Download PDF: Service Manual for Yale B860 (MC10-MC12-MC15) Forklift

SERVICE

DIAGNOSTICS

DIAGNOSTICS 1.00 ALARMS DERIVED FROM “COMBI” CONTROLLER ..................................................................................... 2 2.00 ALARMS DERIVED FROM “EPAS” CONTROLLER ..................................................................................... 25 3.00 ALARMS DERIVED FROM “TILLER” CONTROLLER .................................................................................. 26 4.00 ALARMS DERIVED FROM “DDI” CONTROLLER ......................................................................................... 26

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DIAGNOSTICS

1.00

ALARMS DERIVED FROM “COMBI” CONTROLLER

The alarms which block the machine are displayed on “DDI” with a numerical alarm code preceded by two letters identifying the module in alarm, the LED becomes red as well.

“Co” followed by the alarm number corresponds to the “COMBI” controller.

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SERVICE

SERVICE

DIAGNOSTICS

ERROR CODE: 9024 Truck behaviour: traction and hydraulics disabled, main contactor open LED on DDI: red Error code 9024

Type of failure Short-circuit on the traction motor or on a controller part

Failure explanation Traction motor phase U, V or W shorted to B+ or B-, two phases shorted with each other, controller power stage shorted

Troubleshooting 1. Turn the key to the OFF position and disconnect the battery connector 2. Visually check if there is a short-circuit between the motor phase cable terminals and the controller power terminals B+ or B- (as phase terminals and B+ and B- terminals are close, the cables could be turned in such a way to cause short-circuits with each other) - if there is a short-circuit, remove it and fix the controller terminals by means of screws - if there is not a short-circuit, proceed to point 3 3. Disconnect the motor cables to the controller 4. Check the motor insulation by using a multimeter the resistance should measure minimum 1 MΩ if it does not, replace the traction motor if it does, proceed to point 5 5. Check if the controller phase B+ or B- is shortcircuited by using a multimeter (the controller capacitors should be discharged) if the resistance between the phase terminal and B+ or B- terminal (all three phase terminals should be checked) is lower than 5 kΩ, replace the controller - if the resistance is higher, replace the traction motor after carrying out any check concerning possible mechanical failures of the cables or short-circuits due to these faults and/or short-circuits of the earthing cable of the truck

ERROR CODE: 9088 Truck behaviour: traction and hydraulics disabled, main contactor open LED on DDI: red Error code 9088

Type of failure Short-circuit of the pump motor

Failure explanation Internal short-circuit of the pump motor or external short-circuit between the pump motor cable and B+

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the alarm appears again Turn the key to OFF position and disconnect the battery Disconnect the pump motor cables from the controller Visually check if there are any motor cable faults or possible short-circuit to B+ - if possible, replace the cable and all other damaged truck leads Check if the P- terminal in the controller is shorted to B+ if the resistance between P- and B+ terminals measured by using a multimeter is lower than 40 kΩ, replace the controller If the controller and the pump motor cables are OK, replace the pump motor

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DIAGNOSTICS

SERVICE

ERROR CODE: 9089 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 9089

Type of failure Pump motor connection opened Pump motor shortcircuited with B-

Failure explanation The pump motor is not connected to the controller terminal P- because of a motor internal failure or a loss of power wire connection of the motor or the controller The pump motor cable is short-circuited with B-

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Troubleshooting Tighten the screws on the controller and on the motor side and switch off and on the key switch at intervals of few seconds to see if the error code appears again Turn the key to OFF position and disconnect the battery Check if there is a short-circuit between the motor cable and the controller terminal B-.

If there is, disconnect the pump motor leads from the controller Visually check if the pump motor leads are not interrupted and if the cable and the pump motor terminals are without evidence of arcing or oxidation.

If there is an anomaly, replace the motor leads or just clean the leads, the motor and the controller terminals Visually check the motor lead for any damage and possible short-circuit to BIf there is an anomaly, replace the lead and all other damaged truck leads Check if the P- terminal in the controller is short-circuited with Bif the resistance measured between P- and B- terminals by using a multimeter is lower than 40 kΩ replace the controller Check if the pump motor is in open condition. If the resistance measured between the two motor terminals disconnected from the cables is higher than 0,5Ω, replace the pump motor

SERVICE

DIAGNOSTICS

ERROR CODE: 9090 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 9090

Type of failure Pump overcurrent

Failure explanation The pump current sensor detects a higher current than the one set according to the parameter “maximum pump current” By pressing the lowering push button, the error is cleared and the truck continues its normal operation

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the alarm appears again Check if the pump motor is running check the value of the ParPumpMaxCurr parameter set it to the default value (see service manual) - adjust the maximum pressure to the correct value Check if the pump motor is mechanically blocked, verify there is no binding in the lifting mechanism verify that the weight of the load does not exceed the truck lift capacity listed on the nameplate reduce the load weight replace the maximum pressure valve if it is not working properly or - replace the pump motor if blocked or - replace the controller

ERROR CODE: 12816 Truck behaviour: traction and hydraulics disabled LED on DDI: red Error code 12816

Type of failure Battery overvoltage

Failure explanation The controller detects a voltage higher than 36V

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Troubleshooting Check the battery voltage in the controller between B+ and B- terminals Verify if the battery voltage matches with the voltage listed on the lift truck nameplate - if it does not, install the correct battery Tighten the screws on the controller B+ and + battery terminals as on the main contactor side Check the voltage drop across the main contactor contacts - if the voltage drop is higher than 0,5V at full system current replace the main contactor Check the voltage drop across the fuse on the controller - if the voltage drop is higher than 0,5V at full system current, replace the fuse Check possible damage on the truck leads from the battery to the main contactor and from the main contactor to the controller B+ terminal if there is a damage, replace the leads Check if main contactor contacts are loose due to vibrations if possibility exists, replace that part of wiring Clean all the contacts from the battery to the controller B+ terminal Replace the controller

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DIAGNOSTICS

SERVICE

ERROR CODE: 12832 Truck behaviour: traction and hydraulics disabled LED on DDI: red Error code 12832

Type of failure Battery low voltage

Failure explanation The controller detects a voltage lower than 16V

Troubleshooting Check the battery voltage in the controller between B+ and B- terminals 2. Verify if the battery voltage matches with the voltage listed on the lift truck nameplate If it does not, install the correct battery 3.

Tighten the screws on the controller B+ and + battery terminals as on the main contactor side 4.

Check the voltage drop over the main contactor contacts if the voltage drop is higher than 0,5V at full system current, replace the main contactor 5.

Check the voltage drop across the fuse on the controller if the voltage drop is higher than 0,5V at full system current, replace the fuse 6. Check possible damage on the truck leads from the battery to the main contactor and from the main contactor to the controller B+ terminal if there is a damage, replace the leads 7. Clean all the contacts from the battery to the controller B+ terminal 8. Check the battery state of charge on the DDI recharge the battery install a fully charged battery 9. Check the battery condition (what is its real capacity) install a new battery 10. Replace the controller

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ERROR CODE: 16912 Truck behaviour: traction and hydraulics disabled LED on DDI: red Error code 16912

Type of failure Controller overtemperature

Failure explanation The controller detects a temperature on the power stage higher than 85°C (25°C higher than the one set by means of “Twarning” parameter)

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Troubleshooting Check the air temperature inside the truck - if the air temperature is higher than 45°C, increase the cooling of the motor compartment Check the difference between the temperature on the controller base plate and on the plate with the cooling ribs if the difference is higher than 5°C, check if some silicone grease is present between the base plate and the cooling ribs and if the controller is well fixed to the cooling ribs Reduce the truck use and allow the controller to cool Switch off the key switch and switch it on after 5 minutes. In case the same error code appears again check the temperature on the controller base plate if the temperature is lower than 60°C replace the controller

SERVICE

DIAGNOSTICS

ERROR CODE: 16944 Truck behaviour: traction reduced, hydraulics enabled LED on DDI: red Error code 16944

Type of failure Controller overtemperature

Failure explanation The controller detects a temperature on the power stage higher than 60°C (higher than the temperature set by means of “Twarning” parameter)

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Troubleshooting Check the “Twarning” parameter and verify that the value corresponds to the parameter default value Check the air temperature inside the truck if the air temperature is higher than 45°C, increase the cooling of the motor compartment Check the difference between the temperature on the controller base plate and on the plate with the cooling ribs if the difference is higher than 5°C check if some silicone grease is present between the base plate and the cooling ribs and if the controller is well fixed to the cooling ribs Reduce the truck use and allow the controller to cool Switch off the key switch and switch it on after 5 minutes. In case the same error code immediately appears again check the temperature on the controller base plate if the temperature is lower than 45°C replace the controller

ERROR CODE:16976 Truck behaviour: traction and hydraulic disabled LED on DDI: red Error code 16976

Type of failure Excess of temperature of power output cables

Failure explanation Controller detects an excess of temperature in the output power cables

Troubleshooting Check the air temperature inside the truck - if the air temperature is greater than 45°C increase the compartment cooling 2. Reduce the truck usage and allow the motor to cool 3. Check if the truck is overloaded or the motor is partially blocked 4. Switch off the key switch and switch it on after 10 minutes. In case that the same error code immediately appears again check the resistance of the temperature sensor - if the resitance is zero, replace the temperature sensor 5. Check if the power cables are well fixed to the controller and motor terminals - otherwise fix them with the prescribed driving torque 6. Check if the terminals of power wires are clean and without consequence of voltaic arcs - otherwise replace wiring 7. Check if the power terminals of the controller and of the motor are without consequence of voltaic arcs otherwise brush them 1.

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DIAGNOSTICS

SERVICE

ERROR CODE: 17168 Truck behaviour: traction disabled, hydraulics enabled LED on DDI: red Error code 17168

Type of failure Traction motor overtemperature

Failure explanation The controller detects a temperature of the traction motor higher than 155°C

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Troubleshooting Check the air temperature inside the truck if the air temperature is higher than 45°C, increase the cooling of the motor compartment Reduce the truck use and allow the controller to cool Turn the key to OFF position and disconnect the battery check the resistance between the pins on the motor temperature sensor connector if the resistance is higher than 1450 Ohms and the motor stack temperature is lower than 130 °C, replace the sensor check if the truck wiring is OK if it is not, replace it Check if the truck is overloaded or if the motor is partially blocked Switch off the key switch and switch it on after 10 minutes. In case the same error code immediately appears again, check the temperature of the motor - if the temperature is lower than 130°C, replace the controller

ERROR CODE:17169 Truck behaviour: traction reduced, hydraulics enabled LED on DDI: red Error code 17169

Type of failure Traction motor overtemperature

Failure explanation The controller detects a temperature of the traction motor higher than 120°C

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Troubleshooting Check the air temperature inside the truck if the air temperature is higher than 45°C, increase the cooling of the motor compartment Reduce the truck use and allow the controller to cool Turn the key to OFF position and disconnect the battery check the resistance between the pins on the motor temperature sensor connector if the resistance is higher than 1250 Ohms and the motor temperature is lower than 95 °C, replace the sensor check if the truck wiring is OK if it is not, replace it Check if the truck is overloaded or if the motor is partially blocked Switch off the key switch and switch it on after 10 minutes. In case the same error code immediately appears again, check the temperature on the motor if the temperature is lower than 90°C, replace the controller

SERVICE

DIAGNOSTICS

ERROR CODE: 20756 Truck behaviour: traction and hydraulics disabled LED on DDI: red Error code 20756

Type of failure Pin 1 on 35 pin connector not connected

Failure explanation The controller doesn’t detect any voltage at pin 1

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the alarm appears again Switch off the key switch and disconnect the truck 35 pin connector from the controller switch on the key switch and measure the voltage between pin 1 and B- on the truck connector - if there is no voltage, there should be some problem with the truck wiring or the key switch - if battery voltage is measured on pin 1, switch off the key switch, connect the connector to the controller and after 10 minutes switch on the key switch again - if the same alarm appears immediately, replace the controller - if the alarm appears at intervals of few seconds, check again the state of the key switch and the main contactor

ERROR CODE: 21376 Truck behaviour: traction disabled, hydraulics enabled LED on DDI: red Error code 21376

Type of failure Belly switch failure

Failure explanation The controller has detected the belly switch contact is closed, but the tiller has detected that it is open (problem in the CANopen communication)

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Troubleshooting Check that the belly switch contact on the tiller handle has not been held closed at the start-up Verify if all the tiller handle wiring connections are tight and safe Check the resistance across the switch terminals to see if the belly switch is shortcircuited replace the belly switch

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DIAGNOSTICS

SERVICE

ERROR CODE: 21378 Truck behaviour: traction and hydraulics disabled LED on DDI: red Error code 21378

Type of failure No tiller present

Failure explanation The Combi controller does not detect Tiller through CANopen communication at the system start-up

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Troubleshooting Make sure that all the wiring connections between the tiller board and the controller are tight and safe check if pins 1 and 2 of K3 on the tiller board are connected check if pins 27 and 28 of the signal connector on the controller are connected measure the resistance between pin 1 of K3 on the tiller board and pin 28 on the controller - if the resistance is higher than 0.5Ω, replace the wiring measure the resistance between pin 2 of K3 on the tiller board and pin 27 on the controller - if the resistance is higher than 0.5Ω, replace the wiring if the error code appears when vibrations are active, replace the wiring

ERROR CODE: 21379 Truck behaviour: traction disabled, hydraulics enabled LED on DDI: red Error code 21379

Type of failure Tiller switch failure

Failure explanation The CANopen communication between the controller and the tiller board does not operate well; the controller has detected that the tiller switch has been closed, but the tiller has detected the tiller switch has been opened

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Troubleshooting Make sure that all wiring connections between the tiller board and the controller are tight and safe check if pins 1 and 2 of K3 and pin 3 of K1 on the tiller board are connected check if pins 7, 27 and 28 of the signal connector on the controller are connected measure the resistance between pin 1 of K3 on the tiller board and pin 28 on the controller - if the resistance is higher than 0.5Ω, replace the wiring measure the resistance between pin 2 of K3 on the tiller board and pin 27 on the controller - if the resistance is higher than 0.5Ω, replace the wiring measure the resistance between pin 3 of K1 on the tiller board and pin 7 on the controller - if the resistance is higher than 0.5Ω, replace the wiring If the error code appears when vibrations are active, replace the wiring

SERVICE

DIAGNOSTICS

ERROR CODE: 21380 Truck behaviour: traction disabled, hydraulic enabled LED on DDI: red Error code 21380

Type of failure Dig. In. 7 problem

Failure explanation The controller detects no voltage on Dig. in. 7

Troubleshooting 1. Check if the wiring is used - otherwise replace wiring 2. Disconnect the battery and check if the wire to Dig. In. 7 is OK - if the wire is damaged, replace wiring - If the contact on Dig. In 7 is not OK replace wiring

ERROR CODE: 21392 Truck behaviour: traction disabled, hydraulics enabled LED on DDI: red Error code 21392

Type of failure Throttle problem

Failure explanation The throttle is pressed before the tiller is lowered; by releasing the throttle, the error disappears from DDI and the truck continues its normal operation.

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Troubleshooting Switch off the key switch and switch it on after few seconds Release the throttle, lower the tiller and check if the same error code appears if it does, check if the throttle is mechanically blocked on the tiller handle - if it is, remove the reason of the blocking or replace the tiller handle - if it is not, replace the tiller board Otherwise there was an operator mistake.

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DIAGNOSTICS

SERVICE

ERROR CODE: 21409 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 21409

Type of failure Proportional valve failure

Failure explanation The controller detects that the proportional valve circuit is open

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Troubleshooting Switch off the key switch and switch it on after few seconds. Check if the same error code is repeated if it is, disconnect the battery and check the resistance between one side of the proportional valve and pin 22 on the controller and the resistance between the second side of the proportional valve and pin 23 on the controller - if the wires are damaged (interrupted) or the contacts to pins 22, 23 are not OK, replace the wiring if it is repeated, disconnect the battery and check the resistance of the proportional valve not connected in the truck system - if the resistance is higher than 50Ω, replace the proportional valve if yes, check if voltage exists on prop. valve outlet pin during the fork lowering - otherwise replace controller - if yes, check if voltage exists on prop. valve return pin - if the measured voltage is close to the battery voltage, replace the controller

ERROR CODE: 21410 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 21410

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Type of failure Proportional valve failure

Failure explanation The controller detects a short-circuit in the proportional valve circuit

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated if it is, disconnect the battery and the 35 pin connector from the controller.

Check the resistance between pins 22, 23 on the truck connector - measure the resistance of the proportional valve circuit and replace the proportional valve if the resistance is lower than 8Ω, if it is higher replace the wiring

SERVICE

DIAGNOSTICS

ERROR CODE: 21521 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 21521

Type of failure EV2 failure

Failure explanation The controller detects a short-circuit with B+

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Disconnect the controller connector and check the resistance between pin 15 and pin 1 on the truck 35 pin connector If the resistance is lower than 20Ω replace EV2 replace the wiring Check the resistance between pin 15 and pin 1 on the controller connector if the resistance is lower than 100kΩ, replace the controller

ERROR CODE: 21522 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 21522

Type of failure EV2 failure

Failure explanation The controller detects that the circuit of EV2 coil is open

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Disconnect the controller connector and check the resistance between pin 15 on the truck connector and the key switch If the resistance is higher than 50Ω replace EV2 replace the wiring

ERROR CODE: 21523 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 21523

Type of failure EV2 failure

Failure explanation The controller detects a shor-circuit between EV2 and B-

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Disconnect the controller connector and check the resistance between pin 15 on the truck connector and the controller power terminal B-.

If the resistance is lower than 1000Ω replace EV2 replace the wiring Check the resistance between pin 15 and pin 29 on the controller connector if the resistance is lower than 100kΩ replace the controller

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DIAGNOSTICS

SERVICE

ERROR CODE: 21524 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 21524

Type of failure EV3 failure

Failure explanation The controller detects a short-circuit to B+

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Disconnect the controller connector and check the resistance between pin 16 on the truck connector and the key switch If the resistance is lower than 20Ω replace EV3 replace the wiring Check the resistance between pin 16 and pin 1 on the controller connector if the resistance is lower than 100kΩ, replace the controller

ERRROR CODE: 21525 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 21525

Type of failure EV3 failure

Failure explanation The controller detects that the circuit of EV3 coil is open

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Disconnect the controller connector and check the resistance between pin 16 on the truck connector and the key switch If the resistance is higher than 50Ω replace EV3 replace the wiring

ERROR CODE: 21526 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 21526

Type of failure EV3 failure

Failure explanation The controller detects a short-circuit between EV3 and B-

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Disconnect the controller connector and check the resistance between pin 16 on the truck connector and the controller power terminal B-.

If the resistance is lower than 1000Ω replace EV3 replace the wiring Check the resistance between pin 16 and pin 29 on the controller connector if the resistance is lower than 100kΩ, replace the controller

SERVICE

DIAGNOSTICS

ERROR CODE: 21527 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 21527

Type of failure EV4 failure

Failure explanation The controller detects a short-circuit to B+

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Disconnect the controller connector and check the resistance between pin 17 on the truck connector and the key switch If the resistance is lower than 20Ω replace EV4 replace the wiring Check the resistance between pin 17 and pin 1 on the controller connector if the resistance is lower than 100kΩ , replace the controller

ERROR CODE: 21528 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 21528

Type of failure EV4 failure

Failure explanation The controller detects that the circuit of EV4 coil is open

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Disconnect the controller connector and check the resistance between pin 17 on the truck connector and the key switch If the resistance is higher than 50Ω replace EV4 replace the wiring

ERROR CODE: 21529 Truck behaviour: traction enabled, hydraulic disabled LED on DDI: red Error code 21529

Type of failure EV4 failure

Failure explanation The controller detects a short-circuit between EV4 and B-

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Disconnect the controller connector and check the resistance between pin 17 on the truck connector and the controller power terminal B-.

If the resistance is lower than 1000Ω replace EV4 replace the wiring Check the resistance between pin 17 and pin 29 on the controller connector if the resistance is lower than 100kΩ replace the controller

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DIAGNOSTICS

SERVICE

ERROR CODE: 21533 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 21533

Type of failure Horn failure

Failure explanation The controller detects a short-circuit to B+

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Disconnect the controller connector and check the resistance between pin 20 on the truck connector and the key switch If the resistance is lower than 20Ω replace the horn replace the wiring Check the resistance between pin 20 and pin 1 on the controller connector if the resistance is lower than 100kΩ replace the controller

ERROR CODE: 21534 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 21534

Type of failure Horn failure

Failure explanation The controller detects that the circuit of the horn coil is open

Troubleshooting 1. Switch off the key switch and switch it on after few seconds and check if the same error code is repeated 2. If it is, disconnect the battery 3. Disconnect the controller connector and check the resistance between pin 20 on the truck connector and the key switch If the resistance is higher than 50Ω replace the horn replace the wiring

ERROR CODE:21535 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 21535

Type of failure Horn failure

Failure explanation The controller detects a short-circuit between the horn and B-

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Disconnect the controller connector and check the resistance between pin 20 on the truck connector and the controller power terminal B-.

If the resistance is lower than 1000Ω replace the horn replace the wiring Check the resistance between pin 20 and pin 29 on the controller connector if the resistance is lower than 100kΩ, replace the controller

SERVICE

DIAGNOSTICS

ERROR CODE: 21540 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 21540

Type of failure EV5 failure

Failure explanation The controller detects a short-circuit to B+

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Disconnect the controller connector and check the resistance between pin 19 on the truck connector and the key switch If the resistance is lower than 20Ω replace EV5 replace the wiring Check the resistance between pin 19 and pin 1 on the controller connector if the resistance is lower than 100kΩ, replace the controller

ERROR CODE: 21541 Truck behaviour: traction enabled, hydraulic disabled LED on DDI: red Error code 21541

Type of failure EV5 failure

Failure explanation The controller detects that the circuit of EV5 coil is open

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Disconnect the controller connector and check the resistance between pin 19 on the truck connector and the key switch If the resistance is higher than 50Ω replace EV5 replace the wiring

ERROR CODE: 21542 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 21542

Type of failure EV5 failure

Failure explanation The controller detects a short-circuit between EV5 and GND

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Disconnect the controller connector and check the resistance between pin 19 on the truck connector and the controller power terminal B-.

If the resistance is lower than 1000Ω replace EV5 replace the wiring Check the resistance between pin 19 and pin 29 on the controller connector if the resistance is lower than 100kΩ replace the controller

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DIAGNOSTICS

SERVICE

ERROR CODE: 21543 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 21543

Type of failure EV6 failure

Failure explanation The controller detects a short-circuit to B+

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Disconnect the controller connector and check the resistance between pin 21 on the truck connector and the key switch If the resistance is lower than 20Ω replace EV6 replace the wiring Check the resistance between pin 21 and pin 1 on the controller connector if the resistance is lower than 100kΩ replace the controller

ERROR CODE: 21544 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 21544

Type of failure EV6 failure

Failure explanation The controller detects that the circuit of EV6 coil is open

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Disconnect the controller connector and check the resistance between pin 21 on the truck connector and the key switch If the resistance is higher than 50Ω replace EV6 replace the wiring

ERROR CODE: 21545 Truck behaviour: traction enabled, hydraulics disabled LED on DDI: red Error code 21545

Type of failure EV6 failure

Failure explanation The controller detects a short-circuit between EV6 and B-

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Disconnect the controller connector and check the resistance between pin 21 on the truck connector and the controller power terminal B-.

If the resistance is lower than 1000Ω replace EV6 replace the wiring Check the resistance between pin 21 and pin 29 on the controller connector if the resistance is lower than 100kΩ replace the controller

SERVICE

DIAGNOSTICS

ERROR CODE: 21554 Truck behaviour: traction disabled, hydraulics enabled LED on DDI: red Error code 21554

Type of failure Dig. Input problem

Failure explanation The controller detects that the 1500mm sensor is not open and the 500mm sensor is on

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Check the truck wiring to see if it is damaged replace the truck wiring Check the 1500mm and 500mm sensors replace the damaged sensor

ERROR CODE:21555 Truck behaviour: traction disabled, hydraulics enabled LED on DDI: red Error code 21555

Type of failure Dig. Input problem

Failure explanation The controller detects a problem or an inappropriate state of the side gates

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, check if both side gates are open or closed Disconnect the battery Check the truck wiring to see if it is damaged replace the truck wiring Check if the contacts between the truck wiring and the controller are OK replace the truck wiring Check the sensors for detecting the side gate state replace the damaged sensor

ERROR CODE: 21568 Truck behaviour: traction and hydraulics disabled LED on DDI: red Error code 21568

Type of failure Main contactor problem

Failure explanation The controller detects that the main contactor is not switched on

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Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, check the voltage drop across the contacts of the main contactor if the voltage drop is higher than 2V, replace the main contactor Disconnect the battery Check the fuse on the controller replace the fuse Check the power wires that come to and from the main contactor contacts replace the wires Check if the wires are well tight on the main contactor tighten the wires Check if the wire from the main contactor is well tight on the controller power terminal B+ tighten the wire

19

SERVICE

DIAGNOSTICS

ERROR CODE: 21569 Truck behaviour: traction and hydraulics disabled LED on DDI: red Error code 21569

Type of failure Main contactor problem

Failure explanation The controller detects that the main contactor coil is shorted to B+

1.

2.

3.

Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Disconnect the controller connector and check the resistance between pin 18 on the truck connector and the key switch If the resistance is lower than 10Ω - replace the main contactor check if the truck wiring is damaged and if the wire of the main contactor coil is shorted to B+ - Replace the wiring

ERROR CODE: 21570 Truck behaviour: traction and hydraulics disabled LED on DDI: red Error code 21570

Type of failure Main contactor problem

Failure explanation The controller detects that main remote control switch coil is opened

Troubleshooting

1. Switch off the key switch and switch it on after a few seconds and check if the same error code is repeated 2. If yes, disconnect the battery 3. Measure the resistance of the main remote control switch coil on the truck connector - If the resistance is higher than 50Ω replace the main remote control switch - If the error is repeated after the main remote control switch replacement, replace the wiring

ERROR CODE: 21571 Truck behaviour: traction and hydraulics disabled LED on DDI: red Error code 21571

20

Type of failure Main contactor problem

Failure explanation The controller detects that there is a short circuit between the main remote control switch and B -

Troubleshooting

1. Switch off the key switch and switch it on after a few seconds and check if the same error code is repeated 2. If yes, disconnect the battery 3. Measure the resistance of the main remote control switch coil on the truck connector towards B - If the resistance is lower than 100Ω, replace the wiring and if the still appears, replace the controller

SERVICE

DIAGNOSTICS

ERROR CODE: 25089 Truck behaviour: traction and hydraulics disabled LED on DDI: red Error code 25089

Type of failure Software version problem

Failure explanation The controller detects that the software installed is not correct for a motor with a 48 pulse encoder

1.

2.

3.

Troubleshooting Check the traction motor code No. Check the software version that was installed Install the correct software version

ERROR CODE: 25090 Truck behaviour: traction and hydraulics disabled LED on DDI: red Error code 25090

Type of failure Software version problem

Failure explanation The controller detects that the software installed is not correct for a motor with a 64 or 32 pulse encoder

1.

2.

3.

Troubleshooting Check the traction motor code No. Check the software version that was installed Install the correct software version

ERROR CODE: 28945 Truck behaviour: traction and hydraulics disabled LED on DDI: red Error code 28945

Type of failure Electromagnetic brake problem

Failure explanation The controller detects that the electromagnetic brake coil is shorted to B+

1.

2.

3.

4.

Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Disconnect the controller connector and check the resistance between pin 14 on the truck connector and the key switch If the resistance is lower than 15Ω replace the electromagnetic brake replace the wiring Check the resistance between pin 14 and pin 1 on the controller connector if the resistance is lower than 100kΩ, replace the controller

21

SERVICE

DIAGNOSTICS

ERROR CODE: 28946 Truck behaviour: traction and hydraulics disabled LED on DDI: red Error code 28946

Type of failure Electromagnetic brake problem

Failure explanation The controller detects that the electromagnetic brake coil is shorted to B- or open

1.

2.

3.

Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, disconnect the battery Measure the resistance of the electromagnetic brake coil If the resistance is higher than 50Ω, replace the electromagnetic brake

ERROR CODE: 28947 Truck behaviour: traction and hydraulics disabled LED on DDI: red Error code 28947

Type of failure Electromagnetic brake problem

Failure explanation The controller detects that there is a short circuit between the electromagnetic brake and B -

Troubleshooting

1. Switch off the key switch and switch it on after few seconds and check if the same error code is repeated 2. If yes, disconnect the battery 3. Measure the resistance of the electromagnetic brake coil between pin 14 on the truck connector and B - If the resistance is lower than 100Ω replace the wiring - If the error is repeated after the wiring replacement, replace the controller

ERROR CODE: 29445 Truck behaviour: traction and hydraulics disabled, main contactor switched off LED on DDI: red Error code 29445

Type of failure Encoder problem

Failure explanation The controller detects that the signals or just one signal from the encoder are missing

1.

2.

3.

4.

5.

6.

22

Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated If it is, check if the encoder connector is disconnected Measure the voltage at pin 30 of the controller connector if the voltage is lower than 12V, replace the controller Turn the truck driving wheel and check with an oscilloscope if the encoder signals exist.

If they do not, replace the encoder Disconnect the battery Check the wires between the encoder and the controller if no short-circuit is present, replace the wiring

SERVICE

DIAGNOSTICS

ERROR CODE: 33056 Truck behaviour: traction and hydraulics disabled LED on DDI: red Error code 33056

Type of failure CAN open communication problem

Failure explanation The controller cannot reestablish the CAN communication with the tiller board

1.

2.

3.

4.

5.

Troubleshooting Switch off the key switch and switch it on after few seconds and check if the alarm appears again Make sure all wiring connections between the tiller board and the controller are tight and safe Check for the continuity of the wires that serve for the CAN communication between the tiller board and the controller replace the wiring Internal failure in the tiller board replace the tiller board Internal failure of the controller replace the controller

ERROR CODE: 33057 Truck behaviour: traction and hydraulics disabled LED on DDI: red Error code 33057

Type of failure CAN open communication problem

Failure explanation The controller cannot reestablish the CAN communication with the EPAS controller

1.

2.

3.

4.

5.

Troubleshooting Reset the controller to see if the same error code appears again Make sure all wiring connections between the tiller board and the controller are tight and safe Check for the continuity of the wires that serve for the CAN communication between the EPAS controller and the controller replace the wiring Internal failure in the EPAS controller replace the tiller board Internal failure of the controller replace the controller

ERROR CODE: 36864 Truck behaviour: traction disabled, hydraulics enabled LED on DDI: red Error code 36864

Type of failure EPAS problem

Failure explanation The controller detects that the security line of EPAS has a too low value

1.

2.

3.

4.

5.

6.

Troubleshooting Switch off the key switch and switch it on after few seconds and check if the same error code is repeated Make sure that the EPAS security line connections between the EPAS controller and the Combi controller are tight and safe Check for the continuity of the EPAS security line replace the wiring Check if the EPAS controller fuse is burnt replace the fuse Internal failure in the EPAS steering system replace the failed component in the EPAS system Internal failure of the controller replace the controller

23

DIAGNOSTICS

ERROR CODE: 65281 Truck behaviour: traction reduced, hydraulics enabled LED on DDI: red Error code 65281

24

Type of failure Service

Failure explanation The truck has reached the working hours set for the scheduled service

1.

2.

Troubleshooting Carry out the scheduled service Update the service hours

SERVICE

SERVICE 2.00

DIAGNOSTICS

ALARMS DERIVED FROM “EPAS” CONTROLLER

The alarms which block the machine are displayed on “DDI” with a numerical alarm code preceded by two letters identifying the module in alarm, the LED becomes red as well.

“Ep” followed by the alarm number corresponds to the “EPAS” steering motor control.

CODE

DESCRIPTION

SYMPTOMS

Ep 21588 Co 36864

Power stage, fuse

No assistance, the truck stops

Lack of power supply, error on the power MOSFET, fuse burnt

Check if +24V is present on motor B+ terminal.

If it is not present, check the fuse and the power connections. If the power supply is OK, there might be a failure in the motor - replace the motor.

Straight wheel inductive sensor

No assistance, the truck stops

Bad electrical connection, not correctly installed (the distance between the sensor and the metal surface is too small or too big)

Check if the inductive sensor signal changes condition (from 0 to +24V or vice versa) when the wheel passes to the neutral position. Check the assembly distance and the connections.

Ep 65281 Co 36864

Torque sensor

No assistance, the truck stops

Sensor broken, sensor features not Check the connections and verify that there specified, bad electrical connection on are no short-circuits on the sensor connector. If one of the six sensors everything is OK, replace the sensor.

Ep 65282 Co 36864

Mechanical connection

No assistance, the truck stops

Torque bar broken, reducer broken, mechanical connection lost, bad electrical connection on P1 sensor

Ep 29472 Co 36864

POSSIBLE CAUSES

TEST PROCEDURES

Check the trasmission between tiller and EPAS motor, check the torque bar, check the torque sensor connection on pin 5

25

SERVICE

DIAGNOSTICS

3.00

ALARMS DERIVED FROM “TILLER” CONTROLLER

The alarms which block the machine are displayed on “DDI” with a numerical alarm code preceded by two letters identifying the module in alarm, the LED becomes red as well.

“Ti” followed by the alarm number corresponds to the tiller box board “TILLER”.

CODE

DESCRIPTION

Ti 21024

The permanent memory does not work

Ti 21552

Start the control procedure of truck inputs

SYMPTOMS

POSSIBLE CAUSES

The eeprom does The truck does not work not communicate

The truck is waiting

One or more tiller inputs are not on 0. Caused by an operator or by the bad operation of an input (or of more inputs)

Procedure of potentiometer Proportional acquisition not carried out, or throttle switches disabled sensor or neutral switch not working

TEST PROCEDURES

Replace the tiller board Switch off all the switches and put the throttle in neutral position, release the proportional switches.

If an alarm is still present, check the inputs and replace them if they are broken or not operating.

Repeat potentiometer acquisition. Try to move the throttle. If the error repeats itself, the neutral sensor or the throttle sensor are not working correctly. Check if the neutral switch changes its condition correctly.

Ti 29456

Error in the throttle sensor

Ti 29457

Error in the proportional switches

Ti 33072

The Combi is not connected or does not answer

Bad operation of the Combi controller

CAN connection broken or bad operation of the Combi controller

Check CAN connection between Combi and Tiller, check the Combi

Ti 33073

The Epas is not connected or does not answer

Bad operation of the Epas controller

CAN connection interrupted or bad operation of the Epas controller

Check CAN connection between Epas and Tiller, check the Epas

Ti 33074

Inconsistency between the parameter in the tiller and the truck hardware configuration

Key On

Tiller method parameter in the tiller is not set for the truck provided with a numeric keypad, but the numeric keypad is present

Internal problem in the tiller (Change Ramtron).

Ti 33075

Inconsistency between the parameter in the tiller and the truck hardware configuration

Key On

Tiller method parameter in the tiller is set for the truck provided with a numeric keypad, but the numeric keypad is not present

Internal problem in the tiller (Change Ramtron).

4.00

One or both proportional switches are Replace the damaged switch not working correctly

ALARMS DERIVED FROM “DDI” CONTROLER

The alarms which block the machine are displayed on “DDI” with a numerical alarm code preceded by two letters identifying the module in alarm, the LED becomes red as well.

“Dd” followed by the alarm number corresponds to the “DDI” display control.

CODE

DESCRIPTION

The hours stored in DDI DDI 21008 do not correspond to the Combi ones DDI 21024

26

The permanent memory does not work

SYMPTOMS

The COMBI controller has been replaced

POSSIBLE CAUSES

TEST PROCEDURES

The alarm automatically disappears Carry out the working hour passage procedure 10 minutes after the machine ignition from DDI to COMBI

The eeprom does The truck does not work not communicate

Replace the “DDI” display

SERVICE

DIAGNOSTICS TRUTH TABLE Pedestrian model

9

10

12

13

11

K4/3 K4/2 K5/3 K5/2 K6/2 K7/2 K8/2 K9/2

PROPORTIONAL FORK LIFTING

QUICK FORK LOWERING

PROPORTIONAL FORK LOWERING

RIGHT POSITIONER

LEFT POSITIONER

TILTING FORWARD

TILTING BACKWARD

X

X

X

X X X

X X X

2,5-5

X

X

X

X X X X X X X X X X X X X X X X

X X X X X X X X X X X X X X X X

X X X X X X X X X X X X X X X X

X X X X X X X X X X X X X X X X

X X X X X X X X X X X

X X X X X X X X X X X

X X X X X X X X X X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

in1

in7

in8

in9

in11

in12

in10

DRIVE SPEED PERFORMANCE (slow mode) e.i. 6,39 km/h = (MAX SPEED + KMS)/2 (max speed=145Hz)

FORWARD TRAVEL (slow)

SOFT PERFORMANCE MODE

QUICK FORK LIFTING

X

X X X X X X X X X X X X X X X X

in5

SNAIL

X

X X X X X X X X X X X X X X X X

in3

HORN

X

X X X X X X X X X X X X X X X X

in2

BELLY SWITCH

X

X X X X X X X X X X X X X X X X

TYPE OF TRUCK

X

X X X X X X X X X X X X X X X X

FORKS < 1500 mm

X

2,5-0

FORKS < 500 mm

2,5-5

EPAS SAFETY

X

TOP MAST

X X

TILLER LOCK

X X

SIDE PROTECTION 2

X X

SIDE PROTECTION 1

X X

FLOOR PLATE UP

X X

MAN ON FLOOR PLATE

X X

in4

REVERSE TRAVEL (standard) FORWARD TRAVEL (soft)

QUICK REVERSE

X

X

X

X

X X X X X X X X X X X X X X X X

belly switch is ignored if already in reverse travel, otherwise quick reverse

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

X X

X X

REVERSE TRAVEL (soft)

REVERSE TRAVEL (slow)

DRIVE SPEED PERFORMANCE set to turtle level

FORWARD TRAVEL

DRIVE SPEED PERFORMANCE set to turtle level

FORWARD TRAVEL

REDUCED SPEED PERFORMACE to turtle level

FORWARD TRAVEL

REDUCED SPEED PERFORMACE to value set from speed reduction

FORWARD TRAVEL

SNAIL MODE SPEED PERFORMACE (1 km/h (soft);1,5 km/h (standard); 2 km/h (hard))

FORWARD TRAVEL

REVERSE TRAVEL

REVERSE TRAVEL

REVERSE TRAVEL

REVERSE TRAVEL

REVERSE TRAVEL

DISABLED DRIVE - ENABLED STEER (lowered platform and no man presence)

DISABLED DRIVE

DISABLED DRIVE - ENABLED STEER (only the guard rails are out)

DISABLED DRIVE

DISABLED DRIVE - ENABLED STEER (one guard rail is opened and the other is closed)

DISABLED DRIVE

DISABLED DRIVE - ENABLED STEER (one guard rail is opened and the other is closed)

DISABLED DRIVE

DISABLED DRIVE - DISABLED STEER

ALARM ON EPAS

X

X

X

X

X

X

X

X

ELECTRIC STEER

X

X

X

X

QUICK FORK LIFTING (right lifting push button of the tiller head and speed related to the kind of push button pressed (on-off or proportional)

QUICK FORK LIFTING

X

X

QUICK FORK LOWERING (right lowering push button of the tiller head and speed related to the kind of push button pressed (on-off or proportional)

QUICK FORK LOWERING

X

RIGHT POSITIONER RIGHT POSITIONER

RIGHT POSITIONER (first left push button (3) of the tiller head) LEFT POSITIONER (second left push button (4) of the tiller head) TILTING FORWARD (first optional push button (5) of the tiller head) TILTING BACKWARD (second optional push button (6) of the tiller head)

X X

in6

FORWARD TRAVEL (standard)

DRIVE SPEED PERFORMANCE (soft mode) e.i. 9,11 km/h = 70% MAX SPEED (max speed=145 Hz)

STEER

X X

S2

REVERSE TRAVEL (hard)

DRIVE SPEED PERFORMANCE (stand mode) e.i. 11,44 km/h = 88% MAX SPEED (max speed =145 Hz)

DISABLED DRIVE ENABLED STEER UP TO THE COMPLETE STOP + ALARM

2,5-0

X X

S1

2,5-5

FORWARD TRAVEL (hard)

2,5-5 2,5-0 2,5-5 2,5-0 2,5-5 2,5-0 2,5-5 2,5-0 2,5-5 2,5-0 2,5-5 2,5-0

X X

2,5-0

X

X

X

X

X

X

X X

X X

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

X X

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

TILTING FORWARD

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

TILTING BACKWARD

X

X

X

X

X

X

X

X

X

FLASH BEACON (function enabled only if the SHIFTFUNCTION parameter is OFF in the SET OPTIONS menu)

FLASH BEACON

X

X

X

X

X

X

X

X

X

X

X

X

X

BACKUP ALARM (function enabled only if the SHIFTFUNCTION parameter is OFF in the SET OPTIONS menu)

BACKUP ALARM

X

X

X

X

X

X

X

X

X

X

X

X

X

HORN (function enabled only if the SHIFTFUNCTION parameter is OFF in the SET OPTIONS menu)

HORN

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Combi

Combi

Combi

Combi

Combi

18

14

20 22-23 15

16

17

21

19

21

19

out5

out1

out7

EV1

out2

out3

out4

out8

out6

out8

out6

X

X

X

Combi

X X X X X X X X X X X

X

ALARM

Combi

(EV6)

8

Combi

FLASH BEACON (it can be set if active when the tiller is present or when any function is carried out) REVERSE TRAVEL BUZZER (it can be set if active in f.t. or r.t.)

2

Combi

(EV5)

6

Combi

(EV4)

4

Combi

(EV3)

3

Combi

(EV2)

5

Combi

PROPORTIONAL VALVE (EV1)

7

Combi

HORN

Scheda Scheda Scheda Scheda Scheda Scheda Scheda Scheda Scheda Scheda Scheda Scheda Scheda Scheda Tiller Tiller Tiller Tiller Tiller Tiller Tiller Tiller Tiller Tiller Tiller Tiller Tiller Tiller

ELECTROMAGNETIC BRAKE DISABLED

Combi

MAIN REMOTE CONTROL SWITCH

Combi

LIFTING MOTOR

Combi

STEER MOTOR

Combi

OUTPUTS

DRIVE MOTOR

Combi

SLOW PERFORMANCE MODE

Combi

STANDARD PERFORMANCE MODE

Combi

X X

DRIVE SPEED PERFORMANCE (hard mode) e.i. 13 km/h = 100% MAX SPEED (max speed=145 Hz

QUICK REVERSE FOR BELLY SWITCH PRESSED (speed in BELLY MODE : 3 km/h)

Combi

BELLY SWITCH

OPERATIVE FUNCTION

Combi

TILLER ENABLING SENSOR

FUNCTION DESCRIPTION

Combi

SELECT INPUT 2

IMPORTANT: Forward travel = running in the direction opposite to the forks

Combi

SELECT INPUT 1

PIN/CONNECTOR

Combi

TILLER ENABLING SENSOR

Scheda Scheda Tiller Tiller

POTENTIOMETER PUSH BUTTON ENABLING

X = Input not used

SOFTWARE PREARRANGEMENT

TILLER HEAD TILLER BOARD INPUTS

DRIVE CONTROL HALL EFFECT POTENTIOMETER

= ACTIVE INPUT (input at 1 except in case the belly switch is active at 0 ); ACTIVE OUTPUT

ELECTRONIC CONTROL INPUTS

HARD PERFORMANCE MODE

Model selection inputs

26a

SERVICE

DIAGNOSTICS

TRUTH TABLE Model with swing over tiller

2

8

9

10

12

13

11

K4/3 K4/2 K5/3 K5/2 K6/2 K7/2 K8/2 K9/2

X

X

X

FORWARD TRAVEL (standard)

X

2,5-0

X

X

X

X

X

X

X

X

X

REVERSE TRAVEL (hard)

X

2,5-5

X

X

X

X

X

X

X

X

X

FORWARD TRAVEL (standard)

X

2,5-0

X

X

X

X

X

X

X

X

X

REVERSE TRAVEL (hard)

X

2,5-5

X

X

X

X

X

X

X

X

X

FORWARD TRAVEL (standard)

X

2,5-0

X

X

X

X

X

X

X

X

X

REVERSE TRAVEL

X

X X X X X

2,5-5

X

X

X

X

X

X X X X X

X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

X X

X X

X

X

X

X

X

X

X

X

X

X

X

in5

in1

in7

in8

in9

in11

in12

in10

SLOW PERFORMANCE MODE

TILTING BACKWARD

X

X

in3

SOFT PERFORMANCE MODE

TILTING FORWARD

X

X

in2

HARD PERFORMANCE MODE

LEFT POSITIONER

X

X

in4

SNAIL

X

X

in6

HORN

X

X

S2

BELLY SWITCH

X

X

S1

REVERSE TRAVEL (hard)

TILLER ENABLING SENSOR

X

X

TYPE OF TRUCK

X

2,5-5

FORKS < 1500 mm

2,5-0

X

FORKS < 500 mm

X

REVERSE TRAVEL (hard)

EPAS SAFETY

FORWARD TRAVEL (standard)

TOP MAST

X

TILLER LOCK

X

SIDE PROTECTION 2

X

SIDE PROTECTION 1

X

FLOOR PLATE UP

X

MAN ON FLOOR PLATE

X

BELLY SWITCH

X

TILLER ENABLING SENSOR

X

SELECT INPUT 2

X

SELECT INPUT 1

2,5-5

OPERATIVE FUNCTION

REDUCED SPEED PERFORMACE to turtle level

FORWARD TRAVEL

REDUCED SPEED PERFORMACE to value set from speed reduction

FORWARD TRAVEL

DISABLED DRIVE - DISABLED STEER

REVERSE TRAVEL

X

DISABLED DRIVE ENABLED STEER UP TO THE COMPLETE STOP + ALARM

FORWARD TRAVEL

X

STEER

ELECTRIC STEER

X

QUICK FORK LIFTING (right lifting push button of the tiller head and speed related to the kind of push button pressed (on-off or proportional)

QUICK FORK LIFTING

X

QUICK FORK LOWERING (right lowering push button of the tiller head and speed related to the kind of push button pressed (on-off or proportional)

QUICK FORK LOWERING

X

X

X

X

X

X

X

X

X

X

X

X

X

RIGHT POSITIONER

X

X

X

X

X

X

X

X

X

X

X

X

X

RIGHT POSITIONER

X

X

X

X

X

X

X

X

X

X

X

X

X

TILTING FORWARD

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

RIGHT POSITIONER (first left push button (3) of the tiller head) LEFT POSITIONER (second left push button (4) of the tiller head) TILTING FORWARD (first optional push button (5) of the tiller head) TILTING BACKWARD (second optional push button (6) of the tiller head)

REVERSE TRAVEL

X X

2,5-0 2,5-5 2,5-0

TILTING BACKWARD

X

X

X

X

X

FLASH BEACON (function enabled only if the SHIFTFUNCTION parameter is OFF in the SET OPTIONS menu)

FLASH BEACON

X

X

X

X

X

X

X

X

X

BACKUP ALARM (function enabled only if the SHIFTFUNCTION parameter is OFF in the SET OPTIONS menu)

BACKUP ALARM

X

X

X

X

X

X

X

X

X

HORN (function enabled only if the SHIFTFUNCTION parameter is OFF in the SET OPTIONS menu)

HORN

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Combi

Combi

Combi

Combi

Combi

Combi

Combi

Combi

Combi

18

14

20 22-23 15

16

17

21

19

21

19

out5

out1

out7

EV1

out2

out3

out4

out8

out6

FLASH BEACON (it can be set if active when the tiller is present or when any function is carried out) REVERSE TRAVEL BUZZER (it can be set if active in f.t. or r.t.)

6

Combi

(EV6)

4

Combi

(EV5)

3

Combi

(EV4)

5

Combi

(EV3)

7

Combi

(EV2)

Tiller Tiller Tiller Tiller Tiller Tiller Tiller Tiller Tiller Tiller Tiller Tiller Tiller Tiller board board board board board board board board board board board board board board

PROPORTIONAL VALVE (EV1)

Combi

HORN

Combi

ELECTROMAGNETIC BRAKE DISABLED

Combi

MAIN REMOTE CONTROL SWITCH

Combi

LIFTING MOTOR

Combi

STEER MOTOR

Combi

RIGHT POSITIONER

DRIVE SPEED PERFORMANCE (slow mode) e.i. 6,39 km/h = (MAX SPEED + KMS)/2 (max speed=145Hz)

Combi

PROPORTIONAL FORK LOWERING

DRIVE SPEED PERFORMANCE (soft mode) e.i. 9,11 km/h = 70% MAX SPEED (max speed=145 Hz)

Combi

QUICK FORK LOWERING

DRIVE SPEED PERFORMANCE (stand mode) e.i. 11,44 km/h = 88% MAX SPEED (max speed =145 Hz)

Combi

PROPORTIONAL FORK LIFTING

DRIVE SPEED PERFORMANCE (hard mode) e.i. 13 km/h = 100% MAX SPEED (max speed=145 Hz)

Combi

X

IMPORTANT: Forward travel = running in the direction opposite to the forks

FUNCTION DESCRIPTION

Combi

QUICK FORK LIFTING

PIN/CONNECTOR

Combi

OUTPUTS

DRIVE MOTOR

Tiller Tiller board board

POTENTIOMETER PUSH BUTTON ENABLING

X = Input not used

SOFTWARE PREARRANGEMENT

TILLER HEAD TILLER BOARD INPUTS

DRIVE CONTROL HALL EFFECT POTENTIOMETER

= ACTIVE INPUT (input at 1 except in case the belly switch is active at 0 ); ACTIVE OUTPUT

ELECTRONIC CONTROL INPUTS

STANDARD PERFORMANCE MODE

Model selection inputs

out8

out6

26b

SERVICE

ELECTRIC SYSTEM

CPS22/4

CPS22/3

CPS22/1

CPS22/2

CPS21/3 CPS21/4

CPS21/2

DDI

901-E 900-E

13-L

10-N

900-D

901-D

CPS21/1

ELECTRIC FUNCTIONAL DIAGRAM PEDESTRIAN MODEL

13-I 10-M

CPS2/4

T1

10-B 843

CPS2/5

CPSK/1

CPS2/2

CPSK/2

10

10

CPS2/3

POT1

TILLER CONTROL BOX

POT2

Horn pushbutton

10-I

K9/2

K9/1

K8/2

K8/1

K7/2

K7/1 gnd K3/6

sel 2 K3/5

rs 232/can K3/7 gnd K3/8

K2/2

K2/5

K2/4

K2/6

CPS3/4

CPS3/5

CPS3/3

CPS3/6

-

510

CPS9/2

511

13-H

13-E

512

13-M

CPS11/2

CPS19/5

517

out

19A/2

19B/2 19A/3

-

CPS19/2

CPS19/4

CPS19/3

513

514

515

9/A

8/A

5/A

7/A

10/A

2/A

6/A

4/A

3/A

1/A

18/A

25/A

CPS18/2 CPS18/3 CPS18/4 CPS33/3 CPS33/2

EV2

EV3

EV4

EV5

721

780-A 780-B

724

CPS31/1

EV6

CPS31/2

14/A

34/A

33/A 723

Rx

804

Tx

803

20/A

19/A 780

802

805

EV1

21/A

17/A

16/A

23/A

15/A

22/A

30/A

29/A GND

801

HORN

CPS30/C

CPS30/B

19A/1

sensor

13-B

800

CPS14/2

CPS14/1 CPS30/A

Sw11

ELETTRONIC CONTROL COMBI +12V

24/A

26/A

28/A

31/A

27/A

900-A

32/A

901-A

CPS12/2

ETAC CONNECTOR

CPS9/3 CPS8/2

CPS11/3 CPS10/2

13-N

S3

725

CPS31/3

840

CPS7/2

CPS7/1 10-G

EMB

CPS12/1

OVEERIDE BRAKE

13-C 10-P

CPS13/2 13-D

13-Z 13-A

19C/3

19C/2 19B/3

CPS23/2 CPS23/3

+

11/A

13-G

CPS10/3

+

B

S2

CPS8/3

10-E

CPS6/1

A

S1

MTS

19B/1

T.MT

ELETTRONIC CONTROL EPAS

POWER EPAS

-

19C/1

367

POWER COMBI B-

CPS11/1

541

540

CPS19/1

P

can high can low

CPS20/2

CPS20/1

CPS20/4

CPS20/5

GND

Yellow White

VMNP

CPS23/1 10-R

10-Q

CPS10/1

CPS9/1

CPS6/2

Blue Brown

4 2 5 6

24V

+

1 3 Black Red

+3,3V

RED BLACK BLEU WHITE

S

T2

10-D

13

542

T1

CPS20/6

B

10-L

CPS8/1

13-Z

10-F

P1

B-

K2/1

10-C

CPS20/3

ENC.MT

CPS4/1 CPS4/4 CPS4/3 CPS4/2

A2

K2/3

13

841

A

out

tiller sensor

TORQUE AND POSITION SENSOR P2

-

+

P

13/A

W

K1/4

12/A

W

K1/3

10

Sw1

35/A

V

900-C

Boot-en

MTR

U

V

sel 1 K3/3 gnd K3/4

K3/2 901-C

901-B

K1/1

Belly switch

Snail switch

+

CPS3/1 CPS3/2

10 900-B

U

K1/2

843

D1

+12V

P6

ELETTRONIC TILLER BOARD

0 control K3/1

13

Push button

FLD

K6/2

Speed control

Calibration

ARM

P5

+5V

FU1 415A

PM

P4 K6/1

GND

P3 K5/1

K5/3

K5/2

K5/4

K4/1

FU2 20A

K4/2

K4/4

FU3 10 A

+5V

GND

35

+5V

1

10-A

Key switch

K4/3

CPS2/1

D1

13-T

CPS13/1

CPS18/1 10-Q 10-O

CPS33/1 10-J

10-H 10

280

577 578 13-V 280

Torque output signal

2a

SERVICE

ELECTRIC SYSTEM ELECTRIC FUNCTIONAL DIAGRAM Models with swing over tiller

POT2

CPS2/2

CPS2/1 1

CPSK/2 Key switch

K1/3

K1/4

900-C

K2/3

K2/1

K2/2

+

CPS3/3

901-C

901-B 900-B

CPSK/1

K1/1

CPS3/1 CPS3/2

CPS3/4

K1/2

843

CPS3/5

K3/2

10-B

Belly switch

ELETTRONIC TILLER BOARD Snail switch

sel 1 K3/3 gnd K3/4

0 control

CPS3/6

Horn pushbutton

rs 232/can K3/7 gnd K3/8

13-I

sel 2 K3/5 gnd K3/6

Speed control

CPS2/4

D1

K9/2 +5V

-

10-M

CPS2/5

K9/1

P6 K8/2

K7/1

K7/2

K6/2

P5 K8/1

P4 K6/1

GND

K5/1

K5/3

K5/2

+5V

GND

K4/1

K4/3

+5V

K4/2

K4/4

out

K5/4

CPS22/4

tiller + sensor P

CPS22/3

CPS22/1

CPS22/2

CPS21/3 CPS21/4

901-E 900-E

13-L

10-N

Sw1

DDI

TILLER CONTROL BOX

P3

K3/1

T1

900-D

901-D

CPS21/1 CPS21/2

POT1

10-A

-

K2/5

K2/4

K2/6

CPS2/3 10

10

35

FU3 10 A

CPS37/1 CPS37/2 CPS37/3 CPS37/4

FU2 20A FU1 415A

13

CPS38/1 CPS38/2 CPS38/3 CPS38/4 CPS36/2 CPS36/3

Calibration Push button

PM

843 10

13

CPS34/1

CPS8/2 510

CPS9/2

511

13-H

13-E

D3

CPS11/3

out

-

19C/1

out

D2

L3

-

P

L2

CPS18/2 CPS18/3 CPS18/4 CPS33/3 CPS33/2

EV2

EV3

EV4

EV5

721

780-A

805

780-B

CPS36/5

CPS36/8 CPS36/7

out

19C/2 19B/3

19B/2 19A/3

CPS19/2

CPS19/3

513

514

19A/2 515

in12

724

725

CPS31/1 CPS31/2

EV6

CPS31/3

9/A

8/A

5/A

7/A

11/A

ELETTRONIC CONTROL COMBI

14/A

35/A

34/A

33/A 723

Boot-en

804

Rx

803

Tx

780 802

20/A

19/A

21/A

2/A 17/A

16/A

6/A 15/A

4/A

26/A 30/A

24/A 29/A

801

EV1

CPS36/1

13-B

800

CPS14/2

19A/1

sensor

CPS19/5 13-N

CPS23/2 CPS23/3

Sw11 19B/1

19C/3

517

13-M

+

541

540

CPS19/1

CPS11/2

CPS10/2 512

Sw6

L1

Drive & lock1 + lock2 Sensor sensor P

HORN

CPS30/C

CPS30/B

CPS30/A

out

+

+

CPS14/1

840

CPS7/2

CPS7/1

FB1

10-G

EMB

CPS12/1

OVEERIDE BRAKE

13-C 10-P

CPS13/2 13-D

13-Z 13-A

D1

10-R

367

CPS12/2

ETAC CONNECTOR

CPS11/1

P

CPS10/3

Sw5

10-Q

13/A

13-G

GND

31/A

CPS8/3

10-E

+12V

32/A

28/A

B

S1 S2 S3

MTS

27/A

900-A

A

-

901-A

CPS10/1

-

CPS34/2

ELETTRONIC CONTROL EPAS

POWER EPAS

T.MT

368

POWER COMBI B-

platform + sensor P

TH SW

10-D

CPS9/1

Sw3

3/A

can high can low

CPS20/2

CPS20/1

CPS20/4

CPS20/6

CPS20/5

GND

Yellow White Blue Brown

+3,3V

4 2 5 6

24V

+

1 3

VMNP

B-

S

T2

10-L

CPS8/1

13-Z

13

542

T1

B

RED BLACK BLEU WHITE

A

CPS4/1 CPS4/4 CPS4/3 CPS4/2

A2

-

CPS20/3

ENC.MT +12V

CPS34/3

10-F

P1

Black Red

ARM

CPS23/1

10-C 10-I

841

12/A

P2

23/A

W

1/A

W

CPS36/4 CPS36/6

TORQUE AND POSITION SENSOR

22/A

V

10/A

U

V

18/A

MTR

U

25/A

FLD

D1

13-T

CPS13/1

CPS18/1 10-Q

CPS33/1 10-H

10-J

10-O

280

577 578 13-V 280

10

4a

SERVICE

ELECTRIC SYSTEM CONNECTOR CONNECTION DIAGRAM PEDESTRIAN MODEL

MAIN CONTACTOR KEY

TORQUE SENSOR

CPSK

+

CPS22

1

2

3

4

5

6

CPS3 5 3

2

4

4

3

5

2

6

1

Sw1

CPS10

1

CPS11

2

3 2

3

4

5

6

3

4

3

2

2

3

1

4

3

2

1

1

CPSTS 5

1

1 5

6

2

3

CPS2

2

1

CPS23

1

1

1

2

2

ELECTRONIC CONTROL

CPS1

2 2

1

CPS33 4

3

2

1

1

2 6

CPS18

5

4

3

2

1

1

CPS7

1

EV6

CPS19 1

3

CPS13

2

1

2

3

4

5

6

1

2

3

2

3

EV4

4

4

3

2

2

1

1

5

4

3

2

1

CPS12

3

4

W

V

U

1

2

CPS8

1

EV1

CPS21

TRACTION MOTOR

2

1

2

3

2

3

2

FU3

FAN T6,T7,T8,

CPS14

3 3

1

2 2

2

1 1

CPS19C

CPS31

CPS19B

3

CPS19A

CPS30

EV2 1

1

CPS9

2

1

T3,T4,T5 1

2

2

1

3

5

1

4

2

3

3

2

1

EV3

EV5

3

2

1

1

2

CPS4

3

CPS6

CPS34

CPS20

T9,T10,T11 +

PULSE

CONST.

Sw11

6a

SERVICE

ELECTRIC SYSTEM CONNECTOR CONNECTION DIAGRAM Models with swing over tiller

4

3

2

1

2

1

CPS37 CPS38

CPS36

-

4

D1

8

3

CN 36

CN 37

4

CN 38

KEY

5

D3

1

-

D2

MAIN CONTACTOR

TORQUE SENSOR

CPSK

+

2

3

4

5

6

Sw1

1

4

5 2

3

3

2

4

1

Sw5

3

2 2

1

3

2

1

CPS10

1

CPS11

1

2

3

4

3

2

1

1

2

3 2

1

4

6

5

3

3

3

CPSTS 4

2

5

5

5

3

CPS3 6

CPS2

6

1

Sw6

CPS22

2

1

CPS23

1

1

1

2

2

ELECTRONIC CONTROL

CPS1

2 1

4

3

2

1 5

4

3

2

5

6

1

2

3

EV4

4

V

U

3

2

2

3

CPS31

CPS21

CPS30

3

2

T6,T7,T8, T9,T10,T11

1

2 2

1

2

3

+

1

PULSE

CONST.

Sw11

2

FU3 1

CPS14

1

FAN

3

2

1

3

EV1

1

2

2

TRACTION MOTOR

2

1

2

3

2

1 1

3

3 3

1

2 2

2

1 1

CPS19C

CPS19B

3

CPS19A

1

CPS8

1

EV2 1

1

CPS34

4

W

CPS39

4

CPS9

3

1

2

1

5

1

T3,T4,T5

CPS12

EV3

2

EV5

2

2

CPS4

3

1 1

4

1

2

1

5

3

2

2

4

2

CPS20

3

3

3

1

3

1

4

1

CPS6 2

2

2

2

1

1

1

EV6

3

1

2 6

CPS18

CPS19

1

2

CPS33

CPS7 1

3

CPS13

Sw3

8a

SERVICE

ELECTRIC SYSTEM

ELECTRIC COMPONENTS

11

19 10

9

SWING OVER TILLER

18

8

2 12

6 7 5 4

13

1 3

14

20

21 15 PEDESTRIAN MODEL

17

16

10a

Part N.: 524282843

Keypad

This manual is addressed to the skilled technicians of Yale service network.

MULTIFUNCTIONAL KEYBOARD

SERVICE

Keypad

IMPORTANT Please read carefully this manual in order to avoid accidents and damages and keep it in good conditions so that it is always readable and complete.

This manual does not replace the use and maintenance manual, but it is an integration.

Product support group

Page: 2

Part No.: 524282843 Dec. 2006

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SERVICE

Keypad

Table of contents 1.00 2.00 3.00 4.00 5.00 5.01 5.02 5.03 5.04 5.05 5.06 5.07 6.00 7.00 8.00

INTRODUCTION ............................................................................................................................................... 4 CONNECTIONS ................................................................................................................................................4 KEYBOARD ...................................................................................................................................................... 5 DDI SWITCHING ON AND ENABLING OF THE TRUCK OPERATION .............................................................5 DISPLAY MENU AND PROGRAMMING OF THE IDENTIFICATION CODES OF THE VARIOUS USERS .........6 MAIN MENU / COUNTERS ............................................................................................................................... 7 MAIN MENU / DELETE PIN ..............................................................................................................................9 MAIN MENU / NEW PIN ................................................................................................................................. 10 MAIN MENU / NEW ADM. PIN ....................................................................................................................... 11 MAIN MENU / DELETE DATA ......................................................................................................................... 12 MAIN MENU / DEFAULT ................................................................................................................................. 12 MAIN MENU / DATE - TIME ............................................................................................................................ 13 AUTOMATIC SWITCHING OFF AND LOG-OFF ............................................................................................. 15 CONFIGURATION PARAMETERS .................................................................................................................. 15 ERROR MESSAGES ...................................................................................................................................... 16

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SERVICE

Keypad 1.00 INTRODUCTION

The “Keypad” is a multifunctional device equipped with keyboard, microprocessor and internal storage.

This device allows enabling the truck operation by entering an identification password; moreover it allows storing the following data for every user: • Distance covered in km • Total utilization time of the truck • Total utilization time of the traction function • Total utilization time of the lifting function • Number of impacts happened These data are shown on the DDI display.

SPECIFICATIONS

• • • • • •

Required length for identification code : 4 characters (8 characters for service id code) Maximum allowed number of users : 200 Read in of the last 2000 transactions (data record).

Automatic log-out when the truck is not working (after a few minutes).

Automatic stop when the truck is not in log-off condition (after a few minutes) Safety lockout after 5 wrong access attempts

2.00 CONNECTIONS

Connector K1 connects the keypad with the module “AC COMBI”.

K7

K1

Page: 4

K2

Part No.: 524282843 Dec. 2006

Connector K2 connects the keypad with module DDI. Connection K7 connects the keypad with the key switch

0 1

2

3 4

5 6

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SERVICE

CONNECTION DIAGRAM MODELS WITH “AC COMBI” 400 A CONTROLLER

400 A

UPDATE

0

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2

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Part N.: 524282843

Page: 4a

SERVICE

CONNECTION DIAGRAM MODELS WITH “AC COMBI” 200 A CONTROLLER

200 A

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Part N.: 524282843

Page: 4b

SERVICE

Keypad

3.00 KEYBOARD The keyboard is made up of 10 numeric keys (from 0 to 9), of key “CLR” and key “ENT”.

Keys “2”, “4”, “6” and “8” have a double function because they allow the user to scroll the various menus in the four directions: right (6), left (4), up (8) and down (2).

Key “ENT” is used to confirm an option / a value in the Menus.

Key “CLR” is used to switch off the truck (pressed key) or to have access to the previous menu/cancel a value (impulse).

4.00 DDI SWITCHING ON AND AND TRUCK ENABLING Turn the key switch “ON” in order to switch the DDI on

DDI

The display shows the identification code entering request (PIN).

There are three identification levels:

• User - the identification codes of the various users must be created by the administrator (administrator)

or by the skilled technician (service). By entering a user code by means of the numeric keyboard when the PIN (login) is required and by confirming the datum with key “ENT”, it is possible to enable the user to use the truck.

• Administrator - by entering the administrator code 0000 (default value) by means of the numeric keyboard, when the PIN (login) is required, it is possible to have access to the main menu (Main menu) which allows to enable the administrator to use the truck.

– Counters – Delete PIN – New PIN – New adm. PIN – Date-time

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SERVICE

Keypad

• Service - By entering service code 5555 5555 (default value) in sequence by means of the numeric

keyboard when the PIN (login) is required, it is possible to have access to the main menu (Main menu), which allows enabling the skilled technician to use the truck , or having access to the following menus:

– Counters – Delete PIN – New PIN – New adm. PIN – Delete data – Default – Date-time The service code must be used only by skilled technicians.

5.00 DISPLAY MENU AND PROGRAMMING OF THE IDENTIFICATION CODES OF THE VARIOUS USERS Switch on the DDI, enter service code 5555 5555 in sequence (default value) by means of the numeric keyboard and confirm the datum by pressing key “ENT”.

The display shows the main menu; menu “START” is highlighted.

Press keys

• • • • • • •

or

in order to scroll the various menus from the bottom to the top:

Counters Delete PIN New PIN New adm. PIN Delete data (accessibile solo ai tecnici specialisti) Default (accessibile solo ai tecnici specialisti) Date-time

Press key

Page: 6

“ENT” in order to select a menu.

Part No.: 524282843 Dec. 2006

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SERVICE

Keypad

5.01 MAIN MENU / COUNTERS Menu Counters shows the following data for every user:

• • • • •

Distance covered in km Total time of the truck utilization Total utilization time of the traction function Total utilization time of the lifting function Number of impacts

Distance covered in km.

Press keys

or

to

select the various users

Total time of the truck utilization

UPDATE

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Dec. 2006 Part No.: 524282843

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SERVICE

Keypad

Total utilization time of the traction function

Total utilization time of the llifting function

Number of minor impacts

Number of heavy impacts

Page: 8

Part No.: 524282843 Dec. 2006

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SERVICE

Keypad

5.02 MAIN MENU / DELETE PIN By means of menu Delete PIN it is possible to cancel one stored user at a time.

Press keys

or

in order to scroll the various users:

Press key “CLR” in order to cancel the selected user.

UPDATE

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SERVICE

Keypad 5.03 MAIN MENU / NEW PIN

By means of menu New PIN it is possible to enter a 4 digit identification code in order to enable one or more users.

Enter the new 4 digit code by means of the numeric pad and confirm the datum by pressing key “ENT”.

If the entered code is already existing, the error message “pin exists” is displayed.

Enter the new 4 digit code by means of the numeric pad and confirm the datum by pressing key “ENT”.

Page: 10 Part No.: 524282843 Dec. 2006

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SERVICE

Keypad

5.04 MAIN MENU / NEW ADM. PIN By means of menu New adm. PIN it is possible to change the administrator identification code.

Enter the new 4 digit code by means of the numeric pad and confirm the datum by pressing key “ENT”.

Enter the new 4 digit code by means of the numeric pad and confirm the datum by pressing key “ENT”.

UPDATE

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Dec. 2006 Part No.: 524282843 Page: 11

SERVICE

Keypad

5.05 MAIN MENU / DELETE DATA (ACCESSIBLE BY THE SKILLED TECHNICIANS) To have access to this submenu it is necessary to enter the service password (5555 5555) during the switching on.

By means of menu Delete data the skilled technician can cancel the data concerning all the users and the administrator.

5.06 MAIN MENU / DEFAULT (ACCESSIBLE BY THE SKILLED TECHNICIANS) To have access to this submenu it is necessary to enter the service password (5555 5555) during the switching on. By means of menu Default the skilled technician can cancel all stored users and data.

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Keypad

5.07 MAIN MENU / DATE - TIME By means of menu Date-time it is possible to change the current date and time.

DATE SETTING

The submenu Date is highlighted in bold. Press key “ENT”.

The cursor blinks under the number corresponding to the day. Use keys

or

in order to select the

day.

Press key use keys

in ordert to shift the cursor under the number corresponding to the month or the year and or

in order to select the month and the year.

Confirm the datum by pressing key “ENT”.

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SERVICE

Keypad TIME SETTING

The submenu Date is displayed in bold. Press key

in order to highlight the submenu Time and confirm

the datum by pressing key “ENT”.

The cursor blinks under the number corresponding to the time. Use keys

or

in order to select the

time.

Press key keys

to shift the cursor under the number corresponding to the minutes or the seconds and use or

in order to select the minutes and the seconds.

Confirm the datum by pressing key “ENT”.

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6.00 AUTOMATIC SWITCHING OFF AND LOG-OFF After starting the DDI, the display shows the identification code request (login).

If no code is entered, DDI switches itself off automatically within 5 minutes.

The switching-off time can be set by means of parameter Time sleep.

By switching on the DDI and entering the identification code, it is possible to enable the user to use the truck.

If the user does not use the truck for 10 minutes, the DDI reaches the log-off condition and the display shows the identification code request (login). It is necessary to enter the identification code in order to enable the user to use the truck.

The log-off time can be set by means of parameter Time logoff.

7.00 CONFIGURATION PARAMETERS PARAMETER

DESCRIPTION

TIME SLEEP

Time interval (minutes) concerning the DDI switching off if the identification code has not been entered.

TIME LOGOFF

Time interval (minutes) concerning the truck non-use after which the DDI reaches the log-off condition and the display shows the identification code request. It is necessary to enter the code to enable the user to use the truck.

MAX NUMBER WRONG LOGINS

Number of wrong log-in operations allowed before the keypad is locked.

Time interval (seconds) during which the keypad is locked after the allowed number of wrong DELAY LOCKED KEYPAD log-in operations (max number wrong logins parameter). The keypad can be unlocked only by entering the administrator identification code.

SERVICE ADMINISTRATOR UPPER First string of the service identification code.

4 DIGITS SERVICE ADMINISTRATOR UPPER Second string of the service identification code.

4 DIGITS SERVICE PRIVILEGES

UPDATE

Enabling/disabling of the delete data menu and default menu in the main menu after the log-in with the administrator identification code.

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SERVICE

Keypad 8.00 ERROR MESSAGES

WRONG PIN The identification code entered by the user during the login phase is wrong. Enter the correct code.

LOCKED If the user has entered a wrong identification code during the log-in phase for five times the Keypad locks itself.

To unlock the Keypad the log-in must be carried out by the truck administrator.

Press key “CLR” and enter the administrator password.

PIN EXISTS The identification code that has been entered in order to enable a new user (MAIN MENU / new pin) is already existing.

Enter a new code.

FULL MEMORY The internal storage is full.

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