GUNGHEINRICH Traction Control System MP 1505 F 08.01 68 gnostic Display Basic Functional Testing with Operating Mode and for Display Priority Operating Status Display Priority | Operating ModelStatus | Display During operation itis possi- ble to check the “Travel” (~ function on the control card | _= via the diagnostic display Normal Display eer? ‘Symbols 0 -F; the decimal — | point flashes at a frequency [ of 0.25Hz Diagnostic Display ‘Symbols 0 - F; the decimal point is it If during testing in normal ‘mode the symbols 0 - F flash at a frequency of 1.0 Hz without a decimal point or if in diagnostic mode the symbols 0 - F are displayed without a decimal point, this ‘means that the electronic system has detected an error. I an error ‘occurs during testing and is not displayed by the ciagnostic sys- tem, the drive control system should only be replaced in full f no errors are detected outside the drive control system. 10, ‘Auto reverse mode Slow travel ‘Speed limiter ‘Overcurrent Brake mode ‘Acceleration Travel direction Release Ramp start assistance ‘Operating mode anoaomw Te 8.DUNGHEINRICH Traction Control System MP 1505 F 08.01 69 ‘Operating Mode and Status Normal Display 1. Control hance in brake poston 1. Press ramp collsion safety switch Symbols O-F, 2 Poweron Decimal point ashes, Display Operating Mode Frequency 0.2542 Display erating Mode aaa eee ke 2 | ‘Auto reverse mode / ramp colli- gnostic Display TF _No speed lint fr compound or J. | lan eatery. trun avating tn Symbols O-F L.seres motors reveree/ fork direction Decimal point it Encoder swrtch $1 set to 0 or (G0e.Setings TruckRelated |= pO Values’), Disp ‘Speed limit for series motors, Encoder switch S1 sotto oF (s2e . Settings / Truck Related Values") lay Operating Mode 1 Display in ciagnostic mode only! End limit overload due to over- ‘current or shor-ereut, End limit ‘cut-out via current monitor ci- cuit Intexnal error - cannot be pro duced by travel status. 4. Truck traveling forward | drive directionGUNGHEINRICH Traction Control System MP 1505 F 0801 6.10 7. Truck Waveling foward / ive 1 Forward arive direction vavel Display Operating Mode Clase aT oat acted Display Operating Mode 2 Curenty ruses 4. Truck traveling forward drive direction or in reverse I ork direction Disconnect X2.11 from battery negative terminal Display Operating Mode J, Stow tavel een mode 4. Control handle in brake position 2. Switch on power Display Operating Mode LY Display in clagnostc mode ony! ‘Change of direction or no travel direction selected direction 2. Set travel controller to opposite travel direction Display Operating Mode Brake curent mose 4. Set contrat handle to travel range 2. Select travel direction, Set travel controller to 10° - 15° 3, Set travel control to the max position Display 5 fun Operating Mode 4. Reverse Ifork direction tr Display Reverse fork rection travel Operating Mode Forward ve deeston wavel 4. Set contr handle to travel range = the control handiaorake switch is closed Display Operating Mode Q__Tavelreease ES PTO.DUNGHEINRICH eirecdon Control System MP 1505 F 08.01 eit 7, Block te motor 1 Truck on amp 2. Sot control handle to travel range 2. Control hand in brake zone 3. Settraction controller oii (nthe 3. Set traction controler to reverse Girecton of te fed obstacle} travel direction at approx. 50% Display Operating Mode —— A Overoas (average over 3 min- ean nto Hire 2 Navel tes > nominal value + 10%) Display Operating Mode Current controler at im, K con- Ree a tactor activated intermittently Ct eee ec (pulsing) 41. Truck traveling forward J drive or reversing | fork 2. Settracton cone oi Curent unused Display Operating Mode by, Only displayed in rucks with se |. ries motor - operating mode “E" (s0e ,Seitings / Truck-Related Values") Display Operating ModeDUNGHEINRICH ‘Neutral Position and System Test Error digit display / diagnostic display troubleshooting ‘Troubleshooting and Operational Testing Requirements Battery charged, connections ok (charge status, battery con- nector, wiring connections, cell connections) ‘Control and main current fuses ok. Electrical system and drive control free of foreign bodies and ‘contamination, No visible wire damage, wire connections are secure, ‘Travel switch, travel direction switch and “slow travel” switch set in neutral position, + Jack up truck: the drive wheel must be free to rotate. Traction Control System MP 1505 F 08.01 6.12 Neutral Position and System Test Use the truck wiring diagrams for troubleshooting. The drive con- {sol system should only be replaced i full 29 errors are detected ‘ulside the drive control system, — Display digit code t > Note: Do net confuse symbol ‘and digit code when e e dealing wit errors, _- Decimal point 5° Diagnostic display only availabe in normal mode: Individual digs and the decimal point ight up, E> PTO.DUNGHEINRICH Traction Control System MP 1505 F 08.01 618 Display | Fault / Fault Source “Faulty nominal value read- ing at x25, < 400mV or at > 800mV +Travel switch wire broken 0221415), “Red VB LED it | Travel direction contactor tips (both contact for one travel direction) not open or jammed. “Red VB.LED it “Control handle in dive 1 zone +Travel direction contact .€ closed when power supply switched on “Red VBLED it Intemal error control card error “Red VBLED it Intemal error 1, Thermometer faulty *Red VBLED it Display ‘Cause / Remedy / Test Notes. *< 400m - cheek travel switch wire (broken) tor diver fauty +> BOOM travel switch not re in neutral, check travel TF) Internal eror swith closed when power supply «Check travel switch wire is switched on, Red V6 LED It “Check travel direction con. tactor contol 5) *K contactor tip jamming + Check travel direction |. *Limit bypassed (limit short, contactor circuit) .¢_*K contactor driver fauity “Operating errr (travel poedue Len ‘switch activated when pow- er supply switched on) Intemal errar or cuit faulty * Travel direction contact in aig! *Red V6 LED It travel switch jamming, check A Intemal error "___ Inverse brake evaluation “Replace drive contro! circuit faulty system wig’ *Red VB LED It => PTO “Replace drive contro! system Fault / Fault Source *Colision safety switch Cause / Remedy / Test Notes. “Replace drive control sys- *Main contactor or K contac- tem Operating error (collision safety switch activated when power supply is switched on or *Contact in collision safety ‘switch jamming, check “Check K contactor Check wiring “Replace drive contro! *Contactor tip evaluation c= system “Replace drive contro! systemDUNGHEINRICH Traction Control System MP 1505 F 0801 | 6.14 Display Fault Faut Source | Cause /Remedy Test | | Display Fault/ Faull Source Cause Remedy Test Notes Notes Ieral ror _ Hoa re _ 1. Safety system, ‘system Faulty RAM cells system ‘wry oly “ReaVeLeD it veto! -RoUVOLED it ert Peta LED ora [| Bator ow vologe< 170" -Cheok beter charge depending on type of error. UJ, -Red V6 LED iit ‘condition *-Check power supply intemal error “Replace drive control, wprctarot (620 Operating Voltages" Z. Faulty arver level system ‘ ‘on page 18) Po eee 7) Battery iow voltage Battery? 2 LU, =31V(inpower connection «Check power cables, tight- Intemal error “Replace drive contro! Di and D2 circuit: motor en loose connections 17, +Fautty feedback system system \atotdte" freewheel diode (loose contacts) *Red V6 LED it connection) oo Red V6 LED itDUNGHEINRICH “Travel” Error Conditions => fsmany errors can only be detected by the control electronic sys- tem and displayed via the diagnostic dsplay during travel, the truck should brety travel forward and backward. Dave the truck Unt fll modulation or unt K contactor mode wih subsequent inverse braking. Aterthe eror has been displayed and the faut rectified svteh the power off and on again to reset he contol sys- tom (Reset Use the truck wiring 2 diagrams for trouble shooting, The drive control system should only be replaced in ful if ng errors are detected 0) — outside it Errors resutng ina | system cut-out will cause the red V6 LED (7) to light and in adci- tion "7 willbe dis- played after the ercor tlisplay in diagnostic ‘mode. All control out pus willbe cut-out by the safely disconnect switch =— Traction Control System MP 1505 F 08.01 6.15 Normal Mode Display ‘Symbols 0-7 flash, frequency Hz; the decimal point is nether lt nor ashing. lagnostic Mode Display ‘Symbols 0-7 lit the decimal point is nether lt nor flashing. Display | Fault/Fault Source | Cause/ Remedy / Test Notes. 71 Battery ow voltage; error «Check battery charge isplaye for low voltage «Check resistances of bat- (pulse) < 14V tery / supply cables +Red VB LEO It 1 Travel switch wie Cheek travel switch wires 1, breakage *Check travel switch +Fauly travel switch Displayin *Red V6 LED not lit diagnos tie mode ‘cniy DB :oratenpersure ‘Leave drive contol system *Red V6 LED it to cool Remove cause of overload E> PTO.DUNGHEINRICH Traction Control System MP 1505 F 0801 6.16 Display | Fault/Fault Source | Cause/ Remedy / Test Display | Fault/ Fault Source | Cause/ Remedy /Test Notes Notes F]Teelsteionantatr | Chock ave decton con G, “Pavesi som “San? |. tips closed ‘actor cont |. “overvotage “Check connections, ght- “Travel direction contactor «Check travel dection con- “Loose connections in pow- en necessary tps jammed tactr tips ‘erconnection D1 and D2 «Check connections Wiring eror *Check for power cable creat, ‘Carbon brush(es) not "breakage at D1, D2, At *Coniactor group power working and a2 comectons D102 Collision safety switch jammed + Red V6 LED lit Limit short eiut *K contacter tips closed *K contactor tips jammed Red V6 LED lit *Check carbon brush(es) *Check collision safety switch ‘intemal error, replace ive control system + Check K contactor control system *\Check K contactor tps co missing +Red VB LED It slntemal error in hardware *Red V6 LED It +Error cut-out, all contro! ‘outputs inhibited +Red VB LED it “Replace drive control system