Jungheinrich error code list

By | 10/10/2018

Jungheinrich error code list

See also: Jungheinrich Service Repair Manuals PDF

Jungheinrich DFG320 Fault codes

Jungheinrich DFG320

jungheinrich Error Codes Manual PDF

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Jungheinrich system error table

 

Error Description Component Display text Cause / Action Effect
1 Low voltage during system start F, H, L,

F-AC, H-AC

Low voltage ELECTRICAL SYSTEM Check battery voltage, charge battery; Check wire connection to controller; check main current fuse; check main contactor; replace control part; Replace component;

(Limit VN = 80V: VBatt < 64V or VCap. < 56V

Limit VN = 48V: VBatt < 34V or VCap. < 34V

Limit VN = 24V: VBatt <17V)

Travel is inhibited.

 

Reduced power for travel and lifting.

Warning symbol flashing (Else-Check).

2 Over voltage F, H, L,

F-AC, H-AC

Over voltage BATTERY CONTROLLER Check battery voltage; replace controller part; replace component; (Limit VN = 80V: VBatt > 92 V

Limit VN = 48V: VBatt > 62 V

Limit VN = 24V: VBatt > 28 V)

No travel or hydraulic functions Warning symbol

flashing (Else-Check).

3 Temperature limit for controllers

> 80°C (>70°C MP1510C)

or

ACS only: Info at > 85°C Err at > 115°C Err at < -20°C

F, H, L,

F-AC, H-AC

TEMPERATURE CONTROLLER Check sensor and wire connections Allow controllers to cool down; check fan operation, improve cooling.

Warm up the controller and operate at reduced level until the controller has warmed up.

Reduced power for travel and lifting.

Warning symbol flashing (Else-Check).

4 Emergency Disconnect applied during travel F POWER SUPPLY Warning

(V < 20V MP1510C)

Brake applies, travel inhibited
Error Description Component Display text Cause / Action Effect
1 Low voltage during system start F, H, L,

F-AC, H-AC

Low voltage ELECTRICAL SYSTEM Check battery voltage, chargebattery; Checkwireconnectiontocontroller; check main current fuse; check main contactor; replace control part; Replacecomponent;

(Limit VN = 80V: VBatt < 64V or VCap. < 56V

Limit VN = 48V: VBatt < 34V or VCap. < 34V

Limit VN = 24V: VBatt <17V)

Travel is inhibited.

 

Reduced power for travel and lifting.

Warning symbol flashing (Else-Check).

2 Overvoltage F, H, L,

F-AC, H-AC

Overvoltage BATTERY CONTROLLER Check battery voltage; replace controllerpart; replace component; (Limit VN = 80V: VBatt > 92 V

Limit VN = 48V: VBatt > 62 V

Limit VN = 24V: VBatt > 28 V)

No travel or hydraulic functions Warning symbol

flashing (Else-Check).

3 Temperature limit for controllers

> 80°C (>70°C MP1510C)

or

ACS only: Info at > 85°C Err at > 115°C Err at < -20°C

F, H, L,

F-AC, H-AC

TEMPERATURE CONTROLLER Check sensor and wire connections Allow controllers to cool down; check fan operation, improve cooling.

Warm up the controller and operate at reduced level until the controller has warmed up.

Reduced power for travel and lifting.

Warning symbol flashing (Else-Check).

4 Emergency Disconnect applied during travel F POWER SUPPLY Warning

(V < 20V MP1510C)

Brake applies, travel inhibited

 

Error Description Component Display text Cause / Action Effect
5 Over voltage F, F-AC, H-AC ELECTRICAL SYSTEM Check wire connection to battery, check Battery, replace controller part; Replace component;

(Limit for Retrak: VBatt  > 62 V

Limit for MP1510C: V > 32 V)

Brake applies, travel inhibited
6 Wire breakage:

– Travel set point device

C, I2, I3, I4, I5,

Travel switch

TRAVEL SWITCH Check wire connection; Replace travel set point device; Replace Canion/ Interface; Travel stop. “Warning” symbol flashes (Else-Check). Hydraulic functions possible
7 Key switch applied during travel F,F-AC,H-AC KEY SWITCH Warning

(V < 13V for 200ms MP1510C)

Brake applies, travel inhibited
8 2 travel directions applied simultaneously F-AC, H-AC, C,

MP, S, I2, I3, I5, FS

ELECTRICAL SYSTEM Warning, replace travel direction switch, replace Interface 7 Canion; replace Multi-pilot / Solo-pilot

For twin pedal, check the electrical

system.

Travel stop. “Warning” symbol flashing (Else-Check).

Hydraulic functions possible

9 Operator protection switch faulty I2, FS ELECTRICAL SYSTEM Check switch, check wire connections
10 V Cap. <> V Batt; (main

contactor jammed or not open)

F, H,

F-AC, H-AC L

MAIN CONTACTOR Check main contactor, check wire connection; check output pin 2 (ACS) of traction controller; replace component No travel, hydraulics Warning symbol

Flashing warning (Else-Check).

11 Offset error armature / field current (DC) Stator current (AC); Current measurement

point

F, H, L,

F-AC, H-AC

CONTROLLER Check main current wire, replace component Travel no function
12 Disable driver field rheostat faulty for DC Disable driver power stage faulty (for AC) F, H

F-AC, H-AC L

CONTROLLER Replace component;

for AC: Check flat belt wire connection; replace power part

No travel, hydraulics Warning symbol

Flashing warning (Else-Check).

Error Description Component Display text Cause / Action Effect
13 Disable Watchdog field faulty F, H CONTROLLER Replace components Travel no function
14 –  Main contactor not closed

–  Field power stage cannot be switched on (DC)

F, H,

F-AC, H-AC

CONTROLLER/ MAIN CONTACTOR Check wire connection; check main contactor; check charging connection, Check field supply fuse,

Replace component.

No travel, hydraulics Warning symbol

Flashing warning (Else-Check).

15 Disable field faulty; Illegal address (for AC) F, H,

F-AC, H-AC L

CONTROLLER Replace control part; replace component Travel no function
16 Disable driver armature

actuator faulty; Software reset (for AC)

F, H,

F-AC, H-AC

CONTROLLER Replace control part (AC); replace component Travel no function
17 Disable Watchdog armature faulty F, H CONTROLLER Replace components Travel no function
18 DC: Armature power stage cannot be switched on

AC: one of the 3 phases

cannot be switched on

F, H, F-AC, H-AC L CONTROLLER Check armature wire connection; replace power part; replace component Travel no function
Error Description Component Display text Cause / Action Effect
19 Disable armature faulty; Power stage short circuit (for AC)

The error may be triggered by the faulty speed sensor in connection with AS4814Plus controllers. Sensor wheel wobbles (elliptical) or the sensor- sensor wheel gap is too big. In this case the component is not faulty. A short circuit cannot be resolved by switching the truck off/on.

F, H, F-AC ,H- AC,

L-AC

CONTROLLER Replace power part; Replace component.

Can occur in connection with error 70, in this case:

check power supply behind the main contactor contact, in the event of an error the voltage will be much lower here than the rated operating voltage. Disconnect the positive supply from the components to target the error cause. The exception here is the F1 traction controller which must remain connected. One component overloads the testing voltage due to internal short circuit.

The testing voltage arises by charging the internal capacitor batteries via a resistor to the level of the control voltage supply.

Travel no function
  Check sensor, replace sensor and / or sensor wheel.
20 Armature incorrectly connected F, H ELECTRICAL SYSTEM Check armature main current wire connection Travel no function
21 Armature over voltage (short circuit / high side faulty) F, H, F-AC, H-AC L CONTROLLER/ ELECTR Check main current wire to armature; check settings(for AC);

A Armature > 360A for 250ms (MP1510); Replace component.

Error Description Component Display text Cause / Action Effect
22 Watchdog error; Watchdog does not run out F, H, L, M, S, A, I2, I3, I4, C,

F-AC, H-AC, FS

CONTROLLER/ CANION Truck reset,

Replace controlpart; replace component

No travel, hydraulics Warning symbol

Flashing warning (Else-Check).

23 –  Computer overload

–  Permanent interrupt

–  “ACS” timeout on CAN connection

F, H, L, M, S, A, I2, I3, I4, C,

F-AC, H-AC, FS

CONTROLLER / CAN Check CAN bus connection; Check CANION connector and component;

Replace component

No travel, hydraulics Warning symbol

Flashing warning (Else-Check).

24 EEPROM cannot be contacted / parameters not plausible / parameter set to default

Faulty checksum

F, H, L, I2, I3, I4, C,

F-AC, H-AC

MFC brake MFC hydr. , travel

switch

CONTROLLER/ CANION Check battery cable; check VBatt; set trucktype, set default parameters; replace control part; replace component

Delete logbook, change parameters,

set hourmeter, replace component

Flashing warning symbol (Else- Check).
25 No telegrams:

–  no logon from interface

 

 

 

 

 

 

 

 

 

 

–  no telegrams from Can-Bus travel switch

F, H, I4, I8

F-AC, H-AC L

INTERFACE / CAN Check CANBus connection, check wire connection between proportional valve

– modulation; check fuse 1F8; replace iInterface (I2, I4, I8) ; replace lift potentiometer, Multipilot, Solopilot or interface;

MP1510C: Voltage collapses, controller logs on again, interface does not, controller remains blocked and waits for interface.

Check battery voltage (with load!); charge or replace battery if necessary; AS2409K: no “live” telegram received from CAN Bus travel switch for more

than 300 ms; replace travel switch

Error Description Component Display text Cause / Action Effect
26 Wire breakage:

– Lift potentiometer

M, S, I2, I3 MULTIPILOT / SOLOPILOT / LIFT POTENTIOMETER Check wire connection Lift stop. “Warning” symbol flashes (Else-Check), travel enabled
27 Wire breakage:

– Steering setpoint device;

à  Reach truck: for 45° steering bolster movement no flank from proximity switch.

à  Canion: “Steer angle acquire active” parameter has incorrect value

à  Juniors PM2402L:

“Operating mode” parameter incorrectly set

C, L, I3, I4 STEER ACTUAL ANGLE Check wire connection; Replace steer angle sensor / potentiometer;

Replace Canion / Interface; Replace steering;

 

PM2402L from software version 1.60: set parameter P511 “operating mode” correctly à 1 = analog sensor (potentiometer),

2 = digital sensor on steer motor

Crawl speed,

Flashing warning symbol (Else- Check), hydraulic functions enabled. This error produces an emergency stop on the reach truck and the Juniors.

28 Wire breakage:

– Steering sensor

C, L, I3, I4 STEER NOMINAL ANGLE Check wire connection, replace steering wheel sensor;replace Canion / interface; replace steering Crawl speed,

Flashing warning symbol (Else- Check), hydraulic functions enabled. This error produces an emergency stop on the reach truck

29 Wire breakage:

– Traverse potentiometer

M Traverse nominal value MULTIPILOT Replace Multipilot
30 Wire breakage:

– Tilt potentiometer

M Tilt nominal value MULTIPILOT Replace Multipilot,

Teach Multipilot (Hall sensor 2003 only)

31 Wire breakage:

–  ZH1 setpoint device

 

–  Initial lift / lower Setpoint device

M, S

 

 

Travel switch

Sideshift nominal value MULTIPILOT / SOLOPILOT Replace Multipilot / Solopilot, Teach Multipilot (Hall sensor 2003 only);

 

Travel switch: Check / replace switch

Hydraulic functions stop, “Warning” symbol flashes (Else-Check), travel enabled
Error Description Component Display text Cause / Action Effect
32 Wire breakage:

– ZH2 setpoint device

M, S MULTIPILOT / SOLOPILOT Replace Multipilot / Solopilot,

Teach Multipilot (Hall sensor 2003 only)

Hydraulic functions stop, “Warning” symbol flashes (Else-Check), travel enabled
33 Wire breakage:

– ZH3 setpoint device

M, I8 MULTIPILOT Replace Multipilot
34 CANBus damaged F, H, L, M, S, A,

I2, I3, I4, I5, C, F- AC, H-AC

Travel switch

CAN-BUS Check CAN bus connection; replace faulty component; Check terminal resistances No travel, hydraulics Warning symbol

Flashing warning (Else-Check). Only

stored in logbook (from 2004).

35 No travel zero position Deadman and accelerator pedal applied when truck switched on I2, I3, I4, C

Travel switch

TRAVEL ZERO POSITION Warning, check travel switch; Intermittent contact in interface power supply (12 volts)

Check Canion, for twin pedal check

electrical system

Travel stop,

Flashing warning symbol (Else- Check), hydraulic functions enabled.

36 No lift zero position M, I2, I3,FS LIFT ZERO POSITION Warning, check lift setpoint device. Hydraulic functions stop, “Warning” symbol flashes (Else-Check), travel enabled
37 No steering angle nominal value L CONTROLLER / CAN Check steering setpoint device;Check CANBus connection; check “steer type” parameter; Replace component (I5)
38 Component does not log on, self test not concluded. F, H, L, I2, I3, I4,

C, A, M, S, F-AC, H-AC

CONTROLLER / CAN Check CAN-Bus connection and voltage; check DIL switch 7 encoding (MP1510); steering controller monitoring activated? (AS2412F); check ACS encoding; replace component No travel, lifting Warning symbol

Flashing warning (Else-Check).

Error Description Component Display text Cause / Action Effect
39 Implausible truck type

1. Discovered during the self test phase that at least one component has a different truck type as a parameter.

A different truck type was discovered in operating mode. Caused by intermittent contacts in the

power supply connections

F, H, L, I2, I3, I4, I5, A, M,

F-AC, H-AC

TRUCK TYPE For 1. Set truck type;

For 2. Examine and if necessary replace switch (key switch) or rectify intermittent contact in power supply plug connections.

Set truck type.

40 Motor overtemperature Traction motor overtemperature in operating mode.> 150°C And travel speed < 1km/h For ACS:

Info > 145°C

Err  > 165°C

L, F, H

F-AC, H-AC

TEMPERATURE MOTOR Warning; check motor sensor system and wire connections;

Check motor; traction motor brake open?

Reduced power for travel and lifting.

Warning symbol

flashing (Else-Check). For steering only

warning symbol flashing.

41 Brake magnet potentiometer Potentiometer voltage less than 0.3 volts or greater than 2.7 volts for more than 500ms. L BRAKE MAGNETPOTENTIOM ETER Check potentiometer; check potentiometer attachment; check wire connection
Error Description Component Display text Cause / Action Effect
42 – Short circuit between the output and battery positive. (EJC, ELE)

-Brake magnet control, below minimum difference on potentiometer for 500ms when magnet applied. (150mV ) No brake pressure during initialization. Brake pressure after the Emergency Stop magnet

has applied;

L,F BRAKE MAGNET Check wire connection, check brake

magnet; replace component

43 Adjust brake L ADJUST BRAKE Adjust brake; check potentiometer
44 -Brake not connected or connection wire short circuit

 

-Brake cable torn

Only for steer category_3: Internal driver of fail safe brake cannot connect the relay

Or short circuit bypass (contact jams) on the output during power up test

L,F BRAKE FAULTY -Check brake wiring, replace brake if necessary

-Replace brake cable, check potentiometer; Check potentiometer attachment;

 

Only for steer category_3:

-Check brake driver output, check switch contact plausibility, Replace steer component.

No release
Error Description Component Display text Cause / Action Effect
45 Too many pulses from steering set point device Intermittent contact or perturbing radiation.

More than 255 pulses

identified within 100ms

L,I5 STEERING WHEEL Check wire connection, replace sensor bearing; replace component
46 Steering set point device wrongly connected AS4803L: More than 3 pulses identified in one direction and more than 3 pulses in another within 100ms. L,I5 STEERING WHEEL Check sensor bearing connection; check wire connection AS4803L: Check steering wheel recognition input.
47 No pulses from steer set point device ETVQ steering wheel no pulses from 1st sensor bearing. More than 10 pulses were obtained from the stepper motor but fewer than 3 pulses were counted within 200ms from the sensor bearing. L,I5 STEERING WHEEL Check wire connection, replace sensor bearing; replace component No release

 

Error Description Component Display text Cause / Action Effect
48 Does not match the “Steering type” parameter ETVQ steering wheel no pulses from stepper motor or 2nd sensor bearing.

More than 10 pulses were obtained from the sensor bearing but fewer than 2 pulses were counted within 200ms from the stepper motor sensor bearing.

L STEERING TYPE Set steering type correctly

ETVQ: Check stepper motor coupling, tighten grub screw.

 

Test both setpoint device branches, set defaults and truck type

Otherwise faulty, replace component.

49 CAN supply interrupted; Supply above 14 volts or less than 10 volts, Can or sensor bearing incorrectly

supplied

AS 2412 F,H-AC Can Bus CAN supply Suply on CAN connector greater than 14 volts (electrical system short circuit, component) Travel disabled
50 NRG Multipilot wire breakage Horizontal tilt M Setpoint device horizontal Check Multipilot wire connection Parameter 540 set to 1 by mistake Travel and lifting disabled.
51 Teach-In: steering actual value potentiometer L Incorrect setting SETTING Repeat calibration, check wire connection;check potentiometer;replace component
52 Teach-In: Brake magnet potentiometer L Incorrect setting SETTING Repeat calibration, check wire connection;check potentiometer;replace component
53 Teach-In: Steering setpoint potentiometer L Incorrect setting SETTING Repeat calibration, check wire connection;check potentiometer;replace component
Error Description Component Display text Cause / Action Effect
54 Motor wire breakage during power-up test ETVQ: Temperature voltage level less than 0.3 volts or greater than 2.7

volts

L, F, H MOTOR WIRE BREAKAGE Check wire connection;

Check temperature sensor lines; replace component; replace motor

55 Motor short circuit; Current not ok; Power stage faulty L, F-AC, H-AC SHORT CIRCUIT MOTOR Check wire connection; Replace motor; Replace component Traction motor stops, Hydraulic motor stops Warning symbol

flashing (Else-Check).

56 Motor or actual value transmitter incorrectly connected L,F.H MOTOR REVERSE POLARITY Check motor connection; check actual value transmitter potentiometer; AC: Phases L1,L2 or L3 swapped on motor;
57 No actual value change Motor turns despite control signal L,F,H Steering controller ACTUAL VALUE TRANSMITTER Check motor; check actual angle potentiometer; rectify mechanical wheel block;

AS4803L: Check incremental bearings; replace component;

AC: Check actual value transmitter wire breakage signals

PM2402L check operating mode

58 Steering angle actual value fluctuates

ETVQ: Reference mark 0° could not be started within 5 seconds or no valid segment reached.

Steer motor does not turn

L STEER ACTUAL ANGLE Check actual value transmitter (on steer motor)

Check steer motor, fuse and incremental bearing,

rectify mechanical wheel block; Check proximity switch distance.

Error Description Component Display text Cause / Action Effect
59 Steering angle nominal value fluctuates L Steer angle setpoint device

TILLER

POTENTIOMETER

Check setpoint device potentiometer (on tiller)
60 Swivelling bolster does not follow steering wheel directions

Deviation of > 15° for 100ms

The wheel turns more than 5°without change of nominal value on steering wheel, less than 2°/sec after reaching the nominal position.

Tyres over-tensioned, the actual value cannot follow

the nominal value.

L STEERING CONTROL Check steering bolster mechanics; check chain and chain tension; check motor; check actual value transmitter attachment;

Check tyres, replace wheel if necessary.

61 Power stage error L CONTROLLER Replace controller
62 Power stage error L CONTROLLER Replace controller
63 Sensor power supply out of range

 

AS4803L: < 10V oder

>16V

L,F-AC,H-AC CONTROLLER The 12 volt supply not in valid range. Monitoring of 12 volt sensor supply greater than 15 volts and less than 11 volts.

Switch controller off and on, replace

fuse and controller if necessary.

64 Software version differs L CONTROLLER Different software versions in the AS4803Ls in the ETV-Q. Update software to same level.
Error Description Component Display text Cause / Action Effect
65 NRG Multipilot wire breakage centre shifter M Centre switch MP centre shifter Check Multipilot wire connection Parameter 540 set to 1 by mistake Travel and lifting disabled.
66 NRG Multipilot wire breakage

180° / 360° steering toggle

M 180-360 switch

MP toggle switch 180°/ 360°

Check Multipilot wire connection Parameter 543 set to 1 by mistake Travel and lifting disabled.
67 NRG-Multipilot setpoint device travel direction switch jams on MP when system starts M Travel direction MP setpoint device Check Multipilot switch, values in Judit MP teach window, recalibrate values Travel and lifting disabled.
68 Safety switch wire breakage I2, I3, I4, I5 DEADMAN Check wire connection to safety switch (deadman, seat switch); replace safety switch
69 Both lift and lower requested simultaneously I2, I5, FS LIFT/LOWERSWITCH Check wire connection; check switch
70 Component fails to respond orresponds incorrectly to self test F-AC, H-AC, M, S, A,

I2, C

SELF TEST Check displays on basic component (LED); note other error messages on basic card; Check wireconnectionsandcheck connector; check power supply behind the main contactor contact, in the event of an error the voltage will be much lower here than the rated operating voltage. Disconnect the positive supply from the components to target the error cause. One component overloads the testing voltage due to internal short circuit.

The testing voltage arises by charging the internal capacitor batteries via a resistor to the level of the control

voltage supply.

No travel, hydraulics Warning symbol

Flashing warning (Else-Check).

Error Description Component Display text Cause / Action Effect
71 Lower potentiometer wire breakage I2, FS LOWER POTENTIOMETER Check wire connection; replace lower potentiometer; replace Multipilot; replace interface
72 No lowering zero position I2, FS LOWER RESTPOSITION Warning, check lower setpoint device
73 Valve output interface faulty I2 VALVE OUTPUT Warning, check valve outputs
74 Interface valve output faulty I2 INTERFACE FAULTY Replace interface
75 Proportional valve does not draw any current Correct Multipilot ?? I2,I4,C PROP. VALVE Check wire connection, replace proportional valve;replace Canion / interface; replace proportional valve Flashing warning symbol (Else- Check).
76 Proportional valve short circuit I2, I4C PROP. VALVE Check wire connection, replace proportional valve;replace Canion / interface; replace proportional valve Flashing warning symbol (Else- Check).
77 Button wire breakage I2, BUTTON WIRE BREAKAGE Check wire connection; replace button; replace interface
78 Button and travel switch pressed simultaneously I2 BUTTON / TRAVEL SWITCH Warning: Check wire connection; replace button; replace interface
79 Switch and deadman switch pressed simultaneously I2 BUTTON / DEADMAN Warning: Check wire connection; replace button; replace interface
80 2 travel directions simultaneously I2 ELECTRICAL SYSTEM Check wire connection; replace button; replace interface
81 Different parameters for the two traction controllers F, F-AC MOTORS reset parameters (EFG traction controllers) Travel inhibited
82 Sensor wire breakage I2 ELECTRICAL SYSTEM Safety height: Check wire connection; replace button; replace interface
Error Description Component Display text Cause / Action Effect
83 2 of the same components report on the truck

e.g. AS4803L: Key switch voltage cannot be assigned to components

Elle_1,Elle_2 or Elle_3

F, H, I4, F-AC L-AC ELECTRICAL SYSTEM Check component encoding; check wire connection; replace component; Travel inhibited
84 Faulty speed sensor:

à  AS4803L:

–  Speed changes by 50% within 4ms;

–  Reference speed less than half the rated speed;

–  Steer transmission blocked;

–  Tear identification: a valid sensor reading is reduced to zero within 4ms and remains at this level for 50ms without producing a new valid reading.

à  PM2402L/2 from V1.60:

– Too many pulses on encoder 3 on steer motor

F,H,L-AC SPEED SENSOR Check speed sensor; Sensor bearing drift; Check wire connection; Replace speed sensor; Replace component;

 

 

 

 

 

 

 

 

 

 

 

Check wire routing, do not route together with motor supply wires!

Travel stop, Lift stop,

Flashing warning symbol (Else- Check), hydraulic functions enabled.

85 Power release low voltage Travel/Steer:

Capacitor voltage drops to 30V (48V) for 0.5 seconds

F,H-AC L-AC ELECTRICAL SYSTEM TRAVEL Switch truck on and off; check battery; check battery cable connections; check fuse;

Check power connections; replace component

Travel, hydraulics no function, warning symbol

Flashing warning (Else-Check).

Error Description Component Display text Cause / Action Effect
86 Improbable speed, sudden change:

à  AS4803L: 2 sensor systems differ from each other.

à  PM2402L/2 from V1.60: Encoders 3 and 4 supply different sensor signalse

F,H-AC L-AC SPEED IMPLAUS Check wire connection; Replace speed sensor; Replace component;

Pulse counts correct: 8 or 64 pulses/ revolution?

 

Check wiring and plug connections, check wire routing, do not route together with motor supply wires!

87 Sensor line interrupted AS4803L: no voltage drop on a 100 Ohm internal measurement resistor MFC brake: load wheel

speed sensing

F-AC L-AC

MFC brake

Electrics DISCONNECTION SENSOR BEARING Sensor wire disconnected, motor consumes maximum current and makes buzzing noise. Check sensor wires.
88 Hydraulic speed sensor faulty on AS4814H H (AS4814H) SPEED SENSOR H Check speed sensor;

Check wire connection; replace speed sensor; replace component;

Hydraulics stop,

Flashing warning symbol (Else- Check), travel enabled.

89 Hydraulics power release low voltage H ELECTRICS- HYDRAULICS Check battery, check battery wire connection;

Check fuse; replace component

Reduced power for travel and lifting.

Warning symbol

flashing (Else-Check).

90 Travel with handbrake on C ELECTRICAL SYSTEM Check magnetic brake switch Flashing warning symbol (Else- Check).
91 24 volts out of range Info at <17 V

Err at  <15 V

C ELECTRICAL SYSTEM Check power supply; check wire connection For a warning, only the warning symbol flashes (Else-Check).

For an error, the truck stops.

Error Description Component Display text Cause / Action Effect
92 Wrong component reporting on Canion M, S, A ELECTRICAL SYSTEM Check Master/Solopilot; check display; replace component

Check jumper in XB 27 and XB 44 from

pin 2 to pin 6,

Travel, lifting

function, warning symbol flashes (Else-Check).

93 ACS capacitors not charged F, H, C ELECTRICAL SYSTEM Check charging connection, main contactor

does not apply, check bus voltage,

check transformer, fuses and cable set, Replace component

Travel, lifting no function, warning symbol flashes (Else-Check).
94 SDO error F, H, C SDO ERROR Software incompatible check software version

Reload software. Check jumper in

XB 41 from pin 12 to pin 13.

Travel, lifting no function, warning symbol flashes (Else-Check).
95 Pin code error C PIN CODE ERROR Component pin codes not identical Travel, lifting no function, warning symbol flashes (Else-Check).
96 No zero position for hydraulics Masterpilot, Solopilot, M,S Hydraulics zero position MP/SOLOPILOT Check Master/Solopilot; lift, lower, tilt, ZH1, ZH2, ZH3, horn switch not in zero position

Replace component

Hydraulic functions stop, “Warning” symbol flashes (Else-Check), travel enabled
97 Segment beyond tolerance limits

à  PM2402L/2 from V1.60:

Referencing error on power up, no switch signal from proximity switch (NS) or time interval exceeded

L FAULTY SEGMENT Segment on swivelling bolster not within tolerance level.

 

Check wiring and proximity switch, check distance from switch to trip cam on swivelling bolster

Error Description Component Display text Cause / Action Effect
98 The position of the sensor bearing and proximity switch (segment) deviate by more than 1.1 degrees. When the truck starts up, the direction of rotation from the steering wheel sensor system to the motor power connection or the steer motor sensor system is inversed.

à  PM2402L/2 from V1.60: Referencing error during operation, unexpected switch

signal from proximity switch.

L POSITION DEVIATION Check wiring.

 

 

 

 

 

 

 

 

 

Check wiring and proximity switch, check distance from switch to trip cam on swivelling bolster

99 CANBus damaged; CANBus driver temporarily deactivated F,H,M,S,A, I3, I4, C CAN-BUS Check wire connection, check terminal resistors, install truck anti- interferencemeasures; Travel, hydraulics no function, warning symbol flashes (Else-Check).
100 NRG software versions of internal component parts

implausible

M Multipilot software Replace component part with corresponding component, as flashing currently not possible in the

field.

Error Description Component Display text Cause / Action Effect
101 Input / output error JUBES Jubes input/output Check I/Oa, rectify contact error, check operating voltage, replace external transmitter

Index info in display:

a— Sensor 1 supplies values, but not defined. Check parameters 11-17

b— Sensor 2 supplies values, but not defined. Check parameters 20-26

c— Sensor 3 supplies values, but not defined. Check parameters 29-35

Or a sensor 1-3 supplies a voltage

outside the range of 0.5V – 9.5V.

Shown in the driver’s display with error 101
102 Internal error JUBES Jubes internal Check operating voltage. Index info in display:

a — Communication between access module and data recording faulty, check connection

e — Radio module faulty

f — Radio channel number is “0”, should be >0, check parameter 100 g — Radio transmitting power is “0”,

Check parameter 101

h — Lock number is invalid, replace access module

i — Impact sensor faulty, replace data

recorder

Shown in the driver’s display with error 102
Error Description Component Display text Cause / Action Effect
103 Parameter error JUBES Jubes parameters Set parameters Index info in display:

a — Parameter 5 greater than parameter 6, should be smaller.

b — Differential value of parameter 11 is greater than the differential values of the various stages of parameters 12-17 c — Differential value of parameter 20 is greater than the differential values of the various stages of parameters 21-26 d — Differential value of parameter 29 is greater than the differential values of the various stages of parameters 30-35 e — the stages of parameters 12-17 … f — the stages of parameters 21-26 … g — the stages of parameters 30-35 … h — Impact stages of parameters 47-49

i — Impact stages of parameters 50-52

… …are not in increasing order

Shown in the driver’s display with error 103
104 Sensor bearing provides

no pulses on system start up

F,H (SENSOR BEARING) Check sensor bearing and wire, replace sensor bearing or

controller

105 Motor temperature gauge

provides incorrect values Sensor line wire breakage

F,H,L Temp.Motor Check sensor connection and lines, if

possible replace sensor, otherwise replace the entire motor…

106 Controller temperature gauge provides incorrect

values

F,H,L Temp. controller Internal error, replace controller.
Error Description Component Display text Cause / Action Effect
107 Key switch voltage out of range

Hardware encoding

incorrect

F,H,L

MFC hydr. MFC brake

Electrics Error in controller connection (Saab connector) on component No travel No lifting No steering

Main contactor open

108 Calibration reading incorrect F,H (CONTROLLER

internal)

Internal error, replace controller.
109 Brake pedal faulty MFC brake BRAKE PEDAL Brake pedal signals implausible
110 Current output faulty MFC brake MFC hydr. MFC option CONTROLLER Check outputs for short circuits MFC_Hydr.: no lifting MFC_Brake: crawl speed only
111 Steering controller is monitored by traction controller for signs of life telegrams

Traction controller does not receive these telegrams.

The Can Bus is

overloaded.

F Steering controller Check steering controller Travel inhibited Main contactor open
112 Steering controller_2 is monitored by traction controller_1 for signs of life telegrams

The Can Bus is

overloaded.

F Traction controller Check Can Bus, measure terminal resistor 60Ohm
113 Lift controller does not send lift telegrams H LIFT CONTROLLER
114 No traverse distance reference on power up MFC hydr. Info 32

Traverse reference

None Reduced traverse speed until both stops have been reached once.
Error Description Component Display text Cause / Action Effect
115 Main contactor improbable,

contacts not closed. Wire connection interrupted, faulty main contactor driver on traction

controller

F,H,L

??

Main contactor improbable Check wire connection.

If error 19 is also present, disconnect the shorted power stage

Disconnect the power positive.

Check driver voltage (switched against negative). If reading OK, check contactor coil and mechanics.

No truck functions
116 After software flashing (field operation), the item number of the software is implausible and parameters may also be implausible. F,H,

MFC brake MFC prop

Info 54

 

SET TRUCK TYPE

Set truck type and switch truck off / on (wait approx. 35 seconds).

On request, automatically: all parameters are set to default, the software item number is set to plausible, the log book is deleted, the hourmeter set to zero and entry 116

made in the log book.

In the log book only error 116 stands as a marker for this process and all parameters can be at default.
117 Cab position implausible, rotary potentiometer value does not match 180

degree switch

CANION Cab position Check rotary potentiometer, re-adjust if necessary, check 180 degree switch No TRAVEL release
118 Steering controller reports error L Steering controller Check display on steering controller TRAVEL inhibited, EMERGENCY STOP activated
119 Weigher button faulty MFC brake Button faulty Check wire and button Weighing interrupted
120 Weigher pressure sensor faulty MFC hydraulics Sensor faulty Check wire and sensor Weighing interrupted
121 Battery incorrectly locked F-AC Battery lock Locking strips stuck. Check proximity switch No truck functions
201 Optical sensor faulty Rack height select sensor
Error Description Component Display text Cause / Action Effect
202 Too many reference points during calibration Rack height select Calibration wrong
203 Sensor evaluation improbable Rack height select sensor
204 Error when reading EEPROM Rack height select Controller All settings set to default
205 No Multipilot in truck Rack height select MP missing
240 Internal process interrupted Rack height select Controller
250 No height actual value on job input Rack height select The height is invalid for the warehouse level entered
252 Rack height select incorrect Rack height select
253 Rotary field implausible –

transmission overloaded, excess load on incline

F Controller None, switch truck off/on Main contactor opened
254 Diagnostics piratry Judit Box None Create authorisation No diagnosis possible

Components

A C = 064 Display / Operation (LISA / JULIA)
C = 065 Display / Operation (Else-Check)
C = 066 Display/Operation (CANCode)
C = 067 Display (CANDis)
C = 068 Display/Operation (on board computer)
C = 3 Comfort display [CANopen]
C Canion (Atlas Copco) [CANopen]
C = 1 – Master
C = 11 – Slave
F C = 016 Travel (MP1510C / AS2405F / AS2409K / AS2412F)
C = 016 Travel 1 (MP1514F / AS4814Fplus)
C = 017 Travel 2 (MP1514F / AS4814Fplus)
F-AC C = 016 Travel (AS4812/14F)
C = 8 ACS Traction (Atlas Copco AC 8011/18, Inmotion) [CANopen]
Travel switch C = 096 Can-Bus travel switch
H C = 032 Lift (MP1514H / AS4814Hplus)
H-AC C = 032 Lift (AS4814H)
C = 7 ACS Pump (Atlas Copco AC 8011/18, Inmotion) [CANopen]
Rack height select C = 128 Rack Select
I C = 21 I/O-Board 1 [CANopen]
C = 22 I/O-Board 2 [CANopen]
C = 23 I/O-Board 3 [CANopen]
C = 24 I/O-Board 4 [CANopen]

 

I2 C = 146 Interface 2
C = 155 Interface 21
C = 156 Interface 71
I3 C = 147 Interface 3
I4 C = 148 Interface 4 = MFC_brake
I5 C = 149 Interface 5
I6 C = 150 Interface 6 = MFC_Prop
I7 C = 151 Interface 7
I8 C = 152 Interface 8 = MFC_Option
Jubes C = 069 ISM Access Module
C = 29 ISM Access Module [CANopen]
C = 070 ISM-Data recorder
C = 071 ISM-radio module
L C = 048 Steer (MP1502L / PM2402L / AS4803L)
C = 048 Steer 1 (AS4803L)
C = 049 Steer 2 (AS4803L)
C = 050 Steer 3 (AS4803L)
C = 4 Steer computer [CANopen]
M C = 096 Multipilot / Masterpilot
C = 2 Multipilot / Solopilot [CANopen]
S C = 112 Solopilot / Hand lever

Travel setpoint device: travel potentiometer, accelerator pedal
Steering actual value transmitter: steer potentiometer, proximity switch (on steered wheel)

ONLY in 1st generation!
All messages numbered above 100 come from the interface and correspond to messages 1- xx -99!

Warning / Information Messages
INFO 01 SEAT SWITCH_OPEN
INFO 02 NO_TRAVEL DIRECTION
INFO 03 NO_TRAVEL RELEASE
INFO 04 NO_NOMINAL VALUE
INFO 05 LIFTING OFF
INFO 06 DEADMAN KEY OPEN
INFO 07 START_INCORRECT
INFO 08 PARKING BRAKE
INFO 09 SLOW SPEED
INFO 10 TEMPERATURE DRIVE MOTOR
INFO 11 TEMP_LIFT_MOTOR
INFO 12 TEMP_STEER_MOTOR
INFO 13 BRUSH WEAR OUT_DRIVE_MOTOR
INFO 14 BRUSH WEAR OUT_LIFT_MOTOR
INFO 15 BRUSH WEAR OUT_STEER_MOTOR
INFO 16 DRIVING DISABLE
INFO 17 LIFT END DIS.
INFO 18 SECURITY HEIGHT
INFO 19 DOOR OPEN
INFO 20 AISLE MODE
INFO 21 RESCUE STEERING
INFO 22 STEERING MISSING
INFO 23 DIAGNOSTIC_MODE
INFO 24 SWITCH POWER OFF
INFO 25 TEMP_TRAVEL
INFO 26 TEMP_LIFT
INFO 27 TEMP_STEER
INFO 28 SPARE_1
INFO 29 DISPLAY SWITCHES THE EXTERNAL

BUZZER

 

INFO 30 TWIN PEDAL BOTH APPLIED
INFO 31 NO ZERO POSITION
INFO 32 NO TRAVERSE REFERENCE ON POWER UP
INFO 33 ONLY CRAWL SPEED POSSIBLE AS

BATTERY NOT LOCKED

INFO 34 ONLY CRAWL SPEED POSSIBLE, AS INFO

FROM STEERING CONTROLLER

INFO 35 LOW VOLTAGE TRAVEL
INFO 36 LOW VOLTAGE LIFT
INFO 37 LOW VOLTAGE STEER
INFO 40 CHECK MOTOR SENSOR SYSTEM
INFO 48 IMPACT EVENT VERTICAL FORCE 1
INFO 49 IMPACT EVENT VERTICAL FORCE 2
INFO 50 IMPACT EVENT VERTICAL FORCE 3
INFO 51 IMPACT EVENT HORIZONTAL

FORCE 1

INFO 52 IMPACT EVENT HORIZONTAL

FORCE 2

INFO 53 IMPACT EVENT HORIZONTAL

FORCE 3

INFO 54 SET TRUCK TYPE
INFO 73 CHECK VALVE OUTPUTS