Professional Documents
Culture Documents
Kaizen
Continuosly looking for opportunities for improvement and
ideas of how to do things in a better way
Kaizen
Continuosly looking for opportunities for improvement and
ideas of how to do things in a better way
Genchi Genbutsu
”Go and see” the problem or situation for ourselves
Challenge
The spirit of accepting challange is required a drive for
progress
Kaizen
Continuosly looking for opportunities for improvement and
ideas of how to do things in a better way
Genchi Genbutsu
”Go and see” the problem or situation for ourselves
Respect
Trust, respect and willingness to listen to others
Kaizen
Continuosly looking for opportunities for improvement and
ideas of how to do things in a better way
Genchi Genbutsu
”Go and see” the problem or situation for ourselves
Respect
Trust, respect and willingness to listen to others
Teamwork
Recognizing that the contribution of the team is greater that the
sum of its members
• Objectives
•Steering system
•Drive system
•Hydraulic systems
Travel speed AC 11 11 11 11 11
Lift speed without load (m/s) 0,7 0,7 0,7 0,7 0,7
Component Recognition
MCU:
Main Control Unit
• The trucks main computer, which communicates with the Traction, (ACT) Hydraulic (ACH)
and Steer controllers (EPS) via CAN Bus 2, The MCU also communicates with the Upper
Load Information display within the cab roof (LID) and a connection point for a CAN Bus key
or the PDA truckcom lead. CAN Bus1. The main program for the truck is held within the
MCU, it also handles Error codes.
CID:
Central Information Display
• This unit displays to the operator conditions on the truck, it is also used for displaying error
codes that have been sent from the MCU. Service functions can also be carried out
through this display, altering parameters, checking switches and calibration functions for
hydraulic valves and potentiometers. Contains the same parameter setting as the MCU.
ACT:
AC Traction Controller
ACH:
AC Hydraulic Controller
• The two AC units have the same inputs and outputs, the difference between the two units
is the program selection with an external link. Each unit has outputs that are configured to
operate hydraulic valves. All communication to these units is through CAN Bus. On Startup
they will flash a green LED twice and then the LED will remain on. If an error occurs the
LED will flash once for a warning, (over temp) or twice for an actual error.
EPS:
Electronic Power Steering
• The Steering unit is self contained with its own on board controller. All steering
communication is via the CAN Bus system.
GFU:
General Function Unit
• The GFU is an expansion unit to control extra valves extra inputs and outputs.
The unit is controlled via the CAN Bus system.
FCM:
Fuse Central Module
• The fuse central module houses all the control fuses for the truck. There is a relay
internally used as a key switch, and an emergency switch for parking brake release.
ID Key Log In
and swipe card
LID:
Load Information Display
Lift height
Load weight
Hight preselection
Tilt levelling
Sideshift centring
• This display showes information related to the lift system. Such as Fork Heights, Weight
on the forks, Height preselection, tilt position etc. The truck will work without this being
fitted as it is only connected into the CAN Bus system.
E Bars
Terminal mounts
Optional hand
Controls (multi)
3 DC DC converters
P6 LID
B13 Steering
B35 Horn
To scroll up and
down menus
X3 Battery plug
B11 (M1)
G3 Cooling fan ACH ACT Speed sensor
A5 MCU
B58 Forks
B19 Height height ref
counter
X3 Battery plug
Reach carriage
Section
• Where is S133?
• Where is S133?
• What is the FCM?
• Where is S133?
• Where is S133?
Horn request
Capacitors
The truck can be started in an emergency mode to enable fault find or movement of the truck
IN ALL CASES safety must be adhered to. The emergency mode will override all errors,
therefore it should be used with caution.
Steering
Drive
Hydraulics
System Checks
3. Select the screen number required, using the +/- or enter the
number from the number pad. Press the green button.
Parameters
1 Requested Position B13 Count degrees Customer/ Driver
2 Actual Position EPS encoder count degrees Parameter 1,11,21 - 91 steer progression
3 Steer speed required MCU parameters Factory
4 Actual Steer speed Rpm 1004 Steer servo refer to Repair manual
Oeration Drive
1. Seat switch active B49
2. Left foot pedal active B31
3. Direction selected B36
4. Communication to MCU CAN 1
5. Foot pedal accelerator signal B32
6. Communication MCU to ACT CAN 2
7. Parking brake release Q1
8. Drive motor active M1
9. Drive speed and direction B11
10.Drive speed chek to foot pedal postion
and parameters
3. Select the screen number required, using the +/- or enter the
number from the number pad. Press the green button.
Parameters
1 Requested drive speed B32 Customer/ Driver
2 Actual drive speed B11 Parameter
3. Select the screen number required, using the +/- or enter the
number from the number pad. Press the green button.
MCU signal
1 PWM1 X131:26 Main lift pwn
2 PWM2 X131:40 Main lower pwn
3 PWM3 X131:13 Reach in pwm
4 PWM4 X131:41 Reach out pwn
5 DO17 X131:39 Support arm brake left pwn
6 DO18 X131:12 Support arm brake right pwn
ACH signal
7 PWM1 K1:10 Free lift pwm
8 PWM2 K1:2 Free lower pwm
ACT signal
9 PWM1 K1:10 Cabin tilt up vlv pwn
10 PWM2 K1:2 Cabin tilt down vlv pwn
Valve lis:
Q2 Main mast lift
Q3 Initial free lift, lift
Q4 Main mast loer
Q5 Initial free lift lower
Q6 Reach in
Q7 Reach out
Q8 Sideshift
Q9 Sideshift
Q18 Tilt/sideshift
Q21 Cab tilt down
Q11 Cab tilt up
M3 Start up
Q3 opens 0% to 100% PWM
Fork raise
(Height Ref. B58 passes end
of reference strip B18 starts
counting free lift height)
M3 start up
Q3 closes 100% to 0% PWM
Q2 opens 0% to 100%
Fork raise through free lift to main lift
No decrease in speed
Operation notes:
Height Ref. B58 passes end of reference
strip B18 starts counting free lift height.
Approx. 100mm from top Q3 starts to
close, second lift valve Q2 starts to open
and main mast starts to lift. B19 continues
the height count after B57 mast channel
sensor goes low.
Calibration:
Please refer to the Repair Manual for
details of calibration.
Q4 opens 0% to 100%
Forks lower main lift. Valve (1) moves to
the fow position under spring pressure.
Valve (2) moves into the blocking position
to trap oil.
Operation notes:
B19 counts down the height.
Operation notes:
B19 counts down the height within the main
lift area. Approx 100mm from the top of the free
Operation notes:
B19 counts down the height within the main
lift area. Approx 100mm from the top of the free
1273 Valve MM
** Max free lift height
** Value comes when calibrating
1271 Valve MM
** Height reference
Calibration:
Please refer to the Repair Manual
** Measure from floor
for details of Calibration.
to fork face
Operation notes:
Manual Valve on Valve bank.
Maximum torque 2.5 Nm.
Operation notes:
The reach valves Q6 Q7 require calibrating.
The reach carriage position needs calibrating
Operation notes:
The reach valves Q6 Q7 require calibrating.
The reach carriage position needs calibrating
Parameters:
Calibration Parameter
1265 Reach Distance (mm)
Calibration:
Please refer to the Repair Manual
for details of Calibration.
Operation notes:
The hydraulic pump starts and the valve Q9 for
tilt up operation opens. Hydraulic oil flows over
the mast hydraulic hoses to the valve Q18 (1)
this valve is in its neutral position. The pressure
increases and the tilt cylinder moves out and the
return oil passes back to the hydraulic tank via
valve Q8.
Operation notes:
The hydraulic pump starts and the valve Q8 for
tilt down operation opens. Hydraulic oil flows
over the mast hydraulic hoses to the valve Q18
(1) this valve is in its neutral position. The
pressure increases and the tilt cylinder moves in
and increases pressure on the opisite sid of the
cylinder. The pressure increase opens the load
holding valve (2) and the return oil passes back
to the hydraulic tank via valve Q8.
Operation notes:
The hydraulic pump starts and the valve Q9 for
sideshift operation opens. Hydraulic oil flows
over the mast hydraulic hoses to the valve Q18
(1) this valve is in its sideshift position. The
pressure increases and the sideshift cylinder
moves out and the return oil passes back to the
hydraulic tank via valve Q8.
Operation notes:
The hydraulic pump starts and the valve Q8 for
sideshift operation opens. Hydraulic oil flows
over the mast hydraulic hoses to the valve Q18
(1) this valve is in its sideshift position. The
pressure increases and the sideshift cylinder
moves in and the return oil passes back to the
hydraulic tank via valve Q8.
M3 start up
Q2 opens 0% to 100%
Forks raise on the main lift
Sensor B19 counts height
The set value for cab tilt is reached,
cab starts to tilt.
Operation notes:
Second lift valve Q2 starts to open and main
mast starts to lift. B19 continues the height count
after B57 mast channel sensor goes low. The
cab will start to tilt once the parameter, cab tilt
start, is reached. Q11 activates (3) and the cab
starts to tilt over until the lifting is stoped or the
cab upper position sensor B29is reached. Flow
valve (1) regulates the oil flow from main lift to
cab tilt. and the speed of the cab tilt is regulated
by restrictor (4).
Calibration:
Please refer to the Repair Manual for details of
Calibration.
Factory
1104 Ergo Enable
Profile 0 Profile 1 Profile 2 Profile 3 Profile 4 Profile 5 Profile 6 Profile 7 Profile 8 Profile 9
Block 0 0000 0001 0002 0003 0000 0000 0000 0000 0000 0000
Block 1 5421 7901 1437 3731 1049 9439 7265 1322 2869 1574
Block 2 1787 4854 2907 9175 5799 1490 3031 7392 5622 5023
Block 3 4659 3174 1026 3815 6703 1179 5152 7514 5668 3215
Block 4 9197 7110 5477 3846 9491 5918 8222 6923 8139 7025
Block 5 2549 6276 9879 9658 1690 4042 5201 9807 4332 9715
Block 6 7474 4142 8620 3754 8432 8788 7430 1948 2595 8527
Block 7 1930 1482 7135 2395 7365 7092 4611 2831 4185 6067
Block 8 2876 4731 1022 5377 3257 7334 9009 7881 8843 7436
Block 9 3242 3162 5878 2828 1910 6907 2136 5730 2957 7691
Operator parameters
1-6
Service parameters
General 101-116
Driving 201-212
Hydraulic 301-397
CID1 501-513
Factory parameters
Calibration parameters
General 1001-1016
1. Connect the CAN Bus key, press the green button and then the
Information button.
2. Select the configuration icon using the arrow keys, and the
press the green button.
3. Select the PAR icon using the arrow keys and the press the green
button.
2:nnn MCU
7:nnn GFU
n:1nn Warning Some functions deactivated or reduced n:n10 - n:n19 Can related error codes
n:2nn Error:- All or sections of the hydraulic system deactivated n:n20 - n:n39 Related to Specific Units
n:3nn Truck Brakes Drive disabled. Steering disabled if steer fault n:n40 - n:n59 Related to Specific Units
n:4nn Truck Brakes Key relay disengaged after 5 seconds n:n60 - n:n79 Interrupted outputs
n:5nn Critical Error Main contactor and Key relay disengaged n:n80 - n:n99 Defective signals Sensors
Question paper