhte Temperatur in der Lenksteuerung High Temperature Steer Module 1
2
1
H
I
G
X H
X
X
X
X
H
T
E
M
P
.
X
X
X
C
S
D
M
Explanation:
Temperature in steer drive module exceeds 75°C
Effect on truck:
Normal operation. Display message: Steer module hot
Possible Causes:
- Check the conditions of use and total service hours of the truck. If the conditions of use are arduous, check the SDM for dirt. - - Error in module power circuit. - Power up the truck and press the key at the same time, enter password. Check steer motor current in menu A2.32. If the motor current exceeds 18A when the truck is idle or travelling slowly, take the following measurement. Jack up the truck and measure current in menu A2.32. If the current is less than 5A there is no technical problem with the transmission and the toothing. If the current remains high, replace the steer motor or the steer drive
module.
- If the error persists, monitor the code frequency. If necessary, inform Crown Service.
Status Code 130 LOG BOOK display:
CAN BUS Fehler an der Lenksteuerung Error CAN Bus Steer Module 1
3
0
E
R
R
X O
R
X
X
X
X
h
C
A
N
B
X U
S
X
X
C
S
D
M
Explanation:
Error in CAN BUS communication between VCM and SDM
Effect on truck:
Main contactor deactivated
Possible Causes:
- Error in wire bundle or connection - Power down truck and measure terminal resistance at PC416-1 and 2: 60 Ohm = resistance OK, 120 Ohm = a terminal resistance in VCM or SDM is faulty. - Connect PC205 to VCM and measure resistance on VCM between PC205-22 and 23: Rated resistance = 120 Ohm. If the value is incorrect, replace VCM. If the value is correct, disconnect PC204 from SDM and measure the terminal resistance between pins 10 and 11 on the SDM. If the value is incorrect, replace SDM. - If the truck is operating, this could be a nuisance code. Monitor code frequency. If necessary, inform Crown Service.
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ELECTRICS Statuscode 131 - 160 Status Code 131 Error LOG BOOK display:
1
3
1
X
E
R
R
O R
X
X
X
X
h
E
E
P
R O
X M
X
X
C
S
D
M
Explanation:
Malfunction in memory module of steer drive module
Effect on truck:
None
Possible Causes:
If the truck is operating, this could be a nuisance code. Monitor the code frequency, if necessary replace the steer drive module.
Status Code 160
Fehler im Parkbrems-Stromkreis Error in Brake Circuit
LOG BOOK display:
1
6
0
B
R
A
X K
E
X
X
X
X
h
C
O
I
L
X
X
X
C
Explanation:
Open circuit or excess current on brake steer drive module output.
Effect on truck:
- Truck brought to a halt through plugging - Traction module deactivated - Main contactor ED1 deactivated
Possible Causes:
- Check FU3 - Check brake coil: Resistance = 55 Ohm. Replace brake if the deviation is severe - Check lines and connections - Clean brake and check air gap (0.5mm), adjust if necessary. - In the event of a fault, the truck can be driven out of the working area at creep speed. The following steps must be taken: unplug and then dismantle the brake, and in menu U3.2 set ACCY = YES. This function is only active in the U3.2 menu.
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EEPROM Fehler an der Lenksteuerung EEPROM Error Steer Module
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 180 - 181 Status Code 180 LOG BOOK display:
Fehler am Lenkmotor - Encoder ECR3 Error Steer Feedback Encoder ECR3 1
8
0
E
C
R
X 3
X
X
X
X
H
A
L
L
h S
E
X
X
X
C
N
S
O
R
Explanation:
ECR3 is a 3-channel hall sensor. An error is generated if a channel is not correctly identified or if 2 channels are short-circuited.
Effect on truck:
- Parking brake applied - Traction drive module deactivated - Main contactor deactivated
Possible Causes:
- Check lines and connections - Disconnect PC412 and check +5V between pins 4 and 6. Present: SDM OK. Not present: Replace SDM. - Re-connect plug. Check +5V between PC436-4 and 6. Not present: Check line. Present: Replace motor
Status Code 181
Fehler am Lenkencoder ECR4 Error Steer Encoder ECR4
LOG BOOK display:
1
8
1
E
C
R
X 4
X
X
X
X
h
S
T
E
P
P
X E
R
X
X
C
M O
T
Explanation:
ECR4 is a stage motor which when applied sends an induced voltage signal to the steer drive module. An open line or short circuit are identified.
Effect on truck:
- Parking brake applied - Traction drive module deactivated - Main contactor deactivated
Possible Causes:
- Check lines and connections - Disconnect PC414 and measure +5V between pin 5 or pin 2 (purple line) and BATT NEG. Present: Replace ESR4. Not present: Check connection to SDM, replace steer drive module
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ELECTRICS Statuscode 182 - 183 Status Code 182 LOG BOOK display:
1
8
2
S
F S
X 1
X
X
X
S W
X
h
E
X
P
E
X
X
X
C
C
T
E D
Explanation:
At an angle of 0° (drive wheel forward) the sensor does not change signal as expected.
Effect on truck:
Steering error routine See chapter 6
Possible Causes:
- Set drive wheel to forward position. Now steer 20° to the left and right. Monitor the LED on the sensor. In the right position the LED is off, in the left position it is on. If there is no change: replace sensor. - Remove sensor. Place the sensor against a metal surface and test its operation. If the LED goes on, check the mechanical setting (see chapter 6). If the LED remains off, replace the sensor. Also test the operation of the new sensor. - No operation after replacing the sensor. Check +12V operating voltage between PC439-A and PC439-B and CA203-14 and 15 (display). No voltage present. Check lines for short circuits, replace display if necessary.
Status Code 183
Kein Signal SFS2 No Signal SFS2
LOG BOOK display:
1
8
2
S
F S
X 2
X
X
S W
X
X
h
E
X
P
E
X
X
X
C
C
T
E D
Explanation:
Quadrant recognition error
Effect on truck:
Steering error routine See chapter 6
Possible Causes:
- Set drive wheel to forward position. Now steer 90° to the left and right. Monitor the LED on the sensor. LED should always be on. - Remove sensor. Place the sensor against a metal surface and test its operation. If the LED goes on, check the mechanical setting (see chapter 6). If the LED remains off, replace the sensor. Also test the operation of the new sensor. - No operation after replacing the sensor. Check +12V operating voltage between PC438-A and PC438-B and CA203-14 and 15 (display). No voltage present. Check lines for short circuits, replace display if necessary.
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Kein Signal SFS 1SA No Signal SFS 1SA
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 184 - 200 Status Code 184 LOG BOOK display:
Falsche Antriebsradposition erkannt Wrong Drive Wheel position detected 1
8
4
S
T A
X R
X
T
X
X
X
h
E
R
R
O
X R
X
X
C
S
D M
Explanation:
The stored value for the steering wheel does not match the current position.
Effect on truck:
Steering error routine See chapter 6
Possible Causes:
- Faulty SFS 1SA sensor. - Set drive wheel to forward position. Now steer 20° to the left and right. Monitor the LED on the sensor. In the right position the LED is off, in the left position it is on. If there is no change: replace sensor. - Remove sensor. Place the sensor against a metal surface and test its operation. If the LED goes on, check the mechanical setting (see chapter 6). If the LED remains off, replace the sensor. Also test the operation of the new sensor. - No operation after replacing the sensor. Check +12V operating voltage between PC439-A and PC439-B and CA203-14 and 15 (display). No voltage present. Check lines for short circuits, replace display if necessary.
Status Code 200
Erhöhte Stromaufnahme Hydrauliksteuerung High Current Hydraulic Drive Module
LOG BOOK display:
2
0
0
H
I
G
X H
X
X
X
X
h
C
U
R
R
E
X N
T
X
X
C
H
M
Explanation:
Excessive current detected in power circuit (exceeds 787 A).
Effect on truck:
- Hydraulic and traction drive modules deactivated - Main contactor ED1 deactivated - Parking brake applied
Possible Causes: module power circuit.
- Short circuit in motor feed line or motor coil, or error in hydraulic drive - Switch off the truck and measure the insulation resistance. If necessary replace the hydraulic motor or hydraulic drive module.
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ELECTRICS Statuscode 201 - 210 Status Code 201
Kurzschluss Leistungskreis Hydrauliksteuerung Short Circuit in Power Circuit Hydraulic Drive Module
LOG BOOK display:
2
0
1
S
H
O
X R
X
T
X
X
X
.
X
h
X
C
I
R
C
U
I
T
X
X
C
H
M
Explanation:
A short circuit is detected in the power circuit.
Effect on truck:
- Hydraulic and traction drive modules deactivated - Main contactor ED1 deactivated - Parking brake applied
Possible Causes: module power circuit.
- Short circuit in motor feed line or motor coil, or error in hydraulic drive - Switch off the truck and measure the insulation resistance. If necessary replace the hydraulic motor or the hydraulic drive module.
Status Code 210
Überspannung an der Hydrauliksteuerung High Voltage Hydraulic Module
LOG BOOK display:
2
1
0
H
I
G
H
X
X
X
X
h
V
O
L
T
A
X G
E
X
X
C
H
M
Explanation:
Excess voltage in power circuit, exceeds 63 volts.
Effect on truck:
- Hydraulic and traction drive modules deactivated - Main contactor ED1 deactivated - Parking brake applied
Possible Causes:
- Emergency Disconnect pressed during plugging - Internal error in traction drive module - If the truck is operating, this could be a nuisance code. Monitor code frequency. If necessary, inform Crown Service.
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X
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 211 - 213 Status Code 211
Unterspannung an der Hydrauliksteuerung Low Voltage Hydraulic Module
LOG BOOK display:
2
1
1
X
X
X
X
X
h
L
O W
V
O
L
T
A
G
X
X
E
X
C
H
M
Explanation:
The hydraulic drive module has detected a voltage below 18 volts.
Effect on truck:
- Hydraulic and traction drive modules deactivated - Main contactor ED1 deactivated - Parking brake applied
Possible Causes:
- Check power circuit wiring - Faulty battery. Battery voltage collapses under load. Select menu item A.2.36, lift a heavy load and monitor the battery voltage during lifting. - Check battery cell voltages. If necessary, replace battery.
Status Code 212
15 Volt Spannungsversorgung zu niedrig 15 Volt Supply to low
LOG BOOK display:
2
1
2
1
5
V
O
X
X
L
T
X
X
X
.
X
h
X
S
U
P
P
L
Y
X
X
C
H
M
Explanation:
Internal error in hydraulic drive module 15 volt supply for the pulse width modulation (PWM) of the line transistors is faulty
Effect on truck:
- Hydraulic drive module is deactivated - Truck can operate in creep mode.
Possible Causes:
Internal error, replace control module.
Status Code 213
5 Volt Spannungsversorgung zu niedrig 5 Volt Supply to low
LOG BOOK display:
2
1
3
5
V
O
X L
T
X
X
X
X
h
S
U
P
P
X L
Y
X
X
C
H
M
Explanation:
Internal error in hydraulic drive module 5 volt supply for internal current measurement in power circuit.
Effect on truck:
- Hydraulic drive module is deactivated - Truck can operate in creep mode.
Possible Causes:
Internal error, replace control module.
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ELECTRICS Statuscode 214 - 220 Status Code 214
Hydrauliksteuerung: Kondensatorladezeit überschritten Hydraulic Drive Module: Capacitor Charge exceeded
LOG BOOK display:
2
1
4
X
X
X
X
X
h
C
A
P
C
H
A
R
G
E
X
X
C
H
M
Explanation:
Capacitors are not charged.
Effect on truck:
- Main contactor is not activated
Possible Causes:
- No battery voltage on B+ input of hydraulic drive module - Connect measuring device between B+ and B- on the hydraulic drive module and power up the truck. The voltage at B+ should rise from 0V within approx. 2s. If not, check the lines. - If the voltage is applied, there is an internal error in the hydraulic drive module. Replace the module
Status Code 220
Übertemperatur in der Hydrauliksteuerung Over Temperature Hydraulic Drive Module
LOG BOOK display:
2
2
0
O
V
E
X R
X
X
X
X
h
T
E
M
P
.
X
X
X
C
H
M
Explanation:
Temperature in hydraulic drive module exceeds 115°C
Effect on truck:
- Hydraulic drive module is deactivated - Truck can operate in creep mode. - Error message displayed. Hydraulic module hot
Possible Causes:
- Check the conditions of use and total service hours of the truck. - If the truck does not operate in arduous conditions, check the fans - In menu A1.9 monitor the hydraulic drive module temperature and continually apply one of the hydraulic functions to bring the module to operating temperature. When the temperature exceeds 35°C all the fans should start up. CA201-2 is set to BATT NEG. - If there is no operation: Check fans, lines, connections and power supply. - Remove TDM and HDM and check radiator fins are clean. Clean if necessary. - If the error persists, monitor the code frequency. If necessary, inform Crown Service.
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X
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 221 - 222 Status Code 221
Übertemperatur am Hydraulikmotor Over Temperature Hydraulic Motor
LOG BOOK display:
2
2
1
O
V
E
X R
X
X
X
X
h
X
X
X
C
T
E
M
P
.
H
M O
T
Explanation:
Temperature in motor coil exceeds 165°C
Effect on truck:
- Hydraulic drive module is deactivated - Truck can operate in creep mode. - Error message displayed. Hydraulic motor hot
Possible Causes:
- Check the conditions of use and total service hours of the truck. - If the truck does not operate in arduous conditions, check the fans - In menu A1.9 monitor the hydraulic drive module temperature and continually apply one of the hydraulic functions to bring the module to operating temperature. When the temperature exceeds 35°C all the fans should start up. CA201-2 is set to BATT NEG. - If there is no operation: Check fans, lines, connections and power supply. - Remove TDM and HDM and check radiator fins are clean. Clean if necessary. - If the error persists, monitor the code frequency. If necessary, inform Crown Service.
Status Code 222
Erhöhte Temperatur an der Hydrauliksteuerung High Temperature Hydraulic Drive Module
LOG BOOK display:
2
2
2
H
I
G
X H
X
X
X
X
h
T
E
M
P
.
X
X
X
C
H
M
Explanation:
Temperature in hydraulic drive module exceeds 85°C
Effect on truck:
- Hydraulic drive module current is linearly reduced to 0 A between 85° and 115°C. - Error message displayed. Hydraulic module hot
Possible Causes:
- Check the conditions of use and total service hours of the truck. - If the truck does not operate in arduous conditions, check the fans - In menu A1.9 monitor the hydraulic drive module temperature and continually apply one of the hydraulic functions to bring the module to operating temperature. When the temperature exceeds 35°C all the fans should start up. CA201-2 is set to BATT NEG. - If there is no operation: Check fans, lines, connections and power supply. - Remove TDM and HDM and check radiator fins are clean. Clean if necessary. - If the error persists, monitor the code frequency. If necessary, inform Crown Service.
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ELECTRICS Statuscode 223 - 224 Status Code 223
Temperatur zu tief an der Hydrauliksteuerung Low Temperature Hydraulic Module
LOG BOOK display:
2
2
3
X
X
X
X
X
L
O W
T
E
M
P
.
X
X
X
C
H
M
Explanation:
Temperature in hydraulic drive module is less than –20°C
Effect on truck:
Error message displayed. Hydraulic module cold
Possible Causes:
Check the conditions of use and total service hours of the truck. Attention: The truck has been stored in a cold environment for a long period of time.
Status Code 224
Erhöhte Temperatur am Hydraulikmotor High Temperature Hydraulic Motor
LOG BOOK display:
2
2
4
H
I
G
X H
X
X
X
X
h
X
X
X
C
T
E
M
P
.
H
M O
T
Explanation:
Temperature in motor coil exceeds 145°C
Effect on truck:
Motor current is linearly reduced to 0 A between 145° and 165°C motor temperature. Error message displayed. Hydraulic motor hot
Possible Causes:
- Check the conditions of use and total service hours of the truck. - If the truck does not operate in arduous conditions, check the fans - In menu A1.9 monitor the hydraulic drive module temperature and continually apply one of the hydraulic functions to bring the module to operating temperature. When the temperature exceeds 35° all the fans should start up. CA201-2 is set to BATT NEG. - If there is no operation: Check fans, lines, connections and power supply. - Remove TDM and HDM and check radiator fins are clean. Clean if necessary. - If the error persists, monitor the code frequency. If necessary, inform Crown Service.
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h
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 225 - 230 Status Code 225
Temperatur zu tief am Hydraulikmotor Low Temperature Hydraulic Motor
LOG BOOK display:
2
2
5
X
X
X
X
X
L
O W
T
E
M
P
.
h
X
X
X
C
H
M O
T
Explanation:
Temperature in motor coil is less than –30°C
Effect on truck:
Error message displayed. Hydraulic motor cold
Possible Causes:
Check the conditions of use and total service hours of the truck. Attention: The truck has been stored in a cold environment for a long period of time.
Status Code 230
CAN BUS Fehler an der Hydrauliksteuerung Error CAN BUS Hydraulic Drive Module
LOG BOOK display:
2
3
0
E
R
R
X O
R
X
X
X
X
h
C
A
N
B
X U
S
X
X
C
H
M
Explanation:
Error in CAN BUS communication between VCM and SDM
Effect on truck:
Main contactor deactivated
Possible Causes:
- Error in wire bundle or connection - Power down truck and measure terminal resistance at PC416-1 and 2: 60 Ohm = resistance OK, 120 Ohm = a terminal resistance in VCM or SDM is faulty. - Connect PC205 to VCM and measure resistance on VCM between PC205-22 and 23: Rated resistance = 120 Ohm. If the value is incorrect, replace VCM. If the value is correct, disconnect PC204 from SDM and measure the terminal resistance between pins 10 and 11 on the SDM. If the value is incorrect, replace SDM. - If the truck is operating, this could be a nuisance code. Monitor code frequency. If necessary, inform Crown Service.
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ELECTRICS Statuscode 240 Status Code 240
Eingangsspannung von POT2 über dem Grenzwert Input Voltage from POT2 above Limit
LOG BOOK display:
2
4
0
P
O
T
X 2
X
X
X
X
h
A
B
O
V
E
L
X
X
X
C
I
M
I
T
Explanation:
The loop voltage from POT2 is continually monitored during start-up and operation. The upper limit of 10.8 volt is exceeded during this time.
Effect on truck:
Hydraulic function completely disabled.
Possible Causes:
- Select menu item A2.4 (POT2). Activate “Raise/Lower”. - Take readings from display. Approx. 12V: Short circuit between potentiometer CA407-2 (red) and CA407-1 (green). Check reading with a digital multimeter. Reading confirmed: Replace potentiometer, check wiring. Approx. 5.0 – 6.0 V: correct reading when control lever is in neutral. 0.7 – 1.5 V: correct reading when control lever is in max “Lower” position. 9.5 – 10.5 V: correct reading when control lever is in max “Raise” position. If the readings are correct, there is probably an intermittent fault in the potentiometer circuit. Check wire connections and potentiometer. Note: Recalibrate potentiometer after carrying out repairs
MS-4.3-2140
84
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 241 Status Code 241
Eingangsspannung von POT2 ist unter dem Grenzwert Input Voltage from POT2 under Limit
LOG BOOK display:
2
4
1
P
O
T
X 2
X
X
X
X
h
U
N
D
E
R
L
X
X
X
C
I
M
I
T
Explanation:
The loop voltage from POT2 is continually monitored during start-up and operation. The lower limit of 0.6 volt is exceeded during this time.
Effect on truck:
Hydraulic function completely disabled.
Possible Causes:
- Select menu item A2.4 (POT2). Activate “Raise/Lower”. - Take readings from display. Approx. 0 V: open circuit between potentiometer CA407-2 (red), CA407-1 (green) and VCM or short circuit between CA407-2 (red) and CA407-3 (yellow). Check connection PC407 and PC205. If the wiring is ok, replace the potentiometer. Approx. 5.0 – 6.0 V: correct reading when control lever is in neutral. 0.7 – 1.5 V: correct reading when control lever is in max “Lower” position. 9.5 – 10.5 V: correct reading when control lever is in max “Raise” position. If the readings are correct, there is probably an intermittent fault in the potentiometer circuit. Check wire connections and potentiometer. Note: Recalibrate potentiometer after carrying out repairs
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
85
ELECTRICS Statuscode 243 Status Code 243
Eingangsspannung von POT3 über dem Grenzwert Input Voltage from POT3 above Limit
LOG BOOK display:
2
4
3
P
O
T
X 3
X
X
X
X
h
A
B
O
V
E
L
X
X
X
C
I
M
I
T
Explanation:
The loop voltage from POT3 is continually monitored during start-up and operation. The upper limit of 10.8 volt is exceeded during this time.
Effect on truck:
Hydraulic function completely disabled.
Possible Causes:
- Select menu item A2.5 (POT3). Activate “Reach” function. - Take readings from display. Approx. 12V: Short circuit between potentiometer CA408-2 (red) and CA408-1 (green). Check reading with a digital multimeter. Reading confirmed: Replace potentiometer, check wiring. Approx. 5.0 – 6.0 V: correct reading when control lever is in neutral. 0.7 – 1.5 V: correct reading when control lever is in max “Fwd. Reach” position. 9.5 – 10.5 V: correct reading when control lever is in max “Rev. Reach” position. If the readings are correct, there is probably an intermittent fault in the potentiometer circuit. Check wire connections and potentiometer. Note: Recalibrate potentiometer after carrying out repairs
MS-4.3-2140
86
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 244 Status Code 244
Eingangsspannung von POT3 unter dem Grenzwert Input Voltage from POT3 under Limit
LOG BOOK display:
2
4
4
P
O
T
X 3
X
X
X
X
h
U
N
D
E
R
L
X
X
X
C
I
M
I
T
Explanation:
The loop voltage from POT3 is continually monitored during start-up and operation. The lower limit of 0.6 volt is exceeded during this time.
Effect on truck:
Hydraulic function completely disabled.
Possible Causes:
- Select menu item A2.5 (POT3). Activate “Reach” function. - Take readings from display. Approx. 0 V: open circuit between potentiometer CA408-2 (red), CA408-1 (green) and VCM or short circuit between CA408-2 (red) and CA408-3 (yellow). Check connection PC408 and PC205. If the wiring is ok, replace the potentiometer. Approx. 5.0 – 6.0 V: correct reading when control lever is in neutral. 0.7 – 1.5 V: correct reading when control lever is in max “Fwd. Reach” position. 9.5 – 10.5 V: correct reading when control lever is in max “Rev. Reach” position. If the readings are correct, there is probably an intermittent fault in the potentiometer circuit. Check wire connections and potentiometer. Note: Recalibrate potentiometer after carrying out repairs
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
87
ELECTRICS Statuscode 246 Status Code 246
Eingangsspannung von POT4 über dem Grenzwert Input Voltage from POT4 above Limit
LOG BOOK display:
2
4
6
P
O
T
X 4
X
X
X
X
h
A
B
O
V
E
L
X
X
X
C
I
M
I
T
Explanation:
The loop voltage from POT4 is continually monitored during start-up and operation. The upper limit of 10.8 volt is exceeded during this time.
Effect on truck:
Hydraulic function completely disabled.
Possible Causes:
- Select menu item A2.6 (POT4). Activate “Fork tilt” function. - Take readings from display. Approx. 12V: Short circuit between potentiometer CA409-2 (red) and CA409-1 (green). Check reading with a digital multimeter. Reading confirmed: Replace potentiometer, check wiring. Approx. 5.0 – 6.0 V: correct reading when control lever is in neutral. 0.7 – 1.5 V: correct reading when control lever is in max “Fork tilt down” position. 9.5 – 10.5 V: correct reading when control lever is in max “Fork tilt up” position. If the readings are correct, there is probably an intermittent fault in the potentiometer circuit. Check wire connections and potentiometer. Note: Recalibrate potentiometer after carrying out repairs
MS-4.3-2140
88
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 247 Status Code 247
Eingangsspannung von POT4 unter dem Grenzwert Input Voltage from POT4 under Limit
LOG BOOK display:
2
4
7
P
O
T
X 4
X
X
X
X
h
U
N
D
E
R
L
X
X
X
C
I
M
I
T
Explanation:
The loop voltage from POT4 is continually monitored during start-up and operation. The lower limit of 0.6 volt is exceeded during this time.
Effect on truck:
Hydraulic function completely disabled.
Possible Causes:
- Select menu item A2.6 (POT4). Activate “Fork tilt” function. - Take readings from display. Approx. 0 V: open circuit between potentiometer CA409-2 (red), CA409-1 (green) and VCM or short circuit between CA409-2 (red) and CA409-3 (yellow). Check connection PC409 and PC205. If the wiring is ok, replace the potentiometer. Approx. 5.0 – 6.0 V: correct reading when control lever is in neutral. 0.7 – 1.5 V: correct reading when control lever is in max “Fork tilt down” position. 9.5 – 10.5 V: correct reading when control lever is in max “Fork tilt up” position. If the readings are correct, there is probably an intermittent fault in the potentiometer circuit. Check wire connections and potentiometer. Note: Recalibrate potentiometer after carrying out repairs
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
89
ELECTRICS Statuscode 249 Status Code 249
Eingangsspannung von POT5 über dem Grenzwert Input Voltage from POT5 above Limit
LOG BOOK display:
2
4
9
P
O
T
X 5
X
X
X
X
h
A
B
O
V
E
L
X
X
X
C
I
M
I
T
Explanation:
The loop voltage from POT5 is continually monitored during start-up and operation. The upper limit of 10.8 volt is exceeded during this time.
Effect on truck:
Hydraulic function completely disabled.
Possible Causes:
- Select menu item A2.7 (POT5). Activate “Sideshift” function. - Take readings from display. Approx. 12V: Short circuit between potentiometer CA410-2 (red) and CA410-1 (green). Check reading with a digital multimeter. Reading confirmed: Replace potentiometer, check wiring. Approx. 5.0 – 6.0 V: correct reading when control lever is in neutral. 0.7 – 1.5 V: correct reading when control lever is in max “Sideshift left” position. 9.5 – 10.5 V: correct reading when control lever is in max “Sideshift right” position. If the readings are correct, there is probably an intermittent fault in the potentiometer circuit. Check wire connections and potentiometer. Note: Recalibrate potentiometer after carrying out repairs
MS-4.3-2140
90
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 250 Status Code 250
Eingangsspannung von POT5 unter dem Grenzwert Input Voltage from POT5 under Limit
LOG BOOK display:
2
5
0
P
O
T
X 5
X
X
X
X
h
U
N
D
E
R
L
X
X
X
C
I
M
I
T
Explanation:
The loop voltage from POT5 is continually monitored during start-up and operation. The lower limit of 0.6 volt is exceeded during this time.
Effect on truck:
Hydraulic function completely disabled.
Possible Causes:
- Select menu item A2.7 (POT5). Activate “Sideshift” function. - Take readings from display. Approx. 0 V: open circuit between potentiometer CA410-2 (red), CA410-1 (green) and VCM or short circuit between CA410-2 (red) and CA410-3 (yellow). Check connection PC410 and PC205. If the wiring is ok, replace the potentiometer. Approx. 5.0 – 6.0 V: correct reading when control lever is in neutral. 0.7 – 1.5 V: correct reading when control lever is in max “Sideshift left” position. 9.5 – 10.5 V: correct reading when control lever is in max “Sideshift right” position. If the readings are correct, there is probably an intermittent fault in the potentiometer circuit. Check wire connections and potentiometer. Note: Recalibrate potentiometer after carrying out repairs
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
91
ELECTRICS Statuscode 252 Status Code 252
Eingangsspannung von POT6 über dem Grenzwert Input Voltage from POT6 above Limit
LOG BOOK display:
2
5
2
P
O
T
X 6
X
X
X
X
h
A
B
O
V
E
L
X
X
X
C
I
M
I
T
Explanation:
The loop voltage from POT6 is continually monitored during start-up and operation. The upper limit of 10.8 volt is exceeded during this time.
Effect on truck:
Hydraulic function completely disabled.
Possible Causes:
- Select menu item A2.8 (POT6). Apply 5th function. - Take readings from display. Approx. 12V: Short circuit between potentiometer CA411-2 (red) and CA411-1 (green). Check reading with a digital multimeter. Reading confirmed: Replace potentiometer, check wiring. Approx. 5.0 – 6.0 V: correct reading when control lever is in neutral. 0.7 – 1.5 V: correct reading when control lever is in max “5th function left” position. 9.5 – 10.5 V: correct reading when control lever is in max “5th function right” position. If the readings are correct, there is probably an intermittent fault in the potentiometer circuit. Check wire connections and potentiometer. Note: Recalibrate potentiometer after carrying out repairs
MS-4.3-2140
92
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 253 Status Code 253
Eingangsspannung von POT6 unter dem Grenzwert Input Voltage from POT6 under Limit
LOG BOOK display:
2
5
3
P
O
T
X 6
X
X
X
X
h
U
N
D
E
R
L
X
X
X
C
I
M
I
T
Explanation:
The loop voltage from POT6 is continually monitored during start-up and operation. The lower limit of 0.6 volt is exceeded during this time.
Effect on truck:
Hydraulic function completely disabled.
Possible Causes:
- Select menu item A2.8 (POT6). 5. Activate function. - Take readings from display. Approx. 0 V: open circuit between potentiometer CA411-2 (red), CA411-1 (green) and VCM or short circuit between CA411-2 (red) and CA411-3 (yellow). Check connection PC411 and PC205. If the wiring is ok, replace the potentiometer. Approx. 5.0 – 6.0 V: correct reading when control lever is in neutral. 0.7 – 1.5 V: correct reading when control lever is in max “5th function left” position. 9.5 – 10.5 V: correct reading when control lever is in max “5th function right” position. If the readings are correct, there is probably an intermittent fault in the potentiometer circuit. Check wire connections and potentiometer. Note: Recalibrate potentiometer after carrying out repairs
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
93
ELECTRICS Statuscode 260 Status Code 260
Kurzschluss SVH (Hubventil) Short Circuit SVH (Lift Valve)
LOG BOOK display:
2
6
0
X
X
X
X
S
V
H
L
I
F
T
X
h V
A
L
X
X
V
E
X
C
Explanation:
On the VCM main controller an overcurrent is detected on the SVH output during lifting and the contactor output is cut out.
Effect on truck:
- Hydraulic valves are cut out - Pump continues to operate.
Possible Causes:
Check coil resistance - Disconnect PC807 connector from solenoid valve. Connect measuring device between pins 2 and 3 to the SVH and measure the coil resistance. Resistance = 75 Ohm. - If the coil resistance is excessive or 0 ohms, SVH must be replaced. Missing Positive Test - Power up the truck and record the voltage between PC422-9 and the battery negative. Battery voltage should be applied. - Disconnect PC807 from the solenoid valve and record the voltage between PC422-9 and the battery negative. If battery positive is still applied, there is a short circuit between PC8073 and PC205-1 against the battery positive. After recording, re-connect PC807. - Power up the truck and connect the measuring device between PC4229 and the battery negative. Without applying POT2 (raise/lower) battery positive should be applied. When activating POT2 (raise) the voltage should drop to approx. 15 volt. If not, replace the VCM.
MS-4.3-2140
94
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 261 Status Code 261
Kurzschluss PVL (Absenkventil) Short Circuit PVL (Lower Valve)
LOG BOOK display:
2
6
1
X
X
X
X
P
V
L
L
O W E
R
X
h V
A
X
X
X
L
V
E
C
Explanation:
On the VCM main controller an overcurrent is detected on the PVL output during lifting and the contactor output is cut out.
Effect on truck:
- Hydraulic valves are cut out - Pump continues to operate.
Possible Causes:
Check coil resistance Disconnect PC807 connector from solenoid valve. Connect measuring device between pins 1 and 2 to PVL and measure the coil resistance. Resistance = 27 Ohm. If the coil resistance is excessive or 0 ohms, PVL must be replaced. Missing Positive Test - Power up the truck and record the voltage between PC422-8 and the battery negative. Battery voltage should be applied. - Disconnect PC807 from the solenoid valve and record the voltage between PC422-8 and the battery negative. If battery positive is still applied, there is a short circuit between PC8071 and PC205-42 against the battery positive. After recording, re-connect PC807. - Power up the truck and connect the measuring device between PC4229 and the battery negative. Without applying POT2 (raise/lower) battery positive should be applied. When activating POT2 (lower) the voltage should drop to approx. 33 volt. If not, replace the VCM.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
95
ELECTRICS Statuscode 262 Status Code 262
Kurzschluss PVRT (Ventil Mastvorschub zurück) Short Circuit PVRT (Retract Valve)
LOG BOOK display:
2
6
2
P
V
R
X T
X
X
X
X
h
R
E
T
R
A
X C
T
X
X
C
V
A
.
Explanation:
On the VCM main controller an overcurrent is detected on the PVRT output during a reach operation and the contactor output is cut out.
Effect on truck:
- Hydraulic valves are cut out - Pump continues to operate.
Possible Causes:
Check coil resistance Disconnect PC810 connector from solenoid valve. Connect measuring device between pins 1 and 2 to PVRT and measure the coil resistance. Resistance = 25 Ohm. If the coil resistance is excessive or 0 ohms, PVRT must be replaced. Missing Positive Test - Power up the truck and record the voltage between PC422-16 and the battery negative. Battery voltage should be applied. - Disconnect PC810 from the solenoid valve and record the voltage between PC422-16 and the battery negative. If battery positive is still applied, there is a short circuit between PC8102 and PC205-29 against the battery positive. After recording, re-connect PC810. - Power up the truck and connect the measuring device between PC42216 and the battery negative. Without applying POT3 (fwd. reach) battery positive should be applied. When activating POT3 (rev. reach) the voltage should drop to approx. 35 volt. If not, replace the VCM.
MS-4.3-2140
96
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 263 Status Code 263
Kurzschluss PVRE (Ventil Mastvorschub vor) Short Circuit PVRE (Reach Valve)
LOG BOOK display:
2
6
3
P
V
R
X E
X
X
X
X
h
R
E
A
C
H
V
X
X
X
C
A
L
V
E
Explanation:
On the VCM main controller an overcurrent is detected on the PVRE output during a reach operation and the contactor output is cut out.
Effect on truck:
- Hydraulic valves are cut out - Pump continues to operate.
Possible Causes:
Check coil resistance Disconnect PC808 connector from solenoid valve. Connect measuring device between pins 1 and 2 to PVRE and measure the coil resistance. Resistance = 25 Ohm. If the coil resistance is excessive or 0 ohms, PVRE must be replaced. Missing Positive Test - Power up the truck and record the voltage between PC422-10 and the battery negative. Battery voltage should be applied. - Disconnect PC808 from the solenoid valve and record the voltage between PC422-10 and the battery negative. If battery positive is still applied, there is a short circuit between PC8082 and PC205-15 against the battery positive. After recording, re-connect PC808. - Power up the truck and connect the measuring device between PC42210 and the battery negative. Without applying POT3 (reach) battery positive should be applied. When activating POT3 (fwd. reach) the voltage should drop to approx. 31 volt. If not, replace the VCM.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
97
ELECTRICS Statuscode 264 Status Code 264
Kurzschluss PVAL (Ventil Zusatzfunktionen links) Short Circuit PVAL (Accessory Valve Left)
LOG BOOK display:
2
6
4
P
V
A
X L
X
X
X
X
h
A
C
C
E
S
S
O
X
X
R
Y
X
C L
Explanation:
On the VCM main controller an overcurrent is detected on the PVAL output during an auxiliary operation and the contactor output is cut out.
Effect on truck:
- Hydraulic valves are cut out - Pump continues to operate.
Possible Causes:
Check coil resistance Disconnect PC809 connector from solenoid valve. Connect measuring device between pins 1 and 2 to PVAL and measure the coil resistance. Resistance = 25 Ohm. If the coil resistance is excessive or 0 ohms, PVAR must be replaced. Missing Positive Test - Power up the truck and record the voltage between PC422-12 and the battery negative. Battery voltage should be applied. - Disconnect PC809 from the solenoid valve and record the voltage between PC422-12 and the battery negative. If battery positive is still applied, there is a short circuit between PC8092 and PC205-13 against the battery positive. After recording, re-connect PC809. - Power up the truck and connect the measuring device between PC42216 and the battery negative. Without activating POT4 (fork tilt up) or POT5 (sideshift left), battery positive should be applied. When activating POT4 (fork tilt up) the voltage should drop to approx. 29 volt. If not, replace the VCM.
MS-4.3-2140
98
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 265 Status Code 265
Kurzschluss PVAR (Ventil Zusatzfunktionen rechts) Short Circuit PVAR (Accessory Valve Right)
LOG BOOK display:
2
6
5
P
V
A
X R
X
X
X
X
h
A
C
C
E
S
S
O
X
X
R
Y
X
C R
Explanation:
On the VCM main controller an overcurrent is detected on the PVAR output during an auxiliary operation and the contactor output is cut out.
Effect on truck:
- Hydraulic valves are cut out - Pump continues to operate.
Possible Causes:
Check coil resistance Disconnect PC811 connector from solenoid valve. Connect measuring device between pins 1 and 2 to PVAR and measure the coil resistance. Resistance = 25 Ohm. If the coil resistance is excessive or 0 ohms, PVAR must be replaced. Missing Positive Test - Power up the truck and record the voltage between PC422-11 and the battery negative. Battery voltage should be applied. - Disconnect PC811 from the solenoid valve and record the voltage between PC422-11 and the battery negative. If battery positive is still applied, there is a short circuit between PC8112 and PC205-27 against the battery positive. After recording, re-connect PC811. - Power up the truck and connect the measuring device between PC42211 and the battery negative. Without activating POT4 (fork tilt down) or POT5 (sideshift right), battery positive should be applied. When activating POT4 (fork tilt down) the voltage should drop to approx. 29 volt. If not, replace the VCM.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
99
ELECTRICS Statuscode 266 Status Code 266
Kurzschluss SVT (Magnetventil Neigen) Short Circuit SVT (Tilt Valve)
LOG BOOK display:
2
6
6
X
X
X
X
S
V
T
T
I
L
T
X
h V
A
L
X
X
V
E
X
C
Explanation:
On the VCM main controller an overcurrent is detected on the SVT output during a tilt operation and the contactor output is cut out.
Effect on truck:
- Hydraulic valves are cut out - Pump continues to operate.
Possible Causes:
Check coil resistance Disconnect PC801 connector from fork carriage. Connect measuring device between pins 1 and 2 to connector PC801 and measure the coil resistance. Resistance = 39 Ohm. If the coil resistance is excessive or 0 ohms, SVT must be replaced. Missing Positive Test - Power up the truck and record the voltage between PC422-1 and the battery negative. Battery voltage should be applied. - Disconnect PC801 from the solenoid valve and record the voltage between PC422-1 and the battery negative. If battery positive is still applied, there is a short circuit between PC8011 and PC205-41 against the battery positive. After recording, re-connect PC801. - Power up the truck and connect the measuring device between PC4221 and the battery negative. Without applying POT4 (tilt) battery positive should be applied. When activating POT4 the voltage should drop to approx. 15 volt. If not, replace the VCM.
MS-4.3-2140
100
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 267 Status Code 267
Kurzschluss SVS (Magnetventil Seitenschieber) Short Circuit SVS (Side Shift Valve)
LOG BOOK display:
2
6
7
X
X
X
X
S
V
S
S
I
D
E
X
h S
H
I
X
X
F
T
X
C V
Explanation:
On the VCM main controller an overcurrent is detected on the SVS output during sideshifting and the contactor output is cut out.
Effect on truck:
- Hydraulic valves are cut out - Pump continues to operate.
Possible Causes:
Check coil resistance Disconnect PC801 connector from fork carriage. Connect measuring device between pins 5 and 6 to connector PC801 and measure the coil resistance. Resistance = 39 Ohm. If the coil resistance is excessive or 0 ohms, SVS must be replaced. Missing Positive Test - Power up the truck and record the voltage between PC422-5 and the battery negative. Battery voltage should be applied. - Disconnect PC801 from the solenoid valve and record the voltage between PC422-5 and the battery negative. If battery positive is still applied, there is a short circuit between PC8015 and PC205-12 against the battery positive. After recording, re-connect PC801. - Power up the truck and connect the measuring device between PC4225 and the battery negative. Without applying POT5 (sideshift) battery positive should be applied. When activating POT5 the voltage should drop to approx. 15 volt. If not, replace the VCM.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
101
ELECTRICS Statuscode 268 Status Code 268
Kurzschluss SV5 (Magnetventil 5. Funktion) Short Circuit SV5 (5th Function Valve)
LOG BOOK display:
2
6
8
X
X
X
S
V
5
5
T
H
X
X
h
F
U
X N
C
.
X
X
C
V
A
Explanation:
On the VCM main controller an overcurrent is detected on the SV5 output during sideshifting and the contactor output is cut out.
Effect on truck:
- Hydraulic valves are cut out - Pump continues to operate.
Possible Causes:
Check coil resistance Disconnect PC801 connector from fork carriage. Connect measuring device between pins 8 and 8 to connector PC801 and measure the coil resistance. Resistance = 39 Ohm. If the coil resistance is excessive or 0 ohms, SVS must be replaced. Missing Positive Test - Power up the truck and record the voltage between PC422-18 and the battery negative. Battery voltage should be applied. - Disconnect PC801 from the solenoid valve and record the voltage between PC422-18 and the battery negative. If battery positive is still applied, there is a short circuit between PC801-8 and PC205-26 against the battery positive. After recording, re-connect PC801. - Power up the truck and connect the measuring device between PC422-8 and the battery negative. Without applying POT6 (5th function) battery positive should be applied. When activating POT6 the voltage should drop to approx. 15 volt. If not, replace the VCM.
MS-4.3-2140
102
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 280 - 282 Status Code 280
Offsetfehler Stromsensor Offset Error Current Sensor
LOG BOOK display:
2
8
0
C
U
R
X R
X
.
X
X
X
h
S
E
N
S
X O
X
R
X
C
H
M
Explanation:
Internal monitoring of current measurement sensors in hydraulic drive module power circuit while truck is powered up.
Effect on truck:
- Truck starts up. - Main contactor activated - Hydraulic drive module remains deactivated. - Creep mode possible.
Possible Causes:
Replace hydraulic drive module
Status Code 281
Temperatursensor Kurzschluss oder offener Stromkreis Temperature Sensor Short or Open Circuit
LOG BOOK display:
2
8
1
T
E
M
P
X
X
X
X
X
h
.
S
E
N
S
O
X
X
R
X
C
H
M
Explanation:
Internal monitoring of temperature sensors in hydraulic drive module
Effect on truck:
- Truck starts up. - Main contactor activated - Fwd./rev. reach and lowering possible. - Creep mode possible.
Possible Causes:
Replace hydraulic drive module
Status Code 282
Kurzschluss ECR2 ECR2 Short Circuit
LOG BOOK display:
2
8
2
E
C
R
X 2
X
X
X
X
h
S
H
O
R
T
C
X
X
X
C
I
R
C
.
Explanation:
Short circuit between Channel A and Channel B on hydraulic motor encoder.
Effect on truck:
- Truck starts up. - Main contactor activated - Creep mode travel possible. - Fwd./rev. reach and lowering possible.
Possible Causes:
- Select menu A2.29. Activate reach and check following displays: SET SPEED = 1000 for fwd. Reach or 530 for rev. reach. If these values are present, VCM and HDM are ok. ACTUAL SPEED = 0. No feedback from encoder. - Check line from CA201 to PC429, check encoder cable. - Replace motor or rotor.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
103
ELECTRICS Statuscode 283 - 284 Status Code 283
Offener Stromkreis ECR2 ECR2 Open Circuit
LOG BOOK display:
2
8
3
E
C
R
2
X
X
X
X
O
P
E
N
h C
I
X
X
X
R
C
.
C
Explanation:
Open circuit or no power supply to hydraulic motor encoder.
Effect on truck:
- Truck starts up. - Main contactor activated - Creep mode travel possible. - Fwd./rev. reach and lowering possible.
Possible Causes:
- Select menu A2.29. Activate reach and check following displays: SET SPEED = 1000 for fwd. Reach or 530 for rev. reach. If these values are present, VCM and HDM are ok. ACTUAL SPEED = 0. No feedback from encoder. - Check line from CA201 to PC429, check encoder cable. - Disconnect PC429 and check +12V between pins 1 and 4. Present: HDM OK. Not present: Check line, replace HDM. - Replace motor or rotor.
Status Code 284
Fehlender Kanal von ECR2 Lost Channel from ECR2
LOG BOOK display:
2
8
4
E
C
R
X 2
X
X
X
X
L
O
S
T
h C
H
X
X
X
C
A
N
N
.
Explanation:
No channel A or B on hydraulic motor encoder.
Effect on truck:
- Truck starts up. - Main contactor activated. - Creep mode travel possible. - Fwd./rev. reach and lowering possible.
Possible Causes:
- Select menu A2.29. Activate reach and check following displays: SET SPEED = 1000 for fwd. Reach or 530 for rev. reach. If these values are present, VCM and HDM are ok. ACTUAL SPEED = 0. No feedback from encoder. - Check line from CA201 to PC429, check encoder cable. - Replace motor or rotor.
MS-4.3-2140
104
X
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 285 - 300 Status Code 285
Temperatursensor Kurzschluss oder offener Stromkreis Temp. Sensor Short or Open Circuit
LOG BOOK display:
2
8
5
T
E
M
P
X
X
X
X
X
h
.
S
E
N
S
O
R
X
X
X
C
H
M O
T
Explanation:
Short circuit or open circuit on hydraulic motor temperature sensor.
Effect on truck:
- Truck starts up. - Main contactor activated - Fwd./rev. reach and lowering possible. - Creep mode possible.
Possible Causes:
Faulty temperature sensor. Disconnect PC430 and measure the resistance between pins 1 and 2. Resistance at 25°C approx. 600 ohms. If the resistance level deviates significantly: Replace motor.
Status Code 300
Fahrsteuerung hat konstanten Überstrom Continuous Over Current Traction Module
LOG BOOK display:
3
0
0
H
I
G
X H
X
X
X
X
h
C
U
R
R
E
X N
T
X
X
C
T
M
Explanation:
Excessive current detected in power circuit (exceeds 525 A).
Effect on truck:
- Hydraulic and traction drive modules deactivated - Main contactor ED1 deactivated - Parking brake applied
Possible Causes: module power circuit.
- Short circuit in motor feed line or motor coil, or error in traction drive - Switch off the truck and measure the insulation resistance. If necessary replace the traction motor or the traction drive module.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
105
ELECTRICS Statuscode 301 - 310 Status Code 301
Kurzschluss Leistungskreis an der Fahrsteuerung Short Circuit in Power Circuit Traction Drive Module
LOG BOOK display:
3
0
1
S
H
O
X R
X
T
X
X
X
h
C
I
R
C
X U
I
X
T
X
C
T M
Explanation:
A short circuit is detected in the power circuit. .
Effect on truck:
- Hydraulic and traction drive modules deactivated - Main contactor ED1 deactivated - Parking brake applied
Possible Causes: module power circuit.
- Short circuit in motor feed line or motor coil, or error in traction drive - Switch off the truck and measure the insulation resistance. If necessary replace the traction motor or the traction drive module.
Status Code 310
Überspannung an der Fahrsteuerung High Voltage Traction Module
LOG BOOK display:
3
1
0
H
I
G
H
X
X
X
X
h
V
O
L
T
A
X G
E
X
X
C
T
M
Explanation:
Excess voltage in power circuit, exceeds 63 volts.
Effect on truck:
- Hydraulic and traction drive modules deactivated - Main contactor ED1 deactivated - Parking brake applied
Possible Causes:
- Emergency Disconnect pressed during plugging - Internal error in traction drive module - If the truck is operating, this could be a nuisance code. Monitor code frequency. If necessary, inform Crown Service.
MS-4.3-2140
106
X
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 311 - 313 Status Code 311
Unterspannung an der Fahrsteuerung Low Voltage Traction Module
LOG BOOK display:
3
1
1
X
X
X
X
X
h
L
O W
V
O
L
T
T
A
X G
X
E
X
C
T
M
Explanation:
The traction drive module has detected a voltage below 18 volts.
Effect on truck:
- Hydraulic and traction drive modules deactivated - Main contactor ED1 deactivated - Parking brake applied
Possible Causes:
- Check power circuit wiring - Faulty battery. Battery voltage collapses under load. Select menu item A.2.36, lift a heavy load and monitor the battery voltage during lifting. - Check battery cell voltages. If necessary, replace battery. - Error in traction drive module
Status Code 312
15 Volt Spannungsversorgung zu niedrig 15 Volt Supply to low
LOG BOOK display:
3
1
2
1
5
V
O
X
X
L
T
X
X
X
h
S
U
P
X P
L
X
Y
X
C
T
M
Explanation:
Internal error in traction drive module 15 volt supply for the pulse width modulation (PWM) of the line transistors is faulty
Effect on truck:
- Truck brought to a halt through plugging - Traction drive module deactivated - Fwd./rev. reach and lowering possible.
Possible Causes:
Internal error, replace control module.
Status Code 313
5 Volt Spannungsversorgung zu niedrig 5 Volt Supply to low
LOG BOOK display:
3
1
3
5
V
O
X L
T
X
X
X
X
h
S
U
P
P
X L
Y
X
X
C
T
M
Explanation:
Internal error in traction drive module 5 volt supply for internal current measurement in power circuit.
Effect on truck:
- Truck brought to a halt through plugging - Traction drive module deactivated - Fwd./rev. reach and lowering possible.
Possible Causes:
Internal error, replace control module.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
107
ELECTRICS Statuscode 314 - 320 Status Code 314
Fahrsteuerung: Kondensatorladezeit überschritten Traction Module: Capacitor Charge exceeded
LOG BOOK display:
3
1
4
X
X
X
X
X
h
C
A
P
C
H
A
R
G
E
X
X
C
T
M
Explanation:
Capacitors are not charged.
Effect on truck:
- Main contactor is not activated
Possible Causes:
- No battery voltage on B+ input of traction drive module - Connect measuring device between B+ and B- on the traction drive module and power up the truck. The voltage at B+ should rise from 0V within approx. 2s. If not, check the lines. - If the voltage is applied, there is an internal error in the traction drive module. Replace the module
Status Code 320
Übertemperatur an der Fahrsteuerung Over Temperature Traction Drive Module
LOG BOOK display:
3
2
0
O
V
E
X R
X
X
X
X
h
T
E
M
P
.
X
X
X
C
T
M
Explanation:
Temperature in traction drive module exceeds 115°C
Effect on truck:
- Traction drive module deactivated - Error message displayed. Traction module hot - Fwd./rev. reach and lowering possible.
Possible Causes:
- Check the conditions of use and total service hours of the truck. - If the truck does not operate in arduous conditions, check the fans - In menu A1.9 monitor the hydraulic drive module temperature and continually apply one of the hydraulic functions to bring the module to operating temperature. When the temperature exceeds 35°C all the fans should start up. CA201-2 is set to BATT NEG. - If there is no operation: Check fans, lines, connections and power supply. - Remove TDM and HDM and check radiator fins are clean. Clean if necessary. - If the error persists, monitor the code frequency. If necessary, inform Crown Service.
MS-4.3-2140
108
X
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 321 - 322 Status Code 321
Übertemperatur am Fahrmotor Over Temperature Traction Motor
LOG BOOK display:
3
2
1
O
V
E
X R
X
X
X
X
h
X
X
X
C
T
E
M
P
.
T
M O
T
Explanation:
Temperature in motor coil exceeds 165°C
Effect on truck:
- Traction drive module deactivated - Error message displayed. Traction module hot - Fwd./rev. reach and lowering possible.
Possible Causes:
- Check the conditions of use and total service hours of the truck. - If the truck does not operate in arduous conditions, check the fans - In menu A1.9 monitor the hydraulic drive module temperature and continually apply one of the hydraulic functions to bring the module to operating temperature. When the temperature exceeds 35°C all the fans should start up. CA201-2 is set to BATT NEG. - If there is no operation: Check fans, lines, connections and power supply. - Remove TDM and HDM and check radiator fins are clean. Clean if necessary. - If the error persists, monitor the code frequency. If necessary, inform Crown Service.
Status Code 322
Erhöhte Temperatur an der Fahrsteuerung High Temperature Traction Drive Module
LOG BOOK display:
3
2
2
H
I
G
X H
X
X
X
X
h
T
E
M
P
.
X
X
X
C
T
M
Explanation:
Temperature in traction drive module exceeds 85°C
Effect on truck:
Traction drive module current is linearly reduced to 0 A between 85° and 115°C. Error message displayed. Traction module hot
Possible Causes:
- Check the conditions of use and total service hours of the truck. - If the truck does not operate in arduous conditions, check the fans - In menu A1.9 monitor the hydraulic drive module temperature and continually apply one of the hydraulic functions to bring the module to operating temperature. When the temperature exceeds 35°C all the fans should start up. CA201-2 is set to BATT NEG. - If there is no operation: Check fans, lines, connections and power supply. - Remove TDM and HDM and check radiator fins are clean. Clean if necessary. - If the error persists, monitor the code frequency. If necessary, inform Crown Service.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
109
ELECTRICS Statuscode 323 - 324 Status Code 323
Temperatur zu tief an der Fahrsteuerung Low Temperature Traction Module
LOG BOOK display:
3
2
3
X
X
X
X
X
L
O W
T
E
M
P
.
-
X
X
X
C
T
M
Explanation:
Temperature in traction drive module is less than –20°C
Effect on truck:
Error message displayed. Traction module cold
Possible Causes:
Check the conditions of use and total service hours of the truck. Attention: The truck has been stored in a cold environment for a long period of time.
Status Code 324
Erhöhte Temperatur am Fahrmotor High Temperature Traction Motor
LOG BOOK display:
3
2
4
H
I
G
X H
X
X
X
X
h
X
X
X
C
T
E
M
P
.
T
M O
T
Explanation:
Temperature in motor coil exceeds 145°C
Effect on truck:
- Motor current is linearly reduced to 0 A between 145°C and 165°C motor temperature. - Error message displayed. Traction motor hot
Possible Causes:
- Check the conditions of use and total service hours of the truck. - If the truck does not operate in arduous conditions, check the fans - In menu A1.9 monitor the hydraulic drive module temperature and continually apply one of the hydraulic functions to bring the module to operating temperature. When the temperature exceeds 35° all the fans should start up. CA201-2 is set to BATT NEG. - If there is no operation: Check fans, lines, connections and power supply. - Remove TDM and HDM and check radiator fins are clean. Clean if necessary. - If the error persists, monitor the code frequency. If necessary, inform Crown Service.
MS-4.3-2140
110
h
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 325 - 330 Status Code 325
Temperatur zu tief am Fahrmotor Low Temperature Traction Motor
LOG BOOK display:
3
2
5
X
X
X
X
X
L
O W
T
E
M
P
.
h
-
X
X
X
C
T
M O
T
Explanation:
Temperature in motor coil is less than –30°C
Effect on truck:
Error message displayed. Hydraulic motor cold
Possible Causes:
Check the conditions of use and total service hours of the truck. Attention: The truck has been stored in a cold environment for a long period of time.
Status Code 330
CAN BUS Fehler an der Fahrsteuerung Error CAN BUS Traction Drive Module
LOG BOOK display:
3
3
0
E
R
R
X O
R
X
X
X
X
h
C
A
N
B
X U
S
X
X
C
T
M
Explanation:
Error in CAN BUS communication between VCM and SDM
Effect on truck:
Main contactor deactivated
Possible Causes:
- Error in wire bundle or connection - Power down truck and measure terminal resistance at PC416-1 and 2: 60 Ohm = resistance OK, 120 Ohm = a terminal resistance in VCM or SDM is faulty. - Connect PC205 to VCM and measure resistance on VCM between PC205-22 and 23: Rated resistance = 120 Ohm. If the value is incorrect, replace VCM. If the value is correct, disconnect PC204 from SDM and measure the terminal resistance between pins 10 and 11 on the SDM. If the value is incorrect, replace SDM. - If the truck is operating, this could be a nuisance code. Monitor code frequency. If necessary, inform Crown Service.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
111
ELECTRICS Statuscode 340 Status Code 340
Eingangsspannung von POT1 über dem Grenzwert Input Voltage from POT1 above Limit
LOG BOOK display:
3
4
0
P
O
T
X 1
X
X
X
X
h
A
B
O
V
E
L
X
X
X
C
I
M
I
T
Explanation:
The loop voltage from POT1 is continually monitored during start-up and operation. The upper limit of 10.8 volt is exceeded during this time.
Effect on truck:
Travelling completely disabled.
Possible Causes:
- Select menu item A2.3 (POT1). Depress accelerator. - Take readings from display. Approx. 12V: Short circuit between potentiometer CA418-2 (red) and CA418-1 (green). Check reading with a digital multimeter. Reading confirmed: Replace potentiometer, check wiring. 0.7 – 1.5 V: correct reading when accelerator is in neutral. 9.5 – 10.5 V: correct reading when accelerator is in maximum position. If the readings are correct, there is probably an intermittent fault in the potentiometer circuit. Check wire connections and potentiometer. Note: Recalibrate potentiometer after carrying out repairs. Fully apply the accelerator to attain the upper limit of 1023.
MS-4.3-2140
112
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 341 Status Code 341
Eingangsspannung von POT1 unter dem Grenzwert Input Voltage from POT1 under Limit
LOG BOOK display:
3
4
1
P
O
T
X 1
X
X
X
X
h
U
N
D
E
R
X
X
X
C
I
M
I
T
L
Explanation:
The loop voltage from POT2 is continually monitored during start-up and operation. The lower limit of 0.6 volt is exceeded during this time.
Effect on truck:
Travelling completely disabled.
Possible Causes:
- Power up truck while pressing on the key. Enter password. Select menu item A2.4 (POT2). Activate “Raise/Lower”. - Take readings from display. Approx. 0 V: open circuit between potentiometer CA418-2 (red), CA418-1 (green) and VCM or short circuit between CA418-2 (red) and CA418-3 (yellow). Check connection PC418 and PC205. If the wiring is ok, replace the potentiometer. 0.7 – 1.5 V: correct reading when accelerator is in neutral. 9.5 – 10.5 V: correct reading when accelerator is in maximum position. If the readings are correct, there is probably an intermittent fault in the potentiometer circuit. Check wire connections and potentiometer. Note: Recalibrate potentiometer after carrying out repairs. Gently apply the accelerator to attain the upper limit of 1023 at a gentle pressure.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
113
ELECTRICS Statuscode 343 - 381 Status Code 343
POT1/ACS Status nicht zueinander kompatibel POT1/ACS Status not compatible
LOG BOOK display:
3
4
3
P
O
T
1
X
X
X
X
/
A
C
S
X
h S
T
A
X
X
X
T
U
S
Explanation:
POT1 voltage does not match the ACS switch position.
Effect on truck:
Travelling completely disabled.
Possible Causes:
- In menu A2.9 check ACS function - Check connection PC417 and lines - Replace switch - Check potentiometer POT1 (see A2.3) - Check connection PC418 - Check lines - Replace potentiometer
C
Note: Recalibrate potentiometer after carrying out repairs. Gently apply the accelerator to attain the upper limit of 1023 at a gentle pressure.
Status Code 380
Offsetfehler Stromsensor Fahrsteuerung Offset Error Current Sensor Traction Drive Module
LOG BOOK display:
3
8
0
C
U
R
R
X
.
X
X
X
h
S
E
N
S
X O
X
R
X
C
T
M
Explanation:
Internal monitoring of current measurement sensors in traction drive module power circuit while truck is powered up.
Effect on truck:
- Truck starts up. - Main contactor activated - Traction drive module remains deactivated. - Fwd./rev. reach and lowering possible.
Possible Causes:
Replace traction drive module.
Status Code 381
Temperatursensor Kurzschluss oder Offener Stromkreis Temperature Sensor Short or Open Circuit
LOG BOOK display:
3
8
1
T
E
M
P
X
X
X
X
X
h
.
S
E
N
S
O
X R
X
X
C
T
M
Explanation:
Internal monitoring of temperature sensors in traction drive module
Effect on truck:
- Truck starts up. - Main contactor activated - Creep mode travel possible. - Fwd./rev. reach and lowering possible.
Possible Causes:
Replace traction drive module.
MS-4.3-2140
114
X
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 382 - 383 Status Code 382
Kurzschluss an ECR1 ECR1 Short Circuit
LOG BOOK display:
3
8
2
E
C
R
X 1
X
X
X
X
h
S
H
O
R
T
C
X
X
X
C
I
R
C
.
Explanation: encoder.
Short circuit between Channel A and Channel B on traction motor
Effect on truck:
- Truck starts up. - Main contactor activated - Creep mode travel possible. - Fwd./rev. reach and lowering possible.
Possible Causes:
- Select menu A2.26. Activate travel and check following displays: SET SPEED = 685. If this value is present, VCM and TDM are OK. ACTUAL SPEED = 0. No feedback from encoder. - Check line from CA201 to PC425, check encoder cable. - Replace motor or rotor.
Status Code 383
Leitung unterbrochen an ECR1 ECR1 Open Circuit
LOG BOOK display:
3
8
3
E
C
R
X 1
X
X
X
X
O
P
E
N
h C
I
X
X
X
R
C
.
C
Explanation:
Open circuit or no power supply to traction motor encoder.
Effect on truck:
- Truck starts up. - Main contactor activated. - Creep mode travel possible. - Fwd./rev. reach and lowering possible.
Possible Causes:
- Select menu A2.26. Activate travel and check following displays: SET SPEED = 685. If this value is present, VCM and TDM are OK. ACTUAL SPEED = 0. No feedback from encoder. - Check line from CA201 to PC425, check encoder cable. - Disconnect PC425 and check +12V between pins 1 and 4. Present: TDM OK. Not present: Check line, replace TDM. - Replace motor or rotor.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
115
ELECTRICS Statuscode 384 - 385 Status Code 384
Fehlender Kanal von ECR1 ECR1 Lost Channel
LOG BOOK display:
3
8
4
E
C
R
1
X
X
X
X
L
O
S
T
h C
H
X
X
X
C
A
N
N
.
Explanation:
No channel A or B on traction motor encoder.
Effect on truck:
- Truck starts up. - Main contactor activated. - Creep mode travel possible. - Fwd./rev. reach and lowering possible.
Possible Causes:
- Select menu A2.26. Activate travel and check following displays: SET SPEED = 685. If this value is present, VCM and TDM are OK. ACTUAL SPEED = 0. No feedback from encoder. - Check line from CA201 to PC425, check encoder cable. - Replace motor or rotor.
Status Code 385
Fehlendes Temperatursensorsignal Temperature Sensor Signal missing
LOG BOOK display:
3
8
5
T
E
M
P
X
X
X
X
X
h
.
S
E
N
S
O
R
X
X
X
C
T
M O
T
Explanation:
Short circuit or open circuit on traction motor temperature sensor.
Effect on truck:
- Truck starts up. - Main contactor activated - Creep mode travel possible. - Fwd./rev. reach and lowering possible.
Possible Causes:
Faulty temperature sensor. Disconnect PC427 and measure the resistance between pins 1 and 2. Resistance at 25°C approx. 600 ohms. If the resistance level deviates significantly: Replace motor.
MS-4.3-2140
116
X
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 430 - 431 Status Code 430
CAN BUS Fehler an der Hauptsteuerung CAN BUS Error VCM
LOG BOOK display:
4
3
0
E
R
R
X O
X
R
X
X
X
h
C
A
N
B
X U
X
S
X
C
V
M
Explanation:
Error in CAN BUS communication on VCM
Effect on truck:
Main contactor deactivated
Possible Causes:
- Error in wire bundle or connection - Power down truck and measure terminal resistance at PC416-1 and 2: 60 Ohm = resistance OK, 120 Ohm = a terminal resistance in VCM or SDM is faulty. - Connect PC205 to VCM and measure resistance on VCM between PC205-22 and 23: Rated resistance = 120 Ohm. If the value is incorrect, replace VCM. If the value is correct, disconnect PC204 from SDM and measure the terminal resistance between pins 10 and 11 on the SDM. If the value is incorrect, replace SDM. - If the truck is operating, this could be a nuisance code. Monitor code frequency. If necessary, inform Crown Service.
Status Code 431
Display: CAN BUS Fehler am Display Display: CAN BUS Error Display
LOG BOOK display:
4
3
1
E
R
R
X O
R
X
X
X
X
C
A
N
h D
S
X
X
X
C
P
L
A
Y
Explanation:
Error in CAN BUS communication between VCM and display
Effect on truck:
Main contactor deactivated
Possible Causes:
- Error in wire bundle or connection - Power down truck and measure terminal resistance at PC416-1 and 2: 60 Ohm = resistance OK, 120 Ohm = a terminal resistance in VCM or SDM is faulty. - Connect PC205 to VCM and measure resistance on VCM between PC205-22 and 23: Rated resistance = 120 Ohm. If the value is incorrect, replace VCM. If the value is correct, disconnect PC204 from SDM and measure the terminal resistance between pins 10 and 11 on the SDM. If the value is incorrect, replace SDM. - If the truck is operating, this could be a nuisance code. Monitor code frequency. If necessary, inform Crown Service.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
117
ELECTRICS Statuscode 460 - 462 Status Code 460
ED1 nicht angezogen ED1 not closed
LOG BOOK display:
4
6
0
M
A
I
N
X
C
X
X
X
N
O
T
h C
L
X
X
X
C
O
S
E
D
Explanation:
On the VCM main controller an overcurrent is detected on the ED1 output during power up and the contactor output is cut out.
Effect on truck:
Main contactor not activated
Possible Causes:
- Contactor coil short circuit. Resistance = 150Ohm
Status Code 461
ED1 Schütz: Kontakte verschweißt ED1 contactor: Contacts welded
LOG BOOK display:
4
6
1
M
A
I
X N
X
C
X
X
X
h
W E
L
D
X E
X
X
C
D
Explanation:
Battery voltage applied to VCM, CA205-14, although truck has not been powered up.
Effect on truck:
- Main contactor is not activated
Possible Causes:
- Contacts welded to ED1 contactor. Replace contactor - ED1 contactor jammed. Check contactor and replace if necessary.
Status Code 462
Kurzschluss an Lüfterausgang Short Circuit on Fan Output
LOG BOOK display:
4
6
2
X
X
X
X
X
h
F
A
N
O
U
T
P
U
T
X
X
X
C
Explanation:
On the hydraulic drive module an overcurrent is detected on the fan output during power up and the contactor output is cut out.
Effect on truck:
- Creep mode travel possible. - Fwd./rev. reach and lowering possible.
Possible Causes:
- In menu A1.9 monitor the hydraulic drive module temperature and continually apply one of the hydraulic functions to bring the module to operating temperature. When the temperature exceeds 35° all the fans should start up. CA201-2 is set to BATT NEG. - Disconnect fan 2. Error no longer persists. Replace fan. - Error persists. Disconnect fans 3 and 4. Error no longer persists. Replace fan 3 or 4. - Error persists. Short circuit in PC415 or PC435 connection to hydraulic drive module CA201-2.
MS-4.3-2140
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X
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 463 - 465 Status Code 463
Kurzschluss an der Blitzleuchte Short Circuit Beacon
LOG BOOK display:
4
6
3
B
E
A
C
X
X
O
N
X
X
X
h
O
U
T
X P
U
X
X
C
T
Explanation:
On the VCM main controller an overcurrent is detected on the beacon output CA205-10 and the contactor output is cut out.
Effect on truck:
SVH, PVL, PVRE, PVRT, PVAL, PVAR deactivated
Possible Causes:
- Disconnect PC433 and activate beacon. Note setting in F9 BEACON. - If the error no longer occurs, check relays K9 and K10. Relay resistance = 250 Ohm.
Status Code 464
Kurzschluss Fahralarm Short Circuit Travel Alarm
LOG BOOK display:
4
6
4
A
L
A
R
X
X
M
2
X
X
X
h
O
U
T
X P
U
X
X
C
T
Explanation:
On the VCM main controller an overcurrent is detected on the travel alarm output CA205-11 and the contactor output is cut out.
Effect on truck:
SVT, SVS, SV5 and main contactor deactivated
Possible Causes:
- Disconnect PC421 and activate travel alarm. Note setting in F10 TRAVEL ALARM. - If the error no longer occurs, check relays K7 and K8. Relay resistance = 250 Ohm.
Status Code 465
Allgemeine Kurzschluss-Fehlermeldung General Short Circuit Alarm
LOG BOOK display:
4
6
5
X
X
X
X
X
h
V
M
C
O
U
T
P
U
T
X
X
X
C
S
Explanation:
A short circuit has occurred on the VCM outputs which cannot be directly attributed to any component.
Effect on truck:
SVH, PVL, PVRE, PVRT, PVAL, PVAR deactivated or SVT, SVS, SV5 and main contactor deactivated
Possible Causes:
See corresponding status codes
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
119
ELECTRICS Statuscode 840 - 841 Status Code 840
Vorwärts- und Rückwärtsschalter gleichzeitig betätigt Forward & Reverse Switch simultaneously closed
LOG BOOK display:
8
4
0
F
S
&
R
X
S
X
X
X
h
C
L
O
S
X E
X
X
C
D
Explanation:
The forward (FS) and reverse (RS) switches are identified simultaneously on the VCM inputs.
Effect on truck:
Travelling disabled
Possible Causes:
- Select menu item A2.1 (FS). Travel lever in forward position = ON Travel lever in reverse position = OFF If the display does not change from ON to OFF, check switch or wiring - Select menu item A2.2 (RS). Travel lever in reverse position = ON Travel lever in forward position = OFF If the display does not change from ON to OFF, check switch or wiring - Test the operation of the rocker end limits and adjust if necessary.
Status Code 841
Bremsflüssigkeitsstand zu niedrig Brake Fluid Level to low
LOG BOOK display:
8
4
1
X
X
X
X
X
L
O W
B
R
A
K
E
h F
L
U
I
D
Explanation:
Brake fluid level in main brake cylinder too low
Effect on truck:
The “brake fluid level" warning light in the display is illuminated.
Possible Causes:
- Select menu item A2.15 (BFS) and check switch. OFF: level ok ON: level too low The switch can be checked via the control key in the roof. - Check brake fluid level and replenish as required Check wiring
MS-4.3-2140
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X
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 880 Status Code 880
Kurzschluss am Höhenencoder Kanal A / B Short Circuit Height Encoder channel A/B
LOG BOOK display:
8
8
0
S
H
O
X R
T
X
X
X
X
h
C
I
R
C
U
I
T
Explanation:
Short circuit channel A / B on height encoder.
Effect on truck:
- Lift speed is reduced to half speed. - Lift height display cut out and message displayed: Height encoder off.
Possible Causes:
- Select menu A2.19 (ECR5). Raise fork carriage over free lift and check encoder impulses. The encoder impulses should rise in proportion to the lift height up to a maximum level. - Check lines and connections CA205 (VCM), PC422 (connector panel), PC600 (reach carriage connector panel) and PC803 (height encoder). - Power down the truck. Disconnect CA205 and PC803 and check for short circuit between CA205-9 and CA205.38. - If there is no short circuit, replace the height encoder
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
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ELECTRICS Statuscode 881 Status Code 881
Keine Zählimpulse während der Hubfunktion No Counts during lift
LOG BOOK display:
8
8
N
O
C
x
x
x
x
x
O
U
N
T
S
h L
I
F
T
Explanation:
No count impulses detected during lifting
Effect on truck:
- Lift speed is reduced to half speed. - Lift height display cut out and message displayed: Height encoder off.
Possible Causes:
- Check menu item A2.18 (HGTRS). ON: mast not extended with 2nd stage OFF: 2nd stage extended - Select menu item A2.19 (ECR5). Raise fork carriage over free lift and check encoder impulses. The encoder impulses should rise in proportion to the lift height up to a maximum level. - If there are no impulses: o Check DC/DC converter on height encoder. Connect measuring device to PC803-1 and PC803-3. If there is no battery voltage, check connection between PC803 and PC422. o Connect measuring device to PC803-1 and pin 3 on height encoder. If there is no +5V supply, the DC/DC converter is probably faulty. - Check channel A: Connect measuring device to battery negative and PC422-31. Raise the fork carriage to above the free lift level and slowly raise. At a very low pump speed the voltage should fluctuate between 0V and +5V. If there is a permanent OV supply, there is probably a line interruption to the height encoder. Repeat the measurement at PC803-2. If pulses are detected, there is a line interruption between PC803 and PC422. - Check channel B: Connect measuring device to battery negative and PC422-32. Raise the fork carriage to above the free lift level and slowly raise. At a very low pump speed the voltage should fluctuate between 0V and +5V. If there is a permanent OV supply, there is probably a line interruption to the height encoder. Repeat the measurement at PC803-4. If pulses are detected, there is a line interruption between PC803 and PC422. - Replace encoder
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1
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 883 Status Code 883
Max. Hubhöhe überschritten Max lift height exceeded
LOG BOOK display:
8
8
3
E
X
E
X E
D
X
X
X
X
M
A
X
h H
E
I
G
H
T
Explanation:
Value above maximum lift height (see C7.3.1)
Effect on truck:
- Lift speed is reduced to half speed. - Lift height display cut out and message displayed: Height encoder off.
Possible Causes:
- Check ESR 5 for wear, secure attachment and any slipping between wheel and wiring. Secure or replace wiring as necessary. - Select menu item C7.3 “Encoder” and check the max. lift height is correctly calibrated, re-calibrate if required.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
123
ELECTRICS Statuscode 884 Status Code 884
Keine Zählimpulse während des Absenkens No counts during lower
LOG BOOK display:
8
8
N
O
C
X
X
X
X
X
O
U
N
T
S
h L
O W E
R
Explanation:
No count impulses detected during lowering
Effect on truck:
- Lift speed is reduced to half speed. - Lift height display cut out and message displayed: Height encoder off.
Possible Causes:
- Select menu item A2.19 (ECR5). Raise fork carriage over free lift and check encoder impulses. The encoder impulses should rise in proportion to the lift height up to a maximum level. - If there are no impulses: o Check DC/DC converter on height encoder. Connect measuring device to PC803-1 and PC803-3. If there is no battery voltage, check connection between PC803 and PC422. o Connect measuring device to PC803-1 and pin 3 on height encoder. If there is no +5V supply, the DC/DC converter is probably faulty. - Check channel A: Connect measuring device to battery negative and PC422-31. Raise the fork carriage to above the free lift level and slowly raise. At a very low pump speed the voltage should fluctuate between 0V and +5V. If there is a permanent OV supply, there is probably a line interruption to the height encoder. Repeat the measurement at PC803-2. If pulses are detected, there is a line interruption between PC803 and PC422. - Check channel B: Connect measuring device to battery negative and PC422-32. Raise the fork carriage to above the free lift level and slowly raise. At a very low pump speed the voltage should fluctuate between 0V and +5V. If there is a permanent OV supply, there is probably a line interruption to the height encoder. Repeat the measurement at PC803-4. If pulses are detected, there is a line interruption between PC803 and PC422. - Replace encoder
MS-4.3-2140
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4
ESR4500 06/2004 • Printed in Germany
ELECTRICS Statuscode 885 Status Code 885
Fehler Höhenrücksetzschalter Error Height Reset Switch
LOG BOOK display:
8
8
5
E
R
R
X O
R
X
X
X
X
h
H
G
T
R
S
S W
Explanation:
Height reset switch operational fault
Effect on truck:
- Lift speed is reduced to half speed. - Lift height display cut out and message displayed: Height encoder off.
Possible Causes:
- Select menu item A2.18 (HGTRS). Raise fork carriage over free lift and then lower it. Monitor the display in the process. ON = Mast not extended with 2nd stage (below the free lift) - Check HGTRS setting - If the 2nd mast stage HGTRS is permanently ON, disconnect PC802. If the signal does not change to OFF, line short circuit. - Replace switch
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
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ELECTRICS Statuscode 886 Status Code 886
Fehler Höhenencoderimpulse heben / senken Error Height Encoder Counts lift / lower
LOG BOOK display:
8
8
6
E
R
R
X O
R
X
X
X
X
h
E
C
R
5
-
H
G
T
R
S
Explanation:
The test compares the number of count impulses of a lifting operation with those of a lowering operation. If the permissible tolerance is exceeded, the status code is generated.
Effect on truck:
- Lift speed is reduced to half speed. - Lift height display cut out and message displayed: Height encoder off.
Possible Causes:
- Check ESR 5 for wear and any slipping between wheel and wiring, replace if necessary. - Check HGTRS setting, re-adjust if necessary. NOTE: In the event of an incorrect adjustment, HGTRS can also switch through normal mast movements during travel or when the fork carriage is raised/lowered. When adjusting, make sure the switch has sufficient stroke. - When the fork carriage is fully lowered, power up the truck while holding the switch down. Select menu item A2.17 (HGTRS). Switch “ON” (closed): when the fork carriage is lowered the switch should be “ON” (height reset = switch closed). Adjust, repair or replace as required. NOTE: To facilitate access, HGTRS must be temporarily bypassed in order to raise the mast if required. Switch “OFF” (closed): Activate the lift function and monitor the display. HGTRS should remain closed until the first mast stage is reached. If HGTRS is operating correctly, there may be an intermittent fault, e.g. caused by mast movements during travel or when raising/lowering the fork carriage. If necessary, fine-tune the HGTRS. NOTE: If the truck is operating, this could be a nuisance code. Monitor code frequency. If necessary, inform Crown Service.
M2 (Pumpenmotor): Betriebstemperatur zu hoch FEHLERCODE 825
MS-4.3-2140
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ESR4500 06/2004 • Printed in Germany
ELECTRICS APPENDIX Display not active System does not start up. All LEDs in display deactivated. ●
Replace FU1 (15A).
Main contactor switches continuously ON/OFF The main contactor is activated and deactivated in 1 Hz rythym. ●
Replace FU2 (15A).
Only battery discharge indicator and message display active LED display self-test performed. The battery discharge indicator and the message display is then active. The steering angle and direction display is deactivated. If the „load monitor“ option is switched on, this is also deactivated. ●
There is no battery supply to output CA402-2 of the start up card. - Check battery voltage on CA402-2 of start up card. Not present: Short circuit after NO contact or ED1, e.g. in one of the fans. FU2 does not trip, as ED1 is not closed and the current is limited by the charging resistance. After a short time the thermal fuse F1 in the start up card is triggered as a result of the high current level. Rectify short circuit. Once the error is rectified, the thermal fuse automatically resets itself after a certain time. - Check resistance in the start up card: resistance = 23 Ohm. Not present: replace start up card.
Main contactor briefly activated after power up The main contactor is briefly activated after power up After system self test, it becomes permanently closed approx. 2 seconds later. ●
This error is due to a faulty relay K11 in the start up card.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
127
Blank page
Printed in Germany
128
ELECTRICS Battery Charge Status Display
Service Level Display The operator display is the interface between the truck control module and the operator or service technician. It provides all the relevant information during operation, for servicing and troubleshooting.
●
6 green and 2 orange LED bars indicate the charge status. They disappear linearly from top to bottom as the battery discharges further.
●
If only the two orange LED bars are lit, the battery is discharged to 40% capacity. If just one orange LED bar is lit, 30% of battery capacity remains. If the last orange LED bar starts to flash, the battery is discharged to 20% of capacity. You can travel approx. 5 minutes longer with the truck, lifting is reduced to half speed.
The following section describes the design and functions of the display.
Design and Functions
Operator error display
Steer Angle Display ●
The operator error display can light up in the following cases:
Displays the angle according to the position of the drive wheel.
Travel Direction Display ●
Displays the travel direction selected by the travel switch.
Data capacity monitor with fork height display Function keys
●
When the truck starts.
●
Faulty truck operation, e.g. function activated during start-up, lift or travel command when safety pedal is not applied.
Steer angle display
Travel direction display Battery charge status display
MS-2140-002
Performance setting display
Brake fluid level indicator Operator error display
Service display Parking brake display Steer fault display Message display
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MS-4.3-2140
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ELECTRICS ●
Load exceeds the maximum capacity for the current lift height (at a 600 mm load centre).
Service Display The service key display lights up in the following cases: ●
Temporarily, when the truck starts.
●
When a programmed service interval has expired.
●
Refer to the beginning of this chapter for further information on the capacitor data monitor.
Brake Fluid Level Indicator ●
Lights up when the brake fluid level in the container is too low.
Steer Fault Display
●
When an operational fault occurs. The truck controller simultaneously generates an error code which can be viewed in the LOG EVENTS menu.
Function Keys ●
Use the arrow keys to scroll through the menus and select the various menu items. Press the function key while the truck is being powered up to enter the service level (see following section).
●
The ENTER key is used to select menus and menu items as well as to confirm and save new settings.
●
Lights up when there is an error in the steer module sensor circuit.
Parking Brake Display ●
Lights up when the parking brake is applied.
Performance Setting Display ●
Indicates the currently selected performance setting.
Message Display ●
16 character, two line, alpha-numeric display.
●
Visual interface between operator / service technician and the truck control module.
Capacity Data Monitor ●
The fork symbol indicates the approximate fork carriage height.
●
The LED bars on the left of the fork symbols indicate the maximum lift height for the current load.
●
The circles on the left of the LED bars correspond to the maximum permissible load for the respective lift heights according to the capacity plate.
MS-4.3-2140
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ESR4500 06/2004 • Printed in Germany
ELECTRICS Operator Menu Use the arrow keys to scroll through the menus and select the various menu items. The ENTER key is used to select menus and menu items as well as to confirm and save new settings.
1 7 : 1 2 : 3 4 2 9 . 0 4 . 2 0 0 3
HOUR ME T ERS PRE SS ENTER
L OG E V E N T S PRE SS ENTER
PE R F ORMA NCE PRE SS ENTER
T I ME R PRE SS
ENTER
ESR4500 06/2004 • Printed in GermanyMANY
H 1 RUN H 2 ST EER
1 7 1 1 1 h 1 4 1 1 1 h
H 3 T R A CMO D H 4 H Y D RMO D
1 0 1 1 1 h 6 1 1 1 h
L AS T
=
2 2 6
L - 0 1
=
3 8 5
L - 1 5
=
8 2 8
P1 PRE SS
ENTER
P2 PRE SS
ENTER
P3 PRE SS
ENTER
1 2 : 4 5 : 3 7 S T A RT + S T OP
0
MS-4.3-2140
131
ELECTRICS
OPTION
FORK HE I GH T + L OAD PRE SS ENTER
HE I GH T LOAD
1 0 . 3 8 1 2 4 6
RACK SEL ECT PRE SS ENTER
see page 4-17
SE TUP PRE SS
see pages 4-18 and 4-19
RACK ENTER
FORK POS I T I ON I NG PRE SS ENTER SE T C L OCK + DA T E PRE SS ENTER
Display
Select number or using
Time + Date
m k g
Heights and loads may be shown in in/lb on your truck (due to setting in the service menu).
see page 4-16
S E T T I ME PRESS ENTER 0 0 : 0 0 : 0 0 SET
HOUR
SET
0 0 : 0 0 : 0 0 M I NUTE
SET
0 0 : 0 0 : 0 0 SECOND
SET DA TE PRESS ENTER SET
DAY 2 5 . 0 7 . 2 0 0 3
SET
MON T H 2 5 . 0 7 . 2 0 0 3
SET
Y E AR 2 5 . 0 7 . 2 0 0 3
Tilt Position - Assist On / Off FORK POS I T I ON I NG PRE SS ENTER
MS-4.3-2140
132
ST A TUS : CHANGE
OF F
ST A TUS : CON F I RM
OF F
ST A TUS : CON F I RM
ON
ESR4500 06/2004 • Printed in Germany
ELECTRICS Rack Height Select On / Off
NO R AC K UP
D OWN
L EVE L
0 1
1 0 . 4 0m 1 0 . 2 0m
L EVE L
A 5
7 . 8 0m 7 . 6 5m
Lift to rack A5
Programming Rack Height Select V I EW PRESS
ADD PRESS
ENT ER
ENT ER Choose characters using and
Actual height being displayed
A 1 A 1
3 . 4 5 3 . 3 0
m m
A 2 A 2
6 . 7 5 6 . 6 0
m m
X Y1 1 . 0 0 X Y1 0 . 8 0
m m
SE T RACK A PRESS
CODE ENT ER
SE T RACK A5 PRESS
CODE ENT ER
P U T AWA Y HE I GHT 2 . 7 6m Lift to desired height
P U T AWA Y 1 0 . 4 0m HE I GHT Message appears for 2 s and goes automatically to next step MODIFY PRESS ENTER
Actual height being displayed
PUT
AWA Y
OK RETR I EVA L 1 0 . 4 0m HE I GHT Lift to desired height
RETR I EVA L 1 0 . 2 0m HE I GHT Message appears for 2 s and goes automatically to next step
ESR4500 06/2004 • Printed in GermanyMANY
RETR I EVA L OK
MS-4.3-2140
133
ELECTRICS Programming Rack Height Select ...
ADD PRESS ENTER
EX I T
MO D I F Y PRE SS ENTER
Actual height being displayed
MO D I F Y PRESS ENTER
A1
MO D I F Y PRE SS ENTER
C 4
P U T AWA Y HE I GHT 3 . 1 8m
Lift to desired height
like in submenu ADD
EX I T
DE L ET E PRE SS ENTER
SAVE PRESS
ENTER
VIEW PRESS ENTER
MS-4.3-2140
134
Return to main menu SETUP RACK
DE L ET E CON F I RM
A1
DE L ET E CON F I RM
C4
SAVE CONF I RM
YES
SAVE CON F I RM
NO
ESR4500 06/2004 • Printed in Germany
ELECTRICS Service Level The service menu described in the following pages is divided into “sections”. The terms are not translated from English because the module service menu display is in English. For a description of the terms and their significance in terms of programming the control module, refer to the following pages, under “Service Menu”.
Chapter structure :
A1 STATUS VCM Vehicle Control Module TDM Traction Drive Module HDM Hydraulic Drive Module SDM Steer Drive Module Main C; Main Contactor closed Battery Charge % TEMPTraction Drive Module (TDM) TEMPTraction Motor TEMPHydr. Drive Module (HDM) TEMPHydraulic Motor TEMP Steer Drive Module Escape
A2 INPUTS A2.1 A2.2 A2.3 A2.4 A2.5 A2.6 A2.7 A2.8 A2.9 A2.10 A2.11 A2.12 A2.13 A2.14 A2.15 A2.16 A2.17 A2.18 A2.19 A2.20 A2.21 A2.22 A2.23 A2.24 A2.25 A2.26
FS RS Pot1 Pot2 Pot3 Pot4 Pot5 Pot6 ACS SES SPS BLS BRS BPS BFS FLS HGTS HGTRS ECR5 LS ORS PLS RES1 RES2 I BAT TXN RPM
A2.30 A2.31 A2.32 A2.33 A2.34 A2.35 A2.36 A2.37
I TXN Traction Motor current V Travel speed Pump RPM Pump Motor set & actual speed I PUMP Pump Motor current N Steer Motor Speed I STE Steer Motor current SFS1SA Steer sensor SFS2 Steer sensor Steer wheel angle UBAT Battery Voltage Escape
A3 OUTPUTS
ANALYZER
A1.1 A1.2 A1.3 A1.4 A1.5 A1.6 A1.7 A1.8 A1.9 A1.10 A1.11 A1.12
A2.27 A2.28 A2.29
Forward Switch Reverse Switch Accelerator Pedal Lift / Lower Potentiometer Reach Potentiometer Tilt Potentiometer Sideshift Potentiometer 5th Function Potentiometer Accelerator Switch Seat Switch Safety Pedal Switch Battery Latch Switch Brake Switch Brake Pressure Switch Brake Fluid Switch Free Lift Switch Height Switch Height Reset Switch Height Encoder Load Sensor Override Switch Pressure Load Switch Slow down in Slow down out Battery current Tract Motor set & actual speed
ESR4500 06/2004 • Printed in GermanyMANY
A3.1 A3.2 A3.3 A3.4 A3.5 A3.6 A3.7 A3.8 A3.9 A3.10 A3.11 A3.12 A3.13 A3.14 A3.15 A3.16 A3.17 A3.18
STS SPS SSS SVB Main C SVH PVL PVRT PVRE PVMR PVML SVT SVS SV5 ALM2 BEAC FAN Escape
Set TXN speed Set pump speed Set steer speed Brake output Main Cont. output Lift Valve output Lower Valve output Retract Valve output Reach Valve output Mast Right Valve output Mast Left Valve output Tilt Valve output Sideshift Valve 5th Function output Alarm 2 output, direction Beacon output Fan output
CALIBRATION C1 Accelerator Pedal C1.1 C1.2
Released Depressed
C2 Raise Lower Handle C2.1 C2.2 C2.3
Raise Lower Center
C3 Reach Handle C3.1 C3.2 C3.3
Retract Reach Center
C4 Tilt Handle C4.1 C4.2 C4.3
Tilt up Tilt down Center
MS-4.3-2140
135
ELECTRICS C5 Sideshift Handle 10.3 C5.1 C5.2 C5.3
Right Left Centre
C6 5th Function Handle C6.1 C6.2 C6.3
Right Left Centre
C10.2.1 Change value Escape
C11 Save? C11.1 C11.2
Save no Save yes
FEATURE F1 Truck size
C7 Height F1.1 F1.1
C7.1 R Cut 1 C7.1.1 C7.1.2 C7.1.3
None Override Stop
1.4/1.6t 2.0t
F2 FLS Switch F2.1 F2.2
FLS no FLS yes
C7.2 R Cut 2 F3 Height Encoder C7.2.1 C7.2.2 C7.2.3
None Override Stop
C7.3 Height Encoder C7.3.1 C7.3.2 C7.3.3 C7.3.4 C7.3.5
Saved max. height Enter max. height Saved 2nd height Enter 2nd height Escape
C7.4 Cut Height C7.4.1 C7.4.2 C7.4.3 C7.5
None Cut height Escape
Escape
C8 Weight C8.1 C8.2
No load Enter load
C9 Fork Positioning C9.1 C9.2 C9.3
Adjust tilt up Adjust tilt down Escape
C10 Reach retract slow down C10 Reach C10.1 Reach C10.1.1 Value C10.2 Retract MS-4.3-2140
136
F3.1 F3.2
ECR5 yes ECR5 no
F4 Lower Cut out F4.1 F4.2 F4.3
LCS no LCS inactive LCS yes
F5 Fifth Function F5.1 F5.2 F5.3
5th off 5th on 5th on <LCS
F6 Max Load F7
Capacity Data Monitor CDM
F7.1 F7.2 F7.3 F7.4 F7.5 F7.6 F7.7 F7.8 F8
CDM no CDM yes Enter zones Weight 1=xxx / Height1=xxx Weight 2=xxx / Height 2=xxx Weight 3=xxx / Height 3=xxx Weight 4=xxx / Height 4=xxx Escape
Alarm 2
F8.1 F8.2 F8.3 F8.4
Alarm off Alarm rev Alarm fwd Alarm both
ESR4500 06/2004 • Printed in Germany
ELECTRICS F9 Beacon F9.1 F9.2 F9.3 F9.4 F9.5
HOUR METER Beacon off Active Key Switch on Active forward Active reverse Active forward & reverse
F10 User Performance F10.1 F10.2
User no User yes
H1 Run H2 TDM Traction Drive Module Low / Middle / Full H3 HDM Pump Drive Module Low / Middle / Full H4 VCM Vehicle Controll Module
F11 User Codes H5 SDM Steer Drive Module F11.1 F11.2 F11.3 F11.4 F11.5 F11.6
User code no User code yes View Add Delete Escape
F12 Language F12.1 F12.2 F12.3 F12.4 F12.5 F12.6 F12.7 F12.8
English German French Spanish Dutch Italian Codes Escape
Low / Middle / Full H6 Display H7 Set Service Timer H8 Escape
LOG EVENTS L1 History
F13 Truck lockout
L1.1 . . L1.15
F14 Rack select
L2 Totals
F15 Height & weight on/off F16 Timer on/off F17 Error log on/off F18 Operator Alarm1 on/off F19 Battery low level alarm F20 Fork positioning F21 Change value Euro/US
L2.1 . . L2.X
Code / Work hour / Temperature
Code / Work hour / Temperature
Event 0.. = YYY
Event XXX = YYY
L3 Erase L3.1 L3.2 L3.3
Erase history (Last 16) Erase all Escape
L4 Escape
F22 Save
ESR4500 06/2004 • Printed in GermanyMANY
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ELECTRICS PERFORMANCE P1 Setup P1 P1.1 P1.2 P1.3 P1.4 P1.5 P1.6 P1.7 P1.8 P1.9 P1.10 P1.11 P1.12 P1.13 P1.14 P1.15
Travel speed FWD Travel speed REV Acceleration Plugging Coasting Reduction brake Pedal brake Raise speed Raise acceleration Lower speed Lower stop Reach/Retract speed Tilt speed Sideshift speed Escape
U2 Hour Set U2.1 U2.2
Run = xxx Save
U3 Accy Override U4 Escape
P2 Setup P2 Same as P1 with different default settings P3 Setup P3 Same as P1 with different default settings P4 P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15
BDI setting Travel > LCS Travel > FLS Travel > Custom Lower > Custom Reach > Custom 5th Function left 5th Function right Steer low speed Steer high speed Brake at ramp Save
UTILITIES U1 Software Version U1.1 U1.2 U1.3 U1.4 U1.5 U1.6
MS-4.3-2140
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VCM Vehicle Control Module TDM Traction Drive Module HDM Hydraulic Drive Module SDM Steer Drive Module Display Escape
ESR4500 06/2004 • Printed in Germany
ELECTRICS Overview of Performance Default Settings
P3.14 P3.15
SS speed Escape
P4
BDI Setting Acid Battery Maintenance Free Battery
6 8
P5
Travel > LCS
9
P6
Travel > FLS
9
P7
Travel > Custom 9
P8
Lower > Custom
9
P9
Reach > Custom
9
P10
5th Function left
10
P11
5th Function right
10
P12
Steer low speed
4
P13
Steer high speed
8
P14
Brake at ramp
No
P15
Save
For a description of the terms and their significance in terms of programming the control module, refer to the following pages, under “Service Menu”. P1 Setup P2.1 P2.2 P2.3 P2.4 P2.5 P2.6 P2.7 P2.8 P2.9 P2.10 P2.11 P2.12 P2.13 P2.14 P2.15
P1 Default settings Travel speed FWD Travel speed REV Acceleration Plugging Coasting Reduction brake Pedal brake Lift speed Lift ACC Lower speed Lower stop Reach speed Tilt speed Sideshift speed Escape
P2 Setup P2.1 P2.2 P2.3 P2.4 P2.5 P2.6 P2.7 P2.8 P2.9 P2.10 P2.11 P2.12 P2.13 P2.14 P2.15
12 12 8 8 8 7 9 5 3 9 Soft 5 5 5
P2 Default settings Travel speed FWD Travel speed REV Acceleration Plugging Coasting Reduction brake Pedal brake Lift speed Lift ACC Lower speed Lower stop Reach speed Tilt speed Sideshift speed Escape
P3 Setup P3.1 P3.2 P3.3 P3.4 P3.5 P3.6 P3.7 P3.8 P3.9 P3.10 P3.11 P3.12 P3.13
5
11 11 7 8 8 7 9 5 3 9 Soft 5 5 5
P3 Default settings Travel speed FWD Travel speed REV Acceleration Plugging Coasting Reduction brake Pedal brake Lift speed Lift ACC Lower speed Lower stop Reach speed Tilt speed
ESR4500 06/2004 • Printed in GermanyMANY
10 10 5 6 6 7 9 5 3 9 Soft 5 5 MS-4.3-2140
139
ELECTRICS Overview of menu items
Service Menu
Analyzer
Access to Service Level
Menu A1 (status prompt), A2 (input signals), A3 output signals.
●
Press down on the key.
●
Switch the truck on.
●
Keep pressing on the key until you see the request to enter the service code in the message display.
●
Calibration
Enter the service code. The truck is operational in the service level.
Calibrates the truck components. Feature For programming extended truck options and adapting to special applications. Hour Meter Sets the hour meter and service intervals. Log Events
A
Calls up error codes and frequencies. Deleting the error log.
Analyzer
Performance Programs the performance setting. Utilities C
Calibration
Calls up the software version of the module. The truck service hours are set in menu item U2. Menu item U3 is used to release auxiliary functions in the event of error codes. F
Feature
H
Hour Meter
L
Log Events
P
Performance
U
Utilities MS-2140-003
MS-4.3-2140
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ESR4500 06/2004 • Printed in Germany
ELECTRICS
ESR4500 06/2004 • Printed in GermanyMANY
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141
ELECTRICS Analyzer A1.1 - A1.12 Status A P
N R
A E
L S
Y S
Z
A P
1 R
E E
R N
T
E
R
S S
T S
A
E
T E
U N
S T
E
R
. H
1 I
C
L
V E
A 1 V E
C M C O
.
= O M O D
F U
F L
VCM status display, main truck controller Controls travel functions, hydraulics and system communication A 1 T R
. A
2 C
T
I
T O
D M N
M O
= D
U
O L
N E
M O
= D
U
O L
N E
E
= O M O D
N .
N D
Traction controller status A 1 H Y
. D
3 R
A
U
H L
D M I C
Hydraulic controller status A 1 S T
. E
4 E
S D
R
D M R I
V
Steering controller status A 1 C O
. N
5 T
A
C
M A T O
I R
N
C
H
C
C L
= O
S
O E
= R
X G
X E
X %
A
= M O
D
9 U
5 L
C E
= 1 M O
2 T
5 O
C R
D
7 U
5 L
C E
1 T
3 O
5 R
C
= 1 M O
0 D
5 .
C
Main contactor status A 1 B A
. T
6 T
E
R
Y
Battery residual capacity display A 1 T E
. M
7 P
T
T R
D M A C
.
Traction controller temperature A 1 T E
. M
8 P
T
T R
X A
N C
. .
M
Traction motor temperature A 1 T E
. M
9 P
H
H Y
D M D R
.
= M O
Hydraulic controller temperature A 1 T E
. M
1 P
0 P
P M U M
P P
.
M = M O
Hydraulic motor temperature A 1 T E
. M
1 P
1 S
S T
D M E E R
Steering controller temperature A 1 . J U M
MS-4.3-2140
142
1 P
2 L
E E
S V
C E
A L
P
E U
P
ESR4500 06/2004 • Printed in Germany
ELECTRICS A2.1 - A2.6 Inputs
A P
2 R
E
I S
N S
P
U E
T N
S T
E
R
A F
2 . 1 O R W A
R
F D
S S W
= I
O N T
C
H
F
C
O H
F
T
1
0 1
. 0
3 2
V 3
Forward travel direction switch (ON : activated; OFF: deactivated) A R
2 E
. V
2 E
R
S
R E
S S W
= I
Reverse travel direction switch (ON : aktiviert; OFF: deaktiviert) A A
2 C
. C
3 .
P
E
P D
O A
T L
1
= =
POT1 travel potentiometer, Neutral 0.5-1.0 volts / digital reading = 0 Max setting 9.5 –10.5 volts / digital reading = 1023 If the values min=0 and max=1023 are not reached, this means the potentiometer is not calibrated exactly. A R
2 A
. I
4 S
E
+
P L
O T 2 O W
= =
1
0 1
. 0
7 2
V 3
POT2 Raise / lower potentiometer, Neutral 4.5-5.5 volts / digital reading 450 - 550 Max lower 0.5-1.0 volts / digital reading = 0 Max raise 9.5 –10.5 volts / digital reading = 1023 If the values min=0 and max = 1023 are not reached, this means the potentiometer is not calibrated exactly. A R
2 E
. A
5 C
P
O
T
3
H
= =
1
0 1
. 0
7 2
V 3
POT3 Reach potentiometer, Neutral 4.5-5.5 volts / digital reading 450 - 550 Fwd. reach 0.5-1.0 volts / digital reading = 0 Rev. reach 9.5 –10.5 volts / digital reading = 1023 A T
2 I
. L
6 T
P
O
T
4
= =
1
0 1
. 0
7 2
V 3
POT4 Tilt potentiometer, Neutral 4.5-5.5 volts / digital reading 450 - 550 Fwd. tilt 0.5-1.0 volts / digital reading = 0 Rev. tilt 9.5 –10.5 volts / digital reading = 1023
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ELECTRICS A2.7 - A2.13 Inputs
A S
2 I
. D
7 E
S
H
P I
O F
T T
5
= =
1
0 1
. 0
7 2
V 3
POT5 Sideshift potentiometer, Neutral 4.5-5.5 volts / digital reading 450 - 550 Left sideshift 0.5-1.0 volts / digital reading = 0 Right sideshift 9.5 –10.5 volts / digital reading = 1023 A 5
2 T
. H
8
F
U
P N
O C
T T
6 .
= =
1
0 1
. 0
7 2
V 3
POT6 Hydraulic aux. function potentiometer, Neutral 4.5-5.5 volts / digital reading 450 - 550 5th left 0.5-1.0 volts / digital reading = 0 5th right 9.5 –10.5 volts / digital reading = 1023 A A
2 C
. C
9 E
L
E
A R
C A
S T
.
= S W
I
T
O C
N H
Travel switch (ON : activated; OFF: deactivated) A S
2 E
. A
1 T
0
S E S W I
S T
C
= H
O
N
Seat switch (ON: activated; OFF: deactivated) A S
2 A
. F
1 E
1 T
Y
S
P P
S E
D
= A
O F F S W
L
Safety switch (ON : activated; OFF: deactivated) A B
2 A
. T
1 .
2 L
A
B T
L C
S H
= S W
I
O T
F C
F H
Battery lock switch (ON: activated; OFF: deactivated, battery tray extended) A B
2 R
. A
1 K
3 E
B R S S W I
T
= C
H
O
F
F
Parking brake switch (ON: activated; LED active in display; OFF: deactivated, ready for operation)
MS-4.3-2140
ESR4500 06/2004 • Printed in Germany
Rev. 10/2004
144
ELECTRICS A2.14 - A2.20 Inputs
A B
2 R
. A
1 K
4 E
B P
P E
S S
S
= U
O R
E
F F S W
The pressure switch is located on the brake cylinder and is closed during braking. In addition to the mechanical brake force this activates regenerative electrical braking. (ON : activated; OFF: deactivated) A B
2 R
. A
1 K
5 E
B F
F L
S U
I
= D
O F S W .
F
Brake fluid level monitoring switch (ON : activated; LED active in display; OFF: deaktiviert)
A F
2 R
. E
1 E
6 L
F I
L F
S T
= S W
I
O T
F C
F H
Free lift switch, (ON = fork carriage within mast structure) simultaneous control by LCS switch
A H
2 E
. I
1 G
7 H
H T
G T S S W I
= T
O C
F
F
H
Lift speed reduction mast switch (ON = lift speed reduced) A H
2 E
. I
1 G
8 H
H T
G R
T E
R S
S E
= T
O F F S W .
Height reset switch, Height Encoder measurement start (ON = Mast with 2nd stage not extended)
A H
2 E
. I
1 G
9 H
E T
C E
R N
5 C
= O
X D
X E
X R
X
X
Height Encoder, encoder impulses are displayed
A L
2 O
. A
2 D
0 S
L E
S N
S
O
= R
X
X
X
X
Load Sensor, FKS open (forks tilted fully fwd/back; reading approx. 10-20) FKS closed (for O kg the value is approx. 300 – 400)
ESR4500 06/2004 • Printed in GermanyMANY
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ELECTRICS A2.21 - A2.25 Inputs
A O
2 V
. E
2 R
1 R
I
O D
R E
S
= S W
T
C
O H
N
I
= S W
T
C
O H
N
I
Lift stop – override switch (ON = switch pressed)
A P
2 R
. E
2 S
2 S
U
P R
L E
S
Load sensing pressure switch, ON = Load approx. 0 – 400 kg, OFF = load exceeds 400 kg A S
2 L
. 2 3 O W
D
R E S O W N
1
= A
O R
E
N
A
SLOW Down range sensing for fwd/rev. reach, “OFF“ = Fwd./rev reach speed reduced (OFF = in Slow Down range, ON in “normal” range) RES1 generally activates reach speed reduction
A S
2 L
. 2 4 O W
D
R E S O W N
2
= I
N
/
O O
F U
F T
Slow Down range identified. (ON = Slow Down rear, OFF = Slow Down front) RES2 recognises the position of the mast, in order to start again at the appropriate speed). (If the mast is in the Slow Down range, the speed must be reduced for Fwd. reach activation). For Rev. reach activation start again at normal reverse speed.
A B
2 A
. T
2 T
5 E
R
I Y
B C
A U
T R
= R
X E
X N
X T
A
Current battery current for hydraulic operation and/or travelling.
MS-4.3-2140
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ESR4500 06/2004 • Printed in Germany
ELECTRICS A2.26 - A2.32 Inputs
A T
2 X
. N
2
6 R
P
M
S A
E C
T T
= =
X X
X X
X X
X X
Displays the traction motor speed (SET) prescribed by the VCM and the current traction motor speed (RPMACT), calculated on the basis of the encoder impulses. This display is suitable for troubleshooting if the motor turns slowly or not at all, 1. No SET speed, VCM has recognised a fault (e.g. potentiometer) and does not prescribe a speed. If a SET speed is prescribed by the VCM, there is no functionality block and the system is ok. 2. SET speed but no RPM ACT, check encoder or motor. A T
2 X
. N
2
7 M O
I T
T
X C
N U
= R
R
X E
X N
X T
A
= S
X P
X E
. E
X D
M
S A
E C
T T
= =
X X
X X
X X
X X
= U
R
X R
X E
X N
A T
= S
X P
X E
X E
X D
X
= U
R
R
X E
X N
A T
Traction motor current
A T
2 R
. A
2 V
8 E
V L
K M H
Travel speed in km/h
A P
2 . U M
2 P
9 R
P
Pump motor speed: See 2.26 A P
2 . U M
3 P
0
I M O
P T
M
P C
Pump motor current
A S
2 T
. E
3 E
1 R
N M O
T
Current steer motor speed
A S
2 T
. E
3 E
2 I R M O
S T
T
E C
Steer motor current
ESR4500 06/2004 • Printed in GermanyMANY
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ELECTRICS A2.33 - A2.37 Inputs
A S
2 T
. E
3 E
3 R
S S
F .
S S
1 T
S .
A A
= H
O E
F A
F D
Reset switch for steering angle, when the signal is changed (ON/OFF) the steering angle is set to 0 degrees. At the same time this sensor is used for quadrant monitoring, ON: 1. +90° to 0° quadrant, OFF 2. 0° to -90° quadrant
A S
2 T
. E
3 E
4 R
S S
F .
S Q
2 U
A
D
= R
O A
F N
F T
W H
E
E
= .
A
N
4 G
5 L
D E
For 180° steering
A S
2 T
. E
3 E
5 R
Steering angle display –90° to +90°
A 2 . J U M
3 P
6 L
E E
S V
C E
A L
P
E U
P
Displays the current battery voltage A 2 . J U M
MS-4.3-2140
148
3 P
7 L
E E
S V
C E
A L
P
E U
P
ESR4500 06/2004 • Printed in Germany
ELECTRICS A3.1 - A3.9 Outputs
A P
3 R
E
O S
U S
T
A S
3 E
P E
U N
. T
1
T T
S E
R
T
X
S N
T
S S
P
= E
E
X D
X
X
X
X E
X D
X
X
X E
X E
X D
X
O
F
F
Set traction motor speed from VCM A S
3 E
. T
2 P
S U M
P P
S S
= P
E
Set pump motor speed from VCM A S
3 E
. T
3 S
T
S E
S E
S R
= S
P
Set steer motor speed from VCM A B
3 R
. A
4 K
S O
E
V U
B T
P
= U
T
Brake (ON = activated, OFF = deactivated) A M
3 A
. I
5 N
C
M A O N
I .
N
C O
= U
O P
F U
F T
O T
F .
F
X O
X U
X T
X .
X O
X U
X T
X .
X O
X U
X T
X .
T
Emergency disconnect contactor (ON = activated, OFF = deactivated) A L
3 I
. F
6 T
V
S A
V L
H V
= E
O
U
Lift solenoid (ON = activated, OFF = deactivated) A L
3 . 7 O W E
P V
R
V A
L L
V
= E
T A
= L
Lower proportional valve A R
3 E
. T
8 R
A
C
P T
V
R V
.
Rev. reach proportional valve A R
3 E
. A
9 C
H
P V
V A
R L
E V
= E
Fwd. reach proportional valve
ESR4500 06/2004 • Printed in GermanyMANY
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ELECTRICS A3.10 - A3.16 Outputs
A M
3 A
. S
1 T
0 R
P I
V G
A H
R T
= V
X .
X O
X .
X
X .
X
X
O T
F .
F
O O
F .
F
O V
F .
F O
O
F
F
O
F
F
Proportional valve, RH mast functions (tilt, sideshift and aux. function) A M
3 A
. S
1 T
1 L
P E
V F
A T
L
= V
.
X O
Proportional valve, LH mast functions (tilt, sideshift and aux. function) A T
3 I
. L
1 T
2 V
S A
V L
T V
= E
O
U
Tilt solenoid (ON = activated, OFF = deactivated) A S
3 I
. D
1 E
3 S
S H
V I
S F
= T
V
.
Sideshift solenoid (ON = activated, OFF = deactivated) A 5
3 T
. H
1
4 F
U
S N
V C
5 T
I
= O
N
Hydraulic aux. function solenoid (ON = activated, OFF = deactivated) A A
3 L
. A
1 5 R M
A 2
L M O U
2 T
= P
U
T
Travel alarm output (ON = activated, OFF = deactivated) A B
3 E
. A
1 C
6 O
B N
E O
A U
C T
= P
U
T
Flashing beacon output (ON = activated, OFF = deactivated)
MS-4.3-2140
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ESR4500 06/2004 • Printed in Germany
ELECTRICS A3.17 - A3.18 Outputs
A F
3 A
. N
1
7 O
U
F T
A P
N U
=
O
F
F
T
Fan output (ON = activated, OFF = deactivated) A J
ESR4500 06/2004 • Printed in GermanyMANY
3 . U M
1 P
8 L
E E
S V
C E
A L
P
E U
P
MS-4.3-2140
151
ELECTRICS Calibration C1 - C3 Calibration
C P
A R
L E
I S
B S
R
C
1
A E
T N
I T
O E
N R
A P
C E
C D
E A
L L
C 1 C O
. N
1 F
E
R
A
T
I
O
N
R R M
E
L
E
A
I
=
X
X
.
X
Accelerator calibration: Release pedal and press Enter, C 1 C O
. N
2 F
I
P R R M
E
S
S
=
X
X
.
X
Gently depress the accelerator and press ENTER When C1 is calibrated the system automatically jumps to menu item C2 C
2
R H
A A
I N
S D
E L
/ E
L
O W E
R
Raise/Lower Potentiometer Calibration, C C
2 O
. N
1 F
I
R A R M
I
S
E
=
X
X
.
X
Control lever in Raise position, then press Enter C C
2 O
. N
2 F
I
L O W E R M
R
=
X
X
.
X
Control lever in Lower position, then press Enter C C
2 O
. N
3 F
I
C E N R M
T
E
R
=
X
X
.
X
Control lever in centre position, then press Enter Jump to C3 C
3
R H
E A
A N
C D
H L
E
Reach potentiometer calibration C C
3 O
. N
1 F
I
R E R M
T
R
A
C
=
X
X
.
X
Control lever in Reverse position, then press Enter C C
3 O
. N
2 F
I
R E R M
A
C
H
=
X
X
.
X
Control lever in Forward position, then press Enter C C
3 O
. N
3 F
I
C E N R M
T
E
R
=
X
X
.
X
Control lever in centre position, then press Enter Jump to C4
MS-4.3-2140
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ESR4500 06/2004 • Printed in Germany
ELECTRICS C4 - C5 Calibration
C
4
T H
I A
L N
T D
L
E
Fork tilt potentiometer calibration, C C
4 O
. N
1 F
I
T I R M
L
T
U
P
=
X
X
.
X
Control lever in Rev. tilt position, then press Enter C C
4 O
. N
2 F
I
T I R M
L
T
D
N
=
X
X
.
X
Control lever in Fwd. tilt position, then press Enter C C
4 O
. N
3 F
I
C E N R M
T
E
R
=
X
X
.
X
Control lever in centre position, then press Enter Jump to C5 C
5
S H
I A
D N
E D
L
S E
H
I
F
T
Sideshift potentiometer calibration C C
5 O
. N
1 F
I
R I G R M
H
T
=
X
X
.
X
Control lever in Reverse position, then press Enter C C
5 O
. N
2 F
I
L E R M
F
T
=
X
X
.
X
Control lever in Forward position, then press Enter C C
5 O
. N
3 F
I
C E N R M
T
E
R
=
X
X
.
X
Control lever in centre position, then press Enter Jump to C6
ESR4500 06/2004 • Printed in GermanyMANY
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ELECTRICS C6 - C7.1 Calibration
C
6
5 H
T A
H N
D
F L
U E
N
C
T
I
O
N
Aux. function potentiometer calibration C C
6 O
. N
1 F
I
R I G R M
H
T
=
X
X
.
X
Control lever in Reverse position, then press Enter C C
6 O
. N
2 F
I
L E R M
F
T
=
X
X
.
X
Control lever in Forward position, then press Enter C C
6 O
. N
3 F
I
C E N R M
T
E
R
=
X
X
.
X
Control lever in centre position, then press Enter If the calibration is outside the tolerance limits (e.g. wrong direction or faulty potentiometer) an error message is displayed for 2 seconds and the reading is not accepted. W R C A
O L
N I
G B
R
H
E
I
G
H
T
C S
7 T
. A
1 T
U
R S
A
T
I
O
N
C :
U O
T V
1 E
= R
Jump to C7 C
7
X R
X I
. D
X E
X
Lift stop 1 programming, options are: NONE, no lift stop, OVERRIDE, Bypass the stop via the override switch (ORS) STOP, lift stop cannot be overriden If more than one lift stop is programmed, the lower of the two lift stops must be specified as the “override” C C
7 O
. N
1 F
. I
1 N R M
O
N
E
C S
7 E
. T
1 H
. E
2 I
V T
E
R
G
O H
R
I
D
E
If this function is selected, the display changes to the next display text. L C
I O
F N
T F
I
T O R M
L
I X
M X
I .
T X
X
M
Now raise to the appropriate height and confirm this height. The current height is displayed at the same time.
MS-4.3-2140
154
ESR4500 06/2004 • Printed in Germany
ELECTRICS C7.1.3 Calibration
C S
7 E
. T
1 H
. E
3 I
G
S H
T T
O
P
If this function is selected, the display changes to the next display text. L C
I O
F N
T F
I
T O R M
L
I X
M X
I .
T X
X
M
Now raise to the appropriate height and confirm this height. The current height is displayed at the same time.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
155
ELECTRICS C7.2 Calibration
C S
7 T
. A
2 T
U
R S
C :
U S
T T
2 O
= P
1
1
.
3
2
Lift stop 2 programming (this value must be greater than lift stop 1), options are: NONE, no lift stop, OVERRIDE, Bypass the stop via the override switch (ORS) STOP, lift stop cannot be overriden C C
7 O
. N
2 F
. I
1 N R M
O
N
E
C S
7 E
. T
2 H
. E
2 I
V T
E
R
R
I
D
E
L
I X
M X
I .
T X
X
M
X
M
G
O H
See lift stop 1
C S
7 E
. T
2 H
L C
I O
F N
T F
I
T O R M
. E
3 I
S H
T T
O
P
G
T R
O M
L
I X
M X
See lift stop 1 L C
MS-4.3-2140
156
I O
F N
T F
I
I .
T X
ESR4500 06/2004 • Printed in Germany
ELECTRICS C7.3 Calibration
C H
7 E
. I
3 G
C T
A
H
L E
I N
B C
C S
7 A
. V
3 E
. D
1
R O
A D
T E
M
A
X
I R
O
N
X
X H
X G
X H
X T
M M .
The currently stored value is displayed. If no height has been programmed, ------mm appears. You can use this menu to check the latest reading. Continue with Enter. For 2 seconds the following message is displayed: L M
I A
F X
T
C E
7 N
. T
3 E
H . R
T E
O I G
H
M
X
2
T X
A
X H
X G
X H
X T
M M .
Set the forks horizontal. Extend the mast as far as the stop. Using a measuring tape, measure the height from the fork tips to the ground. Enter the recorded height in mm. The mast must be extended as far as the stop, as the number of encoder pulses counted are stored as a reference value for the max. lift height. C S
7 A
. V
3 E
. D
3
X 2
N
D
X H
X G
X H
X T
M M .
The currently stored value is displayed. If no height has been programmed, ------mm appears. You can use this menu to check the latest reading. Continue with Enter. For 2 seconds the following message is displayed: L
O W E
L
I
F
T
S C
T O O N
P F
R
F
O
R
K
G
A
I
N
+ M R M
E
A
A
I
S
S
U
R
E
Lower the forks until the display changes to LIFT AGAIN (height reset switch changeover point). Now raise again briefly until the display changes to STOP+MEASURE. The height can now be recorded. If the forks have been raised too far after the STOP signal, you can lower them again until LIFT AGAIN is displayed. Now slowly raise them again until STOP + MEASURE is displayed.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
157
ELECTRICS C7.3.4 - C7.5 Calibration
C E
7 N
. T
3 E
. R
4
X 2
N
D
X H
X G
X H
X T
M M .
Enter the currently recorded lift height. It is important that the fork carriage has not been stopped too far below the switch. C J
C C
7 U
. S
4 T
7 . U M
3 P
.
C U O M
T H
H E
5 L
V
E E
S L
C
E
A U
T I
= G
1 H
1 T
.
3
4
N
E
T
H
P P
E
I
G
Programming a user-specific lift height C C
7 O
. N
4 F
. I
1 N R M
O
no user-specific lift height C S
7 E
. T
4 H
. E
2 I
G
C H
U T
E
H
T
Enter the user-specific lift height. On confirmation, the display changes to the next display text. L C
I O
F N
T F
I
T O R M
L
I X
M X
I .
T X
X
M
Now raise to the required height and confirm. The current height is displayed at the same time. C J C J
MS-4.3-2140
158
7 . U M
5 P
7 . U M
4 P
.
L
E V
S E
. E
3 L C L
E A
E V
S E
P U
E P
C L
A
P U
E P
ESR4500 06/2004 • Printed in Germany
ELECTRICS C8 Calibration
C
8
W E
I
G
H
T
Calibrating the load sensor LS. Calibration takes place in 2 stages: in the first stage without load and in the second with a test load. For an exact calibration, the test load must exceed 1000 kg (optimum rated load). C N
8 O
.
1 L
0 O
A
K
G
D
Position the fork carriage 300 mm horizontally above the ground and press ENTER C E
8 N
. T
2 E
R
L
O
A
-
-
-
K
G
D
Lift the test load and record the exact weight, then confirm with ENTER. The weight is entered using the arrow keys, starting with the thousand digit. After selecting the respective number, confirm it with ENTER. Enter the remaining numbers in the same way.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
159
ELECTRICS C9 Calibration
C
9
F P
O O
R S
K I
T
I
O
N
I
N
G
Correction coefficient for fork horizontal position. The “horizontal fork” function can be activated in the driver menu. If the fork carriage is fully tilted up and the tilt lever activated, the fork automatically stops in the horizontal position. If the lever is now returned to the neutral position and applied again, the fork will be set to the end position. The correction coefficient is different for Tilt UP and Tilt Down. The values can be chosen between +3 and -3. +3 means that the forks stops 3 units earlier in the upper position.
C
9
.
C M
1
9 I
. N
A T
D I
J L
1 =
. -
1 3
U T
S
T U
P U M
P A
= X
=
+
3
3
The values are entered with the arrow keys C
9
.
C M
2
9 I
. N
A T
D I
J L
2 =
. -
1 3
U T
S
D
T D
O W N
O W N M A
= X
=
+
3
3
The values are entered with the arrow keys C J
MS-4.3-2140
160
9 . U M
3 P
. L
E
E V
S E
C L
A
P U
E P
ESR4500 06/2004 • Printed in Germany
ELECTRICS C10 - 11.2 Calibration
C 1 0 R E A C H R E T R A C T S L O W D O W N
Adjusts the mast reach speed in both limit areas: mast extended / retracted. C
C
C
1
1
1
0
.
1
C S
1 T
0 D
0
.
2
. =
A D J U S R E A C H
T
1 8
E
.
1
A D R E
J T
.
1
R
U R
S T A C
T
R
T
C S
1 T
0 D
. =
2 7
S
A
V
E
?
C 1 1 C O N
. F
1 I
S A R M
V
E
=
C 1 1 C O N
. F
2 I
S A R M
V
E
=
1
A C H
E
R A
=
8
=
7
N O
Y
E
S
Storing the calibration readings. If these are not stored, the old values will continue to remain active after the truck has been shut down. The changes will only apply after the truck has been started up again.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
161
ELECTRICS Feature F1 - F3 Features
F P
E R
A E
T S
U S
R
F T
1 R
E E
S N
T
U
C
K
E
R
S
I
1 Z
. E
4
F C
1 O
. N
1 F
I
R M
F C
1 O
. N
2 F
I
R M
/
1
.
6
T
1
.
4
/
1
.
6
T
2
.
0
T
Truck capacity setting. This setting is used to load truck-specific values into the VCM.
F F
2 R
E
L
F I
L F
S T
F C
2 O
. N
1 F
F R M
L
S
=
I
F C
2 O
. N
2 F
F R M
L
S
=
I
E
= S W
Y T
I
E C
S H
Y
N
O
E
S
N
O
E
S
Free lift switch activated / deactivated
F
3
H
E
C R 5 E N C
E I
G
H
T
= O
Y
D
E
E S
R
F C
3 O
. N
1 F
E C R M
R
5
=
I
F C
3 O
. N
2 F
E C R M
R
5
=
I
Y
Height encoder activated / deactivated. If the height encoder is inactive, the height / weight, rack select and rack select entry will not be displayed in the operator menu.
MS-4.3-2140
162
ESR4500 06/2004 • Printed in Germany
ELECTRICS F4 - F6 Features
F L
4 O W E
R
L C
C U
F N
4 O
. T
1
F I
4 N
. A
F A
4 C
. T
S T
O
= U
T
Y
E
S
L
L
= E
I
N
L S
C T
S A
2 C
C E
=
I
L V
S
T
3 I
L
C
S
=
V
E
N
O
X
X
X
Y
E
S
D
Lower cutout switch: Possible functions: Not installed / installed For the “installed” setting the LCS can additionally be set to “active” or “inactive”. F 5
5 T
H
F
U
5 N
T H C T
I
F C
5 O
. N
1 F
5 R M
T H
=
I
F C
5 O
. N
2 F
5 R M
T H
=
I
F C
5 O
. N
3 F
5 R M
T H
=
I
O
= N
N
O
O
L
F
F
O
N
C
S
Hydraulic aux. function: OFF: Deactivated / ON : Activated LCS: the 5th function is only active below the LCS switch
F M
6 A
X .
L
O
M L A D
F E
6 N
. T
1 E
=
R
X
X
X
M M
L A
X
X
K
G
=
L
O
A
D
K
G
Entering the maximum load
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
163
ELECTRICS F7 - F7.7 Features
F C
7 A
P
A
C
I
C T
D M Y D
A
= T
N O M .
A
Load Monitor (CDM Capacity Data Monitor): NO: switched off YES: switched on. Enter the zones and the corresponding values in accordance with the load diagram, starting with the highest lift height (WT1/HT1). Use the arrow keys to enter the values, starting with the left hand number. After inputting the respective number, confirm it with ENTER. The remaining numbers are entered in the same way. F C
7 O
. N
1 F
C D M R M
=
I
F C
7 O
. N
2 F
C D M R M
=
I
F E
7 N
. T
3 E
R
F
7
.
4
F
F J
7
.
7 . U M
7
8 P
Y
O
E
S
S Z
E O
T N
E
T T
= =
X
X X
X X
X X
X X
K G M M
W T H T
1 1 * * * 4 4
= =
-
0 -
-
-
-
K G M M
E E
S V
C E
A L
P
E U
P
W H
L
=
N
X
6223
MS-4.3-2140
164
ESR4500 06/2004 • Printed in Germany
ELECTRICS F8 Features
F T
8 R
A A
V
E
L
L M 2 A L A
= R M
O
F
F
The travel alarm can be selected via the display with the following functions: OFF: Off REV: Active only for reverse travel FWD : Active only for forward travel BOTH: Active for both forward and reverse travel
ESR4500 06/2004 • Printed in GermanyMANY
F I
8 N
. A
1 C
T
I
F A
8 C
. T
2 I
V
E
F A
8 C
. T
3 I
V
E
F A
8 C
. T
4 I
V
E
A V
L E
M
A
L F
M 2 = O R W A
A
A
L M R E L F
2
=
O
F
F
R D
E
V
R
2 V
E
= R
S
F W D E
M 2 W D
&
= R
B E
O V
T
H
MS-4.3-2140
165
ELECTRICS F9 - F10 Features
F
9
B
E
A
C
O
N
=
O
F
F
The beacon can be activated via the display with the following functions: OFF: Off KEY: Active when keyswitch is ON REV: Active only for reverse travel FWD : Active only for forward travel BOTH: Active forward and reverse
F U
1 S
0 E
F I
9 N
. A
1 C
T
I
F A
9 C
. T
2 I
V
E
F A
9 C
. T
3 I
V
E
F A
9 C
. T
4 I
V
E
F A
9 C
. T
5 I
V
E
P
U E
S R
E F
R O
R
B V
E E
A
C
=
B
E K
A E
C Y
= O
N
E F
A O
C = R W A
E R
A E
C V
E
E A C F W D
B
B
B
= R M
A
N
O
F
F
K
E
Y
R D
E
V
R
= R
S
F W D E
&
= R
B E
O V
N C
0 E
T
H
Truck performance parameter specification (User Performance) NO: Only P2 possible YES: Levels P1, P2 and P3 can be set by the driver without restriction.
MS-4.3-2140
166
F A
1 C
0 E
. E
1 S
S
U
F A
1 C
0 E
. E
2 S
S
U
S O
E N
R L
S P
E 1
R
= Y
P
P = 2
N
O
E 3
S
2 Y P
ESR4500 06/2004 • Printed in Germany
ELECTRICS F11 Features
F U
1 S
1 E
R
C
C O O D
D E
E
=
N
0
Specification of User Code and User Performance levels NO: Inactive YES: User Code is active, F C
1 O
1 D
. E
1
F C
1 O
1 D
. E
2
I
C N
O A
D C
E T
I
A
C C
O T
D I
E V
E
F 1 1 . 3 P R E S S
V I E E N T
= V
N
O
E
S
E
=
Y
W E R
The VIEW menu shows the various codes with their corresponding performance levels
F P
1 R
1 E
. S
U P
S E
E R
R F
O
1 R M
A
N
C
E
U P
S E
E R
R F
O
1 5 R M
A
N
C
E
A E
D N
D T
E
4 S
1
1
1 P
1 1
6
6
6 P
6 3
R
The ADD menu can be used to create user codes and their respective performance level. U E
S N
E T
R E
R
U
S
1 E
R
-
- @ P C O D
E
Enter the user code and performance level U E
F P
1 R
1 E
. S
S N
5 S
E T
R E
R
D E
E N
L T
E E
P
.
T R
E
1 L
2 E
3 V
4 @ P E L
X
You can use the DELETE menu to delete the user codes individually. U D
S E
E L
R E
T
0 E
1
X
X
X
X @ P
Z
Select the corresponding user code and press ENTER. The display returns to F11.5 F J
ESR4500 06/2004 • Printed in GermanyMANY
1 1 U M
. P
6 L
E E
S V
C E
A L
P
E U
P
MS-4.3-2140
167
ELECTRICS F12 - F14 Features
F S
1 E
2 T
L
A
N
G
U
A
G
E
Language setting in user menu
F T
1 R
3 U
C
F P
1 R
2 E
. S
1 S
I
S
H
T
N R
L
N
E E
G
E
F P
1 R
2 E
. S
2 S
R M
A
N
N
T
E
G R
E
E
F P
1 R
2 E
. S
3 S
E
N
C
H
N
T
E
F R
R
E
F P
1 R
2 E
. S
4 S
I
S
H
T
P R
N
N
S E
A
E
F P
1 R
2 E
. S
5 S
D
U
T
C
H
E
N
T
E
R
F P
1 R
2 E
. S
6 S
I
A
N
T
T R
L
N
I E
A
E
F P
1 R
2 E
. S
7 S
C
O
D
E
S
E
N
T
E
R
F J
1 2 U M
. P
8
E E
S V
C E
A L
P
L
E U
P
T L
C K
K O
= U
Y
E
K
T
L O O C
S
The truck can be blocked by Service. When you switch the truck on, "Truck Lockout On" appears in the display.
F R
1 A
4 C
F P
1 R
3 E
. S
1 S
T E
L N
O T
C E
K R
=
F P
1 R
3 E
. S
2 S
T E
L N
O T
C E
K R
=
R E
A L
C E
Y
E
S
S
K
K C
=
Y
N
O
E
S
T
Activating the “Rack Select” function in the operator menu. Requirement: F3 ECR5=YES
MS-4.3-2140
168
F P
1 R
4 E
. S
1 S
R E
A N
C T
K E
R
=
F P
1 R
4 E
. S
2 S
R E
A N
C T
K E
R
=
Y
N
O
E
S
ESR4500 06/2004 • Printed in Germany
ELECTRICS F15 - F19 Features
F H
1 E
5 I
G
H
T
H E / W E / W E I G
= H
Y
E
S
T
Activating the “HEIGHT AND LOAD” function in the operator menu. Requirement: F3 ECR5=YES
F T
1 I
6 M
E
F P
1 R
5 E
. S
1 S
H E
E N
/ T
W E E R
=
F P
1 R
5 E
. S
2 S
H E
E N
/ T
W E E R
=
T
I
M
R
=
Y
S
E
E
Y
N
O
E
S
R
Activating the “TIMER” function in the operator menu.
F E
1 R
7 R
O
F P
1 R
6 E
. S
1 S
T E
I M N T
E E
R R
=
F P
1 R
6 E
. S
2 S
T E
I M N T
E E
R R
=
E L
L O G O G
=
Y
E
S
R
Y
N
O
E
S
Activating the ERROR LOG function in the operator menu.
F O
1 P
8 E
R
F P
1 R
7 E
. S
1 S
E E
L N
O G T E
R
=
F P
1 R
7 E
. S
2 S
E E
L N
O G T E
R
A
T
A O
L M 1 R A
L
= A
Y R M
=
E
Y
N
O
E
S
S
The operator alarm can be activated or deactivated. Overload and battery alarm remain active
F B
1 A
9 T
T
F P
1 R
8 E
. S
1 S
A E
L M N T
1 E
R
F P
1 R
8 E
. S
2 S
A E
L M N T
1 E
R
T A
L A
= R M
2
0
R
B Y
A
E
A L
=
=
Y
N
O
E
S
%
An additional visual and audible battery warning can be activated. The warning levels are 20%, 30% and 40% .
ESR4500 06/2004 • Printed in GermanyMANY
F P
1 R
9 E
. S
1 S
B E
A N
T T
A E
L R
=
O
F
F
F P
1 R
9 E
. S
4 S
B E
A N
T T
A E
L R
=
4
0
%
MS-4.3-2140
169
ELECTRICS F20 - F22 Features
F F
2 O
0 R
K
P
F O O S
R I
K T
P I
= O
N
Y I
E S N G
The “horizontal fork” function can be activated in the driver menu. If the fork carriage is fully tilted up and the tilt lever activated, the fork automatically stops in the horizontal position. If the lever is now returned to the neutral position and applied again, the fork will be set to the end position.
F C
2 H
1 A
N
F P
2 R
0 E
. S
1 S
F E
O N
R T
K E
P R
=
F P
2 R
0 E
. S
2 S
F E
O N
R T
K E
P R
=
U
I N
U
R O
E
N U
E
G
T I
= T
N
O
Y
E
S
U
R
O
U
S
A
N
O
E
S
Measurement unit setting: EUROPE: Values in “mm, kg, km/h" USA: Values in “inch, lb (pounds), mph”
F
2
F P
2 R
1 E
. S
1 S
U E
N N
I T
T E
= R
F P
2 R
1 E
. S
2 S
U E
N N
I T
T E
= R
S
A
V
E
2
E
?
F C
2 O
0 N
. F
1 I
S R M
A
V
E
=
F C
2 O
0 N
. F
2 I
S R M
A
V
E
=
Y
Storing features: As the changes affect the truck basic setting, they only take effect have it is re-started.
MS-4.3-2140
170
ESR4500 06/2004 • Printed in Germany
ELECTRICS H1 - H3 Hourmeter
H P
O R
U E
R S
M S
H T
1 R
E E
T N
E T
R E
C
R K
U
U
R
N C
= X O M
X P
X L
X E
X T
. E
X
h
Displays the truck’s service hours. The respective service hours are only counted when travel, hydraulics or steering are active. H T
2 R
A
C
T T
D M = I O N
X
X X M O
X D
X U
. L
X E
H
Displays the truck controller's service hours. In the next menu the service hours can be read in FULL, MIDDLE and EASY mode. F X
U X
L X
L X
EASY MIDDLE FULL H H
3 Y
D
R
H A
D M U L
M X
I X
D X
L X
E X
A X
S X
Y X
Controller temperature below 50°C Controller temperature between 50°C and 85°C Controller temperature above 85°C = I
X C
X
X X M O
X D
. .
X
H
Displays the hydraulic controller's service hours. In the next menu the service hours can be read in FULL, MIDDLE and EASY mode. F X
U X
L X
EASY MIDDLE FULL
ESR4500 06/2004 • Printed in GermanyMANY
L X
M X
I X
D X
L X
E X
A X
S X
Y X
Controller temperature below 50°C Controller temperature between 50°C and 85°C Controller temperature above 85°C
MS-4.3-2140
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ELECTRICS H4 - H8 Hourmeter
H V
4 E
H
I
V .
C M = C O N
X T
X R
X O
X .
X . M O
X .
H
Shows the power on time of the VCM module. It starts counting when the keyswitch is turned on. H S
5 T
E
E
S R
D M = M O
X D
X U
X L
X E
X
.
X
H
Displays the steering controller’s service hours. In the next menu the service hours can be read in FULL, MIDDLE and EASY mode. F X
U X
L X
L X
EASY MIDDLE FULL H D
6 I
S
P
D L
I A
S Y
M X
I X
D X
L X
E X
A X
S X
Y X
Controller temperature below 50°C Controller temperature between 50°C and 85°C Controller temperature above 85°C =
X
X
X
X
X
.
X
H
The display power on time can be read. It starts counting when the keyswitch is turned on. H S
7 E
T
S
E
R
V
I
C
= E
X
X T
X I
X H M
SERVICE INTERVAL setting (service timer). H C
7 O
. N
1 F
I
T R M
I
M
E
=
N
O
N
E
NONE: Service timer is switched off and is not displayed the next time the truck starts up. H E
7 N
. T
2 E
T T
R
I I
M M
E E
=
-
-
-
-
H
If a SERVICE INTERVAL is entered, the hours are displayed and reset the next time the truck is started. If the 0 hours limit has been reached, a permanent noise is sounded for 3 seconds when the truck is started up and the message SERVICE NOTWENDIG? Is displayed. The time from here on is counted and displayed as a negative. H J
MS-4.3-2140
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8 U M
P
E L
S E
C V
A E
P L
E U
P
ESR4500 06/2004 • Printed in Germany
ELECTRICS Log Events L1 - L3.2 Features L P
O G R E
S
E S
V
L P
1 R
E E
N N
T T
E
S
S
S E
H
R
I E
S N
T T
O E
R R
Y
HISTORY displays the last 16 error messages with service hours and temperature of the corresponding module whenever a fault occurs.
L P
2 R
E
S
1 O
2 V
0 E
R
2 O
2 V
0 E
R
2 O
2 V
1 E
R
T
O E
T N
S
1
2 T
3 E
4 M
5 P
H .
1
2 S
3 T
C M
1
2 T
3 E
4 M
6 P
H .
1
1
1 P
C M
1
2 T
3 E
4 M
7 P
H .
2 P
2 2 M O
C T
A T
L E
S R
TOTALS displays all the faults and their frequency.
L P
3 R
E
S
E O
V V
E E
N R
T
E O
V V
E E
N R
T
E
R E
A N
S T
.
1
S L
3
T
1 E
2 M
0 P
.
@
T
2 E
2 M
0 P
.
E E
R
E H
R I
A S
S T
E O
S @
R
1 T
0 M
3 P
2 M
Y
Deletes the last 15 error messages in the history.
L
3
.
2
L C
3 O
. N
1 F
. I
1 R M
S
U
R
E
=
L C
3 O
. N
1 F
. I
2 R M
S
U
R
E
=
E A
R L
E L
A
S
Y
N
O
E
S
E
Deletes all stored error messages.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
173
ELECTRICS L3.2.1 - L4 Features
L J L J
MS-4.3-2140
174
4 U M
P
3 . U M
3 P
E L
C V
S E
L C
3 O
. N
2 F
. I
1 R M
S
U
R
E
=
L C
3 O
. N
2 F
. I
2 R M
S
U
R
E
=
E L
S E
C V
A E
P L
U
P
P L
E U
P
A E
Y
N
O
E
S
E
ESR4500 06/2004 • Printed in Germany
ELECTRICS Performance P1 - P1.5.1 Performance P P
E R
R E
F S
O S
R M A E N
N T
C E
E R
P P
1 R
E S
T
U E
P N
T
P E
1 R
P S
1 P
. E
1 E
D
F
O
F W D R W A
P S
1 T
. D
1 =
E
S S
. 1
R
1 2
= D
X
X . X K M H
F
W D M
= A
X X
X =
. 1
X 2
FORWARD travel speed can be set in increments of 0.1 km/h. The display shows the set value, the default value and the max. permissible speed.
P S
1 P
. E
2 E
D
R
E
R V
E E
V R
P S
1 T
. D
2 =
. 1
1 2
S
= E
X
X . X K M H
R
E
V M
= A
X X
X =
. 1
X 2
REVERSE travel speed can be set in increments of 0.1 km/h.
P A
1 C
. C
3 E
L
E
R
A A
C T
C I
P S
1 T
. D
3 =
. 8
1
O
= N A
X
C
C M
= A
X
=
X 9
X
=
X 9
Truck acceleration setting.
P P
1 L
. U
4 G G
U
=
N
P G
L
I
P S
1 T
. D
4 =
. 8
1
P
X
L
U M
= A
Plugging setting. Plugging: Reversing the travel direction with the pedal depressed.
P C
1 O
. A
5 S
=
I
N
C O G
S
T P S
1 T
. D
5 =
1
C
. 8
X
O
S M
= A
X
=
X 9
Coasting setting. Coasting: Pedal reverts to the neutral position.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
175
ELECTRICS P1.6 - P1.10.1 Performance
P R
1 E
. D
6 U
T
I
R O
B N
R
C P S
1 T
. D
6 =
. 7
1
B
= R
A
K
X
R
B
R
E
M
= A
X
=
X 9
Setting for the truck braking pattern from a given speed to a lower speed. The pedal does not revert to the neutral position.
P P
1 E
. D
7 A
L P S
1 T
B
P R
B A
R K
. D
7 =
. 9
1
=
X
E P
B
R M
= A
X
=
X 9
Setting for the additional electrical brake force when brake pedal is activated (signal through BPS). P R
1 A
. I
8 S
E P S
1 T
S
R P
A E
I E
. D
8 =
. 5
1
=
X
D R
A
I M
= A
X
=
X 5
X
=
X 5
Lift speed setting (5: maximum, 1: minimum)
P R
1 A
. I
9 S
E P S
1 T
A
R C
A C
C E
. D
9 =
. 3
1
C L
= E
R
A
T
X .
R
A
C
C M
= A
The acceleration (starting pattern of the forks) up to the selected lift speed can be made in 5 increments. (5: rapid acceleration, 1: slow acceleration) P L
1 . 1 O W E
0 R P S
1 T
L S
O P
S E
P E
D
=
. D
1 =
0 9
.
1
L
X
O
S
P M
= A
X
=
X 9
Lowering speed setting (9: maximum, 1: minimum)
MS-4.3-2140
176
ESR4500 06/2004 • Printed in Germany
ELECTRICS P1.11 - P1.15 Performance
P L
1 . 1 O W E
1 R P S
1 T
L S
O S T O
T P
. O
1 P
. H
1
1 A
=
X
X
X
X
L R
O D
S /
T = S O
S F
O T
F
T
X
=
X 5
X
=
X 5
X
=
X 5
Lowering stop pattern setting (hard / soft). P R
1 E
. A
1 C
2 H P S
1 T
R
R E
R T
S R
.
= S
P
E
. D
1 =
2 5
.
1
R
R
S
E
X D
M
= A
Reach speed setting (5: maximum, 1: minimum)
P T
1 I
. L
1 T
3
P S
S
P
T E
L E
T D
1 T
. D
1 =
3 5
.
=
1
T
X
L
T M
= A
E
X D
M
= A
Tilt speed setting (5: maximum, 1: minimum) P S
1 I
. D
1 E
4
P S
S
H
S I
S F
S T
1 T
. D
1 =
4 5
.
1
= S
P
E
S
S
S
Sideshift speed setting. (5: maximum, 1: minimum) P J
ESR4500 06/2004 • Printed in GermanyMANY
1 . U M
1 P
5 L
E E
S V
C E
A L
P
E U
P
MS-4.3-2140
177
ELECTRICS P2 - P6 Performance
P P
2 R
S S
E S
T
E
P P
3 R
S S
E S
T
E
U E
P N
T
P E
2 R
U E
P N
T
P E
3 R
Performance levels P2 and P3 in the sub-menus are identical to P1 and vary only in terms of their default values.
P P
4 R
E
B S
D S
I
P S
4 T
E
S N
E T
. D
1 =
6
T E
T R
I
B
D
I
N
G
X
C
U R M A
V X
E =
=
6 9
Battery discharge characteristic curve setting. The setting can range from 1 to 9 with the smaller setting resulting in a deeper discharge. P T
5 R
A
V
E
L
P S
5 T
T > . D
1 =
>
L L
C
= S T
X
>
L
9
M
= A
X
=
x 9
Travel speed setting above the LOWER CUT OUT SWITCH. The travel speed can be set in 9 stages. 9 = max. travel speed, 1 = minimum travel speed (creep speed) P5 (Travel>LCS) has the highest priority. If this value is set to 5, for example, at P6 (Travel>FLS) and P7 (Travel>Custom) the value 5 is the highest level (max. speed) that can be selected. The next highest priority is given to P6, i.e. P7 can never be set higher than P6.
P T
6 R
A
V
E
L
P S
6 T
T > . D
1 =
>
F F
L
= S T
9
X
>
F M
= A
X
=
X 9
Travel speed setting above the FREE LIFT SWITCH. The travel speed can be set in 9 stages. 9 = max. travel speed, 1 = minimum travel speed (creep speed)
MS-4.3-2140
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ESR4500 06/2004 • Printed in Germany
ELECTRICS P7 - P10 Performance
P T
7 R
A
V
E
L
P S
7 T
T > . D
1 =
>
C C
U
= S
T
O M
X
T
>
C
9
M
= A
X
X 9
=
Travel speed setting above the COSTUM HEIGHT.? The travel speed can be set in 9 stages. 9 = max. travel speed, 1 = minimum travel speed (creep speed) P L
8 O W E
L R P S
> 8 T
. D
1 =
> C
C U
S
= T
O M
X
T
>
C
5
M
= A
X
X 5
=
Lowering speed setting above the COSTUM HEIGHT.? The lowering speed can be set in 5 stages. 5 = max. lowering speed, 1 = minimum lowering speed P R
9 E
R A
C
H P S
> 9 T
. D
1 =
> C
C U
S
= T
O M
X
R
>
C
5
M
= A
X
X 5
=
Reach speed setting above the COSTUM HEIGHT.? The reach speed can be set in 5 stages. 5 = max. reach speed, 1 = minimum reach speed. P 5
1 T
0 H
U
N
5 C
T
F P S
1 T
0 D
. =
1 1
H L
0
L E
= F
T
5
T
X
X
L
H
L M
= A
X
X =
X 2
L 8
Flow quantity specification in litres for the left hydraulic aux. function.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
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ELECTRICS P11 - P15.2 Performance
P 5
1 T
1 H
U
N
5 C
T
F P S
1 T
1 D
. =
1 1
H R
R I
= G
X T
X
L
H
5
T
H
R M
= A
0
X
X =
X 2
L 8
Flow quantity specification in litres for the right hydraulic aux. function. P S
1 T
2 E
E
R P S
1 T
L
S L S O W
2 D
. =
S
1 4
= P
E
X E
S
L
S
X D
M
T
= I
X N
=
X 3
Steering wheel revolution setting in idle condition. This value gives the number of steering wheel revolutions for 180°. P S
1 T
3 E
E
R P S
1 T
H
S I
H G
3 D
. =
1 8
S H
= S
P
X E
S
H
S
X E
T D
M
= A
X
=
X 1
X 0
Steering wheel revolution setting at max. speed. This value gives the number of steering wheel revolutions for 180°. Linear progression between idle and max. speed. P B
1 R
4 A
K
E
B T
A
A
R R
= A M
N
O
P
P C
1 O
4 N
. F
1 I
B R M
A
R
=
P C
1 O
4 N
. F
2 I
B R M
A
R
=
Y
N
O
E
S
Setting for truck brake pattern on the ramp. NO: The truck rolls back at creep speed. YES: The truck stands on the ramp with pedal position 0. It is maintained by the motor current for 5 seconds and then the parking brake is automatically activated and the current cut out. When the truck starts again, first the current is activated and then the brake released to prevent the truck from rolling back. P
1
5
S
A
V
E
?
P C
1 O
5 N
. F
1 I
S R M
A
V
E
=
P C
1 O
5 N
. F
2 I
S R M
A
V
E
=
Y
N
O
E
S
Storing performance values. The z.Bsp. P1 performance setting which is active in normal operation, remains active in the service level. This means that the P1 changes after storing can be tested directly at the service level.
MS-4.3-2140
180
ESR4500 06/2004 • Printed in Germany
ELECTRICS Utilities U1 - U2 Utilities
U T P R
I E
L S
I S
T
U
1
I E
E N
S T
E
R
S V
O E
F R
T W A S I O
R N
E
Displays software versions of all controllers.
U
2
H
U 8
1 1
. 5
1 7
5
5
V -
C M 0 0
1
-
X
X
X
U 8
1 1
. 5
2 7
5
6
T -
D M 0 0
1
-
X
X
X
U 8
1 1
. 5
3 7
5
7
H -
D M 0 0
1
-
X
X
X
U 8
1 1
. 5
4 7
5
8
S -
D M 0 0
1
-
X
X
X
U 8
1 1
. 5
5 7
5
9
D -
I 0
S 0
P 1
L -
A X
Y X
X
U J
1 . U M
6 P
V
S L
A U
P P
E
E
E E
C
L
O
U
R
E
T
U H
2 1
. R
N
C
R
X E
X A
X S
X E
S
1 U
N
I
X
h
Attention: The truck service hours can only be increased. Enter the numbers individually starting from the left and then confirm. After the last entry the menu automatically jumps to U2.1.1 and the entered value must be confirmed. U C
2 O
. N
1 F
. I
1 S R M
A
U C
2 O
. N
1 F
. I
2 S R M
A
V X
E X
X
= X
X
.
N X
O h
V X
E X
X
= X
X
Y .
E X
S h
Attention: After confirming, the truck must remain switched on for at least 6 minutes (keyswitch ON), as otherwise the value will not be accepted. Reason: The truck controller (VCM) stores the new value every 6 mins (0.1 hour increments), i.e. in the worst case it takes 6 minutes for the new value to be accepted. A T
ESR4500 06/2004 • Printed in GermanyMANY
F I
T M
E E
R I
6 S
M
I S
N T
. O
N R
E W E D
MS-4.3-2140
181
ELECTRICS U3 - U4 Utilities
U A
3 C
C
A O
C V
C E
Y R
R
U C
3 O
. N
1 F
A C C R M
Y
=
I
U C
3 O
. N
2 F
A C C R M
Y
=
I
Y
I
= D
N
O
E
Y
N
O
E
S
The parking brake can be overridden using this function. If the steering controller recognises that there is no brake connected or that the brake has a short circuit, the main contactor is not closed and the truck cannot be moved. If the function is set to YES, the truck can move at creep speed if the brake has been mechanically released by the traction motor. U J
MS-4.3-2140
182
4 U M
P
L
E E
S V
C E
A L
P
E U
P
ESR4500 06/2004 • Printed in Germany
ELECTRICS Procedure
Control Module Safety Test General
●
Switch the truck on.
●
Close the seat switch (sit on the seat), activate the safety pedal and depress the accelerator until the drive wheel starts to turn slowly. Maintain this position and carry out the next step.
●
Disconnect the speed detection 6 pole connector (A, Fig. MS-2140-019) while the drive wheel is turning slowly. The system should respond as follows: The mechanical brake decelerates the drive wheel. The drive module is cut out and the main contactor drops. The service display is illuminated. In LOG EVENTS, error no. 180 “ECR3 HALL SENSOR” is stored.
●
Switch the truck off.
●
Re-connect the speed detection 6 pole connector (A, Fig. MS-2140-019).
●
Switch the truck on. The truck should start up as normal with no error message displayed.
●
Close the seat switch (sit on the seat), activate the safety pedal and depress the accelerator until the drive wheel starts to turn slowly. Maintain this position and carry out the next step.
●
Disconnect the steering motor supply 4 pole connector (B, Fig. MS-2140-019) while the drive wheel is turning slowly. The system should respond as follows:
The EU standard EN 1175-1 requires the safety circuit for electronic controllers in electric lift trucks to be tested. We recommend carrying out this test at least once a year.
Steer Module Safety Test DANGER Danger to personnel in the vicinity! A faulty safety circuit can cause the truck to start suddenly and accidentally. People standing in the way of the truck could be fatally injured. Before carrying out the safety test jack the truck up so that the drive wheel is clear of the ground. Wedge the load wheels with blocks.
Preparatory measures ●
Switch the truck off.
●
Jack up the truck (see Chapter 1 and safety instruction above).
B A
-
The mechanical brake decelerates the drive wheel. The drive module is cut out and the main contactor drops. The service display is illuminated. In LOG EVENTS, error no. 102 “ERROR STEER MOTOR” is stored.
If the test is not successful, the steer module must be replaced before starting the truck again. ●
Remove the panel and the display. Do not disconnect the plug connection. Only put the display down on the side to allow access to the steer module.
ESR4500 06/2004 • Printed in GermanyMANY
MS-4.3-2140
183
ELECTRICS Fit the fuse holder onto the insulating plate. Fit each end of the power cable to the fuse holder.
Drive Module Safety Test DANGER Danger to personnel in the vicinity! A faulty safety circuit can cause the truck to start suddenly and accidentally. People standing in the way of the truck could be fatally injured. Before carrying out the safety test jack the truck up so that the drive wheel is clear of the ground. Wedge the load wheels with blocks.
To carry out the test you will then need 2 off M8 nuts. This attaches the test wiring to the motor terminals.
Preparatory measures ●
Disconnect the battery.
●
Press the horn for approx. 3 seconds. This will fully discharge the drive module capacitors.
●
Jack up the truck (see Chapter 1 and safety instruction above).
●
Fold up the seat and the panel.
WARNING
Procedure Risk of scalding and injury to eyes. The power fuse can burn, causing burning metal particles to explode. These particles can cause serious eye injuries and scald unprotected skin. Always wear protective glasses and appropriate protective clothing. Only use encapsulated power fuses. With these fuses, the fuse strip is covered to prevent liquid metal particles from spraying.
Tools required A self-assembled test unit. You will require: 2 off
35mm² cross section power cable Part no. 812334-004
1 off
Fuse holder Part no. 802817
1 off
200 A power fuse, encapsulated Part no. 802816-004
1 off
MS-2140-021
●
Using an additional M8 nut (A, Abb. MS-2140021) attach one end of the test wiring to the U terminal of the traction motor. Do not loosen the motor cables themselves in the process.
●
Attach the other end of the test wiring to the V terminal of the traction motor using an additional M8 nut. Do not loosen the motor cables themselves in the process.
●
Guide the cables and the fuse holder out of the truck so that the folded down seat panel does not damage the cables when they are on the seat. Fold the seat back up and place the fuse holder on the ground.
●
Connect the battery.
●
Switch the truck on.
Insulating plate, approx. 150 x 100 mm
MS-2140-020 MS-4.3-2140
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ELECTRICS ●
Close the seat switch (sit on the seat), apply the safety pedal and depress the accelerator as far as it will go.
●
The system should respond immediately as follows: The main contactor drops (opens). The service display is illuminated. In LOG EVENTS, error no. 301 “SHORT CIRCUIT TM” is stored.
●
Disconnect the battery again.
●
Press the horn for approx. 3 seconds. This will fully discharge the drive module capacitors.
●
Disconnect the test wiring from the V terminal of the traction motor and connect it to the W terminal with the additional M8 nut. Do not loosen the motor cables in the process.
●
Guide the cables out of the truck so that the folded down seat panel does not damage the cables when they are on the seat. Fold the seat back.
●
Connect the battery.
●
Switch the truck on.
●
Close the sea switch (sit on the seat), apply the safety pedal and depress the accelerator as far as it will go.
●
The system should respond immediately as follows: The main contactor drops (opens). The service display is illuminated. In LOG EVENTS, error no. 301 “SHORT CIRCUIT TM” is stored.
●
Test the operation. Close the seat switch (sit on the seat), apply the safety pedal and gently depress the accelerator (not all the way). The drive wheel turns slowly without error message.
●
Switch the truck off.
●
Jack down the truck.
If the test fails, replace the drive module.
Final procedure ●
Switch the truck off.
●
Disconnect the battery again.
●
Press the horn for approx. 3 seconds. This will fully discharge the drive module capacitors.
●
Remove the test wiring.
●
Connect the battery.
●
Switch the truck on.
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BRAKE
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BRAKE Load Wheel Brake
●
General The load wheel brake is a self-adjusting drum brake. The brake is the same size for all truck models, irrespective of the capacity. There is no need for regular adjustment.
Pull off the load wheel. If necessary, you can set the brake shoe back slightly. The reverse side of the brake contains 4 holes. Holes A (Fig. MS2140-063) provide access to the eccentrics. Twist these slightly to make it easier to pull off the load wheel. Holes B allow the brake lining thickness to be checked.
DANGER
Brake Lining
Risk of injury from pre-tensioned springs.
Disassembly
Pre-tensioned springs can cause serious eye injuries.
DANGER
Always wear a splint-proof protective glasses and suitable clothing to prevent injuries to your eyes and body.
Risk of injury. A non-supported or insufficiently supported truck or truck part can suddenly drop and cause serious injuries if you leave your hands or other body parts underneath it.
●
Remove springs C, E and F (Fig. MS-2140-064).
●
Using a blunt, burr-free lever, lever one brake shoe towards the inside in order to press in the brake cylinder piston. Do not press directly on the piston. This could damage the brake piston sleeve.
●
Remove the brake shoe from the brake piston groove.
●
Remove the other brake shoe in the same way.
Always support a raised truck with wooden blocks or other appropriate equipment to relieve the jack. ●
Switch the truck off. Disconnect the battery.
●
Risk of tipping. It is essential to observe Chapter 1, Jacking up the Truck. Jack up a load arm until you can pull off the load wheel. The load wheel should be a maximum 10 mm clear of the ground. Support the load arm with hard wooden blocks to relieve the jack.
●
C
D
Remove the wheel cap and the retaining ring from the steering knuckle.
F
E
A
MS-2140-064
Assembly ●
B
Clean all components. Remove oil and grease as required with a brake cleaning agent.
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BRAKE ●
Assemble the brake shoes in the reverse order of disassembly.
●
Before installing the load wheel with the brake drum: Set the brake shoes using the eccentric to a distance of 199.4 +/- 0.2 mm. Otherwise you will not be able to push the load wheel over the brake shoes.
A B
C
M0945
Assembly
199,4 +/- 0,2 mm MS-2140-064
●
Fix the load wheel again.
●
Now activate the brake pedal approx. 10 times. This will automatically adjust the brake.
Wheel Brake Cylinder General For safety reasons, wheel brakes cylinders are only available as complete assemblies. They are not designed to be repaired in the field.
Disassembly
●
Remove the grease from all components using a brake cleaning agent.
●
Insert the new wheel brake cylinder and screw it in tight.
●
Re-connect the brake line.
●
Re-install the brake shoes and the load wheel. However, do not yet apply the brake. The brake system must first be bled.
Bleeding the load wheel brake and replacing the brake fluid
DANGER Danger of death! The use of hydraulic oils or lubrication oil instead of the approved brake fluid will cause the brake to fail. Fatal accidents could result. Only use brake fluid which complies with the specifications of the lubricant table (see Chapter 1).
Jack up and secure the truck. See previous section “Brake lining, disassembly”.
Jack up and secure the truck. See previous section “Brake lining, disassembly”.
●
Remove the brake shoes (see previous section).
●
Push a flat tray underneath the jacked up load wheel to collect the brake fluid.
●
Unscrew the brake line (B, Fig. M0945) from the wheel brake cylinder.
Bleeding is normally only required for the wheel brake cylinder that has been replaced. When replacing the brake fluid, open the vent screws (C, Fig. M0945) evenly on both wheel brake cylinders to fully remove the old brake fluid from the brake system (by pumping on the brake pedal). Then start to bleed the brake system as follows:
●
Undo the two mounting studs (A) from the wheel brake cylinder.
●
Remove the wheel brake cylinder.
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BRAKE ➊
Remove the protective cap from the vent screw.
➋
Insert a transparent hose onto the vent screw, placing the free end in a clean container with some new, uncontaminated brake fluid. The hose end should dip into the brake fluid.
➌
Get an assistant to apply the brake pedal.
➍
While the brake pedal is depressed, open the vent screw half a turn.
➎
When the assistant reaches the stop with the brake pedal and the brake fluid still emerges mixed with air, get the assistant to keep pressing on the brake pedal and close the vent screw.
➏
With the vent screw closed, release the brake pedal in order to get brake fluid from the reservoir into the system.
➐
Check the brake fluid level in the main brake cylinder reservoir. Replenish if the brake fluid is below the max. level. This will prevent air from being suctioned.
●
Repeat the steps 3 until 7 until the brake fluid emerges without any bubbles. Then close the vent screw.
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BRAKE Operating Brake
Air gap setting Befestigugs-Schrauben der Bremse am
Disassembly CAUTION Do not allow brake components to come into contact with oil or grease. The item numbers in brackets refer to Figure MP-2140076. ●
Disconnect the battery.
●
Jack up the truck until the drive wheel is free, support the truck and prevent it from rolling away (see chapter 1).
●
Undo the electrical connection (3) from the brake wiring.
●
Undo the brake line (B) at the top of the magnetic body.
●
Unscrew the three hex. socket screws (1).
●
Remove the magnetic body (2) from the motor (including everything connected to it).
TheFahrmotor operating (3 airStück) gap is measured between the magnetic body and the armature plate when the truck is braked. The air gap must be set to 0.3 mm (see Fig. M1467). ●
Unscrew the hollow screws (A) until they rest against the friction plate.
●
Torque the hex. socket screws (1) evenly to 9.5 Nm.
●
Check the operating air gap along several points using a feeler gauge. The air gap should be even all the way along.
●
To increase the air gap unscrew the hollow screws (A) slightly. To reduce the air gap screw the hollow screws (A) into the magnetic body (1). Now, measure again as described above.
●
When the air gap has been correctly set, torque the hex. socket screws (1) again to 9.5 Nm.
Test and Inspection ●
Check the friction plate (6) and rotor (5) for even wear, deep grooves, cracks and signs of burning. Replace any worn or damaged components.
●
Measure the thickness of the rotor (5). The wear limit is 9.5 mm. If the thickness of the rotor is the same as or less than this, replace the rotor.
Assembly ●
Assemble the brake in the reverse order of disassembly.
CAUTION It is essential to correctly reset the air gap after assembly.
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BRAKE
1
B
3
2
Air gap
A 4
5
6
MP-2140-076
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BRAKE Setting the brake pedal clearance Using a steel ruler, measure the brake pedal clearance. The clearance should be 3 +/- 1 mm.
●
If necessary, adjust the clearance. Undo the counternut (A) and adjust the clearance using the adjusting screw (B).
3
+/
-1
m m
●
A
B
MS-2140-065
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STEERING
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STEERING Whenever SFS 1SA is switched, the value calculated by the steer module is set to 0°. This corrects any deviation in the position calculation and allows a zero position to be defined via an error routine (e.g. after the drive wheel has been manually turned).
Steering General Functional Description The steering system consists of the steer module (SDM), the nominal value transmitter (steering sensor ECR4), steering feedback sensor (ECR3) and the steer motor (M3).
The sensors are activated by a cam on the gear unit cover (Fig. MS-2140-036). If the cam turns passed a sensor, the sensor switches. If a sensor has switched, an LED in
SFS 1SA
A steering wheel revolution generates a steering command on the steer module input (SDM) via the nominal value transmitter (ECR4).
Kamm
0°
ECR4 is a stage motor used as a generator. This stage motor generates (induces) a voltage. The phase position of this voltage depends on the direction of turn, while the voltage depends on the speed of turn. A voltage to power the steer motor, which is dependent on the input signal, is produced in the steer module. The
I
SFS 2 - 90°
90° IV
CA204
SDM
4
3
2
1
CA 437
4
3
2
1
Ain 1+
13
1
Ain 1-
14
3
Ain 2+
15
4
Ain 2-
16
6
+5 V out
4
2
CA 412
1
2
3
4
5 6
CA 436
1
2
3
4
5 6
R S T
3
M3 DC
HALL B HALL C HALL A +5 V DC COMM
Motor
III
CA 414 P2 P1 P3
ECR 4
P4
P6
P5
MS-2140-036
the sensor lights up (Fig. MS-2140-045). This allows the status of the sensor to be checked at a glance.
5
CA 413
II
The grey areas in Fig. MS-2140-036 correspond to an angle of approx. +/-5°, with reference to 0°, 90° and-90°. The steer module (SDM) expects the sensors to switch in these sectors.
1 2 3 4 5 6
ECR 3
MS-2140-037
LED steer motor is a brushless DC motor (EC = Electrical Commutated). The position of the steered wheel is monitored by the steering feedback sensor (ECR3) fitted in the steer motor. This encoder consists of three Hall sensors on a PCB. The steering feedback sensor calculates the position of the steered wheel to a tolerance level of +/- 0.5°. This is a 4 quadrant steering system. An inductive proximity switch (SFS 2) recognises the quadrants. The second inductive proximity switch (SFS 1SA) recognises the 0° position of the drive wheel. ESR4500 06/2004 • PRINTED IN GERMANY
MS-2140-045
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STEERING Of the four available quadrants, the first and second are used. This produces a working angle of 180° for the steering. The steering stops electrically at a steer angle of +/- 90°. An additional mechanical stop is applied to a steer angle of +/- 100°.
Quadrant - Definition The quadrants are defined as follows:
Ending the error routine To terminate the error routine and return to normal mode, the SFS 1SA sensor must be recognised once. Now set the accelerator pedal to neutral.
Causes of error routine activation In most cases the cause will be manual turning of the steered wheel (wheel change, repairs carried out while truck is jacked up on the transmission). During the next self test during power up the following error message is entered in the service menu logbook.
I:
1. Quadrant of
90° to
0°
II:
2. Quadrant of
0° to
-90°
Message: 184
III: 3. Quadrant of
-90° to
180°
Cause:
IV: 4th quadrant of
180° to 90°
Error routine INFORMATION The steering system stores the steer angle at the time the truck is switched off. The next time the truck is powered up (during the self test), the steer module (SDM) compares the current position of the steered wheel with the stored value. If the new position of the angle is not in the same quadrant as the stored angle, an error routine begins.
When the error routine starts … ●
... the travel speed is reduced to creep mode.
●
... the software stop of the steering system cuts out at +/- 90° and you can steer as far as the mechanical stop at +/- 100°.
●
... the max. permissible speed of the steer motor is restricted to 1500 rpm.
●
... the steer angle display is switched off.
●
... the steer fault display lights up.
●
... the message „STEERING SENSOR. TURN STEER WHEEL“ is shown on the message display.
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198
Start error SDM
Wrong quadrant detected
The same error message can however be generated by a faulty sensor being identified as faulty during truck power up. If a sensor fails while the truck is travelling, the following error messages may appear in the service menu log. Message: 182 Cause:
SFS 1SA sensor does not switch.
Message: 183 Cause:
SFS 1 SW expected
SFS 2 SW expected
SFS 2 sensor does not switch.
Other error causes With all other errors the steer module SDM interrupts the power supply to the brake (truck brakes) and travelling is disabled. An error message is displayed which will depend on the cause. See Electrics chapter, error messages.
ESR4500 06/2004 • Printed in Germany
STEERING Examples of steer faults Here are 2 examples to provide a better understanding of the causes of steer faults.
Example 1: Manual wheel change, drive wheel turned 160° to the right The steer module has stored an 80° angle as the position of the drive wheel when the truck was parked. The drive wheel is therefore in the 1st quadrant:
What is the result? The next time the truck starts up, the steer module compares the stored position (80°) with the current position (-80°) and detects an incorrect quadrant (2nd quadrant). The error routine starts. Ending the error routine The error routine can only be ended if SFS 1SA has been switched once. You have the choice of 2 directions for steering and normally you do not know the actual position of the drive wheel. Let’s assume you want to steer right first of all. What happens?
SFS 1SA
20° later, the drive wheel reaches the mechanical stop at 100° (see Fig.MS-2140-040). The error routine does not end as you have not reached the switch area of the proximity switch SFS 1 SA.
0°
I
II
SFS 1SA SFS 2 - 90°
90°
0°
MS-2140-038
I
II SFS 2
Let’s suppose you now change the drive wheel. You manually turn the drive wheel 160° to the right in order to access the wheel bolts.
90°
- 90°
MS-2140-040 SFS 1SA
In this situation you can therefore only end the error routine by steering to the left in order to reach the switch area of the proximity switch SFS 1SA.
0°
What happens if you steer left? I
II SFS 2
90°
- 90°
You reach the switch area of proximity switch SFS 1SA. The proximity switch is applied. This switch signal resets the stored and calculated values in the drive module to 0°. If you now release the accelerator pedal, the error routine ends and the truck returns to normal travel mode.
MS-2140-039
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STEERING Example 2: Manual wheel change, drive wheel turned 70° to the right The steer module has stored an 80° angle as the position of the drive wheel when the truck was parked. The drive wheel is therefore in the 1st quadrant.
What happens if you steer left? Starting from the 80° position as the stored value, after a further 10° you reach the software stop at 90°. The steering stops. The steering angle display shows a steer angle of 90°.
SFS 1SA
SFS 1SA 0°
0°
I
II SFS 2
I
- 90°
90°
II SFS 2 - 90°
90°
MS-2140-043
MS-2140-041
Let’s suppose you now change the drive wheel. You manually turn the drive wheel 70° to the right.
However, the steer angle on the drive wheel is actually only 20° with respect to 0° for normal forward travel. The error routine does not start, as the drive wheel is still within the 1st quadrant.
INFORMATION When the truck is started, provided the last stored value and the current calculated value for the drive wheel position are in the same quadrant, the error routine will not start.
SFS 1SA
0°
I
II SFS 2
90°
You will only recognise this error by the fact that the steering wheel display does not match the actual steer angle on the drive wheel. In addition, you will not reach the full steering range of 90° to -90°.
- 90°
What happens if you steer right?
MS-2140-042
What is the result? The next time the truck starts up the steer module compares the stored position (80°) with the current position (10°). As the drive wheel is still in the 1st quadrant, the error routine does not start. Steering remains in normal mode.
MS-6.0-2140
200
Starting from 80° as the stored value, after a further 10° you reach the switch area of the proximity switch SFS 1SA. The proximity switch applies. This switch signal resets the stored and calculated values in the drive module to 0°. The steering angle display now matches the actual position of the drive wheel. The full steering range of 90° to -90° is now available again.
ESR4500 06/2004 • Printed in Germany
STEERING There is no message displayed when the calculated and stored angles are reset, as the steer module is not undergoing the error routine. This happens in normal mode of the steer module every time the cam on the gear unit cover goes into the switch area of the proximity switch SFS 1SA.
SFS 1SA
0°
I
II SFS 2
90°
- 90°
MS-2140-044
To rectify this error, you just need to steer accordingly so that the cam on the gear unit cover goes into the switch area of proximity switch FFS 1 SA.
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STEERING Setting the SFS … proximity switches
●
Switch off the truck and prevent it from being switched on again (disconnect the battery).
●
Open the motor compartment cover.
●
Disconnect the seat switch connector and remove the seat together with the motor compartment cover.
●
Remove connectors PC-436 and PC-437 from the connector console.
●
Remove the 3 mounting screws (14) from the steer motor (13).
●
Pull the steer motor out from the top.
●
In a vice, tension the steer motor around the drive pinion (15) to prevent the motor shaft from twisting (use protective vice chops and only tighten the vice gently).
●
Remove the mounting screw (18) from the drive pinion and the washer (17).
●
Take the steer motor out of the vice and tighten it around the housing.
●
Using a suitable extractor pull out the drive pinion.
MS-2140-046
The proximity switches must be set to a length of 46 +/0.5 mm, measured from the bottom of the mount bracket to the top of the proximity switch.
Assembly CAUTION Risk of damage to the feather key and the drive pinion. Metal hammers will damage the feather key and the drive pinion. MS-2140-047
If the length exceeds 46.5mm, the proximity switch may be damaged by the cam passing by it. If the setting is less than 45.5mm, the proximity switch will either not identify the metal surface of the cam at all, or else switch intermittently and unreliably.
Only use a plastic hammer. Apply a thin layer of type M grease to the drive shaft, the pinion and the contact surface (front side) of the steer motor (see lubricant table Chapter 1). Assemble the steer motor in the reverse order of disassembly.
Replacing the steer motor Disassembly All item numbers refer to figure MP-2140-007.
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STEERING 4
3 2
22
21
20
20
19
19 5
23
23 15
8
13 24
14
1
7
9 25 16
17 18 12
26
6
11
10
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STEERING Steering wheel Disassembly There is an opening on the right hand side of the steering wheel panel. Turn the steering wheel until the hex. socket screw (5, Fig. MP-2140-064) can be reached through the opening. Undo the screw and pull off the steering wheel.
MS-2140-055
Assembly Put the steering wheel onto the shaft. Refit screw 5 and tighten it securely.
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STEERING
2 1
3
4
5
7
8
6
12 17 8 19 13 18 15 16 11 10
14
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MP-2140-064
9
MS-6.0-2140
205
STEERING Steering Sensor (ECR4) Disassembly ●
Remove the steering column cover (9, Fig. MP2140-064 on previous page).
●
Remove connector PC414.
●
Remove the screws (25) and take off the steering sensor (26).
●
Remove the retaining plate from the steering sensor. To do this, remove the screws (23) and nuts (27).
INFORMATION The steering sensor cannot be serviced. If faulty, replace with a new one.
Assembly ●
Attach the retaining plate to the new steer sensor.
●
Assemble the steering sensor back into the steering column in the reverse order of disassembly.
●
Calibrate the new steering sensor (see service menu in Chapter 4).
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STEERING
17
18 19
20
15 3 14
4 12
2
13 31 30 32
1
10
11
2
9
29 5 28
16 8 7
22
6
21 24 28
23 25
26
27
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MAST
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MAST Mast DANGER Risk of trapping and severing limbs! When carrying out work on the mast and the attachments: always block the mast stages and attachments to prevent them from accidentally moving. Make sure the wooden blocks and lifting gear used have sufficient capacity.
General Torque Requirements All screw connections on the mast must be torqued to the standard values. See Chapter 1 for these values.
Lifting Gear Minimum Capacity Note the minimum capacity for the lifting gear whenever carrying out work on the mast.
Lifting Gear Minimum Capacity Mast
Lift Height
Min. capacity for lifting gear *
2.0 to
4,140 mm to 4,592 mm
1,000 kg
2.0 to
5,490 mm to 7,200 mm
1,500 kg
2.0 to
8,120 mm to 11,435 mm
2,000 kg
1.4 / 1.6 to
4,440 mm to 6,090 mm
1,000 kg
1.4 / 1.6 to
6,690 mm to 9,900 mm
1,500 kg
1.4 / 1.6 to
10,230 mm
2,000 kg
* excluding load guard and forks Fork carriage Min. capacity for lifting gear used Al l
1 5 0 kg M01-GB
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MAST Mast Testing (Assembled) Clean the mast channels and test the tracking paths of the rollers in the mast channels. There should only be wear in the rear section of the I beam where the rollers slide. There should not be any grooving or cutting in the I beam caused by the mast rollers. If grooving or cutting is evident, it will normally take place at the side of the roller; 10 mm from the channel face. In this case the mast rollers will have to be adjusted. Remove a shim from underneath the affected mast roller. A recheck of the mast channel will be required. De-grease the running area of the roller in the mast channel and spray on a thin layer of paint. Extend and retract the mast, and then check the tracking path of the roller (the paint will show up the tracking path). If the contact pattern matches requirements, apply grease to the contact surfaces (see lubrication table, chapter 1). When the mast is raised and nearly fully extended, it should not tilt to the right or left but should be even and straight. All mast stages should be aligned. If a tilting condition exists, it is a sign that the shimming is too loose or unbalanced and will need to be adjusted. All hose guide pulleys should move freely, check hoses for chafing.
Flaking It is not uncommon for a new mast to appear as if it is flaking or peeling. This appearance indicates that the rollers are seating on the mast channel and this is considered normal. Eventually, this condition will disappear. The grease applied to the channel will retain these particles.
Mast Shock Absorbers For maintenance and repairs of shock absorbers see the “Fork Carriage” section.
Mast end stops The mast end stops are so-called “Polystop blocks”. They must be checked regularly for wear.
Fork Adjustment With the forks fully lowered and level, adjust so that the top of the fork tip is a maximum of 65 mm off the floor. The maximum fork height (raised) is to be within +/– 25 mm of the fork height specified on the truck data plate. MS-7.0-2140
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MAST Mast Removal and Assembly
DANGER Risk of trapping and severing limbs!
General
Falling assemblies can sever limbs and cause fatal injuries.
DANGER All assembly work on the mast is hazardous. Unsecured stage masts and attachments can sever limbs or even cause fatal injuries. Always block and secure the respective components properly prior to starting assembly.
Note the minimum capacity for the lifting gear required. Additionally secure raised mast stages with square wooden blocks to prevent them from accidentally lowering. ●
Place a flat tray underneath the mast area and collect any spilled hydraulic oil.
●
Now raise the 1st and 2nd mast stages (2, 3) until the main hydraulic line on the distributor and the mast mounting screws (27) are accessible.
High pressure hydraulic oil can cause serious injuries.
●
Whenever a high pressure fluid enters the skin it must be treated as an emergency, even if the skin initially shows no reaction.
Secure the work area: Place square wooden blocks in the tracks of the outer mast and lower the 1st and 2nd mast stages onto them.
●
Unscrew the main hydraulic line from the distributor block located at the bottom of the mast. Seal both ends with filler plugs.
●
Loosen the mast mounting screws (27) from the reach carriage. Do not yet remove the screws!
●
Remove the wooden blocks and lower the 1st and 2nd mast stages.
●
Remove the load sling from the 1st and 2nd mast stages and attach it to the highest cross members of the outer mast (1), of the 1st and 2nd mast stages. Take care not to damage the height encoder wiring in the process.
●
Tension the mast with the crane.
Pressurised hydraulic systems can cause serious injury when the system is opened.
Physical effects may take time to set in. Secure all connections before re-applying system pressure. Keep hands and body away from any ports as high pressure hydraulic oil can emerge. Use absorbent paper to trace leaks, never use your hands! It is necessary to remove the mast in order to replace the mast rollers, to remove the fork carriage and to transport the truck.
Disassembly All item numbers in brackets refer to diagram MP2140-055 on the following page. ●
Extend the mast fully.
●
Remove the forks or the attachment.
●
Remove the load backrest.
●
Attach a load sling around the top cross member of the 1st and 2nd mast stages (2,3).
●
Reduce the system hydraulic pressure: Open the filler neck lid on the hydraulic reservoir.
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MAST
2nd mast stage
1st mast stage
Outer mast 9 25
5
10
4
11 18
26
13
12
17
14 19
8 16
6 23 24 20
7
3 4
9
5
7 21
2 22
10 12 14
7 11 13
31
30 29
15
1
28
27
MP-2140-055
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MAST ●
Now remove the 8 mast mounting screws from the reach carriage and the screws (27) at the bottom of the mast.
A
MS-2140-010
MS-2140-001 ●
Remove the cover (A, Fig. MS-2140-001).
●
Remove the covers (6, 8 and for 2.0 tonne mast also 31) of the lift cylinders on the left and right hand sides of the outer mast.
●
Mark the hydraulic hose connections (Fig. MS2140-010) for the auxiliary function on the left channel of the 1st mast stage for later re-assembly.
●
There is a danger of mixing up the screws.
●
Disconnect the hydraulic hose connection for the auxiliary function. Apply filler plugs to all open ports.
●
Remove the connector and where necessary the wire attachments of all the electrical connections from the reach carriage to the mast. Pull out and upwards all the wires from the reach carriage to the mast. Temporarily attach the loose wires to the mast.
ESR4500 06/2004 • Printed in Germany
●
Secure the fork carriage with a load sling to prevent it from moving in the mast.
●
Raise the mast up out of the reach carriage.
●
Place the mast with its back (the side facing the driver) onto a suitable surface with sufficient capacity (pallets, steel benches).
Assembly Assembly is the reverse of disassembly. After assembling, check or adjust as follows: ●
Bleed the lift cylinders and free-lift cylinder
●
Test the hydraulic system
●
Check / adjust the chain tension
●
Check / calibrate the height encoder
●
Check / calibrate the load sensor
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MAST Dismantling and Assembling the Mast
●
Using a crowbar, push the 2nd mast stage down until the bottom mast rollers are accessible.
●
Remove the bottom mast rollers and shims of the 2nd mast stage. Place the rollers and shims in such a way that they can later be easily fitted back at the same place.
●
Attach 2 load slings (one for the lower and one for the upper section of the 2nd mast stage).
●
Guide the 2nd mast stage (without rollers!) out of the 1st mast stage, using a crane. Place the second mast stage on a suitable surface.
General When dismantling switches and lines (electrical, hydraulic), the mast attachments (base plates, clamps) must always be undone. This facilitates positioning for later re-assembly and normally saves having to adjust the switches. For lift chains it is preferably to loosen the chain bolt, not the chain anchor. Here too you can avoid most of any subsequent adjustment work.
Dismantling
1st Mast Stage Removal ●
Remove the guide pulleys for the hoses and chains at the top left and right of the 1st mast stage.
●
Remove the covers (2, 6) and the brackets (4, 7) from the outer mast (see Fig. MP-2140-086 on the following page).
●
Remove the screws (18 and 16, Fig. MP-2140055) and the locking screws (17) from the lift cylinders.
●
Using a crowbar, push the 1st mast stage up until the mast stage can be attached to the crane with 2 load slings. The ends of the lift cylinder piston rods should no longer be in the mast stage seats, and should be free.
●
Using the crane, pull the 1st mast stage out until the mast stops become visible through the circular hole at the bottom.
●
Undo the mounting screws (9, Fig. MP-2140-055) from the mast stops and remove the mast stops from the channel.
Fork Carriage Removal ●
Remove the mast (see previous section) and place it down horizontally.
●
Remove the free lift switch (FLS), otherwise it will be damaged when the fork carriage is extended.
●
Remove the shock absorbers and the free lift chain.
●
Undo and remove all the hydraulic lines and if applicable the electrical connections to the fork carriage.
●
Attach a load sling around the fork carriage.
●
Using the crane, move the fork carriage “down” from the 2nd mast stage.
2nd Mast Stage Removal ●
Remove all mast cables, hydraulic hoses and lines and if applicable the height encoder and the camera system including all wiring and ropes, up to the outer mast. The wires and hoses should not run into the inner area of the mast stages. This would damage them when the mast is dismantled further.
●
Remove the free lift chain and the pulley from the free lift cylinder. Store the chain so that it is protected from contamination.
●
Remove the lift chains. Store the chains so that they are protected from contamination. Mark the position of the chains (left / right) in order to be able to re-fit them in their original sides.
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MAST
19
21 20 11
9
3 8
10
22
12 13
15
14
16
7 3 18
17
5
6
4
2
1
MP-2140-086
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MAST ●
●
Using a crowbar push the 1st mast stage in the outer mast down until you can remove the top and bottom mast rollers. Now using the crane pull the 1st mast stage completely out of the outer mast. Place the mast stage on a suitable surface.
Mast Roller Assembly Calculating the Roller Diameter You have a choice of 3 roller diameters: Code B, 101,47 mm, Part No. 807334-002
Replacing the Mast Rollers
Code C, 102,14 mm, Part No. 807334-003
General
Code D, 102,45 mm, Part No. 807334-004
You will need the special tool (P/N 810705) to calculate the required roller diameter. The mast roller bearing journals are slightly angled. Calculating the diameter by manually pulling the roller through the channel will produce an incorrect result.
●
INFORMATION Rollers do not run in 500 mm areas (see Fig. MS-2140-012)! Only apply the tool outside these areas in order to calculate the required roller diameter. For fork carriages with 6 rollers, always select the mean roller diameter to be one grade lower than calculated. This will avoid jamming when the rollers enter the mast channel. ●
MS-2140-011
The mast rollers are replaced in 2 main stages: ●
●
Calculating the required roller diameter to prevent jamming or excessive play above the running area of the roller in the mast channel. Calculating the number of shims required to prevent lateral jamming or tipping between the left and right-hand mast channels.
Remove the mast and dismantle it as described in the previous sections. Clean the mast channels and remove all mast rollers and the shims.
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Always start with roller Code D. Fit the roller onto the tool (Fig. MS-2140-011).
Using the tool, pull the roller through the corresponding mast channel (see Fig. MS-2140-012). The roller should not jam at any point, nor should it even become stiff. In this case repeat the process with the next smallest roller until the roller easily rolls along the full running area of the mast channel. Put the roller down so that it can easily be identified at a later stage. Repeat these steps for all the mast rollers and the fork carriage rollers in their respective mast channels.
Calculating the Required Number of Shims There are shim sizes available: 1.6 mm thickness
Part No. 060030-057
0.7 mm thickness
Part no. 060030-85
0.4 mm thickness
Part no. 795534
Outer Mast / 1st Mast Stage ●
Fit both rollers (without shims) at the top of the outer mast.
●
Position the 1st mast stage in the outer mast.
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MAST
Lower mast rollers of 1st mast stage and corresponding running area
500 mm
500 mm
500 mm
500 mm
2nd mast stage
500 mm
500 mm
500 mm
500 mm
1st mast stage
Outer mast
MS-2140-012
Upper mast rollers of outer mast and corresponding running area Upper mast rollers of 1st mast stage and corresponding running area Lower mast rollers of 2nd mast stage and corresponding running area Running area of all mast rollers of the fork carriage
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MAST ●
Using a crowbar push the 1st mast stage in the outer mast down until you can fit the top and bottom rollers (without shims) of the 1st mast stage. Fit the rollers and push the 1st mast stage back into the outer mast (same position as for retracted mast).
●
Prepare a pile of shims, each consisting of a 1.4 mm, 0.7 mm and 0.4 mm shim.
●
In the area of the upper mast rollers, press the 1st mast stage with a crowbar until the opposite mast rollers come into contact with the channel of the outer mast.
●
Take the prepared stack of shims. Try to push the pile into the gap between the outside of the roller and the mast channel. It should be possible to push the shims without them becoming stiff or jamming.
●
If required, increase or decrease the number of shims. Try to use as few shims as possible. Therefore try first with a thick shim before using thinner ones. Often you can use a thick shim instead of several thin ones.
●
When you have calculated the required number of shims, distribute them evenly on either side.
●
Now calculate the number of shims required for the bottom mast rollers. Distribute these evenly on either side as well.
●
Remove the 1st mast stage from the outer mast.
the outer mast. Try to push one of the thinnest shims into the gap between the outside of the roller and the mast channel. It should not be possible to push the shim in, but there should be a small amount of clearance. ●
Push the 1st mast stage back fully into the outer mast.
●
Re-fit both lift cylinders.
●
Re-fit the guide pulleys for the lift chains and hoses. Assemble the hoses and the rollers. It will not be possible to assemble the hoses at a later stage for reasons of space.
1st Mast Stage / 2nd Mast Stage ●
Lift the second mast stage into the first stage.
●
Using a crowbar push the 2nd mast stage down in the first mast stage until you can fit the top and bottom rollers (without shims). Fit the rollers and push the 2nd mast stage back into the 1st mast stage (same position as for retracted mast).
●
Prepare a pile of shims, each consisting of a 1.4 mm, 0.7 mm and 0.4 mm shim.
●
In the area of the upper mast rollers of the 1st stage, press the 2nd mast stage with a crowbar until the opposite mast rollers rest in the channel of the 1st mast stage.
●
Take the prepared stack of shims. Try to push the pile into the gap between the outside of the roller and the mast channel. It should be possible to push the shims without them becoming stiff or jamming.
●
If required, increase or decrease the number of shims. Try to use as few shims as possible. Therefore try first with a thick shim before using thinner ones. Often you can use a thick shim instead of several thin ones.
INFORMATION In the next stage do not distribute the shims crosswise, see Figs. M0381 and Abb. M0382. ●
Place the previously calculated shims under their corresponding mast rollers.
●
Push the 1st mast stage back into the outer mast.
●
Pull the 1st mast stage with the crane as far up as possible into the outer mast until you can re-fit the mast stoppers.
●
Fit the mast stoppers.
●
With the 1st mast stage at the stop, check again the clearance of the mast rollers.
●
Using a crowbar press against the upper mast rollers of the 1st mast stage until the opposite mast rollers come into contact with the channel of
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MAST
The numbers in brackets indicate the number of shims placed underneath.
(1)
(2)
(1)
(1)
(2)
(2)
(2)
(1)
(2)
(1)
M0381
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(1)
(2)
M0382
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MAST ●
When you have calculated the required number of shims, distribute them evenly on either side.
●
Now calculate the number of shims required for the bottom mast rollers. Distribute these evenly on either side as well.
INFORMATION In the next stage do not distribute the shims crosswise, see Figs. M0381 and Abb. M0382. ●
Push the 2nd mast stage down so that you can remove the rollers and insert the shims.
●
Push the 2nd mast stage back into the neutral position.
●
With the exception of the free lift switch, re-fit all the previously disassembled components which are not directly connected to the fork carriage.
thinner ones. Often you can use a thick shim instead of several thin ones. ●
For fork carriages with 6 rollers, push the fork carriage further up until the middle roller are at the end of the mast channel.
●
Prepare a pile of shims, each consisting of a 1.4 mm, 0.7 mm and 0.4 mm shim.
●
Using a crowbar press against the middle mast rollers of the fork carriage until the opposite mast rollers come into contact with the channel.
●
Take the prepared stack of shims. Try to push the pile into the gap between the outside of the roller and the mast channel. It should be possible to push the shims without them becoming stiff or jamming.
●
If required, increase or decrease the number of shims. Try to use as few shims as possible. Therefore try first with a thick shim before using thinner ones. Often you can use a thick shim instead of several thin ones.
●
When you have calculated the required number of shims, distribute them evenly on either side.
●
Pull the fork carriage back out of the 2nd mast stage.
●
The lower rollers on the fork carriage are not accessible in the highest mast position. To calculate the number of shims required, proceed as follows: Initially, use the same number of shims on the lower fork carriage rollers as for the upper (for 4 rollers) or middle (for 6 rollers) rollers.
Fork Carriage
INFORMATION Fork carriages for 2000 kg lift masts have 6 rollers. Fork carriages for lesser capacities have 4 rollers. ●
Fit all rollers (without shims) to the fork carriage. For fork carriages with 6 rollers, always select the mean roller diameter to be one grade lower than calculated. This will avoid jamming when the rollers enter the mast channel.
●
Guide the fork carriage into the 2nd mast stage from below.
●
Push the fork carriage right up until the top rollers are at the end of the mast channel.
●
Prepare a pile of shims, each consisting of a 1.4 mm, 0.7 mm and 0.4 mm shim.
●
Using a crowbar press against the upper mast rollers of the fork carriage until the opposite mast rollers come into contact with the channel.
●
●
Take the prepared stack of shims. Try to push the pile into the gap between the outside of the roller and the mast channel. It should be possible to push the shims without them becoming stiff or jamming. If required, increase or decrease the number of shims. Try to use as few shims as possible. Therefore try first with a thick shim before using
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INFORMATION In the next stage do not distribute the shims crosswise, see Figs. M0381 and M0382. ●
Fit the shims under the fork carriage rollers.
●
Raise the fork carriage back into the 2nd mast stage.
●
Manually push the fork carriage back up as far as the stop. The fork carriage should not jam.
●
Now check the clearance of the lower fork carriage rollers in the 2nd mast stage: Using a crowbar press against the lower mast rollers of the fork carriage until the opposite mast rollers come into contact with the channel. The ESR4500 06/2004 • Printed in Germany
MAST clearance should not be greater than that of the middle or upper rollers. To compare, you can move the fork carriage and check the top and bottom clearance alternately. If the clearance is greater on the bottom rollers, pull the fork carriage out of the 2nd mast stage until the bottom rollers are accessible. Insert a thin shim (0.4 mm) underneath. Manually push the fork carriage back up as far as the stops. Check the clearance again. If necessary, place another thin shim underneath. Important: It should be possible to push the fork carriage manually to the top end without jamming.
Final Work and Settings ●
Re-fit all components that have been removed.
●
Re-fit the mast in the reach mechanism.
●
Bleed the hydraulic system.
●
Check the mast stoppers. When the mast is fully extended it should not tilt to the side. The left and right stops on the mast stages should strike the stoppers at the same time. If necessary, fit shims. Note the position in which the plastic block is installed. The plastic must face the mast stop (see spare parts manual for details).
●
If the height encoder and load monitor are present, they must be re-calibrated (see Chapter 4).
●
Adjust the lift cylinders so that there is no clearance.
●
Check the fork height setting and the lift chain tension.
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MAST Free lift cylinder removal / installation with mast attached
Disassembly DANGER
DANGER
Pressurised hydraulic systems can cause serious injury when the system is opened.
Risk of trapping and severing limbs! When carrying out work on the mast and the attachments: always block the mast stages and attachments to prevent them from accidentally moving. Make sure the wooden blocks and lifting gear used have sufficient capacity.
High pressure hydraulic oil can cause serious injuries.
General
Whenever a high pressure fluid enters the skin it must be treated as an emergency, even if the skin initially shows no reaction.
Torque Requirements
Physical effects may take time to set in. Secure all connections before re-applying system pressure. Keep hands and body away from any ports as high pressure hydraulic oil can emerge.
All screw connections on the mast must be torqued to the standard values. See Chapter 1 for these values.
Lifting Gear Minimum Capacity
Use absorbent paper to trace leaks, never use your hands!
DANGER Risk of trapping and severing limbs! Falling assemblies can sever limbs and cause fatal injuries. Note the minimum capacity for the lifting gear required. Additionally secure raised mast stages with square wooden blocks to prevent them from accidentally lowering. Refer to the start of this chapter for the minimum capacity required for the lifting gear used.
●
Raise the fork carriage until the shock absorbers and the FLS switch are accessible.
●
Secure the fork carriage: Attach a load sling around the fork carriage and hold it with the crane.
●
Remove the shock absorbers and the free lift switch (FLS), otherwise it will be damaged when the fork carriage is extended.
●
Place a flat tray underneath the mast area and collect any spilled hydraulic oil.
●
Remove the protective cover for the hoses / cables and the free lift chain from the top of the free lift cylinder.
●
Depressurise the lift circuit (activate lowering for at least 5 seconds)
●
Undo and remove all the hydraulic lines and electrical connections to the fork carriage. Seal open hydraulic ports with filler plugs.
●
Remove the free lift chain mounting studs.
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MAST ●
Undo the bottom stud at the base of the free lift cylinder.
●
Using the crane lower the fork carriage down onto a pallet positioned underneath it.
●
Place a load sling around the highest cross member of the second mast stage.
●
With the crane slowly raise the 2nd mast stage until the fork carriage rests freely on the pallet.
●
Using a forklift, remove the fork carriage from the work area.
●
Place the second mast stage onto wooden blocks placed underneath it.
●
Remove the pressure line below the free lift cylinder. Fully remove the two steel hydraulic lines attached to the free lift cylinder. Seal the ports with filler plugs.
●
Place a load sling below the middle attachment plate around the free lift cylinder. Gently tension the load sling with the crane. This will prevent the cylinder from falling out when you undo the final two mounting studs.
●
Undo the two mounting studs (24) from the free lift cylinder.
●
Using the crane, lift the cylinder out and put down on one side.
Assembly Assembly is the reverse of disassembly. Before bleeding, replenish with hydraulic oil up to the max. marking. After assembling, bleed the hydraulic system and check the operation of the FLS free lift switch.
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MAST 2nd mast stage
1st mast stage
Outer mast 9 25
5
10
4
11 18
26
13
12
17
14 19
8 16
6 23 24 20
7
3 4
9
5
7 21
2 22
10 12 14
7 11 13
31
30 29
15
1
28
27
MP-2140-055
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MAST
2nd mast stage
1st mast stage
Outer mast 9 25
5
10
4
11 18
26
13
12
17
14 19
8 16
6 23 24 20
7
3 4
9
5
7 21
2 22
10 12 14
7 11 13
31
30 29
15
1
28
27
MP-2140-055
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MAST Lift cylinder removal / assembly DANGER
Disassembly DANGER Pressurised hydraulic systems can cause serious injury when the system is opened.
Risk of trapping and severing limbs! When carrying out work on the mast and the attachments: always block the mast stages and attachments to prevent them from accidentally moving.
High pressure hydraulic oil can cause serious injuries. Whenever a high pressure fluid enters the skin it must be treated as an emergency, even if the skin initially shows no reaction.
Make sure the wooden blocks and lifting gear used have sufficient capacity.
General
Physical effects may take time to set in.
You only need to remove the cylinders when carrying out repairs.
Secure all connections before re-applying system pressure. Keep hands and body away from any ports as high pressure hydraulic oil can emerge.
Lifting Gear Minimum Capacity DANGER
Use absorbent paper to trace leaks, never use your hands!
Risk of trapping and severing limbs! Falling assemblies can sever limbs and cause fatal injuries. Note the minimum capacity for the lifting gear required. Additionally secure raised mast stages with square wooden blocks to prevent them from accidentally lowering. Refer to the start of this chapter for the minimum capacity required for the lifting gear used.
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●
Fully lower the fork carriage.
●
Place a flat tray underneath the work area and collect any spilled hydraulic oil.
●
Remove the cylinder panels (6,8, 31 Fig. MP2140-055) and the top panels (2, 6 Fig. MP-2140086 on following page) with the brackets (4,7).
●
Raise the fork carriage. Now lower the fork carriage onto approx. 20 cm long hard wooden blocks placed in the channels of the outer mast. Now lower the fork carriage further onto approx. 35-40 cm long hard wooden blocks placed in the channels of the 1st mast stage. This will prevent the mast from accidentally lowering.
●
Now lower the fork carriage completely, the lift chains are now discharged.
●
Remove the cylinder attachments (16, 17 and 18, Fig. MP-2140-055). Remove the chain bolts from the top of the cylinder tube connection. Secure the lift chains with wire to prevent them from falling down.
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MAST
19
21 20 11
9
3 8
10
22
12 13
15
14
16
7 3 18
17
5
6
4
2
1
MP-2140-086
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MAST ●
Now depressurise the lift circuit (open the emergency lowering valve on the valve block)
●
Manually pull the piston rod down out of the top seat. Do not use any tools. Tools will damage the piston rod.
●
Press the piston rod into the lift cylinder as far as the stop.
●
Place a load sling below the tappets of the cylinder tube and gently tension the cylinder with the crane.
●
Undo the hydraulic connection to the lift cylinder (seal open hydraulic ports with filler plugs).
●
Raise the lift cylinder out of the mast.
Assembly Assembly is the reverse of disassembly. Note also:
DANGER Risk of trapping and severing limbs! You can injure your hands when inserting the piston rod into the top seat on the mast. Never guide the piston rod with your hands, always hold the cylinder by the cylinder tube. ●
To insert the piston rod in the top seat you will need an assistant to activate lifting (ideally a forklift driver with some experience in using this truck). Guide the piston rod into the seat (only hold the cylinder by the cylinder tube), while the assistant slowly and carefully activates lifting.
Adjust the screw (17 , Fig. MP-2140-055) until there is no longer a gap in the bottom cylinder seat. Torque the screw counternuts to 70 -80 Nm. Before bleeding, replenish with hydraulic oil up to the max. marking. After assembly, bleed the hydraulic system.
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231
MAST Inspection
Lift Chains General Lift chains are a major component of a fork lift truck. The chain system on this mast is designed to transmit the lift force from the hydraulic cylinder to the fork reliably and efficiently. Safe, uninterrupted truck operation depends on careful servicing and maintenance of the lift chains. Most complaints about the chain performance are due to lack of maintenance. Highly stressed precision chains require regular maintenance to ensure a long useful life.
The chain must be inspected every 100 hours for any signs of faults or damage. If used in a corrosive or dusty environment, this interval must be reduced to 50 hours. If this cannot be performed on the truck, the lift chains must be removed. Irrespective of the result of the inspection, the lift chains, detachable chain anchors and anchor bolts must be replaced after max. 6000 service hours or three years, whichever comes first. The inspection should include the following: ●
Chain wear and elongation.
●
Pitting due to rust or corrosion, in particular on the outer surfaces of the connection plates.
●
Pins turning in or extruding from the outside plates.
●
Loss of freedom of movement.
●
Damage to the anchor bolt attachment
●
Wear and corrosion to the anchor bolt and anchor.
●
Wear between the bolts and the connection plates.
The following sections cover the above items in detail.
Cleaning WARNING Never use chemical solvents or steam to clean the chains. The lubricant applied at the factory will be removed from the inner plate surfaces. The chain surface should be cleaned with paraffin, a hard bristle brush and lint-free cloth. After inspection apply another film of chain spray. The oil acts both as a lubricant and as an anti-corrosive protection.
Wear The chain bends as it passes over the chain rollers. This leads to a gradual wearing of the joints. Any slack a chain undergoes during its lifetime is due to wear to the links and the chain plate eyelet.
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MAST DANGER
Freedom of Movement of Chain Links
When checking for chain wear be sure to measure a part of the chain which passes over the guide pulleys. Never repair chains by cutting out the worn section and replacing it with a new section. If a chain is worn, always replace both lift chains.
Each individual chain link must flex freely. Tight joints (Fig. 2775si) increase friction and the chain tension during lifting. Excessive chain tension in turn accelerates material wear.
Chain wear can be measured with a wear gauge (Crown No. 106440) or a steel tape measure (see Fig. 2271). Before testing the chain slack it is important to tension the lift chain if necessary. For non-detachable lift chains the weight of the fork carriage or mast is sufficient. If the lift chain is detached it must be kept taut during measurement. The chain slack test must cover at least ten links, over at least three different points in a section of the chain which always passes over a pulley during operation.
2775si
Possible causes of stiff joints are as follows: ●
Bent pins or plates
●
Rusty joints.
●
Peened plate edges.
Plate edge distortion is caused by: ●
Ruptured chain pinion.
●
Constant overloading of the chain.
●
Chain striking the mast components.
Immediately replace any chains with stiff joints.
Chain Tension
Centre Chain Dimensions (Dimension C in Fig. 2271). New:
10 links = 254 mm
Wear limit:
10 links = 262 mm
Outer Chain Dimensions New:
10 links = 190.5 mm
Wear limit:
10 links = 196 mm
When installed, both lift chains should have the same chain tension to ensure even distribution of the load over the two chains when lifting. When replacing the forks make sure that both forks lie evenly on the surface. If they are not even, compensate the chain length via the chain anchor so that both chains have the same chain tension. After adjusting, tighten the counternuts of the chain anchor again (for correct torques see Chapter 1, Torque table).
DANGER If just one of the faults mentioned in this chapter is detected, both chains together with their chain anchors or bolts must be immediately replaced. Never repair damaged chains! This can result in fatal accidents!
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MAST Chain Anchor and Pulleys
Protruding or Turned Chain Pins DANGER
2774si
Never attempt to repair the chain by driving pins back into the chain. This can result in accidents with severe or even fatal injuries if the chain tears. Fit new chains.
In the course of checking the chain system, the chain anchors, chain bolts and pulleys must be checked for wear. On the chain anchor watch out for wear and cracking of the individual fingers. If one of the above problems occurs replace the chain anchor. Detachable chain anchors and anchor bolts must be replaced after max. 6000 service hours or three years, whichever comes first. Pulleys with heavily worn flanges and contact surfaces must be replaced. Worn flanges are due to misalignment. The chain tension and mast roller setting must be checked.
Worn Connection Plates Generally speaking, material wear is the cause of worn or missing connection plates. The plates near the chain pin hole (Fig. 2774si) can crack after a large number of lifting cycles with heavy loads. Replace both chains immediately if cracking shows or plates are missing.
2776si
Considerable frictional forces between the connection plates and the pins occur when lifting heavy loads with an insufficient or non-existent film of oil. In extreme cases the frictional torque in the joints can be such that the pins turn and gradually work out of the chain (Fig. 2776si). This can result in chain failure. Turned pins can be rapidly identified if the flat ends are not all pointing in the same direction. Chains with twisted or protruding pins must be replaced immediately.
Corrosion
2773si
The chains used on fork lift trucks are highly stressed precision components. It is particularly important to maintain the original fatigue strength throughout its useful life. Corrosion considerably reduces the capacity of a lift chain. It results in cracking in the side plates. Lift chains must therefore be protected from corrosion. The layer of grease applied in the factory hot dip galvanizing process is an excellent protection and fully penetrates the joints.
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MAST Do not remove this layer! After commissioning the chain supplement the factory lubrication through a regular lubrication schedule. Rust film on lift chains can be removed and neutralised by cleaning with chain oil. Always replace heavily corroded and rusting chains. The risk of cracking as a result of rust is too great.
Chain Lateral Wear Wear traces along a stretch of the chain on the pin heads and the outer plates indicate misalignment. This can have one of two causes: uneven chain tension or misalignment between the pulleys and the chain anchors. Uneven Chain Tension When fitting or adjusting the chains make sure that they are evenly charged. If for example the fork heel height or the platform height are changed, the chain anchors must be loosened until both forks touch the ground. Both chains must have equal amounts of air or tension at this point. The lower chain anchor nuts must be tightened by the same number of turns. When the required height has been reached, fix the setting with the top (chain side) lock nut and its respective lock washer. Misalignment of Lift Components Misalignment of the chain pinion and the chain due to the wrong number of washers on the mast or a damaged mast or cylinder components can also contribute to wearing of the chain sides. To test whether this is the case, proceed as follows: Place the truck on a horizontal surface in the service station. Support the fork carriage and detach both ends of the lift chain from the chain anchor and visually inspect the alignment with the anchor slots.
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MAST Lift Chain Lubrication Lubrication is the most important factor in lift chain maintenance. It considerably affects the chain’s useful life. Highly stressed chains under constant use cannot last sufficiently long if they are not regularly lubricated within a planned maintenance schedule.
bolt (see Fig. 277si) and allow the oil to penetrate to the bearing surface on the chain bolt, even when the chain is dirty. In normal operating conditions the chains should be cleaned and immediately lubricated every 100 service hours. In extreme conditions this interval must be reduced accordingly.
As with all contact surfaces, the tensiled steel precision moving parts require a durable lubricant film between the contact surfaces to avoid excessive wear. Maintaining a lubricant film on all the chain surfaces provides the following benefits: ●
Restricts joint wear to a minimum (chain elongation)
●
Avoids corrosion
●
Reduces the risk of chain bolts turning
●
Restricts the danger of chain joints turning in to a minimum
●
Ensures an even movement of the chains and thus reduces noise levels
●
Reduces the chain tension due to less friction in the chain system
Oil film
Key factors when considering which lubricant to use are as follows: ●
High degree of penetration in the narrowest of gaps
●
Maximum tolerance of pressure and shearing forces before the lubricant film comes off.
●
Suitability to the operating temperature range, especially important for cold store trucks.
277si
You will find details of Crown approved chain oils in the Lubricant table in Chapter 1 of this manual. Lubrication intervals depend on the operating conditions and the environment. Trucks parked outdoors, in cold stores or which are subjected to extreme weather conditions must be lubricated more frequently. Dust will gather on oiled chains in dusty environments. However, even in these conditions, regular lubrication can considerably reduce wear. A paste mixture of oil and dirt will gather on the chain joints, but they will not wear as fast as they would if they were left to dry, leaving a metal to metal contact between the pins and plates. Note: A lift chain must never be allowed to dry. In dusty operating conditions the multi-plate chains can be more efficiently lubricated than roller chains. Multi-plate chains consist of several plates. Therefore they provide several paths for the lubricant to reach the chain MS-7-2140
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MAST Detaching Lift Chains Lift chains are supplied by the meter and must be cut to the required length.
Tools and Equipment Required ●
A secure working plate with a hole slightly larger than the head diameter of a chain bolt. The hole must be deeper than the chain bolt length.
●
A bearing ring (washer) with a hole slightly larger than the head diameter of a chain bolt. The bearing ring thickness must be slightly larger than the height of the head of a chain bolt.
●
A grinder.
●
A hole with a diameter slightly shorter than the chain bolt and a hammer. Or a press with a suitable mandrel.
Detachment WARNING Wear protective glasses.
●
Carefully grind the head of the chain bolt. The inner plate surface must not be damaged.
●
Place the bearing ring onto the hole in the working plate. The bearing ring prevents the inner plate surface from being damaged when you drive out the chain bolt.
●
Place the head of the chain bolt to be driven out into the bearing ring.
●
Make sure the chain bolt, the bearing ring and the hole are aligned in the working plate and drive the chain bolt out.
Grinder Connecting plate
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MAST Repairs
Fork Tines
DANGER
General The fork tines (Fig. M0344) must be checked by trained personnel at the specified maintenance intervals (see chapter 1) for cracks, damage and wear. If the forks are used to transport abrasive loads the inspection must be carried out at shorter intervals.
Terms
Never carry out repair welding to surface cracks, damaged or worn parts around the heel of the fork. Fork repairs must only be carried out by the manufacturer / qualified personnel. When repairing supporting members always carry out a load test and check for signs of cracking.
Checking the Fork Fork blade
DANGER Forks showing signs of cracking, distortion or wear beyond the stated tolerance levels must be de-commissioned. They endanger the life of the operator and other people.
Fork hanger
Fork shank
Crack Inspection Inspect all fork tine surfaces for signs of cracks.
Fork heel
M0344
Fatigue cracking tends to occur around the heel of the forks. Check this area with particular care. If necessary carry out a non-rupturing crack test (paint penetration process or Magnaflux).
Fork Identification The data plate is on the side of the fork back (Fig. 0345) and comprises the following data: ●
Capacity
●
Load centre of gravity
●
Manufacturing Data (Month / Year)
●
Company logo
●
Manufacturing site
Welding seams
Cracks M0346
M0347
For upper and lower fork hangers (Fig. M0347) including their fork back attachments check for cracks on the welding seam. If any cracking is discovered which could affect safety remove the relevant fork.
Fork identification
M0345
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MAST Verticality Test
Measuring the Fork Tip Width
Check verticality of fork tip (Fig. M0350). If the tolerance level has been exceeded, de-commission the fork. Fork stop Ruler
2 mm
M0355
250 mm M0350
If the fork tip width S is less than a + 6 mm (a = fork back width) do not use the fork (Fig. 0355).
Fork Tine Height Difference Check the height of the fork tines in relation to each other (Fig. M0354) if the fork is fixed to the fork carriage. If the difference is greater than 3 % of the fork blade length the fork tines must be correctly aligned. Example: If the length of the fork blade is 1150mm the maximum permissible deviation is approx. 35mm.
500 mm
L Ruler 3% from L max. 6 mm
1st fork
Fork Blade Warping Measure the angle deflection between the top of the fork blade and the front of the fork shank (Fig. M0353). If dimension x is outside the tolerance range, the fork must be aligned by a specialist and re-checked.
500 mm
2nd fork
M0354
However, this would prevent the fork from working. In practice, forks must be aligned if the deviation is max. 10 mm.
x - 17 mm x + 8.5 mm
x M0353
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MAST Stop Mechanism
Fork Blade Wear
Check the stop mechanism (Fig. M0356) on both fork tines. The mechanism should lock securely, otherwise the fork must be de-commissioned.
Stop mechanism
Check the fork blade for wear, the heel is particularly subject to wear. If the width is 90 % or less than the original value, the fork must be taken out of service. For the inspection, use the calliper with part no. 107330 (see Fig. 0357).
100%
90%
M0357
M0356
This calliper has 2 opposite tappets. The outer tappet is used to determine the original fork blade thickness at a section with no wear. This is the fork shank. This determines the 100% value. The inner tappets correspond to 90% of the value previously obtained. ●
Scan the thickness of the fork shank using the outer tappets (Point a = 100% in Fig. MS-2232-013). Fix the calliper.
●
Now use the inner tappets (90%) to scan the fork blade between the shank and the start of the curved area. If the calliper fits at any point over the fork blade, then the fork is worn. Take the fork out of service.
a = 100% Scanning area
90% wear limit MS-2232-013
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MAST Reach The reach carriage (see Fig. MS-2140-058) is equipped on each side with 2 rollers and 2 side rollers. The side rollers counter lateral forces and guide the reach carriage in a parallel manner into the outriggers. The side rollers in the left hand side are adjustable. This provides smooth operation with no slack along the entire reach path. A backing roller on each side counters any tilt forces and also stabilises the mast.
●
Turn back the adjusting screws on the right hand side rollers. The side rollers are adjusted after the reach carriage has been installed.
●
Undo the locknuts of the eccentric axles on both backing rollers. They should only be handtightened. Turn the eccentric axles of the backing rollers so that the backing rollers no longer contact the channel of outriggers when the reach carriage is assembled.
●
Push the pre-assembled reach carriage into the outriggers using a crane.
Side Roller Adjustment Rollers ●
Side rollers
Push the reach carriage forward (see Abb. MS2140-056), until the cover plate of the reach carriage (A) covers the back plate (B) of the chassis.
B
Backing roller A
MS-2140-058
Disassembly ●
Remove the mast (see “Mast Disassembly” in this chapter)
●
Make sure that all electric and hydraulic connections have been removed from the reach carriage.
●
Undo the connection between the reach cylinder and the reach carriage.
●
Secure the reach carriage with a crane and move the reach carriage out of the outriggers.
MS-2140-056 ●
Using a mounting iron, press the reach carriage against the channel in the left outrigger until both side rollers are resting against the web of the channel.
●
Record on both sides the gap between the U section of the outrigger and the side panel (see Fig. MS-2140-057 on following page) of the reach carriage around the side rollers.
Assembly ●
Replace any worn rails.
●
Replace any faulty side rollers, rollers and backing rollers on the reach carriage.
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MAST Backing Roller Adjustment
21.5 mm
21.5 mm
Left
Right
INFORMATION The mast must be attached in order to adjust the backing rollers. Without the mast, the additional tilt moment will be lacking, and the setting will be wrong. ●
Refit the mast (see “Mast Disassembly / Assembly” in this chapter)
●
Check the M20 - Umbraco nuts (22, Fig. MS2140-057 on the eccentric axle. They should only be hand-tightened.
MS-2140-057 ●
●
If the difference exceeds +/- 2 mm, compensate the left hand side rollers with additional 1 mm spacers. Note that the same number of spacers must be used on the front and rear rollers to avoid tilting the reach carriage. The aim is to obtain approximately the same gap on the left and right hand side rollers so that the reach carriage is centrally aligned in the chassis.
39 33
Using a mounting iron, press the complete reach carriage once more against the channel in the left outrigger until both side rollers are resting against the web of the channel.
22 17
●
●
●
Turn in both adjusting screws of the side rollers on the right-hand side of the reach carriage until the side rollers are contacting the channel of the outrigger. Secure the adjusting screws with the counternuts (70 +/- 5 Nm, without twisting them. Now test the setting: Manually move the reach carriage 10 times over the full reach path as far as the limit positions. It should be possible to move the reach carriage manually without it jamming. If necessary, correct the setting via the adjusting screws for the right hand side rollers. To calculate the side slack: Using a mounting iron, press the complete reach carriage once more against the channel in the left outrigger until both left hand side rollers touch the web of the channel. Measure the gap on the right hand side and record it. Using a mounting iron, press the complete reach carriage against the channel in the right outrigger until both right hand side rollers touch the web of the channel. Measure the gap again on the right hand side. The max. permissible deviation for these dimensions is 0.5 mm. If necessary, correct the setting via the adjusting screws for the right hand side rollers.
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23 24 25 11
27
15 26
MP-2140-049 ●
Turn the M24 nuts (23) on the eccentric axle (24) manually, until they rest on the reach carriage plate.
●
Turn the eccentric axle (24) of the backing roller (25) with a wrench key – set to 20 - 25 Nm – until the wrench key engages. This will ensure that the backing roller rests on the running strip in the outrigger with the correct pre-tension.
●
Hold up the eccentric axle (24) and torque the M24 nut (23) to 650 - 720 Nm. Do not twist the eccentric axle in the process.
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MAST Reach Cylinder The reach cylinder is installed at the bottom right of the truck. The piston rod is attached to the chassis. The cylinder base is attached to the reach carriage.
Disassembly ●
Extend the reach fully.
●
Lower the fork carriage onto the ground.
●
Depressurise the hydraulic system (see Chapter 2 or Chapter 7).
M1663
●
Switch off the truck and disconnect the battery.
●
Jack up and secure the truck (see Chapter 1).
●
Place a flat tray underneath the truck and collect any spilled hydraulic oil.
●
Remove the hydraulic hoses from the cylinder, seal all ports immediately with filler plugs.
●
●
Remove any attachments present for the cylinder cables and hoses.
●
Drive the bolts out with a plastic hammer and if necessary a soft material mandrel. Do not use steel tools.
●
Lift the cylinder out.
Assembly ●
Re-assemble the reach cylinder in the reverse order.
●
Bleed the hydraulic system (see Chapter 2)
Remove all retaining elements from the cylinder attachments.
MS-2140-059
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MAST Integrated Sideshifter Disassembly (See Figure M1500) ●
Lower the fork carriage onto a pallet.
●
Depressurise the hydraulic system (see Chapter 2 or Chapter 7).
●
Switch off the truck and disconnect the battery.
●
Place a flat tray underneath to collect any spilled hydraulic oil.
●
Remove the load backrest.
●
Unscrew the stopper (25) and remove the forks.
●
Undo all the hydraulic connections to the sideshifter (seal all ports with filler plugs).
●
Unscrew the lug (18).
●
Tilt the frame (20) up and slide it from the frame on the side. Make sure you do not push the slide pieces (12) out of their seats in the process.
●
Dismantle the cylinder if necessary.
Assembly ●
Clean all contact surfaces and lubricate them again.
●
Use new seals and deflector rings if have dismantled the cylinder.
●
Assemble all components in the reverse order of disassembly.
●
Bleed the sideshifter cylinder by moving it from the left to right ends approximately 20 times. The cylinder has an internal valve and is self-bleeding. Bleed the tilt cylinder as usual via the ports (see Chapter 2, note the safety instructions!)
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MAST
M1500
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CYLINDERS applies to the open ports and lines on the truck when you remove any hydraulic components.
Cylinders General
●
Do not refinish any cylinder surfaces! Replace any damaged components.
Safety when working on hydraulic systems
●
When carrying out repairs always replace all the seals in the assembly. Never recycle seals which have already been used.
WARNING Risk of serious injury from pressurized hydraulic oil. Pressurized hydraulic oil can penetrate the skin. This is a serious medical emergency which requires immediate medical attention. The skin will not show any obvious initial damage and the physical effects will not be manifested immediately. Seek medical assistance if your skin has been affected by pressurized hydraulic oil. For your personal protection: Depressurise the hydraulic system before starting assembly work on the hydraulic system. After carrying out assembly work carefully check to see that all ports are tightened before re-pressurising the system. Wear protective clothing, safety glasses and safety gloves when tracing leaks or bleeding the system. Use a piece of absorbent paper to trace leaks, never use your hands. Follow the hydraulic oil manufacturer’s safety instructions when handling these oils.
General Instructions for Repairing Hydraulic Components Hydraulic systems are sensitive to dirt. ●
Thoroughly clean any hydraulic components you have removed before dismantling them and placing them on a workbench.
●
Always repair hydraulic components in a clean working environment.
●
Immediately protect cleaned and de-greased components with a thin coating of hydraulic oil. Use the same type as is used in the truck.
●
Protect all components from re-contaminating until they are installed again.
●
Immediately seal any open hydraulic ports on repaired assemblies with filler plugs. This also
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CYLINDERS Large Rod Seal Assembly
Rod Seal Assembly
Tools required:
General All tools and equipment used for rod seals must be burr-free and not have sharp edges. The tools should be made either of soft metal (aluminium, brass) or a suitable plastic. Do not use hooks to remove seals. The same rule applies: Burr-free, rounded tips and made of soft metal to avoid damaging the seal seat. Screwdrivers or similar tools will damage the seal seats and the seals. This will result in leaks.
●
Tool body (outer diameter must fit the internal diameter of the gland).
●
Three pins (1, 2 and 3). Pin (1) is fixed; pins (2) and (3) are moveable.
Assembly: ●
Apply a thin coating of hydraulic oil to the rod seal and the seal seat in the gland.
●
Place the rod seal over the fixed pin (1).
●
Bend the rod seal under pin (2) (see Fig. MS2232-019).
1 3 2 MS-2232-013
To remove rod seals from the lift cylinder and the freelift cylinder, you will require 2 specially produced tools (see Figure MS-2232-016). If the seal has to be pushed over sharp edges, cracks or nicks, use appropriate protective mechanisms.
Screwdriver, shaft min . 150 mm long, max. 4mm Ø
MS-2232-019
●
Bend the loop created in this way so far up that pin (3) can be pushed into the loop.
●
Now push the tool body into the gland until the rod seal is aligned with the seal seat (see Fig. MS-2232-020).
4mm self-tapping screw 3
Insulating tape Hard-soldered screw, soldering joint sanded.
1
MS-2232-016
We will now demonstrate 2 processes – depending on the seal rod diameter – for ensuring safe assembly.
2
MS-2232-020
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CYLINDERS ●
Pull back pin (3). A section of the rod seal jumps into the seal seat (Fig. MS-2232-022).
Small Seal Rod Assembly Tools required: Groove aligning arbor. The outer diameter must fit the internal diameter of the gland. The arbor should end at the bottom of the seal seat.
3
Arbor to drive in the seal.
2
●
Apply a thin coating of hydraulic oil to the rod seal and the seal seat in the gland.
●
Place the gland onto the groove aligning arbor.
●
Gently squeeze the rod seal together.
●
Place the rod seal at one point of the seal seat.
MS-2232-022
●
Now pull back pin (2). The rod seal is now fully seated in the seal seat.
MS-2232-024 MS-2232-021
●
Pull the tool body out of the gland.
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●
Press the rod seal and the arbor into the seal seat.
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CYLINDERS Rod Seal Assembly, Sealing Lip First The sealing lip is sensitive and must not be damaged. You therefore require special protective sleeves when pushing the seal over the thread and holes. Sealing lip assembly direction: Always to the pressure side!
Protective sleeve Seal Tool
Bearing ring
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MS-2232-025
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CYLINDERS 120 - 140 Nm 0
0
5 - 6 Nm 4
10
9 11
8
12
7
6
5
1
3
2
MP-2140-052
MS-2140-066
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CYLINDERS Lift cylinder
Piston Rod Removal ●
To replace the guide ring (2), first remove the piston rod. Pull the piston rod from off the cylinder tube.
●
Remove the guide ring (2). Take the half shelves (3) off the piston rod.
General Make sure the components and the working area are clean. Thoroughly clean the cylinder before dismantling it. Hydraulic systems are sensitive to contamination. When carrying out repairs, always replace all the seals and bearing rings. Apply a thin layer of hydraulic oil to all the seals and internal metal surfaces prior to assembly. Use hydraulic oil according to the temperature range of the area of application (see Lubricant table in Chapter 1).
Assembly CAUTION Possible damage! Incorrect handling during assembly can result in leaks. Take care not to damage the piston rod and the new seals during assembly. Use guide bushing and burr-free tools without sharp edges.
Removal and Assembly Inspect the piston rod for damage over the full lift height before removing it. Damaged piston rods damage the seals very rapidly. Replace the damaged piston rod whenever you fit new seals. ●
Refer to the Mast chapter for the removal and assembly of the lift cylinders.
Dismantling
Apply a thin coating of hydraulic oil to all seals and components prior to assembly. Observe the general instructions on assembling seal rods in this chapter.
Piston Rod Assembly ●
Insert the half shelves (3) into the groove of the piston rod.
Possible damage!
●
Pull up a new, lubricated bearing ring (2).
The cylinder tube can become damaged when you clamp the cylinder. Do not overtighten the devices for holding the cylinder.
●
Push the piston rod into the cylinder tube.
CAUTION
Installing the Rod Seal ●
Rod Seal Removal ●
Clamp the removed cylinder to prevent it from twisting.
●
Unscrew the cylinder cap (8) from the cylinder tube.
●
Remove the deflector ring (10), the rod seal (9), the bearing ring (7), the guide ring (5) and the O ring (6) from the cylinder cap.
●
Thoroughly clean all metallic components with a suitable light solvent. In particular, the seats of the seals and the bearing rings must be absolutely clean and free of foreign bodies. Apply weak, dry compressed air to the components until they are dry. Immediately protect shiny metal surfaces with a thin film of hydraulic oil (for the oil type refer to the lubricant table in Chapter 1).
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Insert a new deflector ring (10), a new rod seal (9), a new bearing ring (7), a new O ring (6) and a new guide ring (5) into the cylinder cap. Cover threads and sharp edges with suitable means to avoid damage during assembly.
Seal seat
MS-2232-018
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255
CYLINDERS ●
Screw the cylinder cap back on, while taking care not to damage the bearing ring (7).
●
Torque the cylinder cap to 120 – 140 Nm.
●
Refit the lift cylinder (see Mast chapter).
●
Bleed the cylinder (see Hydraulics chapter).
●
Perform a drift test (see Hydraulics chapter).
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CYLINDERS 0
120 - 140 Nm
0
5 - 6 Nm 14 8 13
16 15
12
11
10 7
9 6 1
5
4
3
2
MP-2140-053
MS-2140-067
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CYLINDERS Free-Lift Cylinder
Piston Rod Removal ●
To replace the guide ring (3), first remove the piston rod. Pull the piston rod from off the cylinder tube.
●
Remove the guide ring (3). Take the half shelves (4) off the piston rod.
General Make sure the components and the working area are clean. Thoroughly clean the cylinder before dismantling it. Hydraulic systems are sensitive to contamination. When carrying out repairs, always replace all the seals and bearing rings. Apply a thin layer of hydraulic oil to all the seals and internal metal surfaces prior to assembly. Use hydraulic oil according to the temperature range of the area of application (see Lubricant table in Chapter 1).
Removal and Assembly
Cushion Removal ●
Assembly CAUTION Possible damage!
Inspect the piston rod for damage over the full lift height before removing it. Damaged piston rods damage the seals very rapidly. Replace the damaged piston rod whenever you fit new seals. ●
Incorrect handling during assembly can result in leaks. Take care not to damage the piston rod and the new seals during assembly. Use guide bushing and burrfree tools without sharp edges.
Refer to the Mast chapter for the removal and assembly of the free-lift cylinder.
Dismantling
Remove the inner retaining ring (5). Remove the piston (6) and the spring (7) from the piston rod.
Apply a thin coating of hydraulic oil to all seals and components prior to assembly. Observe the general instructions on assembling seal rods in this chapter.
CAUTION Possible damage! The cylinder tube can become damaged when you clamp the cylinder. Do not overtighten the devices for holding the cylinder.
Rod Seal Removal
Cushion Installation ●
Push the spring (7) and the piston (6) into the piston rod.
●
Fix the spring and the piston with the inner retaining ring (5).
Piston Rod Assembly
●
Clamp the removed cylinder to prevent it from twisting.
●
Place new half shelves (4) on the piston rod and pull up a new guide ring (3).
●
Unscrew the cylinder cap (12) from the cylinder tube.
●
Push the piston rod into the cylinder tube.
●
Remove the deflector ring (14), the rod seal (13), the bearing ring (11), the guide ring (9) and the O ring (10) from the cylinder cap.
●
Thoroughly clean all metallic components with a suitable light solvent. In particular, the seats of the seals and the bearing rings must be absolutely clean and free of foreign bodies. Apply weak, dry compressed air to the components until they are dry. Immediately protect shiny metal surfaces with a thin film of hydraulic oil (for the oil type refer to the lubricant table in Chapter 1).
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Installing the Rod Seal ●
Insert a new deflector ring (14), a new rod seal (13), a new bearing ring (11), a new O ring (10) and a new guide ring (9) into the cylinder cap. Cover threads and sharp edges with suitable means to avoid damage during assembly.
●
Screw the cylinder cap back on, while taking care not to damage the bearing ring (3).
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CYLINDERS
Dichtungssitz
MS-2232-018
●
Torque the cylinder cap to 120 – 140 Nm.
●
Refit the free lift cylinder (see Mast chapter).
●
Bleed the cylinder (see Hydraulics chapter).
●
Perform a drift test (see Hydraulics chapter).
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CYLINDERS 180 - 200 Nm 20 0
19
18 3 17
2 1 17
0
120 - 140 Nm
3 4 5
21
7 6
8 9 10
22
11 12 13
21 14
17 15 16 17
18 19
MP-2140-047
20
MS-2140-068 MS-8.0-2140
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CYLINDERS Reach Cylinder
Piston Rod Removal ●
To replace the guide ring (4) and the rod seal (5), first remove the piston rod. Pull the piston rod from off the cylinder tube.
●
Remove the guide ring (4). Take the seal (5) off the piston rod.
General Make sure the components and the working area are clean. Thoroughly clean the cylinder before dismantling it. Hydraulic systems are sensitive to contamination. When carrying out repairs, always replace all the seals and bearing rings. Apply a thin layer of hydraulic oil to all the seals and internal metal surfaces prior to assembly. Use hydraulic oil according to the temperature range of the area of application (see Lubricant table in Chapter 1).
Assembly CAUTION Possible damage! Incorrect handling during assembly can result in leaks. Take care not to damage the piston rod and the new seals during assembly. Use guide bushing and burr-free tools without sharp edges.
Removal and Assembly Inspect the piston rod for damage over the full lift height before removing it. Damaged piston rods damage the seals very rapidly. Replace the damaged piston rod whenever you fit new seals. ●
Refer to the Mast chapter for the removal and assembly of the reach cylinder.
Dismantling
Apply a thin coating of hydraulic oil to all seals and components prior to assembly. Observe the general instructions on assembling seal rods in this chapter.
Piston Rod Assembly ●
Place a new seal (5) on the piston rod and pull up a new guide ring (4).
●
Push the piston rod into the cylinder tube.
CAUTION Possible damage! The cylinder tube can become damaged when you clamp the cylinder. Do not overtighten the devices for holding the cylinder.
Installing the Rod Seal ●
Insert a new deflector ring (13), a new rod seal (12), a new bearing ring (8), a new O ring (7) and a new guide ring (11) into the cylinder cap. Cover threads and sharp edges with suitable means to avoid damage during assembly.
●
Screw the cylinder cap back in with a new safety plate (9). Torque the cylinder cap to 120 – 140 Nm. Flange the safety plate, it must lie in the notch of the cylinder cap.
●
Push the spacer sleeve (22) and the O rings (21) onto the piston rod. Refit the ball joint (16) with the counternut (15) and washer (14). Do not yet counterfix the nut as the screw depth must still be adjusted on assembly.
Rod Seal Removal ●
●
Clamp the removed cylinder to prevent it from twisting. Unscrew the ball joint (16). Pull the spacer sleeve (22) and the O rings (21) off the piston rod (6). Flange up the safety plate (9) in order to unscrew the cylinder cap. Unscrew the cylinder cap (10) from the cylinder tube.
●
Remove the deflector ring (13), the rod seal (12), the bearing ring (8), the guide ring (11) and the O ring (7) from the cylinder cap.
●
Thoroughly clean all components with a suitable light solvent. In particular, the seats of the seals and the bearing rings must be absolutely clean and free of foreign bodies. Apply weak, dry compressed air to the components until they are dry. Immediately protect shiny metal surfaces with a thin film of hydraulic oil (for the oil type refer to the lubricant table in Chapter 1).
ESR4500 06/2004 • Printed in Germany
MS-8.0-2232
263
CYLINDERS ●
Refit the reach cylinder (see Mast chapter).
●
Bleed the cylinder (see Hydraulics chapter).
MS-8.0-2140
264
ESR4500 06/2004 • Printed in Germany
CYLINDERS
M1500
ESR4500 06/2004 • Printed in Germany
MS-8.0-2232
265
CYLINDERS Sideshift, Cylinder INFORMATION The sideshifter must be removed from the truck in order to repair the cylinder. For removal instructions see chapter 7.
Dismantling WARNING Risk of serious injuries from components flying off at high speed. If you remove the frame (20) and apply the sideshift to extend the piston rods, the piston rods will shoot out like a bullet! Depressurise the hydraulic system prior to dismantling the cylinder. Prevent the truck from being switched on again. Manually pull the piston rods off the cylinder tube, never force them out at pressure. ●
Pull the left and right hand piston rods (6) off the cylinder.
●
Push the washers (4) out of the guides.
●
Remove the deflector rings (5) and the rod seals (3).
●
Remove the slide bearings (2) and the coupling parts (27).
●
Thoroughly clean all components and the seal seats with a solvent.
●
Remove any burrs from the piston rod ends.
●
Replace any components showing signs of grooves or damage.
Assembly ●
Lubricate all components with hydraulic oil.
●
Note the installation position of the rod seals: Pressure seals are installed with the lip facing the pressure side!
●
Re-assemble the cylinder in the reverse order.
MS-8.0-2140
266
ESR4500 06/2004 • Printed in Germany
ELECTRICAL DIAGRAMS
Printed in Germany
267
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Printed in Germany
268
DIAGRAMS
Blank page
ESR4500 06/2004 • Printed in GermanyMANY
MS-DIA-2140
269
DIAGRAMS
Blank page
MS-DIA-2140
270
ESR4500 06/2004 • Printed in Germany
DIAGRAMS
Blank page
ESR4500 06/2004 • Printed in GermanyMANY
MS-DIA-2140
271
DIAGRAMS
Blank page
MS-DIA-2140
272
ESR4500 06/2004 • Printed in Germany
DIAGRAMS Wiring Diagram - AC System EDS
FU 7 = 425 A
A
ED1 200
FU 1 = 15 A
206 / 207
OPTIONS
207
FU5 FU6
+
2
4 48V I/P 1 12V OP 2 0V OP 3 0V I/P
2
K12
K13
2953
2954
K2
2955 2956 2957 2958
2959 2960 2996 2997
48 V BATT.
DC/DC
CA 440
15A
K5
K3
3
Z 316
622
CA 806 4
RES 2 L+
017
C
002
C
003 004
C
CA 604
8
13
CA 422 018
008
2911
009 A
C
023 2909
F
14 BV+
CA 604 2942 11 2949
3
Di 2 FS
4
Di 3 RS
5
Di 4 ACS
18 Di 7 RES 1
PLS
2940
+48 +5
CA 600
3
3
4
CHNL B 4
32
CHNL A 2
2
2
31
B- 1
1
1
15
020
39 Di 17 PLS
CA 418 Acc.- Pedal POT 1 3 606
1
106
CA 407 Lift/lower POT 2 3 601
9
5922
4
POUT_3 15 5905 10
5 5923
POUT_4 29 5906 16
9
POUT_5 13 5908 12
CA 408 Reach POT 3 3 602
CA 409 Tilt POT 4 3 603
1
2 103
CA 410 Sidesh. POT 5
2 104
CA 411 5th. funct. 3 POT 6 604
9
Di 13 Ch A
600
3 605
6
12 V OUT
34 Ain 6 7
GND_OUT
28 BV504
CA 429 307
1 2 3 4
16
CA 430
1
2945
PTC I_Mess
2947
CA 811
2
1
CAP
2948
CA 801 SVT
2
POUT_8 12 5910 5
5
5
SVS
6
POUT_9 26 5911 18
8
8
SV5
7
THS 2
U_Batt
2946
CA 811 PVAR
2
Control Card
CA 809
PVAL
2
1
1
CA 206
U
T
M2
I_Mess
Motor-Shunt
V
U_Mess U_Mess U_Mess
Motor-Shunt
W
3
GND 4 Ch . B 3 ChS1 .A 2 1
S+ 12 V
ECR 2 SPEEDSENSOR
22
Option CA 812
CA 426
006
A
C
7
CA 205 CAN_H
20 Ain 5 2 105
3
Hydraulic Ch. A 5 010 Ch. B 6 011 Drive Gnd 4 608 Module Temp GND 17 609 107 Temp
CA 810
PVRT
2
1
2918
33 310 6
C
10
9
9
313
900
CAN_L CAN_Gnd
8
500 / 505 / 506 508 / 509 / 510 / 511
FKS
B A
D
BRN
p
BLK ORG
RED L+
LS
I
UBto SDM, TDM & Display PC 416 625 319 900/901 905/906 614/615
614
G
FU6
2925
2960
CA 421 1 K7 CA 421 POUT_11 11
G
10
B-
C
CA 422 CA 601 CA 801
23 905
37 Ain 4
305 1
1
PVRE
CA 601 CA 801 5909
36 Ain 3
304
607
21/13 ID GND ID1 12
SVH
1
POUT_7 41
35 Ain 2
303
HDM
CA 201 S+ 12 V
2944
2
CA 808
5925
6
1
2 102
CA 807
2
5926
302 1
2943
CA 808
5924
7
POUT_6 27 5907 11
21 Ain 1 2 101
3
CA 809
120 Ohm 300
5904
38 Di 14 Ch B
503
301 2
1
AN_22 LS/FKS 13 113
UB306
HDM Pin 2
B+
24 POUT_15 ED1
CA 422
4
5918 5919
2
23/22 CA 201 FAN CAN_H 908/909 15/14 CAN_L 617/618 8/7 CAN_Gnd
2942 2938 11 2
CA 435
2
KYS
40 Di 15 ORS
+5V 3
1
POUT_2
BR-LIGHT OUT 021
2 CA 415 5916
1
903/904
CA 422 2921 14
CA 422 CA 604 CA 807 5921 PVL POUT_1 42 5903 8 1 3
AN_21 BLS 12
CA 803
5919
CA 434
CA 810
32 Di 11 BPS
digital input 024
17
501
UB-
2 x 24 V
CA 401
HNS
1
31 Di 10 BFS
CA 422
029 10
CA 402
2933 1
CA 205
25 Di 16 FLS/LCS
5901
3 5914 11
Charge-R1
FAN 4
5915
30 Di 9 HGT(R)S
CA 205 CA 604
2932 1 CA 415
CA 401
2
17 Di 6 KYS 5902
V1
HORN
V2
2929
48 V
33 Di 12 BRS 005 16 Di 5 SPS
CA 419
C1,2
2928
to TDM & Display
FAN 2
CA 604 4 CA 422 022 19 Di 8 RES 2 CA 428 001 2 1 2 Di 1 SES
2916
C5
FAN 3
2930
4 12
START UP CARD
2931
1
B
CA 422
ECR 5
CA 422 019
007
2910
Height Encoder
C
CA 417
2941
2915
1
2921 14
G
A
CA 406
GND
317 315
2913
2914
623
Z
CA 601 3 CA 404
A
3
L- 2
3
2907
2917
GND
2
A
028
A
6
2906
027
L- B
CA 604
F1
2
CA 601
L+
6 CA 422 310
5
V5
10
1
UB-
1
2926
2923
CA 604
CA 805 C
12
A
CA 600
COLDSTORE POWER SUPPLY OPTIONS
2939
K11
502
CA 600
C
LIGHTING BRAKE
RES 1
314
4
CA 802
Kn...
K1,2
4
R2
K11
2904
CA 420
G
CA 422
CA 601 14
FU 2 = 15 A
5928
9
K13
2924
2921
508 / 509 510 / 511
2902
927
2901
CA 801
F
5902
2927
B UB-
4
E
ED1
K12
to Display 2951 A CA 420
C
K6
-
CA 440
Relay-Options
KYS
K4
K1
202
VCM
15A
KEY
206
201 EDS (mechanical)
to TDM and SDM
203 / 204
5913
Travel alarm 3 K7,8
HORN 4
K8
CA 421 513
- BV
2
POUT_14 10 5920 2 K10 CA 433 Beacon LAMP
6 GND Display 5 + 12 V Display 4 1 CAN_H 2 CAN_L 3 CAN GND
K9
K9,10
1
2935
G 2959
3
FU5
4
CA 433
512
- BV
813134_2I_sh1 ESR4500 06/2004 • Printed in Germany
MS-DIA-2140
273
DIAGRAMS Wiring Diagram - AC System A
to "A"
CA 203
E C
202 318 319 507
204 / 205
UB-
906/907
D
19
BV+
14
12 V Out
16
12 V Out
20
GND
1/4 CAN_L
901/902
2/5 CAN_H
615/616
3/6 CAN_GND 18
µ proc. with ext. memory 256 k
DISPLAY 11 V GND CA 203 15
BV+ Key
17
2908
204
205
FU 3 = 15 A
FU 4 = 30 A
624
2903 6
CA 202 902/903
Integrated in START UP CARD
CA 402
2936
V3
BRAKE CA 402 CA 431 14
2950
CA 431 CA 402 CA 402
A
B
5927
13
5
5912
8
B+
B+
D
616/617
CA 439
025
C L+ L-
Z 311
Traction Drive Module
8/7 21/13
9
12
5
2905
S+ 12 V
3
308
Ch. A
5
012
Ch. B
6
013
Gnd
4
610
Temp GND Temp
17
611
16
108
DI 1 SFS 1 SA
A
120 Ohm
11
CAN_H
B
B
CA 425 1 2 3 4
CAN_GND 3 618 CAN_L 10 909
1
CA 427
2
Control Card
904
GND
SFS 2
4
PTC 026
3 L+ L-
CA 414
Ain 1+ 13 109
2 620
SDM
GND 505 506
1
B-
2
B-
Steering Drive Module
UB-
CA 412
1
3
Ain 2+ 15 111
4 6
14
Ain 2-
16
112
+5 V out
4
700
3
2
803
CA 437
4
3
1 802
2
CA 436
1
701
2
702
5
P2 P1 P3
I_Mess
Motor-Shunt
U_Mess U_Mess U_Mess
Motor-Shunt
ECR 4 CAP P4
P6
P5
U
T
V
M1
W
3
GND
4
Ch. B
3
Ch. A
2 1
S+ 12 V
ECR 1 SPEEDSENSOR
B-
2
3
4
2
3
4
UB-
5 6
014 015 016 309
4
1
110
Ain 1-
I_Mess
MOTOR STEPPER
CA 204
DI 2 SFS 2
6
1
CA 413
THS 1
U_Batt
CA 438
Z
1
613
619
to "C"
312
TDM
Z
CA 202
23/22
907/908 15/14
CA 204
SFS 1SA
C
7
CA 204
to VCM, HDM & PC 416
2937
B+
612
5 6
801
1
R S T
3
M3 DC
HALL B HALL C HALL A +5 V DC COMM
Steering
1 2 3 4 5 6
ECR 3 STEERING
813134_2I_sh2 MS-DIA-2140
274
ESR4500 06/2004 • Printed in Germany
DIAGRAMS Wiring Diagram Option
from FU5
1
CA 433 3
BEACON
2991
K9
PC 433 K10
K9,10
K13 2
- BV
POUT_11 (VCM)
3
4
5
6
FU1
FU2
FU3
FU4
FU5
FU6
7
8
9
10
11
12
to SP1
2965
2996 K12
347
CA 442
1
Heater R1-R10
85
85 87 87a
2969
CA 441
526
CA 442 11
Sig. GND
SI
Br-Light out
364
CA 440
508
6
1
372
368
367
CA 449 1
3
3
4 647
4 648
CA 440
646 CA 442 12 631
509 647
CA 440
7
- BV
544
48V I/P
0V I/P
DC/DC
510
DC/DC_24 V
24V O/P 0V O/P
Converter
- BV
354 / 355
JC 447 3 5
642 / 643 4
6
330
642 / 643 4
6
632 652
630 333
380
340
1
334
381
343
366
365 5
5
1 645 8 638
376
1
647
631
4
2
4
648
345
5
Parking 3 Lights 357 370
369 4
4
CA 442
2 651
(2) 85 (5) 87 87a RELAY_12 V
339 1
to GND 12V (630)
2
CA 442-2 GND
CA 443
5
635 342
OPTIONS 12/24 V
K6
Head 356 Lights
373
374 2
2
1 646 CA 442 12 631
351 4
633
2
644
648 12
2
651
1
346 GND 12V (632)
375
336
CA 443
+
K5 Tail Lights
3
SW
WORKING LIGHTS 12V 1 (3) 30 6 CA 442 3 344 (1) 86 341
5
3
(2) 85 (5) 87 87a RELAY_12 V
Indicator
CA 448 4 CA 449 4
521
4
-
7
CA 441
520
363
GND 12V
362
2 x 12 V/21 W
5
10
338
371
2
49a
CA 206 545
87
Brake lights CA 448
3
2
350
CA 450
87
360
CA 451
85
31 646/649
86
-
525
2
12V O/P 0V O/P
1
2995
544
CA 447 3 5
+
+
524
359
2
2x 12 V / 4-5 W
-
(3) 30 (1) 86
30
CA 451
Heater Assy 4 CA 441
SD
358
DRIVING LIGHTS 12V
CA 451
30 86
CA 442
86
+
85 87 87a
49
RELAY_24 V 30
CA 450
30 86
921
CA 449
RELAY_24 V
922
K3
INDICATOR MODUL
CA 450
K1
CA 441
87
2x 12 V / 10 W
3
920
2
1
354 / 355
CA 442
4
361
85
85 87 87a
2968
87
8
335
332
CA 442
7
CA 448
85 87 87a
85
7
337 331
-
-
6
86
+
+
511
30
CA 449
86
30 86
6 2967
Converter
+ 48 V Supply
2961
R = 33 Ohm/25W
30
K4
CA 448
30 86
5
DC/DC
2962
3
523
PC 446 1
RELAY_24 V
CA 440
8
2963
CA 440
4x 12 V / 10 W
RELAY_24 V
CA 441
K2
BRAKE LIGHTS 12 V
4
2995
DC/DC_12 V
CA 440 4
THS3
CA 447
2958
2956
2
3
48V I/P 0V I/P
K13 2954 2957
2953
5
COLDSTORE (48 V)
2
JC 447
2997 PC 421 TRAVEL ALARM
1
2964 2966
1
522 2960
Connect to OPTION LOOM 2955
JC 440
2959 PC 433 BEACON
2960
541
CA 420 2901
POUT_14 (VCM)
CA 440
2 x 24 V / 70 W
2990
1
644
PC 444
348
+12/24V
3
PC 445
4
2x +12V
VIDEO CAMERA MONITOR
GND
to GND 12V (630)
638
WINDSCREEN WIPER INTERIOR LIGHTING XENON FLASH
2x GND
1
CA 442 8
651
3
1
2
639
4
PC 445
PC 444 640
645 2
Options cabin
Options
Working CA 443 1 Lights 349
COLDSTORE CABIN 12 V ADD.
OPTIONS
- BV
KYS C
- BV
CA 433 4
CA 421 4
2
CA 420
A
2
2992
SW
1
OPTIONS
LAMP
ED-sw 2951
K12
2x 12 V / 55 W
K8
K7,8
Working Lights 24 V
ED1
2924
PC 421 HORN
FUSE_BOX from MAIN HARNESS 201
2x 12 V / 55 W
K7
CA 421 3
after ED1 S2 (FU2)
KEY
1
from FU6
+48 V BV
Connect to MAIN LOOM
TRAVEL ALARM
2
637
CA 443 2 634
636
CA 442
- BV
813383_2D ESR4500 06/2004 • Printed in Germany
MS-DIA-2140
275
DIAGRAMS Wiring Diagram Coldstore Cabin 522
CA 447
PC 421 TRAVEL ALARM
1
2
CA 440
7 544
2995
FUSE_BOX from MAIN HARNESS
510 48V I/P 0V I/P
2960
12
31 2901
+
2924
Relay-Options
30
SW_H SW Heater
31
2
2 2
A B
3
3 3
C
4
PC 467 4 4 JC 446
M
M
SW_I
1 1
CA 458
SW_HS
1
CA 457
2
1
UB222
FU 8 = 30 A
+ ED2
Options cabin
29114
29110
CA 460
1
PC 445 +12V
662
GND
391
+12V
660
GND
29111
CA 461
1
LEFT SIDE H.
48 V / 304 W
REAR H.
29117
48 V / 380 W
S1
BUS-BAR
Screw
FRONT H.
+
FU 9 = 50 A
Contactor + 48 V S2
394
1 4 2
637
558
223
NOT-AUS
CA 442-2 SP25 +12 V GND
661
CA 459
ED3
651
3
Screw
221
381 380
663
HEATED SEAT
S1
Contactor + 48 V S2
S1 Screw 220
Screw
652
395
29115
29112
CA 462
1
48 V / 168 W
502
ED1
630 330
393
ED2
337
2
29118
K13
S2 Screw
632 333
CA 442-4
927
200
6
664 87
87 87a
SP1
C
KYS
390
V.01
1
5
CA 463
1
1
48 V / 225 W
A
15
CA 456
TOP H.
2951
CA 446
355 / 643
CA 447 3 4
Interior Lighting
2x 12 V / 5 W
30
-
392
K12
BUS-BAR
- BV
2
354 / 642
48 V / 126 W
KEY
+t
1
Windscreen wiper
RIGHT SIDE H.
9
EDS
87z
15
2
Windscreen wiper
CA 466 29116
87z
CA 440-1
Coldstore Loom 48 V
3
2
+12 V COMPONENTS ASSEMBLY
523 + 48 V
FRONT
PC 433 BEACON
8 7
4
K14 TIME DELAY RELAY
4
SW_F
2955
8
2963
- BV
CA 420
FU2
CA 440
CA 440-2
12 V / 60 W
10
2959
201
FU1
12V O/P 0V O/P
SW_R
11
FU5 FU4 FU3
5 4 3
2956
2953 K12
CA 420
2
3 511
203
EDS
DC/DC_12 V Converter
DC/DC
2962
2958
K13 2996
1
CA 440
REAR
FU6
6 206
2957
2954
2997
12 V / 60 W
207
SP26 GND 12 V
559
ED3
CA 459
2
Heater screen CA 460
2
556
Heater screen CA 461 552
2
Heater screen CA 462 553
Heater screen CA 463
2
554
Heater screen 2 557
Screw
HEATER SCREEN ASSEMBLY
GND Connection Point
FU 7 = 425 A
M
29113
int.-SW FAN
CA 464 555
2985
RED
538
BLACK
550 / 551
+
+
GND Connection Point
BEACON
HEATER / FAN ASSEMBLY CA 464
- BV (Controller traction)
48 V / 10-20 W 48 V / 1500 W
Connection to Beacon Loom 813524
GND Connection Point
48 V BATT. -
29120
- BV (Controller traction) SW door cabin SW_D
29119
- BV
SW SPS SPS
CA 465
JC 419
A
A
FU2 SP9 2914 +48 V BV
B
B
Connection to Harness main loom 812909
C
005 VCM (CANION)
050 C
814564_2A_Wiring diagr. coldstore cabin MS-DIA-2140
276
ESR4500 06/2004 • Printed in Germany
DIAGRAMS The following table contains the numbers of the wire harnesses used on the ESR4500. The list contians the wire harness number and a reference to the area in which the wire harness is located.
Item No.
Assigned to
Page
812909
Main Harness
297,280
812326
Harness Connector Panel to Reach Carriage
283
812327
Harness Reach Carriage
284
813524
Harness Options
285
813774
Harness Beacon Switch
287
813485
Harness Cold store
288
813526
Harness Working Light 12V
289
813779
Harness Working Light 24V
290
813836
Harness Driving Light
291
813527
Harness Travel Alarm
292
814056
Harness DC/DC Converter with Harness Options 813445
293
813753
Harness DC/DC Converter without Harness Options 813445
294
814430
Harness Heated Seat
295
814405
Harness 12V/24V Supply to b/w Monitor
296
814499
Harness s/w Monitor or Connection Box to Connector Panel
297
814407
Harness (Camera) Connector Panel to Reach Carriage
298
814408
Harness (Camera) Reach Carriage to Mast
299
814521
Harness (Camera) Mast to Camera
300
814498
Harness (Camera) TFT Display to Connection Box
301
814526
Harness 12V Supply to Connection Box
302
814475
Harness and Installation Drawing 6th Function
303
814337
Harness Davis Derby System
304
814565-001
Harness 1 Coldstore Cabin
307
814565-002
Harness 2 Coldstore Cabin
308
ESR4500 06/2004 • Printed in GermanyMANY
MS-DIA-2140
277
Blank page
Printed in Germany
278
DIAGRAMS PC 205
(VCM)
5904 SVH 1 2 001 SES 3 002 FS 4 003 RS 004 ACS 5 300 12 V + 6 600 12 V 7 614 CAN GND 8 020 ECR 5 A 9 10 5920 BEACON 11 5913 Travel AL. 5910 SVS 12 5908 PVAL 13 2930 B+ 14 5905 PVRE 15 005 DMS 16 17 2909 KYS 18 018 RES 1 022 RES 2 19 20 104 POT 5 21 106 POT 1 900 CAN H 22 905 CAN L 23 24 5902 ED1 25 017 FL S / LCS SV5 26 5911 27 5907 PVAR 28 504 B 29 5906 PVRT 30 019 HGT(R)S 31 007 32 008 BPS 33 009 BRS 34 105 POT . 6 35 101 POT . LIF 2 36 102 a.POT 3 37 103 POTTIL 4 38 021 ECR 5 B 39 024 PLS 40 023 ORS 41 5909 SVT 42 5903 PVL
(VCM)
PC 206 PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Wire No.
006 BLS 113 LS
PC 204
EDS (aux. Contactor)
PIN Wire No. 505 B1 506 B2 3 618 CAN GND 4 700 025 SFS 1 A 5 026 SFS 2 6 2936 B+ 7 2937 B+ 8 9 5912 BRAKE 10 909 CAN L 11 904 CAN H 12 13 109 A1 + 14 110 A1 15 111 A2 + 16 112 A2 -
PC 411 (POT6 AUX) PIN 1 2 3 4
PIN Wire No. 1 014 B 2 015 C 3 016 A 4 309 5 V+ 5 6 612 GND PC 413 (SDM) PIN Wire No. 1 801 2 802 3 803 4 -
PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
PIN 1 2 3 4
Wire No. 906 CAN L 901 CAN H 615 CAN GND 907 CAN L 902 CAN H 616 CAN GND
318 11 V+ Output 624 GND B319 11 V+ Output
K5 SP5
K6 SP6
Wire No. 304 104 604
PIN 1 2
Wire No. 201 2951
PIN 1 2 3 4
Wire No. 303 103 603
SP3
PC 408 (POT3 Reach)
SP8
PIN 1 2 3 4
2908 B+ KEY 202 B+ perm. 507 GND B-
S1 (LINE-CONT.) Power B+ S Wire No. 200 / 206 / 207 1
S2 (LINE-CONT.) Power B+ S Wire No. 203 / 2923 2
Wire No. 302 102 602
PC 404
(FS)
PIN Wire No. A 2906 B C 002 PC 406
PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Tract. (TCM)
2905 308 12 V + 610 GND 012 CH. A 013 CH. B 616 CA N GND 617 CA N GND
907 CAN L 908 CAN L 108 TMP 611 TMP GND
902 CAN H 903 CAN H
PC 201
Pump (HCM)
PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Wire No. 2929 5919 307 12 V + 608 GND 010 CH. A 011 CH. B 617 CAN GND 618 CAN GND
PIN Wire No. 1 2931 2 5915 PC 402 Start up Card PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
607 607 908 CAN L 909 CAN L 107 TMP 609 TMP GND
(HCM)
(RS)
(BRS) PIN 1 2
180
PC 420 (KYS)
180
wire 110
Wire No. 2911 009
PIN A B C
wire 109
wire 110
wire 109
(ORS) Wire No. PIN 1 2910 ORS 2 023
Wire No. 2951 2901
PIN 1 2 3 4
Wire No. 2925 5913 2960 513
Wire No. 2907 003
BS 1
PC 405
PC 415 (FAN 2) PIN 1 2
PIN A B C
(HNS)
Wire No. 205
Wire No. 500 / 505 / 506 (HCM)
(HCM) B+ S 1
Wire No. 2904 2923 5901 2927 5912 2903 50 ----292 -2902 -5928 5914 2928 5927 2950 --RELAY-OPTIONS
903 CAN H 904 CAN H
PC 421 (Travel Alarm) PIN A B C
Fuse No. PIN Wire No. 1 200 FU 1 15 A / 80 V 7 201 / 202 2 203 / 204 FU 2 15 A / 80 V 8 2926 3 204 FU 3 15 A / 80 V 9 2903 4 205 FU 4 30 A / 80 V 10 2936 / 2937 5 206 FU 5 15 A / 80 V 11 2959 295/ 2996 6 207 FU 6 15 A / 80 V 12 2960 295/ 2997 PC 401 (FAN 1)
PC 202
PIN Wire No. 1 301 + 2 101 S 3 601 4
SP4
K1 SP13
PIN Wire No. 1 2902 2 5902/5928 590
PC 407 (POT2 Lift)
Wire No. PIN 1 900 / 901 CAN H 2 905 / 906 CAN H 3 614 / 615 CAN GND 4 5 319 11 V+ 6 625 GND Display
K1 SP12
ED1 (LINE-CONT.)
PC 409 (POT4 TLT)
PC 416 (CAN-CON.)
SP7
Wire No. 305 105 605
PC 410 (POT5 SS)
PC 203 (Display)
PC 412 (ECR 3)
K SP1
Main Harness
FUSE-BOX
(SDM)
BS 1
3 8
2996 2924
8 8
927 2953
3 8
2997 927
8 8
502 2954
K12
K13
Wire No. 508 / 509 / 510 / 511
Wire No. 5914 501
Wire No. 2932 5916
PC 414 (ECR 4) PIN 1 2 3 4 5 6
Wire No. 109 P1 701 P5 110 P3 111 P4 702 P2 / P5 112 P6
812909_2R_Main-loom_sh1 ESR4500 06/2004 • Printed in Germany
MS-DIA-2140
279
DIAGRAMS Main Harness PC 436 Steer (ECR 3) PIN 1 2 3 4 5 6
PC 418 (POT1 ACC) PIN 1 2 3 4
Wire No. 306 106 606
PC 417 PIN A B C
SP1 after Key B+
Wire No. 014 B 015 C 016 A 309 5V+ 612 GND
PC437 (SDM) PIN 1 2 3 4
PC 438
(ACS) Wire No. 2913 004
K10 SP10
PIN 1 2 3 4 5 6 7 8
Wire No. 2955 2956 2957 2958 508 509 510 511
PC 439 (SFS 1 SA) PIN Wire No. 1A 311 + 12 V 2B 619 GND 3C 025 Sig.
K11 SP11 PC 419 PIN A B 3 C
(DMS) PC 426
Wire No. 2914 005
Wire No. 2928 5901
K9 SP9
(BFS) PIN 1 2
(BLS)
PIN Wire No. A 2918 B C 006
(HORN) PIN 1 2
(SFS 2)
PIN Wire No. 1 312 + 12 V 2 620 GND 3 026 Sig. 4 -
Wire No. 2915 007
(BPS) Cr PIN Wire No. 1 2916 2 008
PC 431 PC 428
SP9
PIN 1 2
(Brake)
(SES) Wire No. 2917 001
PIN A B C
Wire No. 2950 5927
Wire No. 2926 2927 --2929 2930 2931 2906 2907 2910 2911 2952 2932 2925
Wire No. 2901 2924 2904 2905 2908 2909
Wire No. 801 802 803 -
PC 440 OPTION (+/-BV)
SP3 after ED1 (FU2)
----PC 422 P IN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
(MAST)
Wire No. SVT 5909 019 HG T(R )S 017 FLS / LCS 022 RES 2 SVS 5910 310 12 V + 613 GND 12 V 5903 PVL 5904 SVH 5905 PVRE 5907 PVAR 5908 PVAL 018 RES 1 2921 + BV 503 GND -BV PVRT 5906 PSL 024 5911 SV5 ------------------------020 ECR 5 A 021 ECR 5 B 113 LS coldstore coldstore R8 coldstore coldstore R8 ---
SP6 GND 12 V -
SP7 5 V +
Wire No. 600 601 602 603 604 605 606
Wire No. 700 701 702 K8 SP8 Wire No. 5915 5916 5918 5919
SP9 after ED1 (FU2)
Wire No. 2952 2913 2914 2915 2916 2917 2918 2935
2933 2921
SP4
GND BWire No. 500 501 502 503 504 507 512 513
SP5
+12V
Wire No. 300 301 302 303 304 305 306
STARPOINTS SP SP10 11 V + Display
Wire No. 318 310 311 312
SP11 GND Display
Wire No.
624 613 619 620 625
SP12 after FU5 (Option) SP13 after FU6 (Option)
Wire No. 2953 2955 2956 2959 ---
Wire No. 2954 2957 2958 2960 ---
coldstore R 9 coldstore R 9 ---R 10 coldstore ---R 10 coldstore
PC 430 (THS 2) PIN 1 2
Wire No. 107 609
PC 429 Pump (ECR 2) PIN 1 2 3 4
Wire No. 307 010 011 608
PC 425 Tract. (ECR 1) PC 427 PIN 1 2
(THS1)
Wire No. 108 611
PIN 1 2 3 4
Wire No. 308 012 013 610
PC 433 (BEACON) PIN 1 2 3 4
Wire No. 2935 5920 2959 512
PC 434
(FAN 3)
PC 435
(FAN 4)
PIN 1 2
Wire No. 2933 910
PIN 1 2
Wire No. 910 5918
812909_2R_Main-loom_sh2 MS-DIA-2140
280
ESR4500 06/2004 • Printed in Germany
DIAGRAMS Connector Table PARTS_TABLE
PARTS_TABLE
Label / Con.
Pins
Housing / Part-No.:
ORS
2
---
BRS
2
---
HORN
2
---
BPS
2
---
BFS
2
---
EDS
2
---
ED1
2
---
FUSE-BOX
12
806702
R elay-Options
8
811996-001
Screw M10 S1 Power B+ Screw M10 S2 Power B+ Screw M8 B+ HDM Screw M8 B- HDM Screw M8 B- HDM PC
201
1
---
1
---
1
---
1
---
793217-022 813444-001 --793217-037 793409-00 x 793217-038 793409-00 x 793217-036 793409-00 x 793217-035 793409-00 x
Connector
Pins Required
Housing
Anti Backout
Pin No.
PC
401
2
792881-001
793091-001
792883
PC
402
16
116851
PC
404
3
792881-002
793091-002
792883
PC
405
3
792881-002
793091-002
792883
PC
406
3
792881-002
793091-002
792883
4
792881-003
793091-003
792883
PC
408
4
792881-003
793091-003
792883
PC 409
4
792881-003
793091-003
792883
PC 410
4
792881-003
793091-003
792883
PC 411
4
792881-003
793091-003
792883
PC 412
6
814137
814139
PC
413
4
814140
814141
PC 414
6
814157-001
814158-001
PC
415
2
792881-001
793091-001
792883
PC
416
6
792881-004
793091-004
792883
PC
417
3
792881-002
793091-002
792883
PC
418
4
792881-003
793091-003
792883
PC
419
3
792881-002
793091-002
792883
PC
420
3
792881-002
793091-002
792883
PC
421
4
792881-003
793091-003
792883
812339-001
---
793217-034
16
814150
814151 814151 814152 803450-26
PC
422
40
PC
425
4
814142
814154-001 814154-002
PC
426
3
792881-002
PC
427
2
814144
PC
428
2
792880-001
202
13
814150
PC
203
12
803450-25
204
15 (8 small / 7 medium)
814153
116858
PC 407
1
PC
PC
Pin P.-No.: 793217-022 793217-027 793217-022 793217-027 793217-022 793217-027 793217-022 793217-027 793217-022 793409-00 x 793217-022 793217-027 793217-022 793217-027
WIRE_TABLE
792883 814143
205
42 (36 small / 6 medium)
814155
814320-001 814320-002
PC
206
2
814153
814154-001
PC
429
4
814142
814143
793217-042 793217-041
PC
430
2
814144
814143
PC
431
3
792880-002
793090-002
792882
PC
433
4
792881-003
793091-003
792883
PC
434
2
792881-001
793091-001
792883
PC
435
2
792881-001
793091-001
792883
PC
436
6
814145
---
793217-039 793217-040
812909_2R_Main-loom_sh3_PARTS
793090-001
----1 4 2 3 8 3 13 12 15 10 1 2 23 11
PC 202 TDM
1 2 3 4 5 6 7 8 14 15 16 17 22 23
2905 --308 12V+ 610 GND 012 Ch. A 013 Ch. B 616 CAN GND 617 CAN GND 907 CAN L 908 CAN L 108 TMP 611 TMP GND 902 CAN H 903 CAN H
SP 1 --PC 425 PC 425 PC 425 PC 425 PC 203 PC 201 PC 203 PC 201 PC 427 PC 427 PC 203 PC 201
----1 4 2 3 6 7 4 14 1 2 5 22
PC 203 DISPLAY
1 2 3 4 5 6 14 15 16 18 19 20
906 CAN L 901 CAN H 615 CAN GND 907 CAN L 902 CAN H 616 CAN GND 318 11V+ 624 GND B319 11V+ 2908 B+ KEY 202 B+ 507 GND B-
PC 416 PC 416 PC 416 PC 202 PC 202 PC 202 SP 10 SP 11 PC 416 SP 1 FUSE BOX SP 4
2 1 3 14 22 7 ----5 --7 ---
1 2 3 4 5 6 7 8 9 10 11 13 14 15 16
505 BScrew M8 B506 BScrew M8 B618 CAN GND PC 201 700 5V+ SP 7 025 SFS 1SA PC 439 026 SFS2 PC 438 2936 B+ FUSE BOX 2937 B+ FUSE BOX 5912 BRAKE PC 402 909 CAN L PC 201 904 CAN H PC 201 109 A1+ PC 414 110 A1PC 414 111 A2+ PC 414 112 A PC 41
814147
437
4
814149
PC
438
4
792881-003
793091-003
792883
PC
439
3
792881-002
793091-002
792883
PC
440
8
793091-005
792881-005
792883
814148
812909_2R_Main-loom_sh4_PARTS
ESR4500 06/2004 • Printed in Germany
PC 201 HDM
SP 3 SP 8 PC 429 PC 429 PC429 PC 429 PC 202 PC 204 PC 201 PC 201 PC 202 PC 204 PC 430 PC 430 PC 202 PC 204
792882
PC
to Connector Pin-No.: from Connector Pin-No.:
2929 5919 307 12V+ 608 GND 010 CH. A 011 Ch. B 617 CAN GND 618 CAN GND 607 607 908 CAN L 909 CAN L 107 TMP 609 TMP GND 903 CAN H 904 CAN H
814143 793091-002
Wire-No.:
1 2 3 4 5 6 7 8 12 13 14 15 16 17 22 23
792883
PC
Wire 109 & 110
from Connector Pin-No.:
PC 204 SDM
PC 205 VCM
PC 206 CAN ION VCM
Wire-No.:
to Connector Pin-No.:
1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17
5904 SVH 001 SES 003 RS 004 ACS 300 12V+ 600 12V614 CAN GND 020 ECR 5 A 5920 Beacon 5913 Travel AL. 5910 SVS 5908 PVAL 2930 B+ 5905 PVRE 005 SPS 2909 KYS
PC 422 PC 428 PC 406 PC 417 SP 5 SP 6 PC 416 PC 422 PC 433 PC 421 PC 422 PC 422 SP 3 PC 422 PC 419 SP 1
9 2 C C ----3 31 2 2 5 12 --10 C ---
18 19 20 21 22 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
018 RES 1 022 RES 2 104 POT 5 106 POT 1 900 CAN H 017 FLS/LCS 5911 SV5 5907 PVAR 504 B5906 PVRT 019 HGT(R)S 007 BFS 008 BPS 009 BRS 105 POT6 101 POT2 102 POT3 103 POT4 021 ECR 5 B 024 PLS 023 ORS 5909 SVT 5903 PVL
PC 422 PC 422 PC 410 PC 418 PC 416 PC 422 PC 422 PC 422 SP 4 PC 422 PC 422 BFS BPS BRS PC 411 PC 407 PC 408 PC 409 PC 422 PC 422 ORS PC 422 PC 422
13 4 2 2 1 3 18 11 --16 2 Crimp Crimp Crimp 2 2 2 2 32 17 Crimp 1 8
12 13
006 BLS 113 LS
PC 426 PC 422
C 33
812909_2R_Main-loom_sh4_WIRE
Ring-T Ring-T 8 --C 3 10 10 5 15 23 1 3 4 6
MS-DIA-2140
281
DIAGRAMS Connector Table WIRE_TABLE from Connector Pin-No.: Wire-No.: PC 401 1 2931 2 5915 FAN 1 48V PC 402 1 2904 2 2923 Start up Card 3 5901 4 2927 5 5912 6 2903 9 2902 10 5928 11 5914 12 2928 13 5927 14 2950 PC 404 A 2906 C 002 FS PC 405 A 5914 HNS C 501 PC 406 A 2907 C 003 RS PC 407 1 30 1 + 12V POT2 Lift 2 101 S 3 601 GND PC 408 1 30 2 + 12V POT3 Reach 2 102 S 3 602 GND PC 409 1 30 3 + 12V POT4 TLT 2 103 S 3 603 GND PC 410 1 30 4 + 12V 2 104 S POT5 SS 3 604 GND PC 411 1 30 5 + 12V 2 105 S POT6 5th f. 3 605 GND PC 412 1 014 B Steer ECR3 2 015 C 3 016 A 4 309 +5V 6 612 GND PC 413 1 801 APS MOT 2 802 3 803 PC 414 1 1 09 P1 Stepper ECR4 2 7 01 P5 3 1 10 P3 4 1 11 P4 5 702 P2/P5 6 1 12 P6 PC 415 1 2932 2 5916 FAN 2 48V PC 416 1 900/901 CAN H 2 905/906 CAN L CAN-CON 3 614/615 GND 5 31 9 11V+ 6 625 GND PC 417 A 2913 ACS C 004 PC 418 1 30 6 + 12V POT1 ACC. 2 106 S 3 606 GND PC 419 A 2914 SPS C 005 PC 420 A 2951 C 2901 KYS PC 421 1 2925 2 5913 Travel Alarm 3 2960 4 513
MS-DIA-2140
282
WIRE_TABLE to Connector
Pin-No.:
SP 3 SP 8 SP 1 Screw M10 S2 H ORN SP 3 PC 204 FUSE BOX ED1 ED1 PC 405 H ORN PC 431 PC 431 SP 3 PC 205 PC 402 SP 4 SP 3 PC 205 SP 5 PC 205 SP 6 SP 5 PC 205 SP 6 SP 5 PC 205 SP 6 SP 5 PC 205 SP 6 SP 5 PC 205 SP 6 PC 436 PC 436 PC 436 PC 436 PC 436 PC 437 PC 437 PC 437 PC 204 SP 7 PC 204 PC 204 SP 7 PC 204 SP 3 SP 8 PC 205/203 PC 205/203 PC 205/203 PC 203 SP 11 SP 9 PC 205 SP 5 PC 205 SP 6 SP 9 PC 205 EDS SP 1 SP3 PC 205 FUSE BOX SP 4
------Ring-T Crimp --9 9 Crimp Crimp A Crimp B A --3 11 ----4 --35 ----36 ----37 ----20 ----34 --1 2 3 4 6 1 2 3 13 --14 15 --16 ----22 / 2 23 / 1 8/3 16 ----5 --21 ----16 Crimp ----11 12 ---
from Connector PC 422 MAST
PC 425 Tract. ECR1
PC 426 BLS PC 427 THS 1 PC 428 SES PC 429 Pump ECR2
PC 430 THS 2 PC 431 BRAKE PC 433 BEACON
PC 434 FAN 3 24V PC 435 FAN 4 24V PC 436 Steer ECR3
PC 437 APS MOT PC 438 SFS 2 PC 439 SFS 2 PC 440 OPTION (+/-BV)
Pin-No.:
Wire-No.:
to Connector
Pin-No.:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 31 32 33 1 2 3 4 A C 1 2 1 2 1 2 3 4 1 2 A B 1 2 3 4 1 2 1 2 1 2 3 4 6 1 2 3 1 2 3 A B C 1 2 3 4 5 6 7 8
5909 SVT 019 HGT(R)S 017 FLS/LCS 022 RES 2 5910 SVS 310 +12V 613 GND 5903 PVL 5904 SVH 5905 PVRE 5907 PVAR 5908 PVAL 018 RES 1 29 2 1 +BV 503 -BV 5906 PVRT 024 PLS 5911 SV5 020 ECR 5 A 021 ECR 5 B 113 LS 308 012 013 610 2918 006 108 611 2917 001 307 010 011 608 107 609 2950 5927 2935 5920 2959 512 2933 910 910 5918 014 B 015 C 016 A 309 +5V 612 GND 801 802 803 312 +12V 620 GND 026 Sig. 311 +12V 619 GND 025 Sig. 2955 2956 2957 2958 508 509 510 511
PC 205 PC 205 PC 205 PC 205 PC 205 SP 10 SP 11 PC 205 PC 205 PC 205 PC 205 PC 205 PC 205 SP 9 SP 4 PC 205 PC 205 PC 205 PC 205 PC 205 PC 206 PC 202 PC 202 PC 202 PC 202 SP 9 PC 206 PC 202 PC 202 SP 9 PC 205 PC 201 PC 201 PC 201 PC 201 PC 201 PC 201 PC 402 PC 402 SP 9 PC 205 FUSE BOX SP 4 SP 9 PC 435 PC 434 SP 8 PC 412 PC 412 PC 412 PC 412 PC 412 PC 413 PC 413 PC 413 SP 10 SP 11 PC 204 SP 10 SP 11 PC 204 SP 12 SP 12 SP 13 SP 13 Screw M8 HCM Screw M8 HCM Screw M8 HCM Screw M8 HCM
41 30 25 19 12 ----42 1 15 27 13 18 ----29 39 26 9 38 13 3 5 6 4 --12 16 17 --2 3 5 6 4 16 17 14 13 --10 11 ----1 2 --1 2 3 4 6 1 2 3 ----6 ----5 --------Ring-T Ring-T Ring-T Ring-T
from Connector Pin-No.: 1 FUSE BOX 7 2 8 3 9 4 10 5 11 6 12 C rimp EDS C rimp ED1 C rimp C rimp 30 Relay Options 86 K12 85 87
Wire-No.: 200 20 1 / 202 20 3 / 204 2926 204 2903 205 293 6 / 2937 206 295 9 / 2996 207 296 0 / 2997 201 2951 2902 590 2 / 5928 2996 2924 927 2953
to Connector Screw M10 S1 EDS / PC 203 Screw M10 S2 SP 3 FUSE BOX PC 402 Sc rew M8 B+ PC 204 Screw M10 S1 PC 433 / R elay Opt. Screw M10 S1 PC 421 / Relay Opt. FUSE BOX PC 421 PC 402 PC 205 / PC 402 FUSE BOX SP SP13 K13 SP 12
Pin-No.: R ing-T Rin g -T / 19 R ing-T --3 6 R ing-T 7/8 R ing-T 3 / 30 R ing-T 3 / 30 7 A 9 24./ Okt 24 10 11 --86 ---
Wire-No.: from Connector Pin-No.: Ring-T 2 00 / 2 06 / 2 07 Screw M10 S1 Ring-T 203 / 2923 Screw M10 S2 Screw M8 B+ Ring-T 2 05 Ring-T 500 / 505 / 506 Screw M8 BScrew M8 B5 08 / 5 09 / 5 10 Ring-T / 511 BRS Crimp 2911 Crimp 0 09 Crimp 2910 ORS Crimp 0 23 HORN Crimp 2928 Crimp 5901 Crimp 2915 BFS Crimp 0 07 BPS Crimp 2916 Crimp 0 08 30 2997 Relay Options 86 9 27 K13 85 5 02 87 2954
to Connector FUSE BOX FUSE B OX / PC 402 FUSE BOX SP 4 / PC 204
Pin-No.: 1/5/6 2/2 4 --- / 1 / 2
PC 440
5/6/ 7/8
SP 3 PC 205 SP 3 PC 205 PC 402 PC 402 SP 9 PC 205 SP 9 PC 205 FUSE BOX K12 SP 4 SP 13
--33 --40 12 3 --31 --32 12 85 -----
812909_2R_Main-loom_sh5
ESR4500 06/2004 • Printed in Germany
DIAGRAMS Harness: Connector Panel to Reach Carriage JC 422 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Wire No. 1 3 1 2 1 1 2 2 2 2 2 2 2 1 3 2 2
Discription
Colour
SVT HGT(R)S FLS / LCS RES 2 SVS + 12 V GND 12 VPVL SVH PVRE PVAR PVAL RES 1 + BV GND -BV PVRT PLS SV5
GRN / BLK BLU WHT / BLK BLK BLU ORG RED / BLK WHT / BLK RED BLU ORG GRN WHT RED ORG / BLK ORG / BLK GRN / BLK WHT WHT / BLK ORG --------------------GRN / BLK RED / BLK ORG / BLK BLK GRN RED / BLK GRN WHT RED BLK
---------------------
-------------------------
3 3 1 1 1 1 3 3 3 3
ECR5 Ch.A ECR5 Ch.B LS coldst. R 8 coldst. R 8 --coldst. R 9 coldst. R 9 coldst. R 10 coldst. R 10
3 3
1
1
JC 422 1
11
21 31
2
12
22 32
3
13
23 33
4
14
24 34
5
15
25 35
6
16
26 36
7
17
27 37
8
18
28 38
9
19
29 39
10
20
30 40
PC 601
PC 601
SP15 +12 V SP14 +BV
1
7
2
8
3
9
4
10
5
11
6
12
2
2
1
7
2
8
3
9
4
10
5
11
6
12
PC 604 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12
PC 600
3
3
STARPOINTS
2938
SP14 + BV
2939
1
7
2
8
3
9
PC 600
4
10
5
11
6
12
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12
Wire No. --------------------2942 314
Discription RES 2 GND 12 VPVL SVH PVRE PVAR PVAL RES I PVRT PLS + BV + 12 V
Colour BLK RED / BLK WHT / BLK RED BLU ORG GRN WHT ORG / BLK GRN / BLK RED / WHT ORG
Wire No. ----2940 --2941 ---------------
Discription GND -BV ECR5 Ch. A + BV ECR5 Ch. B + BV HGT(R)S ----coldst. R 9 coldst. R 9 coldst. R 10 coldst. R 10
Colour BLK ORG / BLK WHT / BLK RED BLU ORG GRN WHT ORG / BLK GRN / BLK RED / WHT ORG
2940
+ BV (RED)
JC 600 2941 2942 313
SP15 + 12 V + 12 V (ORG)
7
1
8
2
9
3
10
4
11
5
12
6
PC 600 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12
ECR5 (Height Encoder) Wire No. -------------------------
Discription GND -BV ECR5 Ch. A + BV ECR5 Ch. B + BV HGT(R)S ----coldst. R 9 coldst. R 9 coldst. R 10 coldst. R 10
COLDSTORE ! 314
DESCRIPTION
Colour GRN / BLK RED / WHT WHT / BLK RED / WHT BLU RED / BLK --WHT ORG ORG / BLK BLK GRN
Pin 11 & 12 are reserved for R 8 (LS / FKS)
3 4 6 11
PART NO.
Discription SVT + BV FLS / LCS + BV SVS ----SV5 + 12V LS coldst. R 8 coldst. R 8
COLDSTORE !
PC 604
2 5 6
ITEM NO.
Wire No. --2938 --2939 --------313 -------
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12
Pin No. 1 2 3 4
Discription GND -BV ECR5 Ch. A + BV ECR5 Ch. B
PC803
HGT(R)S Pin No. 1 2 3 4
Discription + BV coldst. R 9 coldst. R 9 HGT(R)S
PC802
812326_2G
QUANTITY
2
812338
PIN HOUSING
1
3
792881-006
SOCKET HOUSING
3
4
792883
SOCKET CRIMP
35
5
792882
PIN CRIMP
30
6
793222
BLANKING PIN
11
7
051051-004
CABLE TIE
6
8
---
CABLE
0,5 m
9
793409-007
SHRINK SLEEVE
0,05 m
10
793217-018
BUTT CONNECTOR
2
11
793091-006
ANTI BACKOUT
3 812326_GB-T
ESR4500 06/2004 • Printed in Germany
MS-DIA-2140
283
DIAGRAMS Harness: Reach Carriage
PC 805 PC 805 RES 1 Wire No. 316 622 027
Pin No. A B C
A Discription + 12V GND - 12V RES 1
2 3 6
C
Colour ORG BLU BLK
B
PC 806 1
3
2
4
4 5 6 8
PC 806 RES 2
SP16
JC 604 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12
Wire No. 028 621 5921 5922 5923 5925 5926 027 5924 029 2943 315
Pin No. 1 2 3 4
SP17 SP18
Discription Colour BLK RES 2 GND 12 VBLU WHT / GRN PVL SVH WHT / GRN WHT / GRN PVRE WHT / GRN PVAR PVAL WHT / GRN BLK RES 1 WHT / GRN PVRT BLK PLS + BV RED / WHT ORG + 12V
Wire No. 317 623 028 ---
Discription + 12 V GND - 12 V RES 2 ---
Colour ORG BLU BLK ---
12 14 PC 807 Pin No. 1 2 3
Wire No. 5921 2944 5922
PVL SVH
029 6
5
4
2949
PC 808
12
11
10
2
3 9
7
8
1
PLS
JC 604
Pin No. 1 2
1 7 18
PC 809 Pin No. 1 2
PVRE
PC 810
Wire No. 2945 5923
Wire No. 2946 5924
PVAL
13 14 PC 811
PVAR
Wire No. 2947 5926
Wire No. 2948 5925
Pin No. 1 2
PVRT Pin No. 1 2
15 16
13 14 STARPOINTS SP: 2944 316
2945
SP16 + BV ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
1
792880-006
PIN HOUSING
1
2
792881-002
SOCKET HOUSING
1
3
793091-002
ANTI BACKOUT
1
4
792881-003
SOCKET HOUSING
1
5
793091-003
ANTI BACKOUT
1
6
792883
SOCKET CRIMP
6
7
792882
PIN CRIMP
12
8
793222
BLANKING PIN
1
16
793217-027
INSULATION SLEEVE
2
18
793090-006
ANTI BACKOUT
1
2943
SP17 + 12 V
2946 2947 2948 2949
622
SP18 GND - 12 V
315
621
317
623
812327_2G
812327_GB-T
MS-DIA-2140
284
ESR4500 06/2004 • Printed in Germany
DIAGRAMS Harness Options STARPOINTS SP: SP27 +12 V 2964 2965 2966 524
521 525
632
638
RELAY K 2_24 V
340
Wire No. 334 635 341 342 ---
Pin No. 3 2 1 5 4
SP28 +12 V
WORKING LIGHTS
RELAY K 5_12 V
SP34 GND 12 V
RELAY K 6_12 V
-
18 3 2
1 5 4
-
18 3 2
SP35 +12 V
+
1 5 4
10 11 13 JC 440 Pin No. 1 2 3 4 5 6 7 8
6
2
7
3
8
4
1
2
3
5
3
5
13 9 8
16
PC 447 (DC-DC)
PC 447
SP34 SP35
SP28 SP23 SP24
SP25 SP26 SP27
Wire No. 2960 2961 2962 2963 520 521 522 523
380
330
16 1
651
381
15
1
86 87 87a
+
2
+
87
30
30 85
85
86 87 87a
86
+
87
30 85
-
86
86 87 87a
85
30 85
30
86 87 87a
87
+
30 85
-
+
86
633 634 635 636 637
-
JC 440 5
345
344 346
DRIVING LIGHTS
RELAY K 4_24 V
RELAY K 3_24 V
RELAY K6
Wire No. 332 633 340 345 ---
Pin No. 3 2 1 5 4
BRAKE LIGHTS
85
17 15
631
SP26 GND 12 V
RELAY K5
Wire No. 331 921 2961 922 ---
Pin No. 30 85 86 87 87a
652 -
85
347
Wire No. 922 526 921 338 ---
Pin No. 30 85 86 87 87a
339
343
630
30
333
RELAY K 1_24 V
332 334 335 336 337
RELAY K4
RELAY K3
Wire No. 2965 920 2967 2968 ---
Pin No. 30 85 86 87 87a
COLDSTORE (48 V)
331
SP25 + 12 V
RELAY K2
Wire No. 2966 524 920 2969 ---
Pin No. 30 85 86 87 87a
30
SP24 BV-
RELAY K1
87
2960
86
SP23 + BV
1
4
2
5
3
6
+ BV B+ 12 V GND + 12 V GND
Pin No. 1 2 3 4 5 6
Wire No. 2962 522 330 630 333 632
PC 441 (Coldst.) + BV B+ BV BTHS 3 THS 3
Pin No. 1 2 3 4 5 6
Wire No. 2969 520 2968 525 2964 2967
PC 446 1
3
2
4
PC 446 (48V) + 48 V B-
PC 442 (Drive-L)
ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
4
792880-006
PIN HOUSING
1
5
793090-006
ANTI BACKOUT
1
13
ITEM NO.
Wire No. 342 634 335 341
4
Pin No. 1 2 3 4
3
4 5 13 14
8 9 13
PC 443 (Work-L)
2
3
PC 444 PC 443
PC 442
1
4
3
1
4
6 7 13 14
2
1
7
2
1
9
8
11
10
2
4
12
PC 441
3
6
4
5
1
6
5
Wire No. 339 651 346 380 343 344 347 638 --526 338 631
2
Sign. GND + 12 V Brake L. GND
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12
3
+ 12 V HL GND + 12 V PL + 12 V SD 2 SD 1 + 12 V Indicator GND
+ 12 V GND SW SW
PART NO.
Wire No. --636 --336
6 7 13 6 7 13 PC 445 (Cab 12 V)
GND + 12 V
Pin No. 1 2 3 4
Wire No. 652 637 381 337
GND GND + 12 V + 12 V
813445_2E_Option_wiring - Loom_sh1
DESCRIPTION
QUANTITY
792882
PIN CRIMP
43
793222
BLANKING PIN
5
6
792880-003
PIN HOUSING
4
14
7
793090-003
ANTI BACKOUT
4
15
813444-001
FLAT SOCKET
20
8
792880-004
PIN HOUSING
2
16
813444-002
FLAT SOCKET
4
9
793090-004
ANTI BACKOUT
2
17
811996-001
RELAY SOCKET
4
10
792880-005
PIN HOUSING
1
18
811996-002
SOCKET
2
11
793090-005
ANTI BACKOUT
1
19
051051-004
CABLE TIE (BLK)
2
813445-1_GB-T
ESR4500 06/2004 • Printed in Germany
Wire No. 2963 523 -----
PC 445
PC 444 (Opt. 12 V) Pin No. 1 2 3 4
Pin No. 1 2 3 4
813445-2_GB-T
MS-DIA-2140
285
DIAGRAMS Harness Beacon
BEACON 791036 813774 RELAY K10 Wire No. 2984 5930 924 923 ---
Pin No. 30 85 86 87 87a
85
86
RELAY K9
2985
Wire No. 923 924 2983 2985 ---
Pin No. 30 85 86 87 87a
538
BEACON RELAY K 10_24 V
+
86
86 87 87a
85
30 85
30
86 87 87a
87
85
30
-
+
86
-
30 85
6 7
87
RELAY K 9_24 V
JC 433
BS BEACON Switch
1
3
2
4
JC 433 BEACON Pin No. 1 2 3 4
Wire No. 2983 5930 2984 538
Insert this cable instead of jumper wire, when Beacon Switched is used
2 3 4 USE the Loom 813774 only by BEACON SWITCHED (3rd. Corner) 813524_2F_Beacon Loom
ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
2
792880-003
HOUSING
1
3
793090-003
ANTI BACKOUT
1
4
792882
PIN CRIMP
4
6
813444-001
FLAT SOCKET
8
7
811996-001
RELAY SOCKET
2 813524_GB-T
MS-DIA-2140
286
ESR4500 06/2004 • Printed in Germany
DIAGRAMS
85
86
Harness Beacon Switch
3
2 BEACON Switch
Use only by BEACON SWITCHED (3rd. CORNER) 813774_2B
ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
2
793217-008
FEMALE RECEPTACLE
2
3
813444-001
FLAT SOCKET
2 813774_GB-T
ESR4500 06/2004 • Printed in Germany
MS-DIA-2140
287
DIAGRAMS Harness Coldstore
Pin No. 1 2
1 2 5
R2
R2 FW/REV & HORN Wire No. 2980 536
1
R1
2
1 2 5
1 2
R3 KYS R1 EDS
Wire No. 2979 535
Pin No. 1 2
Pin No. 1 2
Wire No. 2981 537
R3
STARPOINTS SP:
2
JC 441
1
Heater Ass. 796158
R6 BLS Pin No. 1 2
1 2 5
Wire No. 2974 530
4
2
5
3
6
1
SP19 +BV
3 4 5
R6
2970
Connect to OPTION_WIRING - LOOM 2
1 2 5
THS 3 2973
R4 ACS/ACC
JC 441 Pin No. 1 2 3 4 5 6
Wire No. 2970 528 2971 529 2972 2973
2972
2977
SP20 +BV
2978
2976
2979
11
2981
R4
R7
2
1
1
2
SP20 SP22
1 2 5
SP21 -BV 528
R7 HEATER 180 W & FAN
SP19 SP21
Pin No. 1 2
R5 SPS
Wire No. 2971 529
Wire No. 2977 533
Pin No. 1 2
2993 2974 2975 2976 2994
2980
Wire No. 2978 534
Pin No. 1 2
1
ECR5 Height Enc. R10 2994
R5 543
2
5
542 530 531 532 543 533
SP22 -BV
534
532
535 536
Pin 39 of PC 422
537
Pin 40 of PC 422
HGT(R)S R9
1
2993 542
1 2 5
5
Pin 37 of PC 422 Pin 38 of PC 422
LS / FKS R8 2975 531
ITEM MO.
PART NO.
DESCRIPTION
QUANTITY
1
792881-001
SOCKET HOUSING
7
2
793091-001
ANTIBACKOUT
7
3
792881-004
SOCKET HOUSING
1
4
793091-004
ANTIBACKOUT
1
5
792883
SOCKET CRIMP
26
11
793217-009
FEMALE RECEPTACLE ELBOW
2
5
Pin 34 of PC 422 Pin 35 of PC 422
813485_2C_Coldstore Loom
813485_GB-T
MS-DIA-2140
288
ESR4500 06/2004 • Printed in Germany
DIAGRAMS Harness Working Light12 V
JC 443 1
3
2
4
Pin No. 1 2 3 4
Wire No. 348 639 350 351
+ 12 V GND SW SW
2 3 4
Working Light 12 V 348 / 349
JC 443 (Working Light)
639 / 640
350
SW (Switch Working lights)
7 351
7 8
349
Working Light 12 V 640
7 813526_2D_Working Light Loom 12V
ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
2
792881-003
SOCKET HOUSING
1
3
793091-003
ANTI BACKOUT
1
4
792883
SOCKET CRIMP
4
7
793217-022
FASTON RECEPTACLE
6
8
793217-027
INSULATION SLEEVE
2 813526_GB-T
ESR4500 06/2004 • Printed in Germany
MS-DIA-2140
289
DIAGRAMS Harness Working Light 24 V
JC 440 1
5
2
6
3
7
4
8
2991
Pin No. 1 2 3 4 5 6 7 8
Wire No. ----2990 ------541 ---
+ BV
BV-
2 3 4 5
Working Light 24 V
7
JC 440
2992
2990
SW (Switch Working lights) 2991
7 8
2992
Working Light 24 V 541
7
ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
2
792880-005
SOCKET HOUSING
1
3
793090-005
ANTI BACKOUT
1
4
79 2882
SOCKET CRIMP
2
5
793222
BLANKING PIN
6
7
793217-022
FASTON RECEPTACLE
6
8
793217-027
INSULATION SLEEVE
2
813779_2D_Working Light Loom 24V
813779_GB-T
MS-DIA-2140
290
ESR4500 06/2004 • Printed in Germany
DIAGRAMS Harness Driving Light JC 442 (Drive-L) JC 442
SP30
SD (SW Driving Lights) Insert wire 545 to CA 206 pin 7 (Main harness loom)
Head-Lights
PC 451
PC 451 1
4
2
5
3
6
Pin No. 1 2 3 4 5 6
Wire No. 644 373 --369 365 ---
1
7
2
8
3
9
4
10
5
11
6
12
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12
358 360
12
+ 12 V PL + 12 V Ind.
HL = Head Light
SI (SW Indicator)
PL = Parking Light
377 363
PC 450 PC 450 5
3
6
SP32
10 11 GND + 12 V HL + 12 V PL + 12 V Ind.
4 5 8 9 Rear Lights
PC 449
3
2
4
+ 12V Brake + 12V TL + 12V Ind. GND
SP29 +12V Ind.
365
364
366 367 368
SP30 GND
6 7 8 9
646
363 649 361 / 377 / 378
378
Indicator
13 14
Wire insertion view
49
1
Wire No. 372 375 367 648
STARPOINTS SP:
16
49a
PC 449
Pin No. 1 2 3 4
364
TL = Tail Light 49
2
Wire No. 645 374 --370 366 ---
31
SP33
4
Pin No. 1 2 3 4 5 6
49a
1
Sig. GND + 12V Brake GND
359
4 5 8 9 SP29
+ 12V HL GND + 12V PL + 12V SD 2 SD 1 + 12V Ind. GND
2 3 8 9
545 GND + 12 V HL
Wire No. 356 644 357 358 359 360 361 645 --545 362 646
647 648 649
PC 448 1
3
2
4
SP31 +12V Brake
PC 448 Pin No. 1 2 3 4
Wire No. 371 376 368 647
+ 12V Brake + 12V TL + 12V Ind. GND
6 7 8 9
SP31
371
362 372
SP32 +12V HL
31
373
356 374
SP33 +12V PL
369
357
370 375 376
ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
2
792881-006
SOCKET HOUSING
1
3
793091-006
ANTI BACKOUT
1
4
792881-004
SOCKET HOUSING
1
5
793091-004
ANTI BACKOUT
1
6
792881-003
SOCKET HOUSING
1
7
793091-003
ANTI BACKOUT
1
8
792883
SOCKET CRIMP
27
9
793222
BLANKING PIN
5
10
793217-022
FASTON RECEPTACLE
5
11
793217-027
INSULATION SLEEVE
5
12
814320-001
CONTACT
1
13
813444-001
FLAT SOCKET
3
14
811996-001
RELAY SOCKET
1
16
794611-003
RESISTOR
1
lower view of Relay Socket
813836_2C
813836_GB-T
ESR4500 06/2004 • Printed in Germany
MS-DIA-2140
291
DIAGRAMS Harness Travel Alarm RELAY K7
RELAY K8 Wire No. 2988 5931 926 925 ---
Pin No. 30 85 86 87 87a
Wire No. 925 926 2987 2989 ---
Pin No. 30 85 86 87 87a
TRAVEL ALARM RELAY K8_24 V
30
30 85
85
87
86
86 87 87a
85
30 85
30
-
+
+
6 7
86 87 87a
87
-
86
RELAY K7_24 V
JC 421 1
3
2
4
Pin No. 1 2 3 4
Wire No. 2987 5931 2988 540
2 3 4
14 2989
JC 421 TRAVEL ALARM
540
CONNECT THE RED WIRE WITH 2989 & THE GREEN WIRE WITH 540
ALARM CORD / VOLUME ADJUST 796401
TRAVEL ALARM 126035 ALM
RED
HIGH
SET
GRN
TINED
813527_2B_Travel Alarm Loom
ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
2
792880-003
PIN HOUSING
1
3
793090-003
ANTI BACKOUT
1
4
792882
PIN CRIMP
4
6
813444-001
FLAT SOCKET
8
7
811996-001
RELAY SOCKET
2
8
811995-001
RELAY 24 V
2
14
793217-010
BUTT SPLICE
2 813527_GB-T
MS-DIA-2140
292
ESR4500 06/2004 • Printed in Germany
DIAGRAMS Harness DC/DC Converter with Harness Options 813445
DC / DC Converter + 48 V 2995
6 10
- BV 544
JC 447
+ 12 V / 24 V 354 355
6 10
12 V GND
1
4
2
5
3
6
JC 447 (DC-DC) Pin no. 1 2 3 4 5 6
Wire no. 2995 544 354 642 355 643
+ BV B+ 12 V / 24 V GND + 12 V / 24 V GND
2 3 4
642 643
814056_2C_DC-DC Supply-Loom
ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
2
792881-004
SOCKET HOUSING
1
3
793091-004
ANTI BACKOUT
1
4
792883
SOCKET CRIMP
6
6
793217-022
FASTON RECEPTACLE
4
10
793409-007
SHRINK SLEEVE
4 814056_GB-T
ESR4500 06/2004 • Printed in Germany
MS-DIA-2140
293
DIAGRAMS Harness DC/DC Converter without Harness Options 813445
DC/DC Converter + 48 V
Jumper
2986
PC 443 - BV
539
1
3
2
4
8 12
PC 443 (12 V / 24 V) Pin No. 1 2 3 4
Wire No. 353 641 353 352
--GND --+ 12/24 V
2 3 6
+ 12 V
JC 440
352
1
5
2
6
12/24 V GND
3
7
641
4
8
4 5 6 7
JC 440 OPTIONS Pin No. 1 2 3 4 5 6 7 8
Wire No. ----2986 ------539 ---
+ 48 BV
- BV
813753_2E_DC-DC Conv.-Loom_Options
ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
2
792880-003
PIN HOUSING
1
3
793090-003
ANTI BACKOUT
1
4
792880-005
PIN HOUSING
1
5
793090-005
W 8P ANTI BACKOUT
1
6
792882
PIN CRIMP
6
7
793222
BLANKING PIN
6
8
793217-022
FASTON RECEPTACLE
4 813753_GB-T
MS-DIA-2140
294
ESR4500 06/2004 • Printed in Germany
DIAGRAMS Harness Heated Seat
JC 456 from Heated Seat (Special)
Switch (3rd Corner) SH (Switch Heater)
PC 456 Pin No. A B C
+ 48 BV - BV
PC 456 Wire No. 29105 548 ---
29105
A C B
29104
2 3 4
8 9
JC 446 1
4
3
Wire No. 29104 548 -----
2
Pin No. 1 2 3 4
+ 48 BV - BV
5 6 7
JC 446
PC 446 from Harness Option 813445
ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
2
792882
PIN CRIMP
2
3
808123-002
PIN HOUSING
1
4
793090-002
ANTI BACKOUT
1
5
792883
SOCKET CRIMP
2
6
808124-003
SOCKET HOUSING
1
7
793091-003
ANTI BACKOUT
1
8
793217-022
FASTON RECEPTACLE
2
9
793217-027
INSULATION SLEEVE
2
814430_2A_Heated Seat Loom
814430_GB-T
ESR4500 06/2004 • Printed in Germany
MS-DIA-2140
295
DIAGRAMS Harness 12V / 24V Supply to B/W Screen
12 V / 24 V Supply --> to PC 443 from Loom 813753 or to PC 444 from Loom 813445
Input 12 V / 24 V Supply from M55-K Monitor s/w DC 12/24 V
JC 443 / 444 - optional GND + 12/24 V
Pin No. 1 2 3 4
Wire No. --WHT --BRN
JC 443 / 444
1 BRN
3
1
2
4
2
3 4 WHT
2 3 4
+ 12 V / 24 V
GND
5 6
814405_2A_Cable Motec Cam-Supply sw Monitor
ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
2
792883
SOCKET CRIMP
2
3
808124-003
SOCKET HOUSING
1
4
793091-003
ANTI BACKOUT
1
5
116858
FEMALE TERMINAL
3
6
803450-006
PLUG
1 814405_GB-T
MS-DIA-2140
296
ESR4500 06/2004 • Printed in Germany
DIAGRAMS Harness Monitor B/W or Connection Box to Connector Panel
Monitor s/w or MB 1100.12 Box
Mon.-VID
Monitor-VIDEO VID SH VCC GND
Pin No. 1 Shield2braid 4 3 Shield4braid
JC 453
Wire No. WHT braid WHT YEL braid RED
PC 453
1 2 3 4
1
3
2
4
PC 453 Pin No. 1 2 3 4
Wire No. WHT braid WHT YEL braid RED
VID SH VCC GND
2 3 4 SUFFIX 814499-001 814499-002
DISCRIPTION / REMARKS Application for M 55-K Monitor s/w Application for MB 1100.12 Box & MD 3680 TFT Display
814499_2A_Cable Motec Cam.-Monitor Inst draw
ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
2
808123-003
HOUSING
1
3
792882
PIN CRIMP
4
4
793090-003
ANTI BACKOUT
1 814499_GB-T
ESR4500 06/2004 • Printed in Germany
MS-DIA-2140
297
DIAGRAMS Harness (Camera) Connector Panel to Reach Carriage
JC 453 Pin No. 1 2 3 4
VID SH VCC GND
PC 454
JC 453
Wire No. WHT braid WHT YEL BLK
3
1
1
3
4
2
2
4
5 6 7
PC 454 Pin No. 1 2 3 4
Wire No. WHT braid WHT YEL BLK
VID SH VCC GND
2 3 4
8
814407_2A_Cable Motec Cam-Comp-Reach
ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
2
792882
PIN CRIMP
4
3
808123-003
PIN HOUSING
1
4
793090-003
ANTI BACKOUT
1
5
792883
SOCKET CRIMP
4
6
808124-003
SOCKET HOUSING
1
7
793091-003
ANTI BACKOUT
1 814407_GB-T
MS-DIA-2140
298
ESR4500 06/2004 • Printed in Germany
DIAGRAMS Harness (Camera) Reach Carriage to Mast
PC 454
JC 455
JC 454 Pin No. 1 2 3 4
VID SH VCC GND
PC 455
JC 454
Wire No. WHT braid WHT YEL BLK
3
1
1
3
4
2
2
4
2 3 4
PC 455 Pin No. 1 2 3 4
Wire No. WHT braid WHT YEL BLK
VID SH VCC GND
2 3 4 814408_2A_Cable Motec Cam.-Mast
ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
2
792883
SOCKET CRIMP
8
3
808124-003
SOCKET HOUSING
2
4
793091-003
ANTI BACKOUT
2 814408_GB-T
ESR4500 06/2004 • Printed in Germany
MS-DIA-2140
299
DIAGRAMS Harness (Camera) Mast to Camera
PC 455
Fork Camera
JC 455 Pin No. 1 2 3 4
VID SH VCC GND
Cam.-VID
JC 455
Wire No. WHT braid WHT YEL braid RED
3
1
4
2
1 2 3 4
Camera-VIDEO Pin No. 1 2 3 4
Wire No. WHT braid WHT YEL braid RED
VID SH VCC GND
2 3 4 814521_2B_Cable Motec Cam-Fork-Camera Inst draw
ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
2
792882
PIN CRIMP
4
3
808123-003
PIN HOUSING
1
4
793090-003
ANTI BACKOUT
1 814521_GB-T
MS-DIA-2140
300
ESR4500 06/2004 • Printed in Germany
DIAGRAMS Harness (Camera) TFT Display to Connection Box
TFT-Display
MB 1100.12 Box
MB-Box TFT-Display VID SH VCC GND
Pin No. 1 Shield2 braid 3 4 Shield4 braid
Wire No. WHT braid WHT YEL braid RED
Display 1 2 3 4
1 2 3 4 5 6 7 8 9
MB-Box Pin No. 1 2 3 4 5 6 7 8 9
Wire No. VID SH --GND MIRH --POC/VCC -----
814498_2A_Cable Motec Cam-Display-Box
ESR4500 06/2004 • Printed in Germany
MS-DIA-2140
301
DIAGRAMS Harness 12 V Supply to Connection Box
12 V Supply --> to PC 443 Loom 813753 or to PC 444 Loom 813445
Input 12 V Supply MB 1100.12 Box (TFT-Display) DC 12 V
JC 443 / 444 - optional GND + 12 V
Pin No. 1 2 3 4
Wire No. --WHT --BRN
JC 443 / 444
1 BRN / BRN
+ 12 V
3
1
2 WHT
GND
4
2
3 BRN
+12 V
4
2 3 4
5 6 Jumper
814526_2A_Cable Motec Cam-Supply TFT Display
MS-DIA-2140
302
ESR4500 06/2004 • Printed in Germany
DIAGRAMS Harness and Installation Drawing 6th Function
Information: Installation drawing, electrical schematic 6th hydraulic function SP 804 +BV
SP 14 +BV
NOTES: Circuit shown with Momentary SW in relaxed position - in this state the 5th function should operate as normal. Depressing the Momentary SW will cause the 6th function to operate instead of the 5th function.
2921 (SP9 FU2)
CA 422 RED +BV 14
2938
CA 601 + BV 2
CA 801 + BV
7
GRN
GRN +
GRN +
Connection to 5911
GRN
GRN
GRN
18 WHT
8
GRN / WHT
GRN / WHT
35 GRN
12 C61 GRN
C61 GRN / BLK
8 12
SV6
SV5
BLK BLK
Momentary SW & Cable 814475
7 GRN
Connect wire GREEN to cable 5911 from PC 422 pin 18
GRN
Insert wire GREEN to pin 18 from PC 422
GRN / WHT
Insert wire GREEN / WHITE to pin 35 from PC 422
MOMENTARY GRN / WHT GRN GRN GRN / WHT
6
SW_MOMENTARY
5
8
814475_2A_Cable Diagr 6th function
ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
3
793092-00x
PVC SLEEVE
2.2 m
5
792883
SOCKET CRIMP
2
6
793217-007
BUTT SPLICE YELLOW
1
7
793217-010
BUTT SPLICE RED
1
8
796486
SWITCH
1 814475_GB-T
ESR4500 06/2004 • Printed in Germany
MS-DIA-2140
303
DIAGRAMS Harness Davis Derby System Davis Derby EV16 control unit B- (HDM) C1: connection to EV 16 Control Unit / Antenna C2: connection to Remote Keypad / Card Reader
546 / 547
C3: connection to Collision sensor (Shock)
4 22 RELAY K14_24 V
29101 (LIFT)
RELAY K15_24 V
RELAY K14 +
86 87 87a
86
30 85
30
86 87 87a
Pin No. 30 85 86 87 87a
4 23
12
C1
phase U (HDM)
4 21
Wire No. 929 928 212 29103 ---
87
+
85
30 85
-
87
11
-
86
Wire No. 29102 5932 928 929 ---
30
Pin No. 30 85 86 87 87a
RELAY K15
85
546 ITEM 17 ITEM 17 C3 ITEM 17 C3 ITEM 17 C3 ITEM 17 ITEM 16 ITEM 16 29100 29101 211 ITEM 17 ITEM 17 ITEM 17 ITEM 17 ITEM 17 ITEM 17 ITEM 17 ITEM 17 ITEM 17 ITEM 16
GRN (C 1)
Wire No.
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
YEL (C 1)
Pin No.
ITEM 16 210 547 BLU (C1) RED (C1) C2 C2 5932 ITEM 17 ITEM 17 C3 ITEM 17 C3 ITEM 17 ITEM 17 ITEM 16 ITEM 16 ITEM 17 ITEM 17 YEL (C1) GRN (C1) C2 C2
BLU (C 1)
Wire No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
RED (C 1)
Pin No.
208 / 209
29100 (DRIVE)
4 21
+BV S1 (ED1) phase U (TDM)
Davis Derby EV16
JC 420
JC 420 Pin No. A B C
A C B
Wire No. 29102 --29103
7 8 9 10 16 17 18 19 20 4 13 14 24 Fuse Box 1 FU1 7
2 FU2 8
3 FU3 9
4 FU4 10
5 FU5 11
6 FU6 12
Pin No.
Wire No.
Pin No.
Wire No.
1 2 3 4 5 6
208 209 -----------------
7 8 9 10 11 12
210 / 212 211 -----------------
Fuse No. Fuse type FU1 FU2 FU3 FU4 FU5 FU6
5 A / 80 V 5 A / 80 V -----------------
814337_2C_DD EV 16 Trucklog Loom
FUSE_BOX
ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
2
051051-004
CABLE TIE
AR
4
793409-007
SHRINK SLEEVE
7
792880-002
PIN HOUSING
8
793090-002
9
ITEM NO.
PART NO.
4
16
814433
CAVITY PLUG
6
1
17
814432
CAVITY PLUG
25
ANTI BACKOUT
1
18
814431
WIRE SEAL
11
792882
PIN CRIMP
2
19
814320-003
CONTACT
11
10
793222
BLANKING PIN
1
20
814155
PLUG
1
11
813444-001
FLAT SOCKET
8
21
793217-006
RING TERMINAL M8
2
12
811996-001
RELAY SOCKET
2
22
796217-017
RING TERMINAL M8
1
13
806703-002
FUSE 5A (80V)
2
23
793217-013
RING TERMINAL M10
1
14
806702
FUSE BOX
1
24
793217-022
FASTON RECEPTACLE
814337-1_GB-T MS-DIA-2140
304
DESCRIPTION
QUANTITY
4 814337-2_GB-T ESR4500 06/2004 • Printed in Germany
DIAGRAMS Davis Derby EV 16 Circuit Program
INTERFACE UNIT PIN No.
RELAY K14_24 V
+
86 87 87a
CONTROL UNIT
928
5932
SPARE 0V
4
CAN OUT 0V
RED
CAN +5V
5
CAN OUT +5V
YEL
CAN L
18
CAN OUT HIGH
19
CAN OUT LOW
6
CAN EXT 0V
7
CAN EXT +5V
20 21
CAN EXT HIGH CAN EXT LOW
8
OPTO O/P 1 +VE
2
+VE SUPPLY IN
11
SHOCK1 0V
12
SHOCK1 +5V
26
SHOCK1 INPUT
GRN BLU
CAN 0V
SMART CARD CAN +5V READER or KEYPAD CAN H
C2
CAN L
RED YEL GRN
5932 210
929
48 V BATT.
15, 29, 42 BLU CAN 0V
CAN H
C1
87
30 85
30
86
+
30
+
86 87 87a
85
30 85
-
+
86
-
RELAY K15_24 V
85
ED1
87
FU 7 = 425 A
JC 420 C B
EDS
29102
A
KEY SWITCH CONNECTOR (HARNESS MAIN LOOM)
Function
(RED)
29103
806702
212 208
209
GRN
1
FU1
2
5A FU2
3
5A FU3
9
ONLY ONE
BLK
25
SHOCK2 0V
4
FU4
10
C3
BLU
27
SHOCK2 INPUT
5
FU5
11
211
32
INPUT 3 (RED)
30
INPUT 1 (RED / WHT)
31
INPUT 2 (RED / WHT)
22
OPTO O/P 1 -VE
(GRN)
3
-VE SUPPLY IN
(GRN)
7 8
210
COLLISION SENSOR (SHOCK)
211
RED YEL
29100
U
12
1
23
13
CA202 V
W
29100
B-
6
FU6
29101
12
B+ FUSE_BOX
TRACTION DRIVE MODULE (TDM)
29101
BUS-BAR
U
12
1
23
13
CA201
B-
V
546 W
BUS-BAR
B+
547
HYDRAULIC DRIVE MODULE (HDM) 814341_2A_DD EV 16 Trucklog circ-diagr
ESR4500 06/2004 • Printed in Germany
MS-DIA-2140
305
DIAGRAMS Davis Derby S 16 Circuit Program
INTERFACE UNIT PIN No.
FU 7 = 425 A
RELAY K14_24 V
ED1
-
RELAY K15_24 V
-
+
30 85
86 87 87a
+
30 85
CONTROL UNIT
A
EDS
JC 420 C B
KEY SWITCH CONNECTOR (HARNESS MAIN LOOM) 29102
CAN 0V CAN +5V CAN H
C1
4
CAN OUT 0V
RED
5
CAN OUT +5V
YEL
18
CAN OUT HIGH
19
CAN OUT LOW
6
CAN EXT 0V
7
CAN EXT +5V
20 21
CAN EXT HIGH CAN EXT LOW
8
OPTO O/P 1 +VE
2
+VE SUPPLY IN
11
SHOCK1 0V
12
SHOCK1 +5V
26
SHOCK1 INPUT
25
SHOCK2 0V
27
SHOCK2 INPUT
32
INPUT 3 (RED)
30
INPUT 1 (RED / WHT)
31
INPUT 2 (RED / WHT)
22
OPTO O/P 1 -VE
(GRN)
3
-VE SUPPLY IN
(GRN)
GRN
CAN L
BLU RED YEL
86 87 87a
5932
87
86
85
30
87
86
30
+
85
GRN
+
210
929
48 V BATT.
BLU
928
5932
212
29103
806702
209
1
FU1
2
5A FU2
3
5A FU3
7
210
8
211
SMART CARD CAN +5V READER or KEYPAD CAN H
COLLISION SENSOR (SHOCK) ONLY ONE
29100
4 U
12
1
23
13
CA202 V
W
FU4
CAN L
RED YEL GRN GRN
9
RED
T-CONNECTOR Pin CAN 0V (BLU) 4 CAN +5V (RED) 3 CAN H (YEL) 1 CAN L (GRN) 2 5 ---
YEL
BLK
10
C3 5
FU5
211
11
29100
B-
6
FU6
(RED)
CAN 0V
C2 208
Function
BLU
29101
12
B+ FUSE_BOX
TRACTION DRIVE MODULE (TDM)
29101
U
12
1
23
13
CA201
B-
V
546 W
B+
547
HYDRAULIC DRIVE MODULE (HDM)
814532_2A_DD S16 Trucklog circ.-diagr
MS-DIA-2140
306
ESR4500 06/2004 • Printed in Germany
DIAGRAMS Harness 1 Coldstore Cabin Connection Point B551
550
4 8
Heater SCREEN Heater REAR
SUPPLY LINE for FU 8 / FU 9
11 12
PC 460 Pin No. 1 2
220
4 7
Wire No. 29110 552
Heater LEFT
221
PC 461 Pin No. 1 2
Heater RIGHT
1 2
PC 462 Pin No. 1 2
11 12
Wire No. 29111 553
11 12
Wire No. 29112 554
Traction Drive Module B552 553 554
4 8 29110 29111 29112
4 8
ED2 S2
4 10
220 / 221
ED1 S1
ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
7
793217-043
RING -TERMINAL M5
2
8
793217-035
RING -TERMINAL M8
4
9
793217-044
RING -TERMINAL M8
1
10
793217-045
RING -TERMINAL M10
1
11
814817-002
PLUG FEMALE
3
12
814818-002
SOCKET
550 / 551
4 9
Traction Drive Module B-
814565_2A_Coldstore Loom_01
6 814565-001_GB-T
ESR4500 06/2004 • Printed in Germany
MS-DIA-2140
307
DIAGRAMS Harness 2 Coldstore Cabin Time Delay Relay
12 13
15
9 10
ED2 B+ Coil
JC 445 (Options cabin)
12 13
14
Pin No. 1 2 3 4
664
ED2 B- Coil
2x 6 556 / 557 Connection Point B555 FU 9 2x
4
20 21 22
3
JC 466
Wire No. 29116 558 -----
Heater TOP
24 20 21 22
PC 463 Wire No. 29115 557
Pin No. 1 2
6 223
9 10
ED3 S1 (FU9)
6
223
5
FU 8 Wire No. 29113 555
JC 419 Pin No. A B C
Heater FRONT
9 10 PC 459
16 17 23 24
Wire No. 29114 556
9 10 PC 457 Pin No. 1 2
29120
Wire No. 661 393
18 19 22 24
SPS interrupt
12 13 392
390 / 393
SW Heater Screen
29119
ITEM NO.
PART NO.
DESCRIPTION
QUANTITY
5
793217-043
RING -TERMINAL M5
2
6
793217-035
RING -TERMINAL M8
6
9
814817-002
PLUG FEMALE
4
10
814818-002
SOCKET
8
11
814735
CONNECTOR COMPLETE
1
B
SW door cabin
Wire No. 29120 --050
C
4 12
Windscreen wiper FRONT
Pin No. A B C
A
PC 465
JC 419
Pin No. 1 2
Wire No. 29119 --050
B
Pin No. 1 2
814565_2A_Coldstore Loom_02
222
A
PC 464
C
11
ED2 S1 (FU8)
PC 465
Heater / Fan Assembly
Pin No. 1 2 3 4
2
222
JC 466 (+ 48 V)
1
JC 445
12 13 x2 Connection Point B-
Wire No. 662 660 394 391
559 ED3 B- Coil
558 / 559
4
29113
3
29118
663 395
663 / 664
2
29117
Wire No. 662 394
Pin No. 1 2
1
29118
ED3 B+ Coil
ED3 S2
6
PC 458
Interior Lighting
87
660 /661
390 / 391
29116 /29117 87z
15
6 29114 / 29115
31
ED2 S2
30
392
K14 25 RELAY SOCKET 26 27
Windscreen wiper REAR
14 395
12
793217-022
FASTON RECEPTACLE
8
13
793217-027
INSULATION SLEEVE
6
14
052062-001
END SPLICE
2
15
052062-002
END SPLICE
1
16
792880-002
PIN HOUSING
1
17
793090-002
ANTI BACKOUT
1
18
792881-002
SOCKET HOUSING
1
19
793091-002
ANTI BACKOUT
1
20
792881-003
SOCKET HOUSING
2
21
793091-003
ANTI BACKOUT
2
22
792883
SOCKET CRIMP
8
23
792882
PIN CRIMP
2
24
793222
BLANKING PIN
4
25
813444-001
FLAT SOCKET
4
26
813444-003
FLAT SOCKET
1
27
811996-001
RELAY SOCKET
1 814565-002_GB-T
MS-DIA-2140
308
ESR4500 06/2004 • Printed in Germany
HYDRAULIC SCHEMATIC
Printed in Germany
309
Blank page
Printed in Germany
310
HYDRAULIC SCHEMATIC Hydraulic Schematic
Primary Lift Cylinder
Secondary Lift Cylinder
Strainer
Abbreviations see chapter M2 – Hydraulic System, “Operation”
Lift Velocity Fuse
Reach Reach Cylinder
Mast Functions Tilt Cylinder
Sideshift Cylinders
Suction Strainer
Return Filter and Breather (contains a filter) 5th Function Tank MS-2140-070
ESR4500 06/2004 • Printed in Germany
MS-HYD-2140
311
HYDRAULIC SCHEMATIC Hydraulic Lines to the Valve Block to the valve block, port B2 to the valve block, port A2 NOTE 1
Torque to
20 - 25 Nm
NOTE 2
Torque to
24 - 28 Nm
NOTE 3
Torque to
40 - 44 Nm
NOTE 4
Torque to
80 - 88 Nm
NOTE 5
Torque to
34 - 37 Nm
NOTE 6
Torque to 107 - 119 Nm
NOTE 7
Torque to
77 - 85 Nm
to the tank
to the pump
MS-2140-083
ESR4500 06/2004 • Printed in Germany
MS-HYD-2140
312