Linde V12 - 04 - v062005 - EN

Service Training
Order picker
Series V(V1 1/04, V12/04)
img61200440514m1
Edition 06/2005
This service document is provided for use only and remains the exclusive property of Linde AG,
Linde Material Handling Division.
Service Training - W8 054 356 EN - 06/2005

o¿##£cíe~
History of changes
• 01/2005 First edition.

• 06/2005 Chapter Vehicle data, Brake installa¬
tion, Distance sensor for main lift new.
Service T raining - W8 054 356 EN - 06/2005 I

Table of contents
00 Product information
Product information General 00-1
Vehicle data 00-1
Travel speed 00-2
02 Diagnostics
Diagnostics 02-1
Onboard Diagnostics 02-1
Description 02-2
Software 02-8
ParaDig 02-8
General 02-8
Winflash V1.1x- General 02-14
Description 02-14
Preparation for downloading to CAN control system 02-16
Winflash V1.1x- Operating with Winflash-Software 02-17
General 02-17
Selecting a file 02-18
Selecting a truck 02-19
Selecting a control system 02-20
Checking the connection to the CAN control system 02-21
Start programming to CAN control systems 02-22
Close the program 02-23
WinMega for FPS 02-24
General 02-24
Changing the parameters 02-33
Parameter list 02-34
Set configuration 02-38
WinMega configuration list 02-39
WinMega Adjustment 02-42
Tester 02-45
WinMega tester 02-46
Reading out the alarm logbook 02-48
VACC program 02-49
Set hour counter 02-50
Clear EEPROM 02-51
Error lists 02-53

Error list for travel and pump controller (FPS) 02-53
Error list for electrical steering (ELK) 02-67
Error list inductive wire guidance (IZF) 02-7 5
Service T raining - W8 054 356 EN - 06/2005 III

Table of contents
Teach-in 02-112
Setpoint potentiometer traction/hydraulic 02-112
Position sensor main lift 02-113
11 Electric motor
Drive motor 11-1
General 11-1
Test 11-3
Repairs 11-4
Maintenance 11-6
Speed sensor 11-7

General 11-7
Test 11-7
Repairs 11-9
Temperature sensor 11-10

General 11-10
Test 11-10
Repairs 11-11
Carbon brush 11-12

General 11-12
Test 11-13
Repairs 11-14
Maintenance 11-14
Forced ventilation 11-15

General 11-15
22 Mechanical drive axles

Spur-bevel gear 22-1
General 22-1
Test 22-3
Repairs 22-4
Maintenance 22-9
42 Steering system
Electrical steering 42-1
General 42-1
Steering unit 42-3
IV Service Training- W8 054 356 EN -06/2005

Table of contents
General 42-3
Test 42-5
Repairs 42-5
Maintenance 42-8
Setpoint potentiometer 42-9
General 42-9
Test 42-10
Repairs 42-11
Actual value potentiometer 42-11
General 42-11
Test 42-12
Repairs 42-13
Reference switch 42-14
General 42-14
Test 42-14
Repairs 42-14
43 Mechanical guidance
Guiding elements 43-1
General 43-1
Test 43-1
Repairs 43-1
Aisle recognition 43-2

General 43-2
Test 43-2
44 Inductive guidance
Inductive guidance 44-1
General 44-1
Test 44-7
Repairs 44-7
Central unit 44-1 1

General 44-1 1
Test 44-12
Repairs 44-12
Periphery 44-14
Antenna 44-14
Test 44-14
Repairs 44-14
Service T raining - W8 054 356 EN - 06/2005 V

Table of contents
Guide wire 44-15
General 44-15
Guide frequency generator 44-17
General 44-17
Aisle recognition 44-18

General 44-18
Steer angle reduction (LWB) 44-20

General 44-20
Test 44-20
Repairs 44-21
Maintenance 44-23
46 Wheels and tyres

Wheels 46-1
Drive wheel 46-1
General 46-1
Repairs 46-1
Load wheels 46-3
General 46-3
Repairs 46-3
49 Brake installation
Electrical operating brake 49-1
General 49-1
Parking brake 49-3

General 49-3
Test 49-4
Repairs 49-6
Maintenance 49-11
50 Controls
Control panel 50-1
General 50-1
Repairs 50-4
Setpoint potentiometer travel 50-4
Test 50-5
Repairs 50-5
VI Service Training- W8 054 356 EN -06/2005

Table of contents
Setpoint potentiometer hydraulics 50-5
Test 50-5
Repairs 50-6
60 Electric / Electronic
Sensors 60-1
Distance sensor for main lift 60-1
General 60-2
Repairs 60-4
Maintenance 60-15
64 Electronic controls
Drive - and operating hydraulics controller (FPS) 64-1
General 64-1
Test 64-6
Repairs 64-8
Other electrical components 64-9

CAN-Bus 64-9
General 64-9
Test 64-10
90 Special equipments, accessories

End-of-aisle braking (EASS) 90-1
General 90-1
ZAG Universal 90-3
Support material 90-6

Dynometer 90-6
Service T raining - W8 054 356 EN - 06/2005 VII

_ Product information _00
Product information General
Vehicle data
Service T raining - W8 054 356 EN - 06/2005 00-1

Travel speed
/\ WARNING
ItIsprohibitedto raise the speedabo ve the spe¬
cifiedmaximum.
The maximum admissible speeds are definedas
default values in the travelandpump controller.
They can be adjustedor reducedbyalteringpara¬
meters with the diagnosis software (cf. Diagnosis
/ Software / WinMega Parameters).
No inductive guidance
Condition vmax in km/h
Lift height <Parameter P32 (SPEED2 TOP POS, =Fork height <1.2m
9
with auxiliary lift at maximum height)
Inductively guided, lift height <P32 (SPEED2 TOP POS) 4
Lift height >P32 + 1800mm general 2,5
Platform height >P32 and <3m and steering angle <10° (only with active
4
4km/h option)
Platform height >P32 and <3m and steering angle>1 0° 2,5
Positive mechanical or inductive guidance
v (km/h)
SPEED 1 FWD / BWD
OS1
pen / P02
10-
9_ _ RampShift FWD / BWD
P52 / P53
8--
1-
7km/h SPEED3 FWD/BWD ,
6- \ P05/P06
4"
OS2
3- 2,5km/h XÿSPEED4 \
2 - P07
5,2m
h (m)
img61200440613m1
With aisle recognition (steering locked, 2-hand

operation) from height OS1 (adjustable using
00-2 Service Training - W8 054 356 EN - 06/2005

Product information oo
parameters P52 / P53) the maximum speed is

steplessly reduced by the height measurement
system until speed P07 is reached.
Vertexes OS1 , OS2 can be read off in the diagno¬
sis software (cf. Diagnosis / Software / WinMega
Tester).
1 NOTE
The start ofspeed reduction at cornerpoint OS 1
always refers to 11km/h maximum speed. In
trucks with tower maximum speed the speed
reduction does not begin untila corresponding lift
height isreached(cf. diagram), also when vertex
OS 1has reduced to lift height-0.


Diagnostics 02
Diagnostics
Onboard Diagnostics

02 Diagnostics
Diagnostics
Description
Function
f®
©
©
img61200440511m5
1 2 3 4
ffi NOTE
Duringdiagnosis, allthe dispiayand vehicle func¬
tions are inactive. The steering, the manual/au¬
tomatic steering display (1) andthe display field
(2) remainactive.
The onboard diagnosis can be used to check

various switching signals and setpoints from the
operating console without having to connect a
service notebook.
The onboard diagnosis is operated with the Q +
0 keys (3, 4).
The following menus are available:
• 0_ EPROM versions.
• 1_ Battery type.
• 2_ Digital inputs group 20. .27.
• 3_ Analogue inputs 30..34.

o¿##£cíe~ Diagnostics 02
Diagnostics
Starting onboard diagnosis
n
f
> Press the Q + 0 keys simultaneously for >2

seconds. The display shows: Menu0_(5).
> To select the next menu in diagnosis mode,
u
press 0 for <1 second. To return to the previ¬ /
ous menu, press 0 for <1 second. 5
Menu 0_: EPROM versions
np n~i
LU
Under menu points OP, 0C, and OS, various dif¬
ferent software versions are displayed.
> To display Menu 0_: press 0 for >2 seconds.
u U I
The display shows: Menu point OP xxx (6).
> To switch between menu points: press 0 for
1 img6 1200440553ml
<1 second.
> To quit menu point 0: press 0 for >2 seconds.
> To quit diagnosis mode, press 0 for >2 sec¬
onds.
Menu point Version

OP EPROM version of the operating console.
EEPROM version of the master processor (master IC) in the travel and
OC
pump controller.
EPROM version of the monitoring processor (supervisor IC) in the travel
OS
and pump controller.
Menu 1_: Battery type
NOTE
The battery type can also be set using the diag¬
nosis software.
In Menu 10, the battery type is displayed and can

be set here.
> To display Menu 10 (1): press 0 for >2 sec¬
onds. in ÿ
> To activate change mode: press 0+ 0+ 0] iu j
for >2 seconds. The service symbol (2) should
light up. / ~r ¡mgS1200yÍ0553m2
> To change the value (3): press 0 or 0 for <1
second.
> Change mode, storing value and exiting: press
0+0+ 0] for >2 seconds. The service symbol
goes out and an acknowledgement tone is
emitted.
> To quit change mode without saving: press
0+ 0 for >2 seconds.
> To quit Menu 10: press 0 for >2 seconds.

02 Diagnostics
Diagnostics

onds.
Battery Capacity Type
360 Ah/420 L Ah 0
480 Ah 1
Wet battery and & increased performance
600 Ah/560 L Ah 2
700 Ah/720 Ah 3
360 Ah 4
Dry battery 480 Ah 5
600 Ah 6
Menu 2 Digital inputs

In each of menu points 20. .27, 8 digital inputs are
displayed as symbols in the form of a bar code. d_
• Short vertical line (1): LOWIevel=OV.
• Long vertical line (2): HIGH level > 0V (24V or
48V signal).
> To display Menu 20 (3): press 0 for >2 sec¬ Bit 7 6 5 4 3 2 1 0
ettt
onds.
> To switch between menu points: Press the 0 n i i ii i
and Q keys for <1 second.
ui II n ii i
> To quit Menu 20..27: press 0 for >2 seconds. img61200440553m3

onds. 3 1 2
The signals are read into the different CAN con¬
trol systems:
• (1) Travel and pump controller (FPS).
• (2) Operating console control (BPS).
• (3) Electrical steering (ELK).
• (4) Inductive wire guidance (IZF).
Menu 20: Basic signals

Bit Signal Terminal Control
0 EMERGENCY-STOP X2:4 1
1 EMERGENCY-STOP X9:2/4 2
2 Chain switch, right. X3:6 1
3 Chain switch, left X3:5 1
4 External traction cutoff X3:14 1
5 Steering error (ELK), 0V=OK X7:7 1
6 Reference switch, height measuring system X7:10 1
7 Free input X4:6 1

Diagnostics 02
Diagnostics
Menu 21: Operating console buttons

0 |2-handed| button Internal 2
1 2-handed button, additional lift Internal 2
2 [o] button Internal 2
3 0 button Internal 2
4 E button Internal /X2:12 2
5 Manual/automatic steering| button Internal 2
6 |Horn button Internal 2
7 n.c. X2:11 2
Menu 22: Travel

0 Deadman switch, normal open contact X4:4 1
1 Deadman switch, normally closed contact X1:11 2
2 Steering enable CAN 3
3 Steering active CAN 3
4 DS direction signal (drive side) Internal 2
5 LS direction signal (load side) Internal 2
6 Active operating console (0=LS, 1=DS) X2:1 2
Active setpoint potentiometer, steering (0=DS,
7 CAN 3
1=LS)
Menu 23: Lifting, lowering

0 2-handed button Internal 2
1 2-handed button, additional lift Internal 2
Direction signal, LIFTING (setpoint potentiome¬
2 Internal /X1:1 3 2
ter/additional lift)
Direction signal, LOWERING (setpoint poten¬
3 Internal /X1:14 2
tiometer/additional lift)
4
5
Hydraulics enable
2-handed button, additional lift _
load side
X4:5
X2:2
1
2
6 Limit switch, additional lift, BOTTOM X2:4 2
7 Limit switch, additional lift, TOP X2:4 2
Menu 24: Cab, sensors

0 Gate normally open contact X1:9 2
1 Gate, normally closed contact X1:10 2
2 Gate (load side), normally open contact X2:6 2
3 Gate (load side), normally closed contact X2:5 2
4 Pallet switch, normally closed contact X2:8 2
5 Pallet switch, normally open contact X2:7 2

02 Diagnostics
Diagnostics

6 Roof switch, normally open contact X2:9 2
7 Roof switch, normally closed contact X2:10 2
Menu 25: Rail guidance, steering

0 Rail switch, LEFT, normally open contact X8:9 1
1 Rail switch, LEFT, normally closed contact X8:5 1
2 Rail switch, RIGHT, normally open contact X8:10 1
3 Rail switch, RIGHT, normally closed contact X8:6 1
STRAIGHT-ON command from FPS to ELK with
4 CAN 3
aisle recognition and actual value <±5°
Acknowledgement of STRAIGHT-ON actual value
5 CAN 1
from ELK to FPS with aisle recognition
6 Steering setpoint >±5° CAN 3
7 No function
Menu 26: Free inputs chassis, ZAG, PSA, IZF

0 Free input 1, chassis X1:3 1
1 Free input 2, chassis X1:4 1
2 ZAG STOP X9:5 1
3 ZAG REDUCTION X9:6 1
4 Manual/automatic steering| button Internal 2
5 No function
6 Setpoint to steering (potentiometer=0 / IZF=1) CAN 3
7 No function
Menu 27: Free inputs, cab

0 Free input 1 X3:2 2
6 @ button Internal 2
7 [s] button Internal /X2:1 2 2

Diagnostics
Menu 3_: Analogue inputs f >
In menu points 30..34, analogue inputs are dis¬

played.
• When the setpoint potentiometer for travel/hy¬
3
draulics is actuated, the corresponding direc¬
tion signal (1) is also displayed. The displayed
value (2) multiplied by 0.01 gives the setpoint
in volts.
• The value shown in Menu 32 (height mea¬
n nnn
suring system) multiplied by 0.005 gives the
actual value in volts.
> To display Menu 30 (3): press Q for >2 sec¬
3u uuu
onds.
> To switch between menu points: press the Q
/
3
and 0 keys for <1 second.
> To quit Menu 30..34: press Q for >2 seconds. r
uU I 3H]
3n
> To quit diagnosis mode, press Q for >2 sec¬ i
onds.
>
r7 img61200440553m4
Menu Signal Terminal Control

30 Setpoint potentiometer, travel Internal 2
31 Setpoint potentiometer, hydraulics Internal 2
32 Height measuring system X1:9 1
33 Load measurement X1:10 1
34 Free analogue input X8:8 1

02 Diagnostics
Software
ParaDig
General
_
urOotw4uit33
'
E
> A4*. »
ÿSj to »
The service software "ParaDig" (3) is used for 0 tool* Reads 5 0
parameterising and diagnosing different truck 1 . Cavcnlen * .rj lomeflrfVs» »
and control system types. 1 .n) WnM«gi
L*Cnl Qc*d
*
»
The "ParaDig" software is started in the "elec¬ I'f- Erutehingen
JWw
» ,-J
».
.r)
_tt)
FI«hP4lh
FM-t SemctoMM
RasTne 5
»
»
»
tronic documentation system" with "Diagno- ÿ<$ .rj HP Cskt LmwM 4550
-rj HPLateUf
*
»
sis/Parameterising or "Start /Programs/Dia- ¿ifiktrm
* \
.r) ZpWrCoraole 1 00 » .Tj RedMoneqtoai » 3 Dcvre-Cngrw
Mon.. /Client" (1). H<£ ÿ3 ZpWnCorBole 105 ÿ SCTvuefiaaeEnga
Qiy
.=) ZtWVCentto 1 06
GnA«
»
i
f
The matching database (2) ("ServiceBase") for I«íi-i ¿33 7
the truck or control system type must be installed imo61200440557ml
in the notebook. 1
NOTE
CS20(1 OS.STILLI
{hwkkí RK5051 55(3 00. SULL GweMI
'ÿ : VtH '
The databases are updatedin the "Electronic I
PaaOgKiarOrtl 00 GmbH 4€0 1:G|

Documentation System "iftechnically necessary. Pf sDigLReon 00 si* W»>>fi GrrfcH ICo KG]
They usually replace the previous versions. Ifthe

database version does not match the version of
img61200440558ml
the truck or controlsystem type, a warning mes¬
sage is displayed when the connection is set up.
tfan outdated version of the "ParaDig" ora con¬
trol system is stilluseddespite the message, it
may not be possible to display some parameters
or overwrite them. n Servicing Sjltw» 3.1 - P«dDiglZF|1 00)
Ü Antatung |Q Pro«*ol |
Bitte folgen Sie den Anweisungen in der

Kurzanleitung
oder starten Sle elne Aktion aus der Liste.
LECTRONIC
OCUMENTATION
SYSTEM
Ohbgrwiemsueg |ÿ Wtonwi |
lyp I 9ex»chr«jno _ | Status M
33 FrMuí-nrnvsr.u™
'4 1 Anatogvieit Arten W
.51 T rAchln L«*o(f:e* ÿ
i. I' - :
'
ÿ F?0iagnoie ÿ F3:S<hjp»Morttonng |
img6 1200440555m3

Software
Operation DiaMon Servicing Syiten 3.1 PwoDiglZHI-OO)

ÿ
The service software is divided into 2 functional ÿ AnleAng |Q Protafcol |

groups:
Diagnosis (1): Guided adjusting and commis¬
sioning instructions, e.g. measurement of current Bitte folgen sie den Anweisungen in der
Kurzanleltung
or frequency, teaching-in of potentiometers, etc. Oder starten sie eine Aktion aus der Liste.
lectronic
Setup+Monitoring (2): Adjusting and display OCUMENTATION
SYSTEM
pages, e.g. software versions, actual cur¬

rent/voltage values, speeds, configuration, etc.
ÿ2 Didgrnseervtteeg |ÿ At ienen |
Typ I Bejftchfeng _ | Stalus *|
|4| ArwtogwertAritf-n
J
ÿ t ''-fAt-H ;...j I
_ij
¡mg6i200440555m1

02 Diagnostics
Software
"Diagnosis" menu
Data ?
The guided diagnosis operations are organ¬

ised according to function and should be worked
through in sequence. Each point can also be car¬
ried out separately and repeated. Bitte folgen sie den Anweisungen in der
Kurzanleltung
Oder starten sie eine Aktion aus der Liste.
A WARNING
In diagnosis mode, various monitoring functions
are switched off.
Please note the remarks in the diagnosis menu! If
a diagnosis session isaborted or ended, always ÿ2 D*ir»««rwMg |ÿ2 Akbonen |
reset the truck byswitching the key switch OFF Typ I _
[2| FtcQuengrmtung
andthen ONagain.
1 4 1 Arwtogwert Anten
(5| T eachln t.«kolf:et
> F2:d¡spiay d¡agnos¡s| diagnosis menu (1).

> Select the required diagnosis function (2).
> Confirm with |Execute| (3).
img€ 1200440555m2
• Instructions appear in the window (4) with the
option of making an entry for each diagnosis 1 3 2
function.
• Window (5) shows a detailed set of instructions 7 8
for the selected diagnosis function.
> Carry out the instructions (5) and confirm en¬ 0|O F»«ACIi|
tries with |Done/OK| (6).
> If appropriate, follow further instructions. Wohlen S» mrtdera Zeigegeroi
0estofigen Sie to AvtwoM mi Okay
> Acknowledge safety instructions. B«i «infnAbbruch del T n«l« úoí Fahrteugunbitkngl pyigeichal»gn ÿ
> End order/sitting with [Reset].

> In the event of abort or error in the diagno¬
sis function: End the diagnosis function with

(7).
> Protocol! (8) displays a detailed list of all the
operations that have been carried out.
img6 1200440561m 1
4 5 6

Software
"Setup+Monitoring" menu ÿ Jal»!
J tagroi* EF |FahmugMiMMt |Spiral» P>r«mim| EvuwfcsewiA«wr»| (MgrojaArtmwiJ.

I Setup+Monitoring (1) (setting+display) always AJIgemutne SlBuerungsmlormnlionen
starts the first page with general information, e.g.
control system name, software versions, ID code. ir vgBitondiga. GiumPnniiaaung
When |AF9:Page| (2) is selected, an overview of the

diagnosis pages opens with selection options.
The Setup+Monitoring pages are organised ac¬
cording to functions.
Generally, all the necessary signals for a function
are displayed on a Monitoring page.
I TlUdanj TSSpwchwit TSEm¿«n| |.T9Seig| -n0'.tÿta|
A Setup page then follows, on which the corre¬ Hd
sponding values can be displayed and changed.
t ig61200440554ml
T9:SeiIe Seite wahlen... e|

B Alie
Allgemeine Informationen (-unglillig")
Diagnose IZF ( -ungliltig- )
Fahrzeugparametei (ungiitig*)
S pezielle Pararretei (••ungUltig-)
Einstellungen Anlenne (-ungültig-j
Diagnose Antennen / Lenkwinkel (••ungtiHic
Mittelwerte (-ungultig--)
Feldstárke- / Frequeramessungen (-ungülti.
Einstellung Lenkwinkelbegr. / Gang (- ungli
Diagnose Lenkwinkelbegreraung (-ungiittic
ikwinkeiDegien2ung (-unguRic i
>~r
ÿ
.
í'
OR 1| Abbcechen |
img61200440563ml
Monitoring >
The Monitoring pages (1) are updated cycli¬ Diagnose I2F
cally. Values cannot be entered. Values that nmtZr
are not up to date are marked with a yellow dot

(2). The measurement can be started/stopped
with |"F3:Measure/Stop| (3).
Signals that are absolutely essential for the func¬
tion are marked with the status green = OK, red =
not OK (4).
The signals that influence the functions are
marked with the status white = not active, yellow
= active (5). ÿ ret)pyow||
Y
img612q044Q562m1

02
Software
Setup
Diagnostics
Setup pages (1) are updated once or not until a

setup page is opened, depending on the control
system/database. If unclear, reload the values
from the control system with |AF4:Load| (2) (from
appliance).
Changed values are marked with a yellow dot
(3) and are not effective until conformed with
|AF5:Save| (4) (to the appliance). If you wish the
changed values to remain stored in the control
system after switching off, then acknowledge
Save permanently with [Yes] .
When |"FiO:Default| (5) ¡s selected, a window
opens in which individual values, groups, pages
or everything can be selected. After confirming
with [ok] , these areas are written with default val¬
ues.
02-12
DtopwtMZF [~Fitre«u¡)par«neHH|
MjumbbIc I.ihigotcHvnndtgkoilr
ScNachliMnfkm/hJ
Er«puenn[fc"Vh|
UMfgangnpuiVti)
E rgeipul laitiw n [EnAi]
ErgeiQul Artnebiiole in [knuW
HandahtriEkflVh]
T10:Vorgabe Vorgaben laden

/
p~
|7"
f}~
fjF
[il
.
PawUi I Emirfunj» Mems 0
\
Andeibaru FaJHieugparamaiei
Artww, / Urt«w*<1
D« Fahirtvi 'mÿsi' «/ Arnkiungcnt
É3 |y Fahrzeugparameter
S [>/i Maximale Fahrgeschwindigkeiten
Schleichfahit in [km/h]
Einspuren in [km/h]
llbeigang in [km/h]
Eingespurl Lastseite in |km/h]
Eingespurl Anlriebsseite in |km/l
Handfahrt in [km/h]
Einspuren abgesenkt in [km/h]
B [~]Reglereinstellung
RMaxirnaler
"OK"
Solbvinkel Eingespurl
Service Training - W8 054 356 EN - 06/2005

Spun T |
Abtroctan
]
|*F9S«fa| [TlftVarwbel
img6/200440565m1
img61200440664ml
E
ÿ
Diagnostics 02
Software
Making a connection >

For most trucks and control system types, a
CAN-PC adapter (parallel interface (1) with USB
power supply (2) or a USB adapter (4)) and a
connecting cable (3) are needed. From Ver¬
sion V3.xx onwards, the parameters for the PLC
(Digsy, MUX) and inductive wire guidance (LR80)
can also be set using the interface adapter.
img61200410379m
img61200440612m1
> If no connection is made to the truck, an error >

message appears (3). Acknowledge this error STWS0NT4.
message.
Could not reset CAN card !
mg61200440559ml
> Select |Skip| (4) to continue working "offline" or > Hauptgerát Induktive Zwangsführung auswáhlen
end with [Qüg (5) and check the connection. Das GerS ,ndüktlveZwangs(Uhmng konrlte nicl, gefunden „,erden
Wiederholen iUbetspringem Abbrechen
J imgÿi200440560ml

02 Diagnostics
Software
Winflash V1.1x- General

Description
UÿWinFlash V1.13R1 c<SW> [MX-X. MX-Q] Copyright 2002-2004 STW
"Fahrzeug auswáhlen:
¡MX-X. MX-Q
Steuerung auswahlen:
IFZS Fahrzeugkonfiguration (VNA)

rarnmdatei auswahlen:
0_FILE_F0UND.hen
Hinwei:
Fahralug: MX-X, MX-Q; _
Steuferung: Fahrzeugkonfiguration (VNA) in der
Fdnrzeug-Steuerung (FZS), 8U60
Verbir/urig sum Fahrzeug testen:

Prijfe Verbindung
Stei in StaCerung laden:

ÿ Sail Ptogramrnierung
Pararn/ersat: ¡/Steuerung laden:
Start JfTonfiguratiori
P/grarnnn Kenden
ENDE
img6 1200S3045 1m3
1 2 3 4 5 6 7 8 9
1 "Information window" Display window for 5 "Remark" Display field for additional informa¬
operator instructions. In addition, all the tion and instructions.
individual steps for checking the connection 6 "Check connection" This button is used to
and downloading software are recorded in check the connection to the selected control
this window. system.
2 "Select a truck" Selecting the truck/truck 7 "Start programming" This button is used to
group. start the software download.
3 "Select a control system" Selection of the con¬ 8 "END" Using this button, the current settings
trol system to which the software download is in the Winflash software are saved and the
to be transmitted. program is terminated.
4 "Select a file" Selection of the file that is to be 9 "Start configuration"Load configuration
transmitted. recognition from VNAP tool into the FZS.

Diagnostics 02
Software
The Winflash software is used for example for
downloading files to CAN control systems. For
this download, a CAN PC adapter (1 or 4) with
connecting cable (2, 3) is required. From version
V1 ,1x, download is also possible from PLC pro¬
gram blocks into a standard PLC (Digsy) or MUX
PLC from the interface adapter. The Winflash
software is started in the "Electronic Documen¬
tation System" on the notebook via "Diagnosis
/Multifunction programs /Winflash".
NOTE
img61200410378ml
Version V1. Ixofthe Winflash software replaces
the previous version V1.06.
img612004406 12m1

02 Diagnostics
Software
Preparation for downloading to CAN >

control system
For the software download to a CAN control, a
CAN-PC adapter (1 or4)mustbe used.
The CAN-PC adapter is connected to the note¬
book and truck as follows:
> Insert CAN-PC adapter (1) into the parallel
interface of the notebook and connect supply
voltage cable (2) to the USB port of the note¬
book.
> Connect 9-pin plug of the adapter cable (3) to img61200410379ml
the CAN-PC adapter.
> For USB-CAN-PC adapter: Connect USB plug
(4) to the USB port.
> Connect 4-pin round plug of the adapter cable
(3) to the diagnostic interface of the truck.
> Start Winflash software.
img61200440612ml
02-16 Service T raining - W8 054 356 EN - 06/2005

Diagnostics 02
Software
Winflash V1.1x - Operating with Winflash-Software
General
Procedure for transferring a file /a PLC program
block to a control system with the Winflash soft¬
ware:
• Select the truck/truck group, please see "Se¬
lecting a truck".
• Select the truck control system, please see
"Selecting a control system" .
• Select the file that you wish to transfer to the
control system, please see "Selecting afile".
• Check the data connection, please see
"Checking the data connection" .
• Start the software download, please see
"Starting programming".

02 Diagnostics
Software
Selecting afile
-¿hizeug «tRvMNen
After a truck / a truck group and the control system MX13-3.MX15-3

¿(oueiixij «jsrMÍhfen
have been specified, you must select the file that | SedtenpUl |8PS)
Datei auswátten
is to be transferred to the control system. |BPS_V134.HEX
IBM
> Use the mouse pointer to click on the arrow (1). Mocil > Piule Ytft«ndijng< odd >Slait Pic-giamn»-ruiiÿ
Fahrzeug irajptialb 5s emtchaken. Entsprechende
nfo-Fonslei beachlen
—- |
A selection window (2) opens, which contains

files that can be transferred to the selected con¬
PiJe Verbnding
trol system. n Fawreugsteuerung laden
Slat Piogianmierijns |
Programm beenden
NOTE —I / D ENDE
img61200430457ml
Depending on the type of controlsystem, there
maybe one (2) or more (3) files displayed in
the selection window. If "StandardSPS (2400
baud)", "MUX-SPS (2400baud)"or "MUX-SPS
(9600baud)"are selected as the control sys¬ |MX15-4
Sleueiung «ÿjswaUen.
tem, the file "DUMMY.SW"(4) is one ofthe items |MUX SPS I960Q Baud]
shown in this window. This file cannot be used |DUMMY.SW
for a download operation, please see also "SPS |:i •ÿÿÿÿ
r
program download". S6082C3I.
\("-J
> Use the mouse pointer to click on the file you

want to transfer.
The display window closes automatically. Only Piogiamm I
the selected file (5) is then displayed.

img61200430458ml
|£,WinFlaih V1.12R1 0910 03 c<SW>loi W.n_9x [1MX13-3. MX15-3I Copyright 2003 S TV -I 1*1
-
1 1
eihridungc odei >SlailPiogiamn*Muiig< *|

Fahfjeug ir/eihafc 5s emscha*er. Entspiechende
Hinweise i/lnfpFensiei beacWen
0, PiufeVerbndung I
alei r Fawzeugsteuerunj) laden
fQ Slait Piogrammiennu
img61200430459ml

Diagnostics 02
Software
Selecting a truck
In order to carry out a software download for a
file, the truck / truck group must first be selected:
> Use the mouse pointer to click on the arrow (1).
A selection window (2) opens which contains Fatir2e«jg imerhalb yenschallen Entsc
all the trucks / truck groups to which a software

download can be carried out. Vabindung zwti Fahrreug tes! en
> Use the mouse pointer to click on the truck /

truck group.
The display window closes automatically. Only
img61200430452ml
the selected truck / truck group (3) is then dis¬
played.
2 1
Fahrzeug iiyertiafc 5s einschalen Éntspiechende
img61200430453m!

02 Diagnostics
Software
Selecting a control system

After a truck / truck group has been selected,
you must select the control system into which the
sofware download is to be carried out.
> Use the mouse pointer to click on the arrow (1).
A selection window (2) opens which contains all
the control systems for the selected truck / se¬
lected truck group to which a software download
can be made.
ill NOTE imgfil 200430454ml
Depending on the type of truck / truck group, 2 1

there maybe one (3) ormore (2) controlsystems
displayedin the selection window.
|MX15-4
> Use the mouse pointer to click on the control Steueiung •wsnahfcn.
|MUX SP5 [9600
system.
|DUMMYSW
The display window closes automatically. Only
the selected control system (4) is then displayed.
In the "Remark" (5) window, additional informa¬
tion or instructions are displayed for downloading A zun Fahizeug lesien
luteVerbrxiurg |
the software into the selected control system.
imgBI 200430455ml
3
|£.WinFla»hV1 12H1 09 10 03 e<SW>fOI Win_9n IMX13-3. MX15-3) Copynghl 2003 STW HHE3
Macli >RCile Veibinduiig< odei >Slail Piogiamr«eiung<

FahrzeJ) imeikafc 5s emicha*e»i. Entsptechende
Hinwajfe im Irig-Fenslei beacWen /
img61200430456ml
4 5

Software
Checking the connection to the CAN

control system olofcoB CAN STW H«-0w**>ad
Veibridung zur S leueiung testen
'
III K noten anschaltÿn 1'l
Fahizeug auswahlen
J
Steuenng euswahten.
To ensure that the connection to the selected Brtientu*|8PS| J

>alei auswahten
CAN control system works, carry out a test of BPS_Vt34.HEX d
the connection to the control system prior to data Hinwet
Nach >Piute Veitxndung? odei >Stat Rograiwiwaungt J
Fahizeug innerhalt) 5l ersschalen Enlsptecher.de
transfer using the button "Test connection" (1). Hmweise im Info-Fenster beathten
d
> Switch on the truck. Vabndung zim Fahrzeug testen
J
> Use the mouse pointer to actuate the button
"Check connection" (1).
NOTE img61200430460ml
Ifthe Info window (2) displays the message:

then the truck must LUfflTffiiWHHil
be switched off within 5 s andback on after appr. Protofcoft CAN STW Hex-Dww*>a«l
Veibridung zur S teueiurig testen
Fahizeug auswahlen
2s. Ifthis message does not appear, leave the Knot«n.jnscha*«nl |"| J
Steuenng auswahten.
truck switched on. Be«ienm»|8P5l d

daiw auswahten
BPS_V134HEX d
If it was not possible to establish a connection Hinweit
Nach >Piute Veitxndung? odei >Stat Piogiaiwiwauiig< d
to the control system, the following message Fahizeug imerhalb 5t erischaten Entsprechende
Hnweise im Info-Fenster beathten
appears in the info window (3): d

Vetbixking zvm Fahizeug testen
J

or
img61200430460ml

Possible causes of the error:
HÿWinFlath V112R1 09.10 03 c<SW>tm Wtn_9ic IMX13-3. MX15-3] Copynqhl 2003 STW
• Incorrect control system selected.

• Line connection interrupted.
• CAN-PC adapter incorrectly connected.
• Control system defective.
If the connection with the control system is in
order, the following message appears in the info
window (4):

img61200430462ml

02 Diagnostics
Software
Start programming to CAN control sys¬ > lkzsxoo
tems Pialckol CAN STW Hex-Download

Start Prograrnartieru-ig
t|l Knotensnieha»eo i HI
Fahi2eug airewaMen
J
Steuerung auswahlen.
Using the button "Start programming" (1) the Bedervt# IBPSI

jare i auswahlen
J
software download to the selected control system BPS_V1 34 HEX J
is initiated. Hhweis:
Nach > Piule Verbindung< Oder >Stait Piogiamnxetung< J
Fahrzeug inner Mb 5s emschaHen Entsprechende
Hinweise im Info-Fenster beachten
> Switch on the truck.
zl
> Use the mouse pointer to actuate the button Verbindung rum Fahireug te
"Start programming" (1). Dalei n Fawzeugsteuerung laden
NOTE
img6 1200430631ml
Ifthe Info window (2) displays the message:

, the truck must be
switched on within 5seconds, itis not necessary
to switch ¡tonagain ifa connection with the CAN Protokol CAN STW Hex-Download
Start Piogrammiefung
J Fahrzeug amwahlen
controlsystem has previously beendetected. ill Knotenanichatten i I'l

Fehlet: Lokale ID III
ÍMX13-3.MX15-3 zi
Febler:Komte Knoten rich! autriien Steuerung ausnaNett
|Sedrenprit (BPS-) zi
Darei auswahlen
If it was not possible to establish a connection |BPS_V134.HEX zi
to the control system, the following message Hnweis:
Nach>Pru(e Verbtndung< oder >Stait Piogramnneiungt
Fahrzeug iimerhatb 5s etnschaHen Entsprechende
zi
appears in the info window (3): Hinweise im Info-Ferrster beaehlen
zi

Verbindung zum Fahrzeug testen
Q. Piute Verbrrdung |

Datei n Fahizeugsteuerung laden.
1 i.
or -1
Ptogramm beenden
-/- 0 r»nr

/
imgñl 200430632ml
Possible causes of the error:
• Incorrect control system selected. U_.WmFla.hV1 1?H1 0910 03 c<SW>fo. Wm_9x IMX13-3. MX15-3] Copyright 2003 STW I 1-1
• Line connection interrupted. Protekot CAN STW Hex-Download Fahrzeug autwáWerc
Start Profltammienjis
t|t Krwtenansehalten I III |MX13-3.MX15-3 zi
• CAN-PC adapter incorrectly connected. Anzahl von Flash'Seklorenerkannt 11
Zuloschwv 12 345 6 7 8910 Steuerung auswaWen:
loschen von Sektor 10
Gesamtzeit loschen': 4 s |EtedienpiJt (BPS)
zi
• Control system defective. Datergrosse 2726288ytes
Zeistempet 05 11.01 1501:00
Darei auswahlen
Zti* 3576 7 3576
Byte 112233 V 112233 at 312kR/j
|BPS_V134 HEX zi
If the connection to the control system is in order, Geiarrlzeit fcwnloatf: 36 s
Di/chschmltkcheRate 3 04kB/s
rHhweh:-
Geral unleishrtzt CRCs nichl. uberspitngen .
NactoPrufeVerbindungc Oder >Slait PiogiamrntMung zi
the download process is logged in the Info win¬ Gesamtzeit 53 s
Piui/<»niiiiciL»iy erf ulgrerulr I
Fahrzeug imerhalb 5s etnschaHen Entsprechende
Himverse im Irio-Fenster beachlen
dow (4). The progress of the download process zi

is additionally shown by the progress bar (5). Verbindung zum Fahizeug testen
Q, PiuteVerbrrdung |
After completion of the download process, the Dalei ri Fahizeugsteuerung laden
| if-': P':'- i'i ÿ•-•i ''"i |
following message appears in the Info window Programm beenden
Q FNC'F
(4):
img61200430466ml
!


Software
Close the program > tJMfflilMWil

Fahi2eug auswahlen
The Winflash software is closed using the button MX13-3.MX15-3 d

Steuenng auSwiWer.
"END" (1). When the software closes, the last Bedienpi* I8PS1 d
used settings are captured and saved. Oaiei auswahleri
BPS.V134.HEX d
Hinweit
Nach >Piule Veitxnduno? odei > Stent Programriwsungt
Fahizeug imerhalb 5i enschaken Entsptechende
J
Hmweise im Info-Fenster beathten
ÿ1
Vabindung n»n Fahrceug testen
O, PiUeVabinduris |
Dstn in FateeeugHeueung laden
Start Piogia«rimietung |
Plogramm beenden
< C CNOE
¥ img61200430451ml

02 Diagnostics
Software
WinMega for FPS

General >
This software is required in order to configure
and parameterize the truck and as an aid to trou¬
bleshooting.
m note
All functions can only be executedin the ONLINE
mode. The truck must be switchedon. The travel
andpump controller (FPS) must belinkedto the
notebook.
Connecting the notebook to the FPS

> Switch off the truck.
> Connect the plug X1 0 (1) to the interface
adapter (2) Id. no. W8 406 464, socket (3).
> Set the sliding switch (4) of the interface adap-
aterto position 2.
> Connect the interface adapter to the notebook.
> Switch on the truck and notebook.
> Start the WinMegaE software.
ffl NOTE
Itisalso possible to link the notebook directly via
the Id. no. W8408 840 to the FPS.
img61200440598m1

Diagnostics 02
Software
Menu structure
File
Configuration
Connection
Function
Open
Tx from file
Save
Save as
Exit
Com Port
Password
Start
Stop
Parameter
Tester
Alarm Logbook
Parameter Change Program VACC
Set Configuration Set Hour Counter
Adjustment Clear EEPROM
img61200440594m1
Starting the connection >

2 4
> Connect the notebook to the FPS (cf. Win-
Mega General).
> Click onto |start| (1).
or
> In the Connection menu, click on |start| (2).

The following appears in the display:
Connected to: EK-NL WAV3.02

Current truck version, may vary.
Nominal Voltage: 48V
Rated voltage
Nominal Current: 240A img61200440576ml
Nominal current 1 3
Hour: 234 h

02 Diagnostics
Software
Display of operating hours from the operating

console.
Next Service: 999 h
Remaining operating hours until next service.
ALARM:
Current error messages. If any exist, full text
display.
CONNECTION CONNECTED
STATUS:
Status display indicating whether connection is
established to the FPS.
Terminating the connection
> Click onto |stop| (3).

or
> In the Connection menu, click on |stop| (4).
Reading data out of the FPS
/ ÿ -inixi
NOTE fie fort igualen Connection Function tletp
Eatametet f
Once the parameters have beenreadout of the leste»
Alwn Logbook
FPS, parameter configuration and teach-in ofthe ProgtamyACC
C LWA V302
target andactual values can be performed, it is Set Hour Counter
also possible to save complete data records.

N
Clear EEPftOM ii sw i
Nominal CutenL 240 A
Hour 1h
> In the Function menu (1) click on | Parameter] (2). Next Service 993
ALARM
An empty parameter window opens.
CONNECTION STATUS CONNECTED
img61200440578ml
> In the opened window, click onto >

¡Receive from RAM| (4).
I Z ZAPI Pc Console WinMegaE PARAMETER HRB
(Earameier Change ¡1 Sel Cortiguraiion 1 Adjustment 1
— |
Open |
Beceive Irom RAM | OOM |
/ img61200440579m

Software
> The parameters are read out of the FPS. This > l-lafxl
process takes appr. 25s. |

Paiameter Change Set Configuration |fidiustment |
Zap l Conjo le is loadrigccrnOM i
I
img61200440589u
> To quit the active window, click on [cióse] (5). Z ¿API Pc Console WmMegaE PARAMETER - EdQ
Paiaraetai Change |Se» Cocfiguraiion | ¿djustmeni |
P03 SPEED2 FWD
Parameter Name |ParameterValue J

P01 SPEED 1 FWD 11
P02 SPEED 1 BWD 11 I'1 il
P03 SPEED? FWD ]l1 Aq*Ae |
P04 SPEED? BWD 11
P07 SPEED 4 5
P08 SPEEDS 6
to— J
Transmit to EEPR0M | Open

J ««J
Beceive from RAM | Sawn. J
~fz.
imgÿ1
J 200440588m

02 Diagnostics
Software
Saving data from the main menu
NOTE
T""~
Fie ConT"J_«s(cn
/
Open
Before data can be saved, the data must be read Ixfiomtie

S«ve
out of the FPS (cf. reading WinMega data from Save as . f
1
Connected to: EK-NLWA V302
the FPS).
Exit NonwvjIVcAsge; 48 V
Insm
Nomrial Cunent 240 A
> In the File menu (1) click on I Save as..| (2) . A Hour. 1h
dialog window opens -Save File- (4). Next Service: 339 h
ALAflM
> In this window, enter a name in the File name

input box (5). CONNECTION STATUS: CONNECTED
> In the Save as box (6) a directory can be se¬

lected in which the file should be saved. The
default setting is the WinMega file. img61200440584 m2
> Click onto |Save| (7). The file is saved in the

selected directory.
> Pressing I Cancel] (8 ) will cancel the clear
process.
Spechetnjn: [t3Ek12JM 3 Ej m ój mm
»|FahwjgriWi-iefz-jD
Daterjame JEX12.M ;:-3|, ' i<M
Dateiyp: / (".jacl 7] / Atetchm |
img61200440595 m 1
7 8
> If you click on Save, in the Enter a comment >

dialog box (9) it is possible to enter a comment. 10
Confirm this window with [ok] (10). / ÿ -iDlxl
Fie Conligur aliun Conriectioii Fyiiolion Hdo
E ZAPI Pc Console WinMegaE - Entei a f
Enter a Comment: |Schulungsgerat EK1/n

EKÍ/NÑr
Nr 2222
4751 IZF MODULE
img61200440596ml

Software
Saving data using the "Parameters" menu >

> In the Function menu (1) click on I Parameter] (2). / l-IOlxl
Efc Configuration Cgnnection Fyncbon JJdp
Parameter /
Iestet
Alarm Logbook
Program VACC
LV/A V3.02
Set Hour Counter
N
Cleat EEPflOM QO
Nomrnal Current: 240A
Hour 1h
Next Servtw; 999 h
ALARM
CONNECTION STATUS: CONNECTED
img61200440578ml
> The window-Parameter Change- (4) opens.

4
/
B ZAPI Pr Console WinMegaE PARAMETER -
NOTE
Parameter Change |Se« Coagulation |
Ifno data has yet been readout of the FPS, P03 SPEED2 FWD
| Receive from ram| (5) must becarriedout.
Parameter Name IParameterValue
P01 SPEECH FWD
> Click on |Save as...

(6). A dialog window opens P02 SPEECH BWD
P03 SPEED 2 FWD
-Save File- (cf. Saving data via the main P04 SPEED2 0WD
menu). P07SPEED4
SPEEDS
Iranunit to EEPR0m|
RAM | | |
Becÿ rom
Save as. Close
~Fÿ img61200440588m2
Open file over the main menu

> In the File menu (1) click on |Qpen| (2). The
_
ÿ -lalxi
window -Open file- (4) opens. Ble Configurate# Cjme<t»n
Cjn FgncWm I
Open
'
Ixhom lie
Save
Sflve as...
Connected to: EK-NLWA VI02
Normal Voltage 48V gg—Jl

11
Nominal Current 240A
Hour Ih
Next Service: 393 h
ALARM:
img61200440584m3

02 Diagnostics
Software
> In the Search in input box (5) select the direc- >
tory in which a truck file has been stored. The 76 5 4
saved files appear in the selection window (6).
The default setting is the WinMega file.
3 B| ¿al Oj IBjh
> Select the required file (7) by clicking. This
must appear in the -File name- window (8).
> Click onto [Open] (9).

0 atóame; |Fahrzeugriummer
DatMw Zap lile ('.zap J Ahtww.lwi |
imge 1200440587 u
> The file is read in (10). The window -Parameter >

Change- (11) opens. 10
After terminating the read-in process, the param¬ Bl-lalxl
eters are displayed in the -Parameter Change-

window and and can be edited. Underthe selec¬
tion window (12) is a comment User_Comment Parameter Value
(13), which was entered during the save process.
$01 SET BATTERY
img61200440597m!
Open the file via the menu "Parameter

Change"
>
_ 1
/
pi] NOTE
[ Parameter Changej Sel CoQtiguraJian | &d|ustment ]
A file can also be opened via the main menu.

i j
> In the opened -Parameter- window (1), click on

|Open| (2). The window -Open File- opens (cf. ' ?
i
Open file via the main menu).
. Open |
— I
fieceive Irorn RAM |
A-1 Close
img61200440579m2

Software
Save the data record directly in the FPS
ÿ x|
NOTE Configuration Function Help
Open
Before it ispossible to start a download, the con¬ TH ftMIt l«
nection must havebeen established.

Connected lo: EK-NLWA V302
48 V
NwrwvaiVcJteae' iQiO
> In the File menu (1), click on |Txfromfiie| (2). The Ncmnal Current: 240 A
dialogue window -Open file- (4) opens.

> In the Search in input box (5) select the direc¬
tory in which a truck file has been stored. The
saved files appear in the selection window (6). CONNECTION STATUS CONNECTED
> Select the required file (7). This must appear

in the -File name- window (8).
img6 1200440584ml
> Click onto I Qpen| (9). The -Warning- (10) " Are
you sure?" window (confirmation request) ap¬
pears
-ln|x|
3 Ml Ml IMmJ
KJEK12.04
Dateejame |Fahi;eu¡jnijmmei
"««VP ( Zap file I"
v il '
SONNE STATUS CONNECTED
mg6120G440587u
> To cancel the file selection, click onto [Ño] (12). >
Fl< Cpnliourotion Connection Function Help
Connected lo: EK-NL w# V3.0Z
NormalVoltage: 48 V
Norm
Hour i\ Are uau sue?
img61200440604u

02 Diagnostics
Software
> Click onto |ves| (11) ¡n the -Warning- window. alTlnra
The file can be transferred directly to the FPS.

The -Acquisition- window is opened and the
dowload of data can be started. Once the
Corrected to: EK-NLWA V3.IJ2
transmission process is complete, the window
is automatically hidden. I ÿ I
ZAPl Couote G llarisirmng dote tiom He to EEPflOM
img61200440605u

Software
Changing the parameters

4 2 3
Z /API Pe Contole V
/
inMegaE
/
PARA»,ETER -
/
NOTE
Before parameters can be changed, the con¬ P03 SPEED2 FWD
nection between the FPS andnotebook must r irametei Ni ime [Parameter Value
be established. The data must bereadout ofthe P01 SPEED1 FWD
PÚ2 SPEED 1 BWD
FPS ora vehicle file mustbe opened(cf. Reading P03 SPEED 2 FWD J11
WinMega data from the FPS). P04 SPEED? BWD 11 t
P07SPEED4 5 /
P08 SPEEDS 6
> In selection window (1) search for and click IlLT Le
onto the required parameter (2) using the scroll
bar (3).
Transmit lo EEPROM
The selected parameter is displayed over the

selection window with its name and the currently img61200440588m3
entered value(9). Modification of the parameter
is enabled. Parameters displayed in the diagnos¬
tic software red cannot be modified or only with
limitations.
> By clicking on the arrow button 0 (5) increase
the value, by clicking on the arrow button 0 (6) Parameter Change j Se» Certigur alien | Adrameril
reduce the value.

P03 SPEED2 FWD 11
or
PQ1 SPEED1 FV Z ZAPI Pc Console WinMegaE Acquisition
> Actuate 0 or Q on the keyboard.
-
P02 SPEED! BV
POj SPEED 2 Fv
or pi -I "P'hr; i; E\ ZAPI Console is transmitting data to EEPROM

PQ7SPEED4
> Double click into the change window (7) with P08 SPEEDS
the mouse. The number is highlighted in blue

and it is possible to enter a value between 0-9
or 0-19 directly in the window. transmit to EEPROM
Receive horn RAM Save as. |
img61200440601ml
NOTE
Inorder to test the changedparameters orto save
them into the FPS, the data must be transmitted
to the FPS.
> In the Parameter Change window, click on

¡Transmit to EEPROM] (8).
The Acquisition window opens (9) with the mes¬
sage "Zapi Console is transmitting data to EEP¬
ROM" (10) (data is transferred to the FPS).
After transmission of the data, this window closes
automatically.

02 Diagnostics
Software
Parameter list
Pfl NOTE
• Definition of the travel direction: Drive
side-AS, loadside =LS.
• Parameters P90..P93, P95are markedin red
in the diagnosis software and can not be ad¬
justed.
• Parameters P40, P4 1are markedinredin the
diagnosis software and can be adjusted only in
the range from 5- 9 (of. Electricalservice brake /
deadman brake deceleration).
• P52, 53: The value Omm means no reduction
of the tra vet profile. The entered offset value is
subtracted from the default value of 3000 mm.
Example: Input value = 1800mm, deceleration
starts at lift height 1200mm.
Min./max. Default
No. Name Description
value value
Max. speed AS mechanical forced guid¬
P01 SPEED 1 FWD 0-19 11
ance, lift height <3m / P52 (1 1km/h).
Max. speed LS mechanical forced guid¬
P02 SPEED 1 BWD 0-19 11
ance, lift height <3m / P52 (1 1km/h).
Max. speed AS, no forced guidance, lift
P03 SPEED 2 FWD 0-19 11
height <P32 (9km/h).
Max. speed LS, no forced guidance, lift
P04 SPEED 2 BWD 0-19 11
height <P32 (9km/h).
Speed with mechanical or inductive forced
P07 SPEED 4 0-19 5
guidance, deceleration 2.5km/h.
Speed not positively guided, lift height>P32
P08 SPEED 5 0-9 6
and steering angle <10° (4 km/h).
Speed not positively guided, lift height>P32
P09 SPEED 6 0-9 5
and steering angle 10° (2.5 km/h).
External speed reduction 2.5km/h, e.g.
P10 SPEED RED 1 0-9 5
ZAG, PSA.
External speed reduction 1km/h, e.g. chain
P11 SPEED RED 2 0-9 2
breakage, slack chain.
SPEED 3 SHIFT Inductive forced guidance, speed offset at V
P15 0-15 03
FWD >2.5km/h AS in 0.1 km/h increments.
SPEED 3 SHIFT Inductive forced guidance, speed offset at V
P16 0-15 03
BWD >2.5km/h LS in 0.1km/h increments.
IZFCREEP SHIFT Inductive forced guidance, speed offset at V
P17 0-15 03
FWD 2.5km/h AS in 0.1 km/h increments.
IZFCREEP SHIFT Inductive forced guidance, speed offset at V
P18 0-15 03
BWD 2.5km/h LS in 0.1km/h increments.
Acceleration with travel profile vmax, me¬
P20 ACC TIME 1 0-9 9
chanical or inductive forced guidance.
Deceleration with travel profile vmax, me¬
P21 DCC TIME 1 0-9 5
chanical or inductive forced guidance.

Diagnostics 02
Software
Min./max. Default
value value
Acceleration with travel profile 9km/h -
P22 ACC TIME 2 0-9 9
4km/h, no forced guidance.
Deceleration with travel profile 9km/h -
P23 DEC TIME 2 0-9 5
4km/h, no forced guidance.
Acceleration with travel profile Vmax >
P24 ACC TIME 3 P52.53, mechanical or inductive forced 0-9 9
guidance.
Deceleration with travel profile vmax >
P25 DEC TIME 3 P52.53, mechanical or inductive forced 0-9 5
guidance.
P26 ACC TIME 4 Acceleration with travel profile 2.5km/h. 0-9 9
P27 DEC TIME 4 Deceleration with travel profile 2.5km/h. 0-9 3
P30 MAST TOP POS Lift stop, maximum lift height (h3). 0-10000 mm 1900
OPEN GATE TOP Lift stop, maximum lift height with open
P31 0-1000 mm 950
POS gates.
SPEED2 TOP Deceleration, maximum lift height for 9km/h
P32 0-1000 mm 335
POS - stage (SPEED2) with raised auxiliary lift.
BOT CUTBACK
P33 Bottom cutback position. 0-500 mm 100
POS
P34 LIFT STOP 1 POS Intermediate lift stop position 1. 0-10000 mm 500
P35 LIFT STOP 2 POS Intermediate lift stop position 2. 0-10000 mm 500
TRAC CUTOFF 1
P36 Lift height-dependent traction cutoff 1. 0-10000 mm 500
POS
TRAC CUTOFF 2
P37 Lift height-dependent traction cutoff 2. 0-10000 mm 500
POS
LOWER STOP
P38 Lower stop position. mm 500
POS
SAFETY DEC 1 Deadman brake deceleration below 2nd
P40 5-9 7
(red) brake stage switchover (9%g).
SAFETY DEC 2 Deadman brake deceleration above 2nd
P41 5-9 7
(red) brake stage switchover (6%g).
AUTO LOWER
P46 Automatic lower stop position. mm 150
STOP POS
MAST TRANS
P47 Mast transition position. mm 1665
POS
MAST TRANS
P48 Distance before mast transition. mm 30
DIST1
MAST TRANS
P49 Distance after mast transition. mm 20
DIST2
LOWER RAMP
P50 Distance with lower stop P33, P38. 0-1000 mm 250
DIST
Distance with lower stop P30, P31, P34,
P51 LIFT RAMP DIST 0-1000 mm 150
P35.
P52 RAMPSHIFT FWD Lower travel profile in AS travel direction. 0-3000mm 0
P53 RAMPSHIFT BWD Lower travel profile in LS travel direction. 0-3000mm 0
P54 EXTZONEAPOS Zone activation position A. 0-10000 mm 0
P55 EXTZONEBPOS Zone activation position B. 0-10000 mm 0
P56 EXTZONECPOS Zone activation position C. 0-10000 mm 0

02 Diagnostics
Software
Min./max. Default
value value
P57 EXT ZONED POS Zone activation position D. 0-10000 mm 0
FREE CH. PROG Variable for special program FREE CHAS¬
P58 0-10000 0
VAL SIS
FREE CAB PROG
P59 Variable for special program FREE CAB 0-10000 0
VAL
P60 PUMP SPEED1 Main lift, max. lift speed. 0-9 5
Auxiliary lift 1, max. lift speed via operating
P61 PUMP SPEED2 0-9 4
console.
Auxiliary lift 2, max. lift speed via operating
console.
Auxiliary lift 1: Lift speed with LS operation
(const, speed)
Auxiliary lift 1: Load-dependent compensa¬
P64 PUMP COMP4 0-9 7
tion with LS operation.
Auxiliary lift 2: Lift speed with LS operation
(const, speed)
Auxiliary lift 2: Load-dependent compensa¬
P66 PUMP COMP5 0-9 5
tion with LS operation.
Main lift: max. lift speed range transition
damping (P47).
Prop, valve: Ramp when opening (main lift
P70 EVP OPENTIME 0-9 1
+ auxiliary lift 1/2).
Prop, valve: Min. current = minimum
P71 EVP OFFSET 0-9 4
lowering speed.
Main lift: Max. lowering speed above P33
P72 EVP MAX CUR1 0-19 11
(max. current prop, valve).
Main lift: Reduced lowering speed below
P73 EVP BOT CTB1 0-9 3
P33.
Main lift: Time to close the prop, valve
P74 EVP CLOSE T1 0-9 1
(release rocker).
Auxiliary lift 1: max. lowering speed (max.
current prop, valve)
Auxiliary lift 1: Red. lowering speed at end
stop.
P77 EVP CLOSE T2 Auxiliary lift 1: Time to close the prop, valve 0-9 1
Auxiliary lift 2: max. lowering speed (max.
current prop, valve)
Auxiliary lift 2: Red. lowering speed at end
stop.
P80 EVP CLOSE T3 Auxiliary lift 2: Time to close the prop, valve 0-9 5
Main lift: max. lower speed range transition
P81 EVP TRANS CTB 0-9 5
damping (P47).
ARMA MAX CUR
P90 Max. armature current. 5 5
(red)
ARMA NOM CUR
P91 Nominal armature current. 5 5
(red)
WEAK DROPOUT
P92 Field weakening factor. 7 7
(red)

Diagnostics 02
Software
Min./max. Default
value value
FLDNOMCUR
P93 Nominal field current. 5 5
(red)
Starting voltage at the travel motor when
P94 CREEP SPEED 0-9 5
driving off [minimum speed].
PUMP MAX CUR
P95 Max. pump current. 5 5
(red)
Starting voltage at pump motor [minimum
P96 PUMP CREEP 0-9 2
speed]
P97 PUMP ACCTIME Ramp-up time pump motor. 0-9 2
P98 PUMP DECTIME Pump motor cut-out time. 0-9 2

02 Diagnostics
Software
Set configuration
ill NOTE
Before the configuration can be changed, a con¬
nection must be establishedbetween the FPS
andthe notebook. The data must be readout
of the FPS ora vehicle file must be opened cf.
Reading WinMega data from the FPS.
> In the Parameter window, click onto Set Con- >
figuration (1). The selection window is opened
(2). % ZAPI Pe Contolo WinMc |ol IY.IAMETER F?T HEP |
> In selection window (2) search for and click Parametei Change Set ConfiguraiionjjAcljujiinent
onto the required parameter (3) using the scroll CI6 AUTO LOWER ST WHILE MOVING
bar (4). Parameter Nome WHILE MOVING
C13 OPEN GATE OPTION RESENT
The selected parameter is displayed over the [ALWAYS
CI 4AUX FLASH LIGHT ABSENT, IWHILE MOVING
selection window with its name and the currently CI 5 MAST TRANSITION
CI 6 AUTO LOWER STOP whil/moving
entered option (5). Modification of the parameter CI 7 LIFT STOP!
is enabled. CI 8 LIFT STOP 1 QUIT
> Click on the arrow key Q (6). A window opens

with the adjustable options. IrariiffiiUoEEPflOt
> Click required option (7). The option is dis¬

played in the selection window with a new img6 1200440602ml
function.
Pfl NOTE
in order to test the changedparameters orto save
them into the FPS, the data must be transmitted
to the FPS.
> In the Set Configuration window, click on the >

button |Transmitto EEPROM] (8). 9 10
The Acquisition window opens (9) with the mes¬
Paiameler Change S et Conjuration j ¿djustment
sage "Zapi Console is transmitting data to EEP¬
ROM" (10) (data is transferred to the FPS). C16 AUTO LOWER STOP ALWAÿ

automatically and parameters can be changed
again or it is possible to quit the current window
with the I ciosej button.
img6 1200440603ml

Diagnostics 02
Software
WinMega configuration list
NOTE
All configuration settings markedinboldare stan¬

dardsettings /are set after CLEAR EEPROM.
Name Description Selection Meaning

0 360/420L Ah
1 480 Ah
2 600/560L Ah
C01 BATTERY 3 720/700L Ah
Adjustable battery type.
TYPE 4 360 Ah Gel
5 480 Ah Gel
6 560 Ah Gel
7 750 Ah Gel
10° option (free travel ABSENT Not active
C02 4KM/H possible at 4km/h, between
OPTION 1,2m and 3m and steering PRESENT Active
angle <10°, P08).
2.5 km/h general speed ABSENT Not active
C03 10° SPEED
reduction during cornering
REDUCTION PRESENT Active
(P09).
1 STAGE 1 stage
C04 BRAKE TYPE Electromagnetic brake type.
2 STAGE 2 stage
C05 DEADMAN SAME NO contact
Deadman brake type.
LOGIC INVERTED Change-over contact
RUNNING Load cycle
C06 HOUR KEYON Keyswitch
Operating hours counter.
COUNTER Load cycle without
NO LOWER.
lowering
C07 AISLE ABSENT Not active
Aisle switch.
SWITCH PRESENT Active
C08 ZAG/PSA Forced braking at end of ABSENT Not active
MODULE aisle/ PSA. PRESENT Active
Inductive wire guidance ABSENT Not active
C09 IZF MODULE
(IZF). PRESENT Active
ABSENT Not active
C10I-LIFT Auxiliary lift.
PRESENT Active
Stand-on pallet: Type 1 = ABSENT Not active
only with pallet switch, Type TYPE 1 Pallet switch
C11 PALLET
2 - with pallet and gate
switch. TYPE 2 Pallet switch + gate
C12 ROOF ABSENT Not active
Roof switch.
SWITCH PRESENT Active
T ravel with open gate up to ABSENT Not active
C13 OPEN GATE
height P31, OPEN GATE
OPTION PRESENT Active
TOP POS possible.

02 Diagnostics
Software

ABSENT Not active
C14AUX FLASH
2. Flashing light (X6:11,12). TYPE 1 Flashing light
LIGHT
TYPE 2 Continuous light
C15 MAST Electrical mast transition ABSENT Not active
TRANSITION damping. PRESENT Active
ABSENT Not active
C16AUTO LOWER Automatic lowering cut-out
WHILE MOVING only while moving
STOP (pallet protection).
ALWAYS Always active
ABSENT Not active
Intermediate lift type 1, PRESENT active everywhere
validity: outside rails, inside ONLY INSIDE RAILS only active inside rails
C17 LIFT STOP 1
rails, zone dependent ONLY OUTSIDE
(A,B,C,D,A+B,A+B+C) only active outside rails
RAILS
ZONEX Active according to zones
Q-key pressed once Q-key pressed once
C18 LIFT STOP 1 Intermediate lift type 1, WHILE Q Keep Q-key pressed down
ACK acknowledge type: No acknowledgement
NO ACK
possible
ABSENT Not active
Intermediate lift type 2, PRESENT active everywhere
validity: outside rails, inside ONLY INSIDE RAILS only active inside rails
C17 LIFT STOP 2
RAILS
Q-key pressed once
C20 LIFT STOP 2 Intermediate lift type WHILE Q Keep Q-key pressed down
ACK 2Acknowledgement type. No acknowledgement
NO ACK
possible
ABSENT Not active
Lift height dependent PRESENT active everywhere
traction cutoff 1, validity:
C21 TRAC ONLY INSIDE RAILS only active inside rails
outside rails, inside
CUTOFF 1 ONLY OUTSIDE
rails, zone dependent only active outside rails
(A,B,C,D,A+B,A+B+C) RAILS
Q-key pressed once
Lift height dependent trac¬
C22 TRAC WHILE Q Keep Q-key pressed down
tion cutoff 1, acknowledge¬
CUTOFF 1 ACK No acknowledgement
ment type: NO ACK
possible
ABSENT Not active
Lift height dependent PRESENT active everywhere
traction cutoff 2, validity:
C23 TRAC ONLY INSIDE RAILS only active inside rails
outside rails, inside
CUTOFF 2 ONLY OUTSIDE
rails, zone dependent only active outside rails
(A,B,C,D,A+B,A+B+C) RAILS

Diagnostics 02
Software

Q-key pressed once
Lift height dependent trac¬
C24 TRAC WHILE Q Keep Q-key pressed down
tion cutoff 2, acknowledge¬
CUTOFF 2 ACK No acknowledgement
ment type: NO ACK
possible
ABSENT Not active
Lower cutout validity: PRESENT active everywhere
outside rails, inside ONLY INSIDE RAILS only active inside rails
C25 LOWER STOP
RAILS
Q-key pressed once
C26 LOWER STOP Lower cut-out, acknowl¬ WHILE Q Keep Q-key pressed down
ACK edgement type. No acknowledgement
NO ACK
possible
C27 FREE Function free inputs chassis 00 No function
CHASSIS PROG (special program). n 1-99 functions
C28 FREE CABIN Function free inputs cab 00 No function
PROG (special program). n 1-99 functions
C29 SERVICE ABSENT Running
Reset service counter.
DONE PRESENT Restart
ABSENT No display
C30 SERVICE
Service Symbol. Display with service
ALARM PRESENT
counter expired.
C31 SERVICE
Service hours counter. 1000 h Steps of 25
INTERVAL
When reversing, braking ABSENT Not active
C32 MAX
takes place with parameters
REVERSING PRESENT Active
P40, P41 deadman braking.
f NOTE
The service intervalcan be set in25-hour steps
with the arrow keys between 25 and2000 hours.
in order to reset the service counter, set the pa¬
rameter C29 SERVICE DONE to PRESENT,
carry out the transmission andswitch the truck
off and on. The counter restarts with the set
SERVICEINTERVAL time. The time to the next
service can be checkedin the tester (NEXTSER¬
VICE) or in the start window of the WinMega
software (NEXTSERVICE).
Service Training - W8 054 356 EN - 06/2005 02-41

02 Diagnostics
Software
WinMega Adjustment
Reading in the setpoint potentiometertraction, lift
up / down
This process is necessary when the operating
console, the setpoint potentiometer or the FPS
have been exchanged.
Before the setpoint values can be be read in,
a connection must be established between the
FPS and the notebook. The data must be read
out of the FPS or else a truck file must be opened.
> In the Function menu (1) click on | Parameter] (2).

/
Fiic ¿«iyjalui Cgrrc
ÿ
- |D| X|
E«amet« f
lertw
Alarm Logbook
ProgtamVACC
LV/A V9.02
Se* Houi Counter
H Clear EEPfiOM
NommaJ Cunent 240
Hour It.
NextSavioe; 999 h
ALARM
img61200440578ml
> In the opened window - Parameters - click on

|Adjustment| (3). The input window (4) opens. Paramerer Change | Set Configuration [édíntrnenl ¡|
\
\ 1 J
I \
\ \ —
I1 Ü
i
,i
\y \\ i 1
Qecerve from RAM \ \ 0°» 1
\\ \\ \ imfl61200440569ml
5 4 3

Diagnostics 02
Software
> Click on | Receive from RAM| (5). The data is read >
out of the FPS.
img61200440570ml
> In selection window (6) search for and click > ÿ -IDIXI
onto the required parameter (7) using the scroll ÿ

Parameter Change | Set Cogfiguaticn
bar (8). A01 MIN TRAC LEVER PUSH 01 ,0V
The selected parameter is displayed over the Parameter Value

A01 MINTRAC LEVER PUSH
selection window with its name and the currently
entered value (9). Modification of the parameter :LEVER PULL 01,3V
A04MAXTlftAC LEVER pull 08,0V
is enabled.
A06 MAXLIFT QEVER UP \07,4V
> Click on [Ácqu¡re| (10). The previously visible
value changes.
> Execute the relevant function. Transmit to EEPROP
Receive Irom RAM
16130044057*111
> Click onto |stopTeach| . The read-in function for

the selected parameters is terminated. Eararneter Changa |Set Configuration fidjustment j
A01 MIN TRAC LEVER PUSH 10.0V
ffi N0TE |Parameter Name

A01 MIN TRAC LEVER PUSH 10.0V
AO 2 MAX TRAC LEVER PUSH 08.1V
Párametervalue
in order to store the entered values in the FPS, AO 3 MIN TRAC LEVER PULL 01.3V
the data must be transmitted to the FPS. AO 4 MAX TRAC LEVE R PULL 08.0V
A05MIN LIFT LEVER UP 01.2V
A06 MAX LIFT LEVERUP 07.4V
Post I
img61200440571

02 Diagnostics
Software
> In the Adjustment window, click on > a ZAPI Pc Comole WmMegaE - PARAMETER •
¡Transmit to EEPROM|. I
P#wne«er Charge Set c«®hgg>atioo Adjustment |
The Acquisition window opens (12 ) with the A01 MIN TRAC LEVER PUSH 01 ,0V
message "Zapi Console is transmitting data to IParameter Nome IParameter Value

EEPROM" (13 ) (data is transferred to the FPS).
automatically.
> To quit the active window, click on |ciose|. Lo
img«1200440574ml
13 12
Parameter name Function Execution

Slowly move the traction lever
Minimum value for traction forwards. The value is adopted
MIN TRAC LEVER PUSH
potentiometer push. if correctly identified (appr.
0.6..1.7V).
Maximum value for traction forwards without exerting force
MAX TRAC LEVER PUSH
potentiometer push. as far as it will go and hold for 1
second (appr. 7.8 - 9V).
Minimum value for traction back. The value is adopted
MIN TRAC LEVER PULL
potentiometer pull. if correctly identified (appr.
0.6..1.7V).
Maximum value for traction back without exerting force as far
MAX TRAC LEVER PULL
potentiometer pull. as it will go and hold for 1 second
(appr. 7.8 -9V).
Slowly move the lift lever in
Mnimum value for hydraulic the up direction. The value is
MIN LIFT LEVER UP adopted if correctly identified
potentiometer up.
(appr. 0.6..1.7V).
Slowly move the lift lever without
Maximum value for hydraulic exerting force in the up direction
MAX LIFT LEVER UP
potentiometer up. as far as it will go and hold for 1
second (appr. 7.8 - 9V).
Slowly move the lift lever in the
Minimum value for hydraulic down direction. The value is
MIN LIFT LEVER DOWN
potentiometer down. adopted if correctly identified
(appr. 0.6..1.7V).
Slowly move the lift lever without
exerting force in the down
Maximum value for hydraulic
MAX LIFT LEVER DOWN direction as far as it will go and
potentiometer down.
hold for 1 second (appr. 7.8 -
9V).

Software
Tester
NOTE Efc Configuration Canrafon Fyncbon JJdp

ÿ -iDlxl
Parameter
/
Display function for the various statuses of the Iester f
Alarm Logbook
truck (of. WinMega tester list). No settings are Program VACC
possible in this function. Sel Hour Courier

LV/A V3.CG
N
Clear EEPflOM QO
Numeral Current: 240A
> In the Function menu (1), click on |Tester| (2). Hour 1h
The window -Tester- opens. The data for the Nerd Servrw: 999 h
tester is automatically read out of the FPS ALARM
(-Acquisition-) (4).
> In the selection window (5) search for the re¬

quired function (6) using the scroll bar (7) and
select with the mouse.
img6 1200440578m3
The marked function is automatically adopted

in the display window Test Name (8) with the
relevant value Test Value (9).
4
When executing the selected function, the value
changes in the Test Value window (9).
/
A maximum of 4 functions can be displayed si¬ Test Name Test Value
multaneously. If you wish to display other func¬
tions, first one or all functions must be deleted.
X ZAPI Pc Console WinMegaE - Acquisition -
> Click on the function you wish to delete. The
function is stored (10). UFTINQ CONTROL
> Click onto |Clear signal]

(11). The selected func¬
tion is cleared from the display window.
> Click onto |Clear Aii| (12). All functions are
cleared from the display window. ÿear¿l | Clear ¿ignal | £lose |
> Click onto [Close] (13). The system quits the img61200440592ml
active window.
5 6 7 8 10 9
Test Value
MOTOR CURR PU/TR 000A 000A
TRACTION CONTROL 00,00V 06%
LIFTING CONTROL 00,00V 00%
STEERING ANGLE +00c
Í440591m1
12 11 13

02 Diagnostics
Software
WinMega tester
Tester Name Description Value
BATTERY VOLTAGE Current battery voltage V
MOTOR VOLT
Voltage of pump/drive motor VA/
PU/TR
MOTOR CURR
Current of pump/drive motor A/A
PU/TR
FIELD CURRENT Field current, drive motor A
Voltage Main Negative, clocked negative, drive
VMN V
motor (armature)
EVP VOLTAGE Voltage at proportional valve V
TRACTION
Setpoint potentiometer, travel (0V - approx. 10V) V/%
CONTROL
Voltage, setpoint potentiometer for lifting/lowering
LIFTING CONTROL V/%
(0V- approx. 10V)
o
STEERING ANGLE Display of drive wheel position (0°-90°)
ANALOGUE HEIGHT Height measuring system, analogue potentiometer V
LOAD No function 0
TEMP TRAC Temperature of power unit for travel c°
MODULE
TEMP PUMP
Temperature of power unit for pump c°
MODULE
TEMP TRAC MOTOR Temperature, drive motor c°
TEMP PUMP
Temperature, pump motor c°
MOTOR
NEXT SERVICE Next service scheduled h
TRAC LEVER PUSH Drive lever is pressed (travel direction switch) on/off
TRAC LEVER PULL Drive lever is pulled (travel direction switch) on/off
DEADMAN Deadman switch actuated on/off
LIFTING SPEED Display of the lifting and lowering speed (+/-) mm/sec
TRACTION STOP Traction cutoff, input X7: 10 FPS on/off
AISLES Both rail switches active (aisle recognition) on/off
ZAG SPEED RED ZAG deceleration active on/off
FREE DB 2 Operating console input, option on/off
FREE DB 1 Operating console input, option on/off
Drive wheel in straight-on position (output, steering
STEER STRAIGHT on/off
controller)
AISLE LEFT 2 Rail switch left, X8:5 on/off
IZF WHEEL LOCK IZF steering angle limiter active on/off
AISLE RIGHT Rail switch right, X8:10 on/off
IZF SPEED RED Deceleration by IZF on/off
BOARD MAST SIDE Operating console, mast side/load side on/off
LIFT LEVER UP Button for lifting actuated on/off
LIFT LEVER DOWN Button for lowering actuated on/off
l-LIFT Button for additional lift actuated on/off
2. HAND 2- handed button actuated on/off
2.HAND LOAD SIDE 2- handed button load side actuated on/off

Diagnostics 02
Software
Tester Name Description Value

TRACSETPOINT Current setpoint, travel (internal) No value
LIFTSETPOINT Current setpoint, lifting (internal) No value
l-LIFTTOP Additional lift, lift stop reached on/off
l-LIFT BOTTOM Additional lift, mast bottom reached on/off
DIGITAL HEIGHT Height measurement system, digital sensor mm
ROOF Roof switch actuated on/off
Status of the FPS (truck standing 01 , deceleration
TRUCK STATUS 01-10
07, max. speed 10)
Current deceleration value during FPS braking
DEC VALUE No value
(internal)
Current deceleration value during FPS deadman
SDEC VALUE No value
braking (internal)
Current value, travel setpoint potentiometer (inter¬
ACC VALUE No value
nal)
GATES Gate switch closed on/off
RIGHT CHAIN Right chain switch active on/off
LEFT CHAIN Left chain switch active on/off
2. STAGE Lifting height for 2nd braking stage reached on/off
D REFER. HEIGHT Digital position of reference sensor mm
D TOP HEIGHT Digital position of upper end stop mm
A BOTTOM HEIGHT Analogue value of lower end position V
A TOP HEIGHT Analogue value of upper end position V
OS1POSFWD Height end point, max. speed forwards mm
OS1POSBWD Height end point, max. speed backwards mm
OS2POS FWD Height end point, max. speed forwards mm
OS2POS BWD Height end point, max. speed backwards mm
REFERENCE
Status of reference sensor on/off
SENSOR
OPTISPEED
Optispeed system taught in = on on/off
SYSTEM
ZONE CODE 1 Input X3:7 zone 1 active (+24V=off) on/off
ZONE MODUL OK lnputX3:10, zone module ok (+24V=off) on/off
ZONE ERROR FLAG Zone error saved on/off
TRUCK SPEED Truck speed km/h

02 Diagnostics
Software
Reading out the alarm logbook

1 2
NOTE
//
£ic £urfigualiai CjjrnecUui tidp
Eaiameter
Tester
Display function for occurred errors. No settings Alarm Logbook f
are possible In this function. Program VACC 1
LWA VÍ.02
Sel Hour Counter
N
DearEEPfiOM ll "T 1
> In the Function menu (1) click on |Aiarm Logbook| Nomnal Cuter* 240 «
(2). The -Alarm Logbook- window (4) opens. Hour It.
Next Service; 99$ h
Error message in plain text ALARM

Alarm Name:
(cf. Diagnosis /Error lists).
Frequency of displayed
Repetitions:
error.
FPS temperature on
Temperature: img61200440578m5
occurrence of error.
Time on hour counter at
Hour:
which an error occurred.
4 8 10
> Click onto |Update| (6). The alarm logbook is
updated. / J- i-lDlx|
> Click onto |ciearj (7). A confirmation request ACTUAL ALARM:

(8) is accessed, asking you to confirm that you
wish to clear the alarm logbook. AlasmName iRapeMicns / iTempetatuie / |H Mil A
/ -r23*C
J
> Click onto |Yes| (9). The alarm logbook is
4322 12F MODULE 1
J -t23T / Oh
cleared. 0046 EMERGENCr .

re ataim logbook wish to continue?
0DC6VMH NOT OK
> Click onto [Ño] (10). The process is aborted. Í" ||[ tfiST—1|
/
> Click onto |ciose| (11). The system quits the 4750 IZF MODULE 1 ÿ19*C Oh
4746 IZF MODULE Y ÿ19*C Oh
jJ
active window.
NOTE img61200440581ml
J™
A maximum of20 error messages can be dis¬
played.
• Error messages FEOOXXare generatedby the
FPS (cf. ErrorlistFPS).
• Error messages FE3XXare generatedby the
steering unit (cf. Errorlist ELK).
• Errormessages FE4XXXare generatedbythe
controlsystem of the inductive wire guidance IZF
(cf. Errorlist IZF).

Diagnostics 02
Software
VACC program
NOTE
The VA CCprogram is not avaitable. Ifthe menu ÿ -inixi
point VACC program is actuated, the message

"PROGRAM VACC IS NOTA VAiLABLE, FORWARD
PLEASEUSEADJUSTMENT" is displayed in Mmmum I Maximum:
the opened window.

BACKWARD
Minimum: I Maximum:
PROGRAM VACC IS NOT AVAILABLE. PLEASE USEADJUSTMENT!
I ÿ
I EÜ5I
img61200440593U

02 Diagnostics
Software
Set hour counter

> In the Function menu (1) click onto ÿ -lOlxl
Set Hour Counter|
(2). The Set Hour Counter fte [uctÿjdui Cgmecfon Function ü«Hp
window (4) opens. In the input window (5) the E«ameter

/
//
Tester
current operating hours are displayed. Alarm Logbook
ProgtamVACC
> Using the arrow keys Q , Q (6,7) or by double Se* Hour Counter
Clear EEPfiOM
jtV/A V3.02
clicking into the input window (5) the required

number of hours can be entered.
NextSetvioe; 999 h
If this input was incorrect: ALARM
> click ontoAcquire| (8). The original value which

was stored in the control system is restored. CONNECTION STATUS: CONNECTED
If this input was correct:

> click on |Save| (9). The entered value is trans¬ img61200440578m4
mitted to the FPS and stored there. In the

operating console, the newly set value is visi¬
ble after a short delay.
> Click onto |ciose| (10). The system quits the
current window.
ffl NOTE
No save commandis required as a result of
¡Transmit to eeprom| as the data has already been HOUR: |
written to the FPS with |Save| .
img61200440586ml

Diagnostics 02
Software
Clear EEPROM
|T] NOTE
The (ClearEEPROM) function is necessary ifthe
truck software is upgradedor iferror FE01(EEP¬
ROMKO) occurs. Before the dear operation is
performed, alldata such as parameters, configu¬
rationsandthe operating hours counter are noted
andsaved in a file. With the pear eeprom] com¬
mand, a standardparameter recordis activated
in the EPS. When updating the EPSsoftware
(exchanging the Supervisor EPROM), values
previously savedin a file can no longerbeplayed
back into the FPS. The values haveto be manu¬
ally adapted.
After the Clear EEPROM operation, carry out the

following operations:
> If possible, play a previously saved file back
into the FPS (this allows you to omit the follow¬
ing steps if the data is up to date).
> Carry out a teach-in process for the setpoint
potentiometer traction , lift up / down.
> Enter the parameter for the max. lift height.
Carry out a teach-in process for the height
measurement system.
> Check parameters, enter again if necessary.
> Check configuration, enter again if necessary.
> Re-enter the operating hours counter.
All parameters can be set before executing a
|Transmitto EEPROMj.
Clear process
1 2
> In the Function menu (1) click on |Clear eeprom| /
//
(2). A Warning (4) window opens with the en¬ £fc £onfiguabjn Canrafon Function üdp
Eramete
quiry "Do you wish to clear EEPROM?" (5).
filaim Logbook
ProgiamVACC
// M |
Set Houi Counter
LV& V3.02
N
£leai EEPROM 1 Intn
Normal Current: 240 A
Hour 1h
Next Service; 99$ h
ALARM
CONNECTION STATUS; CONNECTED
¡mg61200440578m2

02 Diagnostics
Software
> Pressing [Ño] (6) will cancel the clear process. >
4 5
img61200440582ml
7 6
> Start the cancel process with |Yes| (7). The

Information (8) window appears with the mas¬
sage "KEY OFF THE CHOPPER AND START
CONNECTION AGAIN, PLEASE!" (Switch on
the truck and restore the connection).
> Confirm the keyswitch reset with [ok] (9).
KEY OFF THE CHOPPER AND START CONNECTION AGAIN. PLEASE!
CONNECTION STATIJ. WAITING FOR KEYOFF
img61200440606ml

Diagnostics 02
Error lists
Error list for travel and pump con¬

troller (FPS)
ffi NOTE
Errors marked with (A) are enteredin the error
memory (alarmlist). Errors in the steering and
inductive wire guidance are also entered. There
is a maximum of20 entries. The oldest entries
are overwritten.
FE01 (A) "EEPROM KO"
Description - EEPROM error.

Reaction: None.
Cause: - EEPROM faulty.
- Error during save operation.
Rectification: - Reset by turning the truck off and then on again.
- Save the parameters, carry out CLEAR EEPROM and load parameters.
- Replace the control system.
FE02 (A) "Logic failure #4, CAN BUS KO"
Description - CAN bus error.

Reaction: Emergency stop, open main contactor.
Cause: - Breakdown in communication on CAN bus.
- CAN participant is not responding (faulty or power supply missing, e.g. fuse F7).
- Check CAN bus, power supply.
FE03 (A) "Logic failure #3"
Description - Monitoring of the valve coils with key switch ON.

Reaction: Main contactor not closing.
Cause: - Short circuit, wire breakage.
- Internal error.
- Check wiring.
Description - Monitoring of the 1st brake coil with key switch ON.
Reaction: Main contactors not closing.

02 Diagnostics
Error lists
- Internal error.
- Check wiring.
Description - Monitoring of the main coils with key switch ON.

- Internal error.
- Check wiring.
FE06 (A) "VMN not ok"
Description - Monitoring of the transistor control for drive motor.

Without travel: VMN is not equal to battery voltage.
During travel: VMN not following the clock ratio.
Reaction: Main contactors open.
Cause: - Short circuit, drive motor faulty.
- Internal error.
- Check wiring, drive motor.
FE07 (A) "contactor closed"
Description - The contacts of a main contactor (K1 , K2) are closed when key switch ON.
Cause: - Short circuit, contacts melted.
- Check contactors.
FE08 (A) "contactor open"
Description - The contacts of a main contactor (K1 , K2) do not close when key switch ON.
Cause: - Wiring, contactors faulty.
- Check wiring, contactors.

Error lists
FE09 (A) "I = 0 ever"
Description - No current although travel has been selected

Cause: - Internal error.
FE10 (A) "Pump I = 0 ever"
Description - No current although lifting has been selected

Cause: - Wiring, pump motor faulty.
- Internal error.
- Check wiring, pump motor.
FE11 (A) "STBY I high"
Description - High current although travel not selected

FE12 (A) "Pump STBY I high"
Description - High current although lifting not selected

FE13 (A) "High field current"
Description - High field current although field is switched off.

FE14 (A) "No field current"
Description - No field current although field is switched on.

02 Diagnostics
Error lists

Cause: - Field coil, wiring faulty.
- Internal error.
- Check field coil, wiring.
FE15 (A) "Capacitor charge"
Description - VMN is 0V when key switch ON.

Cause: - Armature coil, wiring faulty.
- Internal error.
- Check armature coil, wiring.
FE16 (A) "Thermal Protection"
Description - Temperature of drive motor power module is >77°C or < -10°C.

Reaction: From 77°C to 92°C, the current is reduced to 0. At <-10°C, reduction to 80%.
Cause: - Overload, ambient temperature too high ortoo low.
- Internal error.
Rectification: - Switch the truck off and leave it to cool down.
FE17 (A) "Thermic Level #2"
Description - Temperature of pump motor power module is >77°C or < -10°C.

Reaction: From 77°C to 92°C, the current is reduced to 0. At <-10°C, reduction to 80%.
Cause: - Overload, ambient temperature too high ortoo low.
- Internal error.
FE18 (A) "Pump temperature"
Description - Temperature of pump motor is >130°C.

Reaction: Lift stop after 15 seconds.
Cause: - Overload, ambient temperature is too high.
- Wiring faulty.
- Motor (carbon brush yoke).
- Check wiring.
- Check motor (carbon brush yoke).

Error lists
FE19 (A) "Motor temperature"
Description - T emperature of drive motor is >130°C.

Reaction: Motor current is reduced by 50% and within 5 mins to 0%.
Cause: - Overload, ambient temperature is too high.
- Wiring faulty.
- Motor (carbon brush yoke) faulty.
- Check wiring.
- Check motor (carbon brush yoke).
FE20 "Battery low"
Description - Battery discharged.

Reaction: Lifting not possible
Cause: - Battery discharged.
- Wiring, connections.
- Check wiring, connections (check battery voltage at FPSX2:1).
- Check battery, recharge if necessary (minimum voltage required to reset EAZ).
FE21 (A) "Driver shorted"
Description - One of the transistors for controlling the main contactors has short-circuited.
Cause: - Short-circuit.
- Internal error.
- Check wiring, contactor coils.
FE22 (A) "Contactor driver"
Description - One of the transistors fortiming the main contactors is permanently open.
- Internal error.
FE23 (A) "Coil shorted"
Description - Short-circuit at one of the coils for the main contactors.


02 Diagnostics
Error lists
- Internal error.
FE24 "VACC not ok"
Description - Travel setpoint is higher than the programmed minimum value when key switch ON
or after 10 sees, in neutral position.
Reaction: Travel stop.
Cause: - Setpoint potentiometer faulty, teach in
- Check setpoint potentiometer, travel direction signal (onboard diagnosis).
- Carry outteaching-in for setpoint potentiometer (diagnosis software).
FE25 "Incorrect start"
Description - Incorrect switching-on sequence.

Reaction: Main contactors not closing, travel stop.
Cause: - Setpoint potentiometer (direction signal), deadman switch or 2-handed button was
actuated during switching on.
- Maintain switching-on sequence.
- Check switch.
FE26 "Forw + Back"
Description - Signals for forwards, reverse or lifting and lowering received at the same time.
Reaction: Travel/lift stop.
Cause: - Switch faulty, wiring.
- Check direction signals, wiring.
- Check switch.
FE27 "Bad steer 0-Set"
Description - STRAIGHT-ON error, steering unit (CAN telegram from the steering unit).
Reaction: Deceleration.
Cause: - Steering unit registering STRAIGHT ON without command from FPS (rail switch).
- Steering unit not registering STRAIGHT ON despite command from FPS.
- Steering unit removes STRAIGHT ON in aisle.
- EMERGENCY-OFF test selected in IZF.
- Steering wheel setting >5° at aisle exit (with steering knob only).

Error lists
- Check STRAIGHT ON with FPS (rail switch).

- Check switch, steering wheel setting, steering unit.
FE28 "Steer sensor ko"
Description - Steering unit error (CAN telegram from the FPS to steering unit and response).
Reaction: Main contactors open, travel stop.
Cause: - Steering unit registers "active" without command by FPS "truck moves".
- No response "Steering active" despite command by FPS.
- Check steering unit.
FE29 "Traction brushes"
Description - Traction brushes in drive motor worn.

Reaction: Travel stop after 10 hrs.
Cause: - Traction brushes, wiring, switch faulty.
- Check traction brushes, wiring, switch.
FE30 "Pump brushes"
Description - Traction brushes in pump motor worn.

Reaction: Travel stop after 10 hrs.
Cause: - Traction brushes, wiring, switch faulty.
- 24V FPS supply missing (fuse F7) from single and triple mast.
- Check traction brushes, wiring, switch.
FE31 (A) "Driver 1 ko"
Description - One of the outputs to the valves has short-circuited.

- Internal error.
- Check wiring, valve coils.
FE32 "Height error"
Description - Monitoring of height measurement system.

Reaction: Reduced travel and lifting speed.
Cause: - Digital height is outside the monitoring window (±0.5V) for the analogue value.
- Lifting/lowering movement without activated movement.

02 Diagnostics
Error lists
- Lifting/lowering movement too fast.

- No pulses although movement activated.
- Check height measuring system, wiring.
- Teach in height measuring system.
FE33 "Input mismatch"
Description - Redundant monitored signals, e.g. normally closed/normally open contacts have
implausible values.
Reaction: Travel/lift stop.
Cause: - Deadman switch, chain breakage switch, lifting/lowering direction register different
values (hardware - CAN bus, operating console signal/FPS)
- Monitoring of motor current, field current, VMN (motor negative), voltage of propor¬
tional valve faulty.
- Check power supply, wiring, peripherals.
FE36 "Aisle stop"
Description - ZAG/PSA registers stop with FPS.

Reaction: Travel stop (can sometimes be acknowledged).
Cause: - ZAG/PSA registers stop during aisle travel
Rectification: - Check ZAG/PSA.
FE37 "Pump acc not ok"
Description - Lifting setpoint is higher than the programmed minimum value when key switch ON
or after 10 sees, in neutral position.
Reaction: Lift stop.
Cause: - Setpoint potentiometer faulty, teach in
- Check setpoint potentiometer, direction signal (onboard diagnosis).
- Carry outteaching-in for setpoint potentiometer (diagnosis software).
FE38 (A) "Micro control ko"
Description - Internal error.

Cause: - One of the microprocessors is not working.

Error lists
FE39 (A) "EV. coil shorted"
Description - Short-circuit at one ofthe coilsforthe hydraulic valves.

Reaction: None.
- Internal error.
- Check wiring, valve coils.
FE40 (A) "Broken chains"
Description - Broken chains.

Reaction: Lifting/lowering stop, deceleration.
Cause: - One ofthe chain switches has been actuated.
Rectification: - Check lifting chains, wiring, switch.
FE41 (A) "slack chains"
Description - Slack chains.

Reaction: Lowering stop, deceleration.
Cause: - Both chain switches have been actuated at the same time.
- 24V power supply missing.
Rectification: - Raise cab.
- Check 24V power supply, wiring, switch.
FE42 (A) "EVP not ok"
Description - Supply voltage for proportional valve not OK.

Reaction: Lowering stop, main contactors open.
Cause: - 24V power supply, wiring, valve coil faulty.
- Internal error.
- Check 24V power supply, wiring, valve coil.
FE43 (A) "Vfield not ok"
Description - Field voltage is not OK.

Cause: - Field coil, wiring faulty.
- Internal error.
- Check field coil, wiring.

02 Diagnostics
Error lists
FE44 (A) "Brake coil shorted"
Description - Coil of the 1st braking stage has shorted.

Cause: - Brake, wiring faulty.
- Check brake, wiring.
FE45 (A) "Brake driver shorted"
Description - Transistor for controlling the 1st braking stage has shorted.
- Internal error.
FE46(-/ A) "Emergency"
Description Emergency-stop.
Cause: Emergency-stop button actuated (no entry in alarm list).
Emergency-stop chain interrupted (ZAG, PSA).
Wiring.
Rectification: Release emergency-stop button.
- Check emergency-stop chain, wiring.
FE47 (A) "MicroMaster ko"
Description - Master EEPROM faulty

FE48 (A) "2nd brake driver sh."
Description - Transistor for controlling the 2nd braking stage has shorted.
- Internal error.

Diagnostics 02
Error lists
FE51 (A) "2nd brake coil sh."
Description - Coil of the 2nd braking stage has shorted.

FE52 "Ref. Sensor error"
Description - Reference switch of the height measuring system not switching in the defined range
(±100mm).
Reaction: Reduced travel, lifting and lowering speed.
Cause: - Reference switch, wiring faulty.
- Teaching-in, position of reference switch invalid.
- Check reference switch, wiring.
- Carry out teaching-in.
FE53 "Brake module error"
Description - Monitoring of the height measuring system to 2nd braking stage not switching in the
defined range (4200-4400mm).
Reaction: Reduced travel, lifting and lowering speed.
Cause: - Height measuring system, wiring, FPS faulty.
- Teaching-in invalid.
- Check height measuring system, wiring, FPS.
- Carry out teaching-in.
FE54 "Zone error"
Description Error in zone recognition (option).

Reaction: Q-LED lights up, reduced travel speed 1km/h, lift stop.
Cause: Zone recognition module registering error (FPS X3:10) or zone code invalid (FPS
X3:7..9).
Rectification: Reset by turning the truck off and then on again.
Reset with correct zone code (drive into the zone again).
Check zone recognition module, wiring.
FE55 "Roof Sw. active"
Description Roof switch has been actuated.

Reaction: Travel and lift stop.
Cause: Obstacle in the area of the overhead guard.

02 Diagnostics
Error lists
Switch, wiring faulty.

Rectification: Lower cab.
Check switch, wiring.
FE60 (A) "ELK CAN timeout"
Description - No CAN telegram from the steering unit.

Cause: - Steering unit, wiring faulty.
- Check steering unit, wiring.
FE61 "ELK not ok"
Description - Steering_ok signal is missing. Signal (FPS X7:7 is HIGH=13V) or CAN information
incorrect.
Cause: - Steering unit, setpoint /actual value potentiometer, wiring faulty.
- Check steering unit, setpoint /actual value potentiometer, wiring.
FE62 "ELK low torque"
Description - Steering unit operating with reduced torque.

Reaction: Creep speed (1km/h).
Cause: - Reduced torque (standstill) is not changed when travel starts.
Rectification: - Reset if torque OK.
- Reset by turning the truck off and then on again.
FE65 (A) "IZF CAN timeout"
Description - No CAN telegram from the IZF.

Cause: - IZF, wiring faulty.
- Check IZF, wiring.
- Check configuration of FPS.
FE66 "IZF rack mismatch"
Description - IZF aisle recognition signal (FPS X8:4) and CAN information do not match.
Cause: - IZF, wiring faulty.
- Check IZF, wiring.

Error lists
FE67 "IZF manual not allowed"
Description - Manual steering has been selected inside aisle.

Reaction: Warning signal, travel stop, creep speed 1km/h with Q-key pressed and 2nd manual
button.
Cause: - Incorrect operating mode selected.
- Aisle recognition has not been reset on leaving aisle.
Rectification: - Check operating mode, aisle recognition.
FE68 "Operating console mismatch"
Description Stored position of the operating console does not fit between FPS and ELK.
Operating console switch-over with FPS is not functioning.
Reaction: Main contactors not closing, travel stop.
Cause: Check configuration of the steering unit (operating console replaceable or set 2
operating consoles).
Software version for FPS / operating console is out of date, possibly booting prob¬
lems (versions: of operating console OP>V3.12, FPS OC>V3.02, OS>V3.20)
- Check configuration of the steering unit
- Check software version for FPS / operating console (possibly update by changing
Eprom, changing control system, EEPROM flash process)
- Check hardware recognition on Casibo A22 X3:1 and response of X3:14.
FE70 "aisle left mismatch"
Description - Redundant signals from LEFT rail switch are not inverted (FPS X8:5 /X8:9)
Reaction: Deceleration (2,5km/h). Green LEDs for rail switch flash on operating console.
Cause: - Switch, wiring faulty.
Rectification: - Check switch, wiring.
FE71 "aisle right mismatch"
Description - Redundant signals from RIGHT rail switch are not inverted (FPS X8:6 /X8:1 0)
Reaction: Deceleration (2,5km/h). LEDs for rail switch flash on operating console.
FE72 "barrier mismatch"
Description - Redundant signals of the barrier switches are not inverted (FPS X1:9/X1 :10).
Reaction: Same as with open barrier. LED for barriers lights up on operating console.

02 Diagnostics
Error lists
FE73 "gate LS mismatch"
Description - Redundant signals of barrier switch for LOAD SIDE are not inverted (FPS X2:5
/X 2:6).
Reaction: Same as with open barrier load side. LED for barriers lights up on operating console.
FE74 "pallet mismatch"
Description - Redundant signals of pallet switch are not inverted (FPS X2:7 /X 2:8).
Reaction: Same as with missing walk-on pallet. LED for barriers lights up on operating con¬
sole.
FE75 "roof mismatch"
Description - Redundant signals of roof switch are not inverted (FPS X2:9 /X2:1 0).
Reaction: Travel/lift stop (same as with active roof switch).
FE90 "FreeChassis error"
Description - Error in option of free chassis program.

Reaction: Program related.
Cause: - Program related.
Rectification: - Program related.
FE91 "FreeCab error"
Description Error in option of free cab.

Reaction: Program related.
Cause: Program related.
Rectification: Program related.

Error lists
Error list for electrical steering

(ELK)
NOTE
Number which are grouped either belong to the
same assembly or the error applies equally for
the components Ustedin the description.
FE3001
Description: Software does not match the hardware version

Reaction: Steering switches off, Steering_OK signal off.
Cause: Old steering hardware.
Replace the steering unit.
FE3002
Description: Internal error.

Cause: No communication with control processor after start-up.
FE3018
Description: Under or overvoltage 15V supply, internal A/D converter.

Reaction:
Steering switches off, Steering_OK signal off.
Cause: Overloading of the 15V power supply.

Check proximity switches, potentiometer, wiring, voltage.
FE3019

Cause: Error in internal A/D converter.
FE3020
Description: - Excess voltage battery supply.


02 Diagnostics
Error lists
Cause: - Battery voltage too high.

- Check battery voltage.
FE3021
Description: - Undervoltage, battery supply.

Cause: - Battery discharged, battery supply interrupted.
- Check battery voltage and supply.
FE3022
Description: - Internal error.

Cause: - Parameterising error.
- Replace the steering unit.
FE3033
Description: - Excess current, amplifier.

Cause: - Steering difficult to turn, steers against steering lock.
- Rectify heaviness, replace steering.
FE3034
Description: - Excess temperature, amplifier.

Cause: - Cooler, ventilator, connection faulty.
- Check cooler, ventilator, connection.
FE3035, FE3036

Cause: - Monitoring phase U, V.

Error lists
FE3047
Description: Wire breakage, actual value potentiometer arm.

Cause: Wire breakage, arm voltage or potentiometer supply too small, potentiometer faulty.
Check wiring, potentiometer, voltage.
FE3049
Description: Wire breakage, setpoint potentiometer supply.

Cause: Wire breakage, potentiometer faulty.
Check wiring ±, potentiometer, voltage.
FE3050
Description: Excess current, setpoint potentiometer.

Cause: Short-circuit, potentiometer faulty.
Check wiringi, potentiometer.
FE3051
Description: Wire breakage, actual value potentiometer supply.

Cause: Wire breakage, potentiometer faulty.
Check wiring ±, potentiometer, voltage.
FE3052
Description: Excess current, actual value potentiometer.

Cause: Short-circuit, potentiometer, proximity switch faulty.
Check wiring ±, potentiometer, proximity switches.
FE3053
Description: - Actual value potentiometer error.


02 Diagnostics
Error lists

FE3054
Description: Setpoint potentiometer error.

Cause: Wiring, potentiometer faulty, evaluation of channels 1+2 invalid.
Check wiring ±, potentiometer, carry out teaching-in.
FE3055
Description: Bolster: position of actual value potentiometer <> position of motor position sensor.
Cause: Wiring, potentiometer, motor position sensor, mechanics faulty.
Wiring ±, potentiometer, check mechanical elements, replace steering unit.
FE3056
Description: Error, motor position sensor.

Cause: Monitoring of motor position sensor.
FE3057
Description: Calibration of actual value potentiometer faulty.

Cause: Self test on switching on.
Carry out A/D converter calibration.
FE3058
Description: - Calibration of setpoint potentiometer faulty.

Cause: - Self test on switching on.
- Carry out A/D converter calibration.

Error lists
FE3059

Cause: - Current sensor values faulty.
Rectification: - Reset by turning the truck off and then on again. Replace the steering unit.
FE3060
Description: - Motor resistance too high.

Cause: - Problem with contact to motor.
- Coil faulty.
- Contacts in power section - check motor, replace steering unit.
FE3061
Description: - Motor resistance too low.

Cause: - Coil faulty.
FE3062
Description: - Setpoint potentiometer error.

Cause: - Wiring, potentiometer faulty, evaluation of channels 1+2 invalid.
- Check wiring ±, potentiometer, carry out teaching-in.
FE3065, FE3066, FE3067, FE3068

Cause: - Error in motor regulation.
FE3069
Description: - Error, motor position sensor.


02 Diagnostics
Error lists
Cause: - Monitoring of motor position sensor.

FE3070

Cause: - Initialisation time exceeded.
FE3071
Description: - Motor start error.

Cause: - Motor not moving, monitoring of motor position sensor.
- Check supply, replace steering unit.
FE3074
Description: - Motor start error.

Cause: - Wrong direction of rotation.
FE3075
Description: - Adjustment error.

Cause: - Torque too low at v>1km/h, overloaded.
- Motor error.
- Check mechanics, load, replace steering unit.
FE3077, FE3081, FE3082, FE3082, FE3083, FE3084, FE3085, FE3088, FE3089, FE3090,
FE3118, FE3119, FE3120

Cause: - Internal process monitoring.

Error lists

FE3121
Description: - No data reception.

Reaction: Steering_OK signal off.
Cause: - CAN bus interrupted, data missing.
- Check CAN bus wiring, check other CAN bus controls.
FE3122
Description: - No data transmission possible.

Reaction: Steering_OK signal off.
Cause: - CAN bus interrupted.
- Check CAN bus wiring.
FE3145, FE3146, FE3147, FE3148, FE3151, FE3152

Cause: - EEPROM memory error.
- Check CAN bus wiring, check other CAN bus controls.
FE3160
Description: Inductive steering, timeout during straight-on travel.

Cause: Steering will not turn, no supply voltage.
Check supply, replace steering unit.
FE3161
Description: - Inductive steering, timeout while searching for edge of proximity sensor.
Cause: - Supply voltage missing, actual value potentiometer not adjusted centrally.
- Proximity switch is set incorrectly or faulty.
- Check supply, proximity switch, actual value potentiometer.
- Adjust the actual value potentiometer centrally.

02 Diagnostics
Error lists
FE3162
Description: Error caused by IZF.

Cause: Steering will not turn, no supply voltage
Check supply, steering unit, IZF.
FE3163
Description: Timeout when starting up straight-on travel.

Cause: Steering will not turn, no supply voltage.
Check supply, replace steering unit.
FE3164
Description: Timeout while searching for edge of proximity sensor.

Cause: Supply missing, proximity switch wrongly adjusted or faulty, actual value poten¬
tiometer not adjusted centrally.
Check supply, proximity switch, actual value potentiometer.
Adjust the actual value potentiometer centrally.
FE3165

Cause: - Neutral position, unknown error.

Diagnostics 02
Error lists
Error list inductive wire guidance

(IZF)
m NOTE
Collatederror numbers are either assigned to an
assembly; or the error applies consecutively to
allthe components Ustedin the description, e.g.
"Antenna 0.. 3" corresponds to FE4750..4753.
The errors are subdividedinto groups:
• 4000: Memory, operating system.
• 4 100: Peripherals.
• 4200: CANbus.
• 4300: Antennas.
• 4400: Adjustment.
• 4500: Aisle recognition.
• 4600: Steering lock.
• 4700: Monitoring functions.
• 4800: Diagnosis functions.
• 4900: Controlfunctions of the monitoringpro¬
cessor.
FE4001, FE4002
Description: - Error reading/writing from data into EEPROM.

Reaction: Immediate travel stop.
Cause: - Hardware error.
- Reload parameters.
FE4003
Description: - Checksum error EEPROM.

Cause: - New software version with new parameters.
- Data in EEprom faulty.
Rectification: - Reload parameters.
- Recalculate checksum and set (diagnosis software/error memory).
FE4004, FE4005


02 Diagnostics
Error lists

FE4006
Description: - Error writing data.

Cause: - Value range exceeded.
- Check variables for valid range.
FE4007
Description: Error reading/writing from data into EEPROM.

Cause: Hardware error.
Reload parameters.
Replace the control system.
FE4010, FE4011
Description: Internal timeout.

Reaction: Emergency stop.
Cause: Hardware error.
FE4020, FE4021, FE4040, FE4041
Description: - Internal program error.

Reaction: Error display.
FE4050, FE4051, FE4052, FE4053
Description: - Internal memory test.


Error lists
- Reload software.
FE4060
Description: - Software status of monitoring processor invalid.

Reaction: Immediate deceleration.
- Reload software.
FE4070, FE4071, FE4072
Description: - Internal Reset.

- Software, reload parameters.
FE4073
Description: - Watchdog monitoring function is switched off.

FE4080, FE4081, FE4082, FE4083
Description: - Internal program error.

- Software, reload parameters.
FE4155, FE4160

02 Diagnostics
Error lists

Cause: - Internal monitoring.
FE4201
Description: - Internal error truck CAN.

Cause: - Initialization error of the CAN interface.
FE4203, FE4204, FE4205
Description: - Internal error truck CAN.

Cause: - Timeout of CAN messages from FPS, FZS, steering.
- Check CAN terminal to FPS, FZS, steering.
FE4208
Description: - Error antenna CAN.

Cause: - Timeout during frequency measurement from antennas.
- Check CAN bus of the antennas.
FE4209
Description: - Error transmitting via a CAN bus.

Cause: - CAN interface faulty or overloaded.
- Check CAN bus
FE4210, FE4212, FE4213
Description: - Error CAN communication during diagnosis, parameter access.

Cause: - Reset by turning the truck off and then on again.

Error lists
Rectification: - Parameters not available, control and diagnosis software do not match.
- Use current software.
.
FE4220, FE4230, FE4231 FE4232, FE4233
Description: - Monitor antenna CAN.

Cause: - Fault in antenna CAN.
- Check CAN bus
FE4240, FE4241, FE4242, FE4243
Description: - Monitor truck CAN.

Cause: - Fault in truck CAN.
- Check CAN bus
FE4250, FE4251, FE4252, FE4253

Cause: - Timeout of CAN messages from antenna 0..3.
- Exchange antenna, control system.
FE4255, FE4256, FE4257, FE4258

Reaction: Emergency stop, only with IZF automatic mode.
Cause: - Timeout initializing antenna 0..3.
- Check antenna CAN bus.
FE4259

Cause: - Timeout initalizing antennas.

02 Diagnostics
Error lists

FE4301, FE4302, FE4303, FE4304

Cause: - Checksum CAN message from antenna 0..3 invalid.
- Check CAN bus, antennas.
FE4310, FE4311, FE4312, FE4313

Cause: - Unknown message from antenna 0..3.
- Check antenna, software version.
- Antenna software, update control system.
FE4314, FE4315, FE4316, FE4317
Description: - Incorrect antenna signal.

Cause: - Antenna mode of antenna 0..3 is invalid with adjustment mode.
- Check antenna.
FE4318, FE4319, FE4320, FE4321
Description: - Wrong antenna mode.

Cause: - Antenna mode of antenna 0..3 is invalid.
- Check CAN bus, antenna.
FE4322, FE4323, FE4324, FE4325
Description: - Wrong antenna channel.

Cause: - Antenna 0..3 does not work on set channel.

Error lists
- Check antenna.
FE4326, FE4327, FE4328, FE4329
Description: - Error antenna distance digital.

Reaction: Emergency stop, only with IZF operating mode automatic and adjustment to wire,
and at a distance of < 10cm.
Cause: - Redundant antenna evaluation of antenna 0..3 is invalid.
- Check antenna.
- Exchange antenna.
FE4330, FE4331, FE4332, FE4333
Description: - Error antenna distance analog.

- Check antenna, adjust analog value for antennas.
- Wiring, check analog signal to IZF.
FE4334, FE4335, FE4336, FE4337
Description: - Error antenna current measurement.

Reaction: Emergency stop, only with IZF mode automatic and current measurement.
- Check antenna.
- Exchange antenna.
FE4338, FE4339, FE4340, FE4341
Description: - Error antenna status.

Cause: - Antenna evaluation of antenna 0..3 is invalid.
- Check antenna.
FE4351
Description: - Error antenna initialization.


02 Diagnostics
Error lists
Cause: - Antennas not initialized.

- Check antennas.
FE4352, FE4353

Cause: - Timeout during error interrogation.
- Check antennas, antenna CAN.
FE4355, FE4356, FE4357, FE4358
Description: - Error analog signal antenna 0..3.

Reaction: Emergency stop, only with IZF mode automatic and valid antenna distance.
Cause: - Antenna evaluation of antenna 0..3 is invalid (analog signal is outside 0.2V..4.9V.
Error antenna = 0.15V).
- Antenna, check analog signal.
FE4360, FE4361, FE4362, FE4363
Description: - Error analog signal antenna 0..3.

Cause: - Antenna signal of antenna 0..3 is invalid (analog signal is outside 0.1V..4.9V).
- Check antennas.
- Exchange antennas, control system.
FE4370, FE4371, FE4372, FE4373
Description: - Error antenna frequency mesaurement.

- Check antennas.
- Exchange antennas, control system.
FE4380
Description: - Frequency range invalid.


Error lists
Cause: - Guide frequency is outside admissible range (5000..12000kHz).

- Check frequency, antennas.
FE4381
Description: - Current range invalid.

Cause: - Guide current is outside admissible range (40..150kHz).
- Check frequency, antennas.
FE4382
Description: - Antenna number invalid.

Cause: - Internal error, antenna number 0..3 admissible.
- Exchange antenna.
FE4383
Description: - Software version of antennas invalid.

Cause: - Software version of antennas does not match IZF version.
- Check antennas.
FE4401, FE4402
Description: - Emergency stop distance of antenna drive side / load side too great (inside aisle).
Cause: - Truck parameters incorrect, speed too fast, distance value of antenna not OK, guide
wire not correctly laid, uneven floor.
Rectification: - Reset by switching truck off and on or disabling IZF.
- T ruck parameters, speed, distance value of antenna, guide wire, check uneven-
ness.
- Carry out teach-in, commissioning
FE4403
Description: - Emergency stop range exceeded (inside aisle).

Cause: - Tracking areas must not be left outside.

02 Diagnostics
Error lists
- Truck parameters, speed, distance value of antenna, guide wire, check uneven-
ness.
FE4404
Description: Adjustment range is not defined.

Cause: Internal error.
Rectification: Reset by switching truck off and on or disabling IZF.
Software, reload parameters.
FE4405
Description: Acceleration too great.

Cause: Speed depending on tracking progress has been exceeded.
Reload parameters.
FE4406
Description: Path exceeded while tracking on corners without guide wire.

Cause: Wrong parameters (max. path distance), incremental encoder faulty.
Reload parameters.
FE4407
Description: Max. antenna distances are limited by emergency stop distance, excessive angle
of truck relative to guide wire.
Cause: Incorrect parameters.
Reload parameters.
FE4408
Description: - Antenna distance from guide wire during cornering too great.
Cause: - Reset by switching truck off and on or disabling IZF.
Rectification: - Incorrect parameters.

Error lists
FE4410
Description: - Diagnosis function invalid.

FE4420
Description: - Selected antenna invalid.

Cause: - Selected antenna not connected, loose contact from antenna plug.
- Connection, check parameters.
FE4430
Description: - T ransfer of steering to IZF must not be requested while rail guidance signal is active.
Cause: - Selected rail guidance.
FE4450
Description: - Path distance to switchover between cornering / straight on travel exceeded.

Cause: - Path distance, incorrect pulse.
FE4461, FE4462
Description: - Emergency stop distance of antenna drive side / load side too great (outside aisle).
Cause: - Truck parameters incorrect, speed to fast, distance value of antenna not OK, guide
wire not correctly laid, uneven floor.
ness.

02 Diagnostics
Error lists
FE4463
Description: Difference between antenna distances is limited by emergency stop distance (out¬
side aisle).
Cause: Truck at excessively high angle relative to guide wire.
Reload truck parameters.
Carry out teach-in, commissioning.
FE4467
Description: Emergency stop range exceeded (outside aisle).

Cause: Wire recognition areas must not be left outside.
Truck parameters, speed, distance value of antenna, guide wire, check uneven-
ness.
Carry out teach-in, commissioning
FE4500
Description: Signal aisle recognition error can be acknowledged.

Reaction: None.
Cause: Internal message.
Rectification: Error is deleted with correct sequence of aisle recognition sensors.
FE4501
Description: Sequence of aisle recognition sensors invalid (outside - inside or inside - outside,
depending on status)
Reaction: Travel stop, creep speed possible with Q button depressed.
Cause: Problem with reflector, e.g.: Same reflector 2x in sequence, one reflector covered,
wrong reflector. Fault signal e.g.: Film which reflects the light barrier signal, light
beams. Incremental encoder faulty, light barrier faulty.
Rectification: Error is only deleted with correct sequence of aisle recognition sensors.
Check connection.
FE4502
Description: - Path monitoring of aisle recognition sensors invalid.

Cause: - Problem with reflector, e.g.: Same reflector 2x in sequence, one reflector covered,

Error lists
Rectification: - Error is deleted with correct sequence of aisle recognition sensors.

- Check connection, light barrier, reflector.
FE4503
Description: - Status of aisle recognition unknown.

FE4504, FE4505
Description: - Path monitoring of aisle recognition sensor "outside / inside aisle".

Cause: - Problem with reflector, e.g.: Same reflector 2x in sequence, one reflector covered,
FE4506
Description: Status change of aisle recogntion invalid, dependent upon aisle zone and travel
direction.
Cause: Problem with reflector, e.g.: Same reflector 2x in sequence, one reflector covered,
Check connection, light barrier, reflector.
FE4507
Description: Saved error from the aisle recognition area is active after reset of the IZF.
Cause: Error was not remedied before switching off.
FE4600
Description: - Error due to activated steering angle limiter(LWB).

Cause: - Checksum error LWB.

02 Diagnostics
Error lists
FE4601
Description: Steering angle too great for steering angle limiter (LWB).
Cause: T arget angle is outside the steering angle limiting angle.
FE4602
Description: Actuated LWB must be acknowledged by the steering unit.

Reaction: Travel stop, only with IZF automatic mode.
Cause: Problem with handshake between IZF and steering unit.
FE4603
Description: Unlocked and locked limit switch closed at the same time (hardware).
Cause: Incorrect connection, steering angle limiter switch.
Check connection, switch.
FE4604
Description: The internal status of the LWB does not agree with the limit switch positions (hard¬
ware).
Cause: Incorrect connection, steering angle limiter switch.
Check connection, switch.
Software, reload parameters, exchange control system.
FE4605
Description: - The internal status of the LWB is unknown.

Cause: - Incorrect connection, steering angle limiter switch.
- Software, reload parameters, exchange control system.

Error lists
FE4607, FE4608
Description: - Monitoring of time for closing / opening LWB exceeded.

Cause: - Incorrect connection, steering angle limiter switch, mechanical jamming.
- Check connection, switch, mechanism.
FE4609
Description: - Current steering angle > max. steering angle with LWB.
Cause: - Jamming.
- Check connection, switch, mechanism.
FE4704
Description: The travel direction determined from incremental encoder signals and actual travel
direction of the FPS must be in agreement.
Cause: Incremental encoder, FPS faulty.
Aisle recognition is incorrectly parameterized.
Check incremental encoder, connections, FPS.
FE4705

Cause: Error reaction must be known for every error
Exchange control system.
FE4707
Description: - The IZF must be shut down correctly when switching off. This is checked when
switching on.
Cause: - Voltage failure, control system defective.
- Exchange control system.

02 Diagnostics
Error lists
FE4708
Description: - Errors can not be internally stored.

- Exchange control system.
FE4710, FE4711, FE4712, FE4713
Description: - Monitoring the guide wire current from antenna 0..3 (inside aisle).
Cause: - In wire recognition status, the current measured by antenna 0..3 must not be 0.
- Ground short circuit, no guide wire current.
- Check antennas, connections, guide wire current.
- Carry outfield strength teach-in.
FE4714
Description: - Monitoring of transfer when IZF takes overguideance.

Cause: - When IZF takes over, the steering unit should signal acknowledgement.
Rectification: - Check steering unit, parameters, configuration.
FE4716
Description: Monitoring when the signal "Rail guidance" occurs with active IZF.
Cause: Incorrect parameters, configuration, wiring.
Rectification: Check parameters, configuration, wiring.
Reset by turning the truck off and then on again.
FE4717
Description: - Monitoring the difference between bogie angle (actual value potentiometer) and
steering angle (max 8°) transmitted by steering unit.
Reaction: Creep speed, only with IZF automatic mode.
Cause: - Incorrect actual value potentiometer, wiring, teach-in.
- Check actual value potentiometer, wiring.
- Carry out actual value potentiometer teach-in (steering unit and/or IZF)

Error lists
FE4718, FE4719
Description: - Monitoring the field strength (guide wire current) from antenna 1+2 / antenna 3+4.
Cause: - When in wire recognition status, the measured field strength must not drop below
1/3 of the set field strength for both antennas.
- Check field strength, guide wire current, antennas.
FE4720, FE4721, FE4722, FE4723
Description: - Monitoring the field strength (guide wire current) from antenna 0..3 (outside aisle).
Cause: - In wire recognition status, the field strength measured by antenna 0..3 must not be
0.
- Check antennas, connections, field strength.
- Check short circuit to ground, guide wire current.
FE4725
Description: - Monitoring the status "Adjustment to the wire" inside the aisle.
Cause: - When travelling inside the aisle, the antennas must be located near the guide wire.
- Check status aisle recognition, function of IZF.
FE4726
Description: - Monitoring speed on steering.

Reaction: Emergency stop, only when IZF is active.
Cause: - Monitoring the speed.
- Check the speed.
FE4730, FE4731, FE4732, FE4733, FE4734
Description: - Monitoring the steering angle limiter.

Cause: - Monitoring of time for opening /closing LWB.
- Monitoring of time during which no switch is tripped.
- Monitoring of time until end status of LWB is reached.
- LWV fails to open when switching on.

02 Diagnostics
Error lists
- After opening the LWB, the start status must be terminated.

- Check switch, mechanism, function.
FE4735
Description: - Monitoring of the maximum actual speed with wire recognition inside the aisle.
Cause: - Maximum speed has been exceeded.
- Check incremental encoder, reload parameters.
- Truck-specific: Readjust speeds in FPS.
FE4736
Description: - Monitoring the maximum actual speed without IZF.

Reaction: Display.
FE4737, FE4738, FE4739
Description: - Monitoring the maximum actual speed with IZF outside the aisle with opened LWB,
depending on wire recognition process.
FE4740, FE4741
Description: - Antennas 1+2/3+4 must be connected when they are used for adjustment.
Cause: - Antenna, wiring faulty.
- Check antenna, wiring, reload parameters.
FE4742, FE4743
Description: - Antennas 1+2 / 3+4 must measure field strength in adjustment area.
Cause: - No field strength, antenna or wiring defective.

Error lists

- Check field strength, guide wire current, antenna, wiring.
FE4744
Description: - Active frequency channel of antennas must agree with set frequency channel.
Cause: - Wrong parameter.
- Check parameter.
FE4745
Description: - Minimum software version of antennas is monitored.

Cause: - Incorrect antenna software version.
- Replace antennas.
FE4746, FE4747, FE4748, FE4749
Description: - Frequencies of channels of antennas 0 / 3 must agree with values of the IZF.
Reaction: T ravel stop, only with IZF automatic mode.
Cause: - Incorrect parameterization.
- Check set frequencies and standard frequencies, write frequencies and correct
standard frequency channel into the antennas again (teach-in or manually).
FE4750, FE4751, FE4752, FE4753
Description: - Field strengths of channels of antennas 0/3 must agree with values of the IZF.
Reaction: T ravel stop, only with IZF automatic mode.
Cause: - Incorrect parameterization.
- Check set field strengths, write field strength again into the antennas (teach-in or
manually).
- Check set frequencies and standard frequencies, write frequencies and standard
frequency channel into the antennas again (teach-in or manually).
FE4755, FE4756, FE4757
Description: - Main and monitoring processor of an antenna must have the same software status,
serial number, specification.
Cause: - Software status, serial number, specification are not identical.

02 Diagnostics
Error lists

- Exchange antenna.
FE4761
Description: - Monitoring the electronic circuit temperature in the IZF.

Reaction: Creep speed.
Cause: - Excess temperature.
- Leave IZF to cool off, check ventilation, ambient temperature.
FE4762, FE4763, FE4764, FE4765
Description: - Monitoring voltage levels: Ub, switched Uc, auxiliary voltage 14V, reference voltage
10V.
Cause: - Level above or below limiting value.
- Check voltage, exchange control system.
FE4766
Description: - Monitoring of voltage 6.5V for antennas (Pin 5+6).

Rectification:
FE4767, FE4768
Description: - Monitoring of 0V supply to outputs (Pin 29).

- Monitoring of 0V supply to the electronic system (Pin 1, 3, 8, 14, 17, 22, 31).
FE4769
Description: - Monitoring of D+ (Pin 2).


Error lists
FE4770
Description: - Monitoring of the power fail input.

FE4771, FE4772
Description: - Output motor LWB (Pin 32, 33) creating short circuit between Ub and 0V supply (Pin
29).
- Check voltage, motor, exchange control system.
FE4773
Description: Output motor LWB (Pin 32, 33) signalling excess temperature.
Cause: Level above or below limiting value.
Check voltage, motor, temperature, exchange control system.
FE4775
Description: Monitoring for minimum voltage when output motor LWB (Pin 32, 33) switched on.
FE4776
Description: Output motor LWB (Pin 32, 33) signalling excess temperature.
FE4778
Description: - Monitoring for minimum voltage when output motor LWB (Pin 32, 33) switched on.

02 Diagnostics
Error lists

- Check voltage, motor, temperature, exchange control system.
FE4784
Description: - Current monitoring max. 6A, when output motor LWB (Pin 32, 33) switched on.
- Check voltage, motor, temperature, exchange control system.
FE4786, FE4787, FE4788
Description: - Monitoring output Pin 25: Excess temperature, wire breakage, short circuit.
- Check temperature, connection, voltage, exchange control system.
FE4789, FE4790, FE4791
Description: - Monitoring output Pin 26: Excess temperature, wire breakage, short circuit.
- Check temperature, connection, voltage, exchange control system.
FE4793, FE4794, FE4795, FE4796
Description: - Monitoring of output Pin 32, 33 for overvoltage when output is switched on.
- Monitoring of output Pin 32, 33 for supply voltage when output is switched off.
- Check connection, voltage, exchange control system.
FE4798
Description: - Monitoring of the minimum software version of the monitoring processor.

Cause: - Software version is invalid.

Error lists
FE4801, FE4802, FE4803, FE4804
Description: - Diagnosis function: Adjustment of the steering angle potentiometer: Setting the
steering angle 0°, 90°, -90°, internal sequence.
Reaction: Immediate display.
Cause: - Malfunction during diagnosis.
- Repeat diagnosis function.
FE4810, FE4811
Description: - Diagnosis function mean value formation: Value range steering angle offset load
side, drive side travel direction
Reaction: Immediate display, only with IZF automatic mode.
FE4812, FE4813
Description: - Diagnosis function mean value formation: Value range mean distance load
side/drive side antenna, load side travel direction.
FE4814, FE4815
Description: - Diagnosis function mean value formation: Value range mean distance load
side/drive side antenna, drive side travel direction.
FE4816, FE4817
Description: - Diagnosis function mean value formation: Value range mean amount of distance
load side/drive side antenna, load side travel direction.

02 Diagnostics
Error lists
FE4818, FE4819
Description: - Diagnosis function mean value formation: Value range mean amount of distance
load side/drive side antenna, drive side travel direction.
FE4820, FE4821
Description: - Diagnosis function write steering angle offset: Write mean steering angle offset load
side / drive side travel direction.
FE4823, FE4824
Description: - Diagnosis function mean value formation (internal error).

FE4830
Description: Request for FZS cornering although cornering is not activated

Cause: Malfunction.
FE4831
Description: IZF is in cornering status although cornering is not activated.

Cause: Malfunction.
FE4832
Description: - IZF is in cornering status although aisle recognition is activated.


Error lists
Cause: - Malfunction.
FE4833
Description: - Steering angle limiter is active although IZF is in cornering status.

FE4834
Description: - Load side antenna emitting incorrect distance value during cornering.
FE4835
Description: - Auxiliary antenna emitting incorrect distance value during cornering.

FE4836, FE4837, FE4838
Description: - Frequency channel invalid during adjustment to load side / drive side / auxiliary
antenna.
FE4839
Description: Drop below limiting speed during cornering.

Cause: Malfunction.
FE4900
Description: - Error message of monitoring processor invalid.

Reaction: Immediate emergency stop.
Cause: - Control function of monitoring processor.

02 Diagnostics
Error lists

- If problem recurrs, exchange control system.
FE4901
Description: - Telegram request is not received simultaneously by the main and monitoring pro¬
cessor.
Reaction: Not an error.
FE4902, FE4903, FE4904, FE4905, FE4906

FE4907
Description: - Timeout during monitoring processor control function.

FE4908
Description: - Internal error. Undeletable error message

Reaction: Display.
FE4909, FE4910, FE4911, FE4912, FE4913, FE4914
Description: - Error reading in from the digital input 1..6.


Error lists
FE4915, FE4916, FE4917, FE4918
Description: - Error reading in from the analog input antenna 0..3.

FE4919, FE4920, FE4921
Description: - Error reading in analog input actual value potentiometer+/-, target value poten¬
tiometer.
FE4922
Description: - Monitoring of the analog GND signal.

FE4923, FE4924
Description: - Monitoring communication timeout with the main processor.

FE4924
Description: - Timeout monitoring communication with the main processor.

FE4925, FE4926, FE4927
Description: - Timeout of CAN messages from FPS, FZS, steering.


02 Diagnostics
Error lists

- Check CAN bus to FPS, FZS, steering. If problem recurrs, exchange control sys¬
tem.
FE4925, FE4926, FE4927
Description: - Timeout of CAN messages from FPS, FZS, steering.

- Check CAN bus to FPS, FZS, steering. If problem recurrs, exchange control sys¬
tem.
FE4928, FE4929
Description: - Timeout of angle/status messages from main processor

FE4930, FE4931
Description: - Internal error. Index of antenna invalid, messages from main and monitoring pro¬
cessor not identical.
Reaction: Immediate display.
FE4932, FE4933, FE4934, FE4935
Description: - Error antenna distance analogodigital.

Rectification: - Check antennas.
FE4936, FE4937, FE4938, FE4939
Description: - Analog signal of antenna 0..3 is invalid (analog signal is outside the admissible
range 0.1V..4.9V).

Error lists

Rectification: - Check antennas.
- Reset by switching the truck off and on again. If problem recurrs, exchange control
system.
FE4940
Description: - Max. antenna distances are limited by emergency stop distance, excessive angle
of truck relative to guide wire.
- Reload parameters. If problem recurrs, exchange control system.
FE4941, FE4942
Description: - Emergency stop distance of antenna drive side / load side too great.
Cause: - Control function of monitoring processor. T ruck parameters incorrect, speed too
fast, distance value of antenna not OK, guide wire not correctly laid, uneven floor.
ness.
- Carry out teach-in, commissioning. If problem recurrs, exchange control system.
FE4943
Description: - Emergencz stop range exceeded.

Cause: - Control function of monitoring processor. Tracking areas must not be left outside.
ness.
- Carry out teach-in, commissioning. If problem recurrs, exchange control system.
FE4945
Description: - Selected antenna invalid.

Cause: - Control function of monitoring processor. Selected antenna not connected, loose
contact from antenna plug.

02 Diagnostics
Error lists
FE4946
Description: T ransfer of steering to IZF must not be requested while rail guidance signal is active.
Cause: Control function of monitoring processor. Rail guidance active.
Connection, check parameters. If problem recurrs, exchange control system.
FE4948
Description: Steering angle too great for steering angle limiter (LWB).
Cause: Control function of monitoring processor. Target angle is outside the steering angle
limiting angle.
If problem recurrs, exchange control system.
FE4949
Description: Actuated LWB must be acknowledged by the steering unit.

Cause: Control function of monitoring processor. Problem with handshake between IZF
and steering unit.
Software, reload parameters. If problem recurrs, exchange control system.
FE4950
Description: Unlocked and locked limit switch closed at the same time (hardware).
Cause: Control function of monitoring processor. Incorrect connection, steering angle
limiter switch.
Check connection, switch. If problem recurrs, exchange control system.
FE4951
Description: - The internal status of the LWB does not agree with the limit switch positions (hard¬
ware).
Cause: - Control function of monitoring processor. Incorrect connection, steering angle
limiter switch.
- Check connection, switch.
- Software, reload parameters. If problem recurrs, exchange control system.

Error lists
FE4954
Description: - Current steering angle > max. steering angle with LWB.
Cause: - Control function of monitoring processor. Jamming.
- Check connection, switch, mechanism. If problem recurrs, exchange control sys¬
tem.
FE4955
Description: - Acceleration too great.

Cause: - Control function of monitoring processor. Speed depending on guide recognition
process has been exceeded.
FE4957
Description: - Signal aisle recognition error can be acknowledged.

Reaction: None.
Cause: - Control function of monitoring processor. Internal message.
Rectification: - Error is deleted with correct sequence of aisle recognition sensors. If problem
recurrs, exchange control system.
FE4958
Description: - Saved error from the aisle recognition area is active after reset of the IZF.
Cause: - Error was not remedied before switching off.
Rectification: - Error is deleted with correct sequence of aisle recognition sensors. If problem
FE4959, FE4960
Description: - Sequence, path monitoring of aisle recognition sensors invalid (outside - inside or
inside - outside, depending on status)
Cause: - Control function of monitoring processor. Problem with reflector, e.g.: Same reflec¬
tor 2x in sequence, one reflector covered, wrong reflector. Fault signal e.g.: Film
which reflects the light barrier signal, light beams. Incremental encoder faulty, light
barrier faulty.
- Check connection. If problem recurrs, exchange control system.

02 Diagnostics
Error lists
FE4961
Description: - Status of aisle recognition unknown.

Cause: - Control function of monitoring processor. Internal error.
- Check connection, light barrier, reflector. If problem recurrs, exchange control
system.
FE4964
Description: Status change of aisle recogntion invalid, dependent upon aisle zone and travel
direction.
Cause: Control function of monitoring processor. Problem with reflector, e.g.: Same reflec¬
tor 2x in sequence, one reflector covered, wrong reflector. Fault signal e.g.: Film
which reflects the light barrier signal, light beams. Incremental encoder faulty, light
barrier faulty.
Check connection, light barrier, reflector. If problem recurrs, exchange control
system.
FE4965

Cause: Control function of monitoring processor. Error reaction must be known for every
error
FE4967
Description: Errors can not be internally stored.

Cause: Control function of monitoring processor. Internal error.
FE4968
Description: - Monitoring of transfer when IZF takes overguideance.

Cause: - Control function of monitoring processor. When IZF takes over, the steering unit
should signal acknowledgement.

Error lists

- Check steering unit, parameters, configuration. If problem recurrs, exchange con¬
trol system.
FE4970
Description: - Monitoring when the signal "Rail guidance" occurs with active IZF.
Cause: - Control function of monitoring processor. Incorrect parameters, configuration,
wiring.
- Check parameters, configuration, wiring. If problem recurrs, exchange control
system.
FE4971
Description: - Monitoring the difference between bogie angle (actual value potentiometer) and
steering angle (max 8°) transmitted by steering unit.
Cause: - Control function of monitoring processor. Incorrect actual value potentiometer,
wiring, teach-in.
- Check actual value potentiometer, wiring.
- Carry out actual value potentiometer teach-in (steering unit and/or IZF) If problem
FE4974
Description: - Monitoring of the target speed with emergency stop at 0.

FE4975, FE4976
Description: - Monitoring processor expecting emergency stop from main processor.

FE4977
Description: - Monitoring the status (adjustment to the wire) inside the aisle.

02 Diagnostics
Error lists
Cause: - Control function of monitoring processor. When travelling inside the aisle, the an¬
tennas must be located near the guide wire.
- Check status of aisle recognition. If problem recurrs, exchange control system.
FE4978, FE4980
Description: - CAN communication: Overflow, send error.

- Check status of aisle recognition. If problem recurrs, exchange control system.
FE4981
Description: - Monitoring of target speed (depending on status of the IZF).

- Check Incremental encoder, parameters. If problem recurrs, exchange control
system.
FE4982, FE4983
Description: - Antennas 1+2/3+4 must be connected when they are used for adjustment.
- Check antenna, wiring, reload parameters. If problem recurrs, exchange control
system.
FE4985
Description: Monitoring of the distance ranges of the antennas in the adjustment mode on the
wire.
Cause: Control function of monitoring processor.
Check antenna, wiring, reload parameters. If problem recurrs, exchange control
system.
FE4986
Description: - Comparison of adjustment ranges of the main and monitoring processor.


Error lists

system.
FE4987
Description: - Antenna distance from guide wire during cornering too great.
system.
FE4988
Description: - Request for FZS cornering when cornering is not activated

- When cornering is not activated, IZF must not be in cornering status.
- T ruck may not be located in the aisle when cornering.
- LWB must be extended during cornering.
- Antenna must read out valid distance value during cornering.
- Limiting speed must not be exceeded during cornering.
system.
FE4989
Description: - Cornering status must be the same in main and monitoring processor.
system.
FE4990, FE4991
Description: - Status of sensor LWB locked/unlocked must be the same in the main and monitoring
processor.
- Check sensors. If problem recurrs, exchange control system.

02 Diagnostics
Error lists
FE4993
Description: - Speed stipulation of main processor (target value) is higher than that of the monitor¬
ing sensor.
FE4994
Description: Aisle recognition status must be the same in main and monitoring processor.
FE4995
Description: Switchover between standard and extended antennas must be the same in the
main and monitoring processor.
FE4996
Description: Selected frequency channel must be the same in main and monitoring processor.
FE4997
Description: Diagnosis function must be the same in main and monitoring processor.
FE4998
Description: - LWB status must be the same in main and monitoring processor.

Error lists

FE4999
Description: - Error writing a byte into the EEPROM


02 Diagnostics
Teach-in
Setpoint potentiometer traction/hy¬

draulic
IrGÜ
General
With this teach-in process, the values are stored
m/
in the travel and pump control system which are
img61200440/11m8
supplied by the traction setpoint potentiometer(1)
and the hydraulic system (2) on their minimum 1
and maximum actuation.
The diagnosis software WinMega is required (cf.
Diagnosis / Software / WinMega / Adjustments).

Diagnostics 02
Teach-in
Position sensor main lift >

General
|"j~l NOTE
Ifthe position sensor is exchanged, the max. lift

height altered, the travelandpump control sys¬
tem exchangedora resetperformed with CLEAR
EEPROM, a repeatedposition sensor teach-in
process is required. Otherwise the functional
characteristics of the truck willbe compromised.
During this teach-in process the values are stored

in the travel and pump controller which the main
lift position sensor delivers when the cab is low¬
ered or raised to the end stop position.
Together with the parameters defined during
commissioning (e.g. max. lift height, lower stop),
the FPS calculates the necessary values for start
and end of the ramp function, ramp speed etc.
If there has been no teach-in of the position sen¬
sor, the main lift can be performed at reduced ¡mg6120050004m2
speed without speed reduction before the me¬

chanical end stops. The speed has been set in
such a way that the mechanical end stops are not
damaged.
Function Reduced speed

T ravel 2.5km/h (P10)
Main lift up 50% or P60
Lower main lift 80% of P72
Prerequisites
• Setpoint potentiometer teach-in for travel /
hydraulics has been completed (cf. Diagnosis
/ Software / WinMega / Adjustments).
• The max. lift height (P30 Mast Top Pos) has
been set (cf. Diagnosis / Software / WinMega
/ Parameters).
• No intermediate lift stop is active.
• Gates closed.

02 Diagnostics
Teach-in
Commissioning
1 8
SERVICE mode and teach-in are performed via
the operating console.
NOTE
When lifting and lowering, always actuate the img61200440511m7
two-handbutton (9).
> ¡Actuate emergency stop| button (1). r

> Press button Q + 0 (2) and hold down, then
actuate button [o] (3) > for 2s (the symbol for
Lower appears in the display (5) and the ser¬ u m
vice symbol flashes (4)).

> ¡Release the emergency stop button|. /
5
> Continue to select Lower until the cab is fully
lowered (actuate lever (8) and button (9)).
> With lever (8) and two-hand button (9) actu¬
ated, press button [o] (counter is set to 0, lower n unnn
value is stored). The operating console gen¬
erates a cyclical acoustic signal. The symbol
nuu.u
for Lift is shown in the display with the target
position (6).
/
6
> Select Lift (actuate lever (8) and button (9)).
The cab lifts slowly and the current height is
f
displayed, during which the reference switch is
automatically registered. c
z 234J
> After registering the reference point, the cab 7
lifts at a higher speed. The max. lift height
(P30) is approached with ramp P51. 7 imgS1200440553m5
> When reaching the max. lift height, the up¬

per value is automatically stored. The display
returns to the normal mode. The teach-in
process is complete. Use button Q or Q (2) to
switch over between the height display in cm
(7) and the hours run counter.

Electric motor 11
Drive motor
General
Function >
The drive motor used in the vehicle is a 48V shunt
motor. The armature and field coils are regulated
separately by the travel and pump controller.
The travel movement is Initiated by applying volt¬
age to the armature and exciting the field. As
soon as the armature voltage is equal to the bat¬
tery voltage, the field current is reduced, in order
to increase the speed. The current speed of the
drive motor is determined by a current measure¬
ment (measuring shunt) in the travel and pump
controller.
Technical data
Type JULI GF 116-QS
Excitation
Shunt
method
Rated voltage 48 V
Rated output 3400 W
Rated speed 2400 r.p.m.
Protection class IP23
img61200440518ml

11 Electric motor
Drive motor
Terminals + - +
Main current terminals A1 A2 F1 F2
A1 - A2 (1, 2) Armature coil
F1 -F2 (3,4) Field coil
Sensors (5)
0V temperature sensor,
X1:1
supply
1+24V carbon brush
X1:2 monitoring
Carbon brush monitoring
X1:3
signal
X1:4 Temperature sensor signal + - - +
A1 A2 F1 F2
_§) [t_ img61200440519ml
irrn61200440520ml

Electric motor 11
Drive motor
Test
The drive motor has a temperature monitor and a
carbon brush monitor which are evaluated by the
FPS. The field and armature coils are also mon¬
itored by the FPS for short-circuits, overloading
and wire breakage.
Insulation protection test
A CAUTION
The converter andthe temperature sensorcan be

damagedduring testing of the insulation value.
All connecting leads to the drive motormust be
disconnected before the insulation test and the
temperature sensor must be short-circuited.
General
The insulation resistance of all coils against the
housing and the coils between each other must
be at least 1000Ü per volt at a direct voltage of
500V.
This gives the following insulation values:
• 24V trucks: 24kí >
• 48V trucks: 48kV
• 80V trucks: 80kfi
Preparation for the insulation protection test
> Disconnect all the connecting leads from the
drive motor.
> Release the push-in connection for the sensor
system.
> Short-circuit the temperature sensor at the

push-in connection with a wire jumper.
Test insulation value
> Connect the measuring device to the motor
housing with a test lead.
> Connect the measuring device to one coil ter¬
minal with the other test lead.
> Take the measurement.
> Repeat the measurement for the other coil
terminals using the same method.
If the measured values are higher than 1000n/V,
the insulation value is in order.
If one of the measured values is below the re¬
quired minimum value, the motor must be re¬
placed.

11 Electric motor
Drive motor
Repairs
Removal >
A WARNING
Once the drive motor has been removed, the
truck is no longer braked.
Before removing the drive motor, secure the truck
to prevent it rolling a way.
> Pull out the battery plug.

> Check the markings on the connecting cables
and mark them if necessary.
> Unscrew the connecting cables.
> Disconnect connector X1 to the carbon brush
yoke.
> Remove the magnetic brake (1).
> Release the 6 hexagon socket screws (2).
> Screw the eyebolt (4 ) into the shaft of the drive
motor.
> Thread the rope loop through the eyebolt (3)
and a lifting bar. img61200440540ml
img61200440539ml

Electric motor 11
Drive motor
> Lay the lifting baron the truck chassis. >

> With a strong jerk, lift the drive motor out of the
gear.
> Set the motor down in a position that ensures

the motor pinion is not damaged.
> Cover the opening in the gear with the protec¬
tive cover.
img61200440538ml
Installation >
To install, follow the removal instructions above
in reverse order.
> Lower the drive motor carefully into the gear
(7) with the lifting gear. Do not tilt the motor, to
prevent damage to the seal (5) and pinion (6).
> Screw the drive motor securely to the drive
plate with screws M8x25. iimg61200440541ml
> Push in or screw on all the electrical connec¬

tions.
> Put the truck into operation and check that it
functions properly.
img61200440542ml

11 Electric motor
Drive motor
Maintenance
Deadlines
Maintenance interval for drive motor: Every 1000
hrs or once a year.
Replacement of bearings: every 12000 hrs or on
every major overhaul.
Test >
A CAUTION
Risk ofshort-circuits andinjury.
Always unplug the batteryplug before carrying
out work on the motor.
Maintenance work between major overhauls

comprises:
• Cleaning: Remove the cover and take out
the brushes. Clean soiled accumulators and
brush unit (1) with a clean cloth moistened with
benzine (not cleaning wool) and dry well. Do
not lift the brush springs higherthan necessary
img61200440543m1
and do not bend them to the side. Blow out the
motor with compressed air (do not breathe in 1
the dust - use a protective mask). Check the
ventilation channels (2) at the gear to ensure
they are clean. Soiling has a detrimental effect
on the air circulation, which leads to raised
temperatures in the motor and can even cause
irreparable damage.
• Visual inspection: Check the field and arma¬
ture coils for signs of overloading (e.g. over¬
heating). Motors with overloading damage like
dark coloured, brittle or burned insulators and
unsoldered accumulators must be replaced
without delay. If you find oil or grease in the
motor (usually a paste consisting of oil mixed img61200440542m2
with dust and carbon abrasion), the cause

must be found and rectified at once.
• Changing damaged components: Only ever
use original spare parts (please see the spare
parts list).
• Checking the accumulator and brush unit: see
the section on carbon brushes.
• Bearings: The ball bearings do not need lu¬
bricating. The grease they are filled with is
sufficient to last between major overhauls.
Major overhauls to a motor should be carried out
by a specially equipped workshop, since special
tools and expertise are needed.

Electric motor 11
Speed sensor
General
Function
The speed sensor(1) is only mounted in trucks
fitted with the optional "Inductive wire guidance
(IZF)" or "Forced braking at end of aisle (ZAG)".
The following are evaluated:
• Travel path.
• Speed.
• Travel direction.
• Truck standstill.
If one of the control systems detects faulty speed
sensor signals, the truck goes to an error status. img6 1200440544m 1
The error status is displayed by an error code in

the operating console.
Terminals
The supply voltage and the sensor signals of the
speed sensor are guided via the block plug X12
(2):
Pin Wire Designation

X12:1 BR +24V supply voltage
Sensor signal channel 1,
X12:2 GN
(24V-switching)
Sensor signal channel 2,
X12:3 YE
(24V-switching)
X12:4 WH 0V supply voltage
Test
Supply voltage
> Disconnect connector X12 from the speed
sensor.
> Connect the voltage measuring device at
X12:1 and X12:4 of the connectorforthe speed
sensor.
> Take the voltage measurement.
The measured voltage should be approx. 24V.
If this is not the case, the supply voltage must be
checked.

11 Electric motor
Speed sensor
Output signals
Signal B
> Connect the voltage measuring device at the
connector of the speed sensor between pin 2
and pin 4 (channel 1).
> Take the voltage measurement, turning the Signal A
motor over slowly at the same time.
The voltage measurement should show a voltage
increase from OV to approx. 24V.
> Connect the voltage measuring device at the
connector of the speed sensor between pin 3 112_40116m1
and pin 4 (channel 2).

> Take the voltage measurement, turning the
motor over slowly at the same time.
The voltage measurement should show a voltage
increase from OV to approx. 24V.
If there is significantly less voltage or no voltage
applied, the speed sensor is faulty and must be
replaced.

Electric motor 11
Speed sensor
Repairs
Removal >
> Disconnect connector (2) from the speed sen¬
sor.
> Release screw (1).

> Pull the speed sensor out of its holder.
Installation
in reverse order.
img61200440544m2
> Secure the speed sensor with the screws. 1 2
> Connect the speed sensor.
functions properly.

11 Electric motor
Temperature sensor
General
Function
The motor temperature is measured by a tem¬
perature sensor (PTC resistor) integrated in the
carbon brush unit and is sent back to the con¬
verter as a voltage value. The converter supplies
the temperature sensor with a constant current
through connector (1). The higher the tempera¬
ture, the greater the resistance value of the tem¬
perature sensor, which consequently increases
the voltage drop through the PTC resistor.
If the motor temperature rises to >130°C, the mo¬
tor output is set to 50%, and then within 5 minutes
img61200440545ml
to 0% (EMERGENCY OPERATING MODE). The
error message " #$ appears on the operating
console and the maintenance display flashes.
Terminals
Pin Designation
X1:1 Temperature sensor (0V)
X1:4 Temperature sensor (+)
Test
> Separate plug connection X6 at the travel and
pump controller.
> Perform a resistance measurement at the

pulled off plug X6 between pins X6:2 and X6:4.
> Measure the temperature at the motor hous¬
ing.
> The measured values must be the same as the
values in the table ±20i2.
T/°C R/fI
27 600
130 1200

Electric motor 11
Temperature sensor
Repairs
The temperature sensor is part of the carbon
brush bridge. In case of faults, the carbon brush
bridge must be replaced.

11 Electric motor
Carbon brush
General
Function >
The rotating armature is supplied with power by 4
carbon brushes via the commutator (2).
The carbon brushes are monitored by 4 normally
closed contacts which are connected in series.
The FPS supplies the carbon brush yoke with +24
V via connector (1). As soon as a carbon brush
is worn down, the signal is interrupted and the
information reported to the FPS.
The error message " %$ appears on the operat¬
ing console and the maintenance display flashes.
After 10 hours, a travel stop is initiated.
img61200440543m2
img61200440545ml
Terminals
Pin Designation
X1:2 Supply (+24V)
X1:3 Carbon brush signal (24V=ok)
Technical data
Length when new 40 mm
Residual length (wear
20 mm
limit)

Electric motor 11
Carbon brush
Test >
> Remove the cover cap and clean the brush
unit if necessary.
> Check the accumulator: The running surface
of the accumulator should be evenly smooth
with a grey-black appearance. The accumu¬
lator must not be worn down, ridged or out
of round. If it has any of the above charac¬
teristics, the accumulator must be reworked
(basic overhaul). Never work on it with afile,
emergy paper or similar equipment. Rapid
wear to the carbon brushes or the accumula¬
tor is usually caused by the effects of oil. The img61200440543ml
oil/grease burns in the brush sparks, leaving a
sharp-edged ash that has an abrasive action.
Consequently, the brushes can wear down fur¬
ther than permitted before the next scheduled
maintenance date.
> Remove the carbon brushes one by one in
sequence. Do not lift the brush springs higher
than necessary and do not bend them to the
side.
> Length of the carbon brushes: Check the
length and replace if necessary. Always re¬
place the entire set of carbon brushes. The
shortest carbon brush should be taken as the
basis for assessment. If the minimum length
has not quite been reached yet, the brushes
should still be replaced, as the remaining ser¬
vice life may be shorter than the interval to
the next scheduled inspection. Never replace
more than 3 sets of carbon brushes in suc¬
cession. After 3 sets have been changed, the
motor must undergo a basic overhaul (at a
specialist workshop).
> If the free brush spring now activates the signal
contact, an error message should be displayed
on the operating console when the truck is
switched on.
> Checking the carbon brush unit: After the car¬
bon brush unit has been cleaned, it should be
easy to move the carbon brushes in their guide
when the spring is raised. If one or more car¬
bon brushes jam, they must on no account be
worked on with emergy paper or similar equip¬
ment. In this event, the entire carbon brush
unit must be replaced, as there is a possibility
that the carbon brushes have been thermally
overloaded. The carbon brushes must not be
broken or bent at the running edges. When

11 Electric motor
Carbon brush
inserting the carbon brushes, do not allow the

carbon brush springs to knock on them.
Repairs >
Removal
> Remove the cover cap.
> Remove the carbon brushes. Do not lift the
brush springs higher than necessary and do
not bend them to the side.
> Cleaning: Clean soiled accumulators and

brush unit (1) with a clean cloth moistened with
benzine (not cleaning wool) and dry well.
Installation
¡mg61200440543m1
> Insert the carbon brushes and connect. Do not

allow the brush springs to knock against the
carbon brushes as you insert them.
Test
> It should be easy to move the carbon brushes
in their guide when the spring is raised.
> Let the carbon brushes run in at a low motor
speed.
Maintenance
Deadlines
Maintenance interval:Every 1000 hrs or once a
year.
Test
• Cleaning.
• Replacing worn or damaged carbon brushes.

Electric motor 11
Forced ventilation
General
Function >
The forced ventilation (1) for the drive motor runs
as long as the truck is switched on and the main
contactors have picked up. A fault or soiling can
cause the temperature monitorforthe drive motor
to respond.
img61200440540m2

11 Electric motor
Forced ventilation

_ Mechanical drive axles 22
Spur-bevel gear
General
Description
img61200440090ml
1 Gearbox housing 7 Drive pinion

2 Air vents for venting the drive motor 8 Housing cover
3 Sprocket for steering 9 Oil top-up screw and oil level control
4 Steering pinion 10 Oil drainage screw
5 Bogie bearing
6 Wheel shaft with centering and contact
surface for load wheel

Spur-bevel gear
Identification
• Gearbox: GK20
The gearbox type (1 1) is cast into the gearbox-
housing on the side of the bearing cover.
The rating plate (12) is mounted on the side of the
gearbox housing.
The gearbox type (13) and transmission ratio (14)
are indicated on the rating plate.
img61200440091ml
21- jw'TH
iCR-H'l 07
4699 803 qqi
img61200440092ml

o¿##£cíe~ Mechanical drive axles 22
Spur-bevel gear
Test
Checking the gear oil level
> Open the oil filler cap (1).
> Remove the oil filler cap (2) and sealing ring.
The correct oil level and the correct oil volume is
reached when the oil level is at the lower edge of
the oil filler cap (3).
> Screw in the oil filler cap with a new sealing
ring. Tightening torque: 22Nm
img61200440094m2
Checking the tooth profile play

The tooth profile play must be checked as follows:
> Measure the tooth profile play at the narrowest
point of the teeth with a suitable feeler gauge
(6).
If the tooth profile play is more than 0.3 mm, the
steering pinion and the toothed gear ring in the
gear must be replaced.
NOTE
Experience has shown that the teeth do not wear

down evenly over the course of time, but rather
that a recess tends to form. The consequence is
noise during steering that becomes increasingly
louder. img61200440096ml
When the steering noises are too loud, the steer¬ 6

ing pinion and toothed gear ring in the gear must
be replaced. 4 Toothed gear ring
5 Steering pinion
6 Tooth profile play

Spur-bevel gear
Repairs
Removing the gear >
A WARNING
Before the gear (1) can be removed, the drive
motormust first be removed. Once the drive
motor has been removed, the truck is no longer
braked.
Before removing the drive motor, secure the truck
to prevent it rolling a way.
> Raise the truck by about 5.. 10 mm with a jack ¡mg61200440542m3

and chock it up with wooden blocks.
> Remove the bumper.
> On trucks with inductive guidance, the antenna
holder must be removed.
> Remove the drive motor.
Pfl NOTE
Depending on what work you have planned, ei¬
ther drain offthe gear oil or cover the gear open¬
ing with the protective cover.
> Unscrew the 6 gear screws (2).

> Pull the gear (1) out under the motor plate,
together with the drive wheel.
> Suspend the gear from a taut rope or chock
it up with wooden blocks to prevent the gear
tilting to one side.
Installing the gear

T o install the gear, follow the removal instructions
above in reverse order.
functions properly.

o¿##£cíe~ Mechanical drive axles 22
Spur-bevel gear
Drain off the gear oil
NOTE
The gear oilmust be drainedoff while itis warm,
i.e. at operating temperature. The maximum
permissible operating temperature is 80 °C.
> Drive the truck onto a level surface.

> Clean the area of the oil filler cap and oil
drainage screw (6,7) thoroughly.
> Set an oil catchment vessel (8) with a volume -J
of at least 4 litres underneath the oil drainage
screw.
ENVIRONMENT NOTE
Do not letthe oilrun into the ground or the waste
water system.
> Unscrew the oil filler cap (6).

> Remove the oil filler cap and sealing ring (9).
img61200440093ml
A WARNING
When the gear hasbeen in continuous operation,
you should expect the oil to have reacheda hig¬
her temperature.
Use temperature resistantgloves.
> Release the oil drainage screw (7).

> Remove the oil drainage screw and sealing
ring (10).
> Allow the gear oil to drain off completely into
the oil catchment vessel.
NOTE
Allow an oil drainage time ofat least 5minutes.

Spur-bevel gear
Filling up the gear oil

> Clean the magnet at the oil drainage screw
(1 1) and insert it again, always using a new
sealing ring (12). Tightening torque: 22 Nm.
> Fill up with gear oil.
ffl NOTE
Use a suction andpressure syringe (13) for filling
up the oil. This is a simple and fast method of
filling the gear with oil.
The correct oil level and the correct oil volume is

reached when the oil level is at the lower edge of
the oil filler cap (14).
> Screw in the oil filler cap with a new sealing
ring (15). Tightening torque: 22 Nm.
ENVIRONMENT NOTE img61200440093rr>3
Remove any oilthat has overflowed with a suit¬

able oilbinding agent.
lmg61200440094ml

Mechanical drive axles 22
Spur-bevel gear
Removing the bogie bearing and toothed >

gear ring for the steering
> Remove the gear.
> Release the hexagonal screws (16).
[f] NOTE
The screws (17) in the oilchamber of the gear
are covered with L OCT/TE243. Forremovalpur¬
poses and for subsequent use of these screws,
the L OCTITE remnants must beremovedfrom
the thread or, preferably, newscrews shouldbe
used.
> Remove the bogie bearing (18) and toothed

gear ring (19) for the steering.
img612004.40095ml

Spur-bevel gear
Mounting the bogie bearing andtoothed gear >

ring for the steering
• The centring and mounting surface for the
toothed gear ring must be clean.
• It must not be possible for foreign particles
or cleaning agents to penetrate through the
threaded holes (20) into the inside of the gear.
> Lay the toothed gear ring for the steering (21)
in position and turn it so that the screw holes
in the toothed gear ring are lined up with the
threaded holes (20).
> Knock the toothed gear ring into place with a
rubber mallet.
> Set the bogie bearing (22) in place right side
up, and turn it so that the screw holes in the
bogie bearing are lined up with the pattern of
holes in the toothed gear ring and housing.
A CAUTION
Always sealthe screws (20) that are in the oil
chamber of the gear.
img61200440095m2
Smear these screws with L OCTITE243 before
inserting them.
> Use the hexagonal screws (23) to screw the

bogie bearing and toothed gear ring to the
gear housing. In orderto prevent inadmissible
fluctuations in screw tension, always tighten
the screws diagonally in several passes to the
prescribed tension of 34 Nm.
Install the gear

Mechanical drive axles 22
Spur-bevel gear
Maintenance
Maintenance interval
• The gear must undergo maintenance every
1000 operating hours or every 6 months.
• The gear oil must be replaced every 2000 op¬
erating hours or once a year.
Maintenance work
> Visual inspection for signs of damage.
> Visual inspection for leaks.
> Visual inspection for loss of oil at the gear oil
level inspection point.
> Checking the gear for noises.
> Checking the gear oil level and topping up if
necessary.
> Lubricating the steering pinion and toothed
gear ring with multi-purpose grease.
Gear lubricants
Oil types
Only oil types which meet the following specifica¬
tion are permitted:
• Classification in acc. with API-GL5.
• Classification in acc. with MIL-L-2105C/D, test
form A (scuffing test), test form C (long-term
wear test).
• SAE class 80W-90, further SAE classes are
based on the ambient temperature.
Lubricants
Permissible lubricants in accordance with:
• ZF lubricant list TE-ML 05
• ZF lubricant list TE-ML 07
Oil filling volume
Total oil volume for gear (GK20): 2.2 litres

22_ Mechanical drive axles_
Spur-bevel gear

Steering system 42
Electrical steering
General
Block diagram
imgS1200440502m1
1 Steering angle display 5 Actual value potentiometer

2 Steering wheel /Target value potentiometer 6 CAN bus
3 Travel and pump controller 7 Reference switch
4 Steering unit (steering control unit, motor,
gearbox)

42 Steering system
Electrical steering
Identification >
The steering is a fully electric ring gear steering
consisting of the following components:
• Steering unit with gearbox (1).
• Actual value potentiometer (2).
• Ring gear (3).
• Steering wheel with target value potentiome¬
ter.
In addition, the truck can be equipped with an
inductive or mechanical wire guidance.
ill NOTE
Steering white standing still will result in in¬

creaseddrive wheel wear! A void excessive
steering during standstill!
img61200440501m!
Function >
When the truck is switched on, the steering is ac¬
tivated immediately on condition that the steering
has not detected any errors during the self-test
carried out after switching on. Errors are dis¬
played on the display in the form of error codes.
By turning the steering wheel a target value
change is generated which is compared with
the actual value in the steering logic. In case of a
difference between target and actual value, the
power module will actuate the motor in order to
compensate the target/actual value difference.
¡mg61200440505m1
The steering logic will receive the information
"T ruck moving/standing" via the CAN bus. During
standstill, Imax = 37A is only possible during the
first 3s following detection of a difference; the
current will then be limited to I = 8A. The drive
wheel position is transmitted via the CAN bus to
the FPS which uses this information to actuate
the steering wheel display via the CAN bus.
If during operation an error in the steering system
occurs, the "Steering OK signal" is switched off
(hardware and CAN bus, redundant). The FPS
immediately causes regenerative braking down
to standstill with deadman delay. At the same
time, travel is blocked. On the display error code

Steering system 42
Electrical steering
(self-extinguishing) or will ap¬
pear.
The steering unit incorporates an incremental
encoder. This is referenced every time the truck
is switched on. This reference position is adopted
as straight-on position.
The actual value potentiometer determines the
current position of the drive wheel, and the drive
wheel is turned roughly into the straight-on po¬
sition. The reference switch (1) at the pivoted
bolster is overrun at reduced speed allowing the
exact position to be transferred at the switching
point.
Steering unit
General
Identification
The steering unit includes:
X49/G X48/C X50/L
• Electronic control system with integrated
power module (1)
• Carbon-brushless synchronous motor with
permanent magnet (2)
• Gearbox (3)
It represents one unit and can only be exchanged
completely.
Technical data
• Type: SL 062-Z1 MHi OOMJiM
• Cyclo gearbox (i=71)

• Voltage: 48V DC
• Speed: 2400rpm
• Output: 500W
• Protection class: IP54
• Insulation class: F
• Steering speed: approx. 727s -> approx.
2.5s/1 80°
img61200440503ml

42 Steering system
Electrical steering
Terminals
Pin assignment, 16-pin connector X47
+48V via main contactor steering
1-4
(power supply)
5-7 OV power supply
8 OV control unit mg61200440506ml
9 n. c.
10 48V supply control unit (UBatt)
1+48V, release steering via key- X48/C
11
operated switch
12 Output "steering OK" (OV active=OK)
13-16 n. c.
Pin assignment, 4-pin plug X48/C

1 CANJH
2 CAN_L
3 1+24V
4 OV
Pin assignment actual value potentiometer, 6-pin

plug X49/G
1 + 12V img61200440507ml
Actual value main potentiometer 6V

2
+-2.5V
3-5 n. c.
X49/G
6 OV
X50/L
Pin assignment target value potentiometer, 6-pin
plug X50/L
1 + 12V
2 Target value main potentiometer
3 n. c.
Target value check potentiometer,
4
90°phase offset
5 n. c.
6 OV
ig6 1200440509m!
Software versions
Version File Remark
Main processor 4.51 Elk451dl.bin Production start 04/2004
Monitoring processor 4.51

Steering system 42
Electrical steering
The steering will be updated using the Winflash
software. The notebook is connected to the CAN
bus diagnostic link.
This allows an update of the main processor. In
order to update the monitoring processor to a
higher version, the complete steering unit must
be replaced!
Test
Test procedure
Testing can only be performed in installed and
connected condition (self-test, functional test).
The diagnostic software offers additional help.
Repairs
Removal >
> Jack up the truck and secure it to prevent it
rolling away.
> Mark the electrical connections (1) and discon¬
nect them.
> Release the lock on the connector (2) by hand
and pull the connector out of the actual value
potentiometer.
> Remove the torque support (3) for the actual
value potentiometer.
> Release the 4 screws M10x45 (4).
> Lift the steering unit up and off and lay it to one
side.
imgS1200440501 m2

42 Steering system
Electrical steering
Removal >
Once the complete steering unit has been re¬
moved, the actual value potentiometer and the
gearwheel can also be removed.
> Release the 4 screws M4x16(1) and pull off
the planetary gear (2).
> Release the retaining washer (3) and screw
(4).
> Pull off the gearwheel (5) from the gear shaft
(6) using an extraction tool.
> As required, the actual value potentiometer
can be unscrewed from the planetary gear
(2) with the steering unit either installed or
removed.
Installation
Installation is carried out in the same way but in
the opposite orderto the removal process.
Potentiometer setting: see steering unit/installa¬
tion.
img61200440504m1

Steering system 42
Electrical steering
Installation >
To install the complete steering unit, follow the
removal instructions above in reverse order. Ob¬
serve the following points:
> Before the complete steering unit is inserted in
the holder (5), the drive wheel must be turned
by hand exactly to the straight-on position.
> The actual value potentiometer mounted on
the steering unit must be set to the straight-on
position while the steering unit is removed.
This is done by turning the gear shaft of the
steering wheel at the gear wheel. The poten¬
tiometer must be held in the position of the final
installation position. For this purpose, make
a resistance measurement between pins 1
+ 2 and pins 1+5 of the actual value poten¬
tiometer. Both measurements must result in
the same value (approx. 1325Í!). The differ¬
ence between the two values must amount to
no more than 50fi, otherwise an error will be
detected during switch-on or teach-in.
> Lower the pre-set steering unit carefully into img61200440501m2
its holder (5) and secure with the 4 screws
M10x45 (tightening torque 46Nm).
> Mount the torque support (3) for the actual
value potentiometer.
> Reconnect all the electrical connections.
> Put the steering unit into operation using the
diagnostic software (see Parameterization).
> For inductive wire guidance: Activate option
"IZF" in the steering unit, perform "teach-in
actual value potentiometer" in the IZF (refer to
IZF/Commissioning).
img6 1200440546ml

42 Steering system
Electrical steering
Setting the parameters >

» +/-20cm
> A newly installed steering unit must be con¬
figured with the diagnostic software "Paradi-
gELK" on a truck-related basis, or a stored
vehicle-related file is loaded into the control
system (e.g. operating console variant, option
inductive wire guidance).
> Perform teach-in of target and actual value po¬
tentiometer using diagnostic software "Paradi-
gELK".
> Use the parameter

to correct the straight-on position. The truck
must be aligned parallel with a straight line (1).
Then travel a distance of approx. 10 m. If the
truck moves in a curve and travels sideways
(2) or (3) or deviates from the ideal line, the
parameter must be changed until the deviation
in both directions is <20cm (in particular with
inductive wire guidance).
> After commissioning, store the current pa¬
rameters in a file (e.g.: File name = vehicle
number).
Function test
When the truck is switched on, the steering is ac¬
tivated immediately on condition that the steering
has not detected any errors during the self-test
carried out after switching on. Errors are dis¬
played on the operating console in the form of
lmg61200440S66m1
error codes.
Maintenance
Deadlines
The steering system is almost maintenance-free.
> Lubricate ring gear and gearwheel annually
as part of the maintenance using general-pur-
pose grease.

Steering system 42
Electrical steering
Setpoint potentiometer
General
IT] NOTE
The potentiometer andthe check function are
identicalto the actual value potentiometer.
Identification >
The setpoint potentiometer (1) can be accessed
after removing and opening the operating con¬
sole housing.
Function
The required steering direction is specified with
the setpoint potentiometer. The potentiometer
has a 2-channel design. It generates 2 setpoint img61200440508ml
signals that have a phase offset of 90° (main and
control potentiometers). Both setpoint signals
are evaluated by the steering logic (redundant
safety). When switching on, the current steer¬
ing wheel position is adopted as the straight on
position, the drive wheel automatically turns to
"straight on". With each revolution of the steering
wheel, the drive wheel turns 30 or 45 degrees
(can be adjusted using the diagnosis software).
The steering wheel has no mechanical stop. If
the steering wheel is turned further, the maxi¬
mum steering angle is limited to ±95° by the ac¬
tual value of the steering unit. When turning back
again from an end position, the current steering
wheel position is immediately adopted as the tar¬
get value. There is no dead band.
An optional steering handle (UPA) with mechan¬
ical stop and central locking position is available.
After switching on and completion of a reference
cycle, the drive wheel turns to the current position
of the steering handle.
Terminals >
Target value, main potentiometer
1
appr. 1-11V
2 Supply +12V
5 Supply 0V
Target value, control potentiometer
6
appr. 1-11V
img61200440546m2

42 Steering system
Electrical steering
Test
Test procedure > v*
12
In case of a defect in the setpoint potentiometer,
an error message appears at the operating con¬
sole.
When mounted, the diagnosis software can be
used to test the following values:
• T arget value signal from the main / control 180° (p
potentiometer. img61200440551m1
• Potentiometer current consumption.

• "Sychronous running" between the main /
control potentiometer, i.e. parallel increase/re¬
duction of the two target value voltage levels.
When not mounted, a resistance measurement
can be performed. The main/control potentiome¬ 200Q
ter have a zero crossing when offset by 90°
• Total resistance between pin 2 + 5.
• Resistance measurement between pin 1 + 2 / img61200440552ml
pin 1 + 5 of the main potentiometer.

• Resistance measurement between pin 6 + 2 /
pin 6 + 5 of the control potentiometer.
• Carry out ohmic alignment of the main po¬
tentiometer between pin 1 + 2 and pin 1+5.
The progression of the resistance value is
non-linear due to parallel switching of the main
/ control potentiometer.
Technical data
Power supply pin 2 +12V
Power supply pin 5 OV
Target value signal from the main / control potentiometer. appr. 1-11V
Current consumption appr. 6mA
Total resistance 1900ft ±15%
Wiper resistance of main / control potentiometer. appr. 200-1700V
Wiper resistance at centre of main potentiometer appr. 1325V

Steering system 42
Electrical steering
Repairs
Removal >
> Raise the mechanical locking mechanism (2),
pull off plug X1 (1).
> Release the 4 screws (3).
> Remove the potentiometer (4).
Installation
pf] NOTE
5 4 3 2 1
img61200440508m3
Ensure that the seating ring (5) is correctly

mounted.
> Plug the potentiometer onto the free stub shaft.

While doing so ensure that the potentiometer
shaft is aligned with the stub shaft.
> Fasten potentiometerwiththe4screws(3).
> Insert the plug X1 (1).
> Carry out the teaching-in process with the di¬
agnosis software.
Settings
The steering force is set permanently (working on
the principle of friction). There is no mechanical
adjustment work to be carried out.
Setting the parameters

The potentiometer is set during teaching-in using
the diagnosis software.
Actual value potentiometer

General
Function
m note
The potentiometer andthe check are identical
with the target value potentiometer.
The actual value potentiometer (1) is used to

determine the position of the drive wheel. The
transmission (2) connects the potentiometer with
the steering unit (3) (transmission ratio steering
unit: potentiometer = 4 : 1). The potentiometer
itself is 2-channel, i.e. it generates 2 actual value
signals; however, only the signal of the "main imp6 1200440505m2
potentiometer" will be evaluated in the steering 3 1 2
unit. In order to ensure redundant safety, the

42 Steering system
Electrical steering
actual value potentiometer is compared with the
signals of the internal incremental encoder of the
steering unit.
Terminals
Actual value main potentiometer

1
approx. 1-11V
2 Supply +12V
5 Supply 0V
Actual value check potentiometer
6
(n.c.)
¡mg61200440546m2
Test
Test procedure Mik
In case of a defect in the actual value potentiome¬
ter, an error message appears at the operating
console. i
i
When mounted, the diagnosis software can be
used to test the following values:
• Actual value voltage from the main poten¬ -180° -90°
-
'''
ÿ
180°
i
(p
tiometer. img61£00440SS1ml
• Potentiometer current consumption.

When not mounted, a resistance measurement
3KQ
can be performed. The main/control potentiome¬
ter have a zero crossing when offset by 90°
• Total resistance between pin 2 + 5.
3KQ'
• Resistance measurement between pin 1 + 2 /
pin 1 + 5 of the main potentiometer.
• Resistance measurement between pin 6 + 2
imgS1200440552ml
/ pin 6 + 5 of the control potentiometer (not in
use).
• Carry out ohmic alignment of the main po¬
tentiometer between pin 1 + 2 and pin 1+5.
The progression of the resistance value is
non-linear due to parallel switching of the main
/ control potentiometer.
Technical data
Power supply pin 2 +12V
Power supply pin 5 OV
Target value signal from the main / control potentiometer appr. 1-11V
Current consumption appr. 6mA

Steering system 42
Electrical steering
Total resistance 1900Í2 ±15%

Wiper resistance of main / control potentiometer appr. 200-1700V
appr. 1325Q (set symmetri¬
Wiper resistance at centre of main potentiometer
cally, max. difference 50L!)
Repairs
Removal
> Lift mechanical lock, pull off plug X1 (1).
> Carefully pull the potentiometer parallel down¬
wards.
!004u40505m3
Installation
NOTE
Ifthe steering unithas not been removed, the
following process is normally sufficient, ifthe
main potentiometer is not ohmicaiiy centraldue
to the tolerance at STRA/GHT-ON, the steering
unitmust beremovedandrealigned.
> T urn drive wheel to straight-on position.

r\4iac-=4 Enotm/
> Check the seat of the sealing ring (5)
> Push the potentiometer onto the stub shaft
(3). Ensure that the potentiometer shaft (6) is
aligned with the stub shaft.
> Fasten potentiometerwiththe4screws(4).
> Attach plug X1 .
> Carry out the teaching-in process with the di¬
agnosis software.

The potentiometer is set during teach-in using
the diagnosis software.

42 Steering system
Electrical steering
Reference switch
General
Function
The reference switch (2) is only used to perform a
reference cycle for straight on travel when switch¬
ing on.
The reverence switch is half covered in the
straight on position by the switching curve (1) at
the bogie.
Test
Test procedure
• The operating distance sensor (2)- index cam img6 12004d40505m4
(1) must be approx. 1mm.

• LED (3) must light up when the reference
switch is switched on.
• In the service software, menu

,the current supply
and the switching signal of the reference
switch are displayed.
• The power supply of the actual value poten¬
tiometer also supplies the reference switch. In
the field

, the current is increased
from approx. 11mA to 15mA when the refer¬
ence switch is enabled.
• In the field

, the voltage
is increased from approx. 0.5V to 8V when the
reference switch is enabled.
Repairs
Removal
> Unplug plug connector (3).
> Release locknut.
> Unscrew reference switch (2) by turning.
Installation
A CAUTION
Danger ofshearing off!
img6 12004d40505m4
Do not screw reference switch too far when in¬
stalling. 1 2 3
> Bring drive wheel in straight-on position.

Steering system 42
Electrical steering
> Check whether target is underneath the

mounting hole of the reference switch.
> Screw in reference switch by turning it.
> Adjust switching distance to the target by turn'
ing the reference key to 1mm.
> Moderately tighten the locknut.
> Plug in the connector plug.
> Functional testing will be performed automati¬
cally during switch-on.

42 Steering system
Electrical steering

Mechanical guidance 43
Guiding elements
General
Function
Trucks with mechanical guidance are guided in
their longitudinal axis via two guide rollers in¬
stalled on each side.
Correctly adjusted straight-on travel of the steer¬
ing system is a condition for trouble-free opera¬
tion.
Test
Test procedure
Í NOTE
In accordance with the generalstipulations, play

of the truck guidance between the guide rails
must be between 0 and +5mm.
> Check the mechanical fastening of the guid¬

ance elements.
> Check that the rollers are running easily.
> The running surfaces must be undamaged.
Uneven or non-concentric wear and an insuffi¬
cient diameter must not impair guidance.
New roller diameter: 125mm
Wear limit: 120mm
Repairs
Setting
The guide elements are factory-set to the spec¬
ified width. The guidance tolerance of the truck
between the guide rails must be set by adding or
removing shims (cf. Spare Parts Catalogue).
Service Training - W8 054 356 EN - 06/2005 43-1

Aisle recognition
General
Function
ffi NOTE
The "aisle recognition" option ( !"
!# $%) must be configured using the
diagnosis software in the travelandpump con¬
troller.
Aisle recognition is activated when traveling into

the rail guidance. As soon as a light sensor for
aisle recognition is actuated, the two green LEDs
flash in the operating console (2). Steering is
still possible and the yellow LED (1) for manual Img61200441027ml
steering is ON.
When the second light sensor for aisle recogni¬
tion is actuated, both green LEDs light up (2).
The signals are evaluated on a redundant basis
in the FPS.
If the steering angle is <5°, the request
"STRAIGHT" is issued to the steering system via
the CAN bus. This automatically sets the drive
wheel to "STRAIGHT ON" and acknowledges
execution to the travel and pump controller. From
this moment, 2-hand operation is required. The
yellow LED (1) for manual steering is OFF.
In trucks with steering wheel, on aisle exit the
current steering target value is automatically
adopted as "STRAIGHT ON", the truck always
travels out of the aisle with "steering target value
0°". Target value changes in the aisle do not exert
any influence.
In trucks with steering handle, the truck is brought
to a standstill within an aisle if the steering target
value from the steering wheel does not signal
"STRAIGHT ON" (central locking position).
Test
Test procedure
> Actuate both light sensors.
> Set the steering angle (actual value) <5°.
> Check automatic straight-on positioning of
the steering and the demand to use 2-handed
control.
If this does not function:
> Test the signals with the onboard diagnosis
(menu 25).

Mechanical guidance 43
Aisle recognition
> Using the diaganosis software, check the

travel and pump controller to see whether
by switching the two light sensors the signal
"aisle recognition" ( !"! ) is activated in
the $!$& menu.

Aisle recognition

o¿##£cíe~ Inductive guidance 44
Inductive guidance
General
Block diagram
¡BIT Li'llllllHiL
CAN2
pari itiiiiirr
•5
CAN1
|,|=-
If
ÿ
j£r-!E?
Ay
m
img61200440533ml
1 Central unit IZF 5 T ravel and pump controller

2 Display elements and manual/automatic 6 Reflex sensors for aisle recognition
switch 7 Antenna 0 = load side / Antenna 1 = drive side
3 Steering unit 8 Optional mechanical steering angle limiter
4 Actual value potentiometer 9 Speed sensor

Inductive guidance
Function
Inductive wire guidance, referred to as IZF in the
following, is a control system for the inductive
guidance of trucks in straight rack aisles.
It comprises one central processing unit and at
least two antennas. A wire recessed into the floor
and supplied with alternating current by a fre¬
quency generator is used as a guidance signal.
The alternating field of the guide wire is picked
up by the antennas and converted into a distance
signal.
Both antennas are evaluated by the IZF control
system in every direction of travel. Using the an¬
tenna signals, the truck is regulated towards the img61200440530ml
guidance point and the necessary adjustment an¬

gle forwarded to the truck steering system. The 1 Guide wire
"guidance point" (4, 5) is located in the longitudi¬ 2 Groove
nal direction in the area of the rigid axle. 3 Electromagnetic alternating field
4 Antenna
The driver selects and deselects the inductive
guidance function. Within the rack aisles, only
guided operation is admissible.
Optionally, a mechanical steering angle limiter
can be actuated.
The IZF system features a safety-integrated de¬
sign.
The IZF reads out information for optical and
acoustic indication of statuses and errors at the
operating console.
Tracking
• Automatic guidance is selected bythedriverby
pressing a button. The signal from the button
is forwarded via the CAN bus to the IZF.
• The IZF limits the speed down to the tracking
speed.
• Once the tracking speed has been reached,
the IZF starts to search for the wire.
• Once it recognizes a guidance signals, the ¡mg61200440529m1
IZF switches over the steering angle signal
to the steering system from manual to IZF. 1 T ransfer/tracking area
Switchover is optically and acoustically sig¬ 2 Recognition area of the guide wire
3 Approach angle
naled at the operating console. The truck is
4 Guidance point on the load side
now automatically steered. 5 Guidance point on the drive side
• The tracking process regulation system per¬
mits the guide wire to be approached at dif¬
ferent approach angles (3) and speeds in the
drive and load direction.
• The tracking algorithm regulates the distance
and the angle of the truck relative to the guide
wire.

Inductive guidance 44
Inductive guidance
• If these two values are small enough, transfer
to the adjustment mode takes place (both an¬
tennas are located in the linear pick-up range
over the guide wire).
• Depending on the distance from the guide
wire, the maximum speed is now increased up
to the transition speed.
• If the distance from the two antennas is less
than the maximum admissible guide wire devi¬
ation (plus supplementary value), the truck is
now tracking the wire.
Tracking process on the load side
• Inductive guidance must be selected before
travelling over the guide wire.
• The antenna on the load side enters the track¬
ing area.
• The tracking process takes place only with the
antenna on the load side until both antennas
pick up the guide wire.
• When both antennas have reached the adjust¬
ment area (linear pick-up area), the system
goes into the adjustment mode.
• In this transition area, the maximum speed is
increased in accordance with the guide wire
distance.
• Once the distance of both antennas is within
the admissible tolerance range above the
guide wire, the tracking process is completed
Tracking process on the drive side
• Inductive guidance must be selected before
traveling over the guide wire.
• The antenna on the drive side enters the track¬
ing area.
• When the antenna on the drive side is travers¬
ing the tracking area, adjustment takes place
in line with the drive side antenna.
• In case of large approach angles, a corner is
turned without guide wire until the antenna on
the load side has reached the tracking area.
• From this point onwards, adjustment takes
place in line with the antenna on the load side.
The drive system now swivels back to the
guide wire.
• Just before the guide wire, the system
switches over to creep speed to give the
steering sufficient time to straighten up.
• Once both antennas have recognized the
guide wire, further tracking takes place with
two antennas.

Inductive guidance
• Once both antennas are within the adjustment
area (linear pick-up area), the system goes
into the adjustment mode.
• In this transition area, the maximum speed is
increased in accordance with the guide wire
distance.
• Once the distance of both antennas is within
the admissible tolerance range above the
guide wire, the tracking process is completed
Tracking travel
Different maximum speeds can be parameter¬
ized for travel in the load and in the drive direc¬
tion. The adjustment function holds the "guid¬
ance point" on the guide wire.
In the case of trucks with steering wheel, the po¬
sition of the steering wheel has no influence.
In the case of trucks with steering handle (cen¬
tral lock-in position) the steering handle must be
located in the straight on position during tracked
travel, as otherwise the truck will cometo a stop.
• The adjustment function stipulates only a lim¬
ited steering angle. The steering angle to be
set is checked again against the parameter
"

and limited if applica¬
ble.
• If the EMERGENCY STOP distance is ex¬
ceeded during adjustment, an emergency stop
is initiated.
• Forthe antenna on the drive side, an additional
EMERGENCY STOP distance is admissible
for travel in the load direction.
• When the mechanical steering angle limiter
option is used, a mechanical steering angle
limiter is applied when the truck is in the induc¬
tively guided mode.
Disabling automatic guidance
Automatic guidance is disabled by the driver us¬
ing a button at the operating console. Inside the
rack aisle, the truck is stopped. A warning signal
is given off. It is only possible to continue with the
[o] button and at creep speed.
Outside the rack aisle, the speed is reduced
from "transition" to "creep speed" and the cur¬
rent steering wheel position is adopted as the
"Straight on target value". When travelling at <
"creep speed" the system switches over to man¬
ual steering and "free travel" speed. Switchover
is indicated by an acoustic signal.

o¿##£cíe~ Inductive guidance 44
Inductive guidance
Specification
NOTE
The maximum specified travelspeeds are condi¬
tional upon adherence to the floor guidelines and
the safety distances!
Vmax inductively
7 kph
guided
Average adjustment
< ±15mm
deviation
Approach angle to wire max. 60°
Guide frequency 5.. 12.5kHz
Guide wire current 40.. 150mA
Laying depth of guide
10 mm
wire
• Parameterization is possible of the guide wire

frequency and current.
• The maximum speed is only enabled subject
to aisle recognition.
• If the truck is not automatically guided once
aisle recognition has taken place, it is stopped.
• The driver selects between manual steering
and inductive guidance by actuating a switch
at the operating console.
• After being selected by the driver, IZF au¬
tomatically transfers from manual to guided
operation and vice versa.
• The change of operating mode (manual/au¬
tomatic guidance) is indicated by an acoustic
signal.
• The tracking process takes place on a con¬
trolled basis.
• The maximum steering angle in the tracking
mode is limited.
• The IZF can be parameterized to different
trucks and guiding frequency systems.
• Parameterization and diagnosis take place via
the CAN bus.
• The system features a wide variety of moni¬
toring functions and signals faults by means of
detailed error codes.
• The exchange of signals with the truck control
system takes place via the CAN bus.
• The emergency stop signal is issued by a float¬
ing relay contact.

Inductive guidance
Display of operating statuses
3 2 1
r®
©
©
img6120044051 1m4
4 5 6 7
1 Manual/automatic switch. 5 Wire tracking / wire recognition active display

2 IZF EMERGENCY STOP 6 T racking active / automatic mode display
3 Steering angle display 7 Error code display
4 Manual steering / inductive guidance display
Manual mode
• Switch (1) is set to manual operation.
• LED (4) = On.
• The truck can be freely steered and driven.
• Switchover to automatic operation and back
again is acknowledged by 4 short acoustic
signals.
Automatic mode
Automatic mode is subdivided into 3 consecutive
phases and initiated by pressing the Manual/Au¬
tomatic switch (1).
• Wire search: The truck can be freely driven at
reduced speed to the guide wire: The red LED
(5) flashes.
• Wire tracking> The truck travels with at least
one of its antenna over the guide wire: Manual
steering is switched off, an acoustic signal
confirms the change to automatic steering. On
recognition with one antenna, the red LED (5)
and the 2 green LEDs (6) flash alternately. On
recognition by two antennas, the two green
LEDs flash (6).
• Rack travel: The truck is located with both an¬
tennas within the admissible tolerance range
above the guide wire. The 2 green LEDs (6)
remain continuously alight. When reversing,
the IZF switches back to the tracking mode at
the point the truck changes direction.

Inductive guidance
Test
Function test
The following functions must be tested:
• Automatic tracking process.
• Tracked travel.
• Aisle recognition.
• Deselection of automatic guidance into aisle.
• Checking that the emergency-stop and emer¬
gency distance function correctly.
• Option mechanical steering angle limiter.
Repairs
The inductive wire guidance is a complex sys¬
tem with different interacting components. After
putting into operation, replacing or repairing indi¬
vidual components, the system must be commis¬
sioned using the following adjusting chart. The
points which are not relevant can be omitted.
Preparation
Tools
• Notebook with software ParaDig IZF and truck-
specific parameter file.
• CAN interface and CAN diagnosis cable.
• Run-in gear with inductive loop and guide fre¬
quency generator.
Prerequisites
• The electrical steering, in particular the
straight-on steering, must be correctly ad¬
justed.
• The "IZF" option must be configured in the
travel and pump controller and the electrical
steering.
Commissioning and adjusting instructions

> Test straight-on travel with the manual steer¬
ing by taking a test run. After 10m travel, the
truck should deviate from the ideal course in
both directions by <200mm. If required, use
the diagnostic software of the steering to cor¬
rect the straight-on travel (refer to Electrical
steering).
> Align the antennas: The antennas are
mounted mechanically in the centre of the
truck (tolerance ±2mm) when the tabs of the
antennas are flush with the holders. Make
sure that the installation is horizontal.

Inductive guidance
> Set the IZF parameters: If required, load stan¬

dard parameterfile with software "ParaDiglZF"
and configure manually or load truck-specific
parameterfile. Check the configuration of
the

option.
Maximum speeds can be reduced if required
by local conditions.
> Teach in the actual value potentiometer:

In ParaDiglZF, start '
and
$(

. Caution: Drive wheel
turns automatically to +95°, -95° and then
STRAIGHT ON.
> Frequency measurement: Drive the truck onto
the wire manually or with inductive guidance
until the antenna distance is < ±30 mm. Switch
over to manual operation, select '

in ParaDiglZF and start )
*

. Follow the operating in¬
structions. The measurement is carried out for
both antennas and stored under the selected
frequency channel in the antenna and in the
IZF control system.
> Field strength measurement: Drive the truck
onto the wire manually or with inductive guid¬
ance until the antenna distance is < ±30 mm.
Switch over to manual operation, select '

in ParaDiglZF and start

(
. Follow the
operating instructions. The measurement is
carried out for both antennas and stored under
the selected frequency channel in the antenna
and in the IZF control system. If possible, carry
out the measurement at different points on the
guide wire. Default value = 80mA, permissible
range: 40. .150mA. If you ascertain strong fluc¬
tuations after several measurements, enter
the mean value manually and save.
> Calibration of the antenna analogue value:
Drive the truck onto the wire with inductive
guidance until it is detected. Switch over to
manual operation, select '
in
ParaDiglZF and start +

. The ana¬
logue/digital antenna distance is compared
and if necessary corrected automatically with
the

parameter.
> Set steering offset. Select ParaDiglZF '

and start !

. The mean value calculation is
activated. As test run, move the truck forwards
and backwards about 20m. Correction values
are entered in the


Inductive guidance
parameter.
Repeat the test run. When offsets >1°, first
set the straight-on setting of the steering. The
setting is correct when the mean steering
offset is <0.2°. Test the truck at maximum
speed. Optimize manually, if required. Manual
calibration: Select !,-

. -
. Reset mean value
calculation by selecting the manual/auto¬
matic function. Repeat test run and optimise
with the

parameter. If the truck
has a tendency to move off centre to one
side, correct with the

/

parameter. Finally,
carry out the !

procedure again.
> Set the steering angle limiter. This is only
necessary when the mechanical steering an¬
gle limiter option is installed. Leave the truck
standing on the guide wire in "automatic op¬
eration" and switch it off. Check whether the
locking mechanism is central to the drive wheel
and whetherthe distance of the guide rollers
to the rim edge is approx. 8mm. Correct me¬
chanically, if required.
> Emergency-stop test: Drive the truck onto the
wire with inductive guidance. Select ParaDi-
glZF '
and start
*
. Set steering angle in direction
of travel AS max. ±9°, in direction of travel
LS max. ±1° and follow operating instruc¬
tions. Test the guide wire deviation after emer¬
gency-stop between the truck and guide wire.
> Function test after repairs: carry out this test.
Function test after repairs
> Perform emergency-stop test (refer to Com¬
missioning and adjusting instructions).
> Test wire recognition. Test the wire recog¬
nition process with a small recognition angle
(10...20°) and a large recognition angle (50
...60°). This is necessary in order to test the
parameterisation of the wheel position, pulse
generator resolution and set current. The
recognition process must be carried out di¬
rectly with a suitable steering angle and must
be completed within a few metres.
> Check the aisle recognition. In an aisle, the
truck must stop when switched over to manual
and a warning signal should sound after ap¬
prox. 3 seconds.

Inductive guidance
> Checkthe steering angle limiter. The steering

angle limiter must go into automatic operation
when the truck has been detected (inside and
outside the aisle). When the truck is switched
overto manual, it should move out of automatic
again.
> Test the max. speed. The -

.
parameter
must be <0.2° (ParaDiglZF).

> The parameters for a newly installed IZF must
be set with the diagnostic software "ParaDi¬
glZF" with a standard parameter file for this
truck.
> The truck must be configured with the "ParaDi¬
glZF" diagnosis software, ora stored truck-re¬
lated file must be loaded into the control sys¬
tem.
> Commissioning and setting instructions follow.
> After commissioning with "ParaDiglZF", the
current parameters must be saved to a file
(example: File name = IZF + truck number).

Central unit
General
Function
The central processing unit monitors and controls
all functions of the IZF.
Technical data
Power supply +24V DC (16-32V)
Operating temperature -32°.. +70°
Control outputs binary 24V, 1,5A, short-circuit proof
Power outputs binary 24V, 5A, short-circuit proof with current detection
Inputs binary +24V
Analog inputs 0..10V
Relay contact 2A, inductive
Protection class IP64
Identification >
Cast aluminium housing (1) with 42-pin connec¬
tor, type plate with ident number.
img6 1200440526ml
Terminals
Pin Signal Pin Signal
1 GND, 0V 22 S-GND, screen antenna cable AS, n.c.
2 D+, 24V signal "memory" 23 Relay contact EMERGENCY STOP (n.o., 1=ok)
3 GND antenna LS 24 Relay contact EMERGENCY STOP (n.o., 1=ok)
4 Analog input antenna LS 25 Digital output aisle recognition, 0V= in aisle
5 +6,5V antenna LS 26 Digital output, n.c.
6 +6,5V antenna AS 27 +10V, n.c.
7 Analog input antenna AS 28 +24V supply for outputs
8 GND antenna AS 29 L-GND, 0V supply for outputs
9 Analog input antenna 3 n.c. 30 CAN-H, truck CAN
10 Analog input antenna 4 n.c. 31 GND, truck CAN
Analog input actual value
11 32 Motor steering angle limiter
potentiometer steering
Analog input actual value
12 33 Motor steering angle limiter
potentiometer -

Central unit
Pin Signal Pin Signal

Analog input target value
13 34 Digital input, LWB locked
potentiometer n.c.
14 Analog GND n.c. 35 Digital input, LWB open
15 CAN-L 36 Digital input, LWB (3° switch) n.c.
16 +UE, 24V 37 Digital input, LWB n.c.
S-GND, screen antenna Digital input, aisle recognition OFF (opening
17 38
cable AL, n.c. signal)
18 CAN2-L antenna LS 39 Digital input, aisle recognition ON (opening signal)
19 CAN2-H antenna LS 40 Digital input speed sensor channel A
20 CAN2-H antenna AS 41 Digital input speed sensor channel B
21 CAN2-L antenna AS 42 +24V supply LWB switch
Test
The central processing unit monitors itself and
IZF functions automatically. Errors are displayed
on the operating console.
A more detailed diagnosis and adjustment can be
performed with the diagnostic software "ParaDi-
glZF". Using the special tool "measuring adapter"
and a digital multimeter, the hardware signals can
be measured.
Repairs
Removal
> Unplug the connector plug.
> Unscrew the central processing unit from the
mounting plate.
Installation
ill NOTE
A newly installed centralprocessing unit must
be set up using the diagnostic software "ParaDi-
g!ZF".

in reverse order.

The setting up and commissioning must be exe¬
cuted with the diagnostic software "ParaDiglZF"
according to the commissioning and setting up
instructions IZF.

Central unit
Functional test after repairs

• Tracked travel.
• Aisle recognition.
• Deselection of automatic guidance into aisle.
• Check the emergency-stop and emergency
distance functions.
• Option mechanical steering angle limiter.

Periphery
Antenna
Test
The antennas are self-checked automatically
and are monitored via the IZF control system.
Errors are displayed on the operating console.
The antenna signals can be displayed using the
diagnostic software "ParaDiglZF".
Repairs
Removal
> Remove collision guard / lift cabin and under¬
pin safely.
> Pull out the antenna plug.
> Unscrew antenna.
Installation
f NOTE
A newly installedantenna must be set up using
the diagnostic software "ParaDiglZF" (refer to
Parameterization).

in reverse order.
Settings
> Install antenna at the truck in the mechanical
centre (±2mm). The antenna is installed in
the mechanical centre of the truck when the
mounting tab of the antenna is flush with the
holder. Make sure that the installation of the
antenna is horizontal.
> The height above the guide wire must be ap-

prox. 60mm.
> The antenna can be screwed directly onto the
metal with the mounting tab.
> There must be no metal directly above the
antenna.

Periphery
f NOTE
A newly installedantenna must be set up using

the diagnostic software "ParaDiglZF". The fre¬
quency and field strength will be stored in the
antenna.
> Teach in guide frequency.

> Teach in field strength.
> Teach in analog value of antenna.
Function test after repairs
• Tracked travel.
• Check functions emergency stop and emer¬
gency distance.
Guide wire
General
As a guide wire, normally a 1.5 mm2 flexible in¬
stallation cable is laid. The maximum length
depends on the resistance of the guide wire and
the output of the frequency generator. It is al¬
ways essential for a constant loop current to be
achieved which complies with the requirements
of the inductively guided truck.

Periphery
Laying
V: 9 ;V P.:'. ° - ar;o°.- .> :;p -;\o ÿ « b'*,. q*/ ó,4. •" q\ •" ó.' '! 7
img61200440537ml
• Groove measurement for the guide wire (9):

Depth (1)=10mm, width (2)=6mm
• Distance of armouring to guide wire (3):
>50mm. A lower distance can be implemented
under certain circumstances. In this case, a
field measurement is required.
• Metal-free area (5) left /right of the guide wire:
>200mm. This does not apply for forced brak¬
ing at the end of the aisle with metal strips
(inductive).
• Distance between 2 guide wires with the same
frequency: >(0.5 x truck width + 500mm).
• Deviation of the guide wire from the theoretical
centre line (7) over the entire aisle length: <
±5mm.
• The guide wire is fixed flexibly in the groove
using a continuous strip of foam rubber. The
groove is sealed using a filler.
• Expansion joints are bridged with a small loop
laid to one side into the joint.
• Faulty guide wire points are bridged by solder¬
ing in a short piece of wire. The surplus wire
can be accommodated in the form of a loop
in a vertical 10 mm borehole in the area of the
repair point.

Periphery
• The changeover aisle must be configured wide

enough to allow the truck to carry out the auto¬
matic wire recognition process.
• The function of the antenna with scanning
coils (8) must not be impaired by any other
metal components.
Guide frequency generator

General
The frequency generator used to feed the guide
wire must be capable of holding a set frequency
and the loop current within the tolerance pre¬
scribed by the antenna.
Frequency deviations >±20Hz can result in loss
of the wire in the truck's evaluation system.Cur¬
rent fluctuations exert a direct effect on the devia¬
tion signal of the antenna. In this case, the control
unit works less precisely. The tolerance limit is
<5mA.
Individual sections of the guide wire can be
supplied with different frequencies. Frequency
switchover can then be performed automatically
in the truck or by driver preselection.
The frequency generator need not be secured
against failure. The evaluation system safety
capability is located in the truck. As a way of
preventing errors, the generator can be secured
against unintentional activation of the supply or
against a power failure. Pilot displays can permit
a visual check to be made of the function.

Aisle recognition
General
¡mg61200440534rn1
A-reflector at aisle entry. B-reflector, at aisle exit and open aisle end.
NOTE
Ifit is notpossible to mount the reflectors on the
right, the reflectors can be mounted on the left-
handshelf side in mirrorimage.
Function
The aisle recognition process takes place with
two reflective light barriers and a double reflector
on the shelf. The aim of automatic aisle recogni¬
tion is for trucks to be guided safely in aisles by
the automatic system.
Two-handed operation is required inside aisles.
• If a truck drives into an aisle with automatic
recognition without the IZF having been se¬
lected beforehand, it is stopped.

Aisle recognition
• In an aisle that has been detected, the truck
is stopped when it is switched over to man¬
ual operation. A warning indicates what the
problem is. Travel can only be continued by
pressing the acknowledgement button and at
creep speed.
• Aisle recognition takes place irrespective of
the direction in which the truck has entered the
aisle.
• The reflectors can also be mounted in mirror
image on the shelves on the opposite side of
the aisle.
• The optional steering angle limiter engages
inside and outside the aisle.
• When on track, the truck can only drive at
reduced speed if the aisle has not been recog¬
nised.
• The two reflective light barriers must switch
one after the other. The switching sequence
is monitored over a path distance by counting
pulses from the drive motor speed sensor.
• Aisle recognition only works if the speed sen¬
sor pulses are provided.
• The status of the aisle recognition system is
stored together with the error status when the
truck is switched off and also registered with
the vehicle control system during operation via
the CAN bus.
• Errors caused by faulty reflector signals can
only be reset by passing the reflectors again
and with the correct signal sequence of the
reflective light barriers.

Steer angle reduction (LWB)
General
Function
The steering angle limiter is an optional technical
safety equipment. It mechanically prevents the
maximum permissible steering angle from being
exceeded in the case of steering failure.
Once the truck has been detected and is within
the aisle, the steering angle limiter (LWB) is
locked. The position "unlocked/locked" of the
steering angle limiter is determined by switches.
The steering angle limiter is moved by a motor
until the relevant end position has been reached.
The moving in/out of the steering angle limiter is
monitored with time-out. The motor is actuated
by the IZF control system (depending on the truck
type with reversal).
Test
Test procedure
Software version IZF Locking Unlocking
Outside aisle: Mode "tracked" Within and outside aisle: in
active and travel speed > manual and at travel speed <
"V_tracking" (parameterizable). "V_creep speed " or in general
Aisle entry: immediately when after the truck is switched back
V2.09 (09/2004 production start) the "tracked" mode is active, on.
irrespective of the travel speed.
Within aisle: immediately when
"tracked" mode is active, also
during standstill.
Within and outside aisle: in
Outside aisle: never.Within
manual and at travel speed <
aisle: when mode "tracked"
> V2.09 "V_creep speed " or in general
and travel speed > "VJracking"
after the truck is switched back
(parameterizable).
on.
ffl NOTE
Ifthe conditions are fulfilled for unlocking fol¬

lowing switch on, an unlockingprocess will be
followed by re/ocking.
In the case of switchover from automatic opera¬

tion to manual operation within the aisle, a warn¬
ing tone will sound due to the switchover "manual
steering in aisle".
The function of the steering angle limiter is moni¬
tored in the IZF control system. The signals of the
limit switch and the motor actuation are displayed
in the diagnostic software "ParaDiglZF". Errors
are displayed on the operating console.

Repairs
Removal >
> Unscrew collision guard.
> Position the drive wheel in straight-on position.
> Switch off the truck and pull the battery plug.
> Pull out the connectors.
> Release the 2 fastening screws (1), lift out the
steering angle limiter.
Installation
¡mg61200440535m1
in reverse order.

Settings
> Align the drive wheel (1) to face precisely for¬
ward.
> Switch off the truck and pull the battery plug.
> Release the swivel lever (2) by releasing the
two screws (3) from the drive motor shaft (4).
> Move the swivel lever to the "unlocked" posi¬
tion.
> Release the lock nut (5).
> Set the swivel lever horizontally into the
"locked"position (2) using adjusting screw (6) ig61200440535m2
and tighten lock nut (5) again. 3 2 4 1

> Check the function of the two limit switches,
set if necessary. Electrical cut-off must take
place before the end stops are reached.
> Fix the swivel lever (2) by tightening the two
screws (3) with the drive motor shaft (4).
> Position the 2 ball bearings (7) using 4 adjust¬
ing screws (8) at a distance of 8 mm from the
drive wheel.
> Fix using the 2 fastening screws (9).
Function test
> Switchover between manual and automatic img61200440536ml
operation within the aisle when the truck has

been detected (refer to testing process LWB).
The steering angle limiter must be unlocked
and locked.
img6 1200440535m3
8 7

Maintenance
Deadlines
Maintenance interval: Every 1000 hrs or once a
year.
Test
> Clean steering angle limiter of coarse dirt.
> Grease all movable parts with all-purpose
grease.
> Check function and setting.


Wheels and tyres 46
Wheels
Drive wheel
General >
Dimension new: 310x125 mm.
The drive wheel (1) needs to be exchanged if:
• the tread is broken out severely or out-of-round
or cracked.
• the tire diameter is reduced by more than 10%.
img6 120044052 1m2
Repairs
Removal >
> Remove collision guard (1).
> Set steering sideways until wheel nuts (2) are
easily accessible.
> Loosen wheel nuts (2) in non-raised position.
> Lift truck using a hydraulicjack.
> Safely underpin truck on both sides using hard¬
wood blocks.
> Unscrew wheel nuts (2).
> Remove drive wheel.
I(ng61200440521m1

46 Wheels and tyres o/*r£cfe-
Wheels
Installation
> Before installing the drive wheel, clean wheel
seat (3) and check for proper condition.
> Position drive wheel and hand tighten the 5
nuts.
> Lower truck.

> Tighten the nuts with a torque wrench alter¬
nately crosswise. Tightening torque: 140Nm.
\V\\\ w-JiJ
imgcM 200440522ml

o¿##£cíe~ Wheels and tyres 46
Wheels
Load wheels
General
Dimension new: 165x150mm.
The load wheels need to be replaced when:
• the tread is broken out severely or out-of-round
or cracked.
• the tire diameter is reduced by more than 10%.
Repairs
Removal
A CAUTION
Danger ofinjuries due to unintentionallowering
of cabin.
Safety underpin cabin with suitable means.
> Raise cabin until load wheels(5) are clear.

> Jack up the truck at the load wheels and secure
it to prevent it rolling away.
> Pull out the 2 securing pins (2).
> Drive out the 2 bolts (3).
> Release the 6 lock nuts (6). 5
> Remove the 6 setscrews (4).
> Remove load wheels (5).
Installation
in reverse order.
¡mg61200440517m1

46 Wheels and tyres
Wheels

Brake installation 49
Electrical operating brake
General >
The service brake acts on the drive wheel by
regeneratively braking the drive motor.
Function of neutral braking

If the driver returns the operating lever (1) to the img612004<
neutral position during travel or if he releases
the operating lever, the truck is regeneratively 1
braked.
The deceleration rate depends on the speed at
which the operating lever is moved back to the
neutral position.
The maximum possible deceleration by the neu¬
tral brake is stored by means of a parameter in the
truck program with limited scope for adjustment.
The degree of deceleration also depends on the
lift height and the engaged load.
Function of the reversing brake

If the driver deflects the operating lever (1) in the
opposite direction in order to reverse the travel
direction during travel, the truck is regeneratively
braked and then accelerated in the other direc¬
tion.
The degree of deceleration depends on the
speed at which the direction of travel is switched
over by the driver.
If the operating lever is released at the moment
at which the travel direction is changed, the truck
comes to a standstill.
The maximum possible deceleration by the re¬
versing brake is stored by means of a parameter
in the truck program with limited scope for adjust¬
ment. The degree of deceleration also depends
on the lift height and the engaged load.
Function of service braking >
The footpedal for the service brake (1) is inte¬
grated in the cab floor.
If the driver places a foot on the pedal, the elec¬
tromagnetic brake is lifted.
If the driver takes his foot off the pedal during
travel, the truck is regeneratively braked. Just
before coming to a standstill, the electromechan¬
ical brake cuts in and brings the truck reliably to
a stop. The degree to which the truck is braked
depends on the lift height and the engaged load.
The deceleration of the service brake is set by img61200440610m1
means of parameters in the factory. After ex¬

changing the FPS, the degree of deceleration

Electrical operating brake
must be checked, minor adjustment can be made

by changing the parameters. The degree of de¬
celeration also depends on the lift height and the
engaged load.
Initiating a braking action

• Braking by releasing the pedal at a lift height
of <4.3m: Braking exclusively using regenera¬
tive braking 1, parameter P40. The admissible
value is 9% +2%, corresponding to decelera¬
tion ofappr. 0.9m/s2+0.2m/s2.
• Braking by releasing the pedal at a lift height
of 4.3m: Braking exclusively using regenera¬
tive braking 2, parameter P41. The admissible
value is 6% +1.5%, corresponding to deceler¬
ation ofappr. 0.6m/s2+0.15m/s2.

Parking brake
General
Function >
As a parking brake and in the EMERGENCY
STOP mode, an electromagnetic spring-loaded
brake (1) with 2 brake stages is used.
If the deadman brake on the cab floor is actuated,
the travel and pump controller (FPS) actuates
both brake stages of the magnetic brake and
releases the brake.
If the driver actuates the emergency stop during
travel or if the truck electronic system detects a
serious malfunction and initiates an emergency
stop, depending on the lift height only the first
or both brake stages are de-energized by the
truck control system and the truck is braked to a
standstill by the magnetic brake.
To prevenían uncontrolled braking action taking
place, at the same time as the emergency stop,
the travel drive system is de-energized by the
travel and pump controller. This ensures that an
additional regenerative braking process does
not take place when the driver lifts his foot off the
deadman brake or releases the operating lever
during an emergency stop situation.
Terminals
The magnetic brake is connected to the travel
and pump controller by means of a 4-pin plug.
img6 12004405 18m2
Pin Wire to Designation

1X44:1 1 A10 / X5:1 1 2+48V braking stage 1
1X44:2 2 A10 / X5:12 0V braking stage 1 (clocked signal)
1X44:3 3 A10 / X5:1 3 1+48V braking stage 2
1X44:4 4 A10 / X5:14 0V braking stage 2 (clocked signal)

Parking brake
Test
Checking the solenoid coils
> Release the connector 1X44 of the magnetic
brake.
> Resistance measurement brake circuit 1 be¬
tween 1X44:1 and 1X44:2
> Resistance measurement brake circuit 2 be¬

tween 1X44:3 and 1X44:4
> If the measured values disagree by more than

±15f2, the magnetic brake must be exchanged.
> Once the solenoid coils have been tested, plug
connector 1X44 back in.
Test values
Brake circuit 1 32fi
Coil resistance
Brake circuit 2 68SJ
Checking brake play

> Do not actuate the deadman switch.
> Using the probe gauge (1) check the brake >
play in three places near the screw between
the magnet section (2) and the anchor plate
(3).
> If the brake play is >< 0.4mm, it must be cor¬
rectly set (cf. Repairs).
Checking the brake deceleration

img61200460148ml
Brake deceleration of the solenoid brake must be
checked to ensure that: 3 1
• the truck is not braked too hard (stability of the
truck must be guaranteed at all times),
• but the truck still comes to a standstill within
the shortest possible braking distance.
Setting the brake decelaration of the 1st

brake circuit
> Drive the truck into the aisle with a rated load,
raise the cab over 4,3m and completely lower
the auxiliary lift.
[J] NOTE
Using the operating keys in the operating
console, the operating console display can be
switched between operating hours and current
lift height. Over 4. 3m the 2nd brake circuit

Parking brake
remainspermanently energized, which reduces

the braking force, it is only possible to check the
2nd brake circuit duringpositive mechanicalor
inductive truck guidance.
> Check whether it is possible to travel at maxi¬

mum speed ("tortoise" symbol in the operating
console is not active).
> Mount the dynometer (7) within view and cali- >
brate (cf. Auxiliary devices / Dynometer).
> Accelerate the truck and carry out an emer¬
gency braking operation by pressing the
EMERGENCY STOP switch.
> Readthe deceleration value off the dynometer.
> Compare the deceleration value with the re¬
quired deceleration value.
If the required brake deceleration value is ex¬
ceeded or not reached, the deceleration of the
magnetic brake must be correctly set (cf. Parking
brake / Repairs).
Test value of the 1st brake circuit

6%+1.5% = appr. 0.6m/s2+0.15m/s2 img61200450115m2
Checking the joint brake deceleration of the

1st and 2nd brake circuit
> Drive the truck into the aisle with a rated load,
completely lower the cab and auxiliary lift.
> Check whether it is possible to travel at maxi¬
mum speed ("tortoise" symbol in the operating
console is not active).
> Mount the dynometer (7) within view and cali- >
brate (cf. Auxiliary devices / Dynometer).
> Accelerate the truck and carry out an emer¬
gency braking operation by pressing the
EMERGENCY STOP switch.
> Read the deceleration value off the dynometer.
> Compare the deceleration value with the re¬
quired deceleration value.
If the required brake deceleration value is ex¬
ceeded or not reached, the deceleration of the
magnetic brake must be correctly set (cf. Parking
brake / Repairs).
Test value of the 1st and 2nd brake circuit

together img61200450115m2
9%+2% = appr. 0.9m/s2+0.2m/s2

Parking brake
Repairs
Removing the magnetic brake >
A WARNING
When the service unitis removed, the traveldrive
is fully without braking action.
Forthis reason, the truck mustalways besecured
against rolling a way before removing the magne¬
tic brake.

> Release the connector 1X44 of the magnetic
brake.
> Release the fastening screws (1). img6120044051 8m3
> Remove the complete magnetic assembly (2)

including compression springs, anchor plate
and adjusting sleeves by lifting upwards. The
brake lining (4) and flange (5) are lying loose
on the motor. The motor pinion(3) is secured
on the motor shaft.
5 img61200461041ml

Parking brake
Mounting the magnetic brake

> Position the flange(5). Align the drilling pat¬
tern.
> Place the brake lining (4) on the motor pinion
(3).
> Place the complete magnet assembly (2) in¬
cluding compression springs, anchor plate and 2
adjusting sleeves on the brake lining.
> Fasten the magnet assembly (2) with the 3
fastening screws.
> Connect the magnetic brake to the connector
1X44.
> Checking the brake play. 3
Exchanging the brake lining

> Remove the magnetic brake.
4
> Remove the old brake lining.
> Clean the motor pinion.
> Insert the new brake lining. 5
> Check for easy running in the axial direction.
> Mount the magnetic brake.
Setting the brake play
> Do not actuate the deadman switch.
> Release the fastening screws (11). Do not
unscrew completely!
> Screw the adjusting sleeves (12) in or out far
enough using the fork wrench until the gauge
probe (13) shows the prescribed brake play
between the magnet assembly (14) and the
anchor plate (15).
> Check brake play.
> Tighten the fastening screws again and check
the brake play again, adjust if necessary. img61200460148m2
Setting the brake deceleration 13

If the brake deceleration test value for the 1st
or 2nd brake circuit does not reach the required
value, the brake requires mechanical adjustment
(cf. Parking brake /Testing).
1 NOTE
When setting the brake, observe the correct se¬
quence of the describedprocedure. The brake

Parking brake
deceleration of the 1st brake circuit (cab >4. 3m)

must be set before the brake deceleration of the
2ndbrake circuit, as at <4. 3m bothbrake circuits
work in conjunction.
Setting the brake decelaration of the
Istbrake circuit (h>4.3m)
The brake deceleration is lowerthan the admissi¬
ble value:
> Turning 3 adjusting screws (1) using a hexag¬
onal socket wrench 1/2 turn in the clockwise
direction increases the brake deceleration.
> Repeat the brake deceleration measurement.
> Repeat the setting process until the brake de¬
celeration value is within the permitted range.
The brake deceleration is higher than the admis¬
sible value:
> Turning 3 adjusting screws (1) using a hexag¬ O
onal socket wrench 1/2 turn in the counter
clockwise direction reduces the brake deceler¬
ation. o

celeration value is within the permitted range. 0
Setting the brake deceleration of the 2nd

brake circuit (h<4.3m)
The brake deceleration is lowerthan the admissi¬
ble value:
¡mg61200440611m1

Parking brake
> Release the locking screw (1). >

> Turning adjusting screw (2) using a hook
wrench socket wrench 112 turn in the clockwise
direction increases the brake deceleration.
> Tighten the locking screw.
The brake deceleration is higher than the admis¬
sible value:
> Release the locking screw.
imgS1200440518m4
> Turning the adjusting screw using a hook
wrench socket wrench 112 turn in the coun¬
terclockwise direction decreases the brake
deceleration.
> Tighten the locking screw.

Parking brake
Mechanically lifting the magnetic brake

Mechanical lifting of the brake is necessary, for
example, if:
• One of the brake coils or a component required
for lifting the brake is defective and the truck
has to be moved out of the rack aisle
or
during commissioning (truck switched off), the
truck chassis has to be pushed.
A DANGER
The truckisunbraked.
Only use this method when the truck is on an
even floor.After transport, remember to remove
the 2 screws (1) again without fail!
> Screw two hexagonal socket screws M5x50

completely into the magnet body ()so that the
brake base plate is drawn directly to the mag¬
net body, releasing the brake disk.
¡mg6120Q440611m2

Parking brake
Maintenance
Every 1000 operating hours or 6-monthly. In case
of multiple shift operation, use in refrigerated en¬
vironments and/or unusual ambient influences,
the maintenance interval must be reduced ac¬
cordingly.
Cleaning the brake lining
A WARNING
Dustproducedby the brake lining is a healthrisk.
Wear a mask during cleaning.
> Clean the brake lining by blasting with oil-free

air.
Checking the brake lining

To check the brake lining, the magnetic brake has
to be removed.
> Measure the thickness of the brake lining

(>7mm, upper and lower lining approximately
the same thickness).
> Check the brake lining for cracks.
> Check the brake lining for even wear.
> Check the axial mobility of the brake lining on
the motor pinion by hand. If necessary, loosen
using copper paste.
> Check the motor pinion for damage.
If one of these points is not complied with, the
brake lining and/or the motor pinion must be ex¬
changed.
Checking the brake play.

Cf. Parking brake /testing.
Checking the brake deceleration

Cf. Parking brake /testing.

49_ Brake installation_
Parking brake

o¿##£cíe~ Controls 50
Control panel
General
Function
The truck is operated essentially via the operating
console and a deadman switch. Depending on
the equipment features, additional switches can
be mounted in the driver's cab.
The truck can be equipped wiht one or two oper¬
ating consoles or an operating console which can
be exchanged between the load and mast side.
Operating elements
1 2
•« O 4»
img&n 20044051 1m2
11 10
1 Auxiliary lift selection key. 9 Hooter button.

2 Acknowledge button. 10 X button for special functions such as operat¬
3 Steering wheel (steering target value). ing console switchover.
4 EMERGENCY STOP key. 11 Main lift selection key and 2-hand functions.
5 S key for special functions. 12 Cursor buttons for switching over the display:
6 Manual/automatic changeover key in the case Operating hours / lift height, display of several
of inductive wire guidance. errors, menu control on-board diagnosis,
7 Up/down target value. activation of teach-in function.
8 Drive / load side target value.

50_ Controls_
Control panel
Display elements
img61200440512ml
1 Steering angle display 9 Cursor button left.

2 Actuate deadman switch request. 10 Cursor button right.
3 2-hand function request. 11 Battery discharge display.
4 Close barriers request. 12 Service symbol.
5 Acknowledge request. 13 IZF EMERGENCY STOP.
6 Deceleration active. 14 PSA active display.
7 No function. 15 PSA error display.
8 Display of operating hours, error code, 17 Display of IZF functions and rail switches.
on-board diagnosis. 18 Manual steering / inductive guidance display
All display elements are mounted on an ex¬

changeable pcb. The pcb is connected to the
operating console board by a plug-in ribbon ca¬
ble.

o¿##£cíe~ Controls 50
Control panel
Terminals
1 2
i
LÚ" 13 14 15
]
"i X9
¡> EPROM
XA
i
1+43VCDX10/1
X! XD 48V 1=1X10/2
—
I 1X11
[=1X12
XC [=1X13
12
1+48V,
5V
1=1X14
=1X15
a /
8
X7 X6
1
r
11
XB
ÿX1
ÿ
ÿ
ÿ
10 X1 X2 X3
Oled
1
X2 I I X3 I I X4 I
F1 3A4=1- F3<=ioaí==;
F2 3A I I F4 <=ioa
7 img61200440513rt)1
1 Operating console rocker right. 9 Distributor board in the cab.

2 Up/down target value potentiometer. 10 Processor /disributor board.
3 Display board. 11 T ravel target value potentiometer.
4 Cursor button right. 12 Operator console board right (hooter, poten¬
5 Cursor button left. tiometer up /down).
6 Key-operated switch. 13 EMERGENCY STOP key.
7 Steering wheel with target value potentiome¬ 14 Manual/auto button (IZF).
ter. 15 S button.
8 Operating console board left (X, Q, 2-hand,
auxiliary lift button).

50 Controls
Control panel
• X11, X12 (see block diagram) are reserved for

a heating board.
• Plugs X14, X1 5 are reserved for special func¬
tions.
NOTE
Ifthe operating console is mounted on the load
side, the I Hooter] button (2) is connected via plug
X9 (see block diagram) as the button is locatedat
the position of the I s button| (1) (option).
Repairs
Removal
> Remove connecting cables X1 and X2 (2) un¬ >
derneath the operating console.
> Remove the 2 hexagon socket head screws
(1)-
> Take operating console out of its holder.
> Unscrew the mounting frame from the base
plate.
Installation
in reverse order.
img61200440515ml
Setpoint potentiometer travel

_ Controls 50
Control panel
Test
Test procedure
Using the on-board diagnosis, the potentiometer
voltage and the direction signal can be displayed
Repairs >
Removal
> Remove the 4 hexagon socket head screws
and take off floor plate.
> Pull off plug XC from the processor circuit
board.
> Release the 2 hexagon socket head screws
(2).
> Release lift arm by releasing the 2 screws (3).
Installation
1 NOTE
img61200440516m1
During installation take care to ensure that the
wiring is notpinched. A newly installedpoten¬
tiometer must bereadinto the truck controlsys¬
tem with the diagnostic software (teach-in).

in reverse order.
Setpoint potentiometer hydraulics

Test
Test procedure
Using the on-board diagnosis, the potentiometer
voltage and the direction signal can be displayed

50 Controls
Control panel
Repairs
Removal
> Remove cover of the lift arm by releasing the 3
hexagon socket head screws (1).
img61200440531ml
> Pull plug X2 (2) off the board.

> Remove potentiometer with operating lever by
releasing the 3 cross-recessed head screws
(3).
Installation
NOTE
During installation take care to ensure that the
wiring is notpinched. A newly installedpoten¬
tiometer must bereadinto the truck controlsys¬
tem with the diagnostic software (teach-in).

in reverse order.
img6t 200440532ml

_ Electric/ Electronic _60
Sensors
Distance sensor for main lift

60 Electric /Electronic
Sensors
General
Pfl NOTE
Repeat teach-in ofthe position sensor is required
in the FPS if the position sensor is exchanged,
the max. lift height changes, the travelandpump
controller is exchanged ora reset is performed
with the diagnosis software (CLEAR EEPROM).
Otherwise the functions of the truck will be re¬
stricted (cf. Diagnosis/ Teach-In).
To determine the lift height, a position sensor (1)

is used which features an incremental encoder
and a potentiometer. The incremental encoder
is monitored by the potentiometer, which is me¬
chanically linked to it. It does this by evaluating
and comparing the two measured values in the
travel and pump controller.
The position sensor is actuated by means of a
highly flexible steel cable which is held under
tension over the entire extension length by a
clockwork motor.
img6120050004ml
3 2 1
Mounting location
In the cab on the lift carriage side (3) behind the
cover.
Identification
Screwed aluminium housing (2) with cable guide
pipe.
Type: WDS-15000-P501-S-P-E-STW.
Technical data
Measurement range 15,000mm
Resolution 1 impulse/mm
Potentiometer, 10-turn 1kO, 1W
Rated voltage of the
24V DC
incremental encoder

o¿##£cíe~ Electric/ Electronic 60
Sensors
Pin assignment
Connection (3) at the housing, view from the out¬
side:
Pin 1 24V supply, incremental encoder

Pin 2 0V supply, incremental encoder
Pin 3 Channel B, incremental encoder
Pin 4 Channel A, incremental encoder
Pin 5 8.5V supply, potentiometer
img612 0050005ml
Pin 6 0V supply, potentiometer
Pin 7 Not occupied
Pin 8 Pickup, potentiometer
Monitoring >
The travel and pump controller monitors the in¬
cremental encoder, the potentiometer and the o®
reference switch for the main lift function. If an
error occurs at this measurement system, a cor¬
responding error code appears in the operating
console display (1) (cf. Diagnosis / Error lists). img6 1200440511m9
The reference switch (2) is fixed at the lift carriage

1
and is actuated by switch plate (3) mounted at the
back of the cab.
The position sensor is checked by the reference
switch. Every time the cab is lifted using the refer¬
ence switch, the measured height is compared to
the stored value in the travel and pump controller.
The mounting height of the reference switch is
determined during the teach-in process. For this
reason, the position must subsequently no longer
be altered (cf. Diagnosis/Teach-In).
img6 120050006ml

Sensors
Repairs
Safety remarks
A WARNING
Danger of damage to the position sensor.
Do not allow the measuring cable to snap, do not
extend further than the specifiedmeasurement
area (max. 30 revolutions ofthe cable drum).
A DANGER
Dangerofinjurydue to pretensioneddock-spring
motorand whiplash effectofthe cable.
The housing of the position sensor may only
be opened by trained staff. When opening the
dock-spring motor, following the work instruc¬
tions precisely.
Error description
Error Cause Remedy Action*
No supply voltage. Determine and remedy cause
Mechanically
Cable/plug damaged. Remedy damage.
in order, no
incremental Encoder defective
Determine cause and remedy,
encoder signal. (overvoltage, wiring error 3,(2,1)
exchange encoder.
or similar).
No supply voltage. Determine and remedy cause
Mechanically Cable/plug damaged. Remedy damage.
in order, no Potentiometer defective
potentiometer (measurement range Exchange potentiometer, check
signal. 1
exceeded, overvoltage, toothed belt.
short circuit, wiring error).
Cable inlet gummed up. Clean cable inlet (brush, alcohol).
Determine cause, new cable,
Sheathing damaged. 2,(1)
possibly new cable inlet.
Measurement Measurement cable Carefully release measurement
2,(1)
cable loose, fails jammed. cable, if damaged mount new cable.
to retract. Check spring and potentiometer,
Belt faulty. 4,(3,2,1)
new belt.
Check belt and potentiometer, new
Spring faulty. 5,(4,3,2,1)
spring.
Measurement Mechanical effect. Check spring, belt.
cable / cable New cable, new potentiometer, (new
fixture. 2,1,(5)
spring).
Action*
The action in brackets ()* must be executed to
allow the repair (no bracket) to be performed,
but only mount new parts if required! (cf. repair
instructions)

Electric/ Electronic 60
Sensors
Action 1 Exchange potentiometer

Action 2 Exchange measurement cable
Action 3 Exchange incremental encoder
Action 4 Exchange belt
Action 5 Exchange spring
Removal
> Delete teach-in values for main lift (cf. Diagno¬
sis /teach-In).
> Raise cab appr. 1 metre and underpin.
> Extend the measurement cable at the cable
eyelet with wire or cord by appr. 0.5m.
> Detach the cable eyelet at the truck frame
and gradually retract the measurement cable
through the cab floor with the extension.
> Lower the cab.
> Remove cover or similar.
> Remove position sensor (4 hexagonal screws
M6).
Installation
> Guide the measurement cable extension from
above through the hole in the cab floor, screw
the position sensor into place.
> Raise the cab and underpin
> Pull out the measurement cable at the ex¬
tension and suspend the cable eyelet at the
fixture on the vehicle frame, remove the mea¬
surement cable extension.
> Carry out teach-in process for main lift (cf.

Diagnosis / teach-in).

Sensors
Repair instruction >
[J] NOTE
Forallrepair work, the sensor andthe entire cable
guide needs to be cleaned (paintbrush, alcohol).
A repair set is also available which contains all

the parts necessary to repair a cable breakage:
(1) Measurement cable
(2) Brass bushing for cable guidance
(3) Potentiometer
(4) Holder
img6120050027ml

Sensors
Exchange potentiometer
NOTE
In case of a cable breakage, cablejumpover,

belt breakage or release of belt tension, the
dock-spring motor causes the potentiometer to
overwind, resulting in mechanicaldamage. For
this reason, the potentiometer must be release
e very time before setting the dock-spring motor.
The potentiometer (1k52, 10 turns) must be ad¬

justed closed to the internal mechanical end stop
img6 120050007ml
when the measurement cable is fully wound up
(resistance appr. 20. ..305! between terminal pin
2 and 3, rising proportionally to the cable exten¬
sion). The pretension on the clock-spring motor
here is only appr. 20 turns.
Mounting:
> Open the sensor housing (10 screws, hexago¬
nal head size 5).
> Release the stud in the potentiometer setting
ring (2).
> Change over the plug from the old to the new
potentiometer (1=white, 2=green, 3=black).
If necessary, bend plug-in contacts slightly
together.
¡mg6120050008m1
> T urn the potentiometer clockwise, seen look¬
ing at the shaft, as far as it will go.
> Insert the potentiometer shaft into the setting
ring in such a way that the shank of the wire
eyelet (1) rests on the hexagonal bolt (3) in the
clockwise direction.
> Tighten the adjusting ring, check the position
of the potentiometer stop.
> Suspend the shank of the wire eyelet (1) in
the slot (4). The potentiometer is then fixed at
an angle removed appr 2-3 degrees from its
internal stop with the cable completely wound
(appr. 20.. .3052).
> Check the function, screw the housing shut. img6 120050009ml
NOTE
Ifthe potentiometeris supplied without wire eye¬

let (1) , mount the old wire eyelet on the new
potentiometer, lock the screw with screw locking
agent (not QLoctite).

Sensors
Exchange the cable >
[j] NOTE
Ifthe cable drum is releasedin an uncontrolled
manner, the dock-spring motor overwinds the
potentiometer causing mechanicaldamage.
> Open the housing, if applicable release the

connecting plug from the sheet metal cover.
> Remove the potentiometer, see above.

> Clamp the housing upedged into a vice so that
img6120050010m1
the wire guide pipe is pointing horizontally to
one side.
> If the old measurement cable is not torn, pull
the cable completely out, clamp a battery-
driven screwdriver or speed-controlled man¬
ual drill on the end of the shaft and leave it
suspended there in order to block the cable
drum.
> If the old cable is torn, the potentiometer must
also always be exchanged. In the event over¬
winding, under certain circumstances the
spring can also be damaged. Remove the
remains of the old cable, check manually
whether the spring has become detached.
Wind up the cable drum using the battery-op¬
erated screwdriver 49 - 51 turns in the clock¬ img6120050011m1
wise direction until the 0.6 mm borehole in the 3

cable drum (1) is close to the cable inlet (2).
> Pull out the crimp sleeve, nip off and remove
the old cable.
> Guide the new cable through the cable inlet (2)
and borehole (1), taking care to avoid loops.
> Plug the crimp sleeve on the end of the cable,
form a loop (3) and push back. Do not allow
the loop to project outwards.
> Crimp on the crimp sleeve using the wire end
ferrule crimping pliers (4).
img6120050012ml

Electric /Electronic 60
Sensors
> Insert the crimped sleeve (2) into the 1.9mm >
borehole (1) of the drum.
> Fix the cable / cable drum and remove the
battery operated screwdriver.
img6 120050013ml
> Evenly wind up the cable using the tension of >

the clock-spring motor onto the cable drum.
For the first few coils, push the cable com¬
pletely toward the 0.6 mm borehole (1) to the
rim of the drum. Do not allow the cable to glide
through your hands.
> Check: If the cable is pulled out 15.0m (pre¬
cisely 30 turns) and released, the wind-up
process must not be affected. The layers must
be lying next to each other. The cable tension
must be even.
> Mount the potentiometer, see above.
img6120050014ml

Sensors
Exchanging the incremental encoder
[j] NOTE
The incrementalencoder (1) is usedasa belt ten¬
sioning fixture. When releasing the fixing screws,
the dock spring motor can unwindin the housing.
If the incremental encoder is exchanged, either

the cable must be carefully deposited or a new
cable must be used. For this, the spring motor
must be relaxed.
> Open the housing, remove the potentiometer, ¡mg6120050015ml
see above. 1
> Clamp the housing upedged into a vice so that
the wire guide pipe is pointing horizontally to
one side.
> Pull the cable completely out and deposit on a
surface completely without loops.
> Clamp a battery operated screwdriver on the
drum shaft to block the clock-spring motor.
> Cut off the cable close to the crimping sleeve >
(2). Pull the crimping sleeve out of the bore¬
hole (1) and carefully allow the cable drum to
run back until the clock-spring motor has com¬
pletely relaxed.
> Unscrew the incremental encoder.
> Mount the new incremental encoder, loosely
mount the fastening screws. The belt must lie
neatly in the toothing.
img6120050013ml

Electric /Electronic 60
Sensors
> Tension the belt (1) by shifting the incremen¬ >

tal encoder, check the belt tension: The belt
tension must allow the belt to be pressed appr.
2 - 3 cm out of alignment by light thumb pres¬
sure. To check this, position a 300g ham¬
mer centrally on the belt (deflection appr. 2 -
3mm). (Belt tension measuring device: 215Hz
±15Hz).
> Tighten the screws, lock the screw heads at
the encoder using locking agent (not Loctite or
similar, as this attacks the plastic).
> Fasten the cables using cable ties.
img6 120050016ml
> Mount the potentiometer, see above.
> If the unwound cable is still in order (not
kinked), it can be reused. The piece of cable
which is lost by cutting off at the crimping
sleeve is of no significance. If the old cable is
too short, a new one must be mounted.
Exchanging the belt >
If a torn belt (1) has to be changed, generally
the potentiometer, the cable and possibly also
the spring are damaged. ()lf a belt is changed
without the above components having sustained
any damage, these can be reused if sufficient
care is taken.
For the relevant procedure, see Exchanging the
potentiometer, measurement cable, incremental
encoder.
img6 120050016ml
Exchanging the spring
[TI NOTE
The springs can break as a result of wear or due
to unbrakedretraction against the direction of
winding, ifpotentiometers andcables are also
defective in such an event, itmakes sense to
replace the whole position sensor. Most spring
damage Is due to cable breakage or incorrect
handling (wrong sense of direction) during as¬
sembly, causing the spring to become detached
in the spring driver.
img6 120050010m2
Checking the spring

> Remove the cable from the cable drum.
> Open the housing, remove the potentiometer,
see above.

Sensors
> Clamp the housing in the vice, mark the cable

drum at the rim (1).
> Clamp a battery operated screwdriver on the
drum shaft and carefully wind up the clock-
spring motor in the clockwise direction as far
as it will go (count appr. 75 turns of the cable
drum).
> Then unwind the drum shaft again appr. 3/4 of
the turns counterclockwise (count the number
of turns).
> Remove the battery operated screwdriver and
manually allow the drum to run back slowly.
The drum must wind back to ±4 turns.
> Repeat the process. During this procedure,
no excess noise should occur, and the force at
the drum should be relatively even, otherwise
the spring must be exchanged.
Exchange / remount the spring >
A DANGER
Danger ofinjury, the spring can unwind!Always
wear protective gloves!
Carefully lift the intermediate plate with spring.
The spring couldjump out! Before removing the
old spring, aiways bindtogether the wire into a
rollusing 3 strong cable ties without fail, and then
remove in one piece using combination pliers.
> Release screws (1) for fastening the interme¬

diate plate (2). img6120050019ml
> Use a wooden strip (3) or similar to fasten the

spring in the spring housing.
> Deposit the intermediate plate with spring
point upwards flat on a suitable underlay. If
the spring is in correct working order, but un¬
hooked from the driver, it does not need to be
changed. Otherwise the spring must be re¬
placed.
img6120050020m1

Sensors
Mounting a new spring
NOTE
Use protective gloves! Only release the spring
safeguard(1) once the spring ispositionedinside
the steelpins andis correctlypositioned. When
the spring tension is released, it can no longer
be moved or turned! Ifthe spring has become
releasedby accident, it can be wound up again in
the open spring housing using the battery oper¬
ated screwdriver.
¡mg6120050021m1
> Position the housing ring (1) over whichever >

hand which is being used to press the new
spring firmly onto the intermediate plate.
> Hold the spring with your fingers around its
periphery (coiling direction clockwise) and
insert between the steel pins and the spring
driver.
> Keep hold of the spring, leaving appr. 6 cm
free at the outside end of the spring.
> Carefully cut off the wire safeguard using side
pliers, allowing the outside end of the spring to
jump forward.
img6120050022m1
> T urn the tensioned spring in such a way that >

the outside end of the spring (1) can be fed
past outside one steel pin and hooked onto the
next steel pin.
> Hook the end of the spring on the steel pin.
> Slip the housing ring from your wrist over the
spring.
> Using yourfree hand, push the spring with a
piece of wood or similar and carefully let it out.
The spring will relax and press firmly from the
inside against the steel pins and the spring
housing.
img6120050023m1
> Check the bent-over shank of the spring in the 1

spring driver. While doing so, hold the spring
down with a wooden strip or similar.

Sensors
> If necessary, apply a small amount of lubricant >

(1) to the free spring coils.
img6120050024m1
> Position the plastic disk (1) centrally on the

spring, check bearing (2) .
> Carefully position the intermediate plate on
the base plate and thread the shaft into the
bearing.
img6120050025m1

Electric/ Electronic 60
Sensors
> Screw the plates together. Do not forget the 2 >

distance sleeves (1).
> Carry out a function test (cf. testing the
springs).
> Fix the screws with a screw locking agent.
> To continue, see Exchanging the cable, Ex¬
changing the potentiometer.
Maintenance
The position sensor is maintenance-free.
Visual inspection:
Check the measurement cable and fixture for
damage.
Every 1000 operating hours or 6-monthly. In case
of multiple shift operation, use in refrigerated en¬
vironments and/or unusual ambient influences,
the maintenance interval must be reduced ac¬
cordingly.
img6 120050026ml

60_ Electric /Electronic_
Sensors

o¿##£cíe~ Electronic controls 64
Drive - and operating hydraulics controller (FPS)
General
Function
• Monitoring and actuation of the drive (1) and
hydraulic (2) power module.
• Monitoring and actuation of main contactors.
• DC/DC converter (3) for +24V control voltage.
• Determination of operating / service hours and
battery discharge display.
• Execution of programmed functions corre¬
sponding to a truck control system (4) with
digital inputs and outputs.
• Teach-in function for: position sensor main
lift, target value potentiometer drive / hydraulic
system.
• Error memory and diagnosis.
The FPS must be correctly set on commissioning img61200440549m!
or after an exchange via the serial interface (5)
6
using the service software "WinMega".
The FPS communicates via the CAN bus with:
Operating console (BPS), electrical steering
(ELK), optional inductive wire guidance (IZF).
The housing of the FPS is potential-free.
On the enclosure is an indication of the serial
number and software version (6).
img61200440547m!

Main current terminals

Terminal Function
GND DC/DC converter
+24V DC/DC converter
+Batt +48V, jumper to (6)
-Batt Jumper to (8)
Armature drive motor
A2
+Batt/A1 Jumper to +Batt
Pump motor A2
-Batt Battery minus
Pump motor D2
Field drive motor F1
Field drive motor F2 img61200440549m2
Batt
1F1
l x
L
\ K2
+Batt
- -Batt
fH_0
F1
|A2
F2
-
-
A2
F1
F2
- +Batt/A1
ÿÿ3) ÿ
D2
A2 . p+
.p-
img61200440548m 1

Electronic controls 64
Pin assignment >

Control circuit board (1) accommodates plugs
X1 to X10, plug X1 1 is located on the DC/DC
converter(2).
img612004547m2
X1 ,free inputs / outputs, Optispeed

Pin Description Pin Description
1 1+24V 6 Free output 2
2 OV 7 +7.5V analog supply.
3 Free input 1, PSA Mode. 8 0V GND analog supply.
4 Free input 2, PSA fault. 9 Analog input position sensor main lift.
5 Free output 1 10 Analog input load sensor n.c.
X2, power supply and EMERGENCY STOP chain

1 2+48V (F5) 5 Contactor check K1 (F5).
2 1+24V (F7) 6 Contactor check K2 (F6).
3 Enable DC/DC converter 1+48V. 7 Main contactor K1, minus.
Monitoring EMERGENCY STOP
4 8 Main contactor K2, minus.
chain.
X3, chain monitoring, Optispeed

1 1+24V 8 Zone recognition Input2.
2 OV 9 Zone recognition Input3.
3 1+24V 10 Zone module OK
4 1+24V 11 n. c.
5 Chain monitoring LEFT. 12 Position sensor main lift channel A.
6 Chain monitoring RIGHT. 13 Position sensor main lift channel A.
7 Zone recognition Inputl. 14 External traction cutoff.

64_ Electronic controls
X4, trailing cable, CAN bus, deadman switch, key-operated switch

1 CAN bus HIGH 4 Deadman switch
2 CAN bus LOW 5 Enable hydraulic system.
3 Key-operated switch 1+48V. 6 Free input.
X5, valves and electromagnetic brake

1 1+24V 8 Switching valve auxiliary lift minus.
Switching valve auxiliary lift 2 2+48V (op¬
2 OV 9
tion).
Switching valve auxiliary lift 2 minus (op¬
3 Proportional valve lower 2+48V. 10
tion).
4 Proportional valve lower minus. 11 Brake stage 1, 2+48V.
5 Switching valve main lift 2+48V. 12 Brake stage 1, minus.
6 Switching valve main lift minus. 13 Brake stage 2, 1+48V.
7 Switching valve auxiliary lift 2+48V. 14 Brake stage 2, minus.
X6, monitoring of motors and lamps

1 1+24V 8 n. c.
2 OV 9 1+24V
3 Carbon brushes, drive motor. 10 Flashing light
4 T emperature sensor drive motor. 11 1+24V
5 Carbon brushes pump motor. 12 Warning lamp (option).
6 T emperature sensor pump motor. 13 1+48V
7 1+24V 14 Hooter
X7, rail switch, aisle recognition

1 1+24V 6 Rail switch RIGHT (n.c. contact).
2 OV 7 Free output
3 Aisle recognition PSA. 8 Free analog input.
4 Aisle recognition IZF 9 Rail switch LEFT (n.o. contact).
5 Rail switch LEFT (n.c. contact). 10 Rail switch RIGHT (n.o. contact).
X8, travel direction, steering OK reference switch

1 1+24V 6 Free input.
2 OV 7 Steering OK.
3 Travel direction FORWARDS (AS). 8 Free input.
4 Travel direction REVERSE (LS). 9 1+24V
Reference sensor height measurement
5 Free input. 10
system.

X9, forced braking at end of aisle (ZAG)

1 1+24V 5 Travel stop (low active).
2 OV 6 Deceleration (low active).
3 Travel direction FORWARDS (AS). 7 Acknowledge ZAG.
4 Travel direction REVERSE (LS). 8 0V GND, n.c.
X10, service interface

1 n.c. 6 n.c.
2 RxD 7 n.c.
3 TxD 8 n.c.
4 n.c. 9 n. c.
5 GND
DC/DC converter
1 Supply +48V 3 Supply +48V
1+48V enable through key-operated
2 4 n. c.
switch.
Discharge display (EAZ)
1 NOTE
To allow the residualbattery charge to be cor¬
rectly determinedby the FPS depending on the
battery used, the "battery type"must be corredty
set by means of the service software or onboard
diagnosis.
In case of a drop below a residual battery charge

of 20%, the red LED of the battery discharge
display flashes in the operating console. A lift
stop is initiated. At the same time, the information
" %& appears in the operating console display.

Test
DC/DC converter
On the board (1), a green LED (2) signals readi¬
ness for operation (1+24V=OK). A fuse (3) "16A
high-speed" is also located there. The DC/DC
converter is actuated via plug X1 1 (4).
Activation of the main contactor

To activate the main contactors K1 and K2, the
following input conditions at the FPS are required:
• Battery plug must be plugged in.
• Key switch enabled (1+48V at X4:3, inter¬
nal bridge to X2:3 - release DC/DG converter
1+48V atX1 1:2).
• Emergency stop chain closed (2+48V at X2:4
of FPS and at contactor coils of K1 and K2).
• Contactor contacts of K1 and K2 are open
(X2:5 and X2:6 must be voltage-free).
• No internal errors must have occurred in the img612004547m3
FPS.
When the input conditions have been fulfilled,
the main contactors K1 and K2 are supplied with
pulsed minus (holding voltage approx. 20V) via
outputs X2:7 and X2:8.The control system auto¬
matically performs a self-diagnosis and switches
off the main contactors in case of faults.
Emergency-stop with FPS

If the FPS detects a serious internal or external
error resulting in an EMERGENCY STOP, the
FPS will react as follows:
• Minus supply to the main contactor K1 and K2
is switched off (X2:7 and X2:8).
• Minus supply to the brake coils 1Y44 is
switched off (X5: 12 and X5:14).
• Minus supply to the hydraulic valves is
switched off.
If the FPS initiates an emergency-stop, an error
code is generally displayed on the operating con¬
sole.
Troubleshooting
The FPS monitors itself and FPS functions auto¬
matically. Errors are normally displayed on the
operating console.
Further diagnosis possibilities:
• Diagnostic software "WinMega": Tester menu,
error memory.

• Onboard diagnosis: Display of digital and ana¬

log inputs on the operating console display.
• Digital multimeter for testing hardware signals.

Repairs
General
• The travel and pump controller A1 0 (FPS) is
only available as a complete unit.
• Only the DC/DC converter (1) and the fuse (3)
"16A high-speed" can be replaced separately.
• Information on the serial number and software
version are contained on the cover.
Removal
> If possible, save old settings to a file before
replacing service software "WinMega".
> Note last error numbers indicated which con¬
cern the FPS on the repair report.
o
> Switch off the truck. ÿa
o
nr
—o o

> Mark the electrical connections and discon¬
nect them. img612004547m3
> Unscrew the control system from the mounting

plate.
Installation
> Apply thermal compound to the reverse side of
the control system.
> Screw-fasten the control system to the mount¬
ing plate.
> Connect the terminals.
> Set the FPS correctly via the service interface
(9-pin SUB-D) using the "WinMega" software
and perform commissioning procedure.

o¿##£cíe~ Electronic controls 64
Other electrical components
can-bus
General
°2W,
For this truck different CAN bus systems may
exist which are intended for data transfer be¬
tween control systems (CAN = Controller Area
Network):
• Truck CAN bus
• Antenna CAN bus (only on trucks with induc¬
CAN2
tive guidance)
Truck CAN bus:
,0, CAN1
The truck CAN bus includes the following compo¬
nents:
• Operating console (BPS) A29
img61200440533m2
• T ravel and pump controller (FPS) A1 0
• Electrical steering (ELK) 3M1
• Inductive wire guidance (IZF) 3A21 (only on
trucks with inductive guidance)
NOTE
Ifthe truck CANbus fails, any error messages

that havebeen sent so far canno longer be trans¬
mitted to the operating console and displayed!
Antenna CAN bus:

The antenna CAN bus is only fitted in trucks with
inductive wire guidance. The antenna CAN bus
includes the following components:
• Inductive wire guidance (IZF) 3A21
• Load side antenna 3W1
• Drive wheel side antenna 3W2

Other electrical components
Test
NOTE
Ifthe truck CAN bus fails, any error messages

thathavebeen sent so far can no longer be trans¬
mittedto the operating console and displayed!
Resistance measurement CAN2

a 'a n
If one of the CAN bus lines CAN High or CAN
CAN1
Low is interrupted, it is possible to check this by
means of a resistance measurement:
1. Resistance %
measurement mg61200440533m2
Correct value: 60Í2

1) Truck CAN bus
One lead
i2on 2) Antennas CAN bus
interrupted:
Voltage measurement
If one of the CAN bus lines is contacting plus or
minus potential, this can be checked with the
truck turned on by means of a voltage measure¬
ment:
2. Voltage measurement CAN high

toGND
2.5-
Correct value:
3.5V
3. Voltage measurement CAN low

toGND
Correct value: ,
Z.D V
Diagnosis interface >

At the truck CAN bus, there is 1 diagnosis in¬
terface in the accessory compartment (1). This
offers the facility to connect the notebook to the
CAN bus and carry out servicing work.
img6 1200440550m 1

Special equipments, accessories 90
End-of-aisle braking (EASS)
General >
Function
The "Forced braking at end of aisle" (ZAG) option
is a facility designed to support the driver which is
only active during forced guidance of the truck.
JaJ
¡mg61200440511m10
The ZAG universal module (4) serves to decel¬

erate the truck at the end of aisle and before
traveling out of the aisle automatically from the
maximum admissible speed to v=2.5km/h. Entry
into the aisle always takes place at the maximum
admissible speed.
It is also possible for the truck to be braked to a
standstill at the end of the aisle. When braking the
truck to a standstill, a difference is drawn between
a stop and an absolute stop (cf. ZAG universal
module /encoding).
With a Stop the truck is decelerated automatically img6120050028m1
to a standstill. The error message FE36 appears
and the Q lamp lights up. After appr. 2s, both
displays are deleted and it is possible to travel
towards the end of the aisle at a speed of 2.5km/h
and towards centre aisle at maximum speed.
With an absolute stop, after speed reduction to
v=2.5km/h and recognition of the additional ab¬
solute stop sensors, the truck is decelerated to
a standstill. In the operating console, the error
message FE36 appears and the red Q lamp (1)
lights up. The truck can be driven towards the end
of aisle with additionally depressed Q button (2)
at v=2.5km/h. It is possible to travel immediately
towards centre aisle at the maximum admissible
speed.
1 NOTE
Ifan aisle switch is recognized when travelling
into an aisle, no forced braking action is per¬
formed at the end of the ais/ei
• During forced braking, the left and right aisle

switch is monitored.
• If no aisle switch is recognized, the ZAG mod¬
ule (4) is not active. The ZAG module also
checks all inputs outside the aisle, but dis¬
ables the outputs for deceleration and travel
stop. Exception: ZAG reflex light also checks
the speed sensor outside the forced guidance
function. For this reason, here deceleration is
activated at v<0.3km/h and the symbol "decel¬
eration" lights up in the operating console.
• As soon as an aisle switch is recognized, the
outputs for the ZAG module are enabled.

• If a zone is not reset, the deceleration remains
active.
• Zone recognition only takes place while the
truck is moving.
• If an aisle switch should fail in the rapid travel
zone, a travel stop is initiated. In the operating
console, the error message FE36 appears and
the red Q lamp (1) lights up. The truck can only
travel with depressed Q button (3) and in creep
speed until the error has been remedied.

ZAG Universal
Function
For the option "Forced braking at end of aisle
(ZAG)" the ZAG universal module is used in this
truck. The module can be encoded for the ver¬
sions ZAG magnetic, inductive, magnetic-diag¬
onal and reflex light. This controls and monitors
the ZAG functions.
The truck's emergency stop chain is guided via ¡mg6120050028m1
the ZAG module. In the event of a fault, the mod¬
ule opens the emergency stop chain.
Encoding
The module can be encoded using plugs: >0<
means pin not assigned, >1< means pin assigned
with +24V.
Truck type
Truck type Pin X3:7 Pin X3:8
Valid encoding 0 0
ZAG version
Version PinX1:13 PinX1:14
inductive 0 0
magnetic-diagonal 0 1
magnetic 1 0
reflex light 1 1
ZAG variant
Variant Pin X2:9 Pin X2:10
Valid sensor logic - 0
Time stop option 1 0

Error code
Acode is displayed in the event of a fault via LEDs
F1-F4 (1) .
\ 1
|X3 1
1 1 X1
1 1
Npre
F1
\REDO O \STOP
OS o OQ
LS o O AS
GE2-Z20 O GE1-Z1
S8 O O S7 X2
S6 O O S5
S4 O O S3
S2 O O S1
¡mg6120050028m1
No. F4 F3 F2 F1 Error Rectification

Incremental encoder 1 channel defective, Check the incremental
1 0 0 0 1 plug not inserted, v<0.3km/h in the direction encoder.
end of aisle or centre aisle.
Travel switch direction is not equal to incre¬ Check travel switch direction,
2 0 0 1 0
mental encoder direction. incremental encoder.
Sudden change of direction, in case of Check the incremental
3 0 0 1 1
v>1.1km/h. encoder.
Travel direction signal: Drive side and load Check travel direction signal
4 0 1 0 0
side =1.
Ind., Magn., Magn.diag.: only one end of Set reed contacts S1-4 to 0.
5 0 1 0 1
aisle=0.
Illogical switch statuses: Ind.: (Inverse Check switch signals.
signals) Magn.: (S1-S4=1) Magn.-diag.:
(S1-S4=0, OR/AND S5-S8=0) Reflex light:
6 0 1 1 0
(with S1=0 OR S2=0, then S3=1 AND S4=1
applies and vice versa, otherwise error; S5=0
AND S6=0.
Ind.: Plate offset too great. Reflex light Pulse
Check plates, switching
7 0 1 1 1
duration too long. signals.
Check switching of reed
8 1 0 0 0 Magn.; Magn.diag.: No pairing of S1-S8.
contacts in pairs.
9 1 0 0 1 Deceleration not OK. Check deceleration.
Reflex light Absolute stop, time stop, v-check Check switch signals.
10 1 0 1 0
outside end of aisle zone.

No. F4 F3 F2 F1 Error Rectification

Magn.diag.: Pulse duration too long. Reflex Check switch signals.
11 1 0 1 1 light Both STOP signals S7 and S8 equal
(debounced).
Reflex light v-check, speed too high when Check deceleration.
12 1 1 0 0
passing the check reflector.
Reflex light Reflector type A/B not ok (reflec¬ Check reflectors.
13 1 1 0 1 tor sequence illogical, path distance from a
reflector too long).
Reflex light Reflector type A/B, path distance Check switch signals.
14 1 1 1 0
too short.
Switch device on/off, carry
Hardware error, ZAG module defective
out reference cycle at a
15 1 1 1 1 (flashing error LEDs indicate difference
switching position in order
between main and monitoring processor).
to record current zone.

Support material
Dynometer >
Function
The brake deceleration value is measured by the
dynometer.
This works using the pendulum principle, which
precisely registers acceleration and deceleration.
At an even speed on the level or at a standstill,
the pendulum always hangs vertically. If correctly
set, the scale dial (1) should show zero. When ac¬
celerating, the indicator deflects in the clockwise
direction and when braking (deceleration) it de¬
flects in the counterclockwise direction.
The value is displayed as a % acceleration due to
gravity g (100% = 9.81 m/s2).
Procedure
> Dampen the rubber suction cups underneath inmS12004501 15m1
the dynometers and fasten with lever (2) on
as horizontal a surface as possible in the lon¬
gitudinal direction of the truck. The viewing
window must be visible seen in the direction of
travel.
> Before measuring deceleration, tilt the mea¬
suring module (3) by appr. 70° so that the main
pointer (4) is showing zero. The main pointer
must be capable of executing almost a com¬
plete revolution to the left and almost a half
revolution to the right from the zero position.
The display range can be tested by tilting the
module.
> Before each brake deceleration measure¬ img61200450116ml
ment, use the rotary knob (6) to move the drag

pointer (5) clockwise towards the main pointer.
During the braking process, the drag pointer
moves together with the main pointer in the
counterclockwise direction as far as the maxi¬
mum end point. The drag pointer then stays in
this position while the main pointer returns to
the zero position.
6 Service Training - W8 054 356 EN - 06/2005

Linde AG
Gescháftsbereich Linde Material Handling
Linde AG
Linde Material Handling Division
W8 054 356 EN - 06/2005

Linde V12 - 04 - v062005 - EN

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Linde V12 - 04 - v062005 - EN

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Service Training

Series V(V1 1/04, V12/04)

Service Training - W8 054 356 EN - 06/2005

• 01/2005 First edition.

Service T raining - W8 054 356 EN - 06/2005 I

Error lists 02-53

Service T raining - W8 054 356 EN - 06/2005 III

Speed sensor 11-7

Temperature sensor 11-10

Carbon brush 11-12

Forced ventilation 11-15

22 Mechanical drive axles

IV Service Training- W8 054 356 EN -06/2005

Aisle recognition 43-2

Central unit 44-1 1

Service T raining - W8 054 356 EN - 06/2005 V

Aisle recognition 44-18

Steer angle reduction (LWB) 44-20

46 Wheels and tyres

Parking brake 49-3

VI Service Training- W8 054 356 EN -06/2005

Other electrical components 64-9

90 Special equipments, accessories

Support material 90-6

Service T raining - W8 054 356 EN - 06/2005 VII

Service T raining - W8 054 356 EN - 06/2005 00-1

Positive mechanical or inductive guidance

With aisle recognition (steering locked, 2-hand

00-2 Service Training - W8 054 356 EN - 06/2005

parameters P52 / P53) the maximum speed is

Service T raining - W8 054 356 EN - 06/2005 00-3

00-4 Service Training - W8 054 356 EN - 06/2005

Service T raining - W8 054 356 EN - 06/2005 02-1

The onboard diagnosis can be used to check

02-2 Service Training - W8 054 356 EN - 06/2005

Starting onboard diagnosis

> Press the Q + 0 keys simultaneously for >2

Menu 0_: EPROM versions

Menu point Version

Menu 1_: Battery type

In Menu 10, the battery type is displayed and can

Service T raining - W8 054 356 EN - 06/2005 02-3

> To quit diagnosis mode, press 0 for >2 sec¬

Menu 2 Digital inputs

> To quit diagnosis mode, press 0 for >2 sec¬

Menu 20: Basic signals

02-4 Service Training - W8 054 356 EN - 06/2005

Menu 21: Operating console buttons

Menu 22: Travel

Menu 23: Lifting, lowering

Menu 24: Cab, sensors

Service T raining - W8 054 356 EN - 06/2005 02-5

Bit Signal Terminal Control

Menu 25: Rail guidance, steering

Menu 26: Free inputs chassis, ZAG, PSA, IZF

Menu 27: Free inputs, cab

02-6 Service Training - W8 054 356 EN - 06/2005

Menu 3_: Analogue inputs f >

In menu points 30..34, analogue inputs are dis¬

Menu Signal Terminal Control

Service T raining - W8 054 356 EN - 06/2005 02-7

The "ParaDig" software is started in the "elec¬ I'f- Erutehingen

PaaOgKiarOrtl 00 GmbH 4€0 1:G|

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