Tungheinrich: Safety

tUNGHEINRICH EKS 110 04.
15 1 (GB)
Safety information
Component layout
Technical specification
Operating instructions
Circuit diagrams (electrical/hydraulic)
Event messages
Parameters
Switch-on routine
EKS 110 tightening torques
General tightening torques
BUS systems used
tUNGHEINRICH 001 000 000 00063 04.15 1 (GB)
Brakes
Drive brake
Spring-loaded brake
Minimum braking and braking distance

measurement (see service manual D
6360.03)
tUNGHEINRICH 002 000 000 00059 07.15 1 (GB)
Electrical System
Display
i
h © •ISM Access Module
(see "ISM" service manual)
•ISM Online
rn-m (see "ISM Online" service manual)
'ISM retrofit
Controls
•Access components (Easy Access)
•Deadman switch
Electrical System
• EKS 110 plugs / connectors
•AS 2412 iS dual controller
ÿMFC10 interface
•Fuses; see chapter F "Checking Fuses" in
the operating instructions
tUNGHEINRICH 003 000 000 00049 04.15 1 (GB)
Power Supply
Battery
i
h © •See chapter D "Battery - Maintenance,
Recharging, Replacement" in the
operating instructions
rn-m
tUNGHEINRICH 004 000 000 00051 04.15 1 (GB)
Travel
Electrical system
i
h © •AS 2412 iS dual controller
•Drive motor with sensor
rn-m
Mechanical system
•Transmission
Wheels
•Drive wheel
•Load wheel
'Guide rollers
tUNGHEINRICH 005 000 000 00052 04.15 1 (GB)
Truck Design
Labelling Idocumentation
•Operating instructions
•Circuit diagrams
Operator position
•Side gates
tUNGHEINRICH 006 000 000 00040 06.15 1 (GB)
Hydraulic System
Electrical system
i,Haiti
•Auxiliary-lift magnetic switch
rn-m
Hydraulic system
'Bleeding the hydraulic cylinders (main lift)
ÿChecking and topping up the hydraulic oil
level
'Checking the line-rupture safety valves
Mechanical system
•Adjusting the fork carriage via the load
chain (auxiliary lift)
•Checking the length of the load chain
(G6355.01)
•Mast rollers
tUNGHEINRICH 007 000 000 00050 04.15 1 (GB)
Commissioning IMaintenance / Customer Service
Commissioning
h © 'Commissioning
(see operating instructions "Transport and
Commissioning")
rn-m
Maintenance
•Notes on how to avoid accidents and
material damage during maintenance, test
and repair work on industrial trucks with
electronic components
(see service manual J 6900.09)
•Notes on how to avoid malfunctions and
material damage when cleaning an
industrial truck
(see service manual Z 0000.15)
•Regular safety inspection
(at least annually)
•Maintenance checklist B
•Maintenance checklist C
'Maintenance checklist (cold-store) B
'Maintenance checklist (cold-store) C
tUNGHEINRICH 008 000 000 00045 04.15 1 (GB)
Steering
Electrical system
•AS 2412 iS dual controller
•Actual-value angle sensor RSC28 MH
•Group rotary angle sensor
dUNGHE/IVR/CH Safety Notes 03.06 1 (GB)
Safety instructions and important explanations are indicated by the following graphics:
Used before safety instructions which must be observed to avoid danger to personnel.
Used before notices which must be observed to avoid material damage.
Q Used before notices and explanations.
A DANGER This notice refers to an acutely hazardous situation which could result in severe and even fatal injuries if ignored. Instructions, safety
regulations, actions or procedures referring to this notice must be followed to avoid the acute risk of severe and fatal injuries.
awarning This notice refers to a potentially hazardous situation which could result in severe and even fatal injuries if ignored. Instructions, safety
regulations, actions or procedures referring to this notice must be followed to avoid the potential risk of severe and fatal injuries.
acaution This notice refers to a situation which could result in minor to medium injuries if ignored. Instructions, safety regulations, actions or
procedures referring to this notice must be followed to avoid the risk of minor to medium injuries.
IMPORTANT This message appears when special precautionary measures are required to ensure the right action is taken or to avoid damage or
malfunctioning of the industrial truck or one of its components.
NOTICE This message appears when particular information, instructions or notices are required with regard to procedures, equipment, tools,
pressures, capacity loads and other special data.
tUNGHEINRICH Component Layout 04.15 1 (GB)
EKS 110 280 ZZ
Item Assembly
1 Pump motor
2 Magnetic brake
3 Valve block
4 Mast retainer blocks
5 AS2412 hydraulic controller
6 Steer motor
7 Transmission
8 Drive motor
9 Hydraulic tank with level display
10 Breather
11 Return filter
12 Hydraulic pump
Item Assembly
13 Auxiliary hydraulics
Assembly
AS 2412-iS traction controller
Contactor
Fuses; see operating instructions

chapter F.
EKS 110 Z 160 E Item Assembly
17 Steer motor
18 Drive motor
19 Transmission
20 Hydraulic tank
21 Lift motor
tUNGHEINRICH Technical Specification 04.15 1 (GB)
Test and Setting Values
Unit EKS 110 Information
Drive system
Drive motor Model 24 V
•Output (S2 = 60 min) kW 2.8
Transmission 'tot 18.16
•Transmission oil I 1.05 Fuchs Titan Cytrac HSY 75W-90
Brake
•Air gap max. mm 0.45
Braking distance w / w.o. load mm Q 001 009 000 00004
Service manual D 6360.03
Service manual D 6360.21
Wheels / axles
Drive wheel diameter mm 230 x 80 |-»| The top wear indication mark on the tyre is the max.
tyre wear limit
Load wheel diameter mm 150 x 130
Steering system
Steer motor Model DC motor with planetary gearbox
Output (S3-20% ED) W 205
Steering transmission / load wheel 'tot 29:1
slewing ring
tUNGHEINRICH Technical Specification 04.15 2 (GB)
Unit EKS 110 Information
Hydraulic system
Oil capacity min./max. I Depends on the truck version; Jungheinrich hydraulic oil 51132827
refer to module "006 023 313
00005 - Hydraulic oil level"
Control valve
Pressure relief System pressure
100E: 175
160E / 190E: bar 140
280ZZ: 120
Auxiliary lift: 125
Pump motor
Output
100E/160E/190E (S3 = 15%): 3
100E/160E/190E (S3 = 5%): kW 2.2
280ZZ (S3 = 20%): 6.0
Pump capacity
100E: 5.0
160E / 190E: cm3/rpm 6.1
280ZZ: 19.0
tUNGHEINRICH 005 007 268 00048 04.15 1 (GB)
EKS 110 Circuit Diagrams (Electrical IHydraulic)
Hydraulic system
Circuit diagram index Hydraulic system
Electrical system Drawing no. Description

50311032 EKS 110 E circuit diagram
Electrical system
50435302 EKS 110 ZZ circuit diagram
Drawing No. Comment
50441596 EKS 110 ZG circuit diagram
99 510 973 EKS 110 circuit diagram
Option
Electrical option
Drawing No. Description
99 517 515 EKS 110 CAN open circuit diagram
0/7.A2
0/5.A1
X30.2Tÿ 160A
0/3.A6
0/3.A1
0/3.A1
XB20 XS20 XB10 XS10 XB64 1 XS64
-
EKS 110 Optionen
Pr.Nr.: 300210933
Schaltplan 99517515
Tastbetrieb L
4F15 Tastbetrieb Z
X30.1 2. Bedienstand
10: 2. Bedienstand +
XP41 | -
Tastbetrieb Not-Aus
Daten-
12 1_
funk
XS56 XB56
+DC/DC -vJ
-DC/DC ->
XB20 XS20 XB10 XS10
4 4 /-_ 4 .7R
77 XP2 +
<3/2 ,A8
XP2 +
-
EKS 110 Optionen
78
7ÿ - <3/2.A8 Pr.Nr.: 300210933
Schaltplan 99517515
X30.3 ÿP3+.ÿ
y 79 <3/2 ,A7
XP4+ 1: Schliisselschalter
<3/2 ,A5 XP4+ 2: Medi ohne Tastenfeld
/2.A50
XP5+ 3: Medi mit Tastenfeld
<3/3.A5
4: ISM
<3/2.E5 /2.E5t> 5: WMS
7 -XP7_
82
tt7t=<3/2.E5 6: Jetpilot
X P7
<3/2.E5 /2.E50-7*
84
7ÿ - <3/2.E5
0/3.D1
7
0/3.D1
4F1 0 XB38 XS38

9M1.1
0)
£
(ti I>/3.D1
tn
u 0/3.E1 10
0) X31.1 0/3.E6
£
a l>/5.F1
to
3
jj
td
-U
CQ tUNEHEINRICH Indexi der Serienfreigabe: Dokument:
300119825 000 05
Teilestatus
series Erst.
Datum Name
15.03.13 Thomanek
Benennung
Schaltplan EKS 110 CANopen
Zeichnungsnummer
Blatt 1
ro Diese Zeichnung und deren Inhalt sind vertraulich und Eigentum des
H Jungheinrich Konzerns, der auch Inhaber samtlicher daran bestehender
Schutzrechte, insbesondere des Copyrights und des eingetragenen Designs ist. 2x k 652106 04.05.15 Thorn. Gepr. 99510973 von 11
Weder die Zeichnung noch deren Inhalt durfen ganz oder teilweise kopiert,
reproduziert oder auf sonstige andere Weise verwendet werden. Index Anderg-Nr Datum Name Freig. 02.06.15 Thomanek Ursprungsteil: Ersatz fur:
i 2 3
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+24V +24V +24V

oben oben oben
XP4+ XP3+
Messausgang +
-
EKS 110 Optionen
Pr.Nr.: 300210933
Schaltplan 99517515
1: Schliisselschalter
2:
3:
4:
Medi ohne Tastenfeld
Medi mit Tastenfeld
ISM
H
5: WMS
6: Jetpilot
MEDI
XB7 XS52
I
I XB52
-/ÿ 106
MFC10
XP10 XS39
1 > -
1XB39
r-?
_1
XP11 0~2 0/3.C1
4 4
±ÿ>±- ,107 22
0/3.C1
1>XB59
k X
r\r~\rÿr\r>r>r>
Servicestecker
k Spannungsversorgung
optional
113
-7ÿ 119
Messausgang
,112 115
-7*
XS14 XB14
,120 1 1 23
-0/3.E1
XP9- XP8- XP7- GND XP5- GND fur ,121 24

-0/3.E1
GNDfur GND fur oben DE X1
ID
DE X3 LO CD CD CD CD
DEX3 CD CD CD CD I I
oben LD LD
LLJ LLJ LLJ LLJ LU oben LLJ LLJ LU LU LLJ oben ÿ ÿ ÿ ÿ O O LU LU
CD CO CO CO 0> CD* CD CD CJ) CT) DD
tUNEHEINRICH Indexi der Serienfreigabe: Dokument:

300119825 000 05
Teilestatus
series Erst.
Datum Name
15.03.13 Thomanek
Benennung
Zeichnungsnummer
Blatt 2
Diese Zeichnung und deren Inhalt sind vertraulich und Eigentum des
Jungheinrich Konzerns, der auch Inhaber samtlicher daran bestehender
Schutzrechte, insbesondere des Copyrights und des eingetragenen Designs ist. Ox k 652106 04.05.15 Thorn. Gepr. 99510973 von 11
i 2 3
CO Is*- T— T— CO
Q <<<<
V-' ÿ Is-.' Is-' Is-'
/1.A7C>-
4
/1 .A80-
+24V +24V
unten unten nur bei EKS 110 280 ZZ
S
/1 .A80- -7ÿ
XP1 + XP5+ 1
> 208
¥ X30.3 \ ¥
. 210
AS2412iS AS2421 i 6R2.1
XS77 XB77 XS75 XB75

ÿ2 1
-ÿ -7ÿ 202 204
-1->±— >206
f
/2.C80- ÿ7ÿ ÿ7ÿ
22 ,203
/2.C80— "7ÿ 2->l J
2_>i. > 207
XB75
>211 6R2.1
0
-7ÿ 212
nur bei EKS 110
/1.D8E>-
/1 .E80-
7
*7ÿ
"7~
4 100 190 -
4
8
/1.E70-
/1.F7E>-
10
/1.F80—
23
/2.E80 "7ÿ
XS24 XB24
1 1 ,215 f
/2.E80 —
24 "7ÿ 216 XP3- GND fur
DE X1
GND fur XP2-
DE X2
unten unten
LOLOLor-~rÿrÿcMc\j CO CO
LLILLILLILLILLIUJUJLJJ LLj LU
ÿ ÿ ÿ ÿ ÿ Is-' "St" "st"

300119825 000 05
Teilestatus
series Erst.
Datum Name
15.03.13 Thomanek
Benennung
Zeichnungsnummer
Blatt 3
i 2 3
XB18 XS18 +24V
unten
xp31
2
Signal
1S5.1 GND
ÿ 2 XP33 26 AS2412iS
1S5.2
XP34
XB19 11
-|i XS19
1S3.1 <j
Signal
1S3.2 GND
2 XP24 XB21 XS21
2S107
XB47
8S3.1
XB17 XS17
8S3.2
8S3.3 -
EKS 110 Optionen
Pr.Nr.: 300210933
Schaltplan 99517515
8S3.4
12: Gangendsicherung mit Reset
XB16
o XS16
1
2 XP29
2 XP3Q
O
XB49
Signal 1 GND fur DE GND fur DE GND fur DE
GND 2 X1 unten X2 unten X1 unten
0 A A A A *A *A *A NT
LU LU LU
CO CO CO

300119825 000 05
Teilestatus Datum Name Benennung
Zeichnungsnummer
Blatt 4
Diese Zeichnung und deren Inhalt sind vertraulich und Eigentum des 7 series Erst. 15.03.13 Thomanek
reproduziert oder auf sonstige andere Weise verwendet werden. Index Anderg-Nr Datum Name Freig. 02.06.15 Thomanek Ursprungsteil: Ersatz fiir:
i 2 3
13
m in
/1 .A7C=2 400
<
CN
<
cm"
"7*
+24V V+ +24V V+ ÿsr
oben Q. oben CL
2S113 X X
401
2S114 m
1
W->- ,402
403
"7*
404
-7*
,405
U8
_
nur bei EKS 110 mit Z Hubgerust
AS2412iS
7S4.1 m XS15 1 XB15 XS40 XB40 XP14 XS14 XB14 XS24 XB24 XB1
_ V >- "7ÿ 443
-lH>1 7 428 ,406 4_ 2 .416 3 3 3
ÿ
3
"T*
421 32 32
. 444 J)_2-ÿ433 /3.D3

/4
2S113.1 m XP15 /7.F3
-W->- . 445
-V1
407
ÿ±_>± ,422 29
3 3 5 5 5 40
7 446 ÿ 430
ÿ5 ÿ ,423
1ÿ- ÿ 431 4 4 ,409 _ 6__p>_5_ 6

ÿ6 424 42
2S114.1 m XP1 6
— W->- -7*
410 1 _
2j
/
418 7 7
-7ÿ 425
30
411 426 27 27
-7*
XP17
9 9 9 28 28
-ÿ9
no -J ÿ 427
-__
2M2 ( M 2S67.1
XP12
2S67.2 no ,413
I
11 11
"7ÿ 449 439
P-
ÿ
2K2 \ 2K2 Z\ <2

>450 12 _L 12
a 2Y63 . 451 _ ÿ 13 ,441

1 1
-H"> -S
I
ÿ 452 14 14 10 10
I ÿst M- GNDfur
11 >1? Q. 0-
DE X1
/1.F80— I X, X
J
te
UJ
A LU
oben
CN CN
tUNGHEINRICH Indexi der Serienfreigabe: Dokument:

300119825 000 05
Teilestatus
series Erst.
Datum Name
15.03.13 Thomanek
Benennung
Zeichnungsnummer
Blatt 5
i 2 3
LO
<
CN
+24V
oben v+
Q.
X
6U9
MFC10
7S6 br
O sw
XS35 XB35
1 1 .512 XS43 XB43
£P20 ,514_ 1 J_ . 500
.ÿ513 X
XB3
515 > 501 35
> 502 36
7S7
o >518
XP21
XS64 • XB64
11 111 ,504 25
-
EKS 110 Optionen 12
-7*
505 33
Pr.Nr.: 300210933
13 ,506 41
Schaltplan 99517515
7: Tastbetrieb L 14 507
"T4
8: Tastbetrieb Z
9: 2. Bedienstand
10: 2. Bedienstand
+ Tastbetrieb
XS7o! XB70
11
1 ÿ11_ "7ÿ 508
17
12 12 32
-7ÿ 509
13 Lm) I3 ÿ7ÿ 510
14
I 14
ÿ7ÿ 511
/2.D4
/8.E5
/9.E7
co oo co
GNDfiir GNDfiir CL CL CL
DE X3
CD
CL
X, DEX3 *A XA *A
CO CO CO
oben u
CM
oben LU LU LU
CN CN CN
HI
CM

300119825 000 05
Zeichnungsnummer
Blatt 6
Diese Zeichnung und deren Inhalt sind vertraulich und Eigentum des H series Erst. 15.03.13 Thomanek
i 2 3
.11
LO LO /1 ,A7E>-
<
CO
<
CO
+24V +24V
+24V V- V+ unten V+ V+ oben -
EKS 110 Optionen
unten CL nur bei Pr.Nr.: 300210933
5K6 EKS 110 Schaltplan 99517515
XB1 XS1 -
100 190 E
. 630 85 ÿ 632 3_ 11: Beleuchtung
U8
AS2412iS
XB31 /3.D3
XS88 XB88 XB86
>
/4.E8
/5.E8
XB20 XS20 XB10 XS10
XB30 XS30
XS85 XB85
ÿ 677 9 9
7S5 XB71 XB84

XP39 XS71
Signal -7+ bl
V j_ A_ 1 37 37
D> GND
XS13
XP40
1B6
XB29
+ 12V
. 602 41 XB84
603 39
A
604
GND
B
. 605 38
1B7
XB72
606 34
Signal -7+
E GND
. 607 22
3B23
XS42 XB42 XB2
1 ÿ60
+ 12V 1 1 7"ÿ™
Sin 2 -7+
609 XB11.1 XS11.1
Cos 3
3 3 . 610
0 GND 4 -7+
611
co co
GND fur CL Cl XS11.2 XB11.2
DE X1
X
a XA
unten UJ. LJ-j X31.1
CO CO

300119825 000 05
Zeichnungsnummer
Blatt 7
i 2 3
in in OO CO CO
< < < < <
cm cvi CM CM CM
1S2 | 1S2 CL
+
Q-
+24V
oben
+24V
oben
v+ v+ y
CNJ
Q.
CM
0.
CM
CL
,700 X X X X X
Antrieb >_ -7*

701
702
3
t
» 703
Gabel >_ U _ -v U
z ,704
L ,715
MFC10 ,716
,717
hr
Dl
_ ÿ br
XS35
7
O
XB35
r
,722
XS43
721
XB43
t
,706
705
7S3 SW
J sw 0
'.N
-
9 707
<0>
t
hi
Dl
5E1
.
WS
XS88
1 )
1
V-
718 2
1r- 1
5 ÿc
ÿ
XS50 XB50
1
12V 1
3B7 Sin 2
,708 5E2
,709 XB83
Cos 3
0 GND 4
ÿ 719
t
,710 XB87 1H3

2S15
,711
J_ÿy5_ <-{#}->
720
,712
EKS 110 Optionen -

Pr.Nr.: 300210933
,713
Schaltplan 99517515
11: Beleuchtung
81 GNDfur
-0/9.F7 CD CD CT>
82 Q. CL CL DE X3
0/9.F7
XA *A XA
CM CM CM
LU LU LU
CM CM CM

300119825 000 05
Zeichnungsnummer
Blatt 8
i 2 3
r-
<
CM*
<
-
EKS 110 Optionen +24V cm
Pr.Nr.: 300210933 oben v+ v+

CO CO
Schaltplan 99517515 CL CL
1S2.1 | 1S2.1 X X 6U9
4->f- 9: 2. Bedienstand
10: 2. Bedienstand MFC10
+ Tastbetrieb XS64 XB64
5
Antrieb
"Hf" -7ÿ 800
,801
/
12.
XB3 /6.F7
>_ U _ -V U
'.7 802 40 /8.E5
X
r'
Gabel
,803 38
L /
804 39
/'
10 _ ÿ 10 j 805
XS68 XB68
i XS70 XB70
7S3.1 br
2 ™ $~2 1
-J> ,806 34
o sw
ÿ1_>1
a
-!>ÿ 818 1.ÿ

XP18
-7ÿ 807
-7*
XS67 XB67
3B22
12V
Sin
1
2
2 4> t 809 12
Q O
Cos 3
0 GND 4 -±_>±- t 810 13
XP19 ,811
-7ÿ 819 -V1

812
2S1.1
,813 37
2S15.1 ,814 23
,815 26
4S1 .1 ,816
10 10 817
-7*
GNDfur GNDfur
DEX3 DE X3 co
Q. 81
X /8.E30—
A
CM
Aco A CO
-82
/8.E30—
LU LU LU
CM CM CM

300119825 000 05
Zeichnungsnummer
Blatt 9
i 2 3
nurbei EKS 110 280 ZZ
2U9
AS2421i
/3.D7
XB80 XB4
2B3 + 12V
,900 41 il
901 38 38_
A "7*
,902 39 39_
B
903 40 40
GND -7*
91 9n
-o L1 ,909
2M9
9e ge
2B4 Signal "7*
904
22 -o L2
E GND
,905
-o L3 .911
XB22 XS22
1 ,906
Signal
2S111.1 B> GND
t
,907
909 ,908 17
-7*
Signal XP13
2S111.2 Co GND ~A

300119825 000 05
Teilestatus
series Erst.
Datum Name
15.03.13 Thomanek
Benennung
Zeichnungsnummer
Blatt 10
i 2 3
1B6 /7.C2 Drehzahlsensor-Fahrmotor 3B22 /9.C1 Sensor-Lenkradstellung A9 12.02 Display
1B7 /7.D2 Temperatursensor-Fahrmotor 3B23 /7.E1 Drehzahl-Sensor-Lenkmotor-Antriebsrad
1H3 /8.D8 Fahren-vorwaerts - Floor-Spot 3B7 /8.C1 Lenkradsensorik F1 /1.C3 Gesamtsteuersicherung
1H6 /7.B8 Blinkleuchte-f.Fahren-inbeiden-Richtungen 3M3 /7.E8 Lenkmotor-Antriebsrad F3.1 /1.D3 Sicherung-24V
1M3 /7.D7 Fahrmotor-Drehstrom-1 F3.2 /1.D3 Sicherung-24V
1S2 /8.A2 Fahrschalter F4 /1.B3 Steuersich.Hauptschuetz
4F1 /1.E3 Steuersicherung-Hupe
1S2.1 /9.A2 Fahrschalter-2 F8 /1.C1 Hauptsich.Plus-Ltg.(VDE0666)
1S3.1 /4.B1 Plattformschalter ZG 800 4F10 /1.E3 Steuersicherung-Lufter
1S3.2 /4.B1 Plattformschalter ZG 800 4F15 /1.B3 Zugangsberechtigung
4H1 /1.E5 Hupe
1S5.1 /4.A1 Hubhoh1200mm
4S1 /8.D1 Taster-Hupe
1S5.2 /4.A1 Hubhoh1200mm K1 /1.A2 Hauptschiitz 1
4S1.1 /9.E1 Taster-Hupe
K5 /1.A3 Hauptschutz 2
2B3 /10.C2 Drehzahlsensor-Pumpenmotor 5E1 /8.C8 Arbeitsleuchte-FSD-links

2B4 /10.C2 Temperatursensor-Pumpenmotor 5E2 /8.D8 Arbeitsleuchte-FSD-rechts
2F1 /1.A4 Sicherung-Pumpenmotor K7 /1.C4 Einschaltschuetz
5E3 /2.B1 Abblendlicht-links
2K2 /5.E2 Pumpen-Schuetz 5E4 /2.C1 Abblendlicht-rechts K7 /1.C4 Einschaltschuetz
2M1 /7.A5 Pumpenmotor-1 5H11 I7.C8 Leselampe
5K6 /2.A1 Relais Abblendlicht
2M2 /5.D1 Pumpenmotor-2
2M9 /10.C7 Pumpenmotor-Drehstrom
6F1 /1.D3 Steuersich.-Entladeanzeigerin-der-plus-LTG
2S1 /8.D1 Taster-Heben S2 /1.C7 Schaltschloss
6R2 /2.C1 Abschlusswiderstand-CAN-Bus
2S1.1 /9.D1 Taster-Heben S5 /1.B6 NOTAUS
2S107 /4.A1 Senkbremse 6R2.1 /3.C8 Abschlusswiderstand
6U9 /2.D4 MFC-Zusatzfunktionen
2S111.1 /10.D1 Hubhoehensensierung 6U9 /6.F7 MFC-Zusatzfunktionen
6U9 /8.E5 MFC-Zusatzfunktionen
2S111.2 /10.D1 Hubhoehensensierung U8 /3.D3 Kombisteuerung-Fahren/Heben
6U9 /9.E7 MFC-Zusatzfunktionen
U8 /4.E8 Kombisteuerung-Fahren/Heben
2S113 /5.A2 Zusatzhub-Heben
U8 /5.E8 Kombisteuerung-Fahren/Heben
2S114 /5.B2 Zusatzhub-Senken 7S3 /8.C1 Totmannschalter U8 /7.E3 Kombisteuerung-Fahren/Heben
7S4 /5.A2 Zweihandbedienung-Fahren
2S113.1 I5.C2 Zusatzhub-Heben
7S4.1 /5.C2 Zweihandbedienung-Fahren
2S114.1 I5.C2 Zusatzhub-Senken
7S5 /7.B1 Stopp bei Tastbetrieb Heben L
2S15 /8.D1 Taster-Senken
7S6 /6.B2 Fahrstandverriegelg.Tuer/Links
2S15.1 /9.D1 Taster-Senken X40 Batteriestecker-Buchse
7S7 /6.B2 Fahrstandverriegelg.Tuer/Recht
2S4 /4.A1 Hubiiberbruckung X41 Batteriestecker-Stift
7Y3 I7.C7 Magnetbremse
XB26 Service-Stecker
2S66 /5.D3 Zusatzhub-Senken
2S67.1 /5.D2 Taster-Senken 8S2 /4.E1 Lastschalter L
2S67.2 /5.D3 Taster-Senken 8S3.1 /4.C1 Gangende
2S7 /4.C1 Hubendschalter L 8S3.2 /4.C1 Gangende
8S3.3 /4.D1 Gangende
8S3.4 /4.D1 Gangende
2U9 /3.D7 Drehstromsteuerung-Hydraulik
8S50 /4.D2 Gangerkennung 1
2U9 /10.E5 Drehstromsteuerung-Hydraulik
8S52 /4.E2 Gangerkennung 2
2Y29 /7.D6 Proportionalventil-Senken

2Y63 /5.E2 Magnetventil-Senken-Zusatzhub
9M1.1 /1.E6 Luefter-Motor-Fahren

300119825 000 05
Zeichnungsnummer
Blatt 11
i 2 3
Option 1: Einschaltung Schlusselschalter
(©) n n \o u-
ÿ ===
CV> (®) -X> ®
O o o o o o
1
1 co 1
1 11 lo 11 co r
1
— 1
CO
1 CD 1 t—
| |
CD ÿ*— ICM I CO I I
c/c/nr/oo
CM CO
XS52
2 S2 Ruck
XP1
1 _ 2 S2 Hin
S2
-/ÿ liar
6R2
> liqr
3
_ CAN_L
CAN H
10 GND
tUNEHEINRICH Indexf der Serienfreigabe: Dokument:

300210933 000 03
Schaltplan EKS 110 CANopen Optionen
Zeichnungsnummer
Blatt 1
Schutzrechte, insbesondere des Copyrights und des eingetragenen Designs ist. Ox h 652106 04.05.15 Thorn. Gepr. 99517515 von 15
i 2 3
Option 2: Einschaltung Medi ohne Tastenfeld / Kartenleser
(©) Xn n \o L~
ÿ ===
(®) ÿ0 ®
o o o o o o
r-
1 cn 1
co 1N- 1 m 1 cd
1
Is--
ÿ
CO
1 CD 1 t—
| |
CD —
t ICNJ 1 CO 1 -sj- 1
C\l CO t
XS52
100 2 S2 Ruck
-7*
"7*
101 XP2
,102 4-2 ÿ 103 S2 Hin
-/ÿ liar
6R2
> liqr
107
4
3
_ CAN_L
CAN H
»
10 GND

300210933 000 03
Zeichnungsnummer
Blatt 2
i 2 3
Option 3: Einschaltung Medi mit Tastenfeld / Kartenleser
Tastenfeld alternativ Kartenleser

(©) n n \o L~ XB53
CV> (®)
ÿ ===
ÿ0 ® n
O o o o o o _j
1
1 co |
ÿ"=1" |io |<o _ —_
r CO
1 CD 1 t—
| |
CD ÿ*— ICM 1 CO I I
S2 Ruck
S2 Hin
CAN_L
CAN H
GND

300210933 000 03
Zeichnungsnummer
Blatt 3
i 2 3
Option 4: Einschaltung ISM
(®) O I—-
cV> (©)
o o
—-xq ®
ÿ
o o o o
N-
m
x
> liar
6R2 [ XS52
2 S2 Riick
liqr
-v1
XP4
>
300
V-
,310 S2 Hin
t 314
t 303
304
-7ÿ
XS680
_ i_ 1 ,305
_ 2_ -7*
306
3_ ,307
4_
5 CAN_H
6_
7 "7ÿ 308
CAN L
8
9 ,309
10_ JO
11_ 11 ,313
12 J2 _KP29
13 13 ,312 4-2 -7ÿ 311
10 GND
14 J4
15 J5
16 16
XB681 XB680

300210933 000 03
Teilestatus
series Erst.
Datum Name
13.06.13 Thomanek
Benennung
Zeichnungsnummer
Blatt 4
i 2 3
Option 5: Adapter WMS
XS91
(1050 mm)
8U37
SPS
XB93
r\ r\
Service
8S70
-O oÿ-o O
8S71
J! 18
"7ÿ -ÿ-O o-ÿ-o Oÿ-
XB90
Display
7
"7ÿ
Service
V V
si I t— I col lo I col I XB94
V V V V V V
P/ N1
\ \ ÿ 420
ÿ7ÿ
XB52 ÿ 421
ÿ 9r
S2 Ruck S2 Ruck
S2 Hin -7*
401 S2 Hin
CAN_L , 402 CAN L
CAN_H , 403 5m can_h
CAN_L , 404
ÿ7ÿ 408
4 CAN L
1 2
CAN_H -7ÿ 405
XP7 CAN_H
1 2
+24V 406 XP8 -7ÿ 410
+24V
1 2
GND 10
-7ÿ 407
XP9 411 10 GND
-T*-
1 2
XP10

300210933 000 03
Teilestatus
series Erst.
Datum Name
13.06.13 Thomanek
Benennung
Zeichnungsnummer
Blatt 5
i 2 3
Option 6: Jetpilot
Abschlusswiderstand
6R2
(©) Xn n \o u- im Jetpilot
Jetpilot
cTj (®) ÿ === _l I
ÿ0 ® Q >
ÿ"4- Z
<
I
z
1
o
z
CO
o z
>
CM
Lenkwinkel
Sollwert
<
o o o o o o
Z c\i
o + o o 0 o </>
XS50
1 cn 1
co 1N- 1 m 1 cd
1 ÿ
1 CD 1 t—
CD —
t ICN1 I CO 1 1
XS12
r- Is-- CO | |
CO
h-
m
>< Bei Montage den vorhandenen Abschlusswiderstand
an XB7 entfernen und durch Pin XB7.4 und XB7.5
von "Stltg. Adapter Jetpilot" ersetzen "7ÿ 516
515 517
-v1 -7*
514 ,518
519
-7*
6R2
XB52 XS52
2
S2 Ruck ,500
— S2 Ruck
S2 Hin
CAN_L ÿ 502
1
6
_ S2 Hin
CAN_L
CAN_H
CAN_L
,503
> 504
5
4
_ CAN H
CAN_L
CAN_H > 505 3 CAN H
+24V ÿ 506 >510 +24V

1 2
XP13
GND 10 ,507 >511 10 GND

1 2
XP14
tUNGHEINRICH Indexf der Serienfreigabe: Dokument:

300210933 000 03
Zeichnungsnummer
Blatt 6
Schutzrechte, insbesondere des Copyrights und des eingetragenen Designs ist. 1x h 652106 04.05.15 Thorn. Gepr. 99517515 von 15
i 2 3
Option 7: Tastbetrieb L
S5.1
XB65
hJ_ ÿ628
XS64 XS65 1S14 1S15
ÿ 600
601 t 629
602 > 630
603 ,631
XP15
ÿ660- 1ÿ2 604
XP16 V. 7*
605
12
"Tÿ 661
ÿH 7ÿ 607
606
"7*
633
13 608
XP17
14 . 662 1 2 609 ,636
610
,637
10 10 639 2S1 .2 m
-7*
> 640
-k— >ÿ-
12 12 ,641 2S15.2
1
XB51 XS51 S5.2
625 1 > 611
/
XB66 XS66
, 643
1C-L > 612 1S14.1 1S15.1
3
ÿ 626 ÿ3 V1
613
"7*
644
, 614
5 5
ÿ 627 615
ÿ
647
"7*
6 6 616
ÿ -t*
> 648
XS70 XP18 > 649

11 663
- y-
XP19 \.
"7*
617
, 618 ,650
12 664 1_ 2 619
T*
XP20
13 ÿ 665 12 >621 2S1.3 m
> 622 10 10
"7*
652 1ÿ >, -> 6
. 653
XP21
14 y 666 1 ÿ
2
"7*
>623
624
12
13
12
13
.654
,655
2S15.3 m
1
> .- 6

300210933 000 03
Teilestatus
series Erst.
Datum Name
13.06.13 Thomanek
Benennung
Zeichnungsnummer
Blatt 7
i 2 3
Option 8: Tastbetrieb Z
S5.3 links rechts
XS64 XB48 XS48 1S14.2 1S15.2 1S14.3 1S15.3
XB57 XS57
2S1.4
2S15.4 m
1
w>-
CD
oo CM
CM CL
XS70 CL
X
X
,711 t 729
f
* *
/ /
12 712 730
"7* "7* -/ÿ 749
13
* 731
,713
rechts
14 ,714 10
C™—
ÿ 10 f 732
—
2S15.5 m
-v >-

300210933 000 03
Teilestatus
series Erst.
Datum Name
13.06.13 Thomanek
Benennung
Zeichnungsnummer
Blatt 8
i 2 3
Option 9: 2. Bedienstand
S5.5
XS64 XB64 +24V
"7*
800
-1ÿ>i oben
XP2+
,801
J> 2 Stromlaufplan EKS 110:
300119825-99510973
802
6U9
, 803
MFC10
1S2.1 | 1S2.1
-7*
804 iy
Antrieb >_ 1
/ 3>t:
ÿ
A
805
XB3
40 40
XS3
3 -7ÿ
,807
J. 38 38_
Gabel >_ o -v u
39 39
I 10 _0
ÿ
10
I
7S3.1 I
XS68 XB68
1 I XB70
XS70
T1
br "7*
,811
810
-1W>i 34
0> sw
4 I
3B22 12
XS67 XB67
1 13
12V
Sin
1
2
,812
"7ÿ 813
ÿHa-
,814
Cos 3
0 GND 4 -7*
815
f-
a 37
2S1.1 I 23
,816 26
4S1 .1
-7ÿ 817 l
2S15.1
,818
I
819 10 10 XP7- GND fur
-A- ÿ
DE X3
I
tUNGHEINRICH Indexf der Serienfreigabe: Dokument:

300210933 000 03
Zeichnungsnummer
Blatt 9
i 2 3
Option 10: 2. Bedienstand + Tastbetrieb - Not-Aus
S5.3
XS64 XB48 XS48
1 f 900
k—ÿ—
f 901 904 t 909
"7*
902 ,910
-7*
905 r 911
"7*
S5.4
t 912
t 906 t 913
ÿk- * 914
907 * 915
"7*
S5.5
10 10 917
-7*
,918
12 12
"7ÿ 903 "7*
919

300210933 000 03
Teilestatus
series Erst.
Datum Name
13.06.13 Thomanek
Benennung
Zeichnungsnummer
Blatt 10
i 2 3
Option 10: 2. Bedienstand + Tastbetrieb
XP2+ +24V
oben
f 6U9
1S2.1 | 1S2.1 XS64 XB64
4->f- > 1000 MFC10
Antrieb >_ 4ÿ4=

±-.y±
>1001
-l XB3
5 <5 >1002 40
4 >1003 -f-
-o- 38
Gabel 1004 39
-7*
L XB57
10
p 10
,1005
ÿ 1006 12
, 1007 13
-7*
1008 _14_g_14 1A
Stromlaufplan EKS 110:
ÿ 1009 300119825-99510973
7S3.1
br
XS68
T*
1
XB68
ÿ
1010
1011
XS70
_ lJ>J
XB70
_ . 34
o sw
I
3B22 12
XS67 XB67
1 ÿ 1013 13
12V 1
ÿ 1014
Sin 2
1015
Cos 3
n GND 4
ÿ 1016
37
2S1.1
1017 23
1>"
ÿ
I 26
4S1.1
ÿ 1018
2S15.1
1 ÿ 1019
lw>i-
-0
I
1020 10 10
GNDfur
XB57 I XP7- DEX3
ÿ 1021
12
ÿ7ÿ 1022
ÿ 1023 13
10
ÿ7ÿ 1024
dUNGHEINRICH Indexf der Serienfreigabe: Dokument:

300210933 000 03
Zeichnungsnummer
Blatt 11
i 2 3
Option 11: Adapterkabel Beleuchtung
r
+24V +24V
oben oben
XP4+ XP2+
6U9
XB82
MFC10 XS88 XB88 ®
- ÿ 5E1
XB3
14 14 2 k 2
XB83
®
3 k 3
5E2
42 42 4 k 4
XB87 1Jjÿ XB87

5 _k 5 "7ÿ
1 / yy\ -n 2
15 15
I
I

-
300119825 99510973
I
I
U8 I
I
AS2412iS
I
I XB86
XB1 XB20
13
ÿ
XS20
13
XB10
13
ÿ
XS10
13 • «
-
> 1H6
XS85 XB85 XB84 5H11 XB84

9 ÿ 9
-W- ,11
<—0—> /Oi ÿ2
15 15 14 14 14 14 10 10
ÿ ÿ ÿi.yL
dUNGHEINRICH Indexf der Serienfreigabe: Dokument:

300210933 000 03
Teilestatus
Erst.
Datum Name
13.06.13 Thomanek
Benennung
Zeichnungsnummer
Blatt 12
Diese Zeichnung und deren Inhalt sind vertraulich und Eigentum des series
i 2 3
Option 12: Gangendsicherung mit Reset
Chainflex 2 x 0,5 - 1500mm
+24V
Signal
8S3.1 Go GND
Chainflex 2 x 0,5 - 1100mm

Signal k XB17
8S3.2 Go GND
A1
o o o o o
8K22 8S4
Chainflex 4 x 0,5 -300mm
8S4 T,X-
CN
I
CO
NT
LO
I
CO
Signal XB46
8S3.3 Go GND
Signal
8S3.4 Go GND Chainflex 4 x 0,5 8H3
<ÿ
8H3
100 — > 5100mm
160 ~> 6200mm
190 — > 6200mm
280 ~> 7200mm

300210933 000 03
Zeichnungsnummer
Blatt 13
i 2 3
Option 14: kein 2. Bedienstand + kein Tastbetrieb
I' —
XS64 . XB64
1
!A-
300119825-99510973
5
H-
i>ÿ
7
10
l> 10
11
12
t- 12
iin \ÿL_
14
Index der Serienfreigabe: Dokument: 300210933 000 03 Teilestatus

Diese Zeichnung und deren Inhalt sind Benennung
vertraulich und Eigentum des Jungheinrich
Konzerns, der auch Inhaber samtlicher
HUNGHEINRICH Schaltplan EKS 110 CANopen Optionen
daran bestehender Schutzrechte, insbesondere
des Copyrights und des eingetragenen Designs ist.
Weder die Zeichnung noch deren Inhalt durfen
ganz oder teilweise kopiert, reproduziert oder senes Datum Name
auf sonstige andere Weise verwendet werden.
Erst. 13.06.13 Thomanek Zeichnungsnummer
Blatt 14
Gepr.
Oxh 652106 04.05.15 Thorn. Freig. 02.06.15 Thomanek 99517515 von 15
Index Anderg-Nr Datum Name Ursprungsteil: Ersatz fur:
1
1H3 /12.C7 Fahren-vorwaerts 4S1.1 /9.E2 Taster-Hupe
1H6 /12.D7 Blinkleuchte-f.Fahren in beide Richtungen 4S1.1 /11.D2 Taster-Hupe
1S14 /7.B6 Tastbetrieb-vorwaerts
1S14.1 /7.D6 Tastbetrieb-vorwaerts 5E1 /12.B7 Arbeitsleuchte-FSD-links
1S14.2 /8.B5 Tastbetrieb-vorwaerts 5E2 /12.C7 Arbeitsleuchte-FSD-rechts
1S14.3 /8.B7 Tastbetrieb-vorwaerts 5H11 /12.E7 Leselampe
1S15 /7.B7 Tastbetrieb-rueckwaerts
1S15.1 /7.D7 Tastbetrieb-rueckwaerts 6U9 /9.F8 MFC-Z usatzf unktione n
1S15.2 /8.B6 Tastbetrieb-rueckwaerts 6U9 /11.F8 MFC-Z usatzf unktio ne n
1S15.3 /8.B8 Tastbetrieb-rueckwaerts
1S2.1 /9.B2 Fahrschalter-2 8H3 /13.E8 Gangendsicherung
1S2.2 /11.A2 Fahrschalter-2 8K22 /13.D5 Relais-Gangendsicherung
2S1.1 /9.E2 Taster-Heben 8S4 /13.D8 Reset-f.Endgangsicherung

2S1.1 /11.D2 Taster-Heben 8S70 /5.C6 Quittieren
2S1.2 I7.C8 Taster-Heben 8S71 /5.C6 Anforderung
2S1.3 I7.E8 Taster-Heben 8U37 /5.D2 Speicherprogrammierbare-Steuer
2S1.4 I8.D8 Taster-Heben
2S1.5 I8.E8 Taster-Heben A9 /5.D7 Anzeigeeinheit
2S15.1 I9.E2 Taster-Senken
2S15.1 /11.E2 Taster-Senken S2 /1.D5 Schaltschloss
2S15.2 I7.C8 Taster-Senken S5.1 /7.A5 NOTAUS
2S15.3 I7.E8 Taster-Senken S5.3 /8.A4 NOTAUS
2S15.4 /8.D8 Taster-Senken S5.5 /9.A2 NOTAUS
2S15.5 /8.F8 Taster-Senken
U8 /12.F1 Kombisteuerung-Fahren/Heben
3B22 /9.D2 Sensor-Lenkradstellung
3B22 /11.D2 Sensor-Lenkradstellung

300210933 000 03
Zeichnungsnummer
Blatt 15
i 2 3
r\
m
w
jT
C (3/8 'BSPP)
VPR33
STF38
5fc
100E: 14 l/min
M
(1/4"BSFP)
ÿ 160/190E: 20 l/min
o-
100E: 170 bar
Ovu 160/190E: 130 bar
VM15
r 1
100E: 4,8 cm³ 24Vdc
160/190E: 5,8 cm³
M 3000W
TC-E4 Datum Name Status

Bearbeiter 19.04.06 Rosenthal 2
Geprüft 19.04.06 Schonefeld Benennung: Schaltplan Hydraulik
EKS 110 E
Material:
50311032 1-1
a 543235 19.4.06 Ros. E
Zustand Änderung Datum Name Ersatz für gleiche Nummer vom
•
er s»ÿ NtwiisBok
gueltig von: 29.10.2004 bis: Version: 00
45 L tr./Min.
40 Llr./Min.
AUgemeintoferanzen StafusschluBssGl
DIN ISO 2768 Genauigk.Gr. .....
bei Schweisskonstruklionen
DIN ISO 13920 Gf.nnuigk. Gr. ....
bei Brennschndden
DIN 2310 Genauigkcitsgrad Racfen Schweiss
bei Abkanlleilen naehte
DIN 6930 / 6935. Werkstoff:
Saosfigc Tofcrcmiea; Rohfefl-Nr.
Fixte8-Nrj
Datum Name
Rosenthal
R osenthol
Norm.
tUNGHBNMCH T 50435302
Datum Name
UEBERGAB E 16.02.04 CAD Vertrautich-Alie Rechte vorbehalten
gueltig von: 29.10.2004 bis: Version: 00
. '/ i'
ÿ -r;
i
—
f3n
o
cm
3
c3
cm
5
<
cm
Q
ÿO
ui
o
to
cO
3
AIIgemeint o!er onzen- StatusscNuesset
CM DIN ISO 2768 Senaaigt.Gr
(—
uO
X
u
bet ScfiweisskMistruklionen
DIN ISO 13920 Genauiqk. Or,
ber Brennschneiden
DIN 2310 Genauigkeilsgrad . Raden
X2
Schw&ss
LU bet AbkanUttiett naehte
M
DIN 6930 / 6 935 Werkstoft
SjMf/rf* T off oaten'- Rohtei-Nrj
xr Passmass Abmass Fixfe#-M*.:
o
i
vr TC-£4 Datum Nome Benemungc Massstct)
o
o
j
CM
Beorb 19.4.04 R osenthol
Gepr. 20.4.04 R osenthol
Schaltplan Hydr.
Norm. EKS 110 ZG
Zeichnungs fit;
tUNGHEINRICH T 50441596
Aenderung Datuv Name Urspr.: ErsX: Ers.d:
UEBERGA&E 20.04.04 CAD Vertrautich-Alfe Rechte vorbehatten.
tUNGHEINRICH Event Messages 03.15 1 (GB)
Event Messages
Q This display units shows a four-digit event message for every
event. Trucks that only use one luminous display (e.g. LED) show
Sub-division of function group "F'
the event through a flashing code (see "Display System"). System:

Each event message is also stored in the master logbook. The Overlapping functions that cannot be assigned to any other
master logbook describes the event in more detail through the sub 0
function group)
index behind the event message (FEXX). Example: seat switch / deadman switch or master controller
Event numbering display 1 Travel

F E XX s
2 Flydraulics (load handling)
F Function group; E Event group
XX Event number S Sub index 3 Steering and travel
The first two characters "F, E" refer to the category. The middle 4 Displays/controls, interface
two digits "XX" refer to the event. From these two digits the range:
• 1 to 50 describes standard events (uniform basic events) 5 Charger (either on-board or external charger)
which can occur in any function group.
6 Reserved
• 51 to 99 describes specific events.
The event is described in further detail through the last characters 7 Reserved
"S" (single digit / multi-digit).
This process ensures that a unique number is assigned to each 8 Reserved
event. Example:
-
F Function group Special functions
9 Example: ISM
E -» Event group
-
XX Event number
—-
i S Sub-index
1 3 0 5 1
The system distinguishes between:

Fault reset or
0 • event messages caused by operator errors.
no fault
• event messages caused by truck errors.
General fault / additional functions
For operator errors there are three versions that can be displayed
1 Example:
in the truck depending on the display unit options.
Logic error, e.g. both directions selected simultaneously
• Event number display (e.g. CANDIS)
Current • Pictogram display
2
(input interface, device-internal, output interface) • Text message display
Voltage For truck errors the event number and possibly a fault graphic icon
3
(input interface, device-internal, output interface) (e.g. service key) will also be displayed.
Trucks that only use one luminous display (e.g. LED) use the
4 Temperature
following flashing code:
Flardware • Each character of the four-digit event number is shown with a
5 Example: Output transformer short circuit. EEPROM not 2 Flz / 0.5 sec frequency (flashing).
responding, ...
Q The figure "zero" is displayed by flashing ten times.
Software
(internal software, application software, data record / • After each character of the four-digit event message there is
6 a pause (LED off) of one second.
parameters)
Example: EEPROM data error • After the complete four-digit event message a 3 second
pause (LED off) is set.
7 Additional modules
8 CAN monitoring
External fault
9
Example: ISM
Description / cause Iaction and effects
The following table lists the event message with a description / cause / action and effect.
Each event group (E) with the corresponding event number (XX) can be combined with different function groups (F), hence in the following
table the placeholder "F" is used for the first character "F" of the four-digit event number.
It also shows the operating status when the event occurred:
Operating status Explanation
Occurs during / directly after truck power up

Bootloader (basic initialisation of components, possible change to flash mode).
Example: Checkina the RAM / ROM fmemorv check)
Occurs during installation of operating software of individual components.

System start Example: correct hardware installed. ...
Occurs during the self-test of each component, as coordinated by the master

Self test
-> The main contactor is then closed
Operation Occurs during operation
System end Occurs during truck power-down (correct powering down of components, ...)
Undefined Can occur at any time

"Event messages" table
F E XX S Operational Description Cause / Triggering Event Action
Status
Evaluation of three key switch inputs. Possible - Check key switch input connection against the
Supply via unexpected key
- 1 01 1 System start encodings are 1, 2 or 4, otherwise the event message is wiring diagram;
switch input
triggered. - Replace controller;
- Test the main contactor output of the controller;

Contact closed instead of On power-up the capacitor voltage should be one volt
- 1 1 Self test - Check wire connection;
open (1 V) below the battery voltage.
- Replace contactor;
When the main contactor has switched on the capacitor - Test the main contactor output of the controller;
Contact open instead of
- 1 2 Self test voltage should be the same as the battery voltage (within - Check wire connection;
closed
500 msec.), otherwise the event message is produced. - Replace contactor;
- Replace controller;
02 Lithium-ion batterv 24V/110Ah (in the case of
An attempt is being made to open the main contactor. repeated faults):
Main contactor permanently The event message is triggered if the monitoring system
- 1 3 Self test - Check the harness of the lithium-ion battery and
on detects that the main contactor has not opened after T >
replace if necessary;
time limit.
- Replace battery contactor;
- Replace battery management system (BMS);
Feedback signal from main contactor status implausible - Test the main contactor output of the controller;
Self test Main contactor feedback
- 1 4 with main contactor control (error activated after limit - Check wire connection;
Operation input implausible
time) - Replace contactor;
Output transformer faulty The semi-jumpers 1, 2 and 3 are controlled in turned for - Replace controller;
1 Self test
(phase U) 50 msec at 25% PWM (pulse width modulation) when
the output transformer is closed ("Output transformer
Output transformer faulty
- 1 03 2 Self test deactivated" signal).
(phase V)
The event message is issued if at the end of the 50 msec
Output transformer faulty period of the respective phase the following applies:
3 Self test Vphase_X < (Vcapacjt0r !2) - 25%
(phase W)
Status
Output transformer faulty - Replace controller;

1 Self test Semi-jumpers 1, 2 and 3 are controlled in turn for
(phase U)
50 msec at 25% PWM (pulse width modulation).
Output transformer faulty The event message is issued if at the end of the 50 msec
- 1 04 2 Self test
(phase V) period of the respective phase the following applies:
Vphase_X > (ÿcapacitor ÿ 4) 25 /o or
Output transformer faulty Vphase_X < (VCapacitor / 4) - 25%
3 Self test
(phase W)
"Error, power stage ID : The power card of the power - Replace controller;
stage can only obtain faulty information (ID) about the
Error bit set for power
- 1 04 4 Operation identity and hence suitability of the card for the intended
stage ID
powering of the operating system when the error bit is
set"
Semi-jumpers 1, 2 and 3 are controlled in turn for - Check motor connection wire (wire breakage);
50 msec at 25% PWM (pulse width modulation). - Replace motor;
The event message is issued if at the end of the 50 msec
- 1 05 1 Self test Motor cutout period of at least one of the two non-controlled phases
the following applies:
Vphase > (ÿcapacitor ÿ 4) 25% or
Vphase < (Vcapacjtor / 4) - 25%
Semi-jumpers 1, 2 and 3 of a combi controller power - Switch the truck off and on again;
part are controlled in turn for 50 msec at 25% PWM - Check the motor connections;
(pulse width modulation). - Check for a short between two power stages
"Combi controller behaviour
The event message is issued if at the end of the 50 msec or motors;
- 1 05 2 Self test for non-controlled power
period of at least one of the semi-jumpers of the other - Replace signal-evaluating controller;
stages" logic implausible
power part the following applies:
VPhase_X > (Vcapacitor / 2) + 15% or
Vphase_X < (ÿcapacitor / 2) - 15%
Status
The safety switch consists of a NC and a NO contact. - Check safety switch wire connection;
When the button is pressed both contacts connect - Check safety switch;
simultaneously. As a result, only the 0/1 and 1/0 - Replace safety switch;
combinations should occur.
Safety switch inputs During operation combinations 0/0 and 1/1 (500 msec.)
|-ÿ| Safety switches can include:
- 1 06 1 Operation - Deadman (foot switch),
implausible trigger the event message.
- Seat switch,
For a valid combination (0/1 or 1/0, 500 msec) the event - Tiller switch.
message and the truck response are reset. For an
implausible condition the seat switch is considered to
be open (-> the truck brakes with the coasting ramp).
- Check wiring with multimeter;

During operation combinations 0/0 and 1/1 trigger the - Check sensor system with multimeter;
Deadman switch inputs
- 1 06 2 Operation event message. The event message can only be reset - Check computer component inputs;
implausible
by resetting the truck. The activation limit is 2000 msec. - Repair faulty components and replace if
necessary;

During operation combinations 0/0 and 1/1 trigger the
- Check sensor system with multimeter;
Slack-chain switch inputs event message. For a valid combination (0/1 or 1/0),
- 1 06 3 Operation - Check computer component inputs;
implausible the event and the truck response are reset. The
- Repair faulty components and replace if
activation limit is 1000 msec.
necessary;

Cabin gate inputs event message. For a valid combination (0/1 or 1/0),
necessary;

Optional cabin gate inputs event message. For a valid combination (0/1 or 1/0),
necessary;
Status

Sideshift index inputs event message after a traverse path of more than 30mm.
implausible For a valid combination (0/1 or 1/0), the event and the
truck response are reset. The activation limit is 0 msec.
necessary;

Aisle recognition right inputs event message after the truck has travelled more than
implausible 100mm. The event message can only be reset by
resetting the truck. The activation limit is 100 msec.
necessary;

Aisle recognition left inputs event message after the truck has travelled more than
implausible 100mm. The event message can only be reset by
resetting the truck. The activation limit is 100 msec.
necessary;

During operation combinations 0/0 and 1/1 trigger the - Test sensor system with multimeter;
Load handling inputs: no
signal
necessary;

If the weight display > 300 kg the load sensors must be - Test sensor system with multimeter;
Load sensing inputs: no
- 1 06 10 Operation applied. The event message can only be reset by - Check computer component inputs;
signal
resetting the truck. The activation limit is 2000 msec. - Repair faulty components and replace if
necessary;

Logic test: signal at working During operation combinations 0/0 and 1/1 trigger the - Test sensor system with multimeter;
- 1 06 11 Operation platform raised inputs event message. The event message can only be reset - Check computer component inputs;
improbable by resetting the truck. The activation limit is 2000 msec. - Repair faulty components and replace if
necessary;
Status

- Test sensor system with multimeter;
Logic test: signal at left/right During operation combinations 0/1 and 1/0 trigger the
gate lock inputs improbable event message. The activation limit is 2000 msec.
necessary;

Logic test: No signal for gate - Test sensor system with multimeter;
During operation no feedback triggers the message
- 1 06 13 Operation lock despite gate lock being - Check computer component inputs;
when applied. The activation limit is 2000 msec.
applied - Repair faulty components and replace if
necessary;

Logic test: Signal for gate - Test sensor system with multimeter;
During operation a feedback triggers the message
- 1 06 14 Operation lock present despite gate - Check computer component inputs;
without being applied. The activation limit is 2000 msec.
lock not being applied - Repair faulty components and replace if
necessary;

Logic test: No signal for gate
During operation no feedback triggers the message - Test sensor system with multimeter;
lock despite the lift
- 1 06 15 Operation when lift mechanism is above the set height. The - Check computer component inputs;
mechanism being above the
activation limit is 2000 msec. - Repair faulty components and replace if
set height
necessary;
The body protection switch consists of a NC and a NO - Check wire connections;

contact. When the button is pressed both contacts - Check operator protection switch;
connect simultaneously. As a result, only the 0/1 and 1/0 - Replace operator protection switch;
Operator protection switch combinations should occur.
- 1 07 1 Operation
inputs implausible During operation combinations 0/0 and 1/1 (500 msec.)
trigger the event message.
For a valid combination (0/1 or 1/0, 500 msec) the event
message and the truck response are reset.
Status
During operation combinations 0/0 and 1/1 (500 msec.) - Check wire connections;
Acknowledge button inputs trigger the event message. - Check button;
- 1 07 2 Operation
implausible For a valid combination (0/1 or 1/0, 500msecs) the event - Replace button;
and the truck response are reset.
The touch mode button consists of a NC and a NO - Check wire connection;

contact. When the button is pressed both contacts - Check touch mode button;
connect simultaneously. As a result, only the 0/1 and 1/0 - Replace touch mode button;
Touch mode switch inputs combinations should occur.
- 1 08 1 Operation
implausible During operation combinations 0/0 and 1/1 (500 msec.)
The "inching" button consists of a NC and a NO contact. - Check wire connections;

When the button is pressed both contacts switch - Check crawl speed button;
simultaneously. As a result, only the 0/1 and 1/0 - Replace crawl speed button;
During operation the combinations
"Crawl speed redundant 0/0 and 1/1 (switched for 500 msec.) activate the event
- 1 08 2 Operation
inputs" logic implausible message.
For a valid combination (0/1 or 1/0, switched for 500
msec.)
the event and truck response are reset. The status is
assessed as an actuated status (adjustable inching
speed active)
The "Stop" button consists of an NC and an NO contact. - Check parameter reading (side pedestrian mode
When the button is pressed both contacts switch activated?);
simultaneously. As a result, only the 0/1 and 1/0 - Check wire connections;
"Stop" button redundant combinations should occur. - Press "Stop" button;
- 1 08 3 Operation
inputs" logic improbable During operation the combinations - Replace "Stop" button;
0/0 and 1/1 (500 msec) trigger the event message.
message and the truck's response are reset.
Status
The "handbrake lever" switch consists of a NC and a NO - Check wire connections;

contact. When the button is pressed both contacts switch - Check "handbrake lever" switch;
simultaneously. As a result, only the 0/1 and 1/0 - Replace "handbrake lever" switch;
Self test "Handbrake lever redundant During operation the combinations
- 1 08 4
Operation inputs" logic implausible 0/0 and 1/1 (switched for 500 msec.) activate the event
message.
For a valid combination (0/1 or 1/0, switched for
500msec) the event message and the truck's response
are reset.
The "parking brake" switch consists of a NC and a NO - Check wire connections;

contact. When the button is pressed both contacts switch - Check options keypad;
simultaneously. As a result, only the 0/1 and 1/0 - Replace options keypad:
"Parking brake switch
Self test During operation the combinations
- 1 08 5 redundant inputs" logic
Operation 0/0 and 1/1 (switched for 500 msec.) activate the event
implausible
message.
For a valid combination (0/1 or 1/0, switched for 500
msec.) the event message and the truck's response are
reset.
The weigher button consists of a NC and a NO contact. - Check wire connection;

When the button is pressed both contacts connect - Check weigher button;
simultaneously. As a result, only the 0/1 and 1/0 - Replace weigher button;
Weigher button inputs combinations should occur.
- 1 09 1 Operation
implausible During operation combinations 0/0 and 1/1 (500 msec.)
F E XX s Operational Description Cause / Triggering Event Action
Status
During operation the combination 1/1 for both buttons - Check wire connection;
pressed simultaneously for 500 msec triggers the - Check button;
Lift/lower digital setpoints following event message. - Replace button;
- 1 10 1 Operation
are invalid For a valid combination (0/0, 0/1 or 1/0 [button not
pressed / only one button pressed]; 500 msec) the event
During operation the limits for 1/1 [both buttons pressed - Check wire connection;
simultaneously] for 500 msec have been exceeded. - Check button;
Lift/lower analog setpoints
- 1 10 2 Operation For a valid combination (0/0, 0/1 or 1/0 [button not - Replace button;
are invalid
pressed / only one button pressed]; 500 msec) the event
The event message is triggered if the following applies - Check wire connection;
Braking setpointand release for T = 250msec: - Check pedal power supply;
- 1 11 1 Operation
contact implausible Vbrake pedal < 12.5% and - Replace pedal;
Logic signal release contact = 1 - Replace signal-evaluating controller;
Braking setpointand release for T = 250msec: - Check pedal power supply;
- 1 11 2 Operation
contact implausible Vbrake pedal > 25% and - Replace pedal;
Braking setpoint and full for T = 250msec: - Check pedal power supply;
- 1 11 3 Operation
brake contact implausible Vbrake pedal < 55% and - Replace pedal;
Logic signal full brake contact = 1 - Replace signal-evaluating controller;
Braking setpoint and full for T = 250msec: - Check pedal power supply;
- 1 11 4 Operation
brake contact implausible Vbrake pedal > 80% and - Replace pedal;
Logic signal full brake contact = 0 - Replace signal-evaluating controller;
Status
Combination "brake - Check brake fluid level;

The event message is triggered
setpoint" against brake - Check proximity sensor;
- 1 11 5 Operation if for T = 250 ms the following applies:
pressure invalid (movement - Check pressure sensors;
* Vbrake pedal > 80% and brake pressure < 40 bar
without brake pressure)
Combination "brake The event message is triggered - Check brake fluid level;
setpoint" against brake if for T = 250 ms the following applies: - Check proximity sensor;
- 1 11 6 Operation
pressure invalid (brake * Vbrake pedal < 20% (> 7 volt ) and brake pressure - Check pressure sensors;
pressure without movement) > 20 bar
- Check the cable connection;

The event message is triggered - check accelerator-pedal power supply /
Sum of the voltages
if for T = 250 ms the following applies: tiller head power supply;
- 1 11 7 Operation "Braking 1 setpoint" to
* Vbrake pedal'' + Vbrake pedal 2 > 5.5 V or - replace accelerator pedal / tiller arm;
"Braking 2 setpoint" invalid
" Vbrake pedal'' + Vbrake pedal 2 < 4.5 V - replace the controller that is evaluating the
signal;
Travel setpoint and release for T = 250msec: - Check accelerator pedal/tiller arm power supply;
- 1 12 1 Operation
contact invalid Vaccelerator pedal < "12.5% and - Replace accelerator pedal / tiller arm;
Travel setpoint and release for T = 250msec: - Check accelerator pedal/tiller arm power supply;
- 1 12 2 Operation
contact invalid Vaccelerator pedal > 25 % and - Replace accelerator pedal / tiller arm;
The event message is triggered - Check wire connection;
Total voltage "Travel 1
if for T = 250 ms the following applies: - Check accelerator pedal/tiller arm power supply;
- 1 12 3 Operation setpoint" to "Travel2
* Vbrake pedal1 + Vbrake pedal 2 > 5.5 V or Vbrake pedal1 + - Replace accelerator pedal / tiller arm;
setpoint" invalid
Vbrake pedal 2 < 4.5 V - Replace signal-evaluating controller;
Status
During operation the combination 1/1 [both travel - Check wire connection;
direction switch / button / twin pedal pressed] for 500 - Check travel direction switch/button/twin pedal;
msec triggers the following event message. - Check travel direction switch/button/twin pedal;
Travel direction 1 and travel
- 1 13 1 Operation For a valid combination (0/0, 0/1 or 1/0 [travel direction - Replace signal-evaluating controller;
direction 2 invalid
switch/button/twin pedal not pressed or only one travel
direction switch/button/twin pedal pressed]; 500 msec)
the event message and the truck response are reset.
- Check parameter settings;

If more than one direction sensor is installed: - Check installed accelerator (hardware);
Direction setting signal While the truck is travelling, the system monitors if by -Check installed Pilots (hardware);
- 1 13 2 Operation improbable (direction mistake more than one direction sensor (travel direction - Check travel direction switch / button / twin
sensor) switch on pilot, external direction sensor or twin pedal) is pedal;
installed. If this is the case, the event is triggered - Replace travel direction switch / button / twin
pedal;
- Rectify mechanical blockage of drive system;

- Check speed sensor power supply;
Motor speed signal Logic test: after a short period of motor control, the
- 1 14 1 Self test - Check wire connection;
implausible speed sensor does not supply any signals
- Replace speed sensor;
- Replace signal-evaluating controller;
Motor powers without Motor powered for 500 msec without setpoint. - Check motor connections;
- 1 15 1 Operation
setpoint Logic: implausible status in controller - Check motor model, replace if necessary;
Motor powers without Convergence problem in monitor for the motor speed - Check motor connections;
- 1 15 2 Operation
setpoint Logic: implausible status in monitor - Check motor model, replace if necessary;

Jump from n_motor > 10% to n_motor < 1% and for - Check wire connection;
- 1 16 1 Operation Irregular speed signal
T = 80 msec, the following applies: n_motor < 1% - Replace speed sensor;
Status
Incrementer damaged - Check incrementer signals with multimeter;

The AC-3 Power Control (U8) has identified the sensor - Check speed sensor power supply;
bearing as being damaged. The AC-3 Power Control - Check wire connection;
(U8) monitors sensor to ensure the impulse wires are - Replace speed sensor;
single-channel, and to check for sudden changes in the - Replace signal-evaluating controller;
pulse rate and for constant power supply.
Sensor is damaged (broken wire, short circuit, incorrect
pulses);
Operating system wrongly flags a fault;
AC-3 Power Control component (sensor bearing control)
is faulty
Irregular speed signal (large Jump from n_Motor> 10 % to n_Motor< 1 % and
- 1 16 2 Operation jump in evaluated speed For T = 80 msec.:
signal) n_motor< 1%
- Manually move the shuttle to the channel start,

remove any blockage (use recovery vehicle);
- Reduce load on shuttle;
- Drive: check setpoint specification, motor
controller 9U19 and drive motor including
No signals from incremental transmitter 1B5.
carbon brushes and incremental transmitter
1B5;
- Check wire connection;
- If the shuttle is overloaded, increase the travel
speed;
- Check speed-sensor power supply;

- Check the wiring;
Implausible value for the Engine control unit is sending an incorrect value for the
- 1 16 3 Operation - Replace speed sensor;
engine-speed signal engine-speed signal.
- Replace the controller that is evaluating the
signal;
Both speed sensor tracks are counted. When the first - Check speed sensor incrementer channels;
A speed sensor channel deviation limit is reached the system waits for a feasible - Replace speed sensor;
- 1 17 1 Operation
does not pulse signal from the suspected broken track. When the - Replace signal-evaluating controller;
second limit is reached the event message is generated.
Status
Incrementer damaged - Check incrementer signals with multimeter;

The AC-3 Power Control (U8) has identified the sensor - Check speed sensor power supply;
bearing as being damaged. The AC-3 Power Control - Check wire connection;
(U8) monitors sensor to ensure the impulse wires are - Replace speed sensor;
single-channel, and to check for sudden changes in the - Replace signal-evaluating controller;
pulse rate and for constant power supply.
Sensor is damaged (broken wire, short circuit, incorrect
A speed sensor channel
- 1 17 2 Operation pulses);
does not pulse
Operating system wrongly flags a fault;
AC-3 Power Control component (sensor bearing control)
is faulty
Both sensor tracks are counted. When the first deviation
limit is reached the system waits for a feasible signal
from the suspected broken track. When the second limit
is reached the event is generated.
No speed signal from the The counts for both incrementers are compared. - Check incrementer signals with multimeter;
travel impulse sensor If the travel incrementer supplies a speed signal of - Check wiring with multimeter;
- 1 17 3 Operation although travel sensor > 0.05 km/h and the travel pulse contact controller - Replace speed sensor;
indicates greater than incrementer a speed signal of 0 km/h, the event is
0.5 km/h. triggered. The activation limit is 100 msec.
The counts for both incrementers are compared. If the - Check incrementer signals with multimeter;
No speed signal from travel
travel incrementer supplies a speed signal of 0 km/h and - Check wiring with multimeter;
sensor although travel
- 1 17 4 Operation the travel pulse contact controller incrementer a speed - Replace speed sensor;
impulse sensor indicates
signal of > 0.05 km/h, the event is triggered. The
greater than 0.5 km/h.
Deviation of more than The counts for both incrementers are compared. If the - Check incrementer signals with multimeter;
0.25 km/h between travel speed signals of both incrementers differ by more than - Check wiring with multimeter;
- 1 17 5 Operation
impulse sensor and travel 0.025 km/h, the event is triggered. The activation limit is - Replace speed sensor;
sensor 100 msec.
Status
The counts for both incrementers are compared. If the - Check incrementer signals with multimeter;
Directions obtained from
speed of both incrementers > 0.01 km/h and the - Check wiring with multimeter;
travel sensor and travel
- 1 17 6 Operation directions of the speed signals for both incrementers are - Replace speed sensor;
impulse sensor are
contradictory, the event is triggered. The activation limit
contradictory
is 100 msec.
One incremental track Both sensor tracks are counted. When the first deviation - Check incrementer signals with multimeter;
height measurement of the limit is reached the system waits for a feasible signal - Check wiring with multimeter;
- 1 17 7 Operation
proportional lift pulses, the from the suspected broken track. When the second limit - Replace speed sensor;
other does not is reached the event is generated.
- 1 17 8 Operation
free lift pulses, the other from the suspected broken track. When the second limit - Replace speed sensor;
does not is reached the event is generated.
- 1 17 9 Operation
auxiliary lift pulses, the other from the suspected broken track. When the second limit - Replace speed sensor;
does not is reached the event is generated.
The counts for both incrementers are compared. If the lift - Check incrementer signals with multimeter;
Main lift does not lower controller incrementer supplies a speed signal, but the lift - Check wiring with multimeter;
- 1 17 10 Operation despite the hydraulic motor height measurement incrementer does not supply a - Replace speed sensor;
turning signal after one second, the event is triggered. The
The counts for both incrementers are compared. If the lift - Check incrementer signals with multimeter;
height measurement incrementer supplies a speed - Check wiring with multimeter;
Main lift lowers despite the
- 1 17 11 Operation signal, but the lift controller incrementer does not supply - Replace speed sensor;
hydraulic motor not turning
a signal after one second, the event is triggered. The
Status
The counts for both incrementers are compared. If the - Check the hydraulic system for leaks;
Excessive deviation incrementers for the lift control and lift height - Check incrementer signals with multimeter;
- 1 17 12 Operation between lift speed and pump measurement are not synchronised within three - Check wiring with multimeter;
speed seconds, the event is triggered. The activation limit is - Replace speed sensor;
100 msec.
- Check incrementer signals with multimeter;

Proportional lift incrementer
- 1 17 13 Operation Channel A or channel B are defective on the incrementer - Check wiring with multimeter;
1: One channel defective

Proportional lift incrementer
2: One channel defective

Free lift incrementer V.
One channel defective

Free lift incrementer 2:

Aux. lift incrementer 1:
The counts for both incrementers are compared. - Check incrementer signals with multimeter;
If the lift controller incrementer supplies a speed signal, - Check wiring with multimeter;
Logic test: Main lift does not
- 1 17 18 Operation but the lift height measurement incrementer does not - Replace speed sensor;
lower despite pump rotating
supply a signal after one second, the event is triggered.
The activation limit is 20 msec.
LH load wheel sensor - Check mounting position of sensor to magnet;

- 1 17 19 Operation Incorrect counting detected between ChA and ChB.
incrementer deviation - Replace sensor;
RH load wheel sensor - Check mounting position of sensor to magnet;

- 1 17 20 Operation Incorrect counting detected between ChA and ChB.
incrementer deviation - Replace sensor;
Status
LH load wheel sensor - Check mounting position of sensor to magnet;

Incorrect counting detected between LH load wheel
- 1 17 21 Operation excessive deviation from - Check tyre quality;
sensor and drive wheel incrementer.
reading to drive wheel - Replace sensor;
RH load wheel sensor - Check mounting position of sensor to magnet;

Incorrect counting detected between RH load wheel
- 1 17 22 Operation excessive deviation from - Check tyre quality;
sensor and drive wheel incrementer.
reading to drive wheel - Replace sensor;
The sensor bearing and three channel incrementer are - Test the electrical function of the sensor bearing
Three channel incrementer
synchronised with respect to each other every 120 mm. - Test the mechanical function of the sensor
- 1 17 23 Operation comparison with sensor
The error is generated if the sensor bearing deviates bearing
bearing incrementer
from the three channel sensor by >= 5 mm.

Speed sensor in load wheel - Check wire connection;
- 1 18 1 Undefined This event message is not currently used.
sensor damaged - Replace speed sensor;
The event message is triggered - Check wiring from controller to platform lower
if for T >= time limit the following applies: limit sensor;
- 1 19 1 Operation Cabin position implausible • A change in status of the platform lower-limit sensor - Check / replace lower limit sensor;
from the neutral position into the "Platform raised" - Check lift motor power cables;
position is detected while driving - Replace the signal-generating controller;
Status
Excessive slip / drive has probably been tipped - Check motor connection wire (wire breakage);
The AC-3 Power Control (U8) has detected excessive - Check motor model, replace if necessary;
deviation (slip) between the phase current frequency and - Check motor and replace if necessary;
the speed.
More torque is required from / placed on the motor than it
- 1 20 1 Operation Drive wheel slip excessive can provide / accept;
Field current is reduced excessively;
Error accompanying sensor bearing control or output
stage protection;
Operating system does not allow enough slip for the
driven motor;
AC-3 Power Control component is damaged
The lift actuator jumper is controlled for max. 40 msec at - Check motor connection wire (wire breakage);
100 % PWM (pulse width modulation). - Check motor model, replace if necessary;
- 1 21 1 Self test Output stage faulty The event message is triggered if the pump voltage - Replace controller;
drops within this time below 10% of the capacitor
voltage. Vpump > Vcapacj(0r / 10.
"Digital signal" logic/signal This event message is triggered if the signal shape or - Replace tiller head;
- 1 22 1
shape implausible modulation of a digital signal is implausible.
- Remove physical blockage from the brake;

The event message is triggered if after the brake applies
Brake response switch - Check wire connection;
- 1 23 1 Operation the feedback switch does not report this status (after
signal implausible (in idle) - Check switch and replace if necessary;
1 sec.).

The event message is triggered if after the brake is
Brake response switch - Check wire connection;
- 1 23 2 Operation released the feedback switch does not report this status
signal implausible (in idle) - Check switch and replace if necessary;
(after 300 msec.).
Status

Brake response switch
signal implausible (speed >
This event message is triggered if the response switch - Check wire connection;
- 1 23 3 Operation
signals applied status during travel. - Check switch and replace if necessary;
1km/h)
- Check brake wear, replace wear parts / brake if

The event message is triggered necessary.
Brake does not hold on a if for T > 250 ms the drive system - Measure current through the magnetic coil (you
- 1 23 4 Operation
ramp (failsafe brake) • reports an actual rotational speed > 20 rpm when the should not be able to measure any current when
brake is applied. the brake is applied).
- Replace signal-issuing controller;

necessary.
Failsafe brake does not hold On system start or engine start, the traction drives are
- Measure current through the magnetic coil (you
- 1 23 5 System start (on system start or motor subjected to a travel request for a test time. If a truck
should not be able to measure any current when
start) actual speed is detected, this event will be triggered.
the brake is applied).

Left load wheel brake not Left load wheel brake not controlled but feedback signal - Check sensor system with multimeter;
- 1 23 6 Operation controlled but feedback is still present - Check computer component inputs;
signal present The activation limit is 1000 msec. - Repair faulty components and replace if
necessary;

Left load wheel brake Left load wheel brake controlled but feedback signal is - Check sensor system with multimeter;
- 1 23 7 Operation controlled although not present - Check computer component inputs;
feedback signal missing The activation limit is 1000 msec. - Repair faulty components and replace if
necessary;

Right load wheel brake not Right load wheel brake not controlled but feedback - Check sensor system with multimeter;
- 1 23 8 Operation controlled but feedback signal is still present - Check computer component inputs;
signal present The activation limit is 1000 msec. - Repair faulty components and replace if
necessary;
Status

Right load wheel brake Right load wheel brake controlled but feedback signal is - Check sensor system with multimeter;
- 1 23 9 Operation controlled although not present. - Check computer component inputs;
feedback signal missing The activation limit is 1000 msec. - Repair faulty components and replace if
necessary;
- Listen to check if emergency stop mechanism

switches:
hydraulic fail-safe brake for 500 msec.: brake energised and pressure on
- 1 23 10 System start - If so, check the pressure sensor and replace if
cannot be released emergency stop mechanism > 3 bar
necessary;
- If not, check the relay and replace if necessary;

necessary;
Parking brake feedback If the combinations 0/0 and 1/1 appear for longer than
- 1 23 11 Operation - Check wire connection;
contacts implausible the limit time, a message is activated.
- Check switch and replace if necessary;
The lift height sensor sequence is implausible. This - Check wire connection;
event message is triggered if the following applies for - Check sensor and replace if necessary;
- 1 24 1 Operation Lift height signal implausible T => 500 msec: - Replace signal-evaluating controller;
Sequence of 2 lift height signals is implausible, e.g.
Top lift height signal without Bottom lift height signal

"Stacking height redundant
- 1 24 2 Operation if for T = 100 ms the following applies: - Check sensor and replace if necessary;
inputs" logic implausible
• NC and NO contacts have the same status - Replace signal-evaluating controller;
if for T = 250 ms the following applies: - Check sensor and replace if necessary;
"Free lift sensor redundant
- 1 24 3 Operation • NC and NO contacts have the same status
When the event occurs, the master assumes that the
truck is in the mast lift stage.
Status
Integrated lift stroke is greater than 2x the set free lift - Check wire connection;
Lifting stroke greater than 2x
height, however sensor indicates free lift. When the - Check sensor and replace if necessary;
- 1 24 4 Operation free lift, however mast lift
event occurs, the master assumes that the truck is in the
has not been detected
mast lift stage.

"Lift limit switch redundant
- 1 24 5 Operation if for T = 100 ms the following applies: - Check sensor and replace if necessary;
• NC and NO contacts have the same status - Replace signal-evaluating controller;
"Initial lowering limit The event message is triggered - Check wire connection;
- 1 24 6 Operation redundant inputs" logic if for T = 100 ms the following applies: - Check sensor and replace if necessary;
implausible • NC and NO contacts have the same status - Replace signal-evaluating controller;
- If possible, do not use the lift system, as the lift

limit is deactivated. The lift mechanism could
move too far and be damaged;
- If absolutely necessary, carefully lower the
platform manually. Note that lowering must end
Logic: lift system limit No positive signal at 7B38.1 - 7B38.4 during lifting or
- 1 24 7 Operation as soon as the shuttle can move freely
switch faulty. lowering.
underneath the pallets;
- Check limit switches 7B38.1-7B38.4; check
signal feedback at inputs R3-R6 of the main
controller 8U37;
- Check the wiring;
Integrated lift stroke is greater than 1.5x the set free lift - Check free-lift sensor (position, contamination);
Lift stroke greater than 1.5x height, however sensor indicates free lift. - Check free-lift height setting (JUDIT);
- 1 24 8 Operation free lift, however mast lift When the event occurs, the master assumes that the - Check pump drive (e.g. worn pump?);
has not been detected truck is in the mast lift stage.
Event is reset when mast lift is detected.

During operation combinations 0/0 and 1/1 trigger the - Check sensor system with multimeter;
Signal on load sensing
inputs is implausible
necessary;
Status

Plausibility test: If the weight display > 300 kg the load
No load sensing signal when sensors must be applied. The event message can only
weight > 300 kg be reset by resetting the truck. The activation limit is
2000 msec.
necessary;
Feedback from a main - Check wiring with multimeter;

Feedback from a main contactor contact or the
contactor contact or the - Check computer component inputs;
emergency stop relay although the Emergency
emergency stop relay - Repair faulty components and replace if
- 1 26 1 Operation Disconnect switch is not activated. The event message
although the Emergency necessary;
can only be reset by resetting the truck. The activation
Disconnect switch is not
limit is 100 msec.
activated.
Feedback from the - Check wiring with multimeter;

Emergency Disconnect Feedback from the Emergency Disconnect switch at - Check computer component inputs;
switch at channel 1 of the channel 1 of the Safe computer although the Emergency - Repair faulty components and replace if
- 1 26 2 Operation Safe computer although the Disconnect switch has not been activated. The event necessary;
Emergency Disconnect message can only be reset by resetting the truck. The
switch has not been activation limit is 100 msec.
activated
Feedback from the main - Check wiring with multimeter;

Feedback from the main contactor level 1 control at
contactor level 1 control at - Check computer component inputs;
channel 1 of the Safe computer although contactor level
channel 1 of the Safe - Repair faulty components and replace if
- 1 26 3 Operation 1 has not been activated. The event message can only
computer although contactor necessary;
be reset by resetting the truck. The activation limit is
level 1 has not been
100 msec.
activated.

100 msec.
activated.
Status
Feedback from the - Check wiring with multimeter;

Emergency Disconnect Feedback from the Emergency Disconnect switch at - Check computer component inputs;
switch at channel 2 of the channel 2 of the Safe computer although the Emergency - Repair faulty components and replace if
- 1 26 5 Operation Safe computer although the Disconnect switch has not been activated. The event necessary;
Emergency Disconnect message can only be reset by resetting the truck. The
switch has not been activation limit is 100 msec.
activated

200 msec.
activated.
No feedback from the - Check wiring with multimeter;

Emergency Disconnect No feedback from the Emergency Disconnect switch at - Check computer component inputs;
switch at channel 1/2 of the channel 1/2 of the Safe computer, although activated - Repair faulty components and replace if
- 1 26 7 Operation
Safe computer although the The event message can only be reset by resetting the necessary;
Emergency Disconnect truck. The activation limit is 200 msec.
switch has been activated
No feedback from relay K1 although the Safe computer - Check wiring with multimeter;
No feedback from relay K1
has been activated. The event message can only be - Check computer component inputs;
- 1 26 8 Operation despite Safe computer
reset by resetting the truck. The activation limit is - Repair faulty components and replace if
activation
200 msec. necessary;
activation
activation
Status
activation
No feedback from main contactor 1 although the Safe - Check wiring with multimeter;
No feedback from main
computer has been activated. The event message can - Check computer component inputs;
- 1 26 12 Operation contactor 1 despite "main
only be reset by resetting the truck. The activation limit is - Repair faulty components and replace if
contactor 1" signal activation
No feedback from main contactor 2 although the Safe - Check wiring with multimeter;
No feedback from main
computer has been activated. The event message can - Check computer component inputs;
- 1 26 13 Operation contactor 2 despite "main
only be reset by resetting the truck. The activation limit is - Repair faulty components and replace if
contactor 2" signal activation
Power up test for emergency stop circuit by the Safe - Check wiring with multimeter;
Test routine for emergency
computer has failed The event message can only be - Check computer component inputs;
- 1 26 14 System start stop circuit by the Safe
computer has failed
20 msec. necessary;
Redundant controllers of the Safe computer have - Check wiring with multimeter;
Different input statuses
detected different input statuses. The event message - Check computer component inputs;
- 1 26 15 Operation between the two Safe
can only be reset by resetting the truck. The activation - Repair faulty components and replace if
computers
limit is 100 msec. necessary;
Comparison of channel A / - Check information in the truck display;

channel B of external The error is triggered for the combination 1/0 or 0/1 . -Assess wiring;
- 1 26 16 System start
Emergency Disconnect of Activation limit 100 ms. - Check CAN-Bus;
APM + PLC for diversity
Monitoring of APM+ - Check information in the truck display;

The Emergency Stop request is withdrawn via the
Emergency Stop cancel -Assess wiring;
- 1 26 17 System start CanBus, however there is no corresponding Emergency
request and the - Check CAN-Bus;
Disconnect feedback.
power supply.
Status
Monitoring of APM+ - Check information in the truck display;

The Emergency Stop request is set via the CanBus,
Emergency Stop cancel -Assess wiring;
- 1 26 18 System start however there is no corresponding Emergency
request and the - Check CAN-Bus;
Disconnect feedback.
power supply.
Main Lift stage has lost height without request. The - Check mast mechanics;
Main Lift lowers without
- 1 27 1 Operation event message appears as soon as the lift height lowers - Check mast hydraulics;
activation signal
by more than 50 mm without request.
Main lift: free lift has lowered The free lift stage has moved hydraulically although the - Check mast mechanics;
- 1 28 1 Operation
before proportional lift proportional lift stage was not fully retracted. - Check mast hydraulics;
Main lift: proportional lift has The proportional lift stage has moved hydraulically - Check mast mechanics;
- 1 28 2 Operation
lowered before free lift although the free lift stage was not fully retracted. - Check mast hydraulics;
Main lift: Permissible - Check mast mechanics;
- 1 29 1 Operation The permissible lowering speed has been exceeded.
lowering speed exceeded - Check mast hydraulics;
Aux. lift: Permissible - Compare actual speed with data sheet values;
- 1 29 2 Operation The permissible lowering speed has been exceeded.
lowering speed exceeded - If it is too high, adjust to data sheet value;
- Compare the actual sideshift speed with the

Sideshift: Permissible speed data sheet values;
- 1 29 3 Operation The permissible sideshift speed has been exceeded.
exceeded - If the sideshift speed has been exceeded, set it
to the data sheet values;
- Compare the actual rotating speed with the data

Rotate: Permissible speed sheet values;
- 1 29 4 Operation The permissible rotating speed has been exceeded.
exceeded - If the rotating speed has been exceeded, set it
to the data sheet values;
- Check the pre-tension torque with JUDIT and

Main lift does not reach pre¬
The pre-tension moment could not be established in the adjust if necessary;
- 1 30 1 Operation tension moment in
set time. - Check mechanical system of the mast;
prescribed time
- Check mast hydraulics;
Status
- Check the pre-tension torque with JUDIT and

Aux. lift does not reach pre¬
The pre-tension moment could not be established in the adjust if necessary;
- 1 30 2 Operation tension moment in
set time. - Check mechanical system of the mast;
prescribed time
- Check mast hydraulics;
- Check the hydraulic setpoint and adjust if

Pallet clamp does not reach
The pallet clamp "CLOSED" end position could not be necessary;
- 1 30 3 Operation the "CLOSED" end position
reached in the set time. - Check the pallet clamp mechanisms for
in the prescribed time
sluggishness;
- Check the hydraulic setpoint and adjust if

Pallet clamp does not reach
The pallet clamp "OPEN" end position could not be necessary;
- 1 30 4 Operation the "OPEN" end position in
reached in the set time. - Check the pallet clamp mechanisms for
the prescribed time
sluggishness;
Emergency stop circuit - Check wiring with multimeter;

CAN-BUS status damaged during booting. The event
power-up test: Emergency - Check computer component inputs;
- 1 31 1 System start message can only be reset by an Emergency Stop reset.
Stop switch activated, but - Repair faulty components and replace if
CAN-BUS not OK necessary;
Emergency stop circuit No pulse contact controller has reported charge circuit - Check the charging voltage on the controllers;
power-up test: no activation activation. The charging of the pulse contact controllers - Check wiring;
of any pulse contact must be finished within 10 seconds. The activation limit
controllers is 1000 msec.
The hydraulic controller has not reported charge circuit - Check the charging voltage on the controllers;
Emergency stop circuit
activation. The charging of the pulse contact controllers - Check wiring;
- 1 31 3 System start power-up test: no lift
must be finished within 10 seconds. The activation limit
controller activation
is 1000 msec.
The traction controller has not reported load circuit - Check the charging voltage on the controllers;
- 1 31 4 System start power-up test: no traction
is 1000 msec.
Status
The steering controller has not reported load circuit - Check the charging voltage on the controllers;
- 1 31 5 System start power-up test: no steering
is 1000 msec.
Emergency stop circuit Feedback contact of second main contactor level not - Check the charging voltage on the controllers;
- 1 31 6 System start power-up test: no release of closed within 10 seconds. The activation limit is - Check wiring;
main contactor level 2 1000 msec.
Emergency stop circuit Other non-separated event message in main contactor -> The event message should not occur.
Otherwise contact troubleshooting specialists;
- 1 31 7 System start power-up test: non-defined circuit. This event message does not occur in normal
EMERGENCY STOP error operation. The activation limit is 1000 msec.
Charge - Check power cables (main current connections,

The AC-3 Power Control (U8) has been activated while integrated charging circuit wiring,...);
its internal capacitors were charging. - Check main current fuses and replace if
The main contactor was opened during active control. necessary;
Power circuit activated during charging. The activation - Replace AC-3 Power Control interface card;
limit is 20 msec.
The main contactor was disconnected during active
power circuit activated
- 1 32 1 System start control;
during charging
The control system was activated before the main
contactor was closed and the internal capacitors were
charged;
Installation of the AC-3 Power Control component is
damaged;
AC-3 Power Control component (voltage measurement)
is damaged;
The capacitor voltage should reduce by at least 1 V - Replace controller;

Capacitor pre-charge cannot
- 1 32 2 Self test within 750 msec, of the pre-charge circuit being switched
be switched off
off.
Status
- Check battery voltage;

- Check key switch voltage;
Capacitor pre-charge
The condition (V-key - V-cap.) < limit voltage is not met - Check controller power connections for short
- 1 32 3 Self test (output stage pre-charge)
within a fixed time after activating the pre-charge circuit. circuits;
not complete
- Check harness for short circuit;
- Replace component;

Ground system track 1 left
actual value sensor system: Switch status of ground sensors unequal. The activation
invalid channel A / channel limit is 20 msec.
- Repair faulty components and replace
B value relationship
if necessary;

- Repair faulty components and replace
if necessary;

necessary;

Ground system track 1 right
necessary;

necessary;
Status

necessary;
Brake force governor: invalid -Check sensor wiring;

Analog sensor value relationship deviates by more than
- 1 34 1 Operation channel A / channel B value - Measure sensor signals with multimeter;
2.5°. The activation limit is 100 msec.
relationship - Replace sensor;
Traverse sensor system: - Check sensor wiring;
- 1 34 3 Operation invalid channel A / channel - Measure sensor signals with multimeter;
B value relationship - Replace sensor;
Rotate sensor system: - Check sensor wiring;
Left hand support - Check sensor wiring;
mushroom: invalid channel Analog sensor value relationship deviates by more than - Measure sensor signals with multimeter;
- 1 34 7 Operation
A / channel B value 2.5°. The activation limit is 100 msec. - Replace sensor;
relationship
Right hand support - Check sensor wiring;

mushroom: invalid channel Analog sensor value relationship deviates by more than - Measure sensor signals with multimeter;
- 1 34 9 Operation
A / channel B value 2.5°. The activation limit is 100 msec. - Replace sensor;
relationship
Steering actual value sensor -Check sensor wiring;

- 1 34 11 Operation systems: invalid channel A / - Measure sensor signals with multimeter;
channel B value relationship - Replace sensor;
Steering setpoint device: - Check sensor wiring;
Status
Steering setpoint device - Check sensor wiring;

- 1 34 15 Operation optional: invalid channel A / - Measure sensor signals with multimeter;
Hydraulic setpoint device: -Check sensor wiring;
Travel setpoint device: - Check sensor wiring;
Hydraulic setpoint device - Check sensor wiring;

Travel setpoint device - Check sensor wiring;
- Check sensor wiring;

Accelerator pedal setpoint - Check sensor;
- 1 34 29 Operation device: invalid channel A/ - Switch the truck off and on again;
channel B value relationship - Inquire about software update;
-Check sensor wiring;
Brake pedal setpoint device: - Check sensor;
- 1 34 31 Operation invalid channel A / channel - Switch the truck off and on again;
B value relationship - Inquire about software update;
Pedestrian right travel - Check sensor wiring;
setpoint device: invalid Analog sensor value relationship deviates by more than - Measure sensor signals with multimeter;
- 1 34 33 Operation
channel A / channel B value 2.5°. The activation limit is 100 msec. - Replace sensor;
relationship
Status
Pedestrian left travel - Check sensor wiring;

- 1 34 35 Operation
relationship
Pedestrian right steer -Check sensor wiring;

- 1 34 37 Operation
relationship
Pedestrian left steer setpoint - Check sensor wiring;

- 1 34 39 Operation device: invalid channel A/ - Measure sensor signals with multimeter;
Referencing of the brake force regulator could not be -Check referencing of the brake force regulator;
Brake force governor:
- 1 35 1 System start completed after the truck has been switched on. The -Teach-in the function via JUDIT;
referencing failed
triggering threshold is 100 ms.
Left hand support Referencing of the left-hand support could not be -Check referencing of the left-hand support;
- 1 35 7 System start mushroom: referencing completed after the truck has been switched on. The -Teach-in the function via JUDIT;
failed triggering threshold is 100 ms.
Right hand support Referencing of the right-hand support could not be - Check referencing of the right-hand support;
- 1 35 9 System start mushroom: referencing completed after the truck has been switched on. The -Teach-in the function via JUDIT;
failed triggering threshold is 100 ms.
Referencing of the "main-lift proportional lift stage" could - Check referencing of the "main lift proportional
Main lift proportional lift
- 1 35 25 System start not be completed after the truck has been switched on. lift stage";
stage: referencing failed
The triggering threshold is 100 ms. -Teach-in the function via JUDIT;
Referencing of the "main-lift free-lift stage" could not be - Check referencing of the "main-lift free-lift
Main lift free lift stage:
- 1 35 27 System start completed after the truck has been switched on. The stage";
referencing failed
triggering threshold is 100 ms. -Teach-in the function via JUDIT;
Referencing of the "auxiliary lift" could not be completed -Check referencing of the "auxiliary lift";
- 1 35 29 System start Aux. lift: referencing failed after the truck has been switched on. The triggering -Teach-in the function via JUDIT;
threshold is 100 ms.
tUNGHEINRICH Event Messages 03.15 33 (§§)
Status
Brake force governor: value -Teach-in the function via Judit;

The teach-in process could not be completed. The
- 1 36 1 Operation range calculated during
Teachln implausible
Left hand support -Teach-in the function via Judit;

mushroom: value range The teach-in process could not be completed. The
- 1 36 7 Operation
calculated during Teachln activation limit is 100 msec.
implausible
Right hand support -Teach-in the function via Judit;

mushroom: value range The teach-in process could not be completed. The
- 1 36 9 Operation
calculated during Teachln activation limit is 100 msec.
implausible
Steering wheel sensor -Teach-in the function via Judit;

- 1 36 13 Operation Teach-in: captured range
too small
Optional steering wheel: -Teach-in the function via Judit;

- 1 36 15 Operation Sensor Teach-in: captured
range too small
Hydraulic control lever: -Teach-in the function via Judit;

- 1 36 21 Operation Teach-in value range too
small
Travel control lever: Teach- The teach-in process could not be completed. The -Teach-in the function via Judit;
- 1 36 23 Operation
in value range too small activation limit is 100 msec.
Optional hydraulic control -Teach-in the function via Judit;

- 1 36 25 Operation lever: Teach-in value range
too small
Optional travel control lever: -Teach-in the function via Judit;

- 1 36 27 Operation Teach-in value range too
small
Status
Accelerator pedal: Teach-in The teach-in process could not be completed. The -Teach-in the function via Judit;
- 1 36 29 Operation
value range too small activation limit is 100 msec.
Brake pedal: Teach-in value The teach-in process could not be completed. The -Teach-in the function via Judit;
- 1 36 31 Operation
range too small activation limit is 100 msec.
Right pedestrian travel -Teach-in the function via Judit;

- 1 36 33 Operation control lever: Teach-in value
range too small
Left pedestrian travel control -Teach-in the function via Judit;

too small
Right pedestrian steer -Teach-in the function via Judit;

- 1 36 37 Operation control lever: Teach-in value
range too small
Left pedestrian steer control -Teach-in the function via Judit;

too small
- Check index switch wiring and signals;

Brake force governor: brake
- Check distance and alignment of index switch
force governor position Deviation between index switch and angle sensor
- 1 37 1 Operation with reference to the trip cams of the sensor
implausible with respect to position. The activation limit is 100 msec.
plate, and align if necessary;
index switch trip point
- Replace index switch;

Traverse sensor system: - Check distance and alignment of index switch
Deviation between index switch and angle sensor
- 1 37 4 Operation traverse position / index with reference to the trip cams of the sensor
position. The activation limit is 100 msec.
switch difference plate, and align if necessary;
Status

Main lift, proportional lift stage: Deviation between index - Check distance and alignment of index switch
switch and lift height position. The activation limit is with reference to the trip cams of the sensor
100 msec. plate, and align if necessary;
- If possible, do not use the lift system, as the lift

limit is deactivated. The lift mechanism could
move too far and be damaged;
No index switch reference - If absolutely necessary, carefully lower the
- 1 37 25 Operation
side platform manually. Note that lowering must end
as soon as the shuttle can move freely
No negative flank on 7B38.1-7B38.4 after the defined underneath the pallets;
time (limit switch) - Manually move the shuttle back or recover if
necessary (use recovery vehicle);
- Check fuse 2F19;
- Check lift motor and motor brushes 7M6, 7M7;
-Check control contactors K8- K11 and 2K10;
- Check limit switches 7B38.1-7BB38.4;
- Check the wiring;

Main lift, proportional lift
stage: difference between Deviation between index switch and lift height position.
index switch / lift height The activation limit is 100 msec.
reference side

Main lift free lift stage: no Deviation between index switch and lift height position.
index switch reference side The activation limit is 100 msec.
Status

Main lift free lift stage:
difference between index Deviation between index switch and lift height position.
switch / lift height reference The activation limit is 100 msec.
side

Aux. lift: no index switch Deviation between index switch and lift height position.
reference side The activation limit is 100 msec.

Aux. lift: difference between - Check distance and alignment of index switch
Deviation between index switch and lift height position.
- 1 37 30 Operation index switch / lift height with reference to the trip cams of the sensor
reference side plate, and align if necessary;
Signals from left-hand - Check the feedback switch.

"extended position" and - Replace the feedback switch;
Both messages supplied simultaneously. The activation
- 1 38 1 Operation "retracted position" current
limit is 20 msec.
collectors received
concurrently
Signals from right-hand - Check the feedback switch.

"extended position" and - Replace the feedback switch;
Both messages supplied simultaneously. The activation
- 1 38 2 Operation "retracted position" current
limit is 20 msec.
collectors received
concurrently
Target position (extend/retract) of the current collector - Check the mechanics run smoothly;
Collector: Time monitoring
- 1 39 1 Operation could not be reached within the set time. The triggering
timeout.
threshold is 20 ms.
Status
Tolerance field violated Upon reaching the target height and starting the stacking - Check Rack Height Select setpoint setting;
- 1 40 1 Operation although lift height is cycle, the parametrised tolerance field for the lift height
positioned was exited.
An invalid program condition was detected. Detailed - Save the detailed information from the log book
Lift request although target
- 1 40 2 Operation information is shown in the log book. The triggering in Judit via the print screen function and send it
lift height exceeded
threshold is 20 ms. to engineering department via VK-B.
An invalid program condition was detected. Detailed - Save the detailed information from the log book
Lower request although
- 1 40 3 Operation information is shown in the log book. The triggering in Judit via the print screen function and send it
below target lift height
threshold is 20 ms. to engineering department via VK-B.
Load wheel sensor system: Channel A of the left sensor on the load wheel sensor -Check sensor wiring;
- 1 41 1 Channel A of the left sensor system not supplying pulses. The activation limit is - Measure sensor signals with multimeter;
not counting 20 msec. - Replace sensor;
Load wheel sensor system: Channel B of the left sensor on the load wheel sensor - Check sensor wiring;
- 1 41 2 Channel B of the left sensor system not supplying pulses. The activation limit is - Measure sensor signals with multimeter;
not counting 20 msec. - Replace sensor;
Load wheel sensor system: Channel A of the right sensor on the load wheel sensor - Check sensor wiring;
- 1 41 3 Channel A of the right system not supplying pulses. The activation limit is - Measure sensor signals with multimeter;
sensor not counting 20 msec. - Replace sensor;
Load wheel sensor system: Channel B of the right sensor on the load wheel sensor -Check sensor wiring;
- 1 41 4 Channel B of the right system not supplying pulses. The activation limit is - Measure sensor signals with multimeter;
sensor not counting 20 msec. - Replace sensor;
Load wheel sensor system: - Check sensor wiring;
The load-wheel sensors are still not delivering impulses
- 1 41 5 Operation None of the sensors - Measure sensor signals with multimeter;
after the time limit has been reached.
counting - Replace sensor;
Load wheel sensor system: -Check sensor wiring;
Distance calculation via load wheel sensor system
Distance calculation via load - Measure sensor signals with multimeter;
- 1 41 6 supplies invalid readings in relation to drive wheel
wheel sensor system - Replace sensor;
sensor system. The activation limit is 20 msec.
implausible
Status
A new reference point will be defined after track - Measure the wiring;
The left-hand load-wheel
alignment or every 5 m. Based on this reference point, - Check seating of the wheel cover;
- 1 41 7 Operation sensor is counting less than
the left-hand load-wheel sensor should not show a - Replace sensor;
the right-hand sensor
shorter distance than the right-hand one.
A new reference point will be defined after track - Measure the wiring;
The right-hand load-wheel
alignment or every 5 m. Based on this reference point, - Check seating of the wheel cover;
- 1 41 8 Operation sensor is counting less than
the left-hand load-wheel sensor should not show a - Replace sensor;
the left-hand sensor
shorter distance than the right-hand one.
Left-hand load wheel - Measure the wiring;

sensor: The difference The difference between channels A and B of the left- - Check seating of the wheel cover;
- 1 41 9 Operation
between channels A and B hand load-wheel incrementer is too large. - Replace sensor;
is too large
Right-hand load wheel - Measure the wiring;

sensor: The difference The difference between channels A and B of the right- - Check seating of the wheel cover;
- 1 41 10 Operation
between channels A and B hand load-wheel incrementer is too large. - Replace sensor;
is too large
- Check wiring;
Both phases of the left-hand Above a measured minimum travel speed, the left-hand
-Test sensor;
- 1 41 11 Operation load-wheel sensors are load-wheel sensor is still not delivering impulses after the
- Replace sensor;
delivering no impulses time limit has been reached.
- Check wiring;
Both phases of the right- Above a measured minimum travel speed, the right-hand
-Test sensor;
- 1 41 12 Operation hand load-wheel sensors load-wheel sensor is still not delivering impulses after the
- Replace sensor;
are delivering no impulses time limit has been reached.
- Check wiring;
The frequency determined
The frequency of one of the load-wheel sensors is above -Test sensor;
- 1 41 13 Operation by the load-wheel sensors is
the limiting value - Replace sensor;
above the valid range
Status
- Check CAN-Bus;
When the truck begins to brake, the maximum brake
- Check truck speed values for plausibility;
time is calculated based on the current travel speed.
- 1 42 1 Operation Truck deceleration too low - Switch the truck off and on again;
As soon as this time is exceeded, the event message is
- Inquire about software update;
triggered.
- Check CAN-Bus;
When the truck begins to brake, the minimum
- Check truck speed values are correct;
permissible brake time is calculated based on the
- 1 42 2 Operation Truck deceleration too great - Switch the truck off and on again;
current travel speed. If this time is not attained, the event
message is triggered.
The event message is triggered - Inquire about software update;
if for T = 100 ms the following applies: - Replace signal-issuing controller;
Actual speed does not follow
- 1 42 3 Operation •Actual rotational speed > limited maximum rotational
rated speed
speed from monitoring function and actual rotational
speed does not approach maximum rotational speed
The event message is triggered when the following - Switch the truck off and on again;
applies: - Check brake system;
- 1 42 4 Operation Truck deceleration too low
•Travel speed > minimum speed and brake ramp < limit - Inquire about software update;
for 500 ms.
Required brake moment > 10% max. brake moment and - Switch the truck off and on again;
- 1 42 5 Operation Brake moment implausible
drive system reports motor operation (> ONm) - Inquire about software update;
During braking, the actual deceleration is calculated on -Check the settings of the inversion brake using
the basis of the change in travel speed (drive wheel). If the brake log;
- 1 42 6 Truck deceleration too low
this is below 4.5% for more than 1 second, the - Set the deceleration values to the data sheet
monitoring function applies. values;
Status
- Check valve coil cable connection;

Actual current value of - Check valve coil (resistance measurement) and
proportional stage is not replace if necessary;
- 1 43 1 Operation if for T = 80 ms the following applies:
enabled (proportional output - Check outputs for short circuits and rectify if
• Actual value > lower limit without release
1-n) necessary;

- Check valve coil (resistance measurement) and
Switch valve active switch Valve actual condition (switch condition) of a blocked replace if necessary;
- 1 43 2 Operation
condition without activation hydraulic function is not zero - Check outputs for short circuits and rectify if
necessary;
Membrane key test contact Keypad test contact (loop over connector 1-n) - Replace keypad;
- 1 44 1 Operation
implausible interrupted for > 100 msec. - Replace control unit;
"Membrane key redundant During the self test a short was detected between the - Replace keypad;
- 1 44 2 Self test
inputs" logic implausible two contacts of at least one key. - Replace control unit;
"Membrane key redundant During operation an invalid condition was detected on at - Replace keypad;
- 1 44 3 Operation
inputs" logic implausible least one key for >100 msec. - Replace control unit;
- Check brake fluid level;

Brake fluid switch reports
- 1 45 1 Operation Brake fluid switch indicates a lack of brake fluid for >2s. - Check the brake system for leaks;
lack of fluid
- Check switch, wires to MFC brakes
The deviation of the wire guidance sensor to the guide - Check distance signals of both sub-systems
wire is compared in both subcomputers System A and over several points along the guide wire;
"Wire guidance sensor system B. - If the wire guidance sensor (8U7.1) sub-systems
redundant values (8U7.1), The event message is triggered deviate, calibrate and teach the guide wire
- 1 46 1
load direction system" logic if the following applies: sensors;
improbable • The deviation of the wire guidance sensor to the guide
wire in both subcomputers is greater than 50 mm
• Truck travels a distance of more than 500 mm
Status
- 1 46 2
curve drive direction system" if the following applies: sensors;
logic improbable (cornering) • The deviation of the wire guidance sensor to the guide
- 1 46 3
drive direction system" logic if the following applies: sensors;
improbable • The deviation of the wire guidance sensor to the guide
- Switch the truck off and back on again, do not

apply any travel setpoint generators when the
"Active safety functions system starts up;
- 1 47 1 Operation if for T >= time limit the following applies:
monitoring" logic improbable - Switch the truck off and back on again with the
• The safety functions expected are not active.
deadman switch applied and not applied;
The event message is triggered - Do not apply hydraulic setpoint device;
- 1 48 1 Operation Maximum lift time exceeded if for T >= time limit the following applies: - Switch the truck off and on again, do not apply
• Uninterrupted modulation of the hydraulic unit any hydraulic setpoint devices;
- Check cable connection;

"Manifold sensor feedback - Check connected consumers (valves ),
if for T > time limit the following applies:
- 1 49 1 Operation input" to nominal condition replace if necessary;
• After lowering has stopped, the valve block sensor
implausible - Check outputs with JUDIT;
reports that lowering is active
Status

"Manifold sensor feedback The number of side changes from the manifold sensor - Check connected consumers (valves, ....),
- 1 49 2 Operation input" to nominal condition deviates too far from the expected value from the replace if necessary;
implausible lowering setpoint. - Check outputs with JUDIT;
- Check the supply voltage;

- Check the signal voltage;
Boost pressure at pressure Pressure sensor A is on the low-pressure side, but is not - Depending on the result, repair the harness or
- 1 50 1 Operation
sensor A is not plausible showing boost pressure. replace the component;
- Check hydrostatic system if the power supply,
the signal voltage and the sensor are OK;

Boost pressure at pressure Pressure sensor B is on the low-pressure side, but is not - Depending on the result, repair the harness or
- 1 50 2 Operation
sensor B is not plausible showing boost pressure. replace the component;

Boost pressure at both the
After starting the engine, an error has occurred during at - Depending on the result, repair the harness or
- 1 50 3 Operation pressure sensors is not
least one step of the self-test. replace the component;
plausible during the self-test
- Check steer sensor power supply;

Setpoint monitoring logic: - Check channels A / B for short circuits or
"Speed for steering angle interruption;
- 1 51 1 This event message is not currently used.
setpoint redundant inputs" - Check wire connection;
too high. - Replace the angle sensor;
Status
Setpoint monitoring logic:

"Rotary direction for steering
angle setpoint redundant
inputs" implausible

"No. of impulses for steering
angle setpoint redundant
inputs" not the same
Setpoint monitoring logic: "Calculated steering angle - Check steer sensor power supply;
setpoint 1" in control and/or monitoring processor - Check channels A / B for short circuits or
Setpoint control 1 implausible (readings differ); interruption;
- 1 54 1 Operation
implausible The setpoint directly from the sensor differs between the - Check wire connection;
control processor and the monitoring processor by more - Replace the angle sensor;
than 500 digits five times in a row (50 ms). - Replace signal-evaluating controller;
- 1 54 2 Operation - Check angle sensor (steering wheel/tiller)

power supply;
- Check channels A / B for short circuits or
"Calculated steering angle The setpoint abandons the permissible unit circuit for T >
Self test interruption;
setpoint" is implausible limit time by more than the permissible limit.
- 1 54 3
Operation (sine, cosine implausible)
- Replace the angle sensor;
- Check angle sensor (steering wheel/tiller) power

Steering specific: The steer wheel change is only maintained if the unit
supply;
"Calculated steer angle circle (Sin-Cos) is satisfied and the results from the
- Check channel A/B for shorts or disconnection;
- 1 54 4 Operation setpoint2" actual value control processor and monitoring processor do not
monitoring logic improbable deviate by more than 5°. No new setpoint could be used
(sine, cosine) for t> limit time.
- Replace signal evaluating controller;
Status
- Switch the truck off and on again;

- Check angle sensor (steering wheel/tiller) power
Steering specific:
supply;
"Calculated steer angle Calculated actual value 2 differs between the control
- Check channels A / B for short circuits or
- 1 55 1 Operation actual value2" actual value processor and the monitoring processor by more than
interruption;
control logic in control and/ 500 digits five times in a row (50 ms).
or monitor processor differs

Setpoint monitoring logic: "Calculated steering angle - Check angle sensor (steering wheel/tiller) power
setpoint 2" differs between the control and monitoring supply;
Setpoint control 2 processor; - Check channels A / B for short circuits or
- 1 56 1 Operation
implausible The calculated setpoint differs between the control interruption;
processor and the monitoring processor by more than - Check wire connection;
500 digits five times in a row (50 ms). - Replace the angle sensor;
This event message is currently not used.
Actual value control
- 1 57 1
implausible Actual-value monitoring logic: "No. of pulses from absolute sensor"
vs. "no. of pulses from sensor bearing" is implausible.
Actual-value monitoring logic: "Calculated steering angle - Check steer sensor power supply;
actual value" in control and/or monitoring processor - Check channels A / B for short circuits or
Actual value control implausible (readings differ); interruption;
- 1 58 1 Operation
implausible The actual value directly from the sensor differs between - Check wire connection;
the control processor and the monitoring processor by - Replace the angle sensor;
more than 500 digits five times in a row (50 ms). - Replace signal-evaluating controller;
Steering: - Check steer sensor power supply;
"Calculated steer angle actual value" actual value control - Check channels A / B for short circuits or
Actual value control logic in control and/or monitor processor implausible interruption;
- 1 58 2 Operation
implausible (sine, cosine unfeasible); - Check wire connection;
Actual value abandons the standard circuit more than - Replace the angle sensor;
30tirmes. (30 * 0.125 msec.) - Replace signal-evaluating controller;
Status
- Check segment position sensor;

- Check segment disk;
Actual-value monitoring
- Check chain tension or gearwheel wear;
- 1 59 1 Self test logic: "Segment width of The first segment was not found during referencing.
- Check swivelling bolster suspension and
segment 1" out of range
- Replace actuating controller;
- Check angle sensor wiring and signals;

Determine angle position,
Crank length excessive during teach-in. The activation - Check index switch wiring and signals;
- 1 59 2 Operation calculated crank length
limit is 20 msec. - Check index switch setting;
implausible
- Re-teach the function via Judit;

Steer crank tolerance setting Crank tolerance violated during teach-in. The activation - Check index switch wiring and signals;
- 1 59 3 Operation
too high limit is 20 msec. - Check index switch setting;

Steer referencing turned too far when searching for
Side position crossed over - Check index switch wiring and signals;
- 1 59 4 System start a side or approaching a position. The activation limit
during referencing - Check index switch setting;
is 20 msec.
Steer referencing: - Check angle sensor wiring and signals;
Position of steer angle
Angle sensor actual value does not match the 0° switch. - Check index switch wiring and signals;
- 1 59 5 System start sensor implausible during
The steering must be "re-taught". The activation limit is - Check index switch setting;
referencing
20 msec. - Re-teach the function via Judit;

Side position crossed over Steer teach-in turned too far when searching for a side or - Check index switch wiring and signals;
- 1 59 6 Operation
during steering teach-in approaching a position. The activation limit is 20 msec. - Check index switch setting;

Expected crank side not No crank side during teach-in; The activation limit is - Check index switch wiring and signals;
- 1 59 7 Operation
found 20 msec. - Check index switch setting;
Status

Error detected during steer Crank error during operation. The activation limit is - Check index switch wiring and signals;
- 1 59 8 Operation
crank monitoring 100 msec. - Check index switch setting;
- Check segment position sensor;

- Check segment disk;
- Check chain tension or gearwheel
wear;
- Check swivelling bolster suspension and
Wrong crank side during
Crank error during referencing. The activation limit replace if necessary;
- 1 59 9 Self-test referencing. Re-reference
is 20msec. - Replace actuating controller
steering.
l/V&S trucks specifically:
- Check index switch setting;
- Re-teach steering via Judit.

Wrong crank side during Crank error during steering teach-in. The steering must - Check index switch wiring and signals;
- 1 59 10 Operation
steering teach-in. be "re-taught". The activation limit is 20 msec. - Check index switch setting;
- Check segment position sensor

Actual-value monitoring - Check segment disk
- 1 59 11 Self test logic: "Segment width of The second segment was not found during referencing. - Check chain tension or gearwheel wear
segment 2" out of range - Check/replace centre pivot plate suspension
- Replace actuating controller
This event message is currently not used.
Actual value control
- 1 60 1
implausible Actual-value monitoring logic: "Segment width of absolute
sensor" differs from sensor bearing
Referencing run was not completed within T=5s after - Only occurs as a result of other errors;
- 1 61 1 Self test Timeout during referencing
the start of the self test
Status
Unexpected engine rotation

- 1 62 1 This event message is currently not used.
direction

This event message is triggered - Check battery cable connection;
Steering controller if the following applies: - Check battery electrolyte level;
- 1 63 1 Operation
overvoltage (brake applies) vcapacitor > limit voltage - Check charger;
(reduce overvoltage through brake (failsafe brake)). - For a new battery wait for five charge cycles;
Relay brake closed instead At the start of the self-test the brake relay is closed - Check wire connection;
- 1 64 1 Self test
of open instead of open. - Replace signal-issuing controller;
Relay brake open instead of - Check wire connection;

- 1 64 2 Self test The brake relay does not close during the self-test.
closed - Replace signal-issuing controller;
Relay brake closed instead At the end of the self-test the brake relay is closed - Replace signal-issuing controller;
- 1 64 3 Self test
of open instead of open.
- Test feedback contact on brake, if necessary

adjust or replace feedback contact;
Pulsed braked for - Measure current through the magnetic coil (you
- 1 64 4 Operation implausible pulsed brake pattern during emergency stop
emergency stop. should not be able to measure any current when
the brake is applied).

Communication between control and monitor processors - Check wire connection;
Control and monitor
- 1 65 1 Self test implausible (CRC checksum in initialisation telegram - Check interference (radio, static charge);
processors damaged
implausible) - If the event message persists (permanently),
replace the signal-issuing controller;
Status

Communication between control and monitor processors - Check wire connection;
Control and monitor
- 1 65 2 Operation implausible (CRC checksum in cyclical telegram - Check interference (radio, static charge);
processors damaged
implausible) - If the event message persists (permanently),

Self test Control and monitor Communication between control and monitor processors
- 1 65 3 - Check interference (radio, static charge);
Operation processors damaged implausible (UART register status message)
- If the event message persists (permanently),

Control and monitor Communication between control and monitor processors
- 1 65 4 Operation -Check interference (radio, static charge);
processors damaged implausible (UART telegram "Start Monitoring" timeout)

- 1 65 5 Self test -Check interference (radio, static charge);
processors damaged implausible (UART telegram "Initialisation" timeout)

- 1 65 6 Operation - Check interference (radio, static charge);
processors damaged implausible (UART pulse flank change timeout)

- 1 65 7 Operation -Check interference (radio, static charge);
processors damaged implausible (UART telegram cyclical timeout)
Status

processors damaged implausible (UART pulse start timeout)

processors damaged implausible (flank change direction implausible)

- 1 65 10 -Check interference (radio, static charge);
Operation processors damaged implausible (1st process error in UART telegram)

- 1 65 11 -Check interference (radio, static charge);
Operation processors damaged implausible (2nd process error in UART telegram)

- Set default values for steering parameters.
- Set default values for Teach parameters.
Teach-in of truck in idle not recognised or Teach
- 1 66 1 Operation Teach-in interrupted - Jack up the truck so that the steered wheel is
sequence not kept
clear of the ground. Carry out teach-in; do not
interrupt the process!
Status

- Check motor wire connections;
Motor (actual value) could not be determined in the
allocated time (timeout while motor turning).
- Check actual value sensor on steered wheel;
- Replace steer motor;

- Check motor wire connections;
No rotary movement on actual value sensor and / or from
steered wheel
- Check actual value sensor on steered wheel;
- Replace steer motor;
- Finish the teach-in, then switch the truck off and

on again;
The straight-ahead position of the steered wheel (no - Set default values for Teach parameters.
- 1 66 4 Operation Teach-in interrupted
zero position) could not be approached - Jack up the truck so that the steered wheel is
Status
- Check wheel freedom of movement on the

ground.
- Check if truck is overloaded;
- Check battery voltage, charge battery if
The steered wheel does not Internal monitoring rule violation: necessary;
- 1 67 1 Operation
follow the setpoint Integral over rated / actual difference too great. - Check steering chain and chain tension;
- Check steering bolster mechanics;
- Check actual value sensor attachment;
- Test steer motor;
- Check tyres, replace wheel if necessary.

ground;
Internal monitoring rule violation: - Check battery voltage, charge battery if
The steered wheel does not Rated ROTATION DIRECTION_NONE; necessary;
- 1 67 2 Operation
follow the setpoint The permissible angle deviation is again out of range. - Check steering chain and chain tension;
(angle difference < XX°). - Check steering bolster mechanics;
- Test steer motor;

ground;
Internal monitoring rule violation:
Rated ROTATION DIRECTION_NONE;
The steered wheel does not necessary;
- 1 67 3 Operation In the small difference0 < angle difference < large
follow the setpoint - Check steering chain and chain tension;
difference range the wheel must follow with at least
minimum rotational speed.
- Test steer motor;
Status

ground;
Internal monitoring rule violation: - Check battery voltage, charge battery if
The steered wheel does not Rated ROTATION DIRECTION_NONE; necessary;
- 1 67 4 Operation
follow the setpoint Where the angle difference > significant the wheel - Check steering chain and chain tension;
should follow at a slow rotational speed. - Check steering bolster mechanics;
- Test steer motor;
Internal monitoring rule violation: - None:
Rate-ROTATION DIRECTION LEFT or refer to truck overload, steered wheel is
The steered wheel does not Rated ROTATION DIRECTION_RIGHT; discharged (steering can swing up);
- 1 67 5 Operation
follow the setpoint Rated/actual rotation direction opposite;
Angle difference > small difference;
Angle difference is not reduced.
Internal monitoring rule violation: - None:

Rate-ROTATION DIRECTION LEFT or refer to truck overload, steered wheel is
The steered wheel does not
- 1 67 6 Operation Rated ROTATION DIRECTION_RIGHT; discharged (steering can swing up);
follow the setpoint
Rated/actual rotational direction same;
Wheel advances (by more than XX0).

ground;
Rate-ROTATION DIRECTION LEFT or
Rated ROTATION DIRECTION_RIGHT;
The steered wheel does not necessary;
- 1 67 7 Operation Rated/actual rotational direction same;
follow the setpoint - Check steering chain and chain tension;
In the small difference0 < angle difference > large
difference range the wheel must follow with at least
minimum rotational speed.
- Test steer motor;
Status

ground;
Internal monitoring rule violation: - Check if truck is overloaded;
Rate-ROTATION DIRECTION LEFT or - Check battery voltage, charge battery if
The steered wheel does not Rated ROTATION DIRECTION_RIGHT; necessary;
- 1 67 8 Operation
follow the setpoint Rated/actual rotational direction same; - Check steering chain and chain tension;
Where the angle difference > significant the wheel - Check steering bolster mechanics;
should follow at a slow rotational speed. - Check actual value sensor attachment;
- Test steer motor;
The steered wheel does not Internal monitoring rule violation: - Switch the truck off and on again;
- 1 67 9 Operation
follow the setpoint Internal status, control status machine implausible
Internal monitoring rule violation: - Switch the truck off and on again;
The steered wheel does not STATUS_STEERING_TYRE_DISCHARGED;
- 1 67 10 Operation
follow the setpoint Setpoint has changed by more than XX0 without the
control processor changing status.
Rate-ROTATION DIRECTION_LEFT or - Replace signal-issuing controller;
If the rated-actual difference > small difference, the
- 1 67 11 Operation system checks whether a current pulse (> YY A) is
follow the setpoint
flowing in the right direction within a particular time
(XX ms).
If this is not the case and the actual-rated difference
rises to > medium difference, an event is triggered.
Rate-ROTATION DIRECTION LEFT or - Replace signal-issuing controller;
- 1 67 12 Operation If the sub index 11 rule is met (current pulse recognised)
follow the setpoint
and the rated-actual difference continues to rise, the
current must not flow in the wrong direction for more
than a certain time (XX ms).
Status
Specified-actual difference too large. - Check wheel freedom of movement on
Rated-actual difference > maximum rated-actual the ground;
difference - Check steering bolster mechanics;
- 1 67 13 Operation On many trucks (e.g. EJC) the maximum difference is - Check actual value sensor attachment;
follow the setpoint
prescribed by the mechanical stops. - Test steer motor;
If the current rated-actual difference is more than the
maximum rated-actual difference plus a value "X",
the event message is triggered
- Check steering sensor power supply;

- Check channels A / B for short circuits or broken
The steered wheel does not Internal monitoring rule violation: connection;
- 1 67 14
follow the setpoint Sudden steer angle actual value change - Check the wiring;
- Check steering sensor power supply;

- Check channels A / B for short circuits or broken
The steered wheel does not connection;
- 1 67 15 Change to the actual value despite small change / no
follow the setpoint - Check the wiring;
change to the setpoint
Internal monitoring rule violation: - Replace signal-evaluating controller;
- 1 67 16 Operation Difference in "target steering angle" between control
follow the setpoint
processor and monitoring processor > 5° for 30 ms.

- 1 67 17 Operation Difference for "travel mode buttons" between control
follow the setpoint
processor and monitoring processor for 30 ms.

- 1 67 18 Operation Difference in "actual travel mode" between control
follow the setpoint
Status

- 1 67 19 Operation Difference in "target travel mode" between control
follow the setpoint

- 1 67 20 Operation Difference in "actual steering mode" between control
follow the setpoint

Self test No feedback from Event message not acknowledged by master within - Check wire connection;
- 1 68 1
Operation regenerative braking 90 msec. - Check interference (radio, static charge);
- Check CAN-Bus;
Error during self-test phase - Look for and replace faulty controller during
Steering not requested within 10 s after power up for self
- 1 69 1 Self test (component has identified self-test.
test
fault) - Inquire about software update;
Error during self-test phase - Inquire about software update;
Steering set to RUNNING although the steering self-test
- 1 69 2 Self test (component has identified
was faulty
fault)
MULTI-PILOT: - Check horizontal tilt parameters;

The horizontal-tilt button consists of a NC and a NO - Check the wire connection between the MULTI-
contact. When the button is pressed both contacts PILOT and the horizontal tilt button;
connect simultaneously. As a result, only the 0/1 and 1/0 - Check the horizontal tilt button;
Horizontal tilt mechanism
- 1 70 1 Operation combinations should occur. - Replace the horizontal tilt button;
inputs implausible
During operation combinations 0/0 and 1/1 (500 msec.) - Replace the MULTI-PILOT;
Status
MULTI-PILOT: - Check the centre-shift parameters;

The centre-shift button consists of a NC and a NO - Check the wire connection between the MULTI-
contact. When the button is pressed both contacts PILOT and the centre-shift button;
connect simultaneously. As a result, only the 0/1 and 1/0 - Check the centre-shift button;
Centre-shift inputs
- 1 71 1 Operation combinations should occur. - Replace the centre-shift button;
implausible
During operation combinations 0/0 and 1/1 (500 msec.) - Replace the MULTI-PILOT;
Only for steering: - Check the steering selector parameters;

During operation the combinations 0/0 and - Check the wire connection between the
1/1 (switched for 500 ms) trigger the event message. Multipilot and the steering selector button;
"Redundant inputs" logic The system also changes to 360° mode. - Check the steering selector button;
implausible - Replace the steering selector button;
- 1 72 1 Operation
(180°/360° steering mode Only MULTI-PILOT: - Replace the Multipilot;
change) During operation the combinations 0/0 and
1/1 (switched for 500 ms) trigger the event message.
For a valid combination (0/1 or 1/0, switched for 500 ms)
the events and truck reaction are reset.
Specific internal combustion - Check engine oil level;

engine: Engine speed is greater than 800 rpm but the oil - Check oil pressure switch and replace if
- 1 73 1 Operation
No oil pressure while the pressure switch indicates no oil pressure. necessary;
engine is running - Check oil pressure;
Internal combustion engine The event message is triggered - Check engine oil level;
- 1 73 2 Operation specific: Oil quality sensor if the following applies: - Check oil quality sensor and replace if
reading implausible • ForT > time limit an engine oil level < limit is measured necessary;
Status
The event message is triggered - Check cable connection;

if for T > 500 ms the following applies: - Check seat switch and dead man switch;
Seat switch and dead man • Combination of seat and deadman switch for the - Note to operator in case of incorrect operation;
- 1 74 1 Operation switch on passenger seat passenger seat is invalid (0/1 or 1/0).
implausible Thus, only the 0/0 and 1/1 combinations should occur.
During normal operation the combinations 0/1 or 1/0
(switched for 500 ms) trigger the event message.
Logic test: - Check power supply for the battery electronics

Signal for battery charger No power supply for the battery electronics (bypass (bypass supply);
- 1 75 1 Operation
detection is implausible supply) is available 500 ms after battery charger - Check battery charger detection;
detection. - Replace battery;
Tiller head: - Replace tiller head;

- 1 76 1 Undefined Brake signal implausible The signal shape or modulation of the brake digital
signal is implausible.
Analog / digital control Tiller head: - Replace tiller head;

- 1 77 1 Undefined
implausible Wrong analog / digital transmitter connected to tiller arm.

- 1 77 2 Undefined Smart Sensor is implausible
Wrong smart sensor connected to the tiller arm.
The event is triggered when the following applies: - Check the wiring;
• When starting the truck, there is no high signal at one of - Check connected sensor system;
the inputs "swivel seat 0°", "swivel seat 90°" or "swivel - Check controller inputs;
- 1 78 1 Operation Swivel seat not in position seat 180°" - Replace controller;
• After the seat has been rotated, there is no high signal
at one of the inputs "swivel seat 0°", "swivel seat 90°" or
"swivel seat 180°"
- Check the wiring;

The event is triggered when the following applies:
Position of the steering - Check connected sensor system;
• Output 0° is active and sensor 0° reports no high signal
- 1 79 1 Operation valve does not correspond - Check controller outputs and inputs;
• Output 180° is active and sensor 180° reports no high
to the target position - Check hydraulic system;
signal
Status
Master: - Check the component shown in the sub index;

Error occurred during self- Slave does not respond 1 second after the request for a - Check CAN-Bus;
- 1 80 1...32 Self test
test phase self-test (self-test request not answered). - Replace the component shown in the sub index;
Sub index matches the CANopen-ID.
Master: - Read out logbook;

Slave reports fault during self-test (component has - Process the events of the component shown in
identified fault). the subindex in the sequential order:
Error occurred during self-
- 1 81 1...32 Self test Sub index matches the CANopen-ID.
test phase
This is a consequential event and always occurs in
conjunction with an event of the tested component (note
the sub index).
- Check ISM sensor 1 parameter settings

ISM: (parameter #11-17);
ISM sensor 1 voltage
- 1 90 1 Operation Invalid voltage at optional sensor 1 (stage 4 only). - Check wire connection to ISM sensor 1;
implausible
The sensor voltage is out of range (0.5 V - 9.5 V). - Check ISM sensor 1 and replace if necessary;

implausible

implausible
- Check wire connection between ISM access

ISM:
ISM access module / ISM module and ISM data recorder;
- 1 91 1 Operation Communication between access module and data
data recorder damaged - Replace ISM data recorder;
recorder interrupted
- Replace ISM access module;
Status
- Check wire connections to ISM radio module;

-Visually inspect the antenna and replace if
ISM:
- 1 91 2 Operation ISM radio module damaged necessary;
Faulty radio module
- Replace ISM radio module;
- Replace ISM data recorder;
ISM radio channel number ISM: - Check radio channel parameter settings (set
- 1 91 3 Operation
implausible "Radio channel" parameter set to 0. "radio channel" parameter to 1);
-Visually inspect the antenna and replace if

necessary;
- Check ISM radio transmission output parameter
No ISM radio transmission ISM: settings (set "radio transmission output"
- 1 91 4 Operation
output Transmission output too low parameter to 31);
- Check receiver;
- Check cable connections to ISM radio module;
- Replace ISM radio module;
- Check wire connections;

ISM access module ISM:
- 1 91 5 Operation - If lock number is invalid replace ISM access
damaged Faulty access module
module;
ISM: - Check wire connections;

- 1 91 6 Operation ISM data recorder damaged
Data recorder faulty - Replace ISM data recorder;
- Check battery voltage / test for faulty cell;

- Check electrolyte level;
Charger: - Check electrolyte level sensor on battery
"Pre-charge" phase (P1) controller and replace if necessary;
- 1 93 1 Undefined Charger: precharge timeout
Maximum charge time (limit) in the "pre-charge" phase - Check charge characteristic against battery data
exceeded (pre-charging of fully discharged battery) plate and adjust as required;
- Check fuse in charging cable, replace charging
cable if required;
- Replace charger;
Status

Charger: Main charge I time "Main charge I (constant)" charge phase (P2) controller and replace if necessary;
- 1 93 2 Undefined
exceeded Maximum charge time (limit) in "Main charge - Check charge characteristic against battery data
I (constant)" charge phase exceeded. plate and adjust as required;
cable if required;
- Replace charger;

Charger: Main charge V time "Main charge V (constant)" charge phase (P3) controller and replace if necessary;
- 1 93 3 Undefined
exceeded Maximum charge time (limit) in "Main charge - Check charge characteristic against battery data
V (constant)" charge phase exceeded. plate and adjust as required;
cable if required;
- Replace charger;

"trickle-charge" phase (P4a) controller and replace if necessary;
- 1 93 4 Undefined Charger: recharge timeout
The trickle charge phase specifications have not been - Check charge characteristic against battery data
achieved. plate and adjust as required;
cable if required;
- Replace charger;
Status
Specific battery - None: This is an operator error

management: battery
- 1 93 5 Undefined No current flow during charging
disconnected from charger
during charging
- Check charge characteristic against battery data

Charger: charge Charger:
- 1 94 1 Operation plate and adjust as required;
characteristic undefined Set charge characteristic is not available.
- Replace battery controller;
Charger: - Check charge characteristic against battery data
Charger: change to safety if the charger could not charge a characteristic curve plate and adjust as required;
- 1 94 2 Undefined
characteristic curve from the battery controller, it changes to a safety - Replace battery controller;
characteristic curve.
Charger: - Check temperature gauge on battery controller

Charger:
- 1 94 3 Undefined if the charge could not receive a battery temperature (between battery cells);
charge at rated temperature
from the battery controller, the rated temperature is used - Replace battery controller;
-Check fuse in charging cable, replace charging

Charger: Charger:
- 1 95 1 Undefined cable if required;
Internal error Internal error
- Replace charger;
- Check the harness of the battery and replace if

Temperature sensor Battery Management System (BMS): necessary;
- 1 95 2
separated A temperature sensor is not functioning. - Check connections and replace if necessary;
- Replace battery;
- Check the harness of the battery and replace if

Temperature sensor Battery Management System (BMS): necessary;
- 1 95 3
separated Several temperature sensors are not functioning. - Check connections and replace if necessary;
- Replace battery;
-Check the harness of the battery and replace if
Battery Management System (BMS): necessary;
- 1 95 4 Voltage sensor separated
At least one voltage sensor is not functioning. - Check connections and replace if necessary;
- Replace battery;
Status
- Charge battery with battery charger and leave

Battery Management System (BMS):
connected to the charger for a long time;
- 1 95 5 Cell voltage different At high or low battery charge status, the difference
- Replace battery (if the problem occurs
between the cell voltages is too high.
repeatedly);
- Charge battery with battery charger and leave

Battery Management System (BMS):
connected to the charger for a long time;
- 1 95 6 Cell voltage different At the normal battery charge status, the difference
between the cell voltages is too high.
repeatedly);
Battery Management System (BMS): - Replace battery (if the problem occurs
- 1 95 7 Cell temperatures different
Difference between the cell temperatures too large. repeatedly);

Charger: - Check fuse in charging cable, replace charging
Charger: communication
- 1 96 1 Undefined communication error in radio network cable if required;
error in radio network
Permanent loss of radio connection - Replace battery controller;
- Replace charger;

Charger: - Check fuse in charging cable, replace charging
Routing error in radio network - Replace battery controller;
- Replace charger;

Charger: -Check fuse in charging cable, replace charging
buffer overflow in radio network - Replace battery controller;
- Replace charger;

-Check fuse in charging cable, replace charging
Charger: communication Charger:
- 1 96 4...n Undefined cable if required;
error in radio network communication error in radio network
- Replace charger;
Status

plate and adjust as required;
Charger:
- Re-start charging;
Charger: maximum charge this event message is triggered if the rated capacity is
- 1 97 1 Undefined - Inquire about software update;
factor exceeded exceeded by a factor of 1.1 (only for pre-, main and
trickle charges). Not for recovery charge).
cable if required;
- Replace charger;
The battery capacity has been reduced to 80% of a new - Replace battery if necessary;
- 1 98 1 Operation Battery useful life expired
battery.
Current reading for I = 0 A (mean current) implausible: - Replace component;

Current reading for l=0A
- 2 01 1 Self test ÿcurrent sensor_U < V]A_should be 10% or
"
implausible
ÿcurrent sensor_U > ÿ0A_should be + 10%

- 2 01 2 Self test
implausible
ÿcurrent sensor_V < ÿ0A_should be 10% or
"
ÿcurrent sensor_V > ÿ0A_should be + 10%

- 2 01 3 Self test ÿcurrent sensor_W < ÿ0A_should be 10% Or
"
implausible
ÿcurrent sensor_W > ÿ0A_should be + 10%
Converter signals damaged - Switch the truck off and on again;

The AC-3 Power Control (U8) monitors the phase - Replace AC-3 Power Control (U8);
current measurement signals (converter). If a sufficiently
- 2 01 4 Operation Current measurement faulty high current is measured when the components are de-
energised and non-active, an error is detected.
Internal pulse controller current measurement faulty The
Implausible current The event message is triggered when the following - Replace component;
measurement for l=0A applies:
- 2 01 5 Self test
(mean current) (current * Vcurrent_sensor_prop < VÿvAmp_target ®% or
"
prop.) * Vcurrent_sensor_prop > VAvAmpÿtarget + 5%

Status
- Replace current sensor(s);

- 2 01 6 Operation Battery sensor defective A transmission error has occurred repeatedly.
- Replace battery;
This event message is triggered if for - Check motor connection cable (short circuit);
"Power connection output" T = 4 ms the following applies: - Check speed sensor, replace if necessary;
- 2 02 1 Operation
current signal too high " 'phaseJJ or 'phase_V or 'phase_W > - Check motor and replace if necessary;
'rated_peak + 20% - Replace component;
- Check motor connection cable (short circuit);

"Power connection output" - Check speed sensor and replace if necessary;
- 2 02 2 Operation if for T = 0.5 ms the following applies:
current signal too high - Check motor and replace if necessary;
• l_phase_U or l_phase_V or l_phase_W > 800 A
Phase current too great - Check power circuit wiring (short circuit);
The AC-3 Power Control (U8) has measured an - Replace AC-3 Power Control interface card;
excessive phase current; the error threshold is 25%
above the maximum phase current limit set by the
controller. This depends on the frequency and
temperature and can be adjusted via a parameter.
Internal overcurrent measurement from pulse controller
faulty. The activation limit is 20 msec.
"Power connection output"
- 2 02 4 Operation The control system has been incorrectly set with regard
current signal too high
to the subordinate current controllers;
Power outputs of the AC-3 Power Control components
have been shorted (either to the power supply or among
each other);
The phase current limit parameter has been adjusted
during operation;
AC-3 Power Control component (current measurement)
is faulty
For 100 msec, the steer current of the control and - Check cable from steer motor to controller A1/
Short circuit steer motor to monitoring processors is different (self-measured A2;
- 2 02 5 Operation
0 V or power supply current |l-steer| < 4A ; measured current of other
processor |l-steer|> 22A)
Status
The event message is triggered - Check consumers for defects;

if the following applies: - Check consumers for short circuits;
- 2 02 6 Operation DC/DC converter overload
• The current of the DC/DC transformer is greater than
the permissible limit for T > time limit
- Check wire connection to brake coil / valve coil;

Default current value of - Check brake coil / valve coil
proportional stage has not (resistance measurement), replace if necessary;
- 2 03 1...n Operation if the following applies:
been reached - Check outputs for short circuits and rectify if
• for T >= control deviation time limit > time limit
(proportional outputs 1...n) necessary;
Insufficient current through
- 2 04 1 Operation if for T = 200 ms the following applies: - Check speed sensor, replace if necessary;
speed sensor
• lmin < 7 mA. - Replace signal-evaluating controller;

Incrementer supply, Incrementer supply, broken wire activation limit for - Check wire connection;
- 2 04 4 Operation
broken wire longer than limit time. - Replace speed sensor;

Additional incrementer Incrementer supply, broken wire activation limit for - Check wire connection;
- 2 04 5 Operation
supply, broken wire longer than limit time. - Replace speed sensor;

Additional incrementer Incrementer supply, broken wire activation limit for - Check the wiring;
- 2 04 6

Additional incrementer Incrementer supply, broken wire activation limit for - Check the wiring;
- 2 04 7
Status

Warning Incrementer supply, broken wire An emergency
Warning Incrementer supply, - Check wire connection;
- 2 04 8 Operation stop follows when the controller power stage is activated.
broken wire - Replace speed sensor;
Excessive current through
- 2 05 1 Operation if for T = 200 ms the following applies: - Check speed sensor, replace if necessary;
speed sensor
" ÿspeed sensor supply < 7 V. - Replace signal-evaluating controller;
Excessive current through
- 2 05 2 Operation if for T > 100 ms the following applies: - Check speed sensor, replace if necessary;
speed sensor (short circuit)
• l_speed sensor supply > 36 mA - Replace signal evaluating controller;
Speed sensor 2 current
- 2 05 3 Operation if for T >= time limit the following applies: - Check speed sensor and replace if necessary;
excessive
• Permissible sensor current exceeded - Replace signal evaluating controller;
Phase wire breakage - Check motor wire connections;
Each time the control system is activated AC-3 Power - Check motor and replace if necessary;
Control (U8) checks all phases for any disconnection of - Replace AC-3 Power Control interface card
the current flow to the motor (wire breakage).
Phase wire breakage when truck stationary. The
Phase wire breakage, truck activation limit is 20 msec.
- 2 06 4 Operation
stationary Broken wire or loosen screws in motor supply lines;
• Motor damage;
• The control system has been incorrectly set with regard
• AC-3 Power Control component (current transformer) is
damaged;
Status
Phase wire breakage - Check motor wire connections;

Each time the control system is activated AC-3 Power - Check motor and replace if necessary;
Control (U8) checks all phases for any disconnection of - Replace AC-3 Power Control interface card
the current flow to the motor (wire breakage).
Phase wire breakage while truck moving (speed). The
Phase wire breakage, truck activation limit is 20 msec.
- 2 06 5 Operation
moving Broken wire or loosen screws in motor supply lines;
• Motor damage;
• The control system has been incorrectly set with regard
• AC-3 Power Control component (current transformer) is
damaged;
Warning No activation for Warning Driver supply 1 interrupted. An emergency stop - Check wiring between safe and power
- 2 07 1 Operation internal driver supply 1 from follows when the controller power stage is activated. The controller;
safety computer. activation limit is 20 msec.
Warning No activation for Warning Driver supply 2 interrupted. An emergency stop - Check wiring between safe and power
- 2 07 2 Operation internal driver supply 2 from follows when the controller power stage is activated. The controller;
safety computer. activation limit is 20 msec.
No activation for internal - Check wiring between safe and power

Internal driver supply 1 or 2 interrupted. The activation
- 2 07 3 Operation driver supply from safety controller;
limit is 20 msec.
computer.
The safety function must be triggered - Switch the truck off and on again;
if the following applies: - Check battery cable connection;
Braking current of the • At a braking setpoint (> 80% of the maximum value), - Check the brakes' electrical system;
- 2 08 1 Operation modulated load wheel brake the current in the outputs of the load wheel brake does - Inquire about software update;
is too low not increases above 2.0 A within T = 200 ms. - Replace signal-issuing controller;
The braking setpoint is a standardised pedal value that is
connected to teach-in values.
-Allow battery to cool:

Discharge current exceeds Overcurrent:
- 2 09 1 Operation - Determine the cause for the overcurrent on the
manufacturer's limit 1 I > current limit 1 for t > time limit 1
truck;
Status

truck;

truck;

truck;

truck;
- Check battery charger;

Charge current exceeds Charge / regenerate:
truck;
- Check battery charger;

Charge current exceeds Charge / regenerate:
truck;

- Check valve coil (resistance measurement) and
The current measured during the self-test is not
Current measurement error replace if necessary;
- 2 13 1...n Self test compatible with the switching status of the proportional
during self-test - Check outputs for broken cables and rectify if
output's digital switching transistor.
necessary;
- Replace signal-generating controller;
Interface: - Check wire connection;
When the front windscreen wiper is switched on the - Check sensor wiper motor and replace if
Front windscreen wiper
- 2 50 1 Operation following is checked in second pulses: necessary;
output implausible
Current < 200 mA, otherwise the event message is - Replace signal-issuing controller;
triggered
Status

When the rear windscreen wiper is switched on the - Check sensor wiper motor and replace if
Rear windscreen wiper
output implausible
Current < 200 mA, otherwise the event message is - Replace signal-issuing controller;
triggered

When the windscreen washing system is switched on - Check windscreen washing system pump and
the following is checked in second pulses: replace if necessary;
Windscreen washing system
- 2 50 3 Operation Current > 5 A, otherwise the event message is triggered - Replace signal-issuing controller;
output implausible
Broken wire detected (OpenLoad detection) when
system switched off -> error message after system
switched on
Interface: - Check the wiring;

When the front left work lights are switched on the - Check front left-hand work light and replace if
Front left work lights output
implausible
Current < 400 mA, otherwise the event message is - Replace signal-generating controller;
triggered

When the front right work lights are switched on the - Check front right-hand work light and replace if
Front right work lights output
implausible
triggered

When the rear left work lights are switched on the - Check rear left-hand work light and replace if
Rear left work lights output
implausible
triggered
Status

When the rear right work lights are switched on the - Check rear right-hand work light and replace if
Rear right work lights output
implausible
triggered

Left indicator output This event message is triggered when the ramp has - Check left-hand indicator lamp and replace if
- 2 50 8 Operation
implausible reached 100 % PWM (pulse width modulation): necessary;
actual current < limit current (VFG E box) - Replace signal-generating controller;

Right indicator output This event message is triggered when the ramp has - Check right-hand indicator lamp and replace if
- 2 50 9 Operation
implausible reached 100 % PWM (pulse width modulation): necessary;
actual current < limit current (VFG E box) - Replace signal-generating controller;
Charger: - Check wire connections (battery, truck

battery current excessive components, . . . ) for short circuits;
Charger: battery current
- 2 90 1 Undefined This event message is triggered
excessive
if for T = 5 msec the following applies:
•bat > 800 A
necessary;
- Check control current fuse and replace if
necessary;
- Check main fuse and replace if necessary;
This event message is triggered - Check key switch / ISM / CANCODE and
- 3 01 1 System start Key switch input low voltage if for T = 100 msec, (system start): replace if necessary;
vkey switch < rated voltage - 30% - Check "key switch discharge" contactor and
- Check controller cable connection;
- Check the components supplied by the key
switch (control and power circuits);
Status

The event message is triggered necessary;
if for T = 100 ms (Operation) the following applies: - Check control current fuse and replace if
vkey switch < rated voltage - 50% necessary;
Onlv applies to svstem trucks: - Check key switch / ISM / CANCODE and
- 3 02 1 Operation Key switch input low voltage
Internal power supply interrupted; replace if necessary;
The AC-3 Power Control (U8) monitors internal supply - Check "key switch discharge" contactor and
voltages for non-permissible deviations; replace if necessary;
In the event of an error the AC-3 Power Control - Check controller cable connection;
component (current transformer) is faulty; - Check the components supplied by the key

necessary;
A digital signal generated outside the processor shows necessary;
the status "key switch low voltage" and automatically - Check main fuse and replace if necessary;
"Key switch input" signal too disables the power stages. - Check key switch / ISM / CANCODE and
- 3 02 2 Operation
small Activation limit, timing and truck response therefore replace if necessary;
depend on the switch and must not be changed through - Check "key switch discharge" contactor and
the software. replace if necessary;
Status

necessary;
necessary;
- Check key switch / ISM / CANCODE and
- 3 02 2
- Check "key switch discharge" contactor and

necessary;
necessary;
Key switch changes to Signal from key switch detection system changes to - Check key switch / ISM / CANCODE and
- 3 02 3 Operation
"OFF" during operation "OFF" during operation (ramp stop in operation) replace if necessary;
Status

necessary;
necessary;
Key switch changes to
Signal from key switch detection system changes to - Check key switch / ISM / CANCODE and
- 3 02 4 Operation "OFF" when truck is
"OFF" when truck is stationary (ramp stop) replace if necessary;
stationary

- Check battery cable connection;
This event message is triggered
Key switch input high - Check battery electrolyte level;
- 3 03 1 Operation if for T = 100 msec the following applies:
voltage - Check charger;
vkey switch > rated voltage + 30% - For a new battery wait for five charge cycles;
Status

- Check the battery's rated voltage;
if for T = 5 s the following applies:
- Check battery cable connections (transfer
ÿcapacitor < V-ated voltage 40%
"
resistance, ...);
- Check controller cable connections (right
Onlv applies to svstem trucks:
connections, transfer resistance, ...);
Low voltage
The AC-3 Power Control (U8) has measured a battery
necessary;
voltage less than 50% of the rated voltage with the
- Check main fuse / power fuses and replace if
Power connection input (+) control system activated;
- 3 04 1 Self test necessary;
low voltage Battery is discharged or incorrect rated voltage;
- Disconnect the battery. Disconnect the
The main contactor was disconnected while the control
component power positive terminal / fuses.
system was active (motor operation);
Connect the components in turn. Connect the
The control system was activated before the main
battery;
contactor was closed and the internal capacitors were
- Check the consumers behind the main contactor
charged;
are using current;
Installation of AC-3 Power Control component is faulty;
- Check the main current wires (except for motor
supply wires);
is faulty;

necessary;
- Check main fuse / power fuses and replace if
necessary;
- Disconnect the battery. Disconnect the
component power positive terminal / fuses.
Power connection input (+) if the following applies for T = 3 sec after the component
- 3 04 2 Self test Connect the components in turn. Connect the
low voltage self-test:
battery;
ÿcapacitor < V-ated voltage 33%
"
- Check the consumers behind the main contactor
are using current;
- Check the main current wires (except for motor
supply wires);
Status

- Check main contactor and replace if necessary;
Power connection input (+) - Check battery electrolyte level;
- 3 05 1 Operation if for T = 100 msec the following applies:
low voltage - Check the main current wires (except for motor
ÿcapacitor < V-ated voltage "30% supply wires);

This event message is triggered - Check main contactor and replace if necessary;
Power connection input (+) if for T = 100 msec the following applies: - Check battery electrolyte level;
- 3 05 2 Operation
low voltage ÿcapacitor < Vrated voltage "16% - Check the main current wires (except for motor
in addition, regenerative braking and lifting are inhibited. supply wires);
The event message is triggered - Switch the truck off and on again;
if for T = 200 ms the following applies: - Check the battery's rated voltage;
ÿcapacitor > V-ated voltage + 30%. - Check battery cable connections (transfer
resistance, ...);
Onlv aoolies to svstem trucks: - Check controller cable connections (right
Overvoltage connections, transfer resistance, ...);
The AC-3 Power Control (U8) has measured a battery - Check battery electrolyte level;
Power connection input (+) voltage greater than 125% of the rated voltage with the - Check charger;
- 3 06 1 Operation
high voltage control system activated; - For a new battery wait for five charge cycles;
Battery is overloaded or incorrect rated voltage; - Replace signal-evaluating controller;
The main contactor was disconnected during active
control (regenerative operation);
Installation of AC-3 Power Control component is
defective;
is defective;
Status
"Phase U output" signal - Disconnect motor connections.

1 Self test
implausible - Measure the phase voltages (U, V, W) against
the potential Vbat(_); if the phase voltages (U, V,
"Phase V output" signal Semi-jumpers 1, 2 and 3 are not controlled. This event
2 Self test W) are not half the battery voltage, and instead:
implausible message is triggered if the following applies for 20 msec:
- 3 07 Vphase X 51 (ÿcapacitor / 2) + 25% or ' Vbat(+) potential is -> check the motor is
connected to Vbat(+).
Vphase_X < (ÿcapacitor / 2) - 25% • Vbat(_) potential is -> check the motor is
"Phase W output" signal
3 Self test connected to Vbat(_).
implausible
The branch is not controlled (lift actuator of a twin - Check motor connection wire (wire breakage);
"Power connection output" controller). This event message is triggered if the - Check motor and replace if necessary;
- 3 08 1 Self test
signal implausible following applies for 20 msec: - Replace signal-issuing controller;
Vpower loss < ÿcapacitor "20%
necessary;
- Check the control current fuse and replace if
necessary;
Signal from emergency disconnect auxiliary contact
Emergency Disconnect - Check key switch / ISM / CANCODE and
- 3 09 1 Operation changes during operation to "Emergency Disconnect"
detected during operation replace if necessary;
(deactivated output transformer during operation)
Status

necessary;
necessary;
Signal from emergency disconnect auxiliary contact - Check main fuse and replace if necessary;
Emergency disconnect
changes to "Emergency Disconnect" when truck is - Check key switch / ISM / CANCODE and
- 3 09 2 Operation detection when truck is
stationary (deactivated output transformer during replace if necessary;
stationary
operation) - Check "key switch discharge" contactor and
- Check components supplied by the key switch
(control and power circuits);
"Accelerator pedal input" for T = 250 msec: - Check accelerator pedal power supply;
- 3 10 1 Operation
signal implausible ÿaccelerator pedal > 92.5% or - Replace accelerator pedal;
ÿaccelerator pedal < 7.5% - Replace signal-evaluating controller;
This event message is triggered - Check wire connection;
"Hydraulic function 1 input" if for T = 250 msec the following applies: - Check hydraulic setpoint device power supply;
- 3 11 1 Operation
setpoint implausible Reading of Vhydi-auiic function— 1 > 90% or - Replace hydraulic setpoint device;
Reading of VflyC|rau|jCfunctj0n_1 < 10%. - Replace control;
- 3 12 1 Operation
setpoint implausible Reading of Vhydrau,icfunction_2 > 90% or - Replace hydraulic setpoint device;
Reading of Vhydrau,icfunction_2 < 10%. - Replace control;
- 3 13 1 Operation
setpoint implausible Reading of VhydraU|jCfunctj0n_3 > 90% or - Replace hydraulic setpoint device;
Reading of Vÿyÿrauijc functj0n 3 < 10%.
— - Replace control;
Status

- 3 14 1 Operation
setpoint implausible Reading of V(1yCjrau|jCfunctj0n_4 > 90% or - Replace hydraulic setpoint device;
Reading of V|nyCjrau|jC functi0n_4 < 10%. - Replace control;
- 3 15 1 Operation
setpoint implausible Reading of Vhydrau,icfunction_5 > 90% or - Replace hydraulic setpoint device;
Reading of Vhydrau,icfunction_5 < 10%. - Replace control;
- 3 16 1 Operation
setpoint implausible Reading of Vhydrauiic function—® > 90% or - Replace hydraulic setpoint device;
Reading of < 10%. - Replace control;

This event message is triggered - Check wire connection polarity;
"Motor temperature input" if for T = 250 msec the following applies: - Check temperature sensor;
- 3 17 1 Operation
actual value implausible ÿtemperature sensor > upper limit voltage or - If possible replace the temperature sensor,
ÿtemperature sensor < lower limit voltage. otherwise replace the motor;

- Check wire connection polarity;
if the following applies for T = 5 s after the event
"Motor temperature input" - Check temperature sensor;
- 3 17 2 Operation
actual value implausible
message 317.1:
- If possible replace the temperature sensor,
ÿtemperature sensor > upper voltage limit or otherwise replace the motor;
ÿtemperature sensor < lower voltage limit. - Replace signal-evaluating controller;
- Check the cable connection;

- Check the polarity of the cable connection;
The input value for the
The engine control unit is sending an incorrect coolant - Check temperature sensor;
- 3 17 3 Operation actual engine temperature is
temperature - If possible, replace the temperature sensor;
not plausible
signal;
Status
This event message is triggered - Replace controller;

"Internal actual value,
- 3 18 1 Operation controller temperature 1"
signal implausible ÿtemperature sensor > upper limit voltage or
ÿtemperature sensor < lows'" limit voltage.
"Internal actual value, This event message is triggered - Replace controller;
controller temperature 2" if for T = 250 msec, (when truck is stationary):
- 3 18 2 Operation
signal implausible ÿtemperature sensor > upper limit voltage or
(truck stationary) ÿtemperature sensor < lower limit voltage
"Internal actual value,
- 3 18 3 Operation controller temperature 1"
signal implausible Vthermai sensor > upper limit voltage or
vthermal sensor < lower limit voltage
"Internal actual value, if for T = 5 msec.
- 3 18 4 Operation controller temperature 2" the following applies:
signal implausible Vthermal sensor > upper limit voltage or
Vthermal sensor < lower limit voltage
"Safety height input" actual
- 3 19 1 Operation This event message is not currently used. - Check sensor and replace if necessary;
value implausible
System start "Input actual value pressure if for T = 500 ms the following applies: - Check sensor and replace if necessary;
- 3 20 1
Operation sensor A " signal implausible Vpressure sensor upper voltage limit, or - Replace signal-evaluating controller;
Vpressure sensor <= lower voltage limit
Pressure sensor implausible -Check if the towing function on the hydraulic
System start Pressure value from the emergency stop device >
- 3 20 2 (pressure reading does not valve block is activated or defective;
Operation limiting value [bar]
match truck's status) - Check sensor and replace if necessary;
Status
The event message is triggered - Check the wiring;

System start "Input actual value pressure if for T = 500 ms the following applies: - Check sensor and replace if necessary;
- 3 20 3
Operation sensor B " signal implausible ÿpressure sensor upper voltage limit, or - Replace the controller that is evaluating the
ÿpressure sensor lower voltage limit signal;

"Steer angle sensor 1 input" if for T = 90 msec the following applies: - Check steer angle sensor 1 and replace if
- 3 21 1 Operation
actual value implausible; Vsensor supply > 12.66 V or necessary;
ÿsensor supply < H -34 V. - Replace signal-evaluating controller;

"Steer angle sensor 2 input" - Check steer angle sensor 2 and replace if
- 3 22 1 Operation This event message is not currently used.
actual value implausible; necessary;
if for T >= time limit the following applies: - Check coolant level sensor power supply;
"Coolant level sensor input"
- 3 23 1 Operation • Voltage at coolant level sensor > upper limiting value - Replace coolant level sensor;
actual value implausible
or - Replace signal evaluating controller;
• Voltage at coolant level sensor < lower limiting value

"Brake pedal input" signal if for T = 250 ms the following applies: - Brake pedal power supply;
- 3 24 1 Operation
implausible * Vbrake pedal > 92.5% or - Replace brake pedal;
* Vbrake pedal < 7.5%. - Replace signal-evaluating controller;

"Input actual value hydraulic - Check wire connection polarity;
if for T = 250 ms the following applies:
- 3 25 1 Operation oil temperature" signal - Check temperature sensor;
implausible ÿtemperature sensor > upper voltage limit or - Re-measure the hydraulic oil temperature;
temperature sensor < lower voltage limit - Replace signal-evaluating controller;
Status
- Check the wiring;

- Check sensor power supply;
"Input tank level sensor" if for T > time limit the following applies:
- 3 26 1 Operation - Replace sensor;
signal implausible Sensor voltage > maximum limiting value, or
sensor voltage < minimum limiting value
signal;
The event message is triggered - Replace controller;

Internal supply voltage out of
if for T > time limit the following applies:
- 3 30 1 Operation range (1.99 V for reference
• Sensor voltage > maximum limiting value, or
voltages)
• sensor voltage < minimum limiting value

Internal power supply out of
- 3 30 2 Operation range
• V3V > 3 V + 5% or
(3.0 volts)
• V3V < 3 V - 5%.

* V3 3 v > 3.3 V + 5% or
(3.3 volts)
•V3ÿv< 3.3 V-5%.

• V5V > 5 V + 6 % or
(5.0 volts)
• V5V < 5 V - 6 %.
- Check connected sensor system and replace if

The event message is triggered necessary. Switch off the truck. Disconnect the
Internal power supply out of if for T = 250 ms the following applies: sensor system. Switch the truck on again.
- 3 30 5 Operation
range (12.0 V) •V12v> 12 V + 20% or Reconnect the sensor system components in
•V12v< 12 V -20%. turn until the event message appears;
Status

Internal power supply out of if for T = 250 ms the following applies:
- 3 30 6 Operation
range (14.0 V) • V14V > 14 V + 20 % or
• V14V < 14 V -20%.
- Check fuses and replace if necessary;

- Check the wiring;
- Check reporting electronics and replace if
Internal power supply out of if for T = time limit the following applies:
- 3 30 7 Operation
range (24.0 V) • V24v > 24 V + 20 % or
necessary (e.g. DC/DC converter);
Lithium-ion batterv:
• V24v < 24 V - 20%.
- Check the lithium-ion battery and replace if
necessary;

Internal power supply out of if for T = 250 ms the following applies:
- 3 30 8 Operation
range (10.0 V) •V10V> 10 V + 20% or
•V10v< 10 V -20%.
• V2 54V > 2.54 V + 20% or
(2.54 V)
• V2 54V < 2.54 V - 20%
The event is triggered when the following applies - Check battery voltage, charge battery if
(hysteresis): necessary;
Power connection input (+) • "On" for T => 100 ms:
- 3 31 1 Operation
low voltage Measured value Vbatt < Vrated - 20%
•"Off" for T =>100 ms:
Measured value Vbatt > Vrated - 17%

"Sideshift position input" if for T = 250 ms the following applies: - Check sideshift position sensor power supply;
- 3 32 1 Operation
actual value implausible *Vsensor> 92-5% or - Replace sideshift position sensor;
,Vsensor< 7-5% - Replace signal-evaluating controller;
Status

"Speed reduction input" if for T = 250 ms the following applies: - Check speed reduction sensor power supply;
signal implausible * ÿsensor > 92.5% or - Replace speed reduction sensor;
* ÿsensor < 7.5% - Replace signal-evaluating controller;

Brake force governor: >4.7 volts measured on the analog input; the activation
channel A wire breakage level is 100 msec
necessary;

Brake force governor: >4.7 volts measured on the analog input; the activation
channel B wire breakage level is 100 msec
necessary;

Traverse sensor: channel A >4.7 volts measured on the analog input; the activation
wire breakage level is 100 msec
necessary;

Traverse sensor: channel B >4.7 volts measured on the analog input; the activation
necessary;

Rotate sensor: channel A >4.7 volts measured on the analog input; the activation
necessary;
Status

Rotate sensor: channel B >4.7 volts measured on the analog input; the activation
necessary;

Left hand support - Check sensor system with multimeter;
>4.7 volts measured on the analog input; the activation
- 3 34 7 Operation mushroom: channel A wire - Check computer component inputs;
level is 100 msec
breakage - Repair faulty components and replace if
necessary;

- 3 34 8 Operation mushroom: channel B wire - Check computer component inputs;
level is 100 msec
necessary;

Right hand support - Check sensor system with multimeter;
- 3 34 9 Operation mushroom: channel A wire - Check computer component inputs;
level is 100 msec
necessary;

- 3 34 10 Operation mushroom: channel B wire - Check computer component inputs;
level is 100 msec
necessary;

Steering actual value - Check sensor system with multimeter;
- 3 34 11 Operation sensor: channel A wire - Check computer component inputs;
level is 100 msec
necessary;
Status

- 3 34 12 Operation sensor: channel B wire - Check computer component inputs;
level is 100 msec
necessary;

Steering setpoint device: >4.7 volts measured on the analog input; the activation
necessary;

Steering setpoint device: >4.7 volts measured on the analog input; the activation
necessary;

Optional steering setpoint - Check sensor system with multimeter;
- 3 34 15 Operation generator: broken wire in - Check computer component inputs;
level is 100 msec
channel A - Repair faulty components and replace if
necessary;

level is 100 msec
channel B - Repair faulty components and replace if
necessary;

Hydraulic setpoint device: >4.7 volts measured on the analog input; the activation
necessary;
Status

Hydraulic setpoint device: >4.7 volts measured on the analog input; the activation
necessary;

Travel setpoint device: >4.7 volts measured on the analog input; the activation
necessary;

Travel setpoint device: >4.7 volts measured on the analog input; the activation
necessary;

Optional hydraulics setpoint >4.7 volts measured on the analog input; the activation - Check sensor system with multimeter;
- 3 34 25 Operation generator: broken wire in level is 100 msec - Check computer component inputs;
necessary;

Optional hydraulics setpoint >4.7 volts measured on the analog input; the activation - Check sensor system with multimeter;
- 3 34 26 Operation generator: broken wire in level is 100 msec - Check computer component inputs;
necessary;

Optional travel setpoint - Check sensor system with multimeter;
- 3 34 27 Operation generator: Broken wire in - Check computer component inputs;
level is 100 msec
necessary;
Status

level is 100 msec
necessary;

Accelerator setpoint - Check sensor;
- 3 34 29 Operation generator': broken wire in - Switch the truck off and on again;
level is 100 msec
channel A - Inquire about software update;

Accelerator setpoint - Check sensor;
- 3 34 30 Operation generator': broken wire in - Switch the truck off and on again;
level is 100 msec
channel B - Inquire about software update;
Brake pedal setpoint - Check sensor;
- 3 34 31 Operation generator: broken wire in - Switch the truck off and on again;
level is 100 msec
channel A - Inquire about software update;

Brake pedal setpoint - Check sensor;
- 3 34 32 Operation generator: broken wire in - Switch the truck off and on again;
level is 100 msec
channel B - Inquire about software update;
Travel setpoint generator - - Check sensor;
- 3 34 33 Operation pedestrian mode right: - Switch the truck off and on again;
level is 100 msec
broken wire in channel A - Inquire about software update;
Status

level is 100 msec
broken wire in channel B - Inquire about software update;
- 3 34 35 Operation pedestrian mode left: broken - Switch the truck off and on again;
level is 100 msec
wire in channel A - Inquire about software update;

level is 100 msec
wire in channel B - Inquire about software update;
Steering setpoint generator - - Check sensor;
level is 100 msec
broken wire in channel A - Inquire about software update;

level is 100 msec
broken wire in channel B - Inquire about software update;
level is 100 msec
wire in channel A - Inquire about software update;
Status

level is 100 msec
wire in channel B - Inquire about software update;

Brake force governor: <0.3 volts measured on the analog input; the activation
channel A short circuit level is 100 msec
necessary;

Brake force governor: <0.3 volts measured on the analog input; the activation
channel B short circuit level is 100 msec
necessary;

Traverse sensor: channel A <0.3 volts measured on the analog input; the activation
short circuit level is 100 msec
necessary;

Traverse sensor: channel B <0.3 volts measured on the analog input; the activation
necessary;

Rotate sensor: channel A <0.3 volts measured on the analog input; the activation
necessary;
Status

Rotate sensor: channel B <0.3 volts measured on the analog input; the activation
necessary;

<0.3 volts measured on the analog input; the activation
- 3 35 7 Operation mushroom: channel A short - Check computer component inputs;
level is 100 msec
circuit - Repair faulty components and replace if
necessary;

- 3 35 8 Operation mushroom: channel B short - Check computer component inputs;
level is 100 msec
necessary;

- 3 35 9 Operation mushroom: channel A short - Check computer component inputs;
level is 100 msec
necessary;

- 3 35 10 Operation mushroom: channel B short - Check computer component inputs;
level is 100 msec
necessary;

- 3 35 11 Operation sensor: channel A short - Check computer component inputs;
level is 100 msec
necessary;
Status

- 3 35 12 Operation sensor: channel B short - Check computer component inputs;
level is 100 msec
necessary;

Steering setpoint device: <0.3 volts measured on the analog input; the activation
necessary;

Steering setpoint device: <0.3 volts measured on the analog input; the activation
necessary;

- 3 35 15 Operation generator: channel A short - Check computer component inputs;
level is 100 msec
necessary;

- 3 35 16 Operation generator: channel B short - Check computer component inputs;
level is 100 msec
necessary;

Hydraulic setpoint device: <0.3 volts measured on the analog input; the activation
necessary;
Status

Hydraulic setpoint device: <0.3 volts measured on the analog input; the activation
necessary;

Travel setpoint device: <0.3 volts measured on the analog input; the activation
necessary;

Travel setpoint device: <0.3 volts measured on the analog input; the activation
necessary;

Optional hydraulics setpoint - Check sensor system with multimeter;
level is 100 msec
necessary;

Optional hydraulics setpoint - Check sensor system with multimeter;
level is 100 msec
necessary;

level is 100 msec
necessary;
Status

level is 100 msec
necessary;

Travel setpoint generator: <0.3 volts measured on the analog input; the activation
necessary;

Travel setpoint generator: <0.3 volts measured on the analog input; the activation
necessary;

Brake setpoint generator: <0.3 volts measured on the analog input; the activation
necessary;

Brake setpoint generator: <0.3 volts measured on the analog input; the activation
necessary;

Travel setpoint generator - - Check sensor system with multimeter;
- 3 35 33 Operation pedestrian mode right: - Check computer component inputs;
level is 100 msec
channel A short circuit - Repair faulty components and replace if
necessary;
Status

level is 100 msec
channel B short circuit - Repair faulty components and replace if
necessary;

- 3 35 35 Operation pedestrian mode left: - Check computer component inputs;
level is 100 msec
necessary;

level is 100 msec
necessary;

Steering setpoint generator - - Check sensor system with multimeter;
level is 100 msec
necessary;

level is 100 msec
necessary;

level is 100 msec
necessary;
Status

level is 100 msec
necessary;
The event message is triggered - Check sensor;

"Tilt sensor actual-value if for T = 250 ms the following applies: - Check connectors and wires;
- 3 36 1 Operation
input" signal implausible (Vsensor > 92.5%) or - Replace sensor
(ÿsensor < 7.5%)
Internal power supply jxp-A - Check component power supply;

- 3 37 2 Operation (drive compartment), system Internal power supply in CANopen Slave out of range - Exchange component
A out of range
Internal power supply jxp- - Check component power supply;

- 3 37 3 Operation Interface IDS, system A out Internal power supply in CANopen Slave out of range - Exchange component
of range
Internal power supply jxp-L, - Check component power supply;

- 3 37 4 Operation Internal power supply in CANopen Slave out of range
system A out of range - Exchange component
- 3 37 6 Operation Interface DPI, system A out Internal power supply in CANopen Slave out of range - Exchange component
of range

- 3 37 7 Operation Interface MIO, system A out Internal power supply in CANopen Slave out of range - Exchange component
of range

- 3 37 12 Operation WGA LD, system A out of Internal power supply in CANopen Slave out of range - Exchange component
range

- 3 37 13 Operation WGA KAR, System A out of Internal power supply in CANopen Slave out of range - Exchange component
range (cornering)
Status

- 3 37 14 Operation WGA DD, system A out of Internal power supply in CANopen Slave out of range - Exchange component
range

DK out of range - Exchange component
E1, system A out of range - Exchange component
Internal power supply jxp-E1 - Check component power supply;
optional (drive - Exchange component
compartment), system A out
of range

- 3 37 24 Operation optional (charger), system A Internal power supply in CANopen Slave out of range - Exchange component
out of range

- 3 37 25 Operation optional (operator position), Internal power supply in CANopen Slave out of range - Exchange component
system A out of range

- 3 37 31 Operation (external controller), system Internal power supply in CANopen Slave out of range - Exchange component
A out of range
Internal power supply jxp-A - Check component power supply;

- 3 37 34 Operation (drive compartment), system Internal power supply in CANopen Slave out of range - Exchange component
B out of range
Status

- 3 37 35 Operation Interface IDS, system B out Internal power supply in CANopen Slave out of range - Exchange component
of range
Internal power supply jxp-L, - Check component power supply;

system B out of range - Exchange component
- 3 37 38 Operation Interface DPI, system B out Internal power supply in CANopen Slave out of range - Exchange component
of range

- 3 37 39 Operation Interface MIO, system B out Internal power supply in CANopen Slave out of range - Exchange component
of range

- 3 37 44 Operation WGA LD, system B out of Internal power supply in CANopen Slave out of range - Exchange component
range

- 3 37 45 Operation WGA KAR, System B out of Internal power supply in CANopen Slave out of range - Exchange component
range (cornering)

- 3 37 46 Operation WGA DD, system B out of Internal power supply in CANopen Slave out of range - Exchange component
range

E1, system B out of range - Exchange component
optional (drive - Exchange component
compartment), system B out
of range
Status

- 3 37 56 Operation optional (charger), system B Internal power supply in CANopen Slave out of range - Exchange component
out of range

- 3 37 57 Operation optional (operator position), Internal power supply in CANopen Slave out of range - Exchange component
system B out of range

- 3 37 63 Operation (external controller), system Internal power supply in CANopen Slave out of range - Exchange component
B out of range
Sensor supply voltage is greater than the maximum - Measure voltage output without load;
Sensor supply voltage is limiting value or smaller than the minimum limiting value. - Check connected sensor system for permissible
- 3 38 1 Operation
outside the tolerance range Subindex = CAN node of the component that is current consumption;
reporting. - Replace component;
- 3 38 2 Operation
- 3 38 3 Operation
- 3 38 4 Operation
Status
- 3 38 6 Operation
- 3 38 7 Operation
- 3 38 21 Operation
- 3 38 22 Operation
- 3 38 23 Operation
- 3 38 24 Operation
- 3 38 25 Operation
Status
- 3 38 26 Operation
- 3 38 31 Operation
- 3 38 33 Operation
- 3 38 34 Operation
- 3 38 35 Operation
- 3 38 36 Operation
- 3 38 38 Operation
Status
- 3 38 39 Operation
- 3 38 53 Operation
- 3 38 54 Operation
- 3 38 55 Operation
- 3 38 56 Operation
- 3 38 57 Operation
- 3 38 58 Operation
Status
- 3 38 63 Operation
- Measure voltage output without load;

Power supply line driver jxp-
Power supply for output driver 1 (24 V) in CANopen - Check connected actuating system for
- 3 39 2 Operation A (drive compartment),
slave less than 14 V permissible current consumption;
system A out of range

- 3 39 3 Operation Interface IDS, system A out
of range

Power supply line driver jxp- Power supply for output driver 1 (24 V) in CANopen - Check connected actuating system for
- 3 39 4 Operation
L, system A out of range slave less than 14 V permissible current consumption;

- 3 39 6 Operation Interface DPI, system A out
of range

- 3 39 7 Operation Interface MIO, system A out
of range

- 3 39 34 Operation A (drive compartment),
Status

- 3 39 35 Operation Interface IDS, system B out
of range

- 3 39 36 Operation
L, system B out of range slave less than 14 V permissible current consumption;

- 3 39 38 Operation Interface DPI, system B out
of range

- 3 39 39 Operation Interface MIO, system B out
of range

- 3 39 53 Operation
E1, system B out of range slave less than 14 V permissible current consumption;

- 3 39 54 Operation
Power supply line driver jxp- - Measure voltage output without load;
E1 optional (drive Power supply for output driver 1 (24 V) in CANopen - Check connected actuating system for
- 3 39 55 Operation
compartment), system B out slave less than 14 V permissible current consumption;
of range - Replace component;
Status

- 3 39 56 Operation E2 optional (charger),
Power supply line driver jxp- - Measure voltage output without load;
E1 optional (operator Power supply for output driver 1 (24 V) in CANopen - Check connected actuating system for
- 3 39 57 Operation
position), system B out of slave less than 14 V permissible current consumption;
range - Replace component;

- 3 39 58 Operation

- 3 39 63 Operation E1 (external controller),
Lilon battery considerable - Charge the battery
- 3 40 1 Operation SOC battery 10% for >30 sec
low voltage
The event is triggered when the following applies: - Charge the battery
Lilon battery critical low • Battery charge status < limiting value for T > time limit
- 3 41 1 Operation
voltage OR
• Cell voltage < limiting value at room temperature
The event is triggered when the following applies: - Charge the battery;
• Battery charge status < limiting value for T > time limit
Lilon battery excessive low
- 3 42 1 Operation OR
voltage
• Cell voltage < limiting value at reduced room
temperature
The event is triggered when the following applies: - Charge the battery;
- 3 42 2 Operation Minimum cell voltage
• Cell voltage < limiting value at low temperature
Status
The event is triggered when the following applies: - Warm battery above 0 'C;
- 3 42 3 Operation Minimum cell voltage • Cell voltage < limiting value at very low temperature - Charge the battery;
(frost range)
The event is triggered when the following applies: - Charge the battery
- 3 43 1 Operation Lilon battery full discharge
• Cell voltage < limiting value for T > time limit
SOC battery (internal) = 0% AND charger not detected - Charge the battery
- 3 43 2 Operation Lilon battery full discharge
for >30 sec
Operating function: - Dispose of battery

• CanCode is switched on AND the cell voltage is below
3 V for longer than 100 ms.
OR
• CanCode is switched off AND no battery charger has
been detected AND the cell voltage is below 3 V for
Low voltage Lilon battery
- 3 44 1 Operation longer than 100 ms.
faulty
SF5:
• Battery charger has been detected AND the cell
voltage is below 3 V for longer than 100 ms.
OR
• Charging current greater than 1 A AND the cell voltage
is below 3 V for longer than 100 ms.
- Reduce energy recovery (i.e. select lower travel

program);
The event is triggered when the following applies: - Check battery charger;
- 3 45 1 Operation Lilon battery overvoltage
• Cell voltage > limiting value 1 for T > time limit 1 - Discharge the battery via self-discharge;
- Replace Battery Management System (BMS);
- Replace battery;
Status

program);
Lilon battery overvoltage The event is triggered when the following applies: - Check battery charger;
- 3 46 1 Operation
charge limit • Cell voltage > limiting value 2 for T > time limit 2 - Discharge the battery via self-discharge;
- Replace battery;

program);
The event is triggered when the following applies: - Check battery charger;
- 3 46 2 Operation Maximum cell voltage
• Cell voltage > limiting value 3 for T > time limit 3 - Discharge the battery via self-discharge;
- Replace battery;

- Check "Water in hydraulic oil" sensor with
multimeter;
- 3 51 1 Operation Water in oil sensor defective "Water in hydraulic oif'sensor reports error status
- Check computer component inputs;
- Repair faulty components or replace if
necessary;
Tiller head sensor: analog Tiller head sensor: - Re-teach the tiller head sensor;
- 3 70 2...n Operation
signal too high Analog signal limit exceeded. - Replace tiller head;
Tiller head sensor: Analog Tiller head sensor: - Re-teach the tiller head sensor;
signal too low Level below analog signal limit. - Replace tiller head;
Tiller head sensor: Analog Tiller head sensor: - Re-teach the tiller head sensor;
signal implausible Angle deviation from calibration table too great. - Replace tiller head;
- Check the wiring;

- Check travel direction switch power supply;
"Travel direction input" Redundancy test failed, broken wire or teach-in values
- 3 80 1 Operation - Re-teach the control element / MULTI-PILOT;
signal implausible faulty. Error remains until the unit is switched off or reset.
- Replace travel direction switch (if possible);
- Replace control element / MULTI-PILOT;
Status
The master must activate an event message if the - Check cable connection;
following conditions apply: - Check external travel direction switch power
- Channel A voltage less than minimum limit OR supply;
"Travel direction input" - Channel B voltage less than minimum limit OR - Replace external travel direction switch;
- 3 80 2 Operation
signal implausible - Channel A voltage greater than maximum limit OR
- Channel B voltage greater than maximum limit OR
- Total voltage less than limit 1 OR
- Total voltage greater than limit 2.
Only applies to control pilot:
if for T = 250 ms the following applies: - Check horn button power supply;
- 3 81 1 Operation "Horn button input" signal
Measured value Vhorn button > 90 % or - Replace horn button setpoint device;
implausible
measured value Vhorn~button < 10 %
A magnetic external field has been detected on the - Check for, and if necessary remove, a
control pilot which affects the Hall sensor system for the permanent magnet in the vicinity of the control
respective function (see sub index). The pilot issues the element
- 3 82 1 Operation External magnetic field
safe zero condition for the function concerned. If the - Check the wiring
detected on axis 1
function is no longer violated it is enabled again and the - Check the control element power supply
current setpoint transmitted. - Replace control element
A magnetic external field has been detected on the - Check for presence of permanent magnet near
control pilot which affects the Hall sensor system for the the control and remove if necessary;
respective function (see sub index). The pilot issues the - Check cable connection;
safe zero condition for the function concerned. If the - Check control power supply;
detected on axis 2
function is no longer violated it is enabled again and the - Replace control;
current setpoint transmitted.
detected on axis 3
Status
detected on axis 4
Control pilot specific:
- 3 82 5 Operation Magnetic external field
detects direction encoder
Only applies to control pilot: control pilot which affects the Hall sensor system for the the control and remove if necessary;
External magnetic field on respective function (see sub index). The pilot issues the - Check cable connection;
- 3 82 6 Operation
axis 5 or changeover button safe zero condition for the function concerned. If the - Check control power supply;
detected function is no longer violated it is enabled again and the - Replace control;
detected on horn button
Only applies to control pilot: control pilot which affects the Hall sensor system for the the control and remove if necessary;
External magnetic field respective function (see sub index). The pilot issues the - Check cable connection;
- 3 82 8 Operation
detected on safe zero condition for the function concerned. If the - Check control power supply;
acknowledgement button function is no longer violated it is enabled again and the - Replace control;
Status
- Charge the battery;

Battery charger:
- Check battery cell voltage, replace if necessary;
"Battery measurement input" battery charger signal too
- Measure battery voltage on charger;
low. The event message is triggered if the following
- Measure battery voltage on the battery;
applies for T = 4 ms:
-Check charging lead (fuses, ...) and replace
VCell < 1-2 volts per cell if necessary;
Self test / "Battery measurement input"
- 3 91 1
Operation signal on charger too low - Replace battery;
- Manually move the shuttle to the channel start

- Charge batteries and replace if necessary
-Check fuse 1F9
Battery measurement input voltage below 1.0V
- Check voltage divider R10
- Check contactors K1 and K5
- Check wire connection.
Status

Battery controller:
- Check battery cell voltage, replace if necessary;
"Battery measurement input" battery controller signal too
"Battery measurement input" - Measure battery voltage on charger;
low. This event message is triggered if the following
3 91 2 Undefined signal on battery controller - Measure battery voltage on the battery;
applies for T = 250 ms. the following applies:
too low - Check wire on battery controller;
-Check charging lead (fuses, ...) and replace
- V Batt < 18 V
if necessary;
- Replace battery;
Battery charger: - Rated voltages of battery and battery charger do
The event message is triggered not match;
if for T = 2 s the following applies: - Use suitable battery charger to charge battery;
Only applies to battery VCell > ÿ volts per cell
management:
Self test /
3 92 1 "Battery measurement input" - Manually move the shuttle to the channel start
Operation
battery charger signal too - Charge batteries and replace if necessary
high -Check fuse 1F9
- Battery measurement input voltage above 8.0V
- Check voltage divider R10
- Check contactors K1 and K5
- Check wire connection
Battery controller: - Measure voltage on battery controller;

"Battery measurement input" "Battery measurement input" battery controller signal too - Replace battery controller;
- 3 92 2 Undefined signal on battery controller high. This event message is triggered if the following
too high applies for T = 250 ms. the following applies:
VBatt>117V
Battery controller: - Check temperature sensor on battery controller
"Battery temperature actual value" signal implausible. (between battery cells);
"Battery temperature actual The event message is triggered - Replace battery controller;
- 3 93 1 Undefined
value" signal implausible if for T = 250 ms the following applies: - Replace controller;
Vtemperature_sensor < "45 C or
Vtemperature_sensor > 125 C
Status
Battery controller: -Check the measuring lead of the battery

"Battery semi-voltage" signal is implausible. The prompt controller is connected to the right cell
is issued after T = 250 ms. (GND, Vbat/2,Vbat)
"Battery semi-voltage" signal The event message is triggered if the following applies - Measure the cell voltage of each battery cell;
- 3 94 1 Undefined
implausible for T = 2 s: - Check battery controller cable connection;
Voltage over half the cells should be half the battery
voltage. If there is a deviation of more than + 1.5 V
between the two halves, the event message is triggered.

plate and adjust as required;
Battery controller: |-ÿ| If the error is not repeated after the battery
Battery full discharge Battery full discharge voltage limit exceeded. has been charged, point out to the customer
- 3 95 1 Operation
voltage limit exceeded The event message is triggered if the discharge voltage that the battery was fully discharged.
is too low before the battery capacity is zero. - Measure the cell voltage of each battery cell;
- Measure the voltage on the connector cables of
the battery controller; compare the reading with
that measured by the battery controller and if
necessary replace the battery controller;
-The charger may continue charging with a low

current. The charge time may be extended. This
Mains voltage <= 0.9*rated voltage for longer than
- 3 96 1 Undefined Mains error low voltage event message is designed for information
60 sec
purposes in case the charge times are not
maintained.
- The charger continues charging. It finally

switches off at 275 V (for the 230 volt model of
Mains voltage >= 1.15*rated voltage for longer than 60
- 3 97 1 Undefined Mains error overvoltage the ELH2430 family). This event message is
sec
designed for information purposes in case the
charge times are not maintained.
Status
"Internal components" temperature range exceeded -Allow the controllers to cool;

(significantly) -Check ventilation inputs and outputs, clean if
The event is triggered when the following applies necessary;
Significant over-temperature (hysteresis): - Check assembly on heat dissipater (heat
for components • "On" when temperature > activation temperature; conductivity);
• "Off' when temperature < activation temperature - 2 ?
The event message remains upon leaving this area and
entering an area with higher temperatures.
"Internal components" temperature range exceeded (too -Allow the controllers to cool;
large) -Check ventilation inputs and outputs, clean if
• The event is triggered when the following applies necessary;
(hysteresis): - Check the air flow through the heat sinks and
• "On" when temperature > lower temperature limit; clean if necessary;
• "Off" when temperature < lower temperature limit - 2? - Check assembly on heat dissipater (heat
The event message remains upon leaving this area and conductivity);
entering an area with higher temperatures. - Test fans and replace if necessary;
Component temperature Onlv applies to svstem trucks:
over-exceeded Non-permissible heatsink temperature;
The AC-3 Power Control (U8) has measured a heatsink
temperature greater than 90 °C or less than -25 °C;
Fans no longer working or air flow through heatsink
restricted;
The AC-3 Power Control has been overloaded;
Ambient temperature is very high and the AC-3 Power
Control is being overloaded;
AC-3 Power Control component (temperature
measurement) is faulty
"Internal components" temperature range exceeded -Allow the controllers to cool;

(critically) -Check ventilation inputs and outputs, clean if
Critical over-temperature for The event is triggered when the following applies necessary;
components (hysteresis): - Check assembly on heat dissipater (heat
• "On" when temperature > upper temperature limit; conductivity);
• "Off" when temperature < upper temperature limit - 2°C - Test fans and replace if necessary;
Status
"Motor" temperature range exceeded - Allow the motor to cool down;

(significantly) -Check ventilation inputs and outputs, clean if
Significant motor over- (hysteresis): - Check fan controller parameters;
temperature • "On" when temperature > activation temperature; - Check brakes can move freely;
• "Off' when temperature < activation temperature - 5°C
The event message remains upon leaving this area and
entering an area with higher temperatures.

(too far) -Check ventilation inputs and outputs, clean if
(hysteresis): - Check fan controller parameters;
• "On" when temperature > lower temperature limit; - Check brakes can move freely;
• "Off" when temperature < lower temperature limit - 5°C - Check temperature measurement wiring
The event message remains upon leaving this area and (controller to motor);
entering an area with higher temperatures. - Check motor temperature sensor;
- Replace motor;
Motor temperature over- Onlv applies to svstem trucks:
exceeded Non-permissible motor temperature;
The AC-3 Power Control (U8) has measured a motor
temperature greater than 125 °C or less than -25 °C;
The motor has been overloaded or motor cooling is not
working sufficiently;
Ambient temperature around the motor is very high and
motor is overloaded;
Motor (temperature sensor) damaged;
AC-3 Power Control component (temperature
measurement) is faulty;
Status

(critical) -Check ventilation inputs and outputs, clean if
Critical motor over-
- 4 06 1...n Operation (hysteresis): - Check fan controller parameters;
temperature
• "On" when temperature > upper temperature limit; - Check brakes can move freely;
• "Off' when temperature < upper temperature limit - Test fans and replace if necessary;
- 5 °C.
The event is triggered when the following applies - Measure the temperature at the location of the
"Internal components" (hysteresis): component;
- 4 07 1...n Undefined temperature range not • "On" when temperature < temperature limit; - Measure the temperature of the component;
achieved (significantly) • "Off' when temperature > temperature limit + hysteresis - Compare the temperatures and replace the
value component if necessary;
-Allow battery to cool;

- Check temperature measurement;
- Check harness;
Significant battery over- The event is triggered when the following applies:
- 4 08 1 Undefined - Replace battery controller;
temperature • Cell temperature > limiting value 1
repeatedly)

- Check harness;
Battery temperature over- The event is triggered when the following applies:
exceeded • Cell temperature > limiting value 2
repeatedly)
Status

- Check harness;
Critical battery over- The event is triggered when the following applies:
temperature • Cell temperature > limiting value 3
repeatedly)
The event is triggered when the following applies -Allow the hydraulic system to cool down;
(hysteresis): - Check and, if necessary, clean the ventilation
"Hydraulic oil" temperature
• "On" when temperature > activation temperature; inlets;
- 4 11 1 Operation range exceeded
• "Off" when temperature < activation temperature - 5 K - Check fan controller parameters;
(significantly)
(the event message remains upon leaving this area and - Check if the lift mast and/or hydraulic motors
entering an area at a higher temperature) can move freely;
The event is triggered when the following applies -Allow the hydraulic system to cool down;
(hysteresis): - Check ventilation inputs and outputs, clean if
"Hydraulic oil" temperature • "On" when temperature > lower temperature limit; necessary;
- 4 12 1 Operation
range exceeded (too high) • "Off' when temperature < lower temperature limit - 5 K - Check fan controller parameters;
(the event message remains upon leaving this area and - Check mast can move freely;
entering an area at a higher temperature)
Battery temperature The event is triggered when the following applies: - Use the battery in a warmer environment
- 4 13 1 Operation
worryingly low • Internal battery temperature is below limiting value 1
Battery temperature too far The event is triggered when the following applies: - Use battery in a warmer environment;
- 4 13 2 Operation
below lower limit • Internal battery temperature is below limiting value 2
- 4 14 1...n Operation temperature range not • "On" when temperature < temperature limit; - Measure the temperature of the component;
achieved (too great) • "Off' when temperature > temperature limit + hysteresis - Compare the temperatures and replace the
Status
- 4 15 1...n Operation temperature range not • "On" when temperature < temperature limit; - Measure the temperature of the component;
achieved (critically) • "Off' when temperature > temperature limit + hysteresis - Compare the temperatures and replace the
The event is triggered when the following applies -Allow the coolant to cool down;
(hysteresis): - Check and, if necessary, clean the inlets and
Coolant temperature range
• "On" when temperature > lower temperature limit; outlets;
- 4 16 1 Operation has been (significantly)
• "Off' when temperature < lower temperature limit - 5 K - Check fan controller parameters;
exceeded
(the event message remains upon leaving this area and - Check if the lift mast and/or hydraulic motors
entering an area at a higher temperature) can move freely;
Power-up test: -Allow battery to cool;

"Battery" temperature range
- 4 17 1 Operation
exceeded
Before connecting the cells together
• Internal battery temperature exceeds the limiting value
Power-up test: - Use battery in a warmer environment;

"Battery" temperature range Before connecting the cells together
- 4 17 2 Operation
not reached • Internal battery temperature does not reach the limiting
value
Status
"Driver circuit output transformer" hardware signal - Switch the truck off and on again;
activated (main jumper); - Check motor cable (short circuit);
External interruption of MOSFET driver circuit activated. - Check speed sensor and replace if necessary;
- Check motor and replace if necessary;
Onlv aoolies to svstem trucks: - Replace component
Output transformer has cut out; (Onlv aoolies to L&S trucks:
The hardware-side output transformer protection of the - Replace AC-3 Power Control interface card);
Output transformer driver
- 5 01 1 Operation AC-3 Power Control (U8)has been triggered and the
connection activated
output transformer has switched into the de-energised
state (three-state logic) if this is possible;
Power outputs of the AC-3 Power Control component
have been short-circuited (either to the power supply or
to each other);
AC-3 Power Control component (output transformer or
output transformer protection) is faulty;

"Output transformer driver connection" hardware signal
- Check motor connection cable (short circuit);
Output transformer driver activated (lift actuator of a combination controller);
- 5 01 2 Operation - Check speed sensor, replace if necessary;
connection activated External interruption of MOSFET driver connection
- Check motor and replace if necessary;
activated.
- Check wire connection to brake coil / valve coil;

"Driver circuit proportional output" hardware signal - Check brake coil / valve coil
Driver circuit proportional activated (proportional output); (resistance measurement), replace if necessary;
- 5 01 3 Operation
output activated External interruption of MOSFET driver connection - Check outputs for short circuits and rectify if
activated. necessary;
The event message is triggered - Check cable from steer motor to controller Ml
"Comparator switch"
if for T = 200 ms the following applies: A2;
- 5 01 4 Operation hardware signal triggered
• HW comparator switch triggered and the current - Replace steer motor;
(steer motor shorted)
reading is less than 10 A - Replace controller;
Status
This event message is triggered - Switch the truck off and on again;
Internal processor control
- 5 02 1 Operation if for T < 10 msec the "external watchdog" hardware - Replace component;
implausible
signal is implausible (processed too quickly).
- 5 02 2 Operation if for T > 100 msec the "external watchdog" hardware - Replace component;
implausible
signal is implausible (processed too slowly).
When the external watchdog runs out the output - Switch the truck off and on again;
"External watchdog" transformers / basic outputs are not switched off. - Replace component;
- 5 02 3 Self test hardware signal improbable "External watchdog" hardware signal implausible
(not output stage disable) Signal permanently displayed / output transformer not
deactivated.
Internal processor control This event message is triggered - Switch the truck off and on again;
- 5 02 4 Operation
implausible if the "external watchdog" does not start within 10 msec. - Replace component;
- 5 02 5 Operation if the initial activation of the external watchdog was not - Replace component;
implausible
successful.
- Clear logbook;
This event message is triggered - Set truck type;
System start
- 5 03 1...n EEProm does not respond if the EEPROM has not responded forty times in - Set hour meter;
Operation
succession. - Set default parameters;
Status
This event message is triggered if for - Check cable connection;

T = 100 ms the following applies: - Check connected consumers (brake magnet,
• Output driver status register has reported a fault; valves, ...) and replace if necessary;
Subindex matches the outout number - Check outputs with JUDIT;
• Status = 1: no load - Replace controller;
• Status = 2: Short circuit to battery (+) or
"Driver connection digital
- 5 04 1...n Operation overtemperature
output" damaged
• Status = 3: Short circuit to battery (-) or overload
Lithium-ion batterv:
• Subindex matches the number of the stack.
• Status 1 = degree of modulation not < 75% and > 25%
• Status 2 = degree of modulation not < 25%
• Status 3 = degree of modulation not > 75%
- Check main fuse;

-Check main contactor / Emergency Disconnect
switch;
This event message is triggered - Check battery cable connection;
"Overvoltage" signal
- 5 05 1 Operation when the "overvoltage" hardware signal is triggered. - Check the battery and charge if necessary;
triggered
External interruption of voltage control activated. - Check electrolyte level;
- Set brake ramp parameters;
- Check charger settings;

Reset by monitoring
- 5 06 1 Undefined Hardware reset activated by watchdog. - Check CAN-Bus;
component
I2C bus error (device-internal communication bus) - Replace component;
- 5 07 1 Undefined Internal error Node ID from logbook corresponds to actuating
component.
SPI bus error (device-internal communication bus) - Replace component;

component.
Status
Serial interface error (UART error) - Replace component;

component.
Error in analog/digital transformer (ADC error) - Replace component;

component.
Error in timer module (RTC error) - Replace component;

component.
Faulty radio module - Replace component;

component.
Flash error -> radio module faulty - Repeat flash process;

Operation
- 5 07 7 ROM or flash error Node ID from logbook corresponds to actuating - Replace component;
Undefined
component.
Improbable readings for - Replace component;

- 5 07 8 Undefined Analog/digital converter error
analog/digital converter
No speed signal from fan present when the fan is - Check fan wire connection;
modulated (fan does not rotate?) - Check fan freedom of movement;
- 5 08 1 Undefined Fan not working correctly
Or - Replace fan;
Fan current implausible - Replace signal-issuing controller;
The event message is triggered - Switch the truck off and on again;
System start Co-processor does not
- 5 09 1 if for T = 2 s the following applies: - Replace component;
Operation communicate
• Processor not triggered by co-processor
Error bit set in jxp Interface for evaluating controls in control panel reports - Contact Technical Support;
- 5 24 1 Self test
component panel fault. The activation limit is 20 msec. - Replace components if necessary;
Status
Error bit set in jxp - Contact Technical Support;

Interface in drive compartment reports error. The
- 5 24 2 Self test component A (drive - Replace components if necessary;
compartment)
Error bit set in jxp Drive compartment interface reports error. The activation - Contact Technical Support;
- 5 24 3 Self test
component Interface IDS limit is 20 msec. - Replace components if necessary;
Interface in operator position / load handler reports error.
- 5 24 4 Self test component L (operator - Replace components if necessary;
position / load handling)
Error bit set in jxp Drive compartment interface (DPI) reports error. The - Contact Technical Support;
- 5 24 6 Self test
component Interface DPI activation limit is 20 msec. - Replace components if necessary;
Error bit set in jxp Interface in operator position / load handler (MIO) reports - Contact Technical Support;
- 5 24 7 Self test
component Interface Mio error. The activation limit is 20 msec. - Replace components if necessary;
Error bit set in jxp Drivel interface reports error. The activation limit is - Contact Technical Support;
- 5 24 9 Self test
component Drivel 20 msec. - Replace components if necessary;
Error bit set in jxp Drive2 interface reports error. The activation limit is - Contact Technical Support;
- 5 24 10 Self test
component Drive2 20 msec. - Replace components if necessary;
Error bit set in jxp Drive3 interface reports error. The activation limit is - Contact Technical Support;
- 5 24 11 Self test
component Drive3 20 msec. - Replace components if necessary;
Wire guidance load direction sensor reports error. The
- 5 24 12 Self test component wire guidance - Replace components if necessary;
load direction sensor

Wire guidance cornering drive direction sensor reports
- 5 24 13 Self test component KAR antenna - Replace components if necessary;
error. The activation limit is 20 msec.
(cornering)

Wire guidance drive direction sensor reports error. The
- 5 24 14 Self test component wire guidance - Replace components if necessary;
drive direction sensor
Status
Error bit set in jxp Interface DK reports error. The activation limit is - Contact Technical Support;
- 5 24 15 Self test
component Interface DK 20 msec. - Replace components if necessary;
RFID reader left reports error. The activation limit is
- 5 24 20 Self test component HPS left (RFID - Replace components if necessary;
20 msec.
reader)
Error bit set in jxp Interface 1 optional type 1 reports error. The activation - Contact Technical Support;
- 5 24 21 Self test
component E1 threshold is 20 msec. - Replace components if necessary;
Error bit set in jxp Interface 1 optional type 2 reports error. The activation - Contact Technical Support;
- 5 24 22 Self test
component E2 limit is 20 msec. - Replace components if necessary;
Interface 2 optional type 1 reports error. The activation
- 5 24 23 Self test component option E1 (drive - Replace components if necessary;
limit is 20 msec.
compartment)

Interface 2 optional type 2 reports error. The activation
- 5 24 24 Self test component option E2 - Replace components if necessary;
limit is 20 msec.
(charger)

Interface 3 optional typel reports error. The activation
- 5 24 25 Self test component option E1 - Replace components if necessary;
limit is 20 msec.
(cabin)
Error bit set in jxp Interface 1 optional type3 reports error. The activation - Contact Technical Support;
- 5 24 26 Self test
component E3 limit is 20 msec. - Replace components if necessary;
Interface for external control optional type 1 reports
- 5 24 31 Self test component E1 external - Replace components if necessary;
error. The activation limit is 20 msec.
controller

RFID reader right reports error. The activation limit is
- 5 24 52 Self test component HPS right (RFID - Replace components if necessary;
20 msec.
reader)
Status
Error of slave set in Safe A CANopen slave in the network reports an error. The - Contact Technical Support;
- 5 24 64 Self test
computers activation limit is 20 msec. - Replace components if necessary;
-Allow the motor to cool down as it may be
The control electronics of the ISKRA steer motor has
overheated;
identified an internal error.
"Steer motor status" signal - Check motor fuses and replace if necessary;
- 5 51 1 Operation The steering controller is informed of the status of the
damaged - If the motor fuses trip again, check the motor
ISKRA steer motor via a separate cable
and replace if necessary. Then replace the
(>16 V = fault).
motor fuses;
-Allow the motor to cool down as it may be

The status "Ready" was not detected after T = 2 s after
overheated;
switching on the steering controller (during initialisation)
"Steer motor status" signal - Check motor fuses and replace if necessary;
- 5 51 2 Operation (flank 24 V to 0 V).
not ready - If the motor fuses trip again, check the motor
The steering controller is informed of the status of the
and replace if necessary. Then replace the
ISKRA steer motor via a separate cable (0 V = ready).
motor fuses;
- Check transponder data;

Transponder: faulty reading Transponder data analysis:
- Re-teach the transponder via JUDIT if
- 5 60 1 Operation or incorrectly programmed The last transponder reading did not contain the
necessary;
transponder expected data. The activation limit is 20 msec.
- Replace the transponder if necessary;
Transponder: position - Check transponder data;
Transponder data analysis:
number in aisle is greater - Re-teach the transponder via JUDIT if
- 5 60 2 Operation The number of transponders configured in the aisle type
than the maximum number necessary;
has been exceeded. The activation limit is 20 msec.
of transponders in the aisle - Replace the transponder if necessary;

Transponder: transponder Transponder data analysis:
- Re-teach the transponder via JUDIT if
- 5 60 3 Operation has the wrong transponder A transponder of the wrong type has been read. The
necessary;
type activation limit is 20 msec.

Transponder: transponder - Re-teach the transponder via JUDIT if
- 5 60 4 Operation The last transponder reading contained a wrong aisle
has the wrong aisle type necessary;
type. The activation limit is 20 msec.
Status

Transponder: transponder - Re-teach the transponder via JUDIT if
- 5 60 5 Operation The last transponder reading contained a wrong aisle
has the wrong aisle number necessary;
number. The activation limit is 20 msec.

Transponder: Sequence of
The last transponder reading contained a wrong - Re-teach the transponder via JUDIT if
- 5 60 6 Operation transponders in aisle is
transponder sequence. The activation limit is 20 msec. necessary;
incorrect
- Check the transponder routing;

Transponder: a transponder
- 5 60 7 An expected transponder was not found. - Check the signal strength of the readers via
was missing
transponders;
Transponder: faulty The last transponder reading contained faulty - Check the signal strength of the readers via
- 5 60 8
transponder data reading transponder data. The activation limit is 20 msec. transponders;
Transponder: transponder The last transponder contains invalid transponder data. - Check the transponder data content and re-
- 5 60 9
data invalid The activation limit is 20 msec. program if necessary.
Transponder: multiple - Check the signal strength of the readers via

Multiple transponder data readings do not match The
- 5 60 10 transponder data readings
transponders;
implausible
Transponder: left and right - Check the transponder routing;

Left and right RFID readers detect a transponder. The
- 5 60 11 RFID readers have received
data
Transponder analysis: aisle The aisle status is active without having detected an - Check the transponder routing;
- 5 60 12 active without transponder entry direction via transponders. The activation limit is 20 - Check the signal strength of the readers via
information msec. transponders;
Transponder analysis: apron - Check the transponder routing;

The 'Apron_distance_without_transponder' parameter is
field distance exceeded - Check the signal strength of the readers via
- 5 60 13 shorter than the distance detected. The activation limit is
without detecting a transponders;
20 msec.
transponder
Status
Reflex marker not identified in the expected area. - Manually move the shuttle to the channel start
The activation limit is 20 msec. - Repeat travel command at channel start
-Check rail hole sensors 7B33.1, 7B33.2 for
contamination, incorrect settings and faults
- Check incremental transmitter 1B5
Warehouse navigation:
- 5 61 1 Operation Expected reflex marker Signal change expected at 7B33.1 - Check drive chain
not found
Signals of 7B33.1 and 7B33.2 differ - Check position of rail holes, they should lie
No signals from incremental transmitter 1B5 directly opposite each other
- Check rail holes and travel channel for
contamination
- Check the shuttle in a different travel channel
Warehouse navigation: - Check the transponder routing;
Reflex marker detected in unexpected position.
- 5 61 2 reflex marker read in - Check the arrangement of the reflex markers;
unexpected position
Warehouse navigation: - Check the transponder routing;

deviation from marker Tolerance window not met for marker position. - Check the arrangement of the reflex markers;
- 5 61 3
position to aisle position The activation limit is 20 msec.
excessive
Minimum marker distance in mm: (2 * marker tolerance) - Check the transponder routing;
+ marker width; if the distance between two markers is - Check the arrangement of the reflex markers;
Horizontal positioning: less than the above minimum distance, the error
- 5 61 4 distance between markers message appears after a job is entered. Remedy: reduce
smaller than tolerance the 'marker tolerance' parameter or set up the
warehouse so that the distance between the markers
is greater.
If the 'positioning tolerance' parameter is less than half - Check parameter setting;
the 'marker width' parameter, the truck must be
Horizontal positioning:
positioned exactly on a marker. The error can occur if
- 5 61 5 positioned within tolerance,
for example the laser scanner attachment is loose or if
but no marker
positions are stored wrongly during teach-in or during
commissioning.
Status
The 'correction stop load direction / drive direction' value - Check parameter setting;
Horizontal positioning: is restricted to 50 mm. When this has been reach, exact
- 5 61 6 adjustment stop value at positioning is not possible. Check the 'HP/LN default
limit, positioning not possible settings - stopping distance, positioning distance and
braking distance' setting

- Check CAN-Bus;
- 6 01 1 System start Software has been reset Software has been reset (internal error).
Internal software error - Switch the truck off and on again;

Accessing non-existent
- 6 02 1 Undefined (Processor-internal interruption activated; - Inquire about software update;
memory cell
activation mechanism is processor-dependent). - Replace controller;

Internal software error
- 6 02 2 Undefined Invalid operation performed - Inquire about software update;
(illegal operation / invalid processor op. code).

Main loop seldom processed - Check CAN-Bus;
- 6 03 1 Operation The main loop has not run forT= 100msec
or not at all - Check CAN-Bus load;

Undefined interruption Processor-internal event. - Check CAN-Bus;
- 6 04 1 Operation
activated A non-defined interruption has occurred - Check CAN-Bus load;
- Set truck type;

Checksum invalid in EEPROM area: - Switch the truck off and on again;
Component initialisation
- 6 06 1 Undefined 0x0000 - OxOOOF - Set hour meter;
invalid
For details see EEPROM layout document - Set default parameters;
Status
- 6 07 1 Checksum invalid in EEPROM area: - Set hourmeter;

0x0010 - 0x001 F(TS-E data ~> Sub 1) - Replace controller;
- 6 07 2 "Component information" 0x0060 - 0x006F (hourmeter 2 -> Sub 2)
Undefined
data EEPROM range invalid 0x0070 - 0x007F (hourmeter 3 -> Sub 3)
- 6 07 3
0x0080 - 0x008F (hourmeter 4 ~> Sub 4)
For details see EEPROM layout document
- 6 07 4
Checksum invalid in EEPROM area: - Set truck serial number;

"Truck information data"
- 6 08 1 Undefined 0x0020 - 0x002F - Set truck name;
EEPROM range invalid
For details see EEPROM layout document - Replace controller;
Safety data record not Safety data record not loaded in Safe computer or not - Load safety data record into Safe.
loaded in Safe computer correct. The activation limit is 20 msec.
Serial number in safety data record does not match the - Load the respective safety data record into Safe.
Serial number in safety data
truck dongle. Invalid safety data record installed for this
- 6 08 3 System start record does not match the
truck or electronic serial number of dongle invalid. The
dongle
activation threshold is 20 msec.
Cross-check of redundant The results of processing the program cycles in the two - Check operating system in the subcomputers A
- 6 08 4 Safe computers does not Safe computers do not match. The activation limit is and B;
match 20 msec.
The Adjustment_Load - Ensure the service parameters are the same in

direction_Load direction The parameter settings in the truck do not match the the Master and the Safe.
- 6 08 5 System start parameter deviates from the service parameters in the Safe. The activation limit is
service parameter setting in 20 msec.
the Safe.
The Adjustment_Drive - Ensure the service parameters are the same in

directionjoad direction The parameter settings in the truck do not match the the Master and the Safe.
the Safe.
Status
The Adjustment_Load - Ensure the service parameters are the same in

direction_drive direction The parameter settings in the truck do not match the the Master and the Safe.
the Safe.
The Adjustment_Drive - Ensure the service parameters are the same in

direction_drive direction The parameter settings in the truck do not match the the Master and the Safe.
the Safe.
The Adjustment_Steer - Ensure the service parameters are the same in

angle_drive direction The parameter settings in the truck do not match the the Master and the Safe.
the Safe.
The Adjustment_Steer - Ensure the service parameters are the same in

anglejoad direction The parameter settings in the truck do not match the the Master and the Safe.
the Safe.
The Adjustment_Steer angle - Ensure the service parameters are the same in
transmission parameter The parameter settings in the truck do not match the the Master and the Safe.
- 6 08 11 System start deviates from the service service parameters in the Safe. The activation limit is
parameter setting in the 20 msec.
Safe.
The Offset_angle_index - Ensure the service parameters are the same in

The parameter settings in the truck do not match the
parameter deviates from the the Master and the Safe.
- 6 08 12 System start service parameters in the Safe. The activation limit is
service parameter setting in
20 msec.
the Safe.
Status
- Non-permissible change to non-volatile memory of - Reset service safety parameter

service safety parameter - Replace controller
- Non-permissible change to working copy of service
safety parameter
Service safety parameter - Non-permissible value with regard to service safety
invalid parameter value range
- Non-permissible default value (with regard to service
safety parameter value range)
-Timeout in communication with parameter setting tool
(Judit)
Discrepancy between - Check master teach-in value

parameter and service - Check safety computer teach-in value
Difference between teach-in value for accelerator pedal
- 6 08 14 System start safety parameter :
zero position between master and safety computer
Accelerator pedal zero
position
Discrepancy between - Check master teach-in value

parameter and service - Check safety computer teach-in value
Difference between teach-in value for accelerator pedal
- 6 08 15 System start safety parameter :
2 zero position between master and safety computer
Accelerator pedal 2 zero
position
- Non-permissible change to non-volatile memory of - Reset safety parameter

Safety computer : safety safety parameter - Replace controller
parameter invalid - Non-permissible change to working copy of safety
parameter
Deviation between - Check master teach-in value;

parameter and "actual steer Difference in teach-in value for "Electric steering actual - Check backup computer teach-in value;
- 6 08 17 System start angle right" service backup value transmitter right teach-in value" between master
parameter for electric and backup computer
steering
Status
Deviation between - Check master teach-in value;

parameter and "actual steer Difference in teach-in value for "Electric steering actual - Check backup computer teach-in value;
- 6 08 18 System start angle left" service backup value transmitter left teach-in value" between master and
parameter for electric backup computer
steering
Checksum invalid in EEPROM areas: - Clear logbook,

"Logbook administration"
- 6 09 1 Undefined 0x0040 - 0x004F (logbook administration) - Replace controller;
Checksum invalid in EEPROM areas: - Clear logbook,

"Logbook entries" EEPROM
- 6 09 2 Undefined 0x0400 - OxOBFF - (logbook entries) - Replace controller;
range invalid
Checksum invalid in EEPROM area: - Set hourmeter;

"Hourmeter" EEPROM
- 6 10 1 Undefined 0x0050 - 0x005F - Replace controller;
range invalid
Checksum invalid in EEPROM area: - Replace controller;

"Calibration data" EEPROM
- 6 11 1...32 Undefined 0x0100 - 0x01 FF
range invalid
- Repeat teach-in, e.g. accelerator pedal,

"Parameters / teach-in Checksum invalid in EEPROM area: brake pedal, load sensor system, steering,
System start,
- 6 12 1 values 1" EEPROM range The subindex records faulty parameter/teach-in group MULTI-PILOT, ... ;
Undefined
invalid (1 - 6) in the EEPROM area. - Set default parameters;

System start,
Undefined
Status

System start,
Undefined

System start,
Undefined

System start,
Undefined

System start,
Undefined
Invalid parameter ID number - Contact Technical Support;
transferred or parameter ID of the parameter file to be created invalid or already - Replace master component if necessary;
with the supplied ID number allocated. The activation limit is 20 msec.
already set up
No pointer issued to data Pointer for parameter file data sink invalid. The activation - Contact Technical Support;
variable limit is 20 msec. - Replace master component if necessary;
Status
- Event message can occur when the software

version is changed, if new parameters need
Excessive data variable Size of data not the same as data source. The activation
- 6 12 12 System start to be initialised.
transmitted limit is 20 msec.
- Switch the truck off and on again to enable
the initialisation.
Data from data source Memory for parameter information could not be read. - Contact Technical Support;
cannot be read The activation limit is 20 msec. - Replace master component if necessary;
Memory for data copy not Data sink cannot be written to. The activation limit is - Contact Technical Support;
responding 20 msec. - Replace master component if necessary;
Faulty parameter file Parameter file checksum invalid. The activation limit is - Contact Technical Support;
checksum 20 msec. - Replace master component if necessary;
Brake force governor: - Check function settings;
The settings for the brake force governor are - Re-teach the brake force governor via Judit;
Invalid parameters for Max
- 6 12 30 System start implausible, i.e. BFGmax less than 0 or BFGmax greater
or Min Brake Force Position
than BFGmin. "BFGmin" must be greater than zero but
less than "BFGmax".The activation limit is 20 msec.
Brake force governor: - Check function settings;

Brake force governor: Basic The calculated speed values for the brake force - Re-teach the brake force governor via Judit;
- 6 12 31 System start values for position setpoint governor are implausible. The minimum speed must be
calculation invalid. less than the maximum speed. The activation limit is
20 msec.

Checksum invalid in EEPROM area:
brake pedal, load sensor system, steering,
"Parameter / taught values" The subindex records the EEPROM address area of the
- 6 12 32.. .n System start MULTI-PILOT, ... ;
EEPROM range data invalid faulty parameter/teach-in group (assignment is subindex
- Set default parameters;
* 16 = starting address in the EEPROM).
Status
- Extend mast bracket forward and back;

Traverse distance reference Specifically for the reach truck:
- 6 13 1 System start - Check the reference sensor and replace if
missing from EEPROM Traverse distance reference missing from EEPROM
necessary;
Calibrated reading out of - Replace controller;
- 6 14 1...n System start The calibrated reading of an analog signal is out of range
range
Material number: Software is not the same as the - Set truck type;
material number stored in the EEPROM. - Switch the truck off and on again;
EEPROM layout does not
- 6 15 1 System start Or - Set hour meter;
match current software.
Actual version or number for a saved parameter group - Set default parameters;
does not match the nominal version or number - Replace controller;

- Check CAN-Bus;
Number of interruptions implausible (internal software
- 6 16 1 Operation Software error - Check CAN-Bus load;
error); triggered in interrupt routine

- Check CAN-Bus;
Number of interruptions implausible (internal software
- 6 16 2 Operation Software error - Check CAN-Bus load;
error); triggered in idle

Software version The software version of another component is not - Check software version compatibility on all
- 6 17 1...n System start
incompatible compatible with the current version. components;

Software version The software version of another component is not - Check software version compatibility on all
- 6 17 65. ..68 incompatible compatible with the current version. components;
Status
- Store operating parameters with the following

System start global save command:
Operating parameters not Operating parameters not saved after changing service
- 6 18 1 Self test "SAVE" at index 1010,
saved backup parameters
Operation Sub-index 1,
Node ID 1
One or more parameters set to default values. -When updating the operating system:
The AC-3 Power Control (U8) operating system has New parameters are set to default when the
calculated invalid parameter combinations and set one truck is switched off and on again, event
or more parameters to the default specified in the message is reset after the truck is switched on;
program. - Check the operating system and install the
The activation limit is 20 msec. correct one if necessary;
The master has specifically set one or more parameters - Replace the AC-3 Power Control (U8);
to default values.
An operating system has been installed on the AC-3
Power Control component with a different AC-3 Power
parameters set to default
- 6 18 4 Self test Control ID than before;
after error
The operating system is faulty and contains default
settings that are out of the permissible setting range for
parameters;
Parameter memory is faulty, the correct value of a
parameter could not be calculated and has therefore
been set to default;
AC-3 Power Control component (parameter memory) is
faulty;
This message is not necessarily an error, but it should at
least be reported to the master.
An invalid combination of several parameters has been - Check the parameter setting via JUDIT and
Invalid parameter set. e.g.: adjust if necessary;
- 6 19 1 Operation
combination • Parameter combination auxiliary hydraulics extension
and acknowledgement button function
Warehouse navigation parameter setting: - Set parameters to valid setting;

Warehouse navigation:
- 6 19 2 type specification undefined. The activation limit is
Incorrect type selection
20 msec.
Status
Warehouse navigation parameter setting: - Set parameters to valid setting;

Warehouse navigation: Aisle The aisle length obtained from rack structure parameters
- 6 19 3
length incorrect does not match the measured aisle length. The
Warehouse navigation: Warehouse navigation parameter setting: - Set parameters to valid setting;
- 6 19 4 warehouse structure Warehouse structure parameters implausible. The
parameters faulty activation limit is 20 msec.
Invalid parameter The parameter combination Aux. Lift extend and lift - Check the parameter setting via JUDIT and
- 6 19 5 Operation
combination cutout option is invalid adjust if necessary;
Invalid parameter - Set motor parameters;

- 6 19 6 System start Drive motor parameter (engine type) has an invalid value
combination
Invalid parameter Load wheel brake parameter and load wheel brake -Change brake parameter;
combination inspection do not match - Check brakes;
- Check "general" parametrisation

Incorrect warehouse
Incorrect parametrisation in the general information - and, if necessary, check/deactivate the actual-
- 6 19 8 Operation parametrisation: General
section of "warehouse configuration display" position sensing
information
- Restart task
-Check "hydraulics" parametrisation
Incorrect warehouse Incorrect parametrisation in the "hydraulics" section of - and, if necessary, check/deactivate the actual-
- 6 19 9 Operation
parametrisation: Hydraulics "warehouse configuration display" position sensing
- Restart task
- Check the heights/zones parametrisation

Incorrect warehouse
Incorrect parametrisation in the "heights/zones" section - and, if necessary, check/deactivate the actual-
- 6 19 10 Operation parametrisation: Heights/
of "warehouse configuration display" position sensing
zones
- Restart task
- Check "driving" parametrisation

Incorrect warehouse Incorrect parametrisation in the "driving" section of - and, if necessary, check/deactivate the actual-
- 6 19 11 Operation
parametrisation: Driving "warehouse configuration display" position sensing
- Restart task
Status
- Check "storage location type" parametrisation

Incorrect warehouse
Incorrect parametrisation in the "storage location type" - and, if necessary, check/deactivate the actual-
- 6 19 12 Operation parametrisation: Storage
section of "warehouse configuration display" position sensing
location type
- Restart task
- Check "level type" parametrisation

Incorrect warehouse Incorrect parametrisation in the "level type" section of - and, if necessary, check/deactivate the actual-
- 6 19 13 Operation
parametrisation: Level type "warehouse configuration display" position sensing
- Restart task
- Check "rack type" parametrisation

Incorrect warehouse Incorrect parametrisation in the "rack type" section of - and, if necessary, check/deactivate the actual-
- 6 19 14 Operation
parametrisation: Rack type "warehouse configuration display" position sensing
- Restart task
- Check "storage blocks" parametrisation

Incorrect warehouse
Incorrect parametrisation in the "storage blocks" section - and, if necessary, check/deactivate the actual-
- 6 19 15 Operation parametrisation: Storage
of "warehouse configuration display" position sensing
block
- Restart task
- Check "correction" parametrisation

Incorrect warehouse Incorrect parametrisation in the "correction" section of - and, if necessary, check/deactivate the actual-
- 6 19 16 Operation
parametrisation: Correction "warehouse configuration display" position sensing
- Restart task
- Check/change the parameter for the maximum

lifting flow rate;
Invalid parameter The parameters for the maximum flow rates or maximum - Check/change the parameter for the maximum
combination engine speed for lifting/lowering have not been set lowering flow rate;
- check/change the parameter for the maximum
engine speed during lifting;
-Check/change idle speed parameter;

Invalid parameter The parameter for idle speed or maximum engine speed
- 6 19 18 Operation - Check/change the parameter for the maximum
combination has not been set
engine speed;
Status
Invalid parameter - Check/change tyre diameter parameter;

- 6 19 19 Operation The parameter for tyre diameter has not been set
combination
Invalid parameter - Check/change fuel type parameter;

- 6 19 20 Operation The fuel and engine type parameters are not compatible
combination
Invalid parameter The engine type and ECU encoding parameters are not -Check/change engine type parameter;
- 6 19 21 Operation
combination compatible
Set A in the LED version and the StVZO lighting - Check/change the Set A parameter;
Invalid parameter
- 6 19 22 Operation (German road traffic equipment) have been configured - Check/change StVZO parameter;
combination
at the same time
System start - Check the parameter setting via JUDIT and

Invalid parameter The Tilt Control option and ZH3 toggle switch parameter
- 6 19 23 Self test adjust if necessary.
combination combination is invalid
Operation
System start Value of parameters "Axle 3, level 1" AND "Axle 4, level -Check/change parameter axle level 1;
Invalid parameter
- 6 19 24 Self test 1" > 0 AND "Axle 3, level 1" is the same as parameter
combination
Operation "Axle 4, level 1"
System start - Check/change parameter axle level 2;

Invalid parameter Parameter values for several of the "Axle 1-4, Ievel2"
- 6 19 25 Self test
combination parameters are greater than 0 and identical
Operation
Value of "Toggle function" parameter is 3 AND a -Check/change "Toggle function" parameter;

Invalid parameter
- 6 19 26 Operation hydraulic function requiring acknowledgement has been - Check/change "Hydraulic function requiring
combination
set acknowledgement"
Invalid parameter At least 2 of the parameters "Key-1" to "Key-6" have the - Check/change parameters "Key-1" to "Key-6"
- 6 19 27 Operation
combination same parameter value NOT EQUAL TO 0
Value of parameter ("Travel lighting" = Bit 2 OR 3 OR 4 -Check/change "Travel lighting" parameter;

Invalid parameter
- 6 19 28 Operation OR 5) AND value of parameter "Auxiliary spotlights" not - Check/change "Auxiliary spotlights" parameter;
combination
equal to 0
Status
The following bits are set simultaneously in the "Auxiliary - Check/change "Auxiliary spotlights" parameter;
spotlights" parameter:
Invalid parameter
- 6 19 29 Operation -Bit 5 AND 6 OR
combination
-Bit 5 AND 7 OR
-Bit 6 AND 7;
The following bits are set simultaneously in the "Front - Check/change "Front spotlights" parameter;
Invalid parameter
combination
-Bit 5 AND 7 OR
-Bit 6 AND 7;
The following bits are set simultaneously in the "Rear -Check/change "Rear spotlights" parameter;
Invalid parameter
combination
-Bit 5 AND 7 OR
-Bit 6 AND 7;
- Check/change "Max travel speed lift height-2"

"Max travel speed lift height-2" parameter value is
Invalid parameter parameter;
- 6 19 32 Operation greater than "Max travel speed lift height-1" parameter
combination - Check/change "Max travel speed lift height-1"
value
parameter;
Invalid parameter Bits 7 AND 13 are set simultaneously in the "OUST -Check "CUST output 1" parameter, adjust if
- 6 19 33 Operation
combination Output 1" parameter necessary;
Invalid parameter Bits 7 AND 13 are set simultaneously in the "OUST - Check "CUST output 2" parameter, adjust if
- 6 19 34 Operation
Invalid parameter Bits 7 AND 13 are set simultaneously in the "OUST - Check "CUST output 3" parameter, adjust if
- 6 19 35 Operation
Status
- Check the following parameters and adjust if

If the Tilt-Control parameter > 0 and if for the "Single
necessary:
System start operation" parameter value the Lift or Tilt bit is activated,
Invalid parameter - Single operation,
- 6 19 36 Self test or if the Tilt-Control parameter > 0 and for the "Hydraulic
combination - Hydraulic functions requiring
Operation function requiring acknowledgement" parameter the Lift,
acknowledgement
Fwd tilt or Rev. tilt bit is activated
- Tilt-Control
Invalid parameter The wrong voltage class is set in the "Battery voltage" - Check the "battery voltage" parameter and
- 6 19 37 Operation
combination parameter adjust if necessary;
In the "Cust-Softkeysymbol 1" parameter a setting not - Check the following parameters and adjust if
equal to 0 has been entered and this setting is not the necessary:
same as the CUST-Softkeysymbol 1 number from the - Cust-Softkeysymbol 1,
display OR - Cust-Softkeysymbol 2,
In the "Cust-Softkeysymbol 2" parameter a setting not - Cust-Softkeysymbol 3,
Invalid parameter equal to 0 has been entered and this setting is not the
- 6 19 38 Operation
combination same as the CUST-Softkeysymbol 2 number from the
display OR
In the "Cust-Softkeysymbol 3" parameter a setting not
equal to 0 has been entered and this setting is not the
same as the CUST-Softkeysymbol 3 number from the
display OR
In the "Cust-lcon 1" parameter a setting not equal to 0 - Check the following parameters and adjust if
has been entered and this setting is not the same as the necessary:
CUST-lcon symbol 1 number from the display OR - Cust-lcon 1,
In the "Cust-lcon 2" parameter a setting not equal to 0 - Cust-lcon 2,
Invalid parameter
- 6 19 39 Operation has been entered and this setting is not the same as the - Cust-lcon 3,
combination
CUST-lcon symbol 2 number from the display OR
In the "Cust-lcon 3" parameter a setting not equal to 0
has been entered and this setting is not the same as the
CUST-lcon symbol 3 number from the display OR
Status
- Check "Control unit" parameter and change if

System start Invalid parameter necessary;
- 6 19 40 • "Control unit" parameter does not match "Steering
Operation combination - Check "Steering characteristics" parameter and
characteristics" parameter
change if necessary;

- 6 19 41 • "Control unit" parameter does not match "Body
Operation combination - Check "Body protection switch" parameter and
protection switch" parameter
change if necessary;

- 6 19 42 • "Control unit" parameter does not match "Platform /
Operation combination - Check "Platform / restraint system" parameter
restraint system" parameter
and change if necessary;
Too many events indicated this message is issued if more than 64 events are issued - Minimise events (<64)
- 6 20 1 Operation
at the same time at the same time - Replace controller
Bootloader - Replace controller;
- 6 21 1 RAM checksum invalid RAM checksum invalid (internal error)
Operation

- 6 22 1 Operation Software error - Inquire about software update;
(stack limit infringement (overrun))

- 6 22 2 Operation Software error - Inquire about software update;
(stack limit infringement (underflow))
- Reset event via emergency stop reset;

- Replace controller
- 6 22 3 Operation HEAP memory used up dynamic data memory fully used up
- If this error occurs permanently contact
Technical Support;
Status

Unknown fatal processor - Replace controller
- 6 22 4 Operation Controller program detects unknown error (EMCY)
error - If this error occurs permanently contact
Technical Support;
Misc. error as the function is being carried
out.
Brake force governor: misc. An unknown error occurred on the brake force governor
- 6 23 1 Operation
error The activation limit is 100 msec.
-Ci¬ eck function and contact Technical Support if
necessary;
-> Misc. error as the function is being carried

out.
Left hand support An unknown error occurred on the left support
- 6 23 7 Operation
mushroom: misc. error mushroom. The activation limit is 100 msec.
necessary;
-> Misc. error as the function is being carried

out.
Right hand support An unknown error occurred on the right support
- 6 23 9 Operation
mushroom: misc. error mushroom. The activation limit is 100 msec.
necessary;
"Discharge indictor" data
- 6 24 1 Undefined OxOOAO - OxOOAF - Replace controller;
"Mac address battery Checksum invalid in EEPROM area: - Switch the truck off and on again;
- 6 25 1 Undefined controller" data EEPROM OxOOBO - OxOOBF - Replace controller;
range invalid For details see EEPROM layout document
"Mac address charger" data
- 6 25 2 Undefined OxOOCO - OxOOCF - Replace controller;
Status
Code for this truck is invalid. The sub index shows the -Wrong release code entered.
Code number position "sub
- 6 26 O CD CO System start position number of the wrong code. The activation limit is - Check the release code via JUDIT and adjust if
index" is incorrect.
20 msec. necessary.
The truck parameter setting The parameter settings in the truck do not match the - Safety data records in the two safe systems do
- 6 27 1 System start does not match the safety approved parameters in the safety data record. The not match.
data record activation limit is 20 msec. - Load safety data records via JUDIT.
Entry in logbook if time is The logbook records the time and date settings before The event message is used to document a
- 6 28 1 Operation
changed - old time the change. The triggering threshold is 20 ms. change in time. No action required.
Entry in logbook when time The logbook records the time and date settings in the The event message is used to document a
- 6 28 2 Operation
is adjusted - new time truck. The triggering threshold is 20 ms. change in time. No action required.
- Check the parameter setting and adjust if

System start Parameter does not match A parameter was set that does not match the wire
- 6 29 1
Operation the wire harness encoding harness encoding (digital input status)
necessary;
- Check signal on encoding input;
"Personal protection switch - Set "personal protection switch function"

"Personal protection switch function" on rider truck not
function" parameter does parameter 0x218A to "brake switch until
- 6 29 2 Operation set as brake switch, with no further option to operate as
not match the wire harness stationary" or "brake switch while personal
service brake. Truck type is encoded via wire harness.
encoding protection switch applied";

necessary;
System start Parameter does not match A parameter was set that does not match the wire
- 6 29 3 - Check signal on encoding input;
Operation the wire harness encoding harness encoding (digital output status)
- Check if coupling unit connection for truck type
is not the same as "ERD series 2 basic model";

System start Parameter does not match A parameter was set that does not match the version of
- 6 29 4 necessary;
Operation the available buttons the lateral pedestrian mode installed.
- Check signal at "Lateral pedestrian mode" input;
"Truck model" parameter - Check the parameter setting and adjust if
System start does not match the inputs The second deadman switch was activated on a truck necessary;
- 6 29 5
Operation "Deadman switch 1" and model with an operator platform. - Check signal at "Deadman switch 2" input;
"Deadman switch 2"
Status
Brake force governor: Analog sensor not taught. Commissioning not - Carry out teach-in via JUDIT;
Potentiometer not taught performed. The activation limit is 100 msec.
Traverse sensor: Analog sensor not taught. Commissioning not - Carry out teach-in via JUDIT;
Rotate sensor: Analog sensor not taught. Commissioning not - Carry out teach-in via JUDIT;
Left hand support - Carry out teach-in via JUDIT;

Analog sensor not taught. Commissioning not
- 6 30 7 System start mushroom: Potentiometer
performed. The activation limit is 100 msec.
not taught
Right hand support - Carry out teach-in via JUDIT;

- 6 30 9 System start mushroom: Potentiometer
not taught
Steering actual value - Carry out teach-in via JUDIT;

- 6 30 11 System start sensor: Potentiometer not
taught
Steering setpoint device: Analog sensor not taught. Commissioning not - Carry out teach-in via JUDIT;
Steering setpoint device - Carry out teach-in via JUDIT;

- 6 30 15 System start optional: Potentiometer not
taught, carry out teach-in
Hydraulic setpoint device: Analog sensor not taught. Commissioning not - Carry out teach-in via JUDIT;
Travel setpoint device: Analog sensor not taught. Commissioning not - Carry out teach-in via JUDIT;
Hydraulic setpoint device - Carry out teach-in via JUDIT;

Status
Travel setpoint device - Carry out teach-in via JUDIT;

Accelerator pedal setpoint - Carry out teach-in via JUDIT;

device optional: Analog sensor not taught. Commissioning not
Potentiometer not taught, performed. The activation limit is 100 msec.
carry out teach-in
Brake pedal setpoint device - Carry out teach-in via JUDIT;

Pedestrian right travel - Carry out teach-in via JUDIT;

setpoint device: Analog sensor not taught. Commissioning not
carry out teach-in
Pedestrian left travel - Carry out teach-in via JUDIT;

carry out teach-in
Pedestrian right travel - Carry out teach-in via JUDIT;

carry out teach-in
Pedestrian left travel - Carry out teach-in via JUDIT;

carry out teach-in
Mechanical stops of brake force governor not set. - Carry out teach-in via JUDIT;
Brake force governor: Brake
- 6 31 1 System start Commissioning not performed. The activation limit is
geometry not taught
100 msec.
Status
Deceleration levels of brake force governor not set. - Carry out teach-in via JUDIT;
Brake force governor:
Deceleration levels not set
100 msec.
Mechanical stops of "traverse" sensor not set. - Carry out teach-in via JUDIT;
Traverse sensor: Geometry
not taught
100 msec.
Position of sideshifter index switch not set. - Carry out teach-in via JUDIT;
Traverse sensor: index
switch not taught
100 msec.
Mechanical stops of "rotate" sensor not set. - Carry out teach-in via JUDIT;
Rotate sensor: Geometry
not taught,
100 msec.
Left hand support Mechanical stops of left support mushroom not set. - Carry out teach-in via JUDIT;
- 6 31 7 System start mushroom: Geometry not Commissioning not performed. The activation limit is
taught 100 msec.
Right hand support Mechanical stops of right support mushroom not set. - Carry out teach-in via JUDIT;
- 6 31 9 System start mushroom: Geometry not Commissioning not performed. The activation limit is
taught 100 msec.
Mechanical stops of proportional lift not set. - Carry out teach-in via JUDIT;
Proportional lift: Geometry
not taught
100 msec.
Free lift: Geometry not Mechanical stops of free lift not set. Commissioning not - Carry out teach-in via JUDIT;
taught performed. The activation limit is 100 msec.
Aux. lift: Geometry not Mechanical stops of auxiliary lift not set. Commissioning - Carry out teach-in via JUDIT;
taught not performed. The activation limit is 100 msec.
Mechanical stops of fork positioner not set. - Carry out teach-in via JUDIT;
Fork positioner: Geometry
not taught
100 msec.
tUNGHEINRICH Event Messages 03.15 146 (gb)
Status
Mechanical stops of optional fork positioner not set. - Carry out teach-in via JUDIT;
Optional fork positioner:
Geometry not taught
100 msec.
Sideshifter: Geometry not Mechanical stops of sideshifter not set. Commissioning - Carry out teach-in via JUDIT;
taught not performed. The activation limit is 100 msec.
Mechanical stops of left current collector not set. - Carry out teach-in via JUDIT;
Left current collector:
Geometry not taught
100 msec.
Mechanical stops of right current collector not set. - Carry out teach-in via JUDIT;
Right current collector:
Geometry not taught
100 msec.
Brake force governor: Switched-on position deviates from switched-off position - Carry out a reference run:
- 6 33 1 System start deviation from switched-off by more than 20° (angle sensor). The activation limit is - Re-teach the brake force governor via Judit;
position 100 msec.
Switched-on position deviates from switched-off position - Carry out a reference run:
Traverse sensor: deviation
- 6 33 3 System start by more than 20° (angle sensor). The activation limit is - Re-teach the traverse sensor via JUDIT;
from switched-off position
100 msec.
Switched-on position deviates from switched-off position - Carry out a reference run:
Rotate sensor: deviation
- 6 33 5 System start by more than 20° (angle sensor). The activation limit is - Re-teach the rotate sensor via JUDIT;
from switched-off position
100 msec.
Left hand support Switched-on position deviates from switched-off position - Carry out a reference run:
- 6 33 7 System start mushroom: deviation from by more than 20° (angle sensor). The activation limit is - Re-teach the left support mushroom via JUDIT;
switched-off position 100 msec.
Right hand support Switched-on position deviates from switched-off position - Carry out a reference run:
- 6 33 9 System start mushroom: deviation from by more than 20° (angle sensor). The activation limit is - Re-teach the right support mushroom via JUDIT;
switched-off position 100 msec.
Rotate: below minimum The set position has been abandoned. The activation - Carry out teach-in via JUDIT;
- 6 35 5 Operation
position limit is 100 msec.
Status
Rotate: above maximum The set position has been abandoned. The activation - Carry out teach-in via JUDIT;
- 6 35 6 Operation
Proportional lift: below The set position has been abandoned. The activation - Carry out teach-in via JUDIT;
- 6 35 31 Operation
minimum position limit is 100 msec.
Proportional lift: above The set position has been abandoned. The activation - Carry out teach-in via JUDIT;
- 6 35 32 Operation
maximum position limit is 100 msec.
Free lift: below minimum The set position has been abandoned. The activation - Carry out teach-in via JUDIT;
- 6 35 33 Operation
Free lift: above maximum The set position has been abandoned. The activation - Carry out teach-in via JUDIT;
- 6 35 34 Operation
Aux. lift: below minimum The set position has been abandoned. The activation - Carry out teach-in via JUDIT;
- 6 35 35 Operation
Aux. lift: above maximum The set position has been abandoned. The activation - Carry out teach-in via JUDIT;
- 6 35 36 Operation

For 300 ms one or more pedestrian mode setpoint
Parameter does not match necessary;
- 6 36 1 Operation devices are detected which do not match the expansion
the buttons connected - Check wire connections from existing buttons to
stage set for the respective option.
controller;
— 6 37 1 Operation Safety functions modified Event issued by changing the service safety parameter - Switch truck off and on again;
Tilt: Geometry not taught, Mechanical stops of tilt sensor not set. The activation - Teach the tilt sensor with JUDIT;
carry out commissioning point is 100 msec.
Data needs to be stored - Store backup with Judit;

Backup:
(STORE) from the controller
- 6 40 1 System start Controller reports the need to store its data in the backup
to the backup medium
medium
(BUD)
Status
Data needs to be restored - Restore backup with Judit;

Backup:
(RESTORE) from the
- 6 41 1 System start Controller reports the need to restore its data from the
backup medium (BUD) to
backup medium
the controller
Write protection (crossover Backup: -Temporarily restore backup with Judit;

- 6 42 1 System start test) on controller and Controller reports a deviation between the set write - Permanently restore backup with Judit;
backup medium (BUD) protection ID of controller and backup medium
Backup: - Check backup dongle (presence);

Error from checking /
- 6 43 1 System start An error is either detected or occurs during checking / - Save backup with JUDIT;
processing
processing of the backup
Hydraulic lever capacitive Hydraulic lever capacitive switch not taught. The - Carry out teach-in via JUDIT;
switch not taught activation limit is 20 msec.
Travel lever capacitive Travel lever capacitive switch not taught. The activation - Carry out teach-in via JUDIT;
switch not taught limit is 20 msec.
Minimum requirements for The software version for this component is too old for the - Update the operating system of the component
- 6 45 1...n
software version not met. truck version. The activation limit is 20 msec. to the required version.
Minimum requirements for The software version for this component is too old for the - Update the operating system of the component
- 6 45 65-68
software version not met. truck version. The activation limit is 20 msec. to the required version.
Information message: truck - Update the operating system of the component

- 6 46 1 The truck software has been changed
software changed to the required version.
"Steer table" data record

- 6 51 1 System start This event message is not currently used.
invalid
Status

"Teach in steer angle actual Data record "Steering angle teach-in actual value" invalid
- 6 52 1 System start - Jack up the truck so that the steered wheel is
value" data record invalid No validity ID in the EEprom

"Teach in steer angle actual Data record "Steering angle teach-in actual value" invalid
value" data record invalid Different values in EEprom
Steering actual value - Check sensor wiring and test operation;

Steering actual value sensor:
- 6 52 3 sensor: captured range too - Replace sensor;
The captured range for the sensor teach-in is too small
small
Steering actual value - Check sensor wiring and test operation;

sensor: No value change Steering actual value sensor: No value change during - Replace sensor;
- 6 52 4
during Teach-in despite Teach-in despite pulse controller turning
pulse controller turning
Steer referencing: Overall - Check sensor wiring and test operation;

- 6 52 5 Steer referencing: Overall timeout of 20 sec. exceeded
timeout of 20 sec. exceeded - Replace sensor;
Steering Teach-in: Overall - Check sensor wiring and test operation;
- 6 52 6 Steering Teach-in: Overall timeout of 20 sec. exceeded
timeout of 20 sec. exceeded - Replace sensor;
Actual-steering-angle - Re-teach sensor and steering;
Actual-steering-angle sensors: Calibration timeout of 30s
- 6 52 7 Operation sensors: Calibration timeout - Replace sensor;
exceeded
of 30s exceeded
Status

"Teach in steer angle Data record "Steering angle teach-in setpoint" invalid
setpoint" data record invalid No validity ID in the EEprom

"Teach in steer angle Data record "Steering angle teach-in setpoint" invalid
setpoint" data record invalid Different values in EEprom

Data record "Steering angle teach-in setpoint" invalid
"Teach in steer angle Teach values deleted.
- 6 53 3 Operation - Jack up the truck so that the steered wheel is
setpoint" data record invalid Automatically calculated zero position does not match
the taught zero position.
Event number unknown Event message not known. - Switch the truck off and on again;
- 6 54 1 Operation
(implausible) Event number received unknown (UART) - Inquire about software update;
Event number unknown Event message not known. - Switch the truck off and on again;
- 6 54 2 Operation
(implausible) Own event number implausible (UART) - Inquire about software update;
Event number unknown Event message not known to control processor. Event - Switch the truck off and on again;
- 6 54 3 Operation
(implausible) response received is implausible (UART) - Inquire about software update;
Status

Stack overrun (lower limit)
-Check interference (radio, static charge);
- 6 55 1 Undefined Software error Stack lower and upper limits protected and monitored
- Check CAN-Bus;
against infringement by test sample.

Stack overrun (upper limit)
-Check interference (radio, static charge);
- 6 55 2 Undefined Software error Stack lower and upper limits protected and monitored
- Check CAN-Bus;
against infringement by test sample.
Analogue/digital channel conversion; - Switch the truck off and on again;
Monitoring of cyclical
- 6 56 1 Operation If no analogue readings are received within a certain - Inquire about software update;
functions activated
time, the event message is generated. - Replace signal-issuing controller;

Monitoring of cyclical Safety-critical functions not performed during system
- 6 56 2 System start - Inquire about software update;
functions activated start

Monitoring of cyclical Safety-critical functions not performed during the
- 6 56 3 Self test - Inquire about software update;
functions activated (initialisation) self-test (time monitoring 5 s)
Safety-critical functions not performed during operation. - Switch the truck off and on again;
Monitoring of cyclical
- 6 56 4 Operation If not all routines are performed once within 20 ms, the - Inquire about software update;
functions activated
event message is triggered. - Replace signal-issuing controller;
The cycle time lay between 20 msec and 22 msec. - Reset event via emergency stop reset;
Cycle time 20 msec. The activation limit is 20 msec. The event message is - If the error occurs permanently contact
- 6 56 5 Operation
exceeded retentive and can only be reset by an Emergency Stop Technical Support;
reset.
The cycle time lay between 22 msec and 24 msec. - Reset event via emergency stop reset;
Cycle time 22 msec. The activation limit is 22 msec. The event message is - If the error occurs permanently contact
- 6 56 6 Operation
exceeded retentive and can only be reset by an Emergency Stop Technical Support;
reset.
Status
The cycle time was above 24 msec. The activation limit - Reset event via emergency stop reset;
Cycle time 24 msec.
- 6 56 7 Operation is 24 msec. The event message is retentive and can only - If the error occurs permanently contact
exceeded
be reset by an Emergency Stop reset. Technical Support;

Timeout for 20ms-cyclical The cycle time between CANopen SYNC and
- 6 56 8 Operation processing synchronicity processing the operating system functionality was more
- If this error occurs permanently contact
with CANopen SYNC than 2 msec.
Technical Support;

The cycle when the operating system is processing must - Replace controller
- 6 56 9 Operation Cycle time 1ms exceeded
be run fewer than 18 times within 20msec. - If this error occurs permanently contact
Technical Support;

Control and monitoring - Set default values for Teach parameters.
During initialisation the parameters between the control
- 6 57 1 Self test processor parameters not - Jack up the truck so that the steered wheel is
and monitoring processors are different.
the same clear of the ground. Carry out teach-in; do not

Self test Steer table in monitoring processor invalid. Permissible
- 6 58 1 Steer table invalid - Inquire about software update;
Operation limits exceeded.
The steering setpoint device type parameter does - Set parameters to the correct setpoint device;
- 6 59 1 Self test Setpoint device invalid not match the steering setpoint device type that is
connected.
Assigned warehouse area - Correct the warehouse area parameter settings

An invalid warehouse area has been configured.
- 6 60 1 Operation is less than 0 or greater via JUDIT;
than 31
Status
Safety clearance set between the rotating and the -Adjust the traverse/rotate movement via JUDIT;
sideshifting load and rack was not observed. The
Traverse/rotate movement:
traverse-rotate operation was cancelled. Monitoring is
- 6 62 1 Operation safety distance too short,
necessary if the load is rotated and swivelled in the
risk of collision with rack
narrow aisle to prevent it colliding with the racking. The
triggering threshold is 20 ms.
Brake force governor: - Check the mechanical freedom of movement;

Analog sensor nominal position deviates by more than
- 6 63 1 Operation difference between rated
20°. The activation limit is 1000 msec.
and actual values too great
Left hand support - Check the mechanical freedom of movement;

mushroom: difference Analog sensor nominal position deviates by more than
- 6 63 7 Operation
between rated and actual 20°. The activation limit is 1000 msec.
values too great
Right hand support - Check the mechanical freedom of movement;

mushroom: difference Analog sensor nominal position deviates by more than
- 6 63 9 Operation
between rated and actual 20°. The activation limit is 1000 msec.
values too great
Wire guidance aisle travel, - Check the guide wire routing:

Wire guidance aisle travel, sensor has lost wire signal.
- 6 70 12 Operation load direction sensor has -Align the truck with the guide wire;
lost wire signal

- 6 70 13 Operation cornering sensor has lost -Align the truck with the guide wire;
wire signal

- 6 70 14 Operation drive direction sensor has -Align the truck with the guide wire;
lost wire signal

- 6 70 44 Operation load direction sensor has -Align the truck with the guide wire;
lost wire signal
Status

- 6 70 45 Operation cornering sensor has lost -Align the truck with the guide wire;
wire signal

- 6 70 46 Operation drive direction sensor has -Align the truck with the guide wire;
lost wire signal
- Flash software again;

Internal software versions MULTI-PILOT:
- 6 71 1 System start - Inquire about software update;
invalid Internal software versions invalid
- Check pilot;
An unknown or faulty reading for the pilot type is read by
- 6 71 2 System start Pilot type incompatible - Check for software update;
the master from the EEPROM of the pilot.
Wire guidance frequency change: Number of - Check parameter set selection
Number of frequencies
- 6 74 1 Operation frequencies exceeds range used. The activation limit is
exceeds range used
20 msec.
Wire guidance frequency change: Number of - Check parameter set selection

Number of frequencies
- 6 74 2 Operation frequencies exceeds permissible range. The activation
exceeds permissible range
limit is 20 msec.
Wire guidance frequency change: Wire guidance - Check sensor frequency setting;
Wire guidance sensors set
- 6 74 3 Operation sensors are set to different frequencies. The activation
to different frequencies
limit is 20 msec.
Collector: "Rack area" - Check current collector parameter;

Collector: "Rack area" parameter set shorter than
- 6 75 1 Operation parameter set shorter than
warehouse area. The activation limit is 20 msec.
warehouse area
Collector: "Entry stop - Check current collector parameter;

Collector: "Entry stop distance to rack area" parameter
- 6 75 2 Operation distance to rack area"
implausible. The activation limit is 20 msec.
parameter implausible
Status
Collector: "Entry inch - Check current collector parameter;

Collector: "Entry inch distance to rack area" parameter
- 6 75 3 Operation distance to rack area"
implausible. The activation point is 20 msec.
parameter implausible.
Guidance change wire / rail: - Check aisle recognition sensor system;

Guidance change wire / rail: wire guidance mode is
- 6 76 1 Operation wire guidance mode is - Check trip point settings;
incorrect, rail guidance expected
incorrect
Guidance change wire / rail: - Check aisle recognition sensor system;

Guidance change wire / rail: rail guidance mode is
- 6 76 2 Operation rail guidance mode is - Check trip point settings;
incorrect, wire guidance expected
incorrect
ISM: "Parameter 5" value > ISM: - Set parameter 5 to less than parameter 6;
- 6 81 1 Undefined
"Parameter 6" Set standby timeout to be lower than truck timeout.
ISM: - Differential value of parameter 11 is less than

ISM: Parameters invalid Set limit 1 (parameter #11) to be greater than the the differential values of the various levels of
- 6 81 2 Undefined
(difference between 2 limits) smallest difference between 2 switch limits parameters 12-17
(parameters #12-17).

- 6 81 3 Undefined

- 6 81 4 Undefined
ISM: -Set parameters 12-17 to be ascending;

ISM: Parameters 12-17 not
- 6 81 5 Undefined Switch limit order
ascending
(parameters #12-17) are not ascending.
ISM: - Set parameters 21-26 to be ascending;

ascending
Status

ascending

ascending

ascending
- Check and, if necessary, reduce the telegram

Overflow of the serial- The internal input buffer of the radio-data-
frequency at the counterpart station (e.g.
- 6 87 1 Operation interface telegram buffer parametrisation function 4 (internal buffer) for the COM1
logistics interface)
COM1 serial interface has been full for more than 2 seconds.
- Switch the truck controller off and on



frequency at the counterpart station (PLC
interface)
COM4 PLC interface has been full for more than 2 seconds.
Status
- Compare the telegram parametrisation with the

Data received after the Further characters were received over the CAN bus after telegram received (above all, the termination
- 6 87 11 Operation termination character the parametrised termination character (COM1) of the character)
(COM1) last telegram - Correct the interface



Data after end symbol Further characters were received over the CAN bus after telegram received (above all, the termination
- 6 87 14 Operation received (COM4, machine the parametrised termination character (COM4) of the character)
interface RASC) last telegram - Correct the interface
Note: - Explain the "long-life mode" option to the
Long-life mode is an option that is used for optimum customer;
battery charging / battery saving. The battery can be - Increase the discharge level set in the
charged when the battery's set discharge level has been parameter (0x256C). Talk to the customer
reached. The discharge level is based on the battery's before changing this parameter;
Long-life mode/ saver mode capacity.
- 6 88 1 Undefined
activated Requirement:
- Battery is not charged despite being connected to the
charger;
Cause:
The current battery capacity is above the discharge level
set in the parameter (0x256C).
Status
EEPROM data implausible Tiller head: - Replace tiller head;

- 6 89 1...n Undefined
(non-critical) One or more data records cannot be read (non-critical).
EEPROM data implausible Tiller head: - Replace tiller head;

(non-critical) One or more data records cannot be read (non-critical).

- 6 91 1 Undefined RAM data error
RAM test failed at time of operation.

- 6 92 1 Undefined Critical variable damaged
Critical variable is implausible.
RAM checksum invalid Tiller head: - Replace tiller head;

(critical) RAM parameter records saved via CRC.
Specific battery management - Check battery parameters against battery data

- 6 94 1 System start Battery parameters invalid Battery parameters (type, rated capacity, charge factor, plate and adjust as required;
serial number, ...) are invalid or not set - Replace battery controller;
RAM checksum invalid Tiller head: - Replace tiller head;

(non-critical) RAM parameter records saved via CRC (checksum).
- Set the correct parameter for the battery as

required. Intended for information to establish by
Characteristic curve If the corresponding object is now described with
- 6 96 1 Undefined whom or when a characteristic curve was
parameters reset a different value than before
adjusted so that the battery was incorrectly
charged;
- Set the correct value on the mechanical

characteristic selector OR better still, set it to 0
Mechanical characteristic and adjust via software; Intended for information
- 6 97 1 Undefined If the mechanical characteristic selector is adjusted
selector applied to establish by whom or when a characteristic
curve was adjusted so that the battery was
incorrectly charged;
Status
Information message: The debug mode is now activated. The truck must only -> Event message should only appear in
development test mode.
- 6 98 1 System start Debug mode activated be operated by test personnel. The activation limit is
in truck software 20 msec.
-Ift his error occurs contact Technical Support;
Information message: An invalid program condition was detected. Detailed -> Event message should only appear in
- 6 99 1 Self test Programming error in truck information is shown in the log book. The triggering
software threshold is 20 ms.
Event message should only appear in
An invalid program condition was detected. Detailed
Lift request although development test mode.
- 6 99 2 Self test information is shown in the log book. The triggering
nominal lift height exceeded
threshold is 20 ms.
-> Event message should only appear in

An invalid program condition was detected. Detailed
Lower request although development test mode.
- 6 99 3 Self test information is shown in the log book. The triggering
below nominal lift height
threshold is 20 ms.
Event message should only appear in
Tolerance field violated An invalid program condition was detected. Detailed development test mode.
- 6 99 4 Self test although lift height is information is shown in the log book. The triggering
positioned threshold is 20 ms.
A truck function has requested truck deceleration - Check truck controller cut-out function;
Undefined Stop monitoring: Travel via the mechanical brakes. However the required
deceleration was not introduced within 1 second.
- 7 01 1
A truck function has requested a main lift hydraulic stop. - Check truck controller cut-out function;
Undefined Stop monitoring: Main Lift However the main lift cut-out was not introduced within
0.5 seconds.
A truck function has requested an aux. lift hydraulic stop. - Check truck controller cut-out function;
- 7 01 2 Undefined Stop monitoring: Aux. lift However the aux. lift cut-out was not introduced within
0.5 seconds.
Status
A truck function has requested a sideshift hydraulic stop. - Check truck controller cut-out function;
- 7 01 3 Undefined Stop monitoring: Sideshift However the sideshift cut-out was not introduced within
0.5 seconds.
A truck function has requested a rotary movement - Check truck controller cut-out function;
- 7 01 4 Undefined Stop monitoring: Rotate hydraulic stop. However the rotary movement cut-out
was not introduced within 0.5 seconds.
- Check slack chain switch status;

Stop monitoring: Lift chain The slack chain switch status is implausible.
- 7 01 5 Undefined - Check slack chain switch and replace if
switching status The activation limit is 1 second.
necessary;
- Check slack chain switch status;

Stop monitoring: Lift chain The slack chain switches report chain not taut.
- 7 01 6 Undefined - Check slack chain switch and replace if
not taut The activation limit is 1 second.
necessary;
Stop monitoring: emergency - Check emergency stop circuit wiring

Emergency stop circuit power-up test: not all feedback
- 7 01 7 Undefined stop circuit all feedback
messages received within 200 msec.
messages
Stop monitoring: Emergency - Check emergency stop circuit wiring

Emergency stop circuit power-up test: feedback
- 7 01 8 Undefined stop circuit feedback
message 3 not received within 200 msec.
messages 3

messages 6

messages 2

messages 5
Status
Stop monitoring: power Emergency stop circuit power-up test: 24 volt power not - Check emergency stop circuit wiring
- 7 01 12 Undefined
emergency stop circuit received within 200 msec.
Stop monitoring: load circuit Emergency stop circuit power-up test: load circuit - Check emergency stop circuit wiring
- 7 01 13 Undefined
emergency stop circuit release not received within 200 msec.
Stop monitoring: power and - Check emergency stop circuit wiring

Emergency stop circuit power-up test: 24 volt power and
- 7 01 14 Undefined load circuit emergency stop
load circuit release not received within 3 seconds
circuit
Stop monitoring: two- Emergency stop circuit power-up test: the signals of - Check emergency stop circuit wiring
- 7 01 15 Undefined channel signal emergency jxpSafeCI and jxpSafe C2 are different for more than
stop circuit 20 msec.

Stop monitoring: steer angle The steer actual value does not follow the steer setpoint, - Check sensor;
- 7 01 16 Undefined nominal/actual value or rather there is a jump in the actual/nominal value. - Switch the truck off and on again;
monitoring The activation limit is 20 msec. - Inquire about software update;
- Check sensor;
Stop monitoring: steer angle The actual value of the steer angle is not ok. The
- 7 01 17 Undefined - Switch the truck off and on again;
sensor system activation limit is 60 msec.
- Check the guide wire routing:

-Align the truck with the guide wire;
Stop monitoring: Wire Aisle travel wire guidance, monitoring limit exceeded.
- 7 01 18 Undefined - Check distance signals for systems A and B, if
guidance steer angle The activation limit is 20 msec.
there is a difference re-calibrate and teach-in the
sensor;
Status

Stop monitoring: Wire - Check sensor;
Aisle travel wire guidance, steering actual value not ok.
- 7 01 19 Undefined guidance steer angle sensor - Switch the truck off and on again;
system - Inquire about software update;
- Check sensor;
Stop monitoring: Wire Aisle travel wire guidance, travel speed not ok.
guidance steer angle speed The activation limit is 20 msec.
- Check the guide wire routing:

-Align the truck with the guide wire;
- Check the truck's behaviour in several lanes, if
Stop monitoring: Wire Aisle travel wire guidance, monitoring limit exceeded.
- 7 01 21 Undefined the deviation is the same in all lanes carry out
guidance distance The activation limit is 20 msec.
wire guidance teach-in, if there is a deviation in
a few lanes reduce the speed or clean the floor
surface.

Stop monitoring: Wire - Check sensor;
Aisle travel wire guidance, steering actual value not ok.
- 7 01 22 Undefined guidance distance sensor - Switch the truck off and on again;
system - Inquire about software update;

- Check sensor;
Stop monitoring: Wire Aisle travel wire guidance, travel speed not ok.
guidance distance speed The activation limit is 20 msec.
Status

Steering referencing in the - Check sensor;
The 0° flank was not detected in the Safe computer
- 7 01 24 Safe computer has not - Switch truck off and on again;
within +1-2°
worked - Inquire about software update;
A truck function has requested truck deceleration via the - Check truck controller cut-out function;
Undefined Endpoint monitoring: Travel inversion brake. However the required deceleration was - Check the brake ramp settings;
not introduced within 1 second.
- 7 02 1
A truck function has requested the termination of - Check truck controller cut-out function;
Endpoint monitoring: Main the main lift operation via the setpoint ramp. However - Check the brake ramp settings;
Undefined
Lift the termination of the main lift operation was not
introduced within 1 second.
the aux. lift operation via the setpoint ramp. However - Check the brake ramp settings;
- 7 02 2 Undefined Endpoint monitoring: Aux. lift
the termination of the aux. lift operation was not
Endpoint monitoring: the sideshift operation via the setpoint ramp. However - Check the brake ramp settings;
- 7 02 3 Undefined
Sideshift the termination of the sideshift operation was not
A truck function has requested the termination of the - Check truck controller cut-out function;
rotary movement via the setpoint ramp. However the - Check the brake ramp settings;
- 7 02 4 Undefined Endpoint monitoring: Rotate
termination of the rotary movement was not introduced
within 1 second.
- Data pack not fully received - Replace controller

Internal communication of - Data pack received indicates wrong number of data - If this error occurs permanently contact
- 7 02 20 Undefined
safety computer interrupted - Consecutive number faulty in data pack received Technical Support;
- Checksum of data pack received faulty
Status
Safety computer data check Faulty data bytes of sub-computer A/B detected within
- 7 02 21 Undefined - If this error occurs permanently contact
interrupted limit time (xxmsec)
Technical Support;
- 7 02 22 Undefined SYNC interrupted Faulty SYNC detected within limit time (xxmsec) - If this error occurs permanently contact
Technical Support;
Faulty CANopen node ID detected within limit time
- 7 02 23 Undefined Slave identity interrupted - If this error occurs permanently contact
(xxmsec)
Technical Support;
- Input image not fully received - Replace controller

-Checksum (TPDO Checksum) according to - If this error occurs permanently contact
- 7 02 24 Undefined Data backup interrupted data backup process faulty Technical Support;
- Consecutive number (TPDO Count) according to data
backup process faulty
Emergency stop by safety - Replace controller

Faulty feedback signals of 24 volt power supply detected
- 7 02 30 Undefined computer 24V power supply - If this error occurs permanently contact
within limit time (xxmsec)
interrupted Technical Support;
Emergency stop by safety - Replace controller

Faulty feedback signals of driver power supply detected
- 7 02 31 Undefined computer slave driver supply - If this error occurs permanently contact
within limit time (xxmsec)
interrupted Technical Support;
Steering emergency stop
- 7 02 32 Undefined Fault in emergency stop circuit of electric steering - If this error occurs permanently contact
circuit faulty
Technical Support;

"Battery latch" safety block Faulty battery latch sensor signals of sub-computer A/B - Check the sensor system attached
- 7 02 40 Undefined
reports fault detected within limit time (xxmsec) - Check outputs / inputs with JUDIT;
Status

"Control pilot" safety block Faulty control pilot signals of sub-computer A/B detected - Check the sensor system attached
- 7 02 41 Undefined
reports fault within limit time (xxmsec) - Check outputs / inputs with JUDIT;
- Replace control;

Faulty total signal or channel A/B sensor signal of - Check the sensor system attached
"Dual pedal" safety block
- 7 02 42 Undefined accelerator pedals (dual pedal) of sub-computer A/B - Check outputs / inputs with JUDIT;
reports fault
detected within limit time (xxmsec) - Replace accelerator pedal;

Faulty total signal or channel A/B sensor signal of - Check the sensor system attached
"Single pedal" safety block
- 7 02 43 Undefined accelerator pedal (single pedal) of sub-computer A/B - Check outputs / inputs with JUDIT;
reports fault
detected within limit time (xxmsec) - Replace accelerator pedal;

"Travel speed transmitter" Faulty speed sensor signals of sub-computer A/B - Check the sensor system attached
- 7 02 44 Undefined
safety block reports fault detected within limit time (xxmsec) - Check outputs / inputs with JUDIT;

"Parking brake release" Faulty parking brake button signal of sub-computer A/B - Check the sensor system attached
- 7 02 45 Undefined
safety block reports fault detected within limit time (xxmsec) - Check outputs / inputs with JUDIT;
- Replace control;

"Seat switch" safety block Faulty seat switch signals (N.C / N.O. contacts) of sub- - Check the sensor system attached
- 7 02 46 Undefined
reports fault computer A/B detected within limit time (xxmsec) - Check outputs / inputs with JUDIT;

"Accumulator brake" safety Faulty accumulator brake signals of sub-computer A/B - Check the sensor system attached
- 7 02 47 Undefined
block reports fault detected within limit time (xxmsec) - Check outputs / inputs with JUDIT;
tUNGHEINRICH Event Messages 03.15 iee (gb)
Status

"Manifold" safety block Faulty feedback of signals of all hydraulic valves of sub- - Check the sensor system attached
- 7 02 48 Undefined
reports fault computer A/B detected within limit time (xxmsec) - Check outputs / inputs with JUDIT;
- Check the sensor system attached

"Cutout paths" safety block Faulty "cutout path" monitoring of sub-computer A/B
- 7 02 49 Undefined - Check outputs / inputs with JUDIT;
reports fault detected within limit time (xxmsec)
Faulty delay in monitoring "control position neutral - Check the sensor system attached
"Control position" safety
- 7 02 50 Undefined setting" monitoring of sub-computer A/B detected within - Check outputs / inputs with JUDIT;
function reports fault
limit time (xxmsec) - Replace controller;
Faulty delay in monitoring "control part neutral setting" - Check the sensor system attached
"Control parts" safety
- 7 02 51 Undefined monitoring of sub-computer A/B detected within limit - Check outputs / inputs with JUDIT;
function reports fault
time (xxmsec) - Replace controller;

"Travel" safety function Faulty delay in monitoring "travel function" monitoring of
reports fault sub-computer A/B detected within limit time (xxmsec)

"Travel direction" safety Faulty delay in monitoring "travel direction" monitoring of
function reports fault sub-computer A/B detected within limit time (xxmsec)

"Parking brake" safety Faulty "parking brake" monitoring of sub-computer A/B
function reports fault detected within limit time (xxmsec)
Faulty delay in monitoring "parking brake release" - Check the sensor system attached
"Parking brake release"
- 7 02 55 Undefined monitoring of sub-computer A/B detected within limit - Check outputs / inputs with JUDIT;
safety function reports fault
time (xxmsec) - Replace controller;

"Parking brake activation" Faulty "parking brake activation" monitoring of sub-
safety function reports fault computer A/B detected within limit time (xxmsec)
Status
- Check connected sensor system;

"Electric steering" safety Faulty "electric steering" monitoring of sub-computer A/B
feature reports fault detected within limit time (xxmsec)

"Hydraulics" safety function Faulty "hydraulics" monitoring of sub-computer A/B
reports fault detected within limit time (xxmsec)

"Attachment" safety function Faulty "acknowledge clamping attachment" monitoring of
reports fault sub-computer A/B detected within limit time (xxmsec)

"Battery latch" safety Faulty delay in monitoring "battery latch" monitoring of
function reports fault sub-computer A/B detected within limit time (xxmsec)

"Speed retention" safety Faulty delay in monitoring "speed retention" monitoring
function reports fault of sub-computer A/B detected within limit time (xxmsec)

Steering setpoint device
- 7 02 70 Undefined Error occurred in electric steering setpoint device - Check outputs / inputs with JUDIT;
safety feature reports fault
Steering actual value - Check the sensor system attached
Error occurred in electric steering actual value
- 7 02 71 Undefined transmitter safety feature - Check outputs / inputs with JUDIT;
transmitter
reports fault - Replace controller;
- Check connected sensor system;

"Travel speed sensor 2" Electric steering only:
safety feature reports fault Error occurred in travel speed sensor 2
Electric steering only: - Check connected sensor system;
"Steering response
Faulty delay in monitoring "steering response" - Check outputs / inputs with JUDIT;
- 7 02 73 Undefined monitoring" safety feature
monitoring of sub-computer A/B detected within limit - Replace controller;
reports fault
time (xxmsec)
Status
The truck function has requested a truck deceleration - Check the inching speed setting against the
Inching speed monitoring:
Undefined to 2.5 km/h. However the required deceleration to crawl data sheet values;
Travel
speed was not introduced within 1 second. - Check the brake ramp settings;
- 7 03 1
The truck function has requested a reduction of the main - Check the inching speed setting against the
Undefined lift speed to crawl speed. However the reduction of the data sheet values;
Main Lift
main lift speed was not introduced within 1 second. - Check the brake ramp settings;
The truck function has requested a reduction of the - Check the inching speed setting against the
- 7 03 2 Undefined aux. lift speed to crawl speed. However the reduction of data sheet values;
Aux. lift
the aux. lift speed was not introduced within 1 second. - Check the brake ramp settings;
The truck function has requested a reduction of the - Check the inching speed setting against the
- 7 03 3 Undefined sideshift speed to crawl speed. However the reduction of data sheet values;
Sideshift
the sideshift speed was not introduced within 1 second. - Check the brake ramp settings;
The truck function has requested a reduction of -Check the inching speed setting against
- 7 03 4 Undefined the rotary speed to crawl speed. However the reduction the data sheet values;
Rotate
of the rotary speed was not introduced within 1 second. - Check the brake ramp settings;
- Check the maximum speed setting against

Maximum speed monitoring: The travel speed has been exceeded by more than
Undefined the data sheet values;
Travel 0.5 km/h.
- Check the brake ramp settings;
- 7 04 1
Maximum speed monitoring: The main lift speed has been exceeded by more
Undefined the data sheet values;
Main Lift than 0.025 m/sec.

Maximum speed monitoring: The aux. lift speed has been exceeded by more
- 7 04 2 Undefined the data sheet values;
Aux. lift than 0.025 m/sec.

Maximum speed monitoring: The sideshift speed has been exceeded by more
Sideshift than 0.025 m/sec.
Status

Maximum speed monitoring: The rotary speed has been exceeded by more than
Rotate 0.25 7sec.
The truck moves despite The travel speed has been exceeded by more than the - Check the maximum speed setting against the
Operation
travel cutout limit. data sheet values;
- Check the brake ramp setting;
- 7 05 1 - Check the application which led to the event
Main Lift raises despite lift Monitoring module: despite an active cutout a speed being triggered (e.g. operation beyond
Operation
cutout above a limit or an active lift drive is detected. specification due to high travel speed on leaving
a ramp)
Main Lift lowers despite Monitoring module: Despite an active cutout a speed - Check truck controller cut-out function;
- 7 05 2 Operation
lower cutout > 10 mm/s is detected - Check the brake ramp settings;
The sideshift moves despite Monitoring module: Despite an active cutout a speed - Check truck controller cut-out function;
- 7 05 3 Operation
lower cutout > 10 mm/s is detected - Check the brake ramp settings;
The truck moves despite Monitoring module: Despite an active cutout a speed - Check truck controller cut-out function;
- 7 05 4 Operation
rotate cutout > 1 °/s is detected - Check the brake ramp settings;
The truck moves despite Monitoring module: Despite a power-up test error - Check truck controller cut-out function;
Operation
power-up test error a speed > 0.1 km/s is detected - Check the brake ramp settings;
- 7 05 10
The Main Lift moves despite Monitoring module: Despite a power-up test error - Check truck controller cut-out function;
Operation
power-up test error a speed > 10 mm/s is detected - Check the brake ramp settings;
The Main Lift moves despite Monitoring module: Despite a stop a speed > 10 mm/s - Check truck controller cut-out function;
- 7 05 11 Operation
an overspeed error is detected - Check the brake ramp settings;
Status
- Check position sensor signal quality;

While travelling the rotary Monitoring module: while the truck is travelling a rotate - Check sensor and replace if necessary;
drive moves position change is detected - Check the hydraulic restraint of the rotary
function;
- 7 05 12
As the Main Lift is moving Monitoring module: while the Main Lift is moving a rotate - Check sensor and replace if necessary;
the rotary drive also moves position change is detected - Check the hydraulic restraint of the rotary
function;

While travelling the Monitoring module: while the truck is travelling a sideshift - Check sensor and replace if necessary;
sideshifter moves position change is detected - Check the hydraulic restraint of the rotary
function;
- 7 05 13
As the Main Lift is moving Monitoring module: while the Main Lift is lifting a sideshift - Check sensor and replace if necessary;
the sideshifter also moves position change is detected - Check the hydraulic restraint of the rotary
function;
Travel inching speed -Check the inching speed setting against

Monitoring module: during an active speed reduction
exceeded despite reduction the data sheet values;
to inching speed a travel speed > VJNCH is detected
to inching speed - Check the brake ramp settings;
- 7 05 14
Main Lift inching speed - Check the inching speed setting against the
Monitoring module: during an active speed reduction to
exceeded despite reduction data sheet values;
inching speed a Main Lift speed > VJNCH is detected
Main lift moves despite error Monitoring module: A speed > 10 mm/s is detected - Check truck controller cut-out function;
- 7 05 15
(lift chain not taut) despite error (lift chain not taut) - Check the brake ramp settings;
Travel inching speed Monitoring module: during an active speed reduction to - Check the inching speed setting against the
- 7 05 16 exceeded despite foot inching speed, due to a foot switch error a travel speed > data sheet values;
switch error VJNCH is detected - Check the brake ramp settings;
Status
Monitoring module: during an active speed reduction to - Check the inching speed setting against the
Travel inching speed
- 7 05 17 inching speed, due to a gate error a travel speed > data sheet values;
exceeded despite gate error
VJNCH is detected - Check the brake ramp settings;
Travel inching speed Monitoring module: during an active speed reduction to - Check the inching speed setting against the
exceeded despite brake inching speed, due to a brake force governor error a data sheet values;
force governor error travel speed > VJNCH is detected - Check the brake ramp settings;
- 7 05 20
The Aux. Lift moves despite Monitoring module: Despite a power-up test error a - Check truck controller cut-out function;
Operation
power-up test error speed > 10 mm/s is detected
The Aux. Lift moves despite Monitoring module: Despite a stop a speed > 10 mm/s is - Check truck controller cut-out function;
- 7 05 21 Operation
an overspeed error detected

As the Aux. Lift is moving Monitoring module: while the Aux. Lift is moving a rotate - Check sensor and replace if necessary;
- 7 05 22
the rotary drive also moves position change is detected - Check the hydraulic restraint of the rotary
function;

As the Aux. Lift is moving Monitoring module: while the Aux. Lift is moving a - Check sensor and replace if necessary;
- 7 05 23
the sideshifter also moves sideshift position change is detected - Check the hydraulic restraint of the rotary
function;
Truck moves despite - Check truck controller cut-out function;

Monitoring module: Despite a PPS stop a speed
personal protection system
> 0.1 km/s is detected
stop
- 7 05 24
Aux. Lift inching speed - Check the inching speed setting against the
exceeded despite reduction data sheet values;
inching speed an Aux. Lift speed > VJNCH is detected
The truck moves despite Monitoring module: Despite a PPS protection field stop a - Check truck controller cut-out function;
- 7 05 25
protection field change error speed > 0.1 km/s is detected
Status
The maximum permitted The maximum permitted speed for the steering angle -Verification of the actuation by the higher-order
- 7 05 26 Operation speed for the steering angle has been exceeded, e.g. due to the steering angle being system (layout)
has been exceeded. changed too quickly.
The sideshifter moves Monitoring module: Despite a power-up test error a - Check truck controller cut-out function;
- 7 05 30
despite power-up test error speed > 10 mm/s is detected
The sideshifter moves Monitoring module: Despite a stop a speed > 10 mm/s is - Check truck controller cut-out function;
- 7 05 31
despite an overspeed error detected

Sideshift or tilt inching speed Monitoring module: during an active speed reduction to - Check lift height sensor system;
- 7 05 34 Operation exceeded despite reduction inching speed an excessive sideshift or tilt speed is - Check load weight sensor system;
to inching speed detected - Inquire about software update;
The rotary drive moves Monitoring module: Despite a power-up test error a - Check truck controller cut-out function;
- 7 05 40
despite power-up test error speed > 5 °/s is detected
The rotary drive moves Monitoring module: Despite a stop a speed > 5 7s is - Check truck controller cut-out function;
- 7 05 41
despite an overspeed error detected
Rotate inching speed - Check the inching speed setting against the
- 7 05 44 exceeded despite reduction data sheet values;
inching speed a rotate speed > VJNCH is detected
The event message is triggered - Read logbook:
Drive slave should be
if for T > 250 ms the following applies: - Send logbook to Technical Support;
- 7 05 50 Operation switched on, but it is
• The master has switched on a slave, but the slave
disabled
reports the "Off' status
Emergency stop through Emergency stop during operation through safety - If this error occurs permanently contact
- 7 06 1 Operation
safety computer computer (response to EMCY emergency stop) Technical Support;
No setpoint available from accelerator pedal (travel - Check traction motor speed sensors, replace if
Prevent accidental start-up
- 7 07 1 Operation setpoint), the speed-evaluating inputs detect a changing necessary.
from stationary position
actual speed.
Status
- Check traction motor speed sensors, replace if

Prevent accidental The speed-requesting inputs do not detect any travel
necessary.
- 7 07 2 Operation acceleration while travelling setpoint changes. At the same time however the speed-
- Check the accelerator pedal and replace if
in the travel direction detecting inputs do detect a changing actual speed.
necessary;
- Check Pilot travel direction signal, if necessary

Prevent the change in
replace Pilot;
direction command not No travel speed reduction detected after a change in
- 7 07 3 Operation - Check twin pedal, replace if necessary;
being recognised during direction command.
- Check external travel direction switch, replace if
travel
necessary;
- Check Pilot travel direction signal, if necessary

replace Pilot;
Prevent incorrect start-up - Check twin pedal, replace if necessary;
After the truck has been stationary, a speed is detected
- 7 07 4 Operation direction from stationary - Check traction motor speed sensors, replace if
that is opposite to the direction selected.
position necessary.
- Check external travel direction switch, replace if
necessary;
Prevent accidental - Check wire connections to the brakes;

automatic deceleration of During travel one of the two brakes (failsafe brakes) - Check brakes, replace if necessary;
- 7 07 5 Operation
drive system (endangering applies independently.
operational stability)
- Check the "Max. truck reverse speed"

parameter;
The speed determined is greater than the values
Prevent speed restriction - Check the "Max. truck forward speed"
- 7 07 7 Operation specified by the "Max. truck reverse speed" parameter
from failing parameter;
and/or the "Max. truck forward speed" parameter.
necessary.
Status
- Check "Maximum speed" setting and adjust if

Prevent speed limit failure necessary;
(taking into account folding The nominal or actual speed of the drive motor - Check "Speed reductions" setting and adjust if
- 7 07 8 Operation platforms and/or protective calculated is greater than permitted in the current necessary;
position of the side operating condition and does not reduce. - Check drive motor speed sensor, replace if
protective mechanisms) necessary;
- Check for software update;
Prevent the brake from - Check wire connections to the brakes;
One or both brakes (failsafe brakes) apply
- 7 07 11 Operation applying independently - Check brakes, replace if necessary;
independently.
(failsafe brakes)
- Check wire connections to the brakes;

Prevent the brake from
At least one of the brakes (failsafe brakes) is released - Check brakes, replace if necessary;
- 7 07 12 Operation releasing independently
without the parking brake setting being removed. - Check traction motor speed sensors, replace if
(failsafe brakes)
necessary.
Prevent automatic braking - Check wire connections to the brakes;

One of the two brakes (failsafe brakes) applies
- 7 07 13 Operation (endangering operational - Check brakes, replace if necessary;
independently.
stability)
- Check "Brake ramp" setting and adjust if

necessary;
Ensure brake function for - Check signal transmitter for the brake command
- 7 07 14 Operation electronically activated A brake command is not converted into actual braking. (e.g. tiller switch, deadman switch);
brakes - Check drive motor speed sensor, replace if
necessary;
Status
- Check hydraulic motor connections (e.g. for

short circuits);
- Check valve connections (e.g. for short circuits);
Prevent automatic lifting or A hydraulic system actuator is controlled even though - Check setpoint device signals, replace setpoint
- 7 07 15 Operation
lowering there is no user command. device if necessary;
- Check hydraulic controller outputs;
- Replace hydraulic controller;
No request made for "Move Attachment" operating - Check Pilot signals, replace Pilot if necessary;
functions. - Check outputs of signal-issuing controller;
Prevent attachments from
- 7 07 17 Operation Nevertheless the valve current reading does not reduce. - replace signal-generating controller;
moving automatically
As a result the valve current reading is sufficient to open
the valve.
- Check "Steering" setpoint sensor system,

Prevent automatic steering The steering controller detects a steer motor actual replace if necessary;
- 7 07 19 Operation
while travelling speed without a specification. - Check "Steering" actual value sensor system,
- Check "Steering" setpoint sensor system,

Transfer to safe condition in
The steering transmission does not convert a nominal replace if necessary;
- 7 07 20 Operation the event of steering failure
steer angle specification into an actual steer angle. - Check "Steering" actual value sensor system,
during travel
The seat switch reports an unoccupied driver s seat. -Check signal issuing controller, replace if
Ensure the operator is in the
- 7 07 22 Operation No falling travel speeds (traction motor speeds) and/or necessary;
normal operating position
decreasing valve currents detected.
With parameter settings for "Belt lock" and "Access - Check belt lock, replace if necessary;
control" an open belt lock is detected during the following
Ensure the driver restraint
- 7 07 23 Operation
systems are used
truck movements / operations:
-Travel operations
- Hydraulic functions activated
Status
- Check "Lift height sensor system option"

parameter;
-Check "Max. speed lift height 1" parameter;
When the respective lift height is exceeded the following - Check "Max. speed lift height 2" parameter;
requirements apply: - Check lift height sensor system, replace if
Failure of speed as a -The actual speed is greater than the "Max. speed lift necessary;
- 7 07 24 Operation
function of the lift height height 1" and the actual speed is not reduced. - Check traction motor speed sensors, replace if
-The actual speed is greater than the "Max. speed lift necessary.
height 2" and the actual speed is not reduced. - Check lift height sensor system, replace if
necessary;
necessary.
- Check "body protection acceleration" setting

and adjust if necessary;
- Check "service brake ramp" setting and adjust if
Failure to transfer to a safe
necessary;
state in the event of Tiller A body protection command is not converted into the
- 7 07 26 Operation - Check body protection command signal
Control failure (EN 1175-1/ actual body protection function.
transmitter and replace if necessary;
5.9.8)
- Check drive motor speed sensor, replace if
necessary;
The monitored ramp stop is requested as a response - Check traction motor speed sensors, replace if
- 7 07 27 Operation Monitored ramp stop from several safety features necessary.
Out of range of speed-dependent deceleration corridor
Deviation of two digital - Check CAN bus connection;

Two digital signals received via backup PDO are unequal
- 7 08 1 Operation signals from backup PDO - Replace SPDO transmitter;
for at least 70 msecs.
implausible - Replace SPDO receiver;
-> Event message should only appear in

"Sub index" test stage Event message for monitoring testing in development.
- 7 51 1...10 Operation
timeout The activation limit is 20 msec.
Status
Wire guidance aisle travel, - Check wire routing;

load direction wire guidance Aisle travel wire guidance, monitoring limit exceeded.
- 7 52 12 Operation
sensor permissible distance The activation limit is 20 msec.
exceeded

cornering sensor Aisle travel wire guidance, monitoring limit exceeded.
- 7 52 13 Operation
permissible distance The activation limit is 20 msec.
exceeded

drive direction wire guidance Aisle travel wire guidance, monitoring limit exceeded.
- 7 52 14 Operation
sensor permissible distance The activation limit is 20 msec.
exceeded
Wire guidance aisle travel, -Check wire routing and ground conditions;
The steer angle actual value has been exceeded by
- 7 53 1 Operation permissible steer angle
more than 1.8°. The activation limit is 20 msec.
actual value exceeded
Wire guidance aisle travel, -Check wire routing and ground conditions;
The steer angle setpoint has been exceeded by more
- 7 53 2 Operation permissible steer angle
than 1.5°. The activation limit is 20 msec.
setpoint exceeded
- Set the shuttle in the travel channel

- Clear the 2nd pallet location in the channel
UPC specific: -Check rail hole sensors 7B33.1, 7B33.2 for
No positive signal at 7B33.1 and 7B33.2.
- 7 54 1 Self test No starting conditions contamination, incorrect settings and faults
Negative signal at 7B35.1
provided - Check pallet detection sensor 7B35.1 for
Status
- Manually move the shuttle to the channel start,

UPC specific:
remove any blockage (use recovery vehicle);
Excessive travel distance recorded
- Check drive chain.
- Check the parameterised distance on the "jog

mode" option;
- 7 55 1 Operation Distance travelled too great - Check wheels for wear (check wheel diameter)
NOTE:
The travel route in jog mode has exceeded the fixed or
Worn wheels will affect the travel distance
parameterised distance
measured.
- Reference to function of jog mode setting
(option)
An operating error may have caused this.
After the positive flank of 7B37.4 there is no positive - Manually move the shuttle to the channel start
UPC specific:
flank at 7B37.2 - Check pallet detection sensors 7B37.1-7B37.4
- 7 56 1 Operation Pallet positioning sensor
After the positive flank of 7B37.3 there is no positive for contamination, incorrect settings and faults
faulty
flank at 7B37.1 - Check wire connection
UPC specific: - Manually move the shuttle to the channel start
- 7 57 1 Operation Invalid travel setpoint Speed specification too high - Repeat the travel command
specification

-Check rail hole sensors 7B33.1, 7B33.2 for
UPC specific: - Check wire connection
- 7 58 1 Operation Too many signal changes at 7B33.1 and 7B33.2
Invalid shuttle position - Check number of rail holes
- Check rail holes and travel channel for
contamination
- Check the shuttle in a different travel channel.
Status
- Manually reverse the shuttle, start the job again

- Check sensors for contamination, incorrect
settings and faults
UPC specific: - Check pallet
- 7 59 1 Operation The job could not be Order runtime in controller exceeded - Check rail holes for contamination
completed -Test drive system (manual travel)
- If the shuttle remains near a rail hole, you may
need to adjust the pallet distance parameters or
the channel end distance parameters slightly.
- Repeat travel job

- Position pallet correctly at first pallet location
- Check pallet
UPC specific: Incorrect signal constellation at sensors 7B37. 1 - 7B37.4 - Check pallet detection sensors 7B37.1-7B37.4
- 7 60 1 Operation
Pallet lift error at start No signals from incremental transmitter 1B5 for contamination, incorrect settings and faults
-Check incremental transmitter 1B5
- Check drive chain
- Manually reverse shuttle

- Repeat travel job
UPC specific: - Check pallet
- 7 60 2 Operation Incorrect signal constellation at sensors 7B37.1 - 7B37.4
Pallet lift error - Check pallet detection sensors 7B37.1-7B37.4
for contamination, incorrect settings and faults
- Manually reverse shuttle while checking for

possible obstacles in the way of the shuttle
- Check obstacle sensors 7B34.1 - 7B34.4 for
UPC specific: contamination, incorrect settings and faults
- 7 61 1 Operation Negative signal at sensors 7B34.1 - 7B34.4
Obstacle detection - Check wire connection
- Check channel for obstacles (load, wooden
remains and shrink wrap)
- Check channel for possible reflection causes
Status

UPC specific:
- The 1st and 2nd pallet locations viewed from the
- 7 62 1 Operation Requirement for travel order Within defined travel distance positive flank at 7B37.1
channel start should not be filled for the
not maintained
"compress at start" function
Reserved for software -

- 7 95 1...n Not included in standard software.
development

development

development

development

- 7 99 1...n
development
Not included in standard software.
Driver error from stack. Sub index means: - Check the physical properties of the CAN Bus;
1: Bus off - Measure the CAN-Bus signal;
The master has been informed via CiA Emergency - Check CAN-Bus signals for frame leakage;
Error Code 8140 that a node is reporting error - Check equipotential bonding;
"Recovered from Bus Off. - Check terminal resistances (60 Q ± 10%);
- 8 01 1 Operation CAN Bus faulty Events are entered with the node number of the - Check CAN-Bus via JUDIT
transmitting component (CAN-Bus load, ...);
The function assembly used is the function assembly - Bypass components connected to the CAN-Bus
of the transmitting component. in turn;
Events recognised by the master are entered with - Replace controller;
node number 1 and function assembly 0.
Status
Driver error from stack. Sub index means: - Check the physical properties of the CAN Bus;
2: Driver switched to "passive" - Measure the CAN-Bus signal;
The master has been informed via EMCY ID 8120 that - Check CAN-Bus signals for frame leakage;
a node is reporting error "CAN in Error Passive Mode". - Check equipotential bonding;
Events are entered with the node number of the - Check terminal resistances (60 Q ± 10%);
- 8 01 2 Operation CAN Bus faulty
transmitting component -Check CAN-Bus via JUDIT
The function assembly used is the function assembly (CAN-Bus load, ...);
of the transmitting component. - Bypass components connected to the CAN-Bus
Events recognised by the master are entered with in turn;
node number 1 and function assembly 0. - Replace controller;
- Check CAN-Bus load via JUDIT;

Driver error from stack. Sub index means:
- Check the physical properties of the CAN Bus;
3: Telegram buffer in CAN driver has overrun
- Measure the CAN-Bus signal;
The master has been informed via EMCY ID 8110 that
- Check CAN-Bus signals for frame leakage;
a node is reporting error "CAN overrun (objects lost)".
- Check equipotential bonding;
Events are entered with the node number of the
- 8 01 3 Operation CAN Bus faulty - Check terminal resistances (60 Q ± 10%);
transmitting component
- Bypass components connected to the CAN-Bus
The function assembly used is the function assembly
in turn;
of the transmitting component.
-Switch optional components off from CAN-Bus,
Events recognised by the master are entered with
e.g. road traffic lighting.
Driver error from stack. Sub index means: - Check CAN-Bus load via JUDIT;
4: Receive buffer (Rx) has overrun (software) -Switch optional components off from CAN-Bus,
Events are entered with the node number of the e.g. road traffic lighting.
Status

Driver error from stack. Sub index means: - Measure the CAN-Bus signal;
5: Transmit buffer (Tx) has overrun (software) - Check CAN-Bus signals for frame leakage;
Events are entered with the node number of the - Check equipotential bonding;
transmitting component - Check terminal resistances (60 Q ± 10%);
The function assembly used is the function assembly -Check CAN-Bus via JUDIT
of the transmitting component. (CAN-Bus load, ...);
Events recognised by the master are entered with - Bypass components connected to the CAN-Bus
node number 1 and function assembly 0. in turn;
- Check power supply of the CAN-Bus component

not found.
- Check parameter setting for the optional
component, e.g. Option ISM, Option Can-
The event message is triggered Code, ...;
if for T = 10 s the following applies: -Via JUDIT try to access the faulty component;
CAN node shows no • Mandatory (necessary) CAN-Bus component has not - Check the physical properties of the CAN Bus;
response been found. - Measure the CAN-Bus signal;
Subindex: - Check CAN-Bus signals for frame leakage;
Node number of the CAN-Bus component not found. - Check equipotential bonding;
- Check terminal resistances (60 Q ± 10%);
in turn;
Status

No service data object (SDO) feedback:
No reply from the component;
CANopen object not present;
-Check CAN-Bus via JUDIT
- 8 03 1...32 Undefined CAN-Bus or software error Sub index not present;
(CAN-Bus load, ...);
Parameter range invalid (too high / too low);
Sub-index:
in turn;
Node number of requested node.
- Replace faulty controller;
- Inquire about JUDIT update;
- Read logbook:
Internal software error - Check terminal resistances (60 Q ± 10%);
- 8 04 1...n Undefined Software error
(error return value of a stack function). -Check CAN-Bus via JUDIT
in turn;
Status
For T = 3.5 x heartbeat time of monitored node: - Check power supply of the component
Heartbeat telegram not received connected to the CAN-Bus (faulty contact);
Sub-index: monitored node. - Check component heartbeat time
The master has been informed via EMCY ID 8130 that (CANopen object 1017);
a node is reporting error "Life Guard Error or Heartbeat - Check the physical properties of the CAN Bus;
Error". - Measure the CAN-Bus signal;
Events are entered with the node number of the - Check CAN-Bus signals for frame leakage;
Heartbeat telegram
8 05 1...32 Operation transmitting component - Check equipotential bonding;
monitoring
The function assembly used is the function assembly - Check terminal resistances (60 Q ± 10%);
- of the transmitting component. -Check CAN-Bus via JUDIT
Events recognised by the master are entered with (CAN-Bus load, ...);
node number 1 and function assembly of the remaining - Bypass components connected to the CAN-Bus
heartbeat. in turn;
The sub index represents the node number of - Replace controller;
the remaining heartbeat.
- Read logbook:
-Check optional components (unexpected
Unexpected CAN node Boot up message of an optional component which is set
report as not being present.
nodes);
- Release / activate or remove unexpected node
by parameter if not required.

Unexpected CAN node self-
- 8 07 1 Self test Unexpected reply of a node to the self-test request - Look for faulty controller during self-test.
test end
The master is informed via EMCY ID 8210 that a node - Inquire about software update;
has received an unexpectedly short process data object
(PDO).
Telegram between master/ Events are entered with the node number of the
- 8 08 1 Operation slave implausible / software transmitting component
error The function assembly used is the function assembly
Status
has received an unexpectedly long process data object
(PDO).
Telegram between master/ Events are entered with the node number of the
- 8 08 2 Operation slave implausible (too long) / transmitting component
software error The function assembly used is the function assembly
The master has been informed via EMCY ID 8230 that - Inquire about software update;
a node is reporting error "DAM MPDO not processed,
destination object not available".
- 8 08 3 Operation Unexpected Multiplex-PDO transmitting component
Events recognised by the master are entered with node
number 1 and function assembly 0.
For T = 3.5 x PDO cycle of the monitored node: - Check the physical properties of the CAN Bus;
PDO not received - Measure the CAN-Bus signal;
Sub-index: monitored node. - Check CAN-Bus signals for frame leakage;
The master is informed via EMCY ID 8250 that a node - Check equipotential bonding;
has not received a receipt PDO in the expected time. - Check terminal resistances (60 Q ± 10%);
Receive error; telegram
- 8 09 1... 32 Operation Events are entered with the node number of the -Check CAN-Bus via JUDIT
remains off
transmitting component (CAN-Bus load, ...);
The function assembly used is the function assembly - Bypass components connected to the CAN-Bus
of the transmitting component. in turn;
Events recognised by the master are entered with node - Replace controller;
number 1 and function assembly 0.
Status

Service data object (SDO) monitoring.
After repeating 4 times (with 10 msec interval) no
No reply to service data - Check terminal resistances (60 Q ± 10%);
- 8 10 1...32 Undefined response from contacted node
object -Check CAN-Bus via JUDIT
Sub-index:
contacted node.
in turn;

Error bit set for
Safe computer missed CANopenSync from slave. The - Check CAN-Bus signals for frame leakage;
- 8 11 1 Self test CANOpenSync in Safe
activation limit is 20 msec. - Check equipotential bonding;
computers
- Check terminal resistances;
- Replace faulty component;

Error bit set for
Safe computer missed process data object (PDO) from - Check CAN-Bus signals for frame leakage;
- 8 11 2 Self test CANOpenPDO in Safe
slave. The activation limit is 20 msec. - Check equipotential bonding;
computers
- Check terminal resistances;

- Measure CAN-Bus signal;
Emergency telegram: JH- The Safe computer has missed the Slave PDO and sent
- 8 11 33 Self test CANopen SafetyPDOs node an emergency telegram with the corresponding node ID.
ID monitoring 1/33 The activation limit is 20msec.
- Check terminal resistances,
Status





Status





Status





Status





Status





Status





Status

Error message evaluated Controller reports faulty (non-defined) emergency |-ÿ| The event message should not occur.
- 8 12 1 Operation
incorrectly telegram. The activation limit is 20 msec. Otherwise contact troubleshooting
specialists;

Master has not received emergency telegram from - Check CAN-Bus signals for frame leakage;
- 8 12 2 Operation No emergency telegram
controller. The activation limit is 20 msec. - Check equipotential bonding;

SRDO monitoring timeout - Check terminal resistances (60 Q ± 10%);
- 8 13 1 Operation 1. No telegram after 2.5x repeat time
telegram 1 - Check CAN-Bus via JUDIT (CAN bus load, ...):
in turn;

SRDO monitoring timeout 2. No telegram after 0.2x repeat time -Check terminal resistances (60 Q ± 10%);
- 8 13 2 Operation
telegram 2 (distance from 1st to 2nd telegram) - Check CAN-Bus via JUDIT (CAN bus load, ...):
in turn;
Status

- 8 13 3 Operation SRDO data implausible 1st and 2nd data (inverted) do not match
- Check CAN-Bus via JUDIT (CAN bus load, ...):
in turn;
CRC checksum or current
number from PDO of a
- 8 13 4 Undefined
monitored CANopen slave
faulty
The master has been informed via EMCY ID 8150 that - Inquire about software update;
a node is reporting the collision of CAN-ID's.
- 8 14 1...32 Operation Collision of CAN-ID's
has received an unexpected SYNCH length.
- 8 15 1...32 Operation Unexpected synch length
Status
The master has been notified via EMCY of a CAN-Open - Inquire about software update;
CiA error code to which no event message has been
Non-assigned CAN-Open assigned.
- 8 16 1...32 Operation CiA error in emergency Events are entered with the node number of the
report of a node transmitting component
- Check the CAN bus;

- Read the ECU error logbook and take
Expected messages from the engine controller are not appropriate actions;
- 8 17 1 Operation Engine CAN bus impaired
being received. - Replace the engine control unit;
signal;
- Check CAN bus (LPG engine) or K line (Diesel

engine);
- Read the ECU error logbook and take
Engine diagnostics bus An error is occurring during a diagnostic inquiry to the
- 8 17 2 Operation appropriate actions;
impaired engine control unit.
- Replace the engine control unit;
signal;
Status
- Release travel switch / accelerator pedal / twin

pedal;
- Check travel switch / accelerator pedal / dual
pedals and replace if necessary;
- Check safety switch and replace if necessary;
The event message is triggered - Check "zero position" parameter;
if for T >= 500 ms the following applies: - Check signal-evaluating controller and replace
• A travel setpoint is present at the system start if necessary;
System start "Safety switch" input and
- 9 01 1 • A travel setpoint was already present when the safety
Operation "travel" setpoint invalid
switch was pressed |-ÿ| Safety switches can include:
This event message can be triggered by incorrect - Deadman (foot switch),
operation. - Seat switch,
- Tiller switch.
For system trucks:
- Switch the truck off and on again.
Do not apply the control lever on power up.
- If the error still occurs, check the sensor
components and recuperating springs;
Status
- Set the "lift" control lever to neutral;

- Check the lift setpoint device and replace if
necessary;
- Check safety switch and replace if necessary;
The event message is triggered - Check "zero position" parameter;
if for T >= 500 ms the following applies: - Check signal-evaluating controller and replace if
• A lifting setpoint is present at the system start necessary;
— 9 02 1
Operation "lift" setpoint invalid
• A lifting setpoint was already present when the safety |-ÿ| Safety switches can include:
switch was pressed - Deadman (foot switch),
This event message can be triggered by incorrect - Seat switch,
operation. - Tiller switch.
For system trucks:
Do not apply the control lever on power up.
- If the error still occurs, check the sensor
- Set the "lower" control lever to neutral;

- Check the lower setpoint device and replace if
The event message is triggered necessary;
if for T >= 500 ms the following applies: - Check safety switch and replace if necessary;
• A lowering setpoint is present at the system start - Check "zero position" parameter;
- 9 03 1 • A lowering setpoint was already present when the - Check signal-evaluating controller and replace if
Operation "lower" setpoint invalid
safety switch was pressed necessary;
This event message can be triggered by incorrect
operation. |-ÿ| Safety switches can include:
- Deadman (foot switch),
- Seat switch,
- Tiller switch.
Status
The event message is triggered - Specify travel direction;

"Travel" setpoint and "no if for T >= 500 ms the following applies: - Check wire connections;
- 9 04 1 Operation travel direction" combination • No travel direction present when travel switch applied - Check direction switch and replace if necessary;
invalid This event message can be triggered by incorrect - Check signal-evaluating controller and replace if
operation. necessary;

This event message is triggered -Check the jog mode button and replace if
"Jog mode" and "travel when the "jog mode" button and travel switch are necessary;
- 9 05 1 Operation switch" setpoint combination pressed simultaneously. - Check the travel switch and replace if
invalid This event message can be triggered by incorrect necessary;
operation. - Check signal-evaluating controller and replace if
necessary;

- Check the jog mode button and replace if
necessary;
This event message is triggered - Check safety switch and replace if necessary;
"Safety switch input" and when the safety switch and the "jog mode" button are - Check signal-evaluating controller and replace if
- 9 06 1 Operation "jog mode" setpoint pressed simultaneously. necessary;
combination invalid This event message can be triggered by incorrect
- Seat switch,
- Tiller switch.
-The buttons must not be pressed
simultaneously;
"Drive direction" and "fork when the "drive direction" and "forks direction" buttons
- 9 07 1 Operation direction" jog mode are pressed simultaneously.
- Check the buttons and replace if necessary;
setpoints invalid This event message can be triggered by incorrect
- Check signal-evaluating controller and replace if
operation.
necessary;
Status
- Close safety switch;

The event message is triggered - Check safety switch and replace if necessary;
if for T >= 500 ms the following applies: - Check signal-evaluating controller and replace if
"Travel and/or lift setpoint"
• Travel or hydraulic setpoint not equal to zero and safety necessary;
- 9 08 1 Operation and "safety switch open"
switch not applied
combination invalid |-ÿ| Safety switches can include:
operation. - Deadman (foot switch),
- Seat switch,
- Tiller switch.
The event message is triggered - Release handbrake;
if for T >= 500 ms the following applies: - Check magnetic brake and replace if necessary
"Travel" and "handbrake" • Travel setpoint not equal to zero and handbrake (feedback contacts);
- 9 09 1 Operation
setpoint combination invalid applied
operation.
- Extend the mast;

- Raise the fork carriage;
"Lift/lower" and "safety - Check wire connections;
if the "lift/lower" and "safety height" setpoint combination
- 9 10 1 Operation height" setpoint combination - Check the "safety height" switch and replace if
is invalid.
invalid necessary;
This event message is an information message.
necessary;
- Close the gate;

- Check the "gate open" switch and replace if
- 9 11 1 Operation "Gate open" signal applied This event message is an information message. necessary;
necessary;
- Check the "aisle travel" sensors and replace if

necessary;
- 9 12 1 Operation "Aisle travel" signal applied This event message is an information message.
necessary;
Status
- 9 13 1 Pin code error This event message is not currently used.
- Do not press the operator protection switch on

system start-up;
Operator protection switch The operator protection switch was pressed on system - Check wire connections;
- 9 14 1 System start applied during system start¬ start-up. - Check the operator protection switch and
up This event message is an information message. replace if necessary;
necessary;
- Do not press the tiller switch on system start-up;

Tiller switch applied during The tiller switch was pressed on system start-up.
- 9 14 2 System start - Check the tiller switch and replace if necessary;
system start-up This event message is an information message.
necessary;
The "battery latch open" signal is applied when the truck - Latch battery / close battery door;
is stationary (< 1 km/h). - Check wire connections;
The event message is triggered - Check "battery latch" sensor, adjust and replace
Battery door not closed and
if for T >= 500 ms the following applies: if necessary;
- 9 15 1 Operation travel speed less than
• Battery door not closed and travel speed less than - Check signal-evaluating controller and replace if
1 km/h
1 km/h necessary;
operation.
The "battery latch open" signal is applied when the truck - Latch battery / close battery door;
is moving (>= 1 km/h). - Check wire connections;
The event message is triggered - Check "battery latch" sensor, adjust and replace
Battery door not closed and
if for T >= 500 ms the following applies: if necessary;
- 9 15 2 Operation travel speed greater than or
• Battery door not closed and travel speed greater than - Check signal-evaluating controller and replace if
equal to 1 km/h
or equal to 1 km/h necessary;
operation.
Status
Battery charger: - Latch battery / close battery door;

The "battery latch open" signal is applied when the truck - Check wire connections;
Battery door not closed is stationary (< 1 km/h). - Check "battery latch" sensor, adjust and replace
when battery management The event message is triggered if necessary;
active and travel speed if for T >= 500 ms the following applies: - Check signal-evaluating controller and replace if
< 1 km/h • Battery door not closed. Battery management active necessary;
and truck travel speed < 1 km/h.
- Insert mains connect in socket again

Plausibility check: main - Check wire connections
if for T >= 500 ms the following applies:
- 9 15 4 Undefined contactor closed BUT - Check controller that is evaluating the signal
• Main contactor closed BUT battery charger connected
charger connected to mains - Check steering controller and freewheel diode if
to mains
necessary;
- Latch battery / close battery door;

Charger:
- Check "battery latch" sensor, adjust and replace
"Battery latch open" signal When the truck is stationary the "battery latch open"
- 9 15 5 System start if necessary;
not applied during charging signal is not applied, but the charger transmission status
- Set battery management parameter to 2.
is present (battery being charged).
necessary;
- Check condition for travel cutout;

This event message is triggered - Check wire connections;
if for T >= 500 msec, (debounce time): - Check travel cutout sensors;
Travel cutout through travel cutout with open input activated through external - Check signal-evaluating controller and replace if
- 9 16 1 Operation
external functions/devices functions/devices. necessary;
|-ÿ| Travel cutout deactivated if the travel
setpoint is zero and the input is closed.
Power-up test: keypad - Switch the truck off and on again.

Power-up test: keypad switch pressed during power up
- 9 16 2 System start switch pressed during power Do not apply the keypad switch on power up.
-> Operating error.
up - Replace the keypad switch;
Status
- Press one pedal only;

if for T >= 500 msec the following applies:
"Travel" and "pedal brake" - Check the accelerator pedal and replace if
Accelerator pedal and brake pedal pressed
- 9 17 1 Operation setpoint combinations necessary;
simultaneously.
invalid - Check the brake pedal and replace if necessary;
operation.
necessary;

Power-up test: function pre¬
Power-up test: function switch pressed during power up Do not apply the function pre-select switch on
- 9 17 2 System start select switch pressed during
-> Operating error. power up.
power up
- Replace the function pre-select switch;
- Close cabin door;

This event message is triggered - Check "cabin door" switch;
if for T >= 500 msec the following applies: - Check safety switch and replace if necessary;
Cabin door not closed. Simultaneously safety switch - Check signal-evaluating controller and replace if
- 9 18 1 Operation Cabin door open necessary;
pressed and travel setpoint > 0
This event message is an information message. |-ÿ| Safety switches can include:
- Seat switch,
- Tiller switch.

Do not apply the foot switch on power up.
Power-up test: foot switch Power-up test: foot switch pressed during power up
- 9 18 2 System start - Check wire connections;
pressed during power up -> Operating error.
-Set the foot switch;
- Replace the foot switch;
- Perform a reference measurement of the load;

-Teach the load measurement;
The maximum load has been exceeded.
- 9 19 1 Operation Lift overload This event message is an information message.
- Check load measurement sensors;
necessary;
Status
The truck brakes to a halt (activated via JUDIT). This tests the service brake.
"Service brake test" service
- 9 20 1 Operation This event message is an information message. The event message and the brake activation are reset when
function
the truck is switched off and on again.
The main contactor is opened by the service engineer (activated via JUDIT). This allows the engineer to
check whether the main contactor can switch as an emergency stop device.
Operation
This event message is an information message. The event message and the JUDIT control are reset when
Information message: travel function test message.

Event for activating the cutout response of the main contactor for UW testing.
Self test
"Emergency Stop test" check whether the main contactor can switch as an emergency stop device.
- 9 21 1
service function active This event message is an information message. The event message and the JUDIT control are reset when
Information message: steering test message

Event for activating the cutout response of the main contactor for UW testing.
Self test
check whether the main contactor can switch as an emergency stop device.
This event message is an information message. The event message and the JUDIT control are reset when
The regenerative brake is switched off by the service engineer to test the mechanical service brake
(activated via JUDIT). This allows the mechanical service brake to be tested in isolation. When the test has
"Mechanical service brake
- 9 22 1 Operation been completed switch the truck off and on again.
test" service function
This event message is an information message. The event message and the regenerative brake cutout are
reset after 5 min. or when the truck is switched off and on again.
"Safety valve test" service To test the safety valve the lowering valve is opened in full (activated via JUDIT).
- 9 23 1 Operation
function This event message is an information message.
Status
When the truck is idle and all hydraulic levers are in -This event message is an information message.
the home position, press the SET key on the display
"Depressurise hydraulic
for 3 seconds to start the process for depressurising
- 9 24 1 Operation manifold" service function
the ZH (auxiliary) functions. The start is indicated by
active
a beep, the end by two beeps. The truck must then be
switched off.
- Switch the truck off and on again. Do not press

the shunting switch during system start-up.
Shunting switch pressed
- 9 25 1 System start Shunting switch pressed during system start-up -Check the shunting switch and replace if
during system start-up
necessary;
- Check signal-evaluating controller and replace
if necessary;
- Check the position of both moving side

Invalid setting combination Combination of digital inputs for gates (1/0) or (0/1) for restraints;
- 9 26 1 Operation
for moving gates more than 500 ms - Check switch;
During the hydraulic emergency stop device self-test -Train driver;
the pedal brake is applied, hence the test cannot be - Check brake pedal;
Pedal brake applied on performed - Check pressure sensor on steering B, replace
system start-up hydraulic emergency stop device released but brake if necessary;
pressure on the load wheel brakes (from brake pedal)
> 5 bar
Status

- Do not press the foot / hand button during
power-up.
The event message is triggered - Test foot / hand button for jamming / activation
System start Platform lift/lower setpoint if for T >= time limit the following applies: during system start
- 9 28 1
Operation activated during system start • At least one button of the "Platform lift/lower" function is - Check wire connections;
active when the system starts up - check foot / hand button and replace if
necessary;
- Check signal-generating controller and replace if
necessary;
The spring-loaded brake of the automatic parking brake - This event message is an information message.
Test spring-loaded brake of
can be applied by the service engineer (activated via The event message and the JUDIT control are
- 9 29 1 Operation automatic parking brake'
JUDIT). This enables service work to be performed on reset when the truck is switched off and on
service function activated
the spring brake cylinder. again.
After the service function "depressurising the valve - This event message is for information only.
Cancelling the active service
block" was activated, depressurised mode was - Switch the system off and on again;
- 9 30 1 Operation function "depressurising the
cancelled by starting the engine or because an error - Check event report;
valve block"
occurred.
- This event message is for information only;

The engine is close to stalling as the loading from the
- 9 31 1 Operation Engine anti-stall is active - Neutral position of working hydraulic control
working hydraulics is too high.
levers
-This event message is for information only;

STVZO mode and driving on Information message that the working hydraulics are
- 9 32 1 Operation - Check to ensure correct parameter setting;
public roads disabled when driving on public roads.
- Use the button sensibly;
Information message: the engine control unit has -This event message is for information only;
- 9 33 1 Operation Particle filter loading is high detected that the limiting value for the particle filter - Read ECU error logbook;
loading has been exceeded. - Proceed according to the repair manual;
Information message: the engine control unit has -This event message is for information only;
Particle filter loading is
- 9 34 1 Operation detected an error during the regeneration of the diesel - Read ECU error logbook;
critical
particle filter. - Proceed according to the repair manual;
Status
-This event message is an information message.

The self-test of the driving functions has been
Service function The event message and the control via JUDIT
- 9 35 1 Self-test deactivated by JUDIT. The truck can still drive at creep
"deactivating the self-test" are reset when the truck is switched off and
speed.
back on again.
Service function -This event message is an information message.

After the drive function self-test has been deactivated via
"deactivating the self-test" The event message and the control via JUDIT
- 9 35 2 Self-test JUDIT, the service function has been cancelled or the
has been cancelled after it are reset when the truck is switched off and
connection to JUDIT has been interrupted.
had been activated. back on again.
-This event message is an information message.

Self-test interrupted during
- 9 36 1 Self-test Self-test has been interrupted during execution. This event reports will be reset when the truck
execution.
has been switched off and on again.
Toggle switch for level 2 -This event message is an information message;

Toggle switch for level 2 applied despite function in level
- 9 37 1 Operation applied and function in level - Note the operating sequence;
1 still being performed
1 not yet completed
Toggle switch for level 2 not -This event message is an information message;
Toggle switch for level 2 applied despite function in level
- 9 37 2 Operation applied and function in level - Note the operating sequence;
2 still being performed
2 not yet completed
Several individual functions requested simultaneously -This event message is an information message;
Several individual functions
- 9 37 3 Operation with the control handle, despite at least one of the - Note the operating sequence;
requested simultaneously
hydraulic functions being set as a single function.
Mechanically interlocked functions requested -This event message is an information message;

Mechanically interlocked simultaneously. - Note the operating sequence;
- 9 37 4 Operation functions requested Example:
simultaneously -ZH1 and ZH4
-ZH2 and ZH3
-This event message is an information message;

- 9 38 1 Operation Battery charge at 0% The discharge indicator shows a battery charge of 0%
Status
Seat switch and deadman The event message is triggered - Check seat / deadman switch on passenger
switch on passenger seat if for T > 500 ms the following applies: seat;
- 9 39 1 Operation
implausible • The combination of seat and deadman switch for the - Note to operator in case of incorrect operation;
passenger seat is invalid (0/1 or 1/0)
Parking brake button applied The parking brake pre-selection is activated and the high -This event message is an information message;
- 9 40 1 Operation for too long level of the parking brake signal has been detected for - Do not apply the parking brake button;
longer than 5 sees.
Backup dongle save or The master saves the parameters in the Backup dongle -This event message is an information message;
- 9 41 1 Operation
restore active or restores the settings from the backup dongle. - Do not switch the system off;
-This event message is an information message;
- 9 42 1 Operation Reservoir level too low The reservoir level is below 2% of the reservoir volume - Replenish in accordance with operating
instructions;
The event message is triggered when the following -This event message is an information message;
Operating position applies: - Perform status change of operating position
- 9 43 1 Operation
monitoring time exceeded • After T > time limit, no operating position change switch;
detected
- Do not apply the MULTI-PILOT;

-Check the MULTI-PILOT zero position;
MULTI-PILOT: - Check wire connections within the MULTI-
This event message is triggered PILOT;
if for T >= 500 msec the following applies: - Check the control on MULTI-PILOT and replace
"Hydraulic setpoint" on When the system starts the setpoint of at least one if necessary;
System start
- 9 51 1...n system start or safety switch hydraulic function is not equal to zero. - Re-teach the MULTI-PILOT;
Operation
application invalid When the safety switch was pressed a setpoint of at - Replace the MULTI-PILOT;
least one hydraulic function was present.
This event message can be triggered by incorrect |-ÿ| Safety switches can include:
operation. - Totmanntaster (FuGtaster),
- Seat switch,
- Tiller switch.
Status
- Do not press the travel direction switch;

- Check the travel direction switch zero position
on the MULTI-PILOT;
MULTI-PILOT: - Check wire connections within the MULTI-
This event message is triggered PILOT;
"Travel direction switch if for T >= 500 msec the following applies: - Check the direction switch on the MULTI-PILOT
applied" on system start-up Travel direction button pressed when the system starts, and replace if necessary;
or safety switch application The travel direction button was pressed when the safety - Re-teach the MULTI-PILOT;
invalid switch was applied. - Replace the MULTI-PILOT;
- Seat switch,
- Tiller switch.
Control specific: Control applied or button pressed, but conditions for - see truck operating instructions data plate;
- 9 53 1 Operation
Incorrect operation function not met.
- Do not apply the control;

- Check home position / zero position of the
Control applied or button pressed, but conditions for
Control specific: control;
- 9 53 2 Operation function not met. Lift height reached and control does not
Incorrect operation - Check wire connection within the control;
pass zero.
-Teach control;
- Replace control;
-This is an information message.
Control unit specific:
For min. 5 seconds a travel mode button is pressed and -Train driver;
- 9 54 1 Self test "Button is pressed - self test
the control unit self-test is running. - If the button(s) is/are pressed for more than 5
cannot start"
seconds, self-test error 181 is activated.
- Check the truck impact and check the impact

limit parameters if necessary;
ISM:
System start Vertical ISM impact event - Carry out electrostatic suppression (ESD)
- 9 61 1 This event message is an information message. A level
operation (level 1) (equipotential bonding measures: controllers,
1 (weak) vertical impact event has occurred.
reservoir return line, seat, earth chain, data
recorder screening case, ...);
Status

ISM:
2 (medium) vertical impact event has occurred.

ISM:
3 (strong) vertical impact event has occurred.

ISM:
System start Horizontal ISM impact event - Carry out electrostatic suppression (ESD)
1 (weak) horizontal impact event has occurred.

ISM:
2 (medium) horizontal impact event has occurred.

ISM:
3 (strong) horizontal impact event has occurred.
Status
-To check the personal protection system (PPS)

Personal Protection System
Personal protection system (PPS) - scanner reports with the SICK software, see chapter
- 9 63 1 Self test (PPS): laser scanner error
error. 005 042 000 00005 "Seven segment displays
message
and indicators"

"Controls applied" error bit
Safe computer detected a control button pressed during Do not apply controls on power up.
- 9 70 1 System start set for power up test in Safe
power-up test. - If the event still occurs, check the sensor
computers

Power-up test: button On power-up test: Do not press the rider mode button on power up.
- 9 71 1 System start pressed in rider mode on rider mode button pressed on power up - If the event still occurs, check the sensor
power up -> Operating error. components and recuperating springs;
- Replace the rider mode button;

Do not press the emergency operation button on
Power-up test: emergency On power-up test:
power up.
- 9 71 2 System start operation button pressed on emergency operation button pressed on power up
- If the event still occurs, check the sensor
power up -> Operating error.
- Replace the emergency operation button;
Status
- Switch the truck off and on again. Do not press

Power-up test: button on the working platform button on insertion;
Power-up test: button on working platform pressed
- 9 71 3 System start working platform pressed - If the event still occurs, check the sensor
during power up. Switch on the truck again.
during power up/insertion components and recuperating springs;
- Replace the working platform button;
Battery controller: - Check electrolyte level;
This event message is displayed when the electrolyte - Check wire connections;
- 9 90 1 Undefined Battery electrolyte level low level sensor sends a "no electrolyte" signal (electrolyte - Check electrolyte level sensor on battery
level sensor not immersed in electrolyte). controller and replace if necessary;
Measurement is carried out if for T = 5 min -> I ~ 0 A. - Replace battery controller;

Charger:
Charger: No radio network This event message is displayed if no connection to the
- 9 92 1 System start cable if required;
established radio network could be established when the battery
management system is switched on
- Replace charger;
CAN-Bus node IDs
CAN-Bus node ID Description Lift of components with fixed CAN-Bus node ID
1 Master
2 MULTI-PILOT / SOLO-PILOT 1 -Multifunction armrest controls;
-CANDIS;
-JULIA;
3 Display 1
-On board computer;
-Multifunction armrest display;
4 Steer 1 -Control processor;
5 Steer 2 (RIGHT load wheel) -Control processor;
6 Steer 3 (LEFT load wheel) -Control processor;
7 Lifting
8 Travel 1
9 Travel 2
10 MULTI-PILOT / SOLO-PILOT 2
-MFC 1 (brakes);
11 Interface 1
-E box;
12 Interface 2 -MFC 2 (hydraulics);
13 Interface 3 -Travel switch;

14 Interface 4 -MFC 05;
15 Display 2
16 Battery controller
17 Charger
18 Spare
19 Display 3 -Rack Height Select;
20 Display 4 -Cold store cab user interface;
-Interface 1 of multifunction armrest;

21 Interface 5
-Auxiliary interface EFG 213-320
-Interface 2 of multifunction armrest;

22 Interface 6
-Auxiliary interface EFG 425-430
23 Interface 7 -Interface 3 of multifunction armrest;
24 Interface 8 -Interface 4 of multifunction armrest;
25 Steer 1 -Control processor;
26 Steer 2 (RIGHT load wheel) -Control processor;
27 Steer 3 (LEFT load wheel) -Control processor;
28 Access 1 -CanCode;
29 Access 2 -ISM;
30 Service PC
31 APM + -Automation interface (PLC);

tUNGHEINRICH Parameters 04.15 1 (GB)
Parameter and Options Setting
No. Function Range Default setting Comments

Travel program 1 (TP1)
256 Acceleration, normal travel mode 20-170 100
0.20 mis2- 1.70 m/s2
257 Acceleration, pedestrian mode 20-170 100

0.20 m/s2 - 1.70 m/s2
260 Coasting brake 30 - 360 140

0.30 m/s2 - 3.60 m/s2
262 Reversing brake 30 - 360 220

0.30 m/s2- 3.60 m/s2
264 Maximum speed in DD (drive direction) 0-110 75 The maximum speed of the EKS 110 depends
0-11.0 km/h 7.5 km/h on the truck version (parameter 2336):
• EKS 110 L/Z 100 E with one/two operating
positions (2336 = 0, 3 or 4)
Maximum value in TP1: 100 => 10.0 km/
h; standard value TP1: 75 => 7.5 km/h
• EKS 110 L/Z 1X0 E with one/two
operating positions (2336 = 1, 5 or 6) and
EKS 110 L/Z 280 ZZ with one/two
operating positions (2336 = 2, 7 or 8)
Maximum value in TP1: 90 => 9.0 km/h;
Standard value TP1: 75 => 7.5 km/h
265 Slow-travel speed switch ISM DD (drive 0-60 25

direction) 0 - 6 km/h 2.5 km/h
266 Speed in pedestrian mode DD (drive 0-40 25

267 Speed in aisle DD (drive direction) 0-110 110 The maximum speed of the EKS 110 depends
0-11 km/h 11 km/h on the truck version (parameter 2336):
• Highest settable maximum speed on the
100 E with one and two operating
positions (2336 = 0 or 1):
110 => 11.0 km h
160 E, 190 E and 280 ZZ with one and
two operating positions (2336 = 2 or 3 or
4 or 5): 100 => 10.0 km/h
268 Maximum speed in FD (fork direction) 0-110 75 The maximum speed of the EKS 110 depends
0-11 km/h 7.5 km/h on the truck version (parameter 2336):
positions (2336 = 0, 3 or 4)
Maximum value in TP1: 100 => 10.0 km/
h; standard value TP1: 75 => 7.5 km/h
Maximum value in TP1: 90 => 9.0 km/h;
Standard value TP1 : 75 => 7.5 km/h
269 Slow-travel speed switch ISM FD (fork 0-60 25

270 Speed in pedestrian mode FD (fork direction) 0-40 25

0 - 4 km/h 2.5 km/h
271 Speed in aisle FD (fork direction) 0-110 110 The maximum speed of the EKS 110 depends
0-11km/h 11 km/h on the truck version (parameter 2336):
110 => 11.0 km/h
4 or 5): 100 => 10.0 km/h

0.20 m/s2- 1.70 m/s2

0.20 m/s2 - 1.70 m/s2

0.30 m/s2- 3.60 m/s2

0.30 m/s2 - 3.60 m/s2
positions (2336 = 0, 3 or 4)
Maximum value TP2: 100 => 10.0 km/h;


direction) 0 - 4.5 km/h 2.5 km/h
110 => 11.0 km/h
4 or 5): 100 => 10.0 km/h
284 Maximum speed in FD (fork direction) 0-110 90 The maximum speed of the EKS 110 depends
positions (2336 = 0, 3 or 4)
285 Slow-travel speed switch ISM FD (fork 0-60 2.5

286 Speed in pedestrian mode FD (fork direction) 0-40 2.5

0-4 km/h 2.5 km/h
110 => 11.0 km/h
4 or 5): 100 => 10.0 km/h

0.20 m/s2- 1.70 m/s2

0.20 m/s2 - 1.70 m/s2

0.30 m/s2- 3.60 m/s2

0.30 m/s2 - 3.60 m/s2
positions (2336 = 0, 3 or 4)


direction) 0-4 km/h 2.5 km/h
300 Maximum speed in FD (fork direction) 0-110 100 100 E with one and two operating
0-11 km/h 10 km/h positions (2336 = 0 or 1):
110 => 11.0 km/h
4 or 5): 100 => 10.0 km/h
301 Slow-travel speed switch ISM FD (fork 0-60 25

302 Speed in pedestrian mode FD (fork direction) 0-40 25

0 - 4 km/h 2.5 km/h
110 => 11.0 km/h
4 or 5): 100 => 10.0 km/h

Global parameters
390 External travel release 0-2 0 EKS 110: Aisle end parameter
0: No reaction at aisle end
1: Crawl speed at aisle end
2: Truck stops at aisle end
393 Standard travel program 0-3 2 Travel program after truck power-up if there is
no device available to specify the program.
0 = no travel release
1 = slow
2 = medium
3 = fast
426 Reduced speed 1 drive direction (MFC06) 0-110 40 Travel speed reduction by the MFC06
0-11 km/h 4 km/h
The maximum speed of the EKS 110 depends
on the truck version (parameter 2336):
427 Reduced speed 1 fork direction (MFC06) 0-110 40 • Highest settable maximum speed on the
0-11 km/h 4 km/h 100 E with one and two operating
110 => 11.0 km/h
428 Reduced speed 2 drive direction (MFC06) 0-110 80
0-11 km/h 8 km/h • Highest settable maximum speed on the
429 Reduced speed 2 fork direction (MFC06) 0-110 80 4 or 5): 100 => 10.0 km/h
0-11 km/h 8 km/h
430 Speed reduced 3 0-110 60 Slow travel speed (softkey)

0-11 km/h 6 km/h Reduced maximum speed applies as soon as
the slow-travel softkey is active. Irrespective
of the operating program and travel direction
449 Curve Control option 0-10 0 0 = function switched off

1 - 10 = add description
The Curve Control function can be activated

with this parameter and the Curve Control
characteristic curves are selected that limit
the travel speed depending on the steering
angle.
452 Pedestrian mode option button 0-1 0 0 = off

1 = pedestrian mode available
Q Deviations between this parameter and

the buttons connected trigger event
messages.
456 "Crawl speed in aisle" option 0-1 0 0 = no crawl speed in aisle

1 = crawl speed in aisle
512 Acceleration ramp lifting 280 ZZ 0-180 0 EKS 110 280 ZZ:
0 = lifting switches off
1 = 10 ms
180= 1.8 s
513 Deceleration ramp lifting 280 ZZ 0-60 0 EKS 110 280 ZZ:
0 = lifting switches off
1 = 10 ms
60 = 0.6 s
818 Lowering speed 500 - 700 = 50 % 650 = 65% The degree of modulation of the PWM signal
PWM control PWM control can be set with which the lowering
proportional valve is controlled. That means
70 % that a voltage is set and not a current.
PWM control
944 Sideshift option (FEM forks) 0-1 0 0 = normal forks

1 = FEM forks (lifting and lowering require
two-hand operation some of the time)
946 Load sensor system option 0-1 0 Load switch, L version

0 = not available
1 = available
978 Soft-landing deceleration time 0-20 0 EKS 110 (2015)

("Pallet off the ground" option) 0 = no function
1 - 20 = On reaching the lift height switch for
the "Pallet off the ground" option,
lowering is continued for max. value *
50 ms. When this time has elapsed
(or if the lowering setpoint is
cancelled), lowering is interrupted. If
the lowering setpoint is applied again,
lowering is continued without further
restrictions.
985 Speed, lowering brake valve 500 - 700 = 50 % 580 = 58% The degree of modulation of the PWM signal
PWM control PWM control can be set with which the lowering
proportional valve is controlled while lowering
70 % via the lowering brake valve. That means that
PWM control a voltage is set and not a current.

Steering parameters
1024 Actual steering angle zero 0 - 65535 0 Not used for teach-in procedure. The
calculated centre point is entered in sub index
2 (value) and is then used.
1025 Actual steering angle right 0 - 65535 0 Teach-in follows automatically after the
setpoint has been "taught".
Teach-in procedure:
1026 Actual steering angle left 0 - 65535 0
The "potentiometer value" is displayed on sub
index 7.
By writing "save" to sub index 8, the
potentiometer value is copied to the value of
sub index 2.
1027 Setpoint steering angle zero 0 - 65535 0 Not used for teach-in procedure. The
calculated centre point is entered in sub index
2 (value) and is then used.
1028 Setpoint steering angle right 0 - 65535 0 Teach-in: Turn the tiller to the right stop, write
"save" to subindex 8. The actual value is then
automatically "taught" when both sides have
been set. When the entire teach-in process
has been completed, write "save" to object
1010 sub index 3.
1029 Setpoint steering angle left 0 - 65535 0 Teach-in: Turn the tiller to the left stop, write
"save" to sub index 8. The actual value is then
automatically "taught" when both sides have
been set. When the entire teach-in process
has been completed, write "save" to object
1010 sub index 3.
1041 Characteristic 0-14 7 Characteristic curves for different trucks and

equipment.
0 = JetPilot / drive wheel 1 to 1
1 = JetPilot / drive wheel acc. to characteristic
curve 2
curve 3
curve 4
curve 5
curve 6
6 = steering wheel / 1 to 1
7 = steering wheel /characteristic curve 1
1043 Steering correction 62 - 194 128 Wheel position correction:

One digit corresponds to a 0.0589 degrees on
the steered wheel.
Value range (in digits): 128 +/-66 (where 128
= 0 degrees)
This produces a setting range of:
Digit: 62 128 194
on the wheel: -4.02 degrees 0 degrees
+4.02 degrees
1044 Steering ratio 40-90 50 Ratio of turns of the steering wheel to turns of
the wheel. The following can be set on the
EKS 110
4-9 turns / 180 degrees
Unit 0.1 turns,
50 = 5 turns / 180 degrees
1120 Valid actual value 0 - 65535 0 This parameter is used automatically during
the "teach-in" procedure.
1121 Valid setpoint 0 - 65535 0

Battery parameters
1377 Battery type 0-9 1 0 = PzS (wet-cell battery);

1 = EPzS (high-performance battery) / ECSM;
2 = PzV (gel / dry-cell battery; maintenance-
free);
3 = US "Flat Plate" type;
4 = US "Pallet Pro" type;
5 = US "Tubular Plate" type;
6 = not supported
7 = not supported
8 = not supported
9 = Hawker XFC
1382 Battery option 1 0-976 125 Adjustment value for calculating the battery
charge status
General battery recovery after use
1 digit ~ 1mV
1389 Discharge monitor function 0-4 1 0 = not active
1 = active
2 = display active, lift cut-off active except for
digital lift input (n/a)
MFC05 lift set points
MFC05 lift set points & digital lift input
1390 Hour meter measuring mode 0-1 1 0 = standard setting

1 = alternative setting
tiUNGHEINRICH Parameters 04.15 18 (GB)

Global parameters
1542 Sounds 0-15 13 Display sounds:

- Bit 0 key tones ( 0 = off; 1 = on)
- Bit 1 indicator tones ( 0 = off; 1 = on)
- Bit 2 information tones ( 0 = off; 1 = on)
- Bit 3 error tones ( 0 = off; 1 = on)
Default: 1101xb = OxD

OxD = 13 decimal
1547 Trigger service department 0 - 65535 65535 Number of service hours at which the service
LED is switched on.
1549 Setting day/month of safety inspection (UW) 0 - 65535 257 Date on which the service LED starts to flash.
1550 Setting year of safety inspection (UW) 0 - 65535 8345 Date on which the service LED starts to flash
1554 Toggling units 0-1 0 BitO:

0: metric / 24h
1: Anglo-American
1680 Automatic cut-off time 0-31 0 Used by CanCode.
Meaning as below for JUSTCAP:
0 = no automatic cut-off
1 - 30: Automatic cut-off after 1 to 30 minutes
31 : Automatic cut-off after 10 seconds
2336 Truck version 0-8 0 0 = EKS 110 L 100 E with one operating
position
1 = EKS 110 L 160 E and 190 E with
one operating position
2 = EKS 110 L 280 ZZ with one operating
position
3 = EKS 110 Z 100 E with one operating
position
4 = EKS 110 Z 100 E with two operating
positions
5 = EKS 110 Z 160 E and 190 E with one
operating position
6 = EKS 110 Z 160 E and 190 E with two
operating positions
7 = EKS 110 Z 280 E with one operating
position
8 = EKS 110 Z 280 E with two operating
positions
2339 Tyre tension release time 1 -9 4 Truck features: Junior:
Specified in 10 seconds steps
(0 = no tyre tension release)
2400 Access module option 0-1 0 0: not available
1: available
2402 Auxiliary interface option 0-1 0 Activates/deactivates the auxiliary interface

option
0: not available
1: available
2405 Lighting option (X1.9) 0-2 0 Activates/deactivates the lighting option
0: Option switched off
1: Travel light permanently switched on
2: Travel light can be switched on with soft key
2411 Warning beacon option (X1.1) 0-10 0 Activates/deactivates the warning beacon
option:
0 = warning beacon when travelling in drive or
fork direction
1 = warning beacon when travelling in fork
direction
2 = warning beacon when travelling in drive
direction
3 = warning beacon when lifting in main lift
4 = warning beacon when lowering in main lift
5 = warning beacon when travelling or lifting
or lowering in main lift
6 = warning beacon when travelling or lifting
in main lift
7 = warning beacon when travelling or
lowering in main lift
8 = warning beacon when travelling in drive
direction or lifting or lowering in main lift
9 = warning beacon when travelling in fork
direction or lifting or lowering in main lift
10 = warning beacon permanently on
2422 Rack Height Select option 0-1 0 EKS 110:
(WMS interface) 0: No WMS
1: WMS interface active
tUNGHEINRICH Switch-On Routine 04.15 1 (GB)
Switch-On Routine
When the emergency disconnect switch has been released, the
following processes take place:
• The battery voltage is switched through to the key switch1.

• The key switch2 switches the first main contactor K1 and the
auxiliary relay K7 on.
• The NO contact of K7 provides all controllers with power.
The boot process is initiated in all controllers.
• After booting successfully, the AS2412iS dual controller
AS2412iS controls the second main contactor K5 via a digital output.
• This powers up the power units of the controllers.
The truck is ready for operation.
K1
K5
K7
1.Display unit (4 inch), keypad, transponder or ISM

2. Display unit (4 inch), keypad, transponder or ISM
tUNGHEINRICH Tightening Torques 03.15 1 (GB)
EKS 110 Tightening Torques
Lift mast
Ma
Item Screw / nut Comment
[Nm]
Hex. screw ISO Secured with Loctite 242 or 243 on

1a 70
4017 M12 x 40 the thread
Secured with Loctite 242 or 243 on

1b 46
the thread
Transmission
Ma
[Nm]
Connex 8 x 24 3 off
2
3 33 Allen screw M8 x 25 4 off
4 21 Screw plug 1 off
5 195 Hex. screw M14 x 1.5 x 55 1 off
6 35 Wheel bolts 5 off

Drive motor
Ma
[Nm]
Philips 4 off
7 4
screw
8 14 Hex. screw 3 off

Valve block
Item Ma [Nm] Screw / nut Comment
9 4 +2 Coil
PWS 10Z- A/F 1
10 45 +10
11-C-N-40-0
Screw plug A/F 6

11 35 +5 VSTI
M14x 1.5
12 25 +5 A/F 27
Screw plug A/F 6

13 35 +5 VSTI
M14x 1.5
Screw A/F 19
14 35 +5
coupling
Emergency A/F 13
15 10.5 +1
lowering
Ma
Item Assembly Screw / nut Comment
[Nm]
Bracket, control
Assembly of control Allen screw
16 25 ±2 panel
panel and bracket ISO 4762
2 off
Steering head
Item Ma [Nm] Screw / nut Comment
17 10 ±10% Allen screws 2 off
18 5 ±10% 4 off
Drivetrain, pre-assembled
Ma
[Nm]
19 23 Allen screw ISO 4762 M8 x 25 2 off
20 9 Brake mounting screws 3 off
Allen screw ISO 4762 M10 x

21 63 4 off
30
22 23 Allen screw ISO 4762 M8 x 25 3 off
23 125 Hex. screw M12 x 50 2 off
Step 1
24 a 10 Wheel nut DIN 74361 (in specified
sequence)
Step 2
24 b 150 Wheel nut DIN 74361 (in specified
sequence)
Lift cylinder
Ma
[Nm]
25 40 Lift cylinder 2 off
Load handler
Ma
[Nm]
26 330 Load handler 2 off

Electrical system
Ma
[Nm]
27 12 ±10 Hex. nut Horn

28 10 ±10 Countersunk screw 2 off
dUNGHE/IVR/CH Torques 07.08 1 (GB)
General Screw Torques
The specified torques MA apply for a friction coefficient in the
screw thread ptot = 0.14 for standard steel screws (shiny or
phosphated) of the specified grade and gently lubricated friction
surfaces.
Adjustments for deviating friction conditions:
• with basic lubricant (grease, oil): |itot =0.125
Reduce torque MA by 8%.
• with MoS2- or graphite-based lubricant: ptot =0.1
• For cadmium screws or nuts: jitot = 0.08...0.09
The general torques do not apply to expansion screws, self-
locking screw connections or when connecting components made
of different materials.
/j\ The specified torques MA are maximums and must not be used for
steel screws in nuts or steel components. Components with a
reduced screw depth and components made of different materials
such as cast iron, aluminium or plastic will be damaged by the
above torques.
Q General torques must only be applied if there are no torques

specified to the contrary in the truck-specific Technical
Specifications or in the service manual or spare parts catalog.
HUNGHEINRICH Torques 07.08 2 (GB)
General Screw Torques (Nm)
Full-size bolts with metric control thread Full-size bolts with metric fine thread
DIN 13, sheet 13 DIN 13, sheet 13
6.8 8.8 10.9 12.9 6.8 8.8 10.9 12.9
Ma (Nm) Ma (Nm)
M4 2,2 3,0 4,4 5,1
M5 4,5 5,9 8,7 10
M6 7,6 10 15 18
M8 18 25 36 43 M 8x1 20 27 39 46
M 10 37 49 72 84 M 10x1,25 39 52 76 90
M 12 64 85 125 145 M 12x1,25 70 93 135 160
M 12x1,5 67 89 130 155
M 14 100 135 200 235 M 14x1,5 110 145 215 255
M 16 160 210 310 365 M 16 x 1,5 170 225 330 390
M 18 220 300 430 500 M 18 x 1,5 250 340 485 570
M 20 310 425 610 710 M 20x1,5 345 475 680 790
M 22 425 580 830 970 M 22x1,5 465 650 920 1050
M 24 535 730 1050 1220 M 24x2 590 800 1150 1350

tUNGHEINRICH Torques 07.08 3 (GB)
General Screw Torques (1bf ft)
Full-size bolts with metric control thread Full-size bolts with metric fine thread
DIN 13, sheet 13 DIN 13, sheet 13
6.8 8.8 10.9 12.9 6.8 8.8 10.9 12.9
Ma (Ibf-ft) Ma (Ibf-ft)
M4 1.62 2.21 3.25 3.76
M5 3.32 4.35 6.42 7.38
M6 5.61 7.38 11.06 13.28
M8 13.28 18.44 26.55 31.72 M 8x1 14.75 19.91 28.77 33.93
M 10 27.29 36.14 53.1 61.96 M 10x1,25 28.77 38.35 56.06 66.38
M 12 47.2 62.69 92.2 106.95 M 12x1,25 51.63 68.59 99.57 118.01
M 12x1,5 49.42 65.64 95.88 114.32
M 14 73.76 99.57 147.51 173.33 M 14x1,5 81.13 106.95 158.58 188.08
M 16 118.01 154.89 228.64 269.21 M 16 x 1,5 125.39 165.95 243.4 287.65
M 18 162.26 221.27 317.15 368.78 M 18 x 1,5 184.39 250.77 357.72 420.41
M 20 228.64 313.46 449.91 523.67 M 20x1,5 254.46 350.34 501.54 582.67
M 22 313.46 427.79 612.18 715.43 M 22x1,5 342.97 479.42 678.56 774.44
M 24 394.6 538.42 774.44 899.83 M 24x2 435.16 590.05 848.2 995.71

tUNGHEINRICH 001 002 000 00004 02.08 1 (GB)
Spring loaded brake 30 Nm
I
Item Description
1 Airscrews (emergency operation) not included with
Cheese head screw M5 x 45 the truck
2 Hex. bolt M5 (secured) *)2
3 Mounting bolts M6 x 20
4 Hub
5 Brake disc (rotor) *)1
6 Countersunk screw
7 Flange
8 Brake armature plate
9 Magnetic component
10 Compression spring
*)1 Wear part
*)2 No nut if thread contained in brake anchor plate.
Air gap check

iHH The air gap a is factory set to 0.3 ±0. 1 mm. If the air gap: a
> 0.6 mm replace the brake disk (5) and the hub (4).
T7P \dt/////;/7A
tUNGHEINRICH 001 002 000 00004 02.08 2 (GB)
Assembly Order
1. Push the hub onto the shaft and secure it with a retaining
ring.
2. Insert the brake disc (5) in the magnetic component (9).
3. Insert 3 mounting bolts (3) in the magnetic component with
the heads in the recesses.
4. Position the flange (7) and the spacers and secure them to
the magnetic component with the countersunk screws (6). It
should be possible to move the brake disc manually.
5. Place the entire brake on the shaft and secure it to the motor
with the mounting bolts (3), tighten the screws slightly.
6. Tighten the mounting bolts (3) evenly: 9.5 Nm.
7. Connect the brake line to the power supply.
8. Disassembly is the reverse order.
To release the brake if the power fails, screw the 2 off M5X45
cheese head screws into the anchor plate until the anchor plate
contacts the magnetic housing and the rotor can be freely axially
V/////////A moved between the anchor plate and the flange.
Remove the M5 X 45 cheese head screws
The truck must not be parked with the brake released.
777777777
tUNGHEINRICH Service Manual D 6360.03 06.12 1 (GB)
Measuring the Minimum Deceleration and Stopping Distance (Service Brake)
Q Testing the parking brakes:

see service manual D 6360.21
Deactivate the pedal brake
EFG series 1, 2 and 3: disconnect the brake switch cable.
EFG series 4 and 5: Bypass the brake pedal switch
Test conditions contact (7S11).
The braking must be carried out on a level, dry, horizontal track Set parameters in accordance with the table
made of concrete or similar.
Parameters Parameter value
If the truck has an operator position, the driver must be in it when
Reduction / Reducing Brake 0 (Min)
recording the braking.
Vmax forward + reverse 9 (Max)
All industrial trucks are recorded with maximum load.
Coasting brake 0 (Min)
The load must be secured to prevent it from slipping. Brake ramp 0 (Min)
Tow trucks are recorded without trailer and load. Option 4 0 (Min)
The load handler must be in the transport position, i.e. freely lifted
After completing the brake test restore the pedal brake to the
as low as possible in the home position. The mast must be tilted
operational status and the parameters to their original range.
back and retracted.
Braking is recorded for both forward and reverse travel in the
straight-ahead direction. Tow trucks are recorded only in the tow
direction.
The brakes are applied suddenly. The wheels must not skid or
block during braking and the truck should handle well.
Prior to testing the brakes

On trucks with traction current control the regenerative braking
must be deactivated.
Minimum deceleration recording
Check the travel speed (with load) from the truck data sheet
or record the maximum travel speed as described in
paragraph 1 of Stopping Distance Recording.
Attach a decelerometer (motometer, dynometer etc.) to the
truck and prepare it for operation. Note the manufacturer's
instructions.
Bring the truck to a halt from the maximum speed.
a Where possible, brake without using an automatic brake (e.g.

magnetic brake) so that the wheels are just before the point of
skidding.
Braking
For pedestrian trucks move the tiller suddenly to the full braking
zone.
Compare the deceleration value shown as % with the
minimum deceleration value for the truck as indicated in the
diagram.
km/h
Travel speed
Group Definition
A1 (all trucks < 16 tonnes except for groups B and C)
B1 (Tow trucks with 1 or 2 braked wheels)
B2 (All-wheel braked tow trucks)
C (Trucks with a rising operator position >1200 mm, lateral
/ three-way order pickers)
Stopping distance recording
Check the travel speed (with load) from the truck's data sheet Group A1 (Junior, ED, ER, ET, EK, EFG, VFG, EJE-KmS,
or travel a 5m distance at maximum speed and record the EJP series etc.)
time taken to cover this distance. Conversion formula:
Time recorded in seconds (t) to km/h (v): v =18 / 1 [km/h] Maximum stopping distances from VDI 2511 (2010)
Travel at maximum speed and then brake to a halt at a given
marking. Travel speed 3 4 5 6 7 8 9
(km/h)
Record the stopping distance and compare this with the
maximum stopping distance for the type of truck. Stopping distance 0,5 0,8 1,2 1,4 1,7 1,9 2,1
(m)
Travel speed 10 11 12 13 14 15 16
(km/h)
Stopping distance 2,4 2,6 2,9 3,1 3,54 3,9 4,5

(m)
Travel speed 17 18 19 20 21
(km/h)
Stopping distance 5,0 5,6 6,2 6,8 7,5

(m)
tUNGHEINRICH Service Manual D 6360.03 06.12 (GB) 4
Group B1 (tow trucks with 1 or 2 braked wheels) Group C (ETX series [except for ETX wire guided and
Maximum permissible braking distance without a trailer from VDI ETX automatic] ESP, ESP wire guided, KmS 1 etc.)
2511 (2010) Maximum stopping distances from VDI 251 1 (2010)
Travel speed 3 4 5 6 7 8 9 Travel speed 3 4 5 6 7 8 9

(km/h) (km/h)
Stopping 0,5 0,7 0,9 1,1 1,2 1,4 1,6
distance (m) Stopping distance 1,0 1,7 2,1 2,5 2,9 3,4 3,8
(m)
Travel speed 10 11 12 13
(km/h) Travel speed 10 11 12 13 14 15 16
(km/h)
Stopping 1,8 2,0 2,1 2,3
distance (m) Stopping distance 4,6 5,6 6,6 7,7 8,9 10,2 11,6
(m)
Group B2 (tow trucks with all-wheel braking)
Maximum permissible braking distance without a trailer from VDI Travel speed 17 18 19 20 21
2511 (2010) (km/h)
Stopping distance 13,1 14,7 16,3 18,0 19,8

Travel speed 3 4 5 6 7 8 9
(m)
(km/h)
Stopping 0,4 0,5 0,7 0,8 0,9 1,1 1,2 ETX wire guided, ETX automatic, etc.
distance (m)
Minimum deceleration:
14% (max. permissible travel speed = 9 km/h)
Travel speed 10 11 12 13
(km/h) Q The load wheel brake must only apply max 6% (+1%/-2%).
Stopping 1,3 1,4 1,6 1,7 Max. permissible stopping distances:

distance (m) The min./max. permissible stopping distance (braking
distance and response time) is indicated on a decal.
Teletrak etc.
Minimum deceleration:
see diagram, Group B or C
Maximum stopping distances:
For driverless vehicles with an anti-collision safety device,
the braking must be performed so that the vehicle comes to
rest within the sphere of influence or deflection path of the
anti-collision safety device.
For brake system setting and maintenance
see service manual 6360.xx, ETX, ESP and AS.
Testing the parking brakes:
see service manual D 6360.21
HUNGHEINRICH SHB D 6360.21 12.00 1 @>
Parking Brakes
(Extract from DIN 0015161 and FEM)
Requirements
The parking brake must be able to stop an industrial vehicle with
max. permissible load or an unladen tow truck without attachment
and without assistence from the driver on the maximum incline
permitted by the manufacturer for ascent, or on the incline descri¬
bed hereafter, whereby the higher value applies.
A Operator seated and standing industrial vehicles

- exclusing B and D constructions - 15%
B Stackers with extending driver's position, dual-sided
trucks, triple-sided trucks 5% Incline Angle a
C Pedestrian and driverless industrial vehicles 5% CM o LO b CO
I
0
10% 10 % 5° 50' -6°

D Narrow aisle industrial trucks (reach trucks, straddle 12.5 % 7° 10' -7°
trucks, high level trucks, low level trucks) 10%
15 % 00 o CO oI
CO o
igp 5% incline means:
Gain in height H of 5 cm for 1 m horizontal length L.
HUNGHEINRICH SHB D 6360.21 12.00 2 (SB)
Tests
Testing can follow either process A or B. Trucks with Spring-Loaded Accumulator
I2=> For industrial trucks with automatic braking (e.g. magnetic brake l®j When the handbrake is applied the full force of the spring-loaded
or spring-loaded accumulator), the automatic brake is also the par¬ brake acts.
king brake.
The truck brakes suddenly.
For pedestrian trucks the tiller acting in the braking zone is also the
parking brake.
Process A
• Drive the industrial truck onto an incline in accordance with
the "Requirements" section and bring to a standstill with the
operating brake.
• Activate the parking brake and then release the operating
brake.
• The parking brake is functional if the truck stops in accor¬
dance with the "Requirements" section.
Process B
• Halt travel (release accelerator / travel switch) and bring the
truck to a standstill with the handbrake.
• The parking brake is functional if the truck achieves the
respective percentage value for braking (recorded with a
delay recording device), in accordance with the "Require¬
ments" section.
tUNGHEINRICH Jungheinrich ISM 06.06 1 (GB)
Jungheinrich ISM
Index Replacing/Adding ISM Components with

Parameter Setting 10
General 2
Replacing a Faulty Access Module 10
Version number display 2 Set the access module parameters according to the truck data
sheet 10
Expansion stages 3
Maintaining the new access module in the customer
Stage 1 3 database 13
Stage 2 3
Stage 3 3 Setting ISM Access Module to Permanent Mode . 14
Stage 4 3 For trucks with JUSTCAP 14
For trucks with CanOpen (Canion) 14
Access module 4
Overriding the ISM access module for recovery purposes 14
Operational Test 4
Access Module Interfaces 5 Supplementing the ISM Components 15
ISM component numbers 15
Data recorder 6
Retrofit assembly matrix 16
Checking the Shock Sensor 6 Retrofit cable for attaching the ISM access module 17
Data Recorder Interfaces 7 Truck-Specific Standard Parameters 18
Reach trucks 18
Radio module 9
Juniors 19
Impact value specifications 21
Error Messages ITroubleshooting 22 General
Error Display in Access Module 22
Operating data acquisition consists of 2 parts.
Troubleshooting 24
1. The evaulation and programming unit (PC with appropriate
Wiring diagrams / Terminal diagrams 25 software) with transponder writer and reader.
Not part of this documentation.
2. The assembly devices in the truck.
The devices that may be contained in the truck include:
- Access module
- Data recorder shock sensors
- Radio transmitter unit
- Optional sensors.
Version number display

Press the green and red keys of the access module
simultaneously to display the software version number of the
access module, data recorder and radio module. This information
is exchanged via the RS232 connections between the access
module and data recorder and between the data recorder and the
radio module.
Display example: Access module "Z01.0031", data recorder
"D01.0016", radio module "F01.004"
If a data recorder is not connected or is faulty, the messages
"DXX.XXXX" and "FXX.XXXX" are displayed.
If the data recorder is connected, but the radio module isn't or is
faulty, the messages "D01.0016" and "F99.9" are displayed.
Expansion stages
Stage 1 Stage 4
(Access module) Stage 3 plus optional sensors plus:
• Simple, key-less truck access via card or transponder • Travel / lifting operating data acquisition on data recorder
• Access check • 3 optional sensor inputs (freely configurable)
• Truck release
• Time out monitoring
• Service mode release with corresponding card/transponder
Stage 2
Stage 1 access module plus:
• Usage evaluation and data transfer to card / transponder
• Evaluation of usage data via PC (not part of this
documentation)
Stage 3
Stages 1 and 2 plus data recorder with shock sensors and radio
module plus:
• Shock acquisition
• Operating data acquisition on data recorder
• Engineer access acquisition when using engineer card
• Data transfer by radio to evaluation computer
Access module
Operational Test
Testing the Transponder Reading Function
Energise the access module (emergency disconnect on).
The display shows "card".
Place the driver's card on the access module until you hear a
beep, (you obtain your driver's card from the fleet manager)
The access module displays "OK?".
For new access modules (new truck, replacement) place the
transponder accompanying the access module onto the
access module.
Each time the power supply is interrupted (emergency
disconnect off/on) the display shows "card"
Each time an access module is replaced, the new module must be
compared with the current system data from the operator's
database.
The access module has several functions:

It provides access to the truck for the operator and service
department, as well as parameter entry via card or transponder.
Cards/transponders are programmed via the evaluation unit and
are not part of this documentation.
ÿ1 JUDIT is required for servicing.
tiUNGHEINRICH Jungheinrich ISM 06.06 5 (GB)
Access Module Interfaces *) Standard potential separation between OV and batt-: Pins 11,13
and 14 are connected in the module.
- JUSTCAP / CANopen 250kB trucks: Pin 11 and batt- are
6U10 connected, which cancels the potential separation of the ISM
components
- CANopen 500kB (system trucks): Potential separation between
OV and batt-
mode
**) Seat, tiller, travel switch etc. for trucks without CAN-Bus (Low
Active)
rA \UAAAMAA2,AA*-'5A6
X680 X681
PIN layout 16 pole SAAB (X680), to truck PIN layout 6 pole SAAB (X681), to data recorder Iemergency
reading
PIN PIN
PIN
1 S2 HIN 9 CAN_L out
1 - batt (OV)
2 S2 BACK 10 12V in
2 + batt
3 +12-48V in or 80V in 11 - batt in (OV) *)
3 RS232
4 - batt in 12 12V out
4 RS232
5 LISA/MFC 13 - batt out (OV) *)
5 OV
6 CAN_H in 14 - batt out (OV) *)
6 NC
7 CAN_H out 15 U-ISM out (24V) for
JUDIT Connector X681 is an RS 232 interface to the customer laptop port
for emergency reading of stored data or connection to the data
8 CAN_L in 16 Sign of life **) recorder.
Data recorder
Checking the Shock Sensor
A shock event can be triggered by tapping on the data recorder.
The access module then displays "shock!" for 30 seconds.
In this case, check the "Shock Procedure" setting with the JUDIT.
The "Displays" option must be selected for this.
After the 30 seconds the access module displays "go!" again
The data recorder can only be replaced as a complete unit.
The data recorder registers the truck's operating data. This

includes truck impacts as well as travel and lifting operations.
These are stored with the time and date.
The data recorder contains a 3 axle shock sensor. The sensor
sensitivity can be set via parameters. This can be made via the
transponder (configuration card) of the customer's computer or via
the service computer. When using the service computer, the data
must be updated on the customer computer using a transponder.
For trucks with a CAN BUS, the travel and lift data is acquired via
the access module in the data recorder. Information is exchanged
via the RS232 interface of the access module.
For trucks without a CAN BUS, the appropriate inputs must be
made on connector X684.
External sensors can be connected to pins 3-8 of connector X684.
Signalling for shock effects can be arranged by connecting pins
13/14 and 15/16 with X684.
Data Recorder Interfaces PIN layout 6 pole SAAB (X682), to access module
PIN
1 - batt
2 + batt
3 RS232
4 RS232
X 682 X 683 X 685 X 684
5 OV
6 NC
6U10 PIN layout 6 pole SAAB (X683), to radio module
PIN
6U12
1 NC
mode
T 2
3
NC
RS232
V
Iv
Iv II'-5
IV II X681 4 RS232
5 OV
6U11 B B IB B B X682 V t r r T b"x683 6 12V out
Analog Digital
A
r
_A _
.... ...
"A
1 j2 [3 [4
[5ÿ6
X685
X684 ]'2 13 4 5 6 T7 8 T9 10 11 "12 "13 T14 "15T16
PIN layout 16 pole SAAB (X684) to aux. sensor connection PIN layout 6 pole SAAB (X685), to customer laptop
and aux. functions for trucks without CAN Bus. connection - emergency reading
PIN PIN
1 0V out 1 - batt
2 12V out 2 + batt
3 Sensor 1 (in) 3 RS232
4 Sensor 1 (0V in) 4 RS232
5 Sensor 2 (in) 5 OV
6 Sensor 2 (0V in) 6 USV (12V in)
7 Sensor 3 (in)
8 Sensor 3 (0V in)
9 Raise signal
10 Lower signal
11 Fwd. travel signal
12 Reverse travel signal
13 Output shock 1 (NC)
14 Input shock 1 (NC)
15 Output shock 2 (N.O.)
16 Input shock 2 (N.O.)
Radio module
The radio module allows data to be exchanged between the

customer computer and the data recorder.
The JUDIT diagnostics allow you to check whether data has been
transferred.
Parameter number 122 "Radio transfer successful":
122 = 1 for data exchange,
122 = 0, if no data has been exchanged.
To do this, at least 1 operation (switching the truck on and off)
must be performed within the range of the receiver antenna.
The radio module can only be replaced as a complete unit.
Replacing/Adding ISM Components with Parameter Setting
When an access module is replaced or supplemented, para¬ Set the access module parameters according to the
meters must be set with the JUDIT box. This is not required if you truck data sheet
are replacing a data recorder or radio module. For this reason we
now give a detailed description of how to replace or supplement The JH ISM evaluation software allows the customer to change
an access module with parameter setting. the access module parameters. It is always necessary to compare
the current parameters with the new access module. The current
Replacing a Faulty Access Module parameters are listed in the truck data sheet. The customer must
print out the data sheet for the service department.
1. Connect the access module to the CAN Bus and the power
supply (see wiring diagrams) fÿl We shall now describe how to generate the truck data sheet using
— the JH ISM.
2. Apply current parameters to the service tool (see "Set the
access module parameters according to the truck data
sheet") 1. Start the Jungheinrich ISM
3. Program the access module with the current parameters ÿJung ho inrich DDE i, o y> x
using the JUDIT box. VnMmw. »Jÿntncr. (1 «
4. Maintain the truck in the customer database
4$
1
IfUM UrtJrXHJLtl
"i •—
i_.
" J""—
2. Select "evaluations"
3. The "Movement Data Evaluations" overview is shown 7. This leads to the system's truck master data
ma
Junÿhatnrich BDE M 7j O 0) 3i m±m
wMmti Junghcinrich DDE u Q CD X
A'
'A
it
1
ÿ
LA
ÿ"Ow
A
jI
_—
>—
d jsI
J -U
A' A"—
A 1
I fH-I- ÿ! ÿ
l-I-44
ÿU xi
ÿ/ T.i fi ÿiwi»WMiffrejr
4. Select "Master data".

5. The "Master Data Evaluations" overview is shown 8. By selecting "Truck" you can select the master data for the
truck into which the new access module is to be fitted.
Junghckririch DDE D B O 0 #
9. Select the normal version of the data sheet.
Select to generate the truck data sheet.
A ' 1 "ÿ
x 1
nrt-f
AuMwrrnrnrcn
6. Select "Truck Data Sheet"

10. The truck data sheet contains the parameters to be set along
with the parameter numbers of the JUDIT service tool.
Fahrzeugstamm iUtfCHMRKH 11. To be safe, first read in all the access module parameters
Fahrzeuggruppe: XXXXX
Kostenstelle: YYYYYYYY
with the JUDIT and store the parameter set onto the hard
Fahrzeug: ZZZZZZZZZZZ
disk of the service laptop.
Nobbv Typ: 12. Using the JUDIT, change the parameters marked with
Fahrzeugnummer:
Seriennummer:
7777 Fahrzeuggruppe:
Kostenstelle:
XXXXXX
YYYYYY parameter numbers from the truck data sheet. This can be up
Hersteller:
Herstellungsdatum:
Jungheinrich Bemerkung:
to 40 parameters.
Finanzierung:
endet am: 13. Store the changed parameters in the access module.
Technische Daten
Hubhohe (in mm): Time-Out Abschaltung (Zeit in s): 900
14. Disconnect the access module power supply by pressing the
Bauhdhe (in mm):
Bauart: AAAAAAA
Time-Out Standby (Zeit in s):
Busausfuhrung:
900
emergency disconnect.
Anbaugerat: vwvvw Betriebsstundenzahler ÿ
Senksignal vorhanden
Ruckwartssignal vorhanden
ÿ
ÿ
Systemstufe:
LISA-Kontakt: offen
When you restore the power, the changed parameters will now be
Dauerbetrieb
Abfrage Fahrzeugzustand
ÿ
ÿ
Schloss Nr:
Einbaulage Schocksensor: . activated in the access module. The changed parameter set
Batteriezustand-Telegramm
Firmware-Version
ÿ
Funk
Hostadresse: 0
should then be transfered to the database (see "Maintaining the
Zugangsmodul:
Funkmodul:
Kanalnummer:
Sendeleistung:
1
31
new access module in the customer database").
Datenrekorder:
Betriebsdaten Letzter Datenempfang:
Nutzungsbeginn: nachste UW:

Nutzungsende: nachste Wartung:
Betriebsstundenzahler: letzte Wartung am:
Erfasst am: Betriebsstunden:
Benutzungsdauer: letzter Technikereingriff:
Stand vom: Benutzungsdauer:
Betriebsstunden:
Konfiquration Konfigurationsstatus: unkonfiguriert
Schaltverzogerung
[ms] Srhu/pll_
Klassifizierung der Stufen
Eingang Ein Aus wert 2 3 4 5
1 50 50 5 OV 1,96 V ; 3,92 V 5,88 V 7,84 V 10 V

2 50 50 5 OV 1,96V : 3,92 V 5,88 V 7,84 V 10 V
3 50 50 5 0% 14,9% I 20% 100% 100% 100%
Schaltverzogerung
[ms]
Schock- Schwellwerte
Signale Ein Aus sensoren Abschaltung schwach mittel stark
Heben 50 50 horizontal keine 50 100 150
Senken 50 50 vertikal keine 50 100 150
Fahren 50 50
Ruckwarts 50 50
Datum des Ausdruckes: 08.07.2004 09:31 Uhr Fahrzeugstamm 1/1

Erzeugt von Jungheinrich BDE
Maintaining the new access module in the customer database
1. Select "Trucks" During this process the "global system parameters" administered
in the background are written to the configuration card.
2. In the "Trucks" overview, select the truck to be configured.
£ ® O ® V
8. Hold the written configuration card on the access module and
jL*nglv«inrl>eh B-DE
wait for the beep.
ft -:
—
-UMrprW
~ ---
-- A 9. Disconnect the access module power supply by pressing the
ft -- emergency disconnect.
10. The hardware parameters are now updated both on the
access module as well as the database.
if jurigheirirKh apg
ftcnfQLfiwr f ih'zttJQ 4.H31

i T> O (D K
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I
4? -|j •£ V li* f» WfC#
a
3. Select "Configure Truck"
4. Insert the configuration card into the customer PC's card
reader and prepare it with "Clearing".
5. Place the prepared configuration card on the truck's access
module and wait until you hear a beep.
6. Place the configuration card with the new truck parameter set
onto the PC card reader and transfer it to the
JUNGHEINRICH ISM with "Read Configuration".
7. To conclude configuration, press the "Configuration" button.
Make sure the configuration card remains on the stationary
card reader.
Setting ISM Access Module to Permanent Mode
If parameter 1 for the Can_Bus version is correctly set, confirm the
For service, the ISM access module can be set to permanent message with "Yes".
mode using the JUDIT so that it does not switch off any more. If the parameter has not yet been set, confirm the message with
"No" and enter the correct parameter to end the project.
For trucks with JUSTCAP Switch the truck off and on again.
Start the ISM JUDIT project via JUDIT.
Q The ISM is now set to permanent mode and CanOpen mode.
In the communications parameter window set parameter 9
"permanent mode" to "1". Q After servicing and/or repairs, set the parameter back to "0" to re¬
activate the access module.
Close the project and switch the truck off and on again. The
change is accepted. Overriding the ISM access module for recovery
purposes
Q After servicing and/or repairs, set the parameter back to "0" to re¬
activate the access module.
Q Overriding of the access module is not intended for service
interventions but is used for recovering the truck in the event of an
For trucks with CanOpen (Canion) access module failure. The override connector is included in the
(EFG 1xx, EFG 4xx, EFG 5xx, EFG D30 and all current customer kit (fleet park manager).
warehouse and system trucks) Switch the truck off.
For trucks with CanOpen the access module must first be changed Unplug the connector from the access module.
to JUSTCAP with parameter 1 before the permanent mode setting
can be made. Connect the override connector.
Switch the truck on and recover it
Q When the ISM JUDIT project is started (> version 1.6) an
information screen appears. After recovering the truck remove the override connector.
Press the "Justcap" button to switch over. Carry out the repairs to the truck.
Switch the truck off and on again. Override connector (51003960): Pin 1/2, 6/7, 8/9, 10/12, 11/13
(connector housing: 50261032; plug contact: 50127945)
Q The ISM is now changed to JUSTCAP.
Start the ISM JUDIT project and set parameter 9 to 1.
• Set parameter 1 back to "4" (EFG) or "6" (W&S).
Supplementing the ISM Components
Supplementing ISM components is based on the system level of ISM component numbers
the operating data acquisition system required by the customer.
The following applies: Component Number
System levels 1 + 2: access module Access module, standard Urn., 12-48V 50433534
System levels 3 +4: access module, data recorder, mobile radio
Access module, cold store, 12-48V 50433570
module
As well as the hardware components, wiring sets, brackets and Data recorder, 12-48V 50433550
panels must be taken into account. These will differ, depending on
the truck model. Access module, standard Urn., 80V 50439150
After assembly, the standard parameter sets of the truck must be Access module, cold store, 80V 50439152
set and stored in the access module. This will be a maximum of 6
parameters. Parameters are set according to section "Set the Data recorder, 80V 50439153
access module parameters according to the truck data sheet",
items 11 -15. Radio module 50433563
The list of truck-specific ISM parameters is attached. Transponder Cards (Rohling) 50433569
After setting the parameters, the access module must still be Pack of 10 50450783
maintained in the database.
Trailer transponder 51036015
To do this, a truck must be created in the customer's database Pack of 10 50470542
software. This procedure is generally performed with a JH ISM
specialist from the relevant sales branch. ISM retrofit cable 51002939
In addition, the changed ISM parameters are transfered to the ZM->DR or DR->FM extension 51002943
customer's database in accordance with section "Maintaining the
new access module in the customer database".
Retrofit assembly matrix
Level 1-2, Level 1-2, Level 1-2, Level 1-2, Level 3-4, Level 3-4, Level 3-4, Level 3-4,
12-48 V, 12-48 V, 80 V, 80 V, 12-48 V, 12-48 V, 80 V, 80 V,
Standard Cold store Standard Cold store Standard Cold store Standard Cold store
51003090 51003091 51003092 51003093 51003094 51003095 51003096 51003097
Access module 12-48 V

Standard X X
Access module 12-48 V
Cold store X X
Access module 80 V
Standard X X
Access module 80 V
Cold store X X
Data recorder 12-48 V X X
Data recorder 80 V X X
ISM retrofit cable X X X X X X X X
ZM -> DR / DR -> FM X X X X
extension cable
Radio module X X X X
ZM -> DR / DR -> FM
extension cable X X X X
(optional)
Retrofit cable for attaching the ISM access module
Pin Name Note
1 S2_Fwd Key switch input
1,0 qmm
2 S2_Rev Key switch output
3 Battery + Connect to the battery positive terminal.
Check the battery voltage class before
assembling the ISM access module
4 Battery - Connect to the battery negative terminal.
5 Lisa contact N/A
11 OV Connect to the battery negative terminal.
14 OV Not applicable if the seat/tiller switch (Pin 16)
switches to "Battery-" when applied and if a
proprietary (potential-free) switch is fitted for
the period of activity. This must then be fitted
between pin 14 and pin 16.
16 Seat/tiller This input is used as a signal transmitter to
signal determine the activity time. Must correspond to
transmitter the "battery" potential when applied, otherwise
open or voltage < 5V. If a proprietary (potential-
free) switch is fitted to acquire the activity time,
it must be installed between pins 14 and 16.
Truck-Specific Standard Parameters
Reach trucks
Truck Bus Version System level *) Service contact Lower sign, pres Assembly pos.
Shock sens. **)
JUDIT: #1 JUDIT: #2 JUDIT: #3 JUDIT: #7 JUDIT: #46
ETVQ20NUTZ JUSTCAP Sales order Battery + Yes Vert, in truck longit /
ETVQ25NUTZ (2) (1,2,3,4) (1) (1) transv.
(2)
ETVQ20 JUSTCAP Sales order Battery + Yes Vert, in truck longit /
ETVQ25 (2) (1,2,3,4) (1) (1) transv.
(2)
ETVCSE JUSTCAP Sales order Battery + Yes Vert, in truck longit /

(2) (1,2,3,4) (1) (1) transv.
(2)
ET320 325 JUSTCAP Sales order Battery + Yes Vert, in truck longit /
ET320 325NUTZ (2) (1,2,3,4) (1) (1) transv.
(BR 3) (2)
ET214 216 JUSTCAP Sales order Battery - Yes Vert, in truck longit /
(BR 2_New) (2) (1,2,3,4) (2) (1) transv.
(2)
ET 10 12 JUSTCAP Sales order Battery + No Vert, in truck longit /
ET 14 16 (2) (1,2,3,4) (1) (0) transv.
ET 14 16NUTZ (2)
*) The "system level" parameters to be set per sales order.

**) The "shock sensor assembly position" parameters stand for the intended assembly position of the shock sensor.
The shock sensor assembly position is not decisive with regard to the system functionality.
The assembly position is important if shocks or impacts are to be correctly assigned to their direction.
Juniors
Truck Bus Version System level *) Service contact Lower sign, pres Assembly pos.
Shock sens. **)
JUDIT: #1 JUDIT: #2 JUDIT: #3 JUDIT: #7 JUDIT: #46
ECE 120/220 JUSTCAP Sales order Battery + Yes Vert, in truck longit /
ECE_120/220_rap (2) (1,2,3,4) (1) (1) transv.
(2)
ESE JUSTCAP Sales order Battery + No Vert, in truck longit /

ESE_rapid (2) (1,2,3,4) (1) (0) transv.
(2)
ERE JUSTCAP Sales order Battery + No Vert, in truck longit /

(2) (1,2,3,4) (1) (0) transv.
(2)
EKS JUSTCAP Sales order Battery - Yes Vert, in truck longit /

(2) (1,2,3,4) (2) (1) transv.
(2)
EJE JUSTCAP Sales order Battery + No Vert, in truck longit /

(2) (1,2,3,4) (1) (1) transv.
(2)
EJD/C JUSTCAP Sales order Battery + Yes Vert, in truck longit /

(2) (1,2,3,4) (1) (0) transv.
(2)
*) The "system level" parameters to be set per sales order.

**) The "shock sensor assembly position" parameters stand for the intended assembly position of the shock sensor.
The shock sensor assembly position is not decisive with regard to the system functionality.
The assembly position is important if shocks or impacts are to be correctly assigned to their direction.
Specialfeature: In system levels 3 and 4 the Hostradio-address_Low (#95) and Hostradioaddress_High (#96) parameters should be
compared with the truck data sheet of another truck.
The standard settings are:
Hostradioaddress_Low = 12345
Hostradioaddress_High = 0
The host radio address can be changed by JH ISM specialist for the entire fleet system. It is essential to avoid any errors, as otherwise the
radio transmission will not work!
ÿ The list of truck-specific standard parameters is continually updated.

Impact value specifications
Truck type Level 1 Level 2 Level 3 Application condition
ERE 85 100 115
ECE 90 100 115
EKE 20 B 90 115 130
ETM/V BR1 25 40 45
ETM/V BR2 30 40 50
ETM/V BR3 30 40 50
ETVC 45 65 85
ETVQ ? ? ?
EFG BR1 90 110 120
EFG BR2 90 110 120
EFG BR3 50 75 90
EFG BR4 19 26 30
EFG BR5 100 110 115
TFG 316 20 25 30
Error Messages / Trou bleshooting
Q When you change the truck data via the JUDIT, the data in the evaluation program must be adjusted (configure truck).
Error Display in Access Module

The access module has an self-diagnostic feature which can be used to restrict sources of error. This self-diagnostic feature is displayed on
the access module if an error occurs:
Err.: 101: Input/output error.
Possible error source: faulty sensors
Err.:101a Invalid voltage at optional sensor 1 (stage 4 only)

No sensor 1 present: set parameters #11-17 to "0"
Sensor 1 present: the sensor voltage is outside the valid range (0.5 - 9.5V)
Err.:101b Invalid voltage at optional sensor 2 (stage 4 only)

Err.:101c Invalid voltage at optional sensor 3 (stage 4 only)

Err.: 102: Internal error.

Possible error sources: Software error, faulty internal hardware
Err.:102a Communication between access module and data recorder interrupted
Err.:102e Faulty radio module
Err.:102f "Radio channel" setting is 0, set parameter to 1.

tiUNGHEINRICH Jungheinrich ISM 06.06 23 (GB)
Err.:102g Transmission output too low, set "radio transmission output" parameter to 31
Err.:102h Faulty access module
Err.:102i Faulty data recorder
Err.: 103: Parameter error.

Possible error source: Inconsistent parameter setting
Err.:103a Select standby timeout (parameter #5) lower than truck timeout (parameter #6)
Err.:103b Select limit 1 (parameter #11) lower than the smallest difference between 2 switch limits (parameters #12-17)
Err.:103c Select limit 2 (parameter #20) lower than the smallest difference between 2 switch limits (parameters #21-26)
Err.:103d Select limit 3 (parameter #29) lower than the smallest difference between 2 switch limits (parameters #30-35)
Err.:103e The order of the switch limits (parameters #12-17) is not increasing
Err.:103f The order of the switch limits (parameters #21-26) is not increasing
Err.:103g The order of the switch limits (parameters #30-35) is not increasing
Err.:103h The order of the shock limits (parameters #47-49) is not increasing
Err.:103i The order of the shock limits (parameters #50-52) is not increasing
Troubleshooting
Error Cause Remedy
Truck cannot be switched on No power supply to access module Check power supply / restore
Transponder no longer valid Read transponder or extend validity
Display shows "XXCARD1...9" error code
Truck cannot be switched on even with Faulty access module Replace access module and update
"Mastercard" configuration.
No shocks listed Sensor sensitivity too high Lower the sensor limit
Set parameters via JUDIT and check with
JH-ISM
Too many shocks listed Sensor sensitivity too low Raise the sensor limit
Set parameters via JUDIT and check with
JH-ISM
No data transferred to system Truck out of range of transmitter/receiver of Drive truck to within transmitting range of
evaluation unit base station, approx. 30m, if possible within
visible range from antenna to antenna
Just one truck does not transmit data. Faulty transmitter unit Check radio transmission in diagnostics
Data be read via transponder Data recorder does not send signals to Replace transmitter unit
transmitter unit Replace data recorder
No trucks transmit data Error in evaluation unit Customer must check system
Wiring diagrams ITerminal diagrams
The wiring diagrams for the JUNGHEINRICH ISM system are contained in the various truck projects.
tUNGHEINRICH ISM Online 03.13 1 (GB)
ISM Online:
•Version, lock number and CAN-bus
version display
•ISM Online system expansion level
•Description of the access module, data
recorder and radio module
•Access module and data recorder
interfaces
•Retrofitting ISM Online components
•Converting ISM shock thresholds to ISM
Online
ISM Online:
•Setting the ISM access module to
permanent mode
•Overriding the ISM access module for
recovery purposes
EFG. VFG. ET and Junior:
•Converting ISM to ISM Online
components
•ISM Online component parameter setting
after replacement, conversion and after
delivery of a new truck
g pto.
tUNGHEINRICH ISM Online 03.13 2 (GB)
System trucks:
•Converting ISM to ISM Online
components
•ISM Online component parameter setting
after replacement, conversion and after
delivery of a new truck
ISM Online components in 500-kbaud
system trucks:
•Retrofitting or replacing ISM Online
components in 500-kbaud system trucks
Setting the CAN-bus version in the access
module
Error messages / troubleshooting
Gateway
Bus systems used
HUNCHEINRICH 002 053 000 00019 03.13 1 (GB)
ISM Online
General Procedure:
• Press the green (1) and red (3) buttons on the access
The ISM Online system consists of two components:
module at the same time.
1. Management portal (not part of the present service manual)
The display (2) of the access module shows:
2. Truck components: - the software version number of the access module,
-Access module (6U10) - the software version number of the data recorder,
- Data recorder with shock sensor (6U11) - the software version number of the radio module,
- Radio module (6U12). - the lock number,
- the CAN-bus version
Display of version, lock number and CAN-bus version in turn.
Requirement: The software version numbers of the:
• Truck is operational. - access module start with "Z1,
• The messages "IDENT?" or - data recorder start with "D",
"CONNECT?" are shown in the - radio module start with "F1,
display (2) of the access module. • If a data recorder is not connected or is faulty, the message
"DXX.XXXX" or "FXX.XXXX" is shown in the display (2) of
the access module.
• If the data recorder is connected, but the radio module isn't or
is faulty, the message "F9.99" is shown on the display (2) of
the access module.
tUNGHEINRICH 002 053 000 00019 03.13 2 (GB)
ISM Online system expansion level Messages in the access module display depending on the
presence of an authorisation list
S The following components belong to the ISM Online system:
Access module (6U10), data recorder with shock sensor (6U11) |->| The transponders with which the truck can be switched on are
and radio module (6U12). saved in the authorisation list.
• Simple, key-less truck access via card or transponder (Mifare
Classic 1K) Message Meaning
• Access check • No authorisation list available in the access module (e.g.
• Truck enabling as delivered)
• Timeout monitoring CONNECT? • Empty authorisation list in the access module
•The truck can only be turned on with the delivery
• Evaluation of the usage data in the management portal (not
transponder
part of this documentation)
• Shock acquisition • Access module is known in the management portal
• Operational data logging on data recorder •Authorisation list with at least one valid transponder
IDENT? present in the access module
• Data transmission via radio •The truck cannot be turned on with the delivery
transponder
Description of the access module
The access module has several functions:
• It provides access to the truck for
operators, fleet managers and service
engineers.
• The transponders are administered by
the management portal. Transponder
administration is not included in the
present service manual.
fÿl JUDIT is required for servicing the access module.
tUNGHEINRICH 002 053 000 00019 03.13 3 (GB)
Access module function test
Testing the transponder read function:
Parametrisation of the Displayed messages / Meaning
• Power up the access module (unlock the emergency status request
disconnect switch).
The messages "IDENT?" or "CONNECT?" are shown in the Deactivated status •"go!" appears in the access module display
display of the access module. request when the transponder is placed on the access
module
Obtain a technician's transponder from the fleet manager.
• Place the technician's or the delivery transponder on the Single-level status •"OK?" appears in the access module display
access module. The transponder to be used depends on the request (standard when the transponder is placed on the access
message in the display of the access module: setting) module
• Press the green button "+".
• "IDENT?" is shown in the display: •"go!" is shown in the display of the access
Place the technician's transponder on the access module module.
and wait until you hear a beep.
• "CONNECT?" is shown in the display: Two-level status request •"OK1?" appears in the access module display
Place the delivery transponder on the access module and when the transponder is placed on the access
wait until you hear a beep. module
• Press the green button "+".
The following messages are shown in the display of the •"OK2?" is shown in the display of the access
access module depending on the parametrisation of the module.
status request. • Press the green button "+" again.
•"go!" is shown in the display of the access
module.
• Each time the power supply is disconnected (press and then

unlock the emergency disconnect switch) the access module
display shows either "IDENT?" or "CONNECT?".
tUNGHEINRICH 002 053 000 00019 03.13 4 (GB)
Access module interfaces *)
Standard potential separation between 0 V and battery.
PIN layout 16-pole SAAB (X680), to truck Pins 11,13 and 14 are connected in the module.
6U10
Seat, tiller, travel switch etc. for trucks without CAN bus (low
active)
CANopen 250-kbaud trucks:
• Pin 11 and battery are connected, which removes the
potential separation of the ISM Online components.
mode CANopen 500 kbaud ICANopen 800 kbaud (system trucks):
2 3 4 5 16 • Potential separation between 0 V and battery.
X681
PIN layout 6 pole SAAB (X681)

PIN Description PIN Description
1 S2 HIN 9 CAN_L out PIN Description PIN Description
2 S2 BACK 10 12 Vin 1 - Batt. (0 V) 4 RS232
+12 V—48 V in or 2 + Batt 5 0V

3
80 Vin
11 - Batt in (0 V) *)
3 RS232 6 Not Connect (NC)
4 - Batt in 12 12 V out
5 LISA/MFC 13 - Batt out (0 V) *)
Q Connector X681 is an RS-232 interface to connect the data
recorder.
6 CAN_H in 14 - Batt out (0 V) *)
U-ISM out (24 V) for
7 CAN_H out 15
JUDIT
8 CAN_L in 16 Sign of life **)
tUNGHEINRICH 002 053 000 00019 03.13 5 (GB)
Description of the data recorder Checking the shock sensor
The data recorder registers the Requirement:
truck's operating data. This includes • Truck is operational.
shock events (shocks) recorded on
• Truck is within the gateway transmission range.
the truck. The shock events are
saved with the time and date. Procedure:
The data recorder contains a 3-axis • The fleet manager must set the following shock level
shock sensor. The sensor sensitivity parameters in the management portal (the parameters are
can be set via parameters. The the same for horizontal and vertical shocks):
setting can only be made through the management portal. • Weak:
Set triggering threshold to "2 G",
For trucks with a CAN bus, the travel and lift data are acquired via Set response to "display".
the access module in the data recorder. Information is exchanged
via the RS-232 interface of the access module. • Medium:
Set triggering threshold to "3 G",
For trucks without a CAN bus, the relevant inputs must be used on Set response to "display".
connector X684. • Strong:
For a shock event in conjunction with the crawl speed parameter Set triggering threshold to "4 G",
in the management portal, signalling (e.g. strobe light,...) can be Set response to "display".
facilitated by occupying pins 13/14 and 15/16 on X684. • Trigger shock event by heavy knocking on the data recorder.
"shock!" is shown on the display of the access module for 30
seconds.
• After 30 seconds the previous message is again displayed on
the access module.
• The fleet manager must reset the shock level parameters to
the previous settings.
tUNGHEINRICH 002 053 000 00019 03.13 6 (GB)
Data recorder interfaces PIN layout 6-pole SAAB (X682), to access module
PIN Description
1 - Batt.
2 + Batt
3 RS232
4 RS232
X 682 X 683 X 685 X 684
5 0V
6 Not Connect (NC)
6U10 PIN layout 6-pole SAAB (X683), to radio module
LCD
PIN Description
6U12
1 Not Connect (NC)
<\g=ai 2 Not Connect (NC)
••
mode
•• +
3 RS232
I I I |||X681
4 RS232
5 0V
6U11 Of C>" ft
X682
IIIIIIX683
6 12 V out
Analogue Digital
A _A _
A C
OOOOOOOOOOOOOOOO
5 j 6
X685
X684 jl 2
|4 13 8 I7
9 j'10 |11 13i15 j 16 112 !' I 14 !
tUNGHEINRICH 002 053 000 00019 03.13 7 (GB)
PIN layout 16-pole SAAB (X684) to connect additional PIN layout 6-pole SAAB (X685)
functions on trucks without CAN bus.
PIN Description
PIN Description
1 - Batt.
1 0 V out
2 + Batt
2 12 V out
3 RS232
3 Sensor 1 (in)
4 RS232
4 Sensor 1 (0 V in)
5 0V
5 Sensor 2 (in)
6 US V (12 V in)
6 Sensor 2 (0 V in)
7 Sensor 3 (in)
8 Sensor 3 (0 V in)
9 Lift signal
10 Lower signal
11 Forward travel signal
12 Reverse travel signal
13 Output shock 1 (NC)
14 Input shock 1 (NC)
15 Output shock 2 (NO)
16 Input shock 2 (NO)
tUNGHEINRICH 002 053 000 00019 03.13 8 (GB)
Description of the radio module Retrofitting ISM Online components
The conversion kit for ISM Online components depends on the
truck used by the customer. If there are no details on the truck in
the spare parts catalogue (JETI-ET), the components indicated in
"ISM Online component numbers" can be used.
As well as the hardware components, wiring sets, brackets and
covers must be taken into account. These hardware components
will differ depending on the truck model.
After installing ISM Online components, the truck's standard
parameter sets must be checked in the access module, see
section "Parametrising when retrofitting ISM Online components"
in chapter 002 053 000 00021 or section "Parametrising when
The radio module allows data to be exchanged between the truck retrofitting ISM Online components (for system trucks)" in
components and the management portal (via the gateway). chapter 002 053 000 00022.
The JUDIT diagnostics allow you to check whether data has been
transferred.
Parameter number 122 "radio transfer successful":
122 = 1 for data exchange,
122 = 0, if no data has been exchanged.
a To do this, at least 1 operation (switching the truck on and off)

must be performed within the transmission range of the gateway.
tUNGHEINRICH 002 053 000 00019 03.13 9 (GB)
ISM Online component numbers
Order
Component
number
Access module, cold store, 12 V - 48 V 51 208 310
Data recorder, 12 V - 48 V 51 208 312
Access module, cold store, 80 V 51 208 311
Data recorder, 80 V 51 208 313
Radio module 50 433 563
Transponder card (ISM Online)

51 232 462
Pack of 10
Transponder tag (ISM Online)

51 232 323
Pack of 10
ISM conversion cable 51 002 939
Extension:
Access module -> data recorder or 51 002 943
data recorder -> radio module
1116141513
tUNGHEINRICH 002 053 000 00019 03.13 10 (GB)
Conversion cable for attaching the ISM Online access
module Pin Name Comment
1 S2_out Key switch input
1,0 qmm 2 S2_back Key switch output
1 i 3 Battery+ Connect to the battery positive terminal.

2 Check the battery voltage class before
3-
installing the ISM access module.

4-
5-
4 Battery- Connect to battery negative terminal.

6-
7- 5 LISA contact N/A

8-
9- 11 0V Connect to battery negative terminal.

10 — 11
-
12 —
14 0V Not applicable if the seat/tiller switch (pin 16)
- switches to "Battery-" when actuated.
14
-
If a different (potential-free) switch is fitted to
-
- l6~ acquire the activity time, it must be fitted
between pins 14 and 16.
— 1 16 Seat/tiller This input is used as a signal transmitter to
— 2 signal determine the activity time.
— 3
— 4 transmitter Must match the "battery-" potential when
— 5 actuated, otherwise open or voltage < 5 V.
— 6 If a different (potential-free) switch is fitted to
— 7
— 8 acquire the activity time, it must be fitted
— 9 between pins 14 and 16.
HUNGHEINRICH 002 053 000 00019 03.13 11
Converting ISM shock thresholds to ISM Online Shock Corresponding Shock Corresponding
P»j In the management portal do not set any G values less than 1 thresholds in G value for ISM thresholds in G value for ISM
(area marked red). digits for ISM Online digits for ISM Online
135 7.41 205 11.25
Shock Corresponding Shock Corresponding 140 7.69 210 11.53
thresholds in G value for ISM thresholds in G value for ISM 145 7.96 215 11.80
digits for ISM Online digits for ISM Online
150 8.24 220 12.08
0 — 60 3.29
155 8.51 225 12.35
5 — 65 3.57
160 8.78 230 12.63
10 — 70 3.84
165 9.06 235 12.90
15 — 75 4.12
170 9.33 240 13.18
20 1.10 80 4.39
175 9.61 255 13.45
25 1.37 85 4.67
180 9.88 250 13.73
30 1.65 90 4.94
185 10.16 255 14.00
35 1.92 95 5.22
40 2.20 100 5.49
45 2.47 105 5.76
50 2.75 110 6.04
55 3.02 115 6.31
120 6.59 190 10.43
125 6.86 195 10.71
130 7.14 200 10.98
tUNGHEINRICH 002 053 000 00019 03.13 12 (GB)
Wiring diagrams for the ISM Online System
The wiring diagrams for the ISM Online system are contained in
the service manuals of the individual trucks.
tUNGHEINRICH 002 053 000 00020 03.13 1 (GB)
Setting the ISM access module to permanent mode Overriding the ISM access module for recovery
purposes
P»j For service, the ISM access module can be set to permanent
mode using the JUDIT to ensure that it is not switched off when
the "TIMEOUT" parameter expires. Q Overriding the access module is not intended for service purposes
but is used to recover the truck in the event of an access module
Requirement: failure.
• Truck is operational. Procedure:
• Connect the service computer to the truck. • Switch off the truck.
• Switch on service computer and truck. • Disconnect the battery.
Procedure: • Unplug the connector from the access module.
• Start the ISM Online project via JUDIT. • Connect the override connector.
• Set parameter 9 "permanent mode" to "1" in the • Reconnect the battery.
"communications parameter" window. • Switch on the truck.
• Quit ISM Online project • Recover the truck.
• Switch the truck off and on again. • After recovering the truck remove the override connector
The change has been accepted. again.
Start repairing the truck.
Q After servicing and/or repairs, reset the parameter to "0" to
re-activate the access module. [ÿj Override connector order number:
— 51 003 960
tUNGHEINRICH 002 053 000 00021 03.13 1 (GB)
Converting from ISM to ISM Online components (for EFG, VFG, ET and Junior trucks)
Requirement Procedure:
• Switch on the truck.
ISM Online components, expansion level 3/4 must be
installed in the truck: • Open JUDIT.
• Access module (6U10) • Mark the "ISM Online" JUDIT project.
• Data recorder with shock sensor (6U 11) • Press the "software download tool" button.
• Radio module (6U12) • Confirm the following window with the "continue" button
(arrow to the right).
Obtain the following data from the truck data sheet (extract
from ISM fleet manager software): • The following three steps must be completed in turn when
converting from ISM to ISM Online:
• CAN-bus version (JUDIT parameter: 1)
Fahrzeug: ISM Online Y = year
• Shock sensor mounting position (JUDIT parameter: 46)
M = month
• Shock thresholds D = day
Truck is switched off. 3 Freigaben alnd verftigbar
Truck is within the gateway transmission range. 1 YYYY-MM-DD Release 1
Connect the service computer to the truck. YYYY-MM-DD Release 2
Switch on the service computer. Release 3
3 YYYY-MM-DD
J
• Replacing the access module bootloader (release 1).
• Flashing the ISM Online firmware onto the access module
(release 2).
• Flashing the ISM Online firmware onto the data recorder
(release 3).
Q The above-mentioned three steps are described on the following

pages.
tUNGHEINRICH 002 053 000 00021 03.13 2 (GB)
Select release 1.
The release selected is shown by an arrow to the right of the
f-ahrzeug: ISM Online
table.
Press the "flash" button (2).
3 Freigaben aind verftigbar
• Follow the instructions in the following window.
I YYYY-MM-DD Release 1 Press the "read ISM components" button (1).
2 YYYY-MM-DD • Follow the instructions in the following window.
a YYYY-MM-DD The software versions of the latest ISM components used in
the truck are read out. The actual and target software
»•
versions are listed in JUDIT.
1.
Hi 2. 4J-
-
-w_* j
Replacing the access module bootloader (for EFG, VFG,

ET and Junior trucks)
Procedure:
• Press the "read ISM components" button (1).
The software versions of the latest ISM components used in
tUNGHEINRICH 002 053 000 00021 03.13 3 (GB)
Flashing the ISM Online firmware onto the access • Disconnect the battery.
module (for EFG, VFG, ET and Junior trucks). • Reconnect the battery.
ahrzeug: ISM Online • Follow the instructions in the following window.
3 Freigaben stnd verftlgbar the truck are read out. The actual and target software
1 YYYY-MM-DD
Messages in the access module display during the flash
2 YYYY-MM-DD Release 2
procedure:
3 YYYY-MM-DD
Message Meaning
r.m. . DownldZM •Access module is being flashed.
1.
-
2-.§->0 ZM
•Flash process successful.
•The software is being checked.
1 2
Procedure:
• Select release 2.
The release selected is shown by an arrow to the riqht of the
table.
• Press the "flash" button (2).
• Switch off the truck.
tUNGHEINRICH 002 053 000 00021 03.13 4 (GB)
Messaaes in the access module displav w hen flashina the data
recorder:
Fahrzeug: ISM Online
Message Meaning
3 Freigaben aind verfGgbar DownldDR •Data recorder is being flashed.
1| YYYY-MM-DD transfer •Transfer software to data recorder.
2 YYYY-MM-DD
3 YYYY-MM-DD Release 3 •Software transferred successfully to data
ready
recorder.
1.
Hi 2. 4J-
-
-w_* j
»• Final tasks
Q The flash procedure has been completed successfully when the

actual and target software versions are the same.
• Press the "exit" button (3).
The software download tool is ended.
Flashing the ISM Online firmware onto the data recorder • Set the parameters of the access module, see "Setting the
(for EFG, VFG, ET and Junior trucks). access module parameters on a new truck (for EFG, VFG, ET
and Junior trucks)" in this chapter.
Procedure:
The software versions of the latest ISM components used In
• Select release 3.
The release selected is shown by an arrow to the riqht of the
table.
• Press the "flash" button (2).
tUNGHEINRICH 002 053 000 00021 03.13 5 (GB)
ISM Online componenl parameter setting when replacing or retrofitting and for delivery of a new truck
(for EFG, VFG, ET and Junior trucks)
After replacing or retrofitting an access module (6U10) or if a new Arrange for the administrative personnel of the Jungheinrich
truck is delivered, the parameters must be set via JUDIT. subsidiary to enter the lock number of the new access
The following instructions outline the tasks to be performed after module in the Jungheinrich SAP system.
replacing or retrofitting an access module or if a new truck is Automatic transfer of lock number from the Jungheinrich SAP
delivered. ERP system into the customer management portal.
This procedure is not required if you are replacing a data recorder • Transaction number "IE02" (service features tab) in SAP
with an shock sensor (6U11) or a radio module (6U12). ERP.
Setting the parameters after replacing the defective

access module (for EFG, VFG, ET and Junior trucks)
Requirement:
Procedure:
• Remove the faulty access module (6U10).
• Connect the new access module (6U10) to the CAN bus and
the power supply (see relevant wiring diagrams for the truck).
• Connect the service computer to the truck.
• Switch on service computer and truck.
• Set the parameters of the access module (6U10) via JUDIT,
see "Parametrieren des Zugangsmoduls (bei EFG, VFG, ET
und Junioren)" in this chapter.
• Read and record the lock number of the new access module:
• Start the ISM Online project via JUDIT.
• Record the "lock number" parameters 123 & 124 .
tUNGHEINRICH 002 053 000 00021 03.13 6 (GB)
Setting the parameters when retrofitting ISM Online • Read and record the lock number of the access module:
components (for EFG, VFG, ET and Junior trucks) • Start the ISM Online project via JUDIT.
Requirement:
• Arrange for the administrative personnel of the Jungheinrich
subsidiary to enter the lock number of the new access
Procedure: module in the Jungheinrich SAP system.
• Install the data recorder with the shock sensor (6U 11) (see • Automatic transfer of lock number from the Jungheinrich SAP
relevant wiring diagrams for the truck). ERP system into the customer management portal.
• Fit the radio module (6U12) (see relevant wiring diagrams for • Transaction number "IE02" (service features tab) in SAP
the truck). ERP.
• Connect the access module (6U10) to the CAN bus and the
power supply (see relevant wiring diagrams for the truck).
tUNGHEINRICH 002 053 000 00021 03.13 7 (GB)
Setting the access module parameters on a new truck Setting the access module parameters (for EFG, VFG,
(for EFG, VFG, ET and Junior trucks) ET and Junior trucks)
Requirement: Requirement:
• Truck is within the gateway transmission range. • Truck is operational.
• Connect the service computer to the truck. • Truck is within the gateway transmission range.
• Switch on service computer and truck. • Connect the service computer to the truck.
Procedure: • Switch on the service computer.
• Read and record the lock number of the access module:
• Start the ISM Online project via JUDIT.
• Arrange for the key user to enter the lock number of the
access module in the Jungheinrich SAP system.
• Transfer of lock number from the Jungheinrich SAP ERP
system into the customer management portal by the key
user.
• Transaction number "IE02" (service features tab) in SAP
ERP.
tUNGHEINRICH 002 053 000 00021 03.13 8 (GB)
Procedure: Using the JUDIT, check the following parameter in the "shock
• Start the ISM Online project via JUDIT. parameters" window and change if necessary.
• Using the JUDIT, check the following parameters in the • Check "shock sensor mounting position" parameter no. 46
"communications parameters" window and change if according to the tooltip and change if necessary.
necessary Parameter 46 = 1 Parameter 46 = 2 Parameter 46 = 3
• Check parameter no. 1 "CAN-bus version" according to Vertical Vertical Vertical
the tooltip and change if necessary.
• Enter "gateway serial number" parameter nos. 95 / 96. * a Horizontal
i Horizontal
Note in the event of several gateways at the
application site. Horizontal
The serial number of the gateway within whose
transmission range the truck operates for the longest
7"
Set the "search gateway" function if the truck is operated
period of time must be entered for the parameters 95 / 96. within range of several gateways (see section "Setting
"search gateways" function").
Q The gateway serial number (2) is to be found on the data plate (1)
on the back of the gateway. The value of "gateway serial number" Now press the "Save" button to store the changed
parameter nos. 95 / 96 corresponds to the gateway serial number parameters.
(2) without the "Ox" prefix. Quit ISM Online project
I*p nw 1nn KW/Baujahr
Calendar Week /Year of manufacture Disconnect the battery.
Oxabcd ) Reconnect the battery.
Lieferanten-Nr.
Type number Supplier no.
Sachnummer
Part number
Revisionnummer
Revision number Press the green switch (1) to switch
LAN1
LAN2
on the truck.
Hersteller
Manufacturer When you switch the truck on
C€ again, the changed parameters will
now be activated in the access
Example: module.
ÿ Gateway serial number (2) is: Oxabcd.
ÿ Value for "gateway serial number" parameter nos. 95 / 96
"gateway serial number" to be set is: abed.
tUNGHEINRICH 002 053 000 00021 03.13 9 (GB)
Setting up the "search gateway function • Setting "search gateway - min. interval" parameter no. 136:
Requirement: • Description of "search gateway - min. interval" parameter
no. 136:
• The truck is within range of several gateways at the
Sets the minimum time interval between two attempts
application site.
(broadcasts) to find other gateways.
• The truck is within range of two gateways for a longer period
• Default value:
of time.
30 (in seconds)
Q The "search gateway" function loads the radio connection to the
gateway For this reason, do not activate the "search gateway"
• Setting "search gateway - max. interval" parameter no. 137:
• Description of "search gateway - max. interval" parameter
function if the truck is only to be used within range of a single no. 137:
gateway.
Sets the maximum time interval between two attempts
Procedure: (broadcasts) to find other gateways.
• Setting "search gateway - trigger" parameter no. 135: • Default value:
• Description of "search gateway - trigger" parameter no. 4 (in minutes)
135:
Sets the maximum number of unsuccessful attempts to
communicate with the gateway before the access module
searches for other gateways.
Q Searching for other gateways is called broadcasting.

• Default values:
0 ("search gateway" function deactivated)
5 ("search gateway" function activated)
tUNGHEINRICH 002 053 000 00021 03.13 10 (GB)
Example:
Description of "search gateway - factor"parameter no. "Search gateway - trigger" parameter no. 135 = 5
138: "Search gateway - min. interval" parameter no. 136 = 30
This parameter sets the factor for the increase of the time "Search gateway - max. interval" parameter no. 137 = 5
interval between the minimum and the maximum "search "Search gateway - factor" parameter no. 138 = 2
gateway" intervals.
Default value: Attempts (Broadcast) to find other gateways
2
Attempt Time
1. • after 30 seconds
(corresponds to parameter no. 136)
2. •after 1 minute
= attempt 1 * parameter no. 138
= 30 seconds * 2
3. •after 2 minutes
= 1 minute * 2
= 2 minute * 2
>5 •after 5 minutes

corresponds to parameter no. 137
Reason:
The result when multiplying attempt 4 with parameter
138 should not be greater than parameter 137.
tUNGHEINRICH 002 053 000 00022 03.13 1 (GB)
Converting ISM to ISM Online components (for system trucks)
Requirement Obtain the following data from the truck data sheet (extract
from ISM fleet manager software):
• ISM components of the expansion level 3/4 must be fitted to
• CAN-bus version
system trucks (with LS software more recent than
LS_05_01): • Shock sensor mounting position
• Access module (6U10) • Shock thresholds
• Data recorder with shock sensor (6U11) Truck is within the gateway transmission range.
• Radio module (6U12) Connect the service computer to the truck.
• 3-meter extension cable to directly connect the access Switch on the service computer.
module and the data recorder (order number: 510 029 43)
Q Alternatively, the data recorder can be removed from the truck.

• Delivery transponder (order number: 512 346 17)
tUNGHEINRICH 002 053 000 00022 03.13 2 (GB)
Replacing the access module bootloader (for system • Press the red button (3) until "800k ZM" is shown in t he
truck) display (2) of the access module.
Press the green button (1).
Procedure:
The message "CanOpen" is shown in the display (2) of the
• Switch on the truck. access module. The truck switches on.
• Log in to truck using the service computer. Wait until the truck is powered-up (at least one minute).
• Open the "computer" visualisation screen in the "status Truck is in standby mode. The message "Please check the
diagnosis" menu. emergency button!!" is shown in the driver's display.
• Enter the value„8.8888" for the setpoint of the ISM access
module in the visualisation screen.
Note the spelling: Enter the value with a dot.
• Confirm the entry with the Enter key.
• Disconnect the battery.
• Press the emergency disconnect switch.
• Obtain assistance from another
person.
• Carry out the following activities
concurrently:
• Press and hold down the red
button (3).
• Get a second persons to
connect the battery.
• Wait until "500k ZM" is shown in
the display (2) of the access
module.
tUNGHEINRICH 002 053 000 00022 03.13 3 (GB)
• Press the "loading" button of the access module in the Flashing the ISM Online firmware onto the access
"computer" visualisation screen. module (for system trucks).
A DOS window opens.
Procedure:
• Close JUDIT.
After a short time the bootloader flash procedure starts
automatically. The flash procedure progress is shown in %. • Press the emergency disconnect switch.
When the flash procedure is complete, the DOS window • Obtain assistance from another person.
closes automatically. "Finished" is shown in the display (2) of • Carry out the following activities concurrently:
the access module. • Press and hold down the red button (3).
• Disconnect the battery. • Get a second persons to connect the battery.
• Unlock emergency disconnect • Wait until "500k ZM" is shown in the display (2) of the access
switch by turning. module.
• Reconnect the battery. • Press the red button (3) until "800k ZM" is shown in the
The message "writing" and then display (2) of the access module.
"2.0000ok" are shown for a short • Press the green button (1).
time in the display (2) of the access
module. The access module The message "CanOpen" is shown in the display (2) of the
access module. The truck switches on.
bootloader (for system trucks) has
been replaced. • Wait until the truck is powered-up (at least one minute).
Truck is in standby mode. The message "Please check the
Q The truck can no longer be switched on
using the access module.
emergency button!!" is shown in the driver's display.
tUNGHEINRICH 002 053 000 00022 03.13 4 (GB)
• Log on to the truck using the service computer and call up Disconnect the battery.
the "computer" visualisation screen in the "diagnostics Unlock the emergency disconnect
status" menu. switch by turning.
-ÿ| "USB inactive" or USB active" in the "computer" visualisation Reconnect the battery.
screen can be ignored. The message "CONNECT?" is
• Enter the value„3.0000" for the setpoint of the ISM access shown in the display (2) of the
module in the visualisation screen. access module. The ISM Online
firmware has been flashed onto the
Q Note the spelling: Enter the value with a dot.
access module (for system trucks).
• Press the "loading" button of the access module in the
"computer" visualisation screen.
A DOS window opens.
• Close JUDIT.
After a short time the firmware flash procedure of the access
module starts automatically. The flash procedure progress is
shown in %. When the firmware flash procedure is complete,
the DOS window closes automatically. "Finished" is shown in
the display (2) of the access module.
tUNGHEINRICH 002 053 000 00022 03.13 5 (GB)
Flashing the ISM Online firmware onto the data recorder • Connecting the access module (6U10) and the data recorder
(for system trucks). with shock sensor (6U11) directly:
• Pull the access module (6U10) out of the cover.
Procedure:
• Remove the plug connector X681 from the access module
• Disconnect the battery. (6U10).
• Glue the delivery transponder onto the access module. • Remove the plug connector X682 from the data recorder
• Obtain assistance from another person. (6U11).
• Carry out the following activities concurrently: • Connect one end of the 3-meter extension cable to contact
• Press and hold down the red button (3) and the green X681 of the access module (6U10).
button (1) on the access module. • Connect the other end of the 3-meter extension cable to
• Get a second persons to connect the battery. contact X682 of the data recorder (6U11).
• Wait until "2JUSTCAP" is shown in the display (2) of the The access module (6U10) and the data recorder (6U11)
access module (at least 10 seconds). have been directly connected.
• Press the red button (3) until "5CanO800" (2) is shown in the • Reconnect the battery.
display (2) of the access module. The message "CONNECT?" and
• Press the green button (1). then "OK?" are shown for a short
The access module will be restarted. The message time in the display (2) of the access
"CONNECT?" and then "OK" are shown for a short time in module.
the display (2) of the access module.
• Wait until "OK?" is shown in the display (2) of the access
Q Error messages which may be appear in
the display (2) of the access module can
module. be ignored.
• Disconnect the battery. • Wait until "OK?" is shown in the
display (2) of the access module.
• Press the green button (1).
The event message "E0617"
appears in the driver's display. This event message can be
ignored.
tUNGHEINRICH 002 053 000 00022 03.13 6 (GB)
• Log on to the truck using the service computer and call up Wait until the truck is powered-up (at least one minute).
the "computer" visualisation screen in the "diagnostics Truck is in standby mode. The message "Please check the
status" menu. emergency button!!" is shown in the driver's display.
• Enter the value„3.0000" for the setpoint of the ISM data Press the "loading" button of the data recorder in the
recorder in the visualisation screen. "computer" visualisation screen.
Q Note the spelling: Enter the value with a dot. A DOS window opens.
Close JUDIT.
• Disconnect the battery. After a short time the firmware flash procedure of the data
• Press the emergency disconnect switch. recorder starts automatically. The flash procedure progress is
shown in %. When the firmware flash procedure is complete,
• Remove the delivery transponder from the access module.
the DOS window closes automatically. "UeberV24" is shown
• Obtain assistance from another person. in the display (2) of the access module. The data are
• Carry out the following activities concurrently: transferred automatically to the data recorder. This process
• Press and hold down the red can take 2 to 3 minutes.
button (3). Wait until "finished" is shown in the display (2) of the access
• Get a second persons to module.
connect the battery.
• Wait until "500k DR" is shown in
the display (2) of the access
module.
• Press the red button (3) until "800k
DR" is shown in the display (2) of
the access module.
• Press the green button (1).
The message "CanOoDR is shown
in the display (2) of the access module. The truck switches on.
tUNGHEINRICH 002 053 000 00022 03.13 7 (GB)
• Disconnect the battery. Final tasks
• Unlock emergency disconnect switch by turning.
• Set the parameters of the access module, see "Access
• Disconnect the extension cable from the access module module parameter setting for a new truck (for system trucks)"
(6U10) and the data recorder with shock sensor (6U11). in this chapter.
• Reconnect the access module (6U10) and the data recorder
(6U11) to the truck.
The wiring diagrams for the ISM Online system are contained in
the service manuals of the individual trucks.
• Reconnect the battery.
• Glue the delivery transponder onto
the access module.
The event message "E0617"
appears in the driver's display
when the truck is switched on. This
event message can be ignored.
The ISM Online firmware has been
flashed onto the data recorder (for
system trucks).
2 3
tUNGHEINRICH 002 053 000 00022 03.13 8 (GB)
ISM Online componenl parameter setting when replacing or retrofitting and for delivery of a new truck
(for system trucks)
After replacing or retrofitting an access module (6U10) or if a new Read and record the lock number of the new access module:
truck is delivered, the parameters must be set via JUDIT. • Note the "lock number" parameter value.
The following instructions outline the tasks to be performed after
Arrange for the administrative personnel of the Jungheinrich
replacing or retrofitting an access module or if a new truck is subsidiary to enter the lock number of the new access
delivered. module in the Jungheinrich SAP system.
This procedure is not required if you are replacing a data recorder Automatic transfer of lock number from the Jungheinrich SAP
with a shock sensor (6U11) or a radio module (6U12). ERP system into the customer management portal.
• Transaction number "IE02" (service features tab) in SAP
Parameter setting when replacing a faulty access ERP.
module (for system trucks)
Requirement:
Procedure:
• Remove the faulty access module (6U 10).
• Connect the new access module (6U10) to the CAN bus and
the power supply (see relevant wiring diagrams for the truck).
see "Access module parameter setting (for system trucks)" in
this chapter.
• Open the "ISM" visualisation screen in the "truck status" menu.
tUNGHEINRICH 002 053 000 00022 03.13 9 (GB)
Parameter setting for retrofitting ISM Online Read and record the lock number of the new access module:
components (for system trucks) • Note the "lock number" parameter value.
Requirement:
Arrange for the administrative personnel of the Jungheinrich
• Truck is within the gateway transmission range. module in the Jungheinrich SAP system.
Procedure: Automatic transfer of lock number from the Jungheinrich SAP
• Equip the data recorder with the shock sensor (6U 11) (see ERP system into the customer management portal.
relevant wiring diagrams for the truck). • Transaction number "IE02" (service features tab) in SAP
• Fit the radio module (6U12) (see wiring diagrams for the ERP.
respective truck).
• Connect the access module (6U10) to the CAN bus and the
power supply (see relevant wiring diagrams for the truck).
this chapter.
• Open the "ISM" visualisation screen in the "truck status"
menu.
tUNGHEINRICH 002 053 000 00022 03.13 10 (GB)
Access module parameter setting for a new truck (for • Read and record the lock number of the new access module:
system trucks) • Note the "lock number" parameter value.
• Arrange for the administrative personnel of the Jungheinrich
Requirement:
• Truck is within the gateway transmission range. module in the Jungheinrich SAP system.
• Connect the service computer to the truck. • Automatic transfer of lock number from the Jungheinrich SAP
• Switch on service computer and truck. ERP system into the customer management portal.
Procedure: • Transaction number "IE02" (service features tab) in SAP
• Set the parameters of the access module (6U10) via JUDIT, ERP.
this chapter.
• Open the "ISM" visualisation screen in the "truck status"
menu.
tUNGHEINRICH 002 053 000 00022 03.13 11 (GB)
Access module parameter setting (for system trucks) • Enter the "gateway serial number" parameter with the prefix
"16#".
Requirement: Note in the event of several gateways at the application
• Truck is operational. site
• Truck is within the gateway transmission range. The serial number of the gateway within whose transmission
• Connect the service computer to the truck. range the truck operates for the longest period of time must
be entered for the "gateway serial number" parameter.
• Switch on the service computer.
Procedure: Q The gateway serial number (2) is to be found on the data plate (1)
on the back of the gateway. The value of the "gateway serial
• Set the CAN-bus version on the access module , see section number" parameter corresponds to the gateway serial number(2)
"Setting CAN-bus versions on the access module" in chapter without the "Ox" prefix.
"002 053 000 00023". Typ KW/Baujahr
r,w mn
Calendar Week /Year of manufacture
• Hold the delivery transponder in £5£ 0xabcd )
y
front of the access module. Type number
Lieferanten-Nr.
Supplier no.
Sachnummer Revisionnummer
• Press the green switch (1) to switch Part number
LAN1
Revision number
on the truck. LAN2
Hersteller
• Log on to the truck using the Manufacturer
service computer and call up the C€

"default setting" visualisation
screen in the "truck status" menu. Example:
• Set the "access-protection type" • Gateway serial number (2) is: Oxabcd.
parameter to 4 in the visualisation • "Gateway serial number" parameter to be set is: 16#abcd
screen in the section "Setting up (see tooltip).
special equipment".
[ÿj The "gateway serial number" to be entered must be prefixed by
• Open the "ISM" visualisation screen in the "truck status" — "16#".
menu.
tUNGHEINRICH 002 053 000 00022 03.13 12 (GB)
Check the "shock sensor installation" parameter according to Setting up the "search gateway function
the tooltip and change if necessary. Requirement:
Parameter = 1 Parameter = 2 Parameter = 3
• "ISM" visualisation screen in the "truck status" menu is open.
Vertical Vertical Vertical
1 '1
4
ÿ
4
• The truck is within range of several gateways at the
application site.
• The truck is within range of two gateways for a longer period
-
Horizontal / Horizontal
r
Horizontal
7 of time.
The "search gateway" function loads the radio connection to the
Set the "search gateway" function if the truck is operated gateway. For this reason, do not activate the "search gateway"
within range of several gateways (see section "Setting function if the truck is only to be used within range of a single
"search gateways" function"). gateway.
Close JUDIT.
Disconnect the battery.
Reconnect the battery.
Press the green switch (1) to switch
on the truck.
When you switch the truck on
again, the changed parameters will
now be activated in the access
module.
tUNGHEINRICH 002 053 000 00022 03.13 13 (GB)
• Setting "search GW - min. inlterval" (2) parameter:
Service P»j GW = gateway

Suche Gateway - Ausloser
• Description of "search GW - min. interval" parameter:
1 Sets the minimum time interval between two attempts
Suche GW-Min. Intervall 2 (broadcasts) to find other gateways.
Suche GW-Max. Intervall 3 • Default value:
30 (in seconds)
Suche Gateway -Faktor 0 4 • Setting "search GW - max. interval" (3) parameter:
J
• Description of "search GW - max. interval" parameter:
Procedure:
Sets the maximum time interval between two attempts
• Setting "search gateway - trigger" (1): (broadcasts) to find other gateways.
• Description of "search gateway - trigger": • Default value:
Sets the maximum number of unsuccessful attempts to 4 (in minutes)
communicate with the gateway before the access module
searches for other gateways.
P»j Searching for other gateways is called broadcasting.
• Default values:
0 ("search gateway" function deactivated)
5 ("search gateway" function activated)
tUNGHEINRICH 002 053 000 00022 03.13 14 (GB)
Example:
"Search gateway - trigger" parameter (1) = 5
Service "Search gateway - min. interval" parameter (2) = 30
Suche Gateway - Ausloser 0
I 1 "Search gateway - max. interval" parameter (3) = 5
"Search gateway - factor" parameter (4) = 2
Suche GW-Min. Intervall 0 ! 2
Suche GW-Max. Intervall « -r- 3 Attempts (broadcasts) to find other gateways
Suche Gateway - Fsktor o ! 4 Attempt Time
1. • after 30 seconds
Setting "search gateway - factor" (4): (corresponds to parameter no. 136)
• Description of the "search gateway - factor" parameter:
This parameter sets the factor for the increase of the time 2. •after 1 minute
interval between the minimum and the maximum "search = attempt 1 * parameter no. 138
gateway" intervals. = 30 seconds * 2
• Default value: 3. •after 2 minutes
2 = attempt 2 * parameter no. 138
= 1 minute * 2
= 2 minute * 2
>5 •after 5 minutes

corresponds to parameter no. 137
Reason:
The result when multiplying attempt 4 with parameter
138 should not be greater than parameter 137.
tUNGHEINRICH 002 053 000 00023 03.13 1 (GB)
Retrofitting or replacing ISM Online components in 500-kbaud system trucks
General information Requirements
The description of the retrofitting or replacement of ISM Online • Delivery transponder present.
components refers to 500-kbaud system trucks with the following
software versions: Q Delivery transponder order number: 512 346 17
• Following ISM Online components of the expansion level 3 /
• D_ (EKS 310)
4 have been ordered:
• HC_ (EKX 410, EKX 513-515 and EKS 513-515)
• Access module (6U10)
• G_(ETX 513/515)
• Data recorder with shock sensor (6U 11)
A It is not possible to set the access module parameters on 500-
kbaud system trucks. The steps described in this chapter must be
• Radio module (6U12)
• ISM-Online-capable truck which meets one of the following
carried out to set the access module parameters.
requirements:
• System trucks with LS software
• 48-V or 80-V Jungheinrich trucks (ET, EFG)
tUNGHEINRICH 002 053 000 00023 03.13 (GB) 2
Installing ISM Online components in an ISM-Online- Retrofitting or replacing ISM Online components using
capable truck an ISM-Online-capable truck
• Switch off the ISM-Online-capable truck.
Retrofit or replacement using a 48-V or 80-V Jungheinrich
• Install the access module (6U10) in the ISM-Online-capable truck
truck.
• Setting the CAN-bus version of the ISM-Online-capable truck If the access module (6U10) has been fitted to a 48-V or 80-V
on the access module: Jungheinrich truck (ET, EFG), the following steps must be carried
out:
• Refer to chapter "Bus systems" for information on the
selection of CAN-bus versions. • For information on parametrising the access module of a new
truck (for EFG, VFG, ET and Juniors), refer to the section of
• Refer to chapter 002 053 000 00024 "Setting CAN-bus the same name in chapter "002 053 000 00021".
versions on the access module" for information on setting
the CAN-bus version. • For information on parametrising the access module (for
EFG, VFG, ET and Juniors), refer to the section of the same
name in chapter "002 053 000 00021".
Set the CAN-bus version on the access module only after
installing it in the 500-kbaud system truck, see section "Setting
CAN-bus versions on the access module" in this chapter.
• Delete the authorisation list in the access module (6U 10) with
JUDIT.
To do this, press the "authorisation list: delete total list"
button in the ISM Online project.
• Switch off the ISM-Online-capable truck.
• Remove the access module (6U10) from the ISM-Online-
capable truck.
• Install the ISM Online components of the expansion level 3 /
4 in the 500-kbaud system truck.
tUNGHEINRICH 002 053 000 00023 03.13 3 (GB)
Retrofit or replacement using a system truck (LS software) Setting the CAN-bus version in the access module
If the access module (6U10) has been fitted in a system truck with • Set the CAN-bus version on the access module to the
LS software , the following steps must be carried out: following value, see section "Setting CAN-bus versions on
• For information on parametrising the access module of a new the access module" in chapter "002 053 000 00024".
truck (for system trucks), refer to the section of the same • 6CanO500 (CANopen with 500 kbaud)
name in chapter "002 053 000 00022".
The 500-kbaud system truck has been equipped with ISM Online
• For information on parametrising the access module (for
components.
system trucks), refer to the section of the same name in
chapter "002 053 000 00022".
Set the CAN-bus version on the access module only after
installing it in the 500-kbaud system truck, see section "Setting
CAN-bus versions on the access module" in this chapter.
• Delete the authorisation list in the access module (6U10) with
JUDIT.
To do this, press the "authorisation list: delete total list"
button in the ISM Online project.
• Switch off the system truck with LS software.
• Remove the access module (6U10) from the ISM-Online-
capable truck.
• Install the ISM Online components of the expansion level 3 /
4 in the 500-kbaud system truck.
tUNGHEINRICH 002 053 000 00024 03.13 1 (GB)
Setting the CAN-bus version in the access module • Setting the CAN-bus version:
• Press the red key (3) until the required CAN-bus version is
Requirement:
shown on the display (2).
• Access module not yet configured in the ISM Online system
• Press the green key (1) to save the displayed CAN-bus
(authorisation list in access module non-existent or empty).
version.
Required tools and materials: • The access module starts with the CAN-bus version set.
• Delivery transponder (order number: 51 234 617)
Sequence of CAN-bus versions displayed on the access
Procedure:
module
• Obtain assistance from another person.
• Carry out the following activities
concurrently: Display Bus system
• Hold the delivery transponder in
front of the access module. 2JUSTCAP Justcap
• Press and hold down the green
4CanO250 CANopen with 250 kBaud
(1) and red (3) keys on the
access module. 5CanO800 CANopen with 800 kBaud
• Get a second persons to
connect the battery. 6CanO500 CANopen with 500 kBaud
Wait until the first CAN-bus version
"2JUSTCAP" is shown in 7noCan No CAN bus
display (2) of the access module (at
8CanOJH Jungheinrich CANopen
least 5 seconds).
tUNGHEINRICH 002 053 000 00025 03.13 1 (GB)
Error Messages / Trou bleshooting
Error messages during the flash procedure
Display Meaning Remedy
•Carry out the access module flash procedure again.

ErrorZM •Access module flash procedure was not successful.
•Replace the access module.
•Carry out the data recorder flash procedure again.

ErrorDR •Data recorder flash procedure was not successful.
• Replace data recorder.
•Old bootloader of access module has been

•Select the most recent software version.
Writing followed by successfully replaced by the new bootloader.
•Carry out the access module flash procedure again.
BL1010ok •However, there is no application software on the
•Carry out the data recorder flash procedure again.
access module.
tUNGHEINRICH 002 053 000 00025 03.13 2 (GB)
Error display in access module
The access module has an self-diagnostic feature which can be used to localise error sources: This self-diagnostic feature is displayed on the
access module if an error occurs:
Er.: 101
Q Er.: 101: Input/output error.

Possible error source: Faulty sensors
Invalid voltage at optional sensor 1 (stage 4 only).

Er.:101a No sensor 1 present: Set parameters #11-17 to "0".
Sensor 1 present: The sensor voltage is out of range (0.5-9.5 volts)

Er.:101b No sensor 2 present: Set parameters #20-26 to "0"

Er.:101c No sensor 3 present: Set parameters #29-35 to "0"
tUNGHEINRICH 002 053 000 00025 03.13 3 (GB)
Er.: 102
Q Er.: 102: Internal error.

Possible error sources: Software error, faulty internal hardware
Er.:102a Communication between access module and data recorder interrupted.
Er.:102e Faulty radio module.
Er.:102f "Radio channel" setting is 0, set parameter to 31.
Er.:102g Transmission output too low, set "radio-transmission output" parameter to 31 .
Er.:102h Faulty access module.
Er.: 102i Faulty data recorder.

tUNGHEINRICH 002 053 000 00025 03.13 4 (GB)
Er.: 103
Q Er.: 103: Parameter error.

Possible error source: Inconsistent parameter setting
Er.:103a Select standby timeout (parameter #5) lower than truck timeout (parameter #6).
Er.:103b Threshold value 1 (parameter #11) lower than the smallest difference between 2 switching thresholds (parameters #12-17).
Er.:103c Threshold value 2 (parameter #20) lower than the smallest difference between 2 switching thresholds (parameters 21-26).
Er.:103d Threshold value 3 (parameter #29) lower than the smallest difference between 2 switching thresholds (parameters #30-35).
Er.:103e The sequence of the switching thresholds (parameters #12-17) is not in ascending order.
Er.:103f The sequence of the switching thresholds (parameters #21-26) is not in ascending order.
Er.:103g The sequence of the switching thresholds (parameters #30-35) is not in ascending order.
Er.:103h The sequence of the shock thresholds (parameters #47-49) is not in ascending order.
Er.:103i The sequence of the shock thresholds (parameters #50-52) is not in ascending order.
Er.: 103j Implausible bus log.
Er.:103k Incorrect baud rate.

tUNGHEINRICH 002 053 000 00025 03.13 5 (GB)
Error / Cause / Remedy
Error Cause Remedy
•Check and restore power supply.
•No power supply to access module
•Arrange for fleet manager to extend the
•Truck cannot be switched on •Transponder no longer valid
transponder validity period in the
Display shows "XIDENT01...09" error code
management portal.
•Truck cannot be switched on even with the •Replace access module and update
•Faulty access module
"master transponder" configuration.
•Reduce the sensor switching threshold.
•No shocks recorded •Sensor sensitivity too high •Parameters are set in the management
portal by the fleet manager.
•Increase the sensor switching threshold.
•Too many shocks recorded •Sensor sensitivity too low •Parameters are set in the management
portal by the fleet manager.
•Drive truck to within transmitting range of
•Truck out of range of transmitter/receiver of
•No data transferred to system the gateway, approx. 30 m, if possible within
evaluation unit
visibility range from antenna to antenna.
•Check radio transmission in JUDIT
•Faulty transmitter
diagnostics.
•A truck does not transmit any data •Data recorder does not send signals to
•Replace transmitter.
transmitter
•Replace data recorder.
tUNGHEINRICH 002 053 000 00026 03.13 1 (GB)
Gateway
Gateway assembly Gateways LEDs and ports:
Requirements for the Gateway assembly location: P»j For details of the Gateway LEDs and ports, refer to the relevant
• GSM reception must be provided. sections in the ISM Online operating instructions.
• Gateway must be in contact with the truck at least once a
day. Gateway technical specifications
The Gateway should therefore be fitted at a location where
the trucks pass by at least once a day, e.g. near the battery Q For details of the Gateway technical specifications, refer to the rel¬
evant section in the ISM Online operating instructions.
charging station etc.
Procedure: Power supply unit technical specifications
• Fit the Gateway upright with the LEDs facing the ground.
Q For details of the power supply unit technical specifications, refer
to the relevant section in the ISM Online operating instructions.
Q The drill hole pattern can be found in the ISM Online operating
instructions.
• Fit the GSM antenna.
• Connect the Gateway to the mains supply.
During the operating phase (approx. 3 - 4 minutes after
power up) the flashing "RSP" and "GSM" LEDs indicate that
the Gateway is connected to the mobile network. If one of the
LEDs is not lit during the operating phase, the Gateway must
be fitted at another location.
tUNGHEINRICH BUS systems 03 15 1 dD
EJC 212-220 (05.08-04.12) X
BUS systems used
EJC B12/B14/B16 X
Truck Jungheinrich
CANopen Justcap EJC 2 14/216/220/212z/214z/ X
250kbaud 216z/220z (04.12-)
Junior EJD 220 (05.05-12.09) X
ECE 118 (08.06-04.10) X EJD 220 (01.10-) X
ECE 118 Co (05.10-04.13) X EJD K18 (02.05-05.08) X
ECE 118 (05.13-) X EJD K18 (06.08-) X
ECE 220 XL (04.04-09.07) X EJE 116-120 (10.03-03.07) X
ECE 220 (04.04-03.07) X EJE 116-120 (04.07-) X
ECE 220/225 (12.06-) X EJE C20 (08.03-09.07) X
ECE 220/225 HP (02.09-) X EJE C 20 (10.07-) X
ECE 310 (02.09-) X EJE 112i (11.11-) X
ECE 320 (02.09-) X EJE 112i (08.14-) X
EJC 110-112 (01.05-08.07) X EJE 220-230 (10.03-04.07) X
EJC 110-112 (09.07-05.12) X EJE 220-235 (05.07-) X
EJC 110/112/212/ X EJR 120n (05.14-) X

112 RK (06.12-)
EKS 110 (07.04-03.15) X
EJC 212-220 (12.05-05.08) X
EKS 110 (04.15-) X
tUNGHEINRICH BUS systems 03 15 2 dD
EMC 110 (04.09-) X ESE 220 (01.05-03.10) X
EMC 110/B 10/110RK (11.14-) X ESE 320 (01.05-03.10) X
ERC 212-216 (10.01-01.04) X ESE 220/320 (03.10-) X
ERC 212-216 (02.04-03.11) X ESE 420-430 (11.04-07.09) X
ERC 212-216 (03.11-) X ESE 420-430 (07.09-) X
ERC 215a (11.12-) X ESE 530 (11.04-03.10) X
ERD220 (11.03-06.10) X ESE 533 (03.10-) X
ERE 120 (09.05-04.08) X EZS 010 (09.10-) X
ERE 120 (05.08-07.12) X EZS 130 (08.08-07.09) X
ERE 120/C20 (07.12-) X EZS 130 Co (08.09-) X
ERE 220 (10.03-09.07) X EZS 330/350 XL (04.06-04.07) X
ERE 225 (10.07-) X EZS 350 XL (05.07-03.11) X
ERE 225a (10.13-) X EZS 350 (08.09-03.11) X
ESC 214-216/ X EZS 350/350XL/C40 (04.11-) X

316/316z (08.09-)
EZS 570 (07.08-) X
ESD 120 (01.05-) X
EZS 570/580/590 (02.15-) X
ESD220 (01.05-06.10) X
ESD 220 (07.10-) X
ESE 120 (01.05-) X

HUNGHEINRICH BUS systems 03.15
ETV Q 20/ Q 25 (04.02-) X

BUS systems used
ETV Q 20/ Q 25 (- 08.10) X
Truck Jungheinrich
CANopen Justcap ETV Q 20/ Q 25 (10.10-) X
250kbaud
ETR 230/235 (06.15-) X
Spare Parts
ETR 314/320 (03.06-11.09) X
ETM/V 110-116 (04.99-11.05) X
ETR 335d/340/345 (05.14-) X
ETV 110-116 (12.05-06.14) X
ETV 110-112 (07.14-) X
ETM/V 214-216 (10.03-11.05) X
ETM/V 214/216 (12.05- 08.11) X
ETMN 214/216 (09.11-) X
ETM/V 320/325 (12.04-11.05) X
ETM/V 320/325 (12.05-09.11) X
ETM/V 318-325 (09.11-) X
ETV-H 320 (06.99-12.04) X
ETV C 16/ C 20 (05.99-05.08) X
ETV C 16/C20 (06.08-02.15) X
ETV C16/C20 (03.15-) X
ETV-Q 20/25 (08.89-04.02) X

ERC 215a (11.12-) X

BUS systems used
ERE 225a (10.13-) X
Truck Jungheinrich
CANopen CANopen ETX 513-515 (10.04-06.11) X
CANopen
500 kbaud 800 kbaud
250kbaud
ETX 513-515 (03.11-)
X
System ETX a
EFX 410-413 (10.04-03.13) X
EFX 410-413 (04.13-) X
EKS 210a (10.12-) X
EKS 208-312 (03.09-) X
EKS 308 (03.06-01.10) X
EKS 310 (07.04-07.09) X
EKS 314 (05.05-03.10) X
EKS 513-515 (12.03-06.07) X
EKS 513-515 (05.07-) X
EKX410 (11.03-04.12) X
EKX410 (05.12-) X
EKX 513-515 (01.04-06.07) X
EKX 513-515 (05.07-)

X
EKX a
BUS systems used

BUS systems used
Truck CANopen Jungheinrich
Truck CANopen Jungheinrich 250kbaud Justcap CANopen
250kbaud Justcap CANopen 250kbaud
250kbaud
EFG
EFG
EFG 535-550 (01.04-10.09) X
EFG 110-115 (01.04-11.09) X
EFG 535-550 (11.09-08.13) X
EFG 110-115 (11.09-) X
EFG 535k-S50 (09.13-06.14) X
EFG 213-220 dc (01.04-08.04) X
EFG 535k-S50 (07.14-) X
EFG 213-220 (08.04-12.08) X
EFG 213-220 (06.08-09.14) X

BUS systems used
EFG 213-220 (10.14-) X
EFG 316-320 (08.04-12.08) X 250kbaud Justcap CANopen
250kbaud
EFG 316-320 (06.08-09.14) X
DFG/TFG
EFG 316-320 (10.14-) X
DFG 316s/320s (07.08-11.09) X
EFG Vdc 16-20 (06.99-10.04) X
DFG 316s/320s (12.09-) X
EFG 425-430 (12.03-10.09) X
DFG 316s/320s (11.14-) X
EFG 425-430 (11.09-03.12) X
DFG 420s/430s (07.04-) X
EFG 425-430 (04.12-06.14) X
DFG 425s-435s (11.07-) X
EFG 425-S30 (07.14-) X
BUS systems used

BUS systems used
250kbaud Justcap CANopen Truck
CANopen
250kbaud Justcap
250kbaud
DFG / TFG Shuttle

DFG 425s-435s (09.14-) X UPC (09.10-) X
DFG 20-30 BS (05.97-07.04) X
DFG 540s/550s (07.04-07.08) X
DFG 540s/550s (05.12. -)
DFG 540s-s50s (12.14-)
TFG 316s/320s (07.08-11.09) X
TFG 316s/320s (12.09-)
TFG 316s/320s (11.14-) X
TFG 420s/430s (07.04-) X
TFG 425s-435s (11.07-) X
TFG 425s-435s (09.14-) X
TFG 540s/550s (07.04-07.08)
TFG 540s-s50s (12.14-)

tUNGHEINRICH 002 053 000 00032 06.15 1 (GB)
Retrofitting the ISM Components
Description Requirements
The ISM comes in 4 levels and can be retrofitted onto the truck. • Truck securely parked on level ground.
Levels 1 and 2 only require the ISM access module (6U10), Levels • Load handler fully lowered.
3 and 4 also require the ISM data recorder (6U1 1) as well as the • Work area secured / cordoned off.
ISM radio module (6U12). • Truck switched off.
a- General ISM information:

see ISM service manual.
• Battery disconnected.
- see ISM Online service manual.

tUNGHEINRICH 002 053 000 00032 06.15 2 (GB)
Mounting position of ISM components Installing the access module (6U10)
Procedure
Mounting position of access module The access module (2) is fitted in the control panel (1) in place of
the key switch.
• Remove the key switch from the control panel (1).
• Remove the plug connector between the key switch and the
truck.
• Connect the electrical supply to the access module (2):
• Insert the access module (2) in the control panel (1).
Ensure that the access module (2) engages in the cover.
[ÿj The ISM components data recorder and radio module are installed
in different positions on the EKS 110 E and the EKS 110 ZZ.
*>$
tUNGHEINRICH 002 053 000 00032 06.15 3 (GB)
EKS 110 E
Installing the data recorder (6U11)

Procedure
• Raise the operator position (1) until
the mounting position is easily
accessible.
• Secure the operator position with
hard wooden blocks (2).
• Remove the control panel (3):
Pull the control panel
upwards out of the Snaplock
bracket at the steering and
the grip of the travel switch.
• Place the control panel (3) so that
the mounting position (4) is easily
accessible.
4
tUNGHEINRICH 002 053 000 00032 06.15 4 (GB)
• Drill 4 holes (1) in the rear wall (2)

of the operator platform above the
battery compartment.
Q Pay attention to the dimensions (in mm).

tUNGHEINRICH 002 053 000 00032 06.15 5 (GB)
Install the data recorder (3) in its

mounting position (1) using the
screws (2).
The data recorder has been
installed.
Radio module
X683
Access module
X682 .k
tUNGHEINRICH 002 053 000 00032 06.15 6 (GB)
EKS 110 E
Installing the radio module (6U12)

Procedure
The mounting position (Y) of the radio
module is above the battery
compartment in the rear wall (2) of the
operator platform.
/7 • Drill holes (3) in the rear wall (2) of
the operator platform above the
crr uu battery compartment.
Q Pay attention to the dimensions (in mm).
o
tUNGHEINRICH 002 053 000 00032 06.15 7 (GB)
• Install the radio module (2) above

the battery compartment using the
screws (1).
The radio module has been
installed.
tUNGHEINRICH 002 053 000 00032 06.15 8 (GB)
EKS 110 ZZ
Installing the data recorder (6U11)

Procedure
• Raise the operator position (1) until
the mounting position is easily
accessible.
• Secure the operator position with
hard wooden blocks (2).
• Remove the control panel (3):
Pull the control panel
upwards out of the Snaplock
bracket at the steering and
the grip of the travel switch.
• Place the control panel (3) so that
the mounting position (4) is easily
accessible.
tUNGHEINRICH 002 053 000 00032 06.15 9 (GB)
• Drill 4 holes (1) in the rear wall (2)

of the operator platform above the
B-8 Q Pay attention to the dimensions (in mm).
O;
<J>.
Ol
tUNGHEINRICH 002 053 000 00032 06.15 10 (GB)
Install the data recorder (3) in its

mounting position (2) using the
screws (1).
The data recorder has been
installed.
Access module
X682 modu
>rX683
tUNGHEINRICH 002 053 000 00032 06.15 11 (GB)
EKS 110 ZZ
Installing the radio module (6U12)

Procedure
Q The mounting position (Y) of the radio

module is above the battery
compartment in the rear wall (1) of the
operator platform.
• Drill holes (2) in the rear wall (1) of
the operator platform above the
fÿl Pay attention to the dimensions (in mm).
tUNGHEINRICH 002 053 000 00032 06.15 12 (GB)
• Install the radio module (2) above

the battery compartment using the
screws (1).
• Remove the lower mounting of the
protective screen.
• Route cable with connector under
the protective screen.
• Plug in the connector.
• Install the lower mounting of the
protective screen.
The radio module (2) covers up the "Do
not reach through the mast" prohibition
plate (50007121).
• Glue on a new prohibition plate (3)
to the left of the radio module.
The radio module has been
installed.
Final tasks
• Restore all the electrical
connections.
• Install the control panel.
• Connect the battery.
• Test the ISM components.
tUNGHEINRICH 002 006 506 00004 04.15 1 (GB)
Access Components (Easy Access)
Commissioning
If the truck is equipped with a keypad or a transponder reader, it
can only be operated using the keys in the display unit. The
keypad and the transponder reader have to be activated by the
operating company.
Q To adjust and operate the display unit, keypad and transponder

reader, refer to the truck operating instructions.
Access codes
Default code: 1-2-3-4
Default master code: 2-4-1-2
Q When a valid code is entered or a valid transponder used, a green

tick appears in the display unit.
Trucks without a key switch and without ISM When an invalid code has been entered or a invalid transponder
used, a red cross is displayed, and the entry must be repeated.
The display unit (1) can be used as an access control facility and
an additional keypad (2) or transponder reader (3) can be added
to it.
Access codes are stored in the display unit. The keypad or
transponder reader do not work without the display unit.
The access codes must be re-entered when the display unit has
been replaced.
tUNGHEINRICH 002 006 318 00001 03.09 1 (GB)
Deadman Button Setting
1. Switch off the truck and disconnect the battery.
2. Disassemble the deadman
button (9).
• Remove the step mat from the
operator position.
• Remove the two hex. socket
screws (8) from the bracket (10).
Y = 3 mm
• Remove the deadman button (9)
Z = 29 mm
from its bracket (10).
3. Screw the adjusting nut (4) fully onto
the sensor (5).
4. Push the sensor (5) from the rear through the bracket (3).
5. Use the adjusting nut (4) to set the gap:
• "X" of 2 mm and
2 mm • "Y" of 3 mm
between the sensor (5) and rocker (1) of the deadman
button.
6. Counter fix the setting with the jam nut (2).
tUNGHEINRICH 002 006 318 00001 03.09 2 (GB)
7. Attach the connector of the sensor (5) to the bracket (3) and
connect to the truck.
8. Attach the wire of the sensor (5) to the cable tie on the
bracket (3).
. 9. Set the pedal pressure on the deadman button to approx.

45 Nm:
• Set the spring pre-tension (dimension "Z") via the hex. nut (6)
Y = 3 mm
to 29 mm.
Z = 29 mm
10. Fit the deadman button (9):
• Insert the deadman button (9) in the
8
p i?
bracket (10). <£
n
• Attach the deadman button (9) via i 1
the two hex. socket screws (8) to the
2 mm
© bracket (10).
• Place the step mat in the operator
position.
11. Reconnect the battery and power up 10ÿ©
the truck.
tUNGHEINRICH 002 047 303 00054 04.15 1 (GB)
Pin Assignment
Travel switch 1S2
Connector Pin Signal Signal size (switched/unswitched)
1 Power supply +24 V
2
3 Drive direction release 0.221 V
4
5 Potentiometer target value 0.221 -3.68 V
6 GND 0V
7 n.c.
8 n.c.
9 Fork direction release 0.221 V
tUNGHEINRICH 002 047 303 00054 04.15 2 (GB)
Travel switch 1S2.1 (2nd operating position)
2
3 Drive direction release 0.221 V
4
5 Potentiometer target value 0.221 -3.68 V
6 GND 0V
7 n.c.
8 n.c.
9 Fork direction release 0.221 V
Proportional lowering valve 2Y29

1 Proportional valve + +24 V
2 Proportional valve -
Lowering valve, Z version, 2Y63

2 AS 2412iS output
tUNGHEINRICH 002 047 303 00054 04.15 3 (GB)
Horn 4H1
2 AS 2412iS output
WMS PLC connection RS-232 8U37

N2 1 Operating voltage test +24 V
2 GND 0V
3 RS232 RxD RS-232 C
4 RS-232 TxD RS-232 C
5 Test +24 V - only for programming
6 n.c.
tUNGHEINRICH 002 047 303 00054 04.15 4 (GB)
WMS PLC connection inputs 8U37

X12 1 Operating voltages out +24 V
2 IN 00 > 0-4-0.7 UB switch-on level
3 Operating voltages out +24 V
9 GND 0V
10 GND 0V
11 GND 0V
tUNGHEINRICH 002 047 303 00054 04.15 5 (GB)
WMS PLC connection power supply 8U37

P/N1 1 Operating voltages +24 V
2 GND 0V
3 CAN 1 L 1-4 V (data)
4 CAN 1_H 1-4 V (data)
5 CAN 1 L 1-4 V (data)
6 CAN 1_H 1-4 V (data)
tUNGHEINRICH 002 047 303 00054 04.15 6 (GB)
ISM (to truck)
XS680 1 S2 OUT 24 V/ 0 V DC
2 S2 BACK 24 V/ 0 V DC
3 +12-48 V in or 80 V in +24 V
4 - Batt in 0V
5 LISA/MFC
6 CAN H in 1-4 V (data)
7 CAN H out 1-4 V (data)
8 CAN Lin 1-4 V (data)
9 CAN L out 1-4 V (data)
10 12 Vin +12 V
11 - Batt in (0 V) 0V
12 12 V out +12 V
13 - Batt out (0V) 0V
14 - Batt out (0V) 0V
15 U-ISM out (24V) for JUDIT +24 V
16 Life sign 24 V/ 0 V DC
tUNGHEINRICH 002 047 303 00054 04.15 7 (GB)
ISM (to data recorder)
XS681 1 - batt (0V) 0V
2 + batt +24 V
3 RS232 RS-232C
4 RS232 RS-232C
5 0V 0V
6 NC
ISM (to access module)

XS682 1 - batt (0V) 0V
2 + batt +24 V
3 RS232 RS-232C
4 RS232 RS-232C
5 0V 0V
6 NC
tUNGHEINRICH 002 047 303 00054 04.15 8 (GB)
ISM (to radio module)
XS683 1 NC
2 NC
3 RS232 RS-232C
4 RS232 RS-232C
5 0V 0V
6 NC
Battery (+) X40 (+)

1 Battery voltage + +24 V
2
Battery (-) X40 (-)

1 Battery voltage - 0V
2
Battery connector truck X41 (+)

1 Battery voltage + +24 V
2
tUNGHEINRICH 002 047 303 00054 04.15 9 (GB)
Battery connector truck X41 (-)
1 Battery voltage - 0V
2
tUNGHEINRICH 002 047 303 00054 04.15 10 (GB)
Dual controller AS 2412 iS U8
X1 1 Indicator lamp travel F/R Digital output (1 A, group C)
2 Horn Horn negative connection (2 A)
3 Horn 0 V for horn modulation
4 CANJHigh 1-4 V (data)
5 CAN Low 1-4 V (data)
6 Battery latch Digital input
7 Lift limit, L version Digital input
8 Lift height 1200 mm Digital output (1 A, group B)
9 LED travel light Digital output (1 A, group A)
10 Lowering brake Digital input
11 Proportional valve + Proportional valve, positive connection (1.5 A)
12 Proportional valve - Proportional valve, negative connection (1.5 A)
13 Not used Digital input
14 Platform, Z version 800 Digital input
15 Cab light Digital output (1 A, group C)
16 12-volt power supply for service connector 12 V(+/- 1 V), 300 mA
17 GND GND for digital inputs
20 Battery measurement input Battery measurement input
21 Key switch Key switch input
22 Drive motor temperature sensor - Drive motor temperature negative connection
HUNGHEINRICH 002 047 303 00054 04.15 11
23 Main contactor Digital output (1 A)
24 Load switch, L version Digital input
25 Aisle end Digital input
26 Lift height override Digital output (1 A, group B)
27 Pump contactor, Z version Digital output (1 A, group B)
28 Lowering valve, Z version Digital output (1 A, group A)
29 Lifting, Z version Digital output (1 A, group C)
30 Lowering, Z version Digital output (1 A, group C)
Digital output with resistor in series
31 Red LED 1570 ohms: red LED
32 Two-hand operation Digital input
33 Magnetic fail-safe brake Digital output (3 A, group A)
34 Drive motor temperature sensor + Drive motor temperature positive connection
Digital output with resistor in series
35 Green LED 1570 ohms: green LED
36 Reserved for load sensor Digital input; alternative: analogue input
37 Stop when lifting, pedestrian mode, L version Digital input
38 Rotational-speed generator track B Digital input: e.g. sensor bearing channel B
39 Rotational-speed generator track A Digital input: e.g. sensor bearing channel A
40 Lift limit, Z version Digital input
41 12-volt rotational-speed generator 12-volt supply for sensor bearing
42 Lowering limit, Z version Digital input
tUNGHEINRICH 002 047 303 00054 04.15 12 (GB)
Dual controller AS 2412 iS U8
X2 1 Steer motor connection A1 Digital input / 12 mA / < 1 kO = 1, > 6 kQ = 0
3 Aisle recognition 1 Digital input
4 Aisle recognition 2 Digital input
5 Group rotary angle sensor, steer motor GND for Group actual-steering-angle sensor
6 Group rotary angle sensor, steer motor Cosine signal of Group rotary angle sensor
7 Group rotary angle sensor, steer motor Sine signal of Group rotary angle sensor
12 V (+/- 1 V), 300 mA for Group rotary angle
8 Group rotary angle sensor, steer motor sensor
9 Steer motor connection A2 Steer motor connection A2
13
14
15
16
tUNGHEINRICH 002 047 303 00054 04.15 13 (GB)
Multifunction controller M FC 10 6U9
X3 1 24 V supply 24 V output
2 12 volts for both Group rotary angle sensors 12-volt supply (both Group rotary angle sensors)
3 GND for both Group rotary angle sensors GND supply (both Group rotary angle sensors)
5 CAN_Low 1-4 V (data)
6 Group rotary angle sensor, sine signal, operating position 1 Analogue input, rotary angle sensor, sine signal
Analogue input, rotary angle sensor, cosine
7 Group rotary angle sensor, cosine signal, operating position 1 signal
8 Key switch input 2 Key switch input 2
9 GND for digital inputs GND for digital inputs
10 Horn button, operating position 1 Digital input
11 GND for CAN GND for CAN
12 Group rotary angle sensor, sine signal, operating position 2 Analogue input, rotary angle sensor, sine signal
13 Group rotary angle sensor, cosine signal, operating position 2 Analogue input, rotary angle sensor, cosine signal
14 Operator position lighting, left Digital output
15 Blue Spot, drive direction Digital output
16 Lowering button, operating position 1 Digital input
17 Pedestrian mode, lifting Redundant digital input
20 Travel switch, fork direction, operating position 1 Digital input
21 24 V key switch 1 Key switch input 1
HUNGHEINRICH 002 047 303 00054 04.15 14
22 Travel switch, drive direction, operating position 1 Digital input
23 Horn button, operating position 2 Digital input
24 Deadman, NO contact, operating position 1 Redundant digital input
25 Pedestrian mode, fork direction Redundant digital input
26 Lowering button, operating position 2 Digital input
27 Travel switch analogue input, operating position 1 Analogue input travel switch 1
28 Power GND Power GND
29 Not used Digital output
30 Lifting button, operating position 1 Digital input
31 LED Service LED
32 Pedestrian mode, lowering Redundant digital input
33 Pedestrian mode, drive direction Redundant digital input
34 Deadman, NO contact, operating position 2 Redundant digital input
35 LH door Redundant digital input
36 RH door Redundant digital input
37 Lifting button, operating position 2 Digital input
38 Travel switch analogue input, operating position 2 Analogue input travel switch 2
39 Travel switch, fork direction, operating position 2 Digital input
40 Travel switch, drive direction, operating position 2 Digital input
41 Pedestrian mode release (both directions) Redundant digital input
42 Operator position lighting right Digital output
tUNGHEINRICH 002 047 303 00054 04.15 15 (GB)
Lift controller AS 2421 2U9

X4 1
2
3
4 CAN high 1-4 V (data)
5 CAN low 1-4 V (data)
6 Lift height ZT 1 Digital input
7 Digital input
8
9 Motor temperature + Motor temperature +
10
11 Lift height ZT 2
12
13
14
15
16
17
18 Terminal resistor 1-4 V (data)
19 Terminal resistor 1-4 V (data)
20
21 Key switch Key switch 1
22 Motor temperature - Motor temperature -
HUNGHEINRICH 002 047 303 00054 04.15 16
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38 Incrementer B Incrementer B
39 Incrementer A Incrementer A
40 GND 0V
41 12V sensor bearing 12 V sensor bearing
42
tUNGHEINRICH 002 047 303 00054 04.15 17 (GB)
Medi display A9
X7 1 Power supply +24 V
2 CAN-HIGH in 1-4 V (data)
3 CAN-LOW in 1-4 V (data)
4 CAN-HIGH out 1-4 V (data)
5 CAN-LOW out 1-4 V (data)
6 CAN-GND 0V
7 GND 0V
8 Switch contact, key switch 1 24 V/0VDC
9 Switch contact, key switch 2 24 V/0VDC
10 CAN-GND 0V
11 CAN2-HIGH out 1-4 V (data)
12 CAN2-LOW out 1-4 V (data)
13 Access module power supply
14 Access module GND 0V
tUNGHEINRICH 002 047 303 00054 04.15 18 (GB)
Contactor mounting plate, control panel (signal 1) (in the control panel)

XB10 1 Emergency disconnect switch return - main contactor 2 24 V/ 0 V DC
XS10 2 Emergency disconnect switch out 24 V/ 0 V DC
3 Emergency disconnect switch: radio data; key switch out 24 V/ 0 V DC
4 Key switch return 24 V/ 0 V DC
5 Control voltage X30.3 +24 V
9 GND 0V
10 GND 0V
11 GND 0V
12 GND 0V
13 Indicator lamp, forward/reverse travel 24 V/ 0 V DC
14 Cab light 24 V/ 0 V DC
tUNGHEINRICH 002 047 303 00054 04.15 19 (GB)
Steer motor

XB11 1 Steer motor + 24 V/0VDC
XS11 2 Steer motor - 24 V / 0V DC
JetPilot
XB12 1 +24V 24 V/0VDC
XS12 2 GND 24 V/0VDC
3 CAN high 1-4 V (data)
4 CAN low 1-4 V (data)
5
6 Actual-value transmitter sine signal 0-5V 0.5—4.5 V
7 Actual value transmitter cosine signal 0-5V 0.5—4.5 V
8 0V (GND) for actual-value analogue sensor GND
9 GND
10
tUNGHEINRICH 002 047 303 00054 04.15 20 (GB)
Magnetic brake

XB13 1 Magnetic brake 7Y3 +24 V
XS13 2 GND 0V
Contactor mounting plate, control panel (signal 2) (in the control panel)
XB14 1 GND 0V
XS14 2 GND 0V
3 Two-hand operation 24V/ 0V DC
4 Lifting, Z version 24V/ 0V DC
5 Lift limit, Z version 24V/ 0V DC
6 Lowering limit, Z version 24V/ 0V DC
7 Lowering, Z version 24V/ 0V DC
8 Pump contactor, Z version 24V/ 0V DC
9 Lowering valve, Z version 24V/ 0V DC
10
tUNGHEINRICH 002 047 303 00054 04.15 21 (GB)
Platform peripheral equipment (in the platform)
XB15 1 Two-hand button, backrest 24V/ 0V DC
XS15 2 GND for two-hand button, backrest 0V
3 Lifting, Z version, backrest 24V/ 0V DC
6 Lowering, Z version, backrest 24V/ 0V DC
7 GND 0V
8 GND 0V
9 GND 0V
10 GND 0V
11 + 24 V for 2K2 +24 V
12 GND for 2K2 from controller 0V
13 + 24 V +24 V
14 GND 0V
Aisle recognition
XB16 1 +24 V +24 V
XS16 2 Aisle recognition 1 24/OV DC
3 Aisle recognition 2 24/OV DC
4 GND 0V
tUNGHEINRICH 002 047 303 00054 04.15 22 (GB)
Aisle end detection
XB17 1 Aisle end 24/OV DC
XS17 2 GND 0V
Lift height override

XB18 1 Lift height override 24/OV DC
XS18 2 GND 0V
Platform switch

XB19 1 Platform switch, Z version 800 24/OV DC
XS19 2 Jumper
3 Jumper
4 GND 0V
tUNGHEINRICH 002 047 303 00054 04.15 23 (GB)
Contactor mounting plate, control panel (signal 1) (on the contactor mounting plate)

XB20 1 Emergency disconnect switch return - main contactor 2 24V/ 0V DC
XS20 2 Emergency disconnect switch out 24V/ 0V DC
3 Emergency disconnect switch: radio data; key switch out 24V/ 0V DC
4 Key switch return 24V/ 0V DC
9 GND 0V
10 GND 0V
11 GND 0V
12 GND 0V
13 Indicator lamp, forward/reverse travel 24V/ 0V DC
14 Cab light 24V/ 0V DC
Lift limit switch

XB21 1 Lift limit switch, L version 24/OV DC
XS21 2 GND 0V
HUNCHEINRICH 002 047 303 00054 04.15 24 (GB)
Lift height ZT

XB22 1 Lift height ZT 1 24/0V DC
XS22 2 Lift height ZT 2 24/0V DC
3 GND 0V
4
Contactor mounting plate, control panel (signal 2) (on the contactor mounting plate)

XB24 1 GND 0V
XS24 2 GND 0V
3 Two-hand operation 24V/ 0V DC
4 Lifting, Z version 24V/ 0V DC
7 Lowering, Z version 24V/ 0V DC
8 Pump contactor, Z version 24V/ 0V DC
9 Lowering valve, Z version 24V/ 0V DC
10
tUNGHEINRICH 002 047 303 00054 04.15 25 (GB)
Lift height 1200mm

XB25 1 Lift height 1200 mm (gate) 24/0V DC
XS25 2 Jumper 24/OV DC
3 Jumper 24/0V DC
4 GND 0V
Service connector

XB26 1 n.c.
XS26 2 can-bus o v 0V
3 CAN LOW
4 n.c. 1-4 V(data)
5 GND OV
6 +24 V switched +24 V
7 n.c.
8 CAN HIGH 1-4 V (data)
9 can-bus +12 v +12 V
tUNGHEINRICH 002 047 303 00054 04.15 26 (GB)
Lowering brake

XB27 1 Lowering brake 24/0V DC
XS27 2 GND 0V
Drive motor speed sensor

XB29 1 Incremental encoder, V+ +12 VDC
XS29 2 Incremental encoder, channel A 0/12 V DC
3 Incremental encoder, channel B 0/12 VDC
4 Incremental encoder, V- GND
Relay, travel light

XB30 1 Relay, LED travel light 24/0 V DC
XS30 2 GND 0V
tUNGHEINRICH 002 047 303 00054 04.15 27 (GB)
Clamp point
XB30.1 1 +24 V +24 V
XS30.1 2 +24 V +24 V
3 +24 V +24 V
4 +24 V +24 V
5 +24 V +24 V
Clamp point

XB30.2 1 +24 V +24 V
XS30.2 2 +24 V +24 V
3 +24 V +24 V
4 +24 V +24 V
5 +24 V +24 V
6 +24 V +24 V
7 +24 V +24 V
tUNGHEINRICH 002 047 303 00054 04.15 28 (GB)
Clamp point
XB30.3 1 +24 V +24 V
XS30.3 2 +24 V +24 V
3 +24 V +24 V
4 +24 V +24 V
5 +24 V +24 V
Clamp point

XB31.1 1 GND GND
XS31.1 2 GND GND
3 GND GND
4 GND GND
5 GND GND
6 GND GND
7 GND GND
8 GND GND
9 GND GND
10 GND GND
11 GND GND
tUNGHEINRICH 002 047 303 00054 04.15 29 (GB)
Platform peripheral equipment (in the platform)
XB35 1 +24 V for doors +24 V
XS35 2 +24 V for doors +24 V
3 Signal left door 24/0 V DC
4 Signal right door 24/0 V DC
5 GND for doors 0V
6 GND for doors 0V
7 +24 V for deadman switch +24 V
8 Signal deadman switch 24/0 V DC
9 GND for deadman switch 0V
10
Fan
XB38 1 Fan +12 V
XS38 2 GND 0V
CAN bus contactor mounting plate - control panel (in the control panel)

XB39 1 Can-Bus H 1-4 V (data)
XS39 2 Can-Bus L 1-4 V (data)
tUNGHEINRICH 002 047 303 00054 04.15 30 (GB)
Control panel platform (signal 1) (in the control panel)
XB40 1 Two-hand button, backrest 24/0 V DC
XS40 2 Lifting, Z version, backrest 24/0 V DC
3 Lift limit, Z version 24/0 V DC
4 Lowering limit, Z version 24/0 V DC
5 Lowering, Z version, backrest 24/0 V DC
6 GND 0V
7 +24 V for pump contactor auxiliary lift +24 V
8 Signal pump contactor auxiliary lift 2K2 24/0 V DC
9 +24 V for lowering valve Z version +24 V
10 Signal, lowering valve, Z version 24/0 V DC
Actual value steering

XB42 1 Power supply +12 V
XS42 2 Actual value transmitter sine signal 0-5V 0.5—4.5 V
3 Actual value transmitter cosine signal 0-5V 0.5—4.5 V
tUNGHEINRICH 002 047 303 00054 04.15 31 (GB)
Control panel platform (signal 2) (in the control panel)
XB43 1 +24 V for doors +24 V
XS43 2 Signal left door 24/0 V DC
3 Signal right door 24/0 V DC
4 GND for doors OV
5 +24 V for deadman switch +24 V
6 Signal deadman switch 24/0 V DC
8
9
10
Aisle end (under the panel)

XB46 1 Reset button 24/0 V DC
XS46 2 Reset button 24/0 V DC
3 Lamp 8H3 24/0 V DC
4 Lamp 8H3 24/0 V DC
tUNGHEINRICH 002 047 303 00054 04.15 32 (GB)
Aisle end (in battery compartment)
XB47 1 Aisle end 8S3.1 24/0 V DC
XS47 2 Jumper to XS47.3 24/0 V DC
3 Jumper to XS47.2 24/0 V DC
8 GND 0V
9
10
tUNGHEINRICH 002 047 303 00054 04.15 33 (GB)
Jumper connector, emergency disconnect switch (pedestrian mode - in the backrest)
1 Emergency disconnect switch, pedestrian mode, Z version,

XB48 jumper 24 V/0VDC
XS48 jumper 24 V/0VDC
jumper 24 V/0VDC
jumper 24 V/0VDC
jumper 24 V/0VDC
jumper 24 V/0VDC
jumper 24 V/0VDC
jumper 24 V/0VDC
jumper 24 V/0VDC
jumper 24 V / 0 V DC
tUNGHEINRICH 002 047 303 00054 04.15 34 (GB)

jumper 24 V/0VDC
jumper 24 V/0 VDC
13
14
Load switch, L version

XB49 1 Option, pressure switch, load, L version 24/0 V DC
XS49 2 GND 0V
tUNGHEINRICH 002 047 303 00054 04.15 35 (GB)
Steering setpoint

XB50 1 Power supply +12 V
XS50 2 Setpoint generator sine signal 0-5 V 0.5—4.5 V
3 Setpoint generator cosine signal 0-5 V 0.5—4.5 V
Emergency disconnect switch - pedestrian mode release (L version)

XB51 1 Jumper pedestrian mode 24/0 V DC
XS51 2 Jumper pedestrian mode 24/0 V DC
3 Jumper pedestrian mode 24/0 V DC
tUNGHEINRICH 002 047 303 00054 04.15 36 (GB)
Interface, switch on (JetPilot/WMS)
XB52 1 Key switch out +24 V
XS52 2 Key switch return +24 V
3 CAN H 1-4 V (data)
4 CAN_L 1-4 V (data)
5
6
7
8
9
10 GND 0 VDC
tUNGHEINRICH 002 047 303 00054 04.15 37 (GB)
Keypad Icard reader (Medi)

XB53 1 CAN_H 1-4 V (data)
XS53 2 CAN L 1-4 V (data)
3 +24 V +24 V
4
5
6
7 GND 0V
8
9
10
11
12
13
14
Radio data preparation

XB56 1 DC/DC converter +24 V
XS56 2 DC/DC converter 0V
tUNGHEINRICH 002 047 303 00054 04.15 38 (GB)
Pedestrian mode, travel, Z version (in the backrest)
XB57 1 Pedestrian mode, fork direction, Z 24V/ 0V DC
XS57 2 Pedestrian mode, drive direction, Z 24V/ 0V DC
3 Release, pedestrian mode, travel 24V/ 0V DC
4 GND for pedestrian mode Z 0V
5 Jumper, pedestrian mode release 24V/ 0V DC
6 Jumper, pedestrian mode release 24V/ 0V DC
7 Signal, pedestrian mode, lifting Z 24V/ 0V DC
8 Signal, pedestrian mode, lowering Z 24V/ 0V DC
9 GND, pedestrian mode, lifting/lowering Z 0V
10 GND pedestrian mode Z 0V
Power supply (optional in the control panel)

XB59 1 Reserve distribution +24 V +24 V
XS59 2 Reserve distribution 0 V DC 0 VDC
tUNGHEINRICH 002 047 303 00054 04.15 39 (GB)
2nd operating position + emergency disconnect switch (1) (in the control panel)

XB64 1 Emergency disconnect switch out 24V / 0V DC
XS64 2 Emergency disconnect switch return 24V / 0V DC
3 Emergency disconnect switch out 24V / 0V DC
4 Emergency disconnect switch return 24V / 0V DC
5 + 24 V + 24 V
6 + 24 V + 24 V
7 Travel switch, backrest, drive direction 24V / 0V DC
8 Travel switch, backrest, analogue 24V / 0V DC
9 Travel switch, backrest, fork direction 24V / 0V DC
10 GND 0V
11 Pedestrian mode, fork direction, Z 24V / 0V DC
12 Pedestrian mode, drive direction, Z 24V / 0V DC
13 Pedestrian mode release 24V / 0V DC
14 GND for pedestrian mode Z 0V
tUNGHEINRICH 002 047 303 00054 04.15 40 (GB)
Jumper connector
XB64 1 Jumper, emergency disconnect switch +24 V
XS64 2 Jumper, emergency disconnect switch +24 V
Pedestrian mode, travel, L version (in the control panel)

XB65 1 Emergency disconnect switch out +24 V
XS65 2 Emergency disconnect switch return +24 V
3 Emergency disconnect switch out +24 V
4 Emergency disconnect switch return +24 V
5 Pedestrian mode, travel, fork, L version, left 24V / 0V DC
6 Pedestrian mode, travel, drive, L version, left 24V / 0V DC
7 GND 0V
8 Pedestrian mode, lifting, L version, left 24V / 0V DC
9 Pedestrian mode, lowering, L version, left 24V / 0V DC
10 GND 0V
11 Jumper, pedestrian mode release 24V / 0V DC
12 GND 0V
13
14
tUNGHEINRICH 002 047 303 00054 04.15 41 (GB)
Pedestrian mode, travel, L version (in the control panel)
XB66 1 Emergency disconnect switch out +24 V
XS66 2 Emergency disconnect switch return +24 V
3 Emergency disconnect switch out +24 V
4 Emergency disconnect switch return +24 V
5 Pedestrian mode, travel, fork, L version, right 24V / 0V DC
6 Pedestrian mode, travel, drive, L version, right 24V / 0V DC
7 Release, pedestrian mode, travel 24V / 0V DC
8 Pedestrian mode, lifting, L version, right 24V / 0V DC
9 Pedestrian mode, lowering, L version, right 24V / 0V DC
10 GND 0V
11 GND 0V
12 GND 0V
13 Jumper, pedestrian mode release 24V / 0V DC
14
Steering setpoint (2nd operating position)

XB67 1 Power supply Group rotary angle sensor + 12 V
XS67 2 Setpoint generator sine signal 0-5 V 0.5—4.5 V
3 Setpoint generator cosine signal 0-5 V 0.5—4.5 V
4 0 V (GND) for actual-value analogue sensor GND
tUNGHEINRICH 002 047 303 00054 04.15 42 (GB)
Deadman (2nd operating position)
XB68 1 +24 V for deadman switch +24 V
XS68 2 Signal for deadman switch 24/OV DC
4
2nd operating position + pedestrian mode (2) (in the control panel)

XB70 1 Deadman 2nd operating position signal 24/0 V DC
XS70 2 12 V for Group rotary angle sensor 2nd operating position +12 V
3 Sine Group rotary angle sensor 2nd operating position 0.5—4.5 V
4 Cosine Group rotary angle sensor 2nd operating position 0.5—4.5 V
5 GND 0V
6 Lift platform 2nd operating position 24/0 V DC
7 Horn button 2nd operating position 24/0 V DC
8 Lowering platform 2nd operating position 24/0 V DC
9 GND 0V
10 GND 0V
11 Signal, pedestrian mode, lifting 24/0 V DC
12 Signal, pedestrian mode, lowering 24/0 V DC
13 GND 0V
14 GND 0V
tUNGHEINRICH 002 047 303 00054 04.15 43 (GB)
Stop during pedestrian mode lifting, L version

XB71 1 Pedestrian mode lifting option 24/0 V DC
XS71 2 GND 0V
Temperature sensor drive motor

XB72 1 Temperature sensor, t2 (+) 24/0 V DC
XS72 2 Temperature sensor, t1 (-) 24/0 V DC
CAN-bus contactor mounting plate lift controller (on the contactor mounting plate)

XB75 1 CAN High 1-4 V (data)
XS75 2 CAN Low 1-4 V (data)
CAN-bus contactor mounting plate (on the contactor mounting plate)

XB77 1 CAN High 1-4 V (data)
XS77 2 CAN Low 1-4 V (data)
tUNGHEINRICH 002 047 303 00054 04.15 44 (GB)
Rotational speed /temperature sensor, lift motor
XB80 1 Incremental encoder, V+ +12 VDC
XS80 2 Incremental encoder, Channel A 0/12 V DC
3 Incremental encoder, channel B incremental encoder, channel B 0/12 VDC
4 Incremental encoder, V- GND
5 Temperature sensor, t2 (+) 24/0 V DC
6 Temperature sensor, t1 (-) 24/0 V DC
Operator position lighting (left)

XB82 1 Operator position lighting, left +24 V DC
XS82 2 GND 0 VDC
Operator position lighting (right)

XB83 1 Operator position lighting right +24 V DC
XS83 2 GND 0 VDC
Cab light

XB84 1 Cab light +24 V
XS84 2 GND 0 VDC
tUNGHEINRICH 002 047 303 00054 04.15 45 (GB)
Cab light

XB85 1 Cab light +24 V
XS85 2 GND 0 VDC
Indicator lamp travel F/R

XB86 1 Indicator lamp, forward/reverse travel +24 V
XS86 2 GND 0 VDC
Floor Spot
XB87 1 Floor spot +24 V
XS87 2 GND 0 VDC
tUNGHEINRICH 002 047 303 00054 04.15 46 (GB)
Preparation for lighting
XB88 1 Operator position lighting, left +24 V
XS88 2 GND 0 VDC
3 Operator position lighting right +24 V
4 GND 0 VDC
5 Floor Spot +24 V
6 GND 0 VDC
7 Indicator lamp, forward/reverse travel +24 V
8 GND 0 VDC
9 Operator position lighting +24 V
10 GND 0 VDC
LED travel light (panel)

XB89 1 LED travel light, panel +24 V
XS89 2 GND 0 VDC
tUNGHEINRICH 002 047 303 00054 04.15 47 (GB)
WMS display

XB90 1
XS90 2 Operating voltages out +24 V
3 GND 0 VDC
4 CAN1 H 1-4 V (data)
5 CAN1 L 1-4 V (data)
WMS radio data terminal

XB91 1 RxT RS-232C
XS91 2 DxT RS-232C
3 GND 0V DC
WMS power radio data terminal

XB92 1 24 V 24 V
XS92 2 GND GND
tUNGHEINRICH 002 047 303 00054 04.15 48 (GB)
WMS service radio data terminal

XB93 1 RxT RS-232C
XS93 2 DxT RS-232C
3 GND 0 VDC
WMS service display

XB94 1 RS-232 TxD RS-232C
XS94 2 RS-232 TxD RS-232C
3 Test +24 V - only for programming
tUNGHEINRICH 002 044 165 00006 04.15 1 (GB)
MFC10 Interface
Item Description
1 Data plate
2 Membrane
3 XS3 42-pin controller connector
The MFC10 multifunction controller is a CAN-bus-controlled

interface with analogue and digital input interfaces, switch outputs
and PWM outputs.
The controller is maintenance-free.

ÿjS. The controller must not be opened.
tUNGHEINRICH 002 044 165 00006 04-15 2 (gb)
Technical specification
Operating voltage: 24 V ±30%

Maximum voltage (operation for t < 5 s) 33.6 V
Maximum voltage (operation for t < 100 s) 36 V
Key switch current consumption < 400 mA at 24 V operating voltage
Key switch inrush current 17 A at 24 V operating voltage (typical value)
Service life At least 5,000 service hours
Insulation resistance Greater than 500 kO between live connections and ground
Insulation voltage 500 V AC between live connections and ground
Digital outputs Maximum 1 A ( short-circuit-proof), 3 A in total
12-volt supply Maximum current output at X1.2 is 0.3 A in total
Digital inputs Switched to GND, input current each approx. 13 mA
Angle transmitter connection 12-volt supply of the target/actual-value transmitter on the steering at X1.2,
two analogue signals offset by 90° for two transmitters,
output of the transmitter 0-5 volt to GND (X1.6, X1.7, X1.12 and X1.13)
LED outputs External LED can be connected to X1.31
CAN-bus interface Communication with peripheral equipment by means of CAN-bus interface (X1.4,
X1.5, X1.18 and X1.19); Jungheinrich CAN-bus protective circuit; no terminal resistors
present
tUNGHEINRICH 002 044 165 00006 04.15 3 (GB)
1-ZÿV
A
4
L-ca-
+
Battery
I
X1.4
t=D-
MFC10 X1.18
X1.5
ÿCD-
+24V
CD- (X1.1)
ÿCD- A
tD-
ÿCD-
tD-
ÿCD-
CD-
tD- Circuit
CD- as X1.14
tn-
Circuit
o as X1.14
ÿcn-
o Circuit
as X1.1
ÿCD-
CD-
ÿCD-
tm-
4
Key
-Q- analogue amplifier

-f-Ohmic/inductive load
"p-|7T
tUNGHEINRICH 002 044 165 00006 04.15 4 (GB)
SAAB Connector XS3
n
01 02 03 04 05 06 07 08 09 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 41 42
Q
TJ
View of controller connectors
Pin assignment
Q For SAAB connector pin assignment refer to module "Pin assignment 002 047 303 00054".
tUNGHEINRICH 004 014 224 00001 02.06 1 (GB)
2.5 kW drive motor with Beru sensor
As of February 2005 the 2.5 kW AC drive motor is equipped with
an external sensor (Beru sensor) instead of a sensor bearing.
The sensor (1) supplies a signal to the controller for rotary
direction and speed.
If the sensor develops a fault it must be replaced.
PIN Meaning
2
1 V batt(+)
Signal A
_
Signal sequence
L±J_LLLI_
'1 1 ! 1 ! ! 1
1 ii 1 1 1 1 1
_L —±— L -1—
3 GND 1 0 1 1 1 Pin 2
J. - J_ -
. 1 .
1 1 1 1 1 1 1
4 Signal B
tUNGHEINRICH 004 036 140 00003 05.13 1 (GB)
Transmission
Preparing the truck for maintenance and repairs Procedure
Required tools and materials: Drive wheel disassembly
Jack Drain the transmission oil.
Hard wooden blocks Lever out the cap (1) with a screwdriver.
• Grease: Polylub GA 352P (29202050) Q The cap is damaged when removed.

Wipe down the flat faces.
Procedure Fit the new cap (1).
Park the truck securely, see operating instructions chapter F, Add transmission oil, see "Adding transmission oil" on
"Preparing the truck for maintenance and repairs". page 7.
Jack up the truck making sure the appropriate safety notices Fit the drive wheel.
are in place.
The cap is now removed.
Use suitable hard wooden blocks to prevent the truck from
slipping and tipping over.
Truck prepared for maintenance or repairs.
Replacing the protective cap

Required tools and materials:
Spanner wrench
Screwdriver
New protective cap
tUNGHEINRICH 004 036 140 00003 05.13 2 (GB)
Replacing the debris guard and seal
P»j When removing the debris guard and the seal, we distinguish
between removal with a slide hammer and with ejector screws.
The slide hammer method is used for debris guards with keyholes
(2).
The ejector screw method is used for debris guards without
keyholes (3).
The seal can only be replaced when the transmission is removed.
i±
The debris guard and seal are destroyed when removed.
Required tools and materials:
Slide hammer (51243058)
M6 screw tap
Tap wrench (51108712)
Power drill
M6 bolts (approx. 30 mm)
Half round file (95201120)
tUNGHEINRICH 004 036 140 00003 05.13 3 (GB)
Removing the debris guard and seal with a slide hammer
Procedure
Remove the wheel.
Drain the oil.
Remove the transmission and the drive motor.
Loosen the debris guard with the slide hammer.
Penetrate the seal at two opposite points with a sharp object

and lever it out.
Clean the surfaces.
tUNGHEINRICH 004 036 140 00003 05.13 4 (GB)
Removing the debris guard and seal without a slide hammer
Procedure
Drill 2 opposite holes (5 mm) into the debris guard.

Cut M6 thread with the tap wrench into the holes.
tUNGHEINRICH 004 036 140 00003 05.13 5 (GB)
Lever out the debris guard with a suitable tool

Insert the M6 bolts into both holes
• Turn the M6 bolts until the debris guard is pushed up. . Penetrate the seal at tw0 opposite points with a sharp object
and lever it out.
tUNGHEINRICH 004 036 140 00003 05.13 6 (GB)
Installing the debris guard and seal
Lubricate the seal lip and the hub adequately.
Fit the seal with a plastic hammer using the assembly ring
from the repair kit. Keep checking to ensure the seal is
correctly positioned.
Fit the debris guard.
If necessary, deburr the edge of the debris guard with the half
round file.
tUNGHEINRICH 004 036 140 00003 05.13 7 (GB)
When the drive motor (1M1) has been disassembled,

transmission oil can be added from the top into the
transmission
(see arrow direction).
Q When adding transmission oil make sure the spur wheel (5) is
immersed approx. 2mm in the transmission oil. Refer to the
operating instructions for the correct transmission oil.
A Do not overfill the transmission oil.

Assemble the drive motor (1M1)
5
tUNGHEINRICH 004 039 019 00018 04.15 1 (GB)
Removing/Installing the Drive Wheel
Removing the drive wheel Requirements
A An unsecured industrial truck can cause accidents

The truck must be parked on level ground when removing or
installing the drive wheel.
When jacking up the truck, take appropriate measures (hard
wooden blocks) to prevent the truck from slipping or tipping over.
• Load handler fully lowered.
• Truck securely parked on level ground.
• Work area secured / cordoned off.
• Steering turned fully to the right
wctiemtcH (drive wheel (3) at 90° position).
• Truck switched off.
• Truck supported by wedges under the load wheels to prevent
it from moving.
• Truck jacked up securely:
• Jack up the truck under the corresponding
imisxcM* labels (1).
• Place hard wooden blocks underneath the
truck chassis.
A\ Risk of material damage when jacking up the

truck
Avoid damaging the electrical components, electric wires and
hydraulic hoses.
• Lower and remove the jack.
• Drive compartment cover (2) removed.
tUNGHEINRICH 004 039 019 00018 04.15 2 (GB)
Procedure for removing the drive wheel
Procedure:
• Remove the wheel nuts (2):
• Operate the travel switch until one wheel nut (2) can be
removed through the opening (1) in the chassis.
Repeat this until all five wheel nuts (2) have been removed.
lu*wem,cn
A Risk of crushing your hands when removing the drive wheel

Hand injuries can occur due to the weight of the drive wheel.
• Take hold of the drive wheel in such a way that it cannot fall
onto your hands.
• Pull the drive wheel (3) off the wheel bolts.
• Pull the drive wheel (3) out from under the chassis.
The drive wheel (3) has been removed.
tUNGHEINRICH 004 039 019 00018 04.15 3 (GB)
Fitting the drive wheel
When fitting a new drive wheel (1), replace the used wheel nuts (2)
with new ones.
Fitting the drive wheel

Procedure:
• Place the drive wheel (3) onto the wheel bolts (4) of the
lu*wem,cn transmission (5).
• Loosely screw the wheel nuts (2) onto the wheel bolts (4).
• Tighten the wheel nuts (2) through the opening (1)
crosswise (A-E) to 10 Nm.
Q See example on the left:

• Wheel nutA, then
• wheel nut B,
• to wheel nut E.
Tighten the wheelnuts to 150 Nm.
The drive wheel (3) has been fitted.
*
tUNGHEINRICH 004 039 019 00018 04.15 4 (GB)
Final tasks
When a new drive wheel has been fitted, the adjustment of the
support skids must be checked (see chapter "Tilt safety device" in
the operating instructions).
• Remove the hard wooden blocks:
• Jack up the truck under the corresponding
M
labels (1).
• Remove the hard wooden blocks.
• Remove the wedges from the load wheels.
• Fit the drive compartment cover (2).
tUNGHEINRICH 004 039 019 00018 04.15 5 (GB)
Drive Wheel Wear Limits
Q See service manual E 1001 "Vulkollan Wheel Wear Limits".

tUNGHEINRICH 004 039 198 00015 04.15 1 (GB)
Removing/Installing the Load Wheels
Removing the load wheel
Required tools
• Ladder
Requirements
• Park the truck securely on level ground.
• Secure / cordon off the work area.
• Raise auxiliary lift (see illustration).
• Raise the operator position and secure it to prevent
unintentional lowering:
• Insert the mast retainers (1); refer to the chapter "Mast
retainer assembly and removal" in the operating
instructions.
Q On the EKS 110 280ZZ only the lower mast retainers are required.
tUNGHEINRICH 004 039 198 00015 04.15 2 (GB)

2
• Leave the truck using the ladder.
Risk of tip-over when jacking up the truck
Incorrect jacking up of the truck can cause it to tip over or slip.
• Jack up the support arm (2) with a jack.
• Push a hard wooden block (5 cm) underneath the support
arm.
tUNGHEINRICH 004 039 198 00015 04.15 3 (GB)
Removal
• Remove the hex screws (M6 x 20) (1).
• Remove the axle (2) from the support arm (3).
• Remove the load wheel (4).
->| The load wheel can be removed from above.
• Note the sequence and number of 1-mm shims and 0.5-mm
shims.
ÿ;,Y im
ÿ |j|.
T
tUNGHEINRICH 004 039 198 00015 04.15 4 (GB)
Installing the load wheel
It is easier to install the load wheel from below as described below.
Requirements
A Risk of tip-over when jacking up the truck

Incorrect jacking up of the truck can cause it to tip over or slip.
• Jack up the support arms alternatively, placing hard wooden
blocks below them, until the load wheel (1) has enough room
under the support arm.
tUNGHEINRICH 004 039 198 00015 04.15 5 (GB)
Procedure
• Lubricate the axle (3).
During assembly, use the same number of shims as were fitted
before disassembly.
• Fit two shims (2) onto the axle (3).
• Fit the load wheel (1) onto the axle (3).
1 The axle must only protrude to the extend needed to fit the shims
(5). If the axle is pushed through further, it can be damaged when
2
lowering the support arms.
• Fit two shims (5) onto the axle (3).
• Position the load wheel (1) under the support arm (4).
tUNGHEINRICH 004 039 198 00015 04.15 6 (GB)
• Secure the load wheel (2) so that it cannot roll off.

That is important to allow the truck and the support arms to be
lowered without damaging the shims, axle or load wheel.
• Jack up the support arms alternatively, remove the hard
wooden blocks one at a time, and slowly lower the support
arms.
• Fit the axle (1).
• Fit the hex screws (M6 x 20) (3).
Final tasks
• Step on the operator position using the ladder.
• Lower the auxiliary lift.
• Raise the operator position.
• Leave the operator position using the ladder.
• Remove the mast retainers; refer to the chapter "Mast
retainer assembly and removal" in the operating instructions.
• Lower the operator position.
tUNGHEINRICH 004 039 198 00015 04.15 1 (GB)
Guide Roller
Settings Q In narrow aisles with guide rails the truck is guided by four rail
guide rollers. The guide rollers come in two sizes.
\ Dimensions and wear limits

i\j
B6 -5 mm
B6 +5mm
Small guide roller Large guide roller
Outside diameter 75 mm 100 mm
— 0
1
U-ÿ ;-Cÿ'-y : ÿ,-1 Rim diameter 60 mm 80 mm
Tyre thickness new 7.5 mm 10 mm

I Diameter wear limit 68 mm 90 mm
73.5 ±3 mm
8-18 mmT
B6 -5 mm
B6 +5mm
tUNGHEINRICH 005 016 287 00004 04.15 1 (GB)
Side Gates: Replacing the Switch Left/Right (7S7 17S6)
Q The switches right/left (7S7/7S6) on the side gates (1) are located
below the lower bar (3).
Required tools
• Ladder
Requirements
• Secure Icordon off the work area.
• Place the ladder next to the truck.
• Raise the operator position (2) and secure it to prevent
• Insert the mast retainers; refer to the chapter "Mast
instructions.
p»| On the EKS 110 280ZZ only the lower mast retainers are required.
• Leave the truck using the ladder.
• Close the gate.
• Uncover the connector:
• To remove the operator platform cover, refer to module
006 023 313 00005.
tUNGHEINRICH 005 016 287 00004 04.15 2 (GB)
Replacing the switch 7S7 or 7S6

• Undo the hex. screw (2) of the gate post (1).
• Remove the screws (4) from the plate (3).
• Remove the plate (3).
• Remove the Allen screws (5).
tUNGHEINRICH 005 016 287 00004 04.15 3 (GB)
• Open the gate (1).
A Trapping hazard
The gate must be secured in the open position to prevent it from
falling and crushing your fingers or hands.
• Secure the gate (1) against falling.
• Remove the hex. screws (2) of the gate post (1).
• Remove the plate nut (3).
• Remove the hex. nut (5) from the switch (4).
1 2
tUNGHEINRICH 005 016 287 00004 04.15 4 (GB)
• Remove the switch (1) from below.

• Pull the connector (3) off the switch (1).
Q The cable (2) must be routed through a tube (4) that is too small
for the switch.
• Cut the cable (2) below the proximity switch (1).
• Cut the cable of the new proximity switch at the connector.
Using the old cable, pull the end of the new cable through the tube
into the space below the operator position.
• Replace the connector on the new cable.
• Push on the connector (3).
tUNGHEINRICH 005 016 287 00004 04.15 5 (GB)
• Install the switch (1) using the hex. nut (3).
Q The dimension X must be 23 ±1 mm.

• Fit the plate nut (2).
sQB-
tUNGHEINRICH 005 016 287 00004 04.15 6 (GB)
• Fit the hex. screws (2) of the gate post (1).

• Fit the Allen screws (4).
• Install the plate (3).
The switch has been replaced and adjusted.
Final tasks
• Test the switch.
• Install the operator platform cover; refer to module
006 023 313 00005.
• Raise the operator position (5).
• Leave the operator position using the ladder.
• Lower the operator position (5).
tUNGHEINRICH 006 023 313 00005 04.15 1 (GB)
Checking the Hydraulic Oil Level and Adding Hydraulic Oil
Requirements
• Main and auxiliary lift fully lowered.
• Truck switched off.
• Truck supported by wedges under the load wheels to prevent
it from moving.
• Front panel (1) removed.
Tools and material required

- Tape measure
\
tUNGHEINRICH 006 023 313 00005 04.15 2 (GB)
Checking and topping up the hydraulic oil level for the main
lift versions 100E, 160E and 190E
Procedure
• Measure the distance "h" below the "Max" (1) mark of the oil
tank (2) with a tape measure.
The distance "h" measured varies according to the truck version:
Main lift versions Distance "h" (minimum and maximum value)
EKS 110- 100E 190 mm - 210 mm

EKS 110 - 160E 170 mm -190 mm
EKS 110 - 190E 145 mm -165 mm
• The hydraulic oil level measured must lie within this range.
• If necessary, add fresh hydraulic oil; refer to module
"Technical Specification".
• Remove the lid (3).
• Add hydraulic oil.
• Check the hydraulic oil level again and top up if necessary.
• Replace the lid (3).
• Fit the front panel.
The hydraulic oil level has now been checked and topped up.
2
tUNGHEINRICH 006 023 313 00005 04.15 3 (GB)
Checking and topping up the hydraulic oil level for the main
lift version 280ZZ
- Tape measure
Procedure
• Measure the distance "h" below the "Max" (2) mark of the oil
tank (3) with a tape measure.
Q Distance "h": 60 mm - 80 mm (minimum and maximum value)

• Replace the lid (1).
tUNGHEINRICH 006 023 313 00005 04.15 4 (GB)
Checking and topping up the hydraulic oil level for the
auxiliary lift
Requirements
• Operator platform cover removed; see "Removing/installing
the operator platform cover" in this chapter.

- Tape measure
Procedure
• Measure the distance "h" below the upper edge of the oil tank
(1) with a tape measure.
Distance "h": 25 mm - 35 mm (minimum and maximum value)
\ • Replace the lid (2).

o
tUNGHEINRICH 006 023 313 00005 04.15 5 (GB)
Removing/Installing the Operator Platform Cover
Q The operator platform cover (2) only needs to be removed when

carrying out maintenance work on the EKS 110 with auxiliary lift.
Removing the operator platform cover
- Philips screwdriver
Procedure
• Remove the floor mat (1) from the operator platform.
Q Remove spray adhesive residue.

• Remove the two mounting screws (3).
• Lift up the operator platform cover (2) and place it to one side.
The operator platform cover has been removed.
tUNGHEINRICH 006 023 313 00005 04.15 6 (GB)
Installing the operator platform cover

Requirements
- The operator platform cover has been removed.
• Insert the operator platform cover (2) in the cutout in the
operator platform.
• Fit the operator platform cover (2) with the two mounting
screws (3).
• Fit the floor mat (1) in the operator platform using spray
adhesive.
Q Observe the operating instructions and safety data sheet of the

spray adhesive.
The operator platform cover has been installed.
Final tasks
• Remove the wedges from under the load wheels.
tUNGHEINRICH 006 013 290 00021 04.15 1 (GB)
Main Lift: Adjusting the Magnetic Switch of the Lift-Limit Cut-Out
Requirements
Height "X" is the maximum lift height that the operator position
should reach unladen. The maximum lift height for the different
truck versions varies.
Maximum lift height
EKS 110 100E EKS 110 160E
Setting: Height X 1193 ±8 mm 1803 ±8 mm

Operator position raised
l T without load
EKS 110 190E EKS 110 280ZZ
Setting: Height X 2103 ±8 mm 3003 ±8 mm

Operator position raised
without load
tUNGHEINRICH 006 013 290 00021 04.15 2 (GB)
Procedure for EKS 110 100E

• Remove the cover (1) from the control panel.
• Remove the screws (3) of the magnetic switch (2).
• Adjusting the magnetic switch (2):
• Pay attention to the maximum height; refer to "Maximum
height" in this module.
• Adjust the magnetic switch (2) in the slotted holes so that
the lift movement is stopped before the lift cylinder
reaches its mechanical stop.
• Tighten the screws (2) hand-tight.
• Fit the cover (1).
The magnetic switch has been adjusted.
2 3
tUNGHEINRICH 006 013 290 00021 04.15 3 (GB)
Checking the adjustment on the EKS 110 100E

• Pull out the emergency disconnect switch.
• Fully raise the operator position.
• Measure the height "X".
• Check whether the measured value is in the adjustment
range; refer to section "Maximum lift height".
• Readjust if necessary.
I// ///?// ////////// ///7V/X

tUNGHEINRICH 006 013 290 00021 04.15 4 (GB)
Procedure for EKS 110 160E and 190E
Q On the EKS 110 160E and 190E the magnetic switch on the right-
hand mast section cannot be adjusted. Instead, the switching
magnet under the operator position is adjustable.
instructions.
• Remove the screws (1) from the bracket (4).
• Remove bracket with switching magnet (3).
The switching magnet has been removed.
• Loosen the screw (2) of the switching magnet.
• Adjusting the switching magnet (3):
• Adjust the switching magnet (3) in the slotted holes so that
• Install switching magnet (3) and bracket (4) with screws (1).
The switching magnet has been adjusted.
tUNGHEINRICH 006 013 290 00021 04.15 5 (GB)
Checking the adjustment on the EKS 110 160E and 190E

• Fully lower the operator position.
2nd person required who is permitted to operate the truck.
• 2nd person: Fully raise the operator position.
• 2nd person: Fully lower the operator position.
tUNGHEINRICH 006 013 290 00021 04.15 6 (GB)
Procedure for EKS 110 280ZZ
Q On the EKS 110 280ZZ the magnetic switch on the right-hand

mast section cannot be adjusted. Instead, the switching magnet
on the inner mast is adjustable.
instructions.
Q On the EKS 110 280ZZ only the lower mast retainers are required.
• Remove the screws (1) from the bracket (1).
• Adjusting the switching magnet (3):
• Adjust the switching magnet (3) in the slotted holes so that
The switching magnet has been adjusted.
tUNGHEINRICH 006 013 290 00021 04.15 7 (GB)
Checking the adjustment on the EKS 110 280ZZ

Q 2nd person required who is permitted to operate the truck.

• 2nd person: Fully raise the operator position.
Q A ladder may be required.

• 2nd person: Fully lower the operator position.
I// ///?// ////////// ///7V/X
tUNGHEINRICH 006 051 290 00004 07.15 1 (GB)
Auxiliary-Lift Magnetic Switch
Requirements
1 • Park the truck securely on level ground.
Replacing the magnetic switch for lift height sensing

(2S111.1 I2S111.2)
Procedure
• Remove the screws (1).
• Remove the cover (2) under the control panel on the load
side.
• Remove the screws (3) from the magnetic switch (4).
• Remove the connector.
The magnetic switch has been removed.
2 3 4
tUNGHEINRICH 006 051 290 00004 07.15 2 (GB)
• Install new connector.

• Adjusting the magnetic switch (1):
• Adjust the magnetic switch (1) in the slotted holes so that
the upper edge of the magnetic switch is 24 ±3 mm from
24 ±3 mm
the upper edge of the plate (2).
• Fit the screws (3).
• Install the cover (4) using the screws.
1 Magnetic switch (1) has been installed and adjusted.
2
tUNGHEINRICH 006 051 290 00004 07.15 3 (GB)
Replacing the lift-limit magnetic
switch (2S66)
Procedure
Q Carefully mark the mounting position of

the magnetic switch.
• Remove the screws (1) from the
magnetic switch (2).
• Remove the connector.
The magnetic switch has been
removed.
tUNGHEINRICH 006 051 290 00004 07.15 4 (GB)
• Install new connector.

• Install the magnetic switch (1) in the marked mounting
position using the screws (4).
5 ±3 mm
P>] Carry out adjustments without load.
• Raise the auxiliary lift to the lift limit.
• Check whether the clearance between the mechanical end
stop (Allen screw) (2) and the support roller (3) is 5 ±3 mm.
• If necessary, move the magnetic switch (1).
• Lower the auxiliary lift and raise once more to the lift limit.
• Recheck the clearance.
• Repeat this procedure if necessary.
Magnetic switch (1) has been installed and adjusted.
tUNGHEINRICH 006 023 106 00010 04.15 1 (GB)
Bleeding the Hydraulic Cylinders
Requirements
Tools required
• Ladder
Procedure for EKS 110 100E

• Place a ladder next to the operator position.
• Fully raise the operator position (1).
The bleed screw (2) is now accessible.
• Leave the operator position via the ladder.
tUNGHEINRICH 006 023 106 00010 04.15 2 (GB)
Because the bleed screw (3) has a short thread, make sure that
the bleed screw (3) does not come out of the cylinder when
loosened.
Slowly loosen the bleed screw (3).
Risk of accidents and injury
The piston (1) and operator position can lower independently
during bleeding.
s> Wait until the hydraulic oil emerges without bubbles and
free of foam.
Tighten the bleed screw (3) again.
If the bleed screw (3) does not seal correctly, the sealing ring (2)
must be replaced. Fully lower the load handler before fitting the
sealing ring (2).
• Clean the main lift cylinder of any hydraulic oil that may have
escaped.
The hydraulic cylinder has been bled.
A If necessary, top up the hydraulic oil in the hydraulic tank; refer to

module 006 023 313 00005.
HUNCHEINRICH 006 023 106 00010 04.15 3 (GB)
EKS 110 160E / 190E
Requirements
Tools required
• Ladder
Procedure for EKS 110 160E 1 190E

The EKS 110 160E and 190E are equipped with a two-stage
telescopic synchronous cylinder. This cylinder has two bleed
screws.

• Fully raise the operator position (1).
The bleed screws (2) are now accessible.
tUNGHEINRICH 006 023 106 00010 04.15 4 (GB)
->| Because the bleed screws (3, 4) have short threads, make sure
that the bleed screws (3, 4) do not come out of the cylinder when
loosened.
Slowly loosen the lower bleed screw (4).

55 The piston (1) and operator position can lower independently
during bleeding.
Wait until the hydraulic oil emerges without bubbles and
free of foam.
Retighten the lower bleed screw (4).
Repeat the bleeding process with the upper bleed
screw (3).
Q To completely bleed the hydraulic cylinder, the operator position

must be fully lowered and then raised again.
Climb onto the truck using the ladder.
Fully lower the operator position.
1 Fully raise the operator position again.
The bleed screws (3.4) are now accessible.
Switch off the truck.
Leave the operator position via the ladder.
Slowly loosen the lower bleed screw (4).
tUNGHEINRICH 006 023 106 00010 04.15 5 (GB)

during bleeding.
free of foam.
Retighten the lower bleed screw (4).
55 screw (3).
If the bleed screws (3, 4) do not seal correctly, the sealing rings (2)
sealing ring (2).
escaped.
/i\ If necessary, top up the hydraulic oil in the hydraulic tank; refer to
module 006 023 313 00005.
1
HUNCHEINRICH 006 023 106 00010 04.15 6 (GB)
EKS 110 280ZZ
Requirements
Tools required
• Ladder
Procedure for EKS 110 280ZZ

The EKS 110 280ZZ is equipped with two two-stage telescopic
synchronous cylinders. These cylinders each have two bleed
screws.

• Raise the operator position (1) by approx. 2.20 m.
The bleed screws (2) are now accessible.
tUNGHEINRICH 006 023 106 00010 04.15 7 (GB)
->| Because the bleed screws (3, 4) have short threads, make sure
that the bleed screws (3, 4) do not come out of the cylinder when
loosened.
Slowly loosen the lower bleed screws (4).

55 The piston (1) and operator position can lower independently
during bleeding.
free of foam.
Retighten the lower bleed screws (4).
screws (3).
Climb onto the truck using the ladder.
Fully lower the operator position.
Raise the operator position(1) again by approx. 2.20 m.
The bleed screws (3.4) are now accessible.
Leave the operator position via the ladder.
Slowly loosen the lower bleed screws (4).
tUNGHEINRICH 006 023 106 00010 04.15 8 (GB)

during bleeding.
free of foam.
Retighten the lower bleed screws (4).
55 screws (3).
If the bleed screws (3.4) do not seal correctly, the sealing rings (2)
sealing ring (2).
escaped.
/i\ If necessary, top up the hydraulic oil in the hydraulic tank; refer to
module 006 023 313 00005.
tUNGHEINRICH 006 021 341 00001 06.15 1 (GB)
Checking the Line-Rupture Safety Valve of the E Mast and ZZ Mast
Checking the line-rupture safety valve of the E Mast
Requirements
• Park the truck securely on level ground as close to a wall as
possible.
• Disassemble the front panel.
Procedure
Undo the knurled nut (1).
Pull off the magnet (2).
Remove the directional control valve (3) with the ring
spanner.
© Remove the lowering brake valve (4) with the long-nose
pliers.
Fit the directional control valve (3) and magnet (2).
Tighten the knurled nut (1).
Switch on the truck.
Raise a test load (200 kg).
Secure the test load with lashing straps to prevent it slipping
off.
Raise the operator position with load handler to approx. 1 m.
Leave the truck via the ladder.
tUNGHEINRICH 006 021 341 00001 06.15 2 (GB)
Make sure there is nobody in the hazardous area!
• Open the knurled bolt (1) of the emergency lowering valve

quickly to the end stop.
The operator position loses height.
The function has been successfully tested when the line-rupture
safety valves is triggered and the operator position stops lowering
(clearly audible engagement).
If the test is successful, tighten the knurled bolt (1).

Fully raise the operator position and then fully lower it.
Undo the knurled nut (2).
Pull off the magnet (3).
Remove the directional control valve (4) with the ring
spanner.
Install the lowering brake valve (5) with the long-nose pliers.
Install the directional control valve (4) and magnet (3).
Tighten the knurled nut (2).
Switch on the truck.
Fit the front panel.
tUNGHEINRICH 006 021 341 00001 06.15 (GB)
3
Checking the line-rupture safelty valve of the ZZ Mast
Requirements
• Park the truck securely on level ground as close to a wall as
possible.
• Raise a test load (approx. 650 kg).
• Secure the test load with lashing straps to prevent it slipping
off.
• Raise the operator position with load handler to approx. 1 m.
• Leave the truck via the ladder.
• Remove the front panel (1).
Procedure
• Connect service computer to the truck using a USB cable.
Make sure there is nobody in the hazardous area!
tUNGHEINRICH 006 021 341 00001 06.15 4 (GB)
• Select Judit symbol "Safety Test"

I (1) on the home page.
*
Carry out the following steps
consecutively as quickly as possible.
• Press "Test" button under the
lowering valve (line-rupture test)
(3).
• Open the emergency lowering
valve (2) as far as the end stop as
quickly as possible.
JUNGHEINRICi
The operator position loses height.
SICHERHEITSTEST IJ ®»1J
I Wiiwii ÿ
The function has been successfully
Bromio gonotaloroch imagnetocti
tested when the line-rupture safety
valves is triggered and the operator
position stops lowering (clearly audible
engagement).
H i
• If the test is successful, tighten the
emergency lowering valve.
• Enter the truck.
• Remove the service computer.
MfitlUM*Vt+Q*n
J • Raise the operator position and fully
_j
MflSateurg ÿ
| * | !'"ÿ*ÿ
lower it again.
.
©0 70 JO
MC • Fit the front panel.
Hauutochutz / Snntvonll (Rohrbuichleali

I f—
"\
V. J
3>J * s
tUNGHEINRICH 006 022 172 00003 04.15 1 (GB)
Auxiliary Lift: Adjusting the Fork Carriage via the Load Chain
Adjustment dimension
P»j The distance between the fork carriage (1) and the ground (2)
should be approx. 9 mm ±3mm.
n Requirements
• Fully lower the main and auxiliary lift.
o
tUNGHEINRICH 006 022 172 00003 04.15 2 (GB)
Procedure
• Remove the cover (2).
• Loosen the locknut (4).
• Set the adjustment dimension using the hex. nut (3).
• Tighten the locknut (4).
• Install the cover (2) using the screws (1).
The fork carriage has been adjusted.
tiUNGHEINRICH Service Manual G 6355.01 05.15 1 (GB)
Load Chains (Cleaning, Inspection and Lubrication)
Cleaning
If the chain becomes so contaminated on the outside during
operation that the lubricant cannot penetrate, clean between the
link plates to remove contamination, grease or other particles.
The contamination prevents the lubricant from penetrating
between the link plate and pin.
Only lubricate a load chain when the chain has been unloaded.
Chains must only be cleaned with paraffin derivatives such

as petroleum, turpentine or diesel.
Special cleaner: 50002003
Tungard Clean: 51025050
<ÿtop> After cleaning always apply chain spray (29201280) to the chain.
ÿ Never clean load chains with steam jet high pressure cleaners or
chemical cleaning agents.
This can cause direct damage to chains through gassing.
Inspection
a Load chains wear rapidly if not lubricated. The intervals stated in

the service checklist apply to normal duty use. More demanding
If the truck is fitted with two lift chains,
both chains must always be replaced.
conditions (dust, temperature) require more regular cleaning and This is the only way to ensure even
lubrication. load distribution over the two chains.
When replacing a chain, replace also
The chain must be replaced immediately if:
the chain adjuster (3) and pin (4). All
the chain has elongated significantly within a short period of used parts must be scrapped. Do not
time. replace individual chain links.
signs of external wear or heavy corrosion are visible.
an error has occurred that could have resulted in a peak
voltage in the chain.
Item Description
there is excessive contamination.
1 Chain pulley
Q However, careful inspection is made more difficult if the chain is
coated with a thick layer of grease. The inspection will not be 2 Maximum wear area
reliable unless the chain has been thoroughly cleaned 3 Chain adjuster
beforehand.
4 Pin
If the chain is removed for inspection, it should be re-installed in

the reverse order of disassembly.
Checking the chain wear level Broken link plates
Check the wear level on the edge of the chain links: Broken link plates are indicated by a
©3)
rising of the respective plate near
near an anchor point the plate head or by a missing part
on sections that rest on pulleys during transportation, as of the head.
these are subject to greater wear levels. _ÿ| Corrosion can also be a cause of a
Check chains for torn or missing link plates, extended holes, broken link plate.
cracking in the outer link plates, loose, worn or damaged pins and Chains with broken link plates are unsafe for operation. The chain
cotter pins. must be replaced immediately.
Chains should also be replaced immediately if visible damage is
noted, as such damage causes permanent breakage over time. Twisted pins
Normal Twisted
bolt bolt
Re-tensioning
The chain setting must be checked during an inspection and
re-adjusted if necessary.
If there are twisted pins, this means the blockage in the chain joint
is already so severe that the press fit between the pin and outer
plate has been overcome.
Chains with twisted pins are unsafe for operation. The chain must
be replaced immediately.
Stiff joints Checking chains for corrosion

Check chains for corrosion, in particular inside the link plates.
Corroded, worn or damaged chains must be replaced, as the
corrosion can ultimately lead to permanent breakage.
If the chain links cannot return to their operational position after

leaving the pulley, the chain joint is not functional. This
appearance can be caused by cold welding, friction corrosion or
excessive contamination.
£top> If the stiff joints cannot be rectified by cleaning and lubricating, the
chain must be replaced.
Plate hole wear
'stoÿ If plates have impact markings or other deformities, or if wear is

detected on the plate holes, the chain must be immediately
replaced.
Checking the wear limit of link plate height "H"

Example of a chain where division P = 1" (25 mm):
Check if the chain has excess wear to link plate height "H", e.g.
due to constant contact with chassis / mast sections
The max. permissible reduction of the link plate height is 5% of the Dimension of link plate height "H" = 24 mm
overall height of link plate height "H", irrespective of whether the Maximum wear (5% of 24 mm) = 1.2 mm
wear is showing on one or both sides.
Minimum plate height (24 mm - 1.2 mm) = 22.8 mm
/j\ If the wear exceeds this level, the chains must be replaced.
ppTj.— —|Tp |—
H = Link plate height
P = Separation
Checking chains for elongation The bore hole gauge / wear gauge can measure chain elongation
of 3% with precision. This means that for a 3% chain elongation 33
2 1 chain links or 33 pins [1 to 34 pins] lie between the markings of the
bore hole gauge / wear gauge.
For safety reasons, Jungheinrich recommends replacing load
chains when they elongate by 2.9%.
This means that the maximum elongation of a segment or of the
whole chain must not exceed 2.9% of the length of the chain.
A The permissible elongation of chains is tested at 10% of the rated

load. The length of the laden chain must be measured over 17
double links or 34 chain pins [1 to 35 chain pins],
Measure the chains at three different points, in particular the
sections that lie over the pulleys (2) during transport as these
are subject to greater wear levels.
If the truck is fitted with two lift chains, both chains must always be
replaced. This is the only way to ensure even load distribution over
the two chains.
When replacing a chain, replace also the chain adjuster (3) and
pin (4). All used parts must be scrapped. Do not replace individual
chain links.
Item Description Item Description
1 Chain pulley 4 Pin
2 Maximum wear area 5 Double link
3 Chain adjuster 6 Chain link
Tool: Bore hole gauge,

Wear gauge in UW test kit
The following table shows the dimensions produced for a 2.9% If the truck is fitted with two lift chains,
elongation of a specific section of a load chain (17 double links both chains must always be replaced.
over 34 pins [1 to 35 pins]): This is the only way to ensure even load
distribution over the two chains.
When replacing a chain, replace also
Chain Dimension over Wear limit (dimension
the chain adjuster (3) and pin (4). All
dimension = 17 double links or over 17 double links
used parts must be scrapped. Do not
Separation P 34 pins + 2.9%)
replace individual chain links.
mm (inch) mm inch mm inch
12,7 1/2 431,80 17.00 444,32 17,49 Item Description
15,875 5/8 539,75 21.25 555,40 21,87 1 Chain pulley
19,05 3/4 647,70 25.50 666,48 26,24 2 Maximum wear area
25,4 1 863,60 34.00 888,64 34,99 3 Chain adjuster
31,75 1 1/4 1079,50 42.50 1110,81 43,73 4 Pin
38,1 1 1/2 1295,40 51.00 1332,97 52,48
44,45 1 3/4 1511,30 59.50 1555,13 61,23
50,8 2 1727,20 68.00 1777,29 69,97
76,2 3 2590,80 102.00 2665,93 104,96
Replace the entire chain including the chain adjuster (3) and
pin (4) when the wear limit has been reached. Do not replace
individual chain links. All used parts must be scrapped.
Lubrication
General Instructions When the chains have been cleaned they should be
lubricated by applying a thorough layer of grease and
Effective chain lubrication protected against corrosion. The lubricants to be used are
extends a chain's service life listed in the operating instructions (in the "Consumables"
several times over. The section).
amount of oil used is not the It is not sufficient to lubricate only the top of the bearings.
only factor; how much oil
actually reaches the lubrication The drip method should preferably be used for disassembled
points in the chain joint (5) is chains.
equally important. The chain Mark the assembly position of the chains and remove them
must be lubricated shortly from the truck. Clean the chains then soak them in lubricant
before commissioning. for an hour.
The amount of lubricant used is Remove the chains from the immersion bath, allow the
sufficient if: lubricant to drip off and install the chains back on the truck in
• when you run your finger along the chain it is coated with a
the reverse order (note markings).
thin, clear layer of oil. Lubricate the chain tensioning bolts before and after chain
The chain surface should be coated with a thin layer of oil to
assembly.
provide the necessary corrosion protection.
Q It is advisable to carry out a test run on the load chains to remove
oil drips and to check whether unusual noise or vibrations occur.
Q Never apply so much lubricant to the chain that it starts to drip off.
/j\ The chain lubricant also protects the chain from corrosion. It is
essential that all link plates and pin surfaces are coated with
lubricant as corrosion can cause rusting of the link plates, which in
turn could result in chain breakage with unexpectedly low loads.
The chains must be lubricated in accordance with the
maintenance intervals listed in the operating instructions.
The chain tensioning bolts must be lubricated after the chain
has been assembled and all subsequent adjustments made.
Lubricants
The lubricants to be used are listed in the operating instructions (in
the "Consumables'' section).
The prescribed chain spray must be used in accordance with the
instructions. Applying grease externally will not provide sufficient
lubrication.
Poisonous and hazardous vapours can be produced when using
lubricants / fluids. Therefore, apply the appropriate safety
regulations when handling these materials.
tiUNGHEINRICH 006 022 222 00004 07.15 1 (GB)
Q Pay attention to potential hazards when working on the mast

rollers; refer to "Operational Safety" - "Removing and Installing
the Mast Rollers and Mast Sections".
Adjusting the lateral play
Material required:
Available shims: 36177010, 36177020, 36177030
Procedure
If the permissible channel or lateral play is exceeded, the mast
components will have to be adjusted.
• Measure the mast components in-situ.

• Check the lateral play in the upper position (mast extended).
Channel clearance
t When the shims have been correctly installed, the fork carriage
0 must be parallel to the mast and must not be canted.
Lateral clearance
tUNGHEINRICH 006 022 222 00004 07.15 2 (GB)
Channel wear
Impact marks, indentations, chatter marks, » max. 0.5 mm

roller running tracks
Increased mast channel wear results in increased "clattering

noises" due to the increased play between the mast roller and the
mast channel.
To reduce this play to a minimum, as a first step it is sensible to
reduce the "clattering noises" by replacing the mast rollers with
oversized mast rollers.
Mast rollers
0D
Standard Oversize
97.9 98.3 (part no.: 05108330)
tUNGHEINRICH SHB J 6900.09 09.90 1 dD
Instructions for the prevention of accidents and damage to equipment when performing servicing,
checking and repair operations on fork lift trucks equipped with electronic assemblies
1. Safety measures 3. Correct handling of electronic printed circuit boards
Observe the operating instructions, section "Repair". When removing or installing electronic mounting boards or when
fitting the test adapter ensure that
Remove all rings, bracelets and similar objects before com¬
mencing any operations on fork lift trucks. the electric system is dead (switch off battery main switch and
key switch),
Repairs, as well as removal and installation of electronic com¬
ponents and fuses must only be performed on a dead system. the contact pins are not deformed,
Unplug the battery plug or disconnect the battery.
the cooling on the multipoint connector corresponds with the
Connect the battery and switch on control voltages only, if coding on the mounting board,
required for checking operations. Exercise care during all
the contacts of the mounting board and multipoint connector
operations (hazard of arcing).
are facing each other correctly when there is no coding),
If not instructed otherwise, the vehicle must be jacked up for
the mounting board is correctly inserted into the guide rail,
checking to allow the drive wheels to move freely. (Ensure
absolutely that the vehicle cannot slip.) a seized mounted board is not removed or installed by force
(contacts will be deformed),
Use a tool (brass sockets) for the removal of printed circuit
2. Electric welding operations boards which are fitted by means of lugs.
Before commencing any electric welding operations on a fork lift

truck, ensure that all control current plugs and all cable connec¬
tions have been disconnected from the electronic assemblies, and
that all electronic mounting boards have been removed.
During electric welding operations on the vehicle, the welding cur¬
rent causes in the cables an inductive voltage with high voltage
peaks which is liable to destroy the semi-conductors incorporated
in the electronic assemblies.
tUNGHEINRICH SHB J 6900.09 09.90 2 (GB)
4. Handling of electronic components (MOS- 6. Installation of heat-sensitive components

components, E-PROM and others) (Diodes, thyristors, transistors, cooling elements, etc.)
These electronic components are very sensitive against static Heat-sensitive components must be installed using heat conduc¬
charges and might be destroyed by such static charges. ting compound, heat-conducting mats or foils.
Always ensure that the electronic components, when not required, Do only apply enough heat-conducting compound to the threads
are placed with their connecting contacts on metallic, bare sup¬ of electronic components or into tapped holes accepting such
ports, or that they are in conductive foam rubber. components, or onto the surfaces of cooling elements that the
New electronic components are always supplied on a strip of con¬ threads or any unevenness in the cooling element surfaces are
ductive foam rubber and for transportation purposes the replaced just filled or evened out.
electronic components must be set back into the conductive foam If excessive heat-conducting compound is applied, the compound,
rubber. which softens when the components become heated, will leak out
(leaving hollows) thus impairing its heat conducting properties.
5. Changing the EPROM
|gp In case of varnished boards, do not exchange the EPROM.
Do not bend or damage the connecting contacts of the EPROM! 7. Cleaning operations
Lift the EPROM equally out of the plug connector by putting Cleaning operations must only be performed on dead
the tool - order no. 081.0996 (plastic pliers) - under the narrow installations. Unplug the battery plug or disconnect the
edges. battery.
When replacing the EPROM, ensure that the sides are cor¬ Do not use a steam jet when cleaning electronic components,
rectly placed. EPROM and plug connector are marked by a but use low-pressure compressed air and a brush.
notching. • See SHB 0000.15.
HUNGHEINRICH SHBZ 0000.15 02.89 1 dD
Instructions for the prevention of functional failures and damage to equipment when performing
cleaning operations on fork lift truck
1. Cleaning operations, general The entire vehicle must be perfectly dry, before operations in
cold storage facilities are resumed.
Unplug the battery connector or disconnect the battery, before
commencing any cleaning operations. Perform several braking tests (drying out the brakes) before
putting the vehicle into operation again.
Only non-inflammable liquids must be used when performing
cleaning operations (for cleaning and servicing of chains refer No sealing spray should be used, as sprayed surfaces tend to
to section 2). increase the attraction of dust and dirt.
Do not use water or a steam jet when cleaning electric and Limit the application of contact spray to as little an area as
electronic assemblies or components. Use vacuum intake air, possible.
weak compressed air and a non-metal brush.
Carefully cover all delicate components, especially electric
and electronic assemblies and components before applying
water or a steam jet.
After completion of steam jet cleaning, grease the vehicle in
accordance with the lubrication schedule. Friction surfaces,
guide rollers and chains must only be greased with the lubri¬
cant specified for the respective operating conditions (normal
operating conditions/operation in cold storage facilities).
Parts susceptible to corrosion must be subjected to the pres¬
cribed after-treatment.
Before putting the vehicle into operation again, ensure that
the electric/electronic assemblies are dry. If necessary, dry
them using air. Ensure that any residual water or liquid deter¬
gent still present on the chassis or inside the vehicle cannot
penetrate into electric or electronic assemblies as a result of
vehicle movements.
HUNGHEINRICH SHBZ 0000.15 02.89 2 dD
2. Cleaning and servicing of chains
Lifting chains fall into the category of safety elements. Their ser¬
vicing and lubrication must be carried out with great care, as befits
safety elements. Lack of lubrication causes rapid wear of chains.
The intervals indicated in the servicing checklist apply to normal
operating conditions. Under rugged working conditions (dust, high
temperatures) more frequent lubrication becomes necessary. It is
advisable to use the chain spray indicated in the lubrication sche¬
dule. With a clean chain (dust and grease crusts to be removed
beforehand) this will ensure penetration of the lubricant. Mere
external application of grease does not provide adequate
lubrication.
Chains should not be excessively dirty.
Do not clean chains hy means of steam jets, i.e. do not direct
the steam jet directly on to the chain.
Paraffin derivates only must be used for cleaning purposes
(petrol, petroleum or diesel fuel).
Chains must be lubricated whenever they have been cleaned.
Corrosive products and acids must not come into contact with
chains, as they will lead to their destruction.
When servicing or replacing lift chains, check for uniform ten¬
sion and for aligned and smooth passage over the guide
rollers.
tfUNCHEINRICH
Machines. Ideas. Solutions.
EKS 110 (05.15 - )
Serial no. Customer
Model Address 1
Year of manufacture Service hours Address 2
Date Post Code
Inspected by Serv.Rep.No.
Comments
Signed
2.3.674.0 - 15.06.2015 07:42:25

tfUNCHEINRICH
EKS 110 (05.15 - )
Brakes
Test the brake and the brake power.
Electrics
Test the warning and safety devices in accordance with operating instructions.
Test the Emergency Disconnect switch.
Check key switch is present and test it.
Check that the key switch closure matches the truck type
(Pedestrian: 701; sit-down / stand up: 702).
Check the electric wiring for damage (insulation damage, connections) and check the
fuse ratings.
Carry out a frame leakage test.
Power supply
Check the battery, battery cable and cell connectors for damage, contamination and
ensure they are secure.
Compare the details (battery voltage, battery weight) on the battery data plate with those
on the data plate of the truck.
Test the battery lock / battery attachment.
Check the battery connector for damage, test it and make sure it is secure.
Driving
Test the deadman switch.
Test the travel speeds.
Check the transmission and motor attachments.
Check the wheels for wear and damage. Make sure they are tight and check the
compressed air if necessary.
Chassis and superstructure

Check the chassis and screw connections for damage.
Check the operating instructions and relevant documents are accessible,
e.g. operating instructions for attachments.
Check labels are legible, complete and plausible.
Check safety, instruction, capacity and where applicable tow force decals are legible and
present.
Check the capacity rating for the truck and all attachments that are used with it.
Test the operator’s platform and check for damage.
Test the attachment of the panels and covers as well as the floor plate and supports.
Ensure they work and are safe.
Check the mast attachment / mounting.
Check the overhead guard and / or cab are secure and check for damage.
Test the protective mechanism against trapping and shearing is present, secure,
damage and dirt-free and effective.
Hydr. movements
Test the safety valve.
Visually inspect the supporting elements, cross members and weld seams for damage
and cracks.
2.3.674.0 - 15.06.2015 07:42:25

tfUNCHEINRICH
EKS 110 (05.15 - )

Check the load chains and chain guide for wear and damage. uuu
Check the lateral clearance of the mast connections and the fork carriage. uuu
Check the mast section for any deviations from the original dimensions (section slack). uuu
Check hydraulic hoses for damage, leaks and remaining service life. uuu
Test the emergency lowering system. uuu
Test the pressure relief valve. uuu
Check the mast tilt. uuu
Check that hydraulic ports, hose and pipe lines are secure, check for leaks, damage, uuu
blisters and kinks.
1 ÿ nn
Agreed performance
Carry out a test run with rated load, if necessary with a customer-specific load. uuu
Note:
In the event of impact damage test the neighbouring components individually and check
for damage.
nn
1ÿ
Steering
Test the electric steering and its components. uuu
Check the steering components for slack and damage. uuu
Option(s)
Access module
Electrics
Check the key switch or ISM access module is present and test accordingly.
Test access module, check for damage and make sure it is secure.
Aisle recognition
System components
Test aisle recognition magnetic switch and/or light button, check for contamination and
damage.
Audible warning devices
Electrics
Test buzzer / warning alarm, check for damage and make sure it is secure.
Data radio
System components
Test scanner, check for damage and make sure it is clean.
Check fuse ratings.
Check wiring is secure and check for damage.
2.3.674.0 - 15.06.2015 07:42:25

tfUNCHEINRICH
EKS 110 (05.15 - )
Discharge strap
Electrics
Check anti-static discharge strap/chain is present and not damaged.
End of aisle safety device - magnet
System components
Test end-of-aisle safety device and aisle-detection functions.
Fire extinguisher
Agreed performance
Check fire extinguisher is present, secure and check the test interval.
Lateral battery removal
Power supply
Lift cutout
Hydr. movements
Test lift cutout, check for damage and make sure it is secure.
Other inspections
Agreed performance
Tests on other options and special parts such as data radio, access modules (ISM) must
be recorded in the test report.
Overhead guard

Check the frame and safety equipment (e.g. overhead guard) for cracks, damage,
deformation and any changes that could affect safety.
Rail guidance
Electrics
Test two-hand operation in narrow aisles.
Driving
Check the distance between the guide rollers and the guide rails over the entire length of
the rails.
2.3.674.0 - 15.06.2015 07:42:25

tfUNCHEINRICH
EKS 110 (05.15 - )
Shock sensor / data recorder
Electrics
Check shock sensor / data recorder are secure and check for damage.
Side gates / railing

Test the operation and dimensions of the gates, railings and doors and check for
damage
Strobe light / beacon
Electrics
Test the lights.
Work lights
Electrics
Test lighting.
2.3.674.0 - 15.06.2015 07:42:25

tfUNCHEINRICH
EKS 110 (05.15 - )
Serial no. Customer
Model Address 1
Date Post Code
Comments
Signed
2.3.674.0 - 25.06.2015 08:19:18

tfUNCHEINRICH
EKS 110 (05.15 - )
Brakes
Test the brakes.
Check magnetic brake air gap, adjust if necessary.
Electrics
Test the cable and motor attachments.
Test the displays and controls.
Test the micro switch and adjust if necessary.
Check the fuse ratings.
Check the carbon brushes, replace if necessary.
Note:
When replacing the carbon brushes, apply pressurised air to the motor.
Check the electric wiring for damage (insulation damage, connections).
Make sure wire connections are secure.
Power supply
Check acid density, acid level and battery voltage.
Check battery cable connections are secure, check for dirt and grease terminals if
necessary.
Check the battery and battery components.
Driving
Check the transmission for noise and leakage.
Note:
Replace the transmission oil if service life exceeded (10000 h).
Check the wheel suspension and attachment.
Check the wheels for wear and damage.

Check the doors and covers.
Test the adjustable floor plate and make sure it is secure.
Check the mast guard for damage.
Hydr. movements
Check the cylinders and piston rods for damage and leaks, and make sure they are
secure.
2.3.674.0 - 25.06.2015 08:19:18

tfUNCHEINRICH
EKS 110 (05.15 - )

Check the settings and wear levels of slide pieces and stops and adjust the slide pieces
if necessary.
Check the load chain lubrication and lubricate if necessary.
Check the load chain setting and tension if necessary.
Check the lateral clearance of the mast connections and the fork carriage.
Visually inspect the mast rollers.
Check the wear on the running surfaces.
Test the hydraulic system.
Check that hydraulic ports, hose and pipe lines are secure, check for leaks and damage.
Test the emergency lowering system.
Check the hydraulic oil level and top up if necessary.
Test the pressure relief valve.
Check forks, load handler (e.g. mandrel) for wear and damage.
Agreed performance
Carry out a test run with rated load, if necessary with a customer-specific load.
Demonstration after servicing.
Lubricate the truck according to the lubrication schedule.
Steering
Test the electric steering and its components.
Check the steering head bearings, steering play and steering toothing or steering chain.
Lubricate the steering toothing and steering chain.
Option(s)
Access module
Electrics
Aisle recognition
System components
damage.
Aquamatik
Power supply
Test Aquamatik plug, hose connections and float and check for leaks.
Test flow indicator and check for leaks.
Electrics
2.3.674.0 - 25.06.2015 08:19:18

tfUNCHEINRICH
EKS 110 (05.15 - )
Battery refill system
Power supply
Test battery refill system and check for leaks.
Data radio
1 JUU
System components
Test scanner, check for damage and make sure it is clean. uuu
Check fuse ratings. uuu
Check wiring is secure and check for damage. uuu
Discharge strap
Electrics
Electrolyte circulation
Power supply
Check hose connections and test the pump.
Replace air filter wadding.
System components
Power supply
Lift cutout
Hydr. movements
Overhead guard

2.3.674.0 - 25.06.2015 08:19:18

tfUNCHEINRICH
EKS 110 (05.15 - )
Rail guidance
Electrics
Driving
the rails.
Check the rail guide roller bedding and attachment.
Check the rail guide rollers for wear and damage.
Electrics

damage
Electrics
Test the lights.
Work lights
Electrics
Test lighting.
2.3.674.0 - 25.06.2015 08:19:18

tfUNCHEINRICH
EKS 110 (05.15 - )
Serial no. Customer
Model Address 1
Date Post Code
Comments
Signed
2.3.674.0 - 25.06.2015 08:19:18

tfUNCHEINRICH
EKS 110 (05.15 - )
Brakes
Test the brakes.
Electrics
Note:
Power supply
necessary.
Driving
Note:

Hydr. movements
secure.
2.3.674.0 - 25.06.2015 08:19:18

tfUNCHEINRICH
EKS 110 (05.15 - )

if necessary.
uuu
Check the load chain lubrication and lubricate if necessary. uuu
Check the load chain setting and tension if necessary. uuu
Visually inspect the mast rollers. uuu
Note: uuu
The hydraulic oil filter and vent/breather must be changed after 2000 service hours or
every two years.
Test the hydraulic system. uuu
Check that hydraulic ports, hose and pipe lines are secure, check for leaks and damage. uuu
Check the hydraulic oil level and top up if necessary. uuu
Replace the hydraulic oil after 2000 service hours or every two years. uuu
Check forks, load handler (e.g. mandrel) for wear and damage. uuu
1ÿ ÿÿ
Agreed performance
Demonstration after servicing. uuu
Lubricate the truck according to the lubrication schedule. uuu
1 ÿ nn
Steering
Check the steering head bearings, steering play and steering toothing or steering chain. uuu
Option(s)
Access module
Electrics
Aisle recognition
System components
damage.
Aquamatik
Power supply
2.3.674.0 - 25.06.2015 08:19:18

tfUNCHEINRICH
EKS 110 (05.15 - )
Electrics
Power supply
Data radio
System components
Check fuse ratings.
Discharge strap
Electrics
Power supply
System components
Fire extinguisher
Agreed performance
Power supply
2.3.674.0 - 25.06.2015 08:19:18

tfUNCHEINRICH
EKS 110 (05.15 - )
Lift cutout
Hydr. movements
Overhead guard

Rail guidance
Electrics
Driving
the rails.
Electrics

damage
Electrics
Test the lights.
Work lights
Electrics
Test lighting.
2.3.674.0 - 25.06.2015 08:19:18

tfUNCHEINRICH
EKS 110 (05.15 - )
Serial no. Customer
Model Address 1
Date Post Code
Comments
Signed
2.3.674.0 - 25.06.2015 08:19:18

tfUNCHEINRICH
EKS 110 (05.15 - )
Brakes
Test the brakes.
Electrics
Note:
Power supply
necessary.
Driving
Note:

Hydr. movements
secure.
2.3.674.0 - 25.06.2015 08:19:18

tfUNCHEINRICH
EKS 110 (05.15 - )

if necessary.
uuu
Note: uuu
every two years.
1ÿ ÿÿ
Agreed performance
1 ÿ nn
Steering
Option(s)
Access module
Electrics
Aisle recognition
System components
damage.
Aquamatik
Power supply
2.3.674.0 - 25.06.2015 08:19:18

tfUNCHEINRICH
EKS 110 (05.15 - )
Electrics
Power supply
Data radio
System components
Check fuse ratings.
Discharge strap
Electrics
Power supply
System components
Power supply
Lift cutout
Hydr. movements
2.3.674.0 - 25.06.2015 08:19:18

tfUNCHEINRICH
EKS 110 (05.15 - )
Overhead guard

Rail guidance
Electrics
Driving
the rails.
Electrics

damage
Electrics
Test the lights.
Work lights
Electrics
Test lighting.
2.3.674.0 - 25.06.2015 08:19:18

tfUNCHEINRICH
EKS 110 (05.15 - )
Serial no. Customer
Model Address 1
Date Post Code
Comments
Signed
2.3.674.0 - 25.06.2015 08:19:18

tfUNCHEINRICH
EKS 110 (05.15 - )
Brakes
Test the brakes.
Electrics
Note:
Power supply
necessary.
Driving
Note:

Hydr. movements
secure.
2.3.674.0 - 25.06.2015 08:19:18

tfUNCHEINRICH
EKS 110 (05.15 - )

if necessary.
uuu
Note: uuu
every two years.
1ÿ ÿÿ
Agreed performance
1 ÿ nn
Steering
Option(s)
Access module
Electrics
Aisle recognition
System components
damage.
Aquamatik
Power supply
2.3.674.0 - 25.06.2015 08:19:18

tfUNCHEINRICH
EKS 110 (05.15 - )
Electrics
Power supply
Data radio
System components
Check fuse ratings.
Discharge strap
Electrics
Power supply
System components
Fire extinguisher
Agreed performance
Power supply
2.3.674.0 - 25.06.2015 08:19:18

tfUNCHEINRICH
EKS 110 (05.15 - )
Lift cutout
Hydr. movements
Overhead guard

Rail guidance
Electrics
Driving
the rails.
Electrics

damage
Electrics
Test the lights.
Work lights
Electrics
Test lighting.
2.3.674.0 - 25.06.2015 08:19:18

tUNGHEINRICH 004 013 114 00020 04.12 1 (GB)
AS2412iS Combination Controller
Notes on how to avoid accidents and material damage
Q For notes on how to avoid accidents and material damage in

industrial trucks with electronic components see J 6900.09.
/j\ Measures taken to conduct heat (shiny contact surfaces) must
remain intact during repair work.
Any disassembly or assembly of components not listed in the
spare parts catalogue is not permitted. This could affect heat
conductivity and insulation.
<ÿtop> Used before safety instructions which must be observed to avoid

danger to personnel.
Used before notices which must be observed to avoid material
damage.
Q Used before explanations.

tUNGHEINRICH 004 013 114 00020 04.12 2 (GB)
Controller
The AS2412iS combination controller contains power electronics
to control the AC threephase drive motor, the DC lift motor and a
permanently energised DC steer motor.
Interface functions in the form of analog inputs and outputs can be
used.
The CAN-Bus interface is used to communicate with other
components.
A radio module interface can be added by the manufacturer as an
option.
Non-volatile memories in the form of EEPROMs are used to set
and store event messages.
Operating software adapted to a range of trucks can be stored via
the CAN-Bus interface.
Settings Idiagnostics
Program download and setting via CAN-Bus.
Use of Jungheinrich JUDIT service tool through CANOpen
Can protocol.
Diagnostics via external LED on service SAAB adaptor in the
event of CAN-Bus malfunction.
tUNGHEINRICH 004 013 114 00020 04.12 3 (GB)
Performance data Control part data
Operating mode Traction controller Main contactor driver (X6.23): Max. control current 1 A (short
circuit proof)
Operating voltage 24 V, +30%/ -30%
Speed transmitter connection: 2 signals, 90° right angle
Temporarily permissible low 15- 16.8 Vfor 100 ms electrically displaced, "open collector" transmitter output,
voltage impulse no./track = 64
Minimum switch-on voltage 19 V Signal connections: 42 pin SAAB connector
Switch-on current (X6.21) 13 A for 10 ms All sensor wires must be routed separately from the motor and
power supply cables. The CAN-Bus cables must be twisted.
Current consumption (X6.21) 1 A at 24 V
Drive motor (AC power part)
Phase current S2 60min 90 Aeff
Phase current S3 5min 230 Aÿ
Travel phase current restriction max. 250 Aeff
Lift motor (DC power part)
Max. current lift limit 300 A
Steer motor (DC power part)
Current applied for 1 min 30 A
tUNGHEINRICH 004 013 114 00020 04.12 4 (GB)
Ports
Item Description / Function

1 B+ battery positive
2 B- battery negative / power earth
3 Pump motor positive terminal
4 Drive motor phase W
5 Drive motor phase V
6 Drive motor phase U
7 Connector 16 pin
8 SAAB connector 42 pin
tUNGHEINRICH 004 013 114 00020 04.12 5 (GB)
SAAB connector X6
m i—i
s\
01
p a
02 03 04 05 06 07
1ÿ1 fol
08 09 10 11 12 13 14
1ÿ1 fgl FqI 1ÿ1 ÿÿ1 1ÿÿ 1ÿÿ 1ÿ71 1ÿ71
p
15 16 17 18 19 20 21 22 23 24 25 26 27
a fÿl 1ÿÿ f«1 rÿl 1ÿÿ ÿÿ1 1ÿ71 ÿ51
28
29 30 31 32 33 34 35 36 37 38 39 40 41 42
in LJ I_ I
a
Connector layout
For the SAAB connector layout see "Connector Layout".
Connector X7
ft rs— r°i m
SJ,
09
- 10 11 12 13 -
- 14 15 16
1 1 1-1 i-1 i-1 i 1 i 1 i-1 i-1
01 02
- 03 04 - 05 - 06 - 07 - 08
1-1 i 1 i- 1 i- 1 i 1 i 1 i 1 i 1
L— L
I LJ u J
Connector layout
Q For the SAAB connector layout see "Connector Layout".

Иктон
Lift
Connection diagram
motor
tUNGHEINRICH
Иктоп
Иктнл Иктоо
плйр
Сёі Иктнм
Иктнп
плйр
Сёі
Икто
Иктн
Drive
motor
CM
ЩТЬ Иктм
Иктор Иктпи
хЛЮї¬¬ Иктл
Иктпк по К Иктпз
Иктмп Иктпп
Иктнз Иктпо
Иктни
5 1 Yl
Иктпй
Иктк
Иктп
Иктй
Иктпр
Иктпн Иктпл
г Иктп
Иктпм
Иктом
Иктол Иктоз
Иктно
Иктнй
Иктмр Иктнр
г Иктоз
Иктмо
H V. 57 57 57 57 Yl Yl Yl Yl Yl YL
004 013 114 00020
Иктнк г Иктоз Икти

х
Ийтпк по К г Иктоз Икток
Кх
·І Ийтпл
у г Иктоз Иктой
Ѕ± Ийтпм
рК Ийтпн г Иктоз Иктз

Ийти по К
Кх
·І Ийтй Иктои
г Иктоз
Ѕ± Ийтк
рК Ийтл Иктнн
Ийтпо
Ийтпп Ийтп
V. Yl
Ийтпр
Ийтм
У
Б
Steer
Ийтз
motor
Ийтн
04.12
Ийто
ЩТЬ
6
(GB)
tUNGHEINRICH 008 013 166 00004 06.06 1 (GB)
RSC28 MH Angle Sensor
For use as: Specifications:
• Steering actual value transmitter (3U9)
Angle measuring range: 360°, mechanical 360° continuous
• Pivot/rotate actual value transmitter (8U28)
Resolution Analog signal allows sufficient
• Traverse Actual Value Transmitter (8U29)
measuring resolution of 0.1°.
• Power steering sensor (3B1)
Output signals: Signal 1, of 0.5...4.5V
In an electric steering system the non-contact angle sensor sine curve,
detects the nominal and actual angles over the two-channel/ Signal 2, of 0.5. ..45V
redundant 360° range without a mechanical lock. cosine curve
The sensor has two analog output signals that represent the sine Output driver suitable for 2.5 mA
(signal 1) and the cosine (signal 2) of the angle. currents.
Outputs temperature-compensated
The task of the sensor is to report to the steering controller on the and short-circuit protected against
actual value side the absolute position of the steered drive wheel earth.
and on the nominal value side the absolute position of the tiller or
steering wheel. Operating voltage: 7.5-24 VDC +30%, reverse-polarity
proof.
The voltage levels for the centre position, left turn and right turn for
the rated and actual values are stored in the controller as Operating temperature: 40...+85°C
calibrated values (Judit/Cancode). Safety rating: IP65
EMC test in accordance
with: EN 12895
tUNGHEINRICH 008 013 166 00004 06.06 2 (GB)
Voltage curve from signals 1 and 2 for 360° turn of angle Angle sensor connection
sensor:
5V
4,5 V
I
/G\
4V
3,5 V
/ Z
3V
A-2 3
2,5 V
/ A
4
2V
\ / /
V / /
1,5 V
1V
X/ y \cd/
0,5 V
0V
0° r
9( 180° 27 0° 360 1 White 8 - 30 V (Ub)
2 Brown Out 1 (signal 1)
3 Green Out 2 (signal 2)
4 Yellow 0 V(GND)
VllNGHEINRICH 008 013 299 00003 04.15
Electrical Steering - required value sensor (Group Rotary Angle Sensor)
Replacing the required value sensor on the steering
wheel
Q The drive wheel and the steering wheel must be in the straight-
ahead position (± 5°).
Procedure
• Remove the cap (1).
• Remove the steering wheel (2).
• Remove the control panel (4).
• Replace the setpoint generator (6).
• Install the control panel.
• Install the steering wheel.
• Fit the cap (1).
A. Ensure the cable is connected correctly .

Tungheinrich: Safety

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tUNGHEINRICH EKS 110 04.

Minimum braking and braking distance

•Auxiliary-lift magnetic switch

Used before notices which must be observed to avoid material damage.

Q Used before notices and explanations.

4 Mast retainer blocks

5 AS2412 hydraulic controller

9 Hydraulic tank with level display

AS 2412-iS traction controller

Fuses; see operating instructions

Electrical system Drawing no. Description

XB20 XS20 XB10 XS10 XB64 1 XS64

4F1 0 XB38 XS38

+24V +24V +24V

XP9- XP8- XP7- GND XP5- GND fur ,121 24

tUNEHEINRICH Indexi der Serienfreigabe: Dokument:

AS2412iS AS2421 i 6R2.1

XS77 XB77 XS75 XB75

tUNEHEINRICH Indexi der Serienfreigabe: Dokument:

2 XP24 XB21 XS21

tUNEHEINRICH Indexi der Serienfreigabe: Dokument:

. 444 J)_2-ÿ433 /3.D3

1ÿ- ÿ 431 4 4 ,409 _ 6__p>_5_ 6

2K2 \ 2K2 Z\ <2

a 2Y63 . 451 _ ÿ 13 ,441

tUNGHEINRICH Indexi der Serienfreigabe: Dokument:

13 Lm) I3 ÿ7ÿ 510

tUNEHEINRICH Indexi der Serienfreigabe: Dokument:

7S5 XB71 XB84

tUNEHEINRICH Indexi der Serienfreigabe: Dokument:

Antrieb >_ -7*

,710 XB87 1H3

EKS 110 Optionen -

tUNEHEINRICH Indexi der Serienfreigabe: Dokument:

Pr.Nr.: 300210933 oben v+ v+

-!>ÿ 818 1.ÿ

-7ÿ 819 -V1

tUNEHEINRICH Indexi der Serienfreigabe: Dokument:

tUNEHEINRICH Indexi der Serienfreigabe: Dokument:

2B3 /10.C2 Drehzahlsensor-Pumpenmotor 5E1 /8.C8 Arbeitsleuchte-FSD-links

2Y29 /7.D6 Proportionalventil-Senken

tUNEHEINRICH Indexi der Serienfreigabe: Dokument:

tUNEHEINRICH Indexf der Serienfreigabe: Dokument:

tUNEHEINRICH Indexf der Serienfreigabe: Dokument:

Tastenfeld alternativ Kartenleser

tUNEHEINRICH Indexf der Serienfreigabe: Dokument:

tUNEHEINRICH Indexf der Serienfreigabe: Dokument:

CAN_L , 402 CAN L

CAN_H , 403 5m can_h

tUNEHEINRICH Indexf der Serienfreigabe: Dokument:

CAN_H > 505 3 CAN H

+24V ÿ 506 >510 +24V

GND 10 ,507 >511 10 GND

tUNGHEINRICH Indexf der Serienfreigabe: Dokument:

602 > 630

XS70 XP18 > 649

tUNEHEINRICH Indexf der Serienfreigabe: Dokument:

XS64 XB48 XS48 1S14.2 1S15.2 1S14.3 1S15.3

tUNEHEINRICH Indexf der Serienfreigabe: Dokument:

tUNGHEINRICH Indexf der Serienfreigabe: Dokument:

tUNEHEINRICH Indexf der Serienfreigabe: Dokument:

Antrieb >_ 4ÿ4=

dUNGHEINRICH Indexf der Serienfreigabe: Dokument: