Still Mx15-3 (ingles 02-2001).pdf

Workshop Manual

MX15-3

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

to go to the list of contents click here to go to the list of chapters click here to go to the guide of components click here

1/0105

First issued: Last update:

02/01

Workshop Manual

MX15-3

Id. No. W8 054 223

Foreword

Foreword

This workshop manual (WM) is a collection of technical data and functional descriptions for the standard vehicle.

5/0002

It is intended as a guide which should be kept at hand at all times, to help explain the technical features of the vehicle and consequently ensure that maintenance and repair are carried out correctly.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

The WM is updated on a regular basis.

5/0003

Updating workshop manuals Our range of equipment is subject to continuous development and improvement. A consequence of this is that components or assemblies are sometimes replaced or their function changed. 5/0004

In order to guarantee that the owner of a workshop manual is always in possession of up-to-date and relevant documentation, the manual must be updated using the method described overleaf.

8/3000

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

I

Foreword Updating workshop manuals (Continued)

1. Replacing incorrect sheets

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

If a sheet contains an error, e.g. if adjustment values have been altered, the sheet in question must be replaced. The new sheet can be identified by the lefthand side of the page footer (1). The date of issue is updated here in the Issue line (2). The date of issue of the sheet which needs replacing is specified in the Replaces issue line (3). The sheet no. remains the same (4). Every time a change is made, the cover sheet is replaced. The date of first issue and the date of the last update are shown in field (9). This means that the workshop manual edition is immediately obvious.

Workshop MX15-3 Sheet no. A Manual

Issue: 02/01 Replaces issue:

1

If new, altered or additional components are introduced to the series, it may be necessary to insert one or more additional sheets. An additional sheet can be identified by the changes at the left and right of the page footer (5 + 6). At the left, in the Issue line, is the current date of issue (7). At the right, the additional sheet is marked with the sheet no. with a consecutive index (8). The list of contents for the component in question must also be replaced. We send new sheets, whether they are replacement or additional sheets, and new lists of contents, to all the vehicle owners we know of by mail.

Workshop Manual

1

4

2 Page footer of a corrected sheet Workshop MX15-3 Sheet no. A Manual

Issue: 07/01 Replaces issue: 02/01

1

3 Page footer of a cover sheet Workshop MX15-3 Manual

First issued: 02/01 Last update:

2. Inserting new sheets

Issue: 02/01 Replaces issue:

Page footer of an existing sheet

Id.No. ...

9

Page footer of an existing sheet Workshop MX 15-3 Sheet no. A Manual

Issue: 02/01 Replaces issue:

1

6

5 Page footer of an additional sheet Workshop MX15-3 Sheet no. A Manual

Issue: 07/01 Replaces issue:

7

MX15-3

1.1

8

Sheet no.

II

Foreword Notes, imprint

We can accept no liability for warranty claims relating to work carried out in accordance with the instructions in this workshop manual.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

The warranty terms remain unaffected.

STILL WAGNER works continuously on the development of its trucks. We would ask for your understanding that we reserve the right to make alterations and that errors cannot be excluded, and that no warranty claims may be based on the information, illustrations or descriptions contained in this workshop manual.

STILL WAGNER GmbH & Co. KG Trainingcenter Ernst-Wagner-Weg 1-5 72766 Reutlingen

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

III

List of contents List of contents • List of chapters......................................................................................P. XI • Guide to components ...........................................................................P. XII

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Chapter 1: Vehicle data - Guide to information plates and vehicle number...............P. - Hydraulic settings..............................................................P. - Vehicle speed ...................................................................P. • Outside aisle................................................................P. • Inside aisle...................................................................P. • Chapter 2: Drive motor - General .............................................................................P. - Technical data for the drive motor ....................................P. - Drive mor terminals...........................................................P. - Temperature sensor integrated in the carbon brush yoke............................................................P. - Carbon brush monitoring ..................................................P. - Replacing the carbon brushes ..........................................P. - Checking the brush springs ..............................................P. - Removing the drive motor.................................................P. - Installing the drive motor...................................................P. - Drive motor maintenance..................................................P.

1-01 1-02 1-03 1-03 1-03

2-01 2-01 2-01 2-02 2-03 2-04 2-04 2-05 2-06 2-07

• Chapter 3: Drive wheel - Replacing the drive wheel.................................................P. 3-01 - Removing the drive wheel.................................................P. 3-01 • Chapter 4: Gear - Oil change.........................................................................P. 4-01 - Removing the gear............................................................P. 4-02 • Chapter 5: Electromagnetic brake - Function ............................................................................P. - Removal............................................................................P. - Replacing the brake linings...............................................P. - Adjusting the brake clearance...........................................P. - Mechanical brake release .................................................P. - Testing the brake coils ......................................................P. - Continuous release of the second stage...........................P. - Measuring the braking deceleration..................................P. - Checking the braking deceleration....................................P. - Adjusting the braking deceleration....................................P.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

5-01 5-02 5-03 5-04 5-05 5-05 5-06 5-07 5-08 5-10

IV

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

List of contents • Chapter 6: Steering - Adjusting the steering .......................................................P. • General........................................................................P. • Adjusting sequence .....................................................P. • Turning the potentiometer of the steering controller to the centre position ..................................................P. • Adjusting the rotary force at the handwheel ................P. • Adjusting the retaining force in the straight-on position .......................................................................P. • Adjusting potentiometers R11/R12..............................P. • Adjusting the setpoint potentiometers .........................P. • Adjusting the actual value potentiometer.....................P. • Adjusting the max. steering angle ...............................P. • Correction of straight-on ..............................................P. - Rail guidance.........................................................P. - Free travel .............................................................P. • Teaching-in the wheel position display........................P. - Steering controller.............................................................P. • Description...................................................................P. • Guide to the potentiometer and LEDs .........................P. • Service switch..............................................................P. • Pin assignment ............................................................P. • Main current terminals .................................................P. - Steering motor ..................................................................P. • General........................................................................P. • Terminal designations on terminal board ....................P. • Replacing the carbon brushes.....................................P. • Emergency steering.....................................................P. • Maintenance ................................................................P.

6-01 6-01 6-02 6-03 6-04 6-04 6-05 6-06 6-07 6-08 6-09 6-09 6-09 6-10 6-11 6-11 6-12 6-12 6-13 6-14 6-15 6-15 6-15 6-15 6-15 6-15

• Chapter 7: Mast - Removing the mast ...........................................................P. 7-01 - Installing the mast .............................................................P. 7-05 - Mast table .........................................................................P. 7-06 • Chapter 8: Vehicle control system 8U60 - General .............................................................................P. 8-01 - Description ........................................................................P. 8-01 - Pin assignment .................................................................P. 8-02 • Chapter 9: Travel and pump controller A10 - General .............................................................................P. - Terminals ..........................................................................P. - Pin assignment .................................................................P. - Block diagram ...................................................................P. - Signal processing..............................................................P. - Response of the main contactors .....................................P. Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

9-01 9-01 9-02 9-04 9-05 9-06

V

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

List of contents • Chapter 9: Travel and pump controller A10 - Control OK ........................................................................P. - Temperature monitor fo the drive and pump motors.........P. • Testing the temperature sensors.................................P. - Temperature monitor for the travel and pump controller...P. - Carbon brush monitor for the drive and pump motors ......P. - Incremental encoder monitor ............................................P. • Testing the incremental encoder of the drive motor ....P. • Testing the incremental encoder of the pump motor ...P.

9-07 9-08 9-08 9-09 9-10 9-12 9-14 9-15

• Chapter 10: Operating console 8U62 - Operating elements...........................................................P. - Block diagram ...................................................................P. - Operating console board...................................................P. - Pin assignment .................................................................P. - Keyboard boards 1, 2 and 3..............................................P. - Operating console display.................................................P. • General........................................................................P. • Basic display................................................................P. • Operating hours...........................................................P. • Remaining battery capacity .........................................P. • Wheel position display.................................................P. • Display LED for manual steering .................................P. • Status and maintenance symbols................................P. • "Deadman switch not actuated" display ......................P. • "Creep speed" display .................................................P. • "2-handed operation not actuated" display..................P. • "Barrier open" display ..................................................P. • "Maintenance" display .................................................P. • "LR80 error" display.....................................................P. • "Acknowledgement required" display ..........................P. • "Reserve1" display ......................................................P. • "Reserve2" display ......................................................P. - Operating console display.................................................P. • Error display ................................................................P. • Information display ......................................................P. • Switching-on test .........................................................P. • Switching over the operating console display..............P. • LR80 operating status display .....................................P. - Replacing the setpoint potentiometer ...............................P. • Removing the setpoint potentiometer..........................P. • Installing the setpoint potentiometer............................P. • Rough adjustment of the setpoint potentiometer.........P. • Fine adjustment of the setpoint potentiometer ............P. • Teaching-in the setpoint potentiometer .......................P. - LR80 board (option) ..........................................................P. • Description.............................................................P. • Pin assignment ......................................................P.

10-01 10-02 10-03 10-04 10-05 10-06 10-06 10-07 10-07 10-07 10-07 10-08 10-08 10-08 10-08 10-09 10-09 10-09 10-09 10-10 10-10 10-10 10-11 10-11 10-11 10-12 10-12 10-12 10-13 10-13 10-15 10-17 10-19 10-20 10-21 10-21 10-22

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

VI

List of contents

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Chapter 11: Load handling control 8U61 - General .............................................................................P. 11-01 - Description ........................................................................P. 11-01 - Pin assignment .................................................................P. 11-02 • Chapter 12: EMERGENCY-STOP and amplifier module 7A22 - General .............................................................................P. 12-01 - Description ........................................................................P. 12-01 - Pin assignment .................................................................P. 12-02 - Safety relays K33 and K34 ...............................................P. 12-04 - Safety relay K35................................................................P. 12-05 - Key switch relay K36.........................................................P. 12-06 - Relay K37 (steering error).................................................P. 12-07 - "Enable hydraulics" signal.................................................P. 12-08 - Chain monitoring...............................................................P. 12-09 - Adaptation of the steering setpoint ...................................P. 12-12 - Control of the electromagnetic brake ................................P. 12-13 - Evaluation of the setpoint potentiometer for the main lift ..P. 12-14 - Adaptation of incremental encoder signals .......................P. 12-15 • Chapter 13: Distributor board A13 - General .............................................................................P. 13-01 - Structure ...........................................................................P. 13-02 • Chapter 14: Negative feeder module A13 - General .............................................................................P. - Description ........................................................................P. - Terminals ..........................................................................P. - Pin assignment X1 ............................................................P.

14-01 14-01 14-01 14-01

• Chapter 15: Main contactors K1 and K2 - General .............................................................................P. - Coil holder suppression ....................................................P. - Spacing distance...............................................................P. - Contact pressure...............................................................P.

15-01 15-01 15-01 15-01

• Chapter 16: DC/DC converter - General .............................................................................P. - Description ........................................................................P. - Electrical connections .......................................................P. - Technical data...................................................................P.

16-01 16-01 16-01 16-01

• Chapter 17: Distance sensor for the main lift - General .............................................................................P. - Location ............................................................................P. - Identification......................................................................P. - Technical data...................................................................P.

17-01 17-01 17-01 17-01

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

VII

List of contents • Chapter 17: Distance sensor for the main lift - Pin assignment .................................................................P. - Monitor ..............................................................................P. - Safety instructions.............................................................P. - Description of errors..........................................................P. - Removing and installing the distance sensor....................P. - Repair instructions • 1. Replacing the potentiometer....................................P. • 2. Replacing the cable .................................................P. • 3. Replacing the incremental encoder .........................P. • 4. Replacing the belt....................................................P. • 5. Replacing the spring................................................P.

17-01 17-02 17-03 17-04 17-05 17-06 17-07 17-09 17-10 17-11

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Chapter 18: Distance sensor the for additional lift - General .............................................................................P. 18-01 - Monitor ..............................................................................P. 18-02 • Chapter 19: Distance sensor for swivelling - General .............................................................................P. 19-01 - Monitoring .........................................................................P. 19-01 • Chapter 20: Distance sensor for side shifting - General .............................................................................P. 20-01 - Monitor ..............................................................................P. 20-02 • Chapter 21: USER mode - Description ........................................................................P. 21-01 • Chapter 22: Teaching-in process - General .............................................................................P. - Commissioning .................................................................P. - Deleting teaching-in values...............................................P. - Preparation for teaching in................................................P. - Teaching in the main lift distance sensor..........................P. - Teaching in the additional lift distance sensor ..................P. - Teaching in the swivelling distance sensor.......................P. - Teaching in the side shift distance sensor ........................P.

22-01 22-02 22-03 22-04 22-04 22-05 22-06 22-07

• Chapter 23: Reference sequence - General .............................................................................P. 23-01 - Reference sequence for the main lift ................................P. 23-01 - Reference sequence for the additional lift.........................P. 23-01 • Chapter 24: Chassis valve block - Functional elements..........................................................P. 24-01

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

VIII

List of contents • Chapter 24: Chasis valve block - Setting the maximum pressure .........................................P. - Parameterising the main lift ..............................................P. - Soiling indicator ................................................................P. - High presure filter .............................................................P. • Changing the filter - removal .......................................P. • Changing the filter - installation...................................P. - Removing the chassis valve block....................................P. - Fine control of lowering main lift .......................................P.

24-02 24-02 24-03 24-04 24-04 24-04 24-05 24-06

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Chapter 25: Attachment valve block - Functional elements .........................................................P. 25-01 - Adjusting work ..................................................................P. 25-02 - Parameterising the ancilliary movements .........................P. 25-02 • Chapter 26: Pump motor - General .............................................................................P. - Technical data for the pump motor ...................................P. - Pump motor terminals ......................................................P. - Temperature sensor integrated in carbon brush yoke ......P. - Carbon brush monitoring ..................................................P. - Replacing the carbon brushes ..........................................P. - Checking the brush springs ..............................................P. - Pump motor maintenance ................................................P.

26-01 26-01 26-01 26-02 26-03 26-04 26-04 26-05

• Chapter 27: Hydraulic motor - Function ............................................................................P. - Commissioning .................................................................P. - Technical data ..................................................................P. - Checking for leaks ............................................................P. - Removal ...........................................................................P.

27-01 27-01 27-01 27-02 27-03

• Chapter 28: Pump - Removing the pump .........................................................P. 28-01 • Chapter 29: Oil level indicator - -Oil level indicator .............................................................P. 29-01 • Chapter 30: Ventilation filter - Function ............................................................................P. 30-01 - Removal ...........................................................................P. 30-01 - Maintenance .....................................................................P. 30-01 • Chapter 31: Trilateral head (TLH) - Adjusting work on the TLH ...............................................P. 31-01 - Adjusting the tooth profile play .........................................P. 31-02

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

IX

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

List of contents • Chapter 31: Trilateral head (TLH) - Adjusting the eccentric rollers for the overshift function....P. - Adjusting the swivel shaft for the additional lift .................P. - Removing the lift carriage .................................................P. - Adjusting the radial play on the lift carriage ......................P. - Adjusting the axial play on the lift carriage........................P. - Adjusting the potentiometer for side shifting .....................P. - Adjusting the poentiometer for swivelling..........................P. - Adjusting the 90° swivelling range ....................................P. - Adjusting the switching lug for side shifting ......................P. - Adjusting the limit switches for swivelling .........................P. - Adjusting the magnetic sensors ........................................P.

31-06 31-09 31-11 31-12 31-12 31-14 31-16 31-17 31-18 31-19 31-20

• Chapter 35: Error codes - General .............................................................................P. - Travel function ..................................................................P. - Steering function ...............................................................P. - Main lift function ................................................................P. - Additional lift function ........................................................P. - Side shift function..............................................................P. - Swivel function ..................................................................P. - Synchronous swivel-shift movement 180° ........................P. - Synchronous swivel-shift movement 90° ..........................P. - CAN bus error ...................................................................P. - General errors...................................................................P. - Automatic braking at end of aisle function (EASS) ...........P. - Option errors .....................................................................P. - Travel and pump controller errors (FPS) ..........................P.

35-01 35-02 35-03 35-05 35-07 35-08 35-09 35-10 35-11 35-12 35-13 35-16 35-17 35-18

• Chapter 36: Troubleshooting guide - Power supply function.......................................................P. • General........................................................................P. • Battery voltage.............................................................P. • 1+battery voltage after key switch ...............................P. • 1+24V ..........................................................................P. • 1+battery voltage after 1+24V .....................................P. • EMERGENCY-STOP chain.........................................P. • 2+battery voltage.........................................................P. • 2+24V ..........................................................................P.

36-01 36-01 36-02 36-04 36-06 36-07 36-08 36-10 36-12

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

X

List of chapters List of chapters Chapter 1: Vehicle data Chapter 2: Drive motor Chapter 3: Drive wheel Chapter 4: Gear Chapter 5: Brake

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Chapter 6: Steering Chapter 7: Mast Chapter 8: Vehicle control system (FZS) Chapter 9: Travel and pump controller (FPS) Chapter 10: Operating console Chapter 11: Load handling control (LHC) Chapter 12: EM.-STOP and amplifier module (NAV) Chapter 13: Distributor board Chapter 14: Negative feeder module Chapter 15: Main contactors Chapter 16: DC/DC converter Chapter 17: Distance sensor for main lift

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

XI

List of chapters List of chapters Chapter 18: Distance sensor for additional lift Chapter 19: Distance sensor for swivelling Chapter 20: Distance sensor for side shifting Chapter 21: USER mode Chapter 22: Teaching-in process Chapter 23: Reference sequence Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Chapter 24: Chassis valve block Chapter 25: Attachment valve block Chapter 26: Pump motor Chapter 27: Hydraulic motor Chapter 28: Pump Chapter 29: Oil level indicator Chapter 30: Ventilation filter Chapter 31: Trilateral head TLH

Chapter 35: Error codes Chapter 36: Troubleshooting

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

XII

Guide to components

Guide to components • Drive wheel ................................................................................P. 3-01 • Operating console 8U62 ............................................................P. 10-01 ff • DC/DC converter U30 ................................................................P. 16-01 • Electromagnetic brake 1Y44 ......................................................P. 5-01 ff • Drive motor 1M3.........................................................................P. 2-01 ff • Travel and pump controller A10 .................................................P. 9-01 ff • Vehicle control system 8U60......................................................P. 8-01 ff • Fine control of lowering main lift.................................................P. 24-06 • Gear ...........................................................................................P. 4-01 ff Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Main contactors K1 and K2 ........................................................P. 15-01 • Distance sensor for the main lift.................................................P. 17-01 ff • Distance sensor for the additional lift .........................................P. 18-01 ff • Hydraulic motor ..........................................................................P. 27-01 ff • Load handling control 8U61 .......................................................P. 11-01 ff • Steering motor 3M1....................................................................P. 6-15 • Steering controller 3A20.............................................................P. 6-11 ff • Oil level indicator........................................................................P. 29-01 • Pump motor 2M1........................................................................P. 26-01 ff • Negative feeder module A14......................................................P. 14-01 • Trilateral head ............................................................................P. 31-01 ff • Attachment valve block ..............................................................P. 25-01 ff • Chassis valve block....................................................................P. 24-01 ff • Distributor board A13 .................................................................P. 13-01 ff • Distance sensor for shifting........................................................P. 20-01 ff • Distance sensor for swivelling....................................................P. 19-01 • EMERGENCY-STOP and amplifier module 7A22 .....................P. 12-01 ff

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

XIII

Chapter 1

Vehicle data

Guide to information plates and vehicle number UVV check Vehicle no. on chassis

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Vehicle no. on TLH

Carrying load diagram

Vehicle no. on mast Nameplate Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

1-01

Chapter 1

Vehicle data

Hydraulic settings Remark: The prerequisite for the following settings is a pre-set system pressure of 250bar, see also sheet no. 24-02. Without load Hydraulic function

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Lifting main lift

Lowering main lift Lifting additional lift Lowering additional lift Side shift left/right Swivelling left/right End position swivelling SSSB 90°/180° Fork adjustment 1 cyl. Fork adjustment 2 cyl.

With load of 1500kg Hydraulic function Lifting main lift

Lowering main lift Lifting additional lift Lowering additional lift Side shift left/right Swivelling left/right End position swivelling SSSB 90°/180° Fork adjustment 1 cyl. Fork adjustment 2 cyl.

Issue: 02/01 Replaces issue:

Speed

Tolerance

Pressure

Tolerance

450mm/sec.

±30mm/s

Tele: 80bar Triplex: 100bar

420mm/sec. 450mm/sec. 200mm/sec. 250mm/sec. 180° in 7secs. 0m/sec. 180° in 9secs. Not currently used Not currently used

±20mm/s ±30mm/s +30mm/s +50mm/s ±1s +3s Not used Not used

50bar 90bar 80bar 190bar 170bar 100bar 100bar

+60bar +30bar (h1-related) +15bar +30bar +20bar +50bar ±30bar +20bar +20bar

Speed

Tolerance

Pressure

Tolerance

400mm/s

±30mm/s

Tele: 130bar Triplex: 180bar

420mm/sec. 400mm/sec. 350mm/sec. 250mm/sec. 180° in 7secs. 0m/sec. 180° in 9secs. Not currently used Not currently used

±20mm/s ±30mm/s +30mm/s +50mm/s ±1s +3s Not used. Not used

180bar 100bar 80bar 190bar 170bar 100bar 100bar

+50bar +30bar (h1-related) +30bar +30bar +20bar +50bar ±30bar +20bar +20bar

Workshop Manual

MX15-3

Sheet no.

1-02

Chapter 1

Vehicle data

Vehicle speed Outside aisle • Standing height of driver <1.2m and add. lift <1.2m: vmax = 9km/h • Standing height of driver >1.2m or add. lift >1.2m:

vmax = 2.5km/h

Remark: When the cab is lowered as far as possible, the standing height of the driver is 45cm. • Fork outside the vehicle contour:

vmax = 2.5km/h

Inside aisle Remark: When the vehicle is in an aisle, the max. speed depends on the height to which the cab and the additional lift are raised. The current lift height is calculated from 100% main lift + 50% additional lift, see sheet no. 5-06. Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Lift height/m 9 8 7 6 5 4 3 2 1 V / km/h 1

2

3

4

• Fork outside the vehicle contour: • Setpoint deviation, steering >5°:

5

6

7

8

9

10

11

vmax = 2.5km/h vmax = 2.5km/h

Remark: The current lift height of the vehicle also affects the ramp function for side shifting and swivelling. The higher the lift height, the sooner the ramp function is initiated by the Optispeed for side shifting and swivelling. Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

1-03

Chapter 2

Travel drive

General The travel motor is made up of the following components:

2

Field winding (1) Armature winding (2)

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Travel motor, technical data Model:

GF 146-X5

Motor type:

Shunt motor

Voltage:

80V

Rated current:

394A

Revolutions max.:

1650 rpm

Output:

6,4KW

Protection class:

IP23

0/0282

1

3

4

Travel motor connections Armature winding

A2

(3)

Armature winding

A1

(4)

Field winding

F1

(5)

Field winding F2 Block connector X15 Carbon brush monitoring and temperature sensor Block connector X12 Speed sensor Block connector X1 Electromagnetic brake

Issue: 02/01 Replaces issue:

(6) (7) (7) (8)

0/0282

5

7

9

7

8

(9)

Workshop Manual

MX15-3

Sheet no.

2-01

Chapter 2

Travel drive

Temperatursensor integriert in der Kohlenbürsten-Brücke If the temperature in the drive motor between the carbon brushes and stator of the drive motor rises to 160°C, the output of the drive motor is reduced by the travel and pump controller (emergency operation). The error code "FE2197" appears on the operating console display (1), see sheet no. 35-21.

Q PSA

PSA Fehler

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

To test the temperature sensor, the push-in connector X15 to the travel motor must be disconnected. A resistance measurement must then be made at the sensor end between pins X15:4 and X15:1. The temperature at the motor housing must then be measured. The measured values must match those in the table to the right ±20Ω. Remark:

The temperature sensor is mounted in the carbon brush yoke. If the sensor is faulty, the entire carbon brush yoke must be replaced.

Issue: 02/01 Replaces issue:

Workshop Manual

8/3044

1

Temperature °C

Resistance Ω

25

600

50

720

70

840

100

1020

130

1220

150

1360

160

1450

MX15-3

Sheet no.

2-02

Chapter 2

Travel drive

Carbon brush monitor The carbon brush yoke (1) in the travel motor is fitted with a monitoring switch (break contact) (2). When the minimum brush length is reached, this switch is opened by the brush spring (3). This switching signal is sent to the travel and pump control system via the signal leads (4) and (5). The error code "FE2195" appears on the operating console display, see sheet no. 35-21.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Note:

When the brush spring rests on the monitoring switch, the spring pressure on the carbon brush is greatly reduced. This causes the carbon brush to spark and there is a potential danger that the commutator may start to burn. For this reason, it is absolutely essential to replace the carbon brushes immediately when required. The entire set of carbon brushes (6) must always be replaced together (4 brushes)!

0/0280

3

1

6

2

4 5 New carbon brush

1

2

Worn carbon brush

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

6/0172

Sheet no.

6/0173

2-03

Chapter 2

Travel drive

Replacing the carbon brushes The carbon brushes must be replaced when they reach a minimum length of 20mm (1).

1

Length of a new carbon brush: 34mm Always replace the complete set of four carbon brushes.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• • • •

Pull out the battery plug. Remove the travel motor tensioning belt. Lift off the brush spring with a loop of wire (2). Pull out the carbon brushes at the connecting cable. • Disconnect the connecting cable. • Clean out the commutator compartment with compressed air. Note: Never breathe in carbon dust. • Mount the new carbon brushes.

6/0163

Remark: The motor must not be run at full power immediately after the carbon brushes have been replaced. The carbon brushes run in relatively quickly under minimal loads.

2

Checking the brush springs Brush springs with insufficient pre-tension cause the commutator to burn. Ensure that the carbon brushes run easily in the shaft 0/0279

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

2-04

Chapter 2

Travel drive

Removing the drive motor Note:

Once the drive motor has been removed, the vehicle is no longer braked. For this reason, always secure the vehicle to prevent it rolling away before removing the motor!

• Pull out the battery plug.

• Remove the entire induced ventilation fan, including its support. 0/0267

1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Disconnect the induced ventilation hoses.

• Check that the motor connection cables are marked, and if not, mark them appropriately.

• Disconnect all the electrical connections.

• Releae the 6 screws (1) on the drive motor.

Remark: Screws that cannot be accessed from the rear hatch can be reached easily from the battery compartment side when the battery has been removed.

0/0268

2

3

• Lay the metal bar (2) crossways over the rear hatch support.

• Lay the loop of the special cable pull (3) around the fan supports and motor with screw-mounted electromagnetic brake.

Remark: Ensure that none of the electrical connections can be crushed. 0/0269

3

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

2-05

Chapter 2

Travel drive

Removing the drive motor • Push crowbar through the loop (1) and lay it on the metal bar (2). Lift out the drive motor with the crowbar. Remark: First raise slightly at the fan support with your free hand and then, jerking firmly at the same time, lift the drive motor out of the gear.

• Set the motor down on the motor support so that the motor pinion is not damaged. 0/0270

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

1

2

• Lift the motor out of the vehicle and set it down on wooden chocks (3) or some similar kind of support. Ensure that the motor pinion is not damaged.

0/0271

3

Installing the drive motor To install the drive motor, follow the instructions for removal in reverse order, see sheet no. 2-05. Remark: Clean all dirt out of the gear opening before inserting the drive motor. Ensure that the drive motor is inserted vertically in the gear, so that the motor pinion is not damaged. Remark: The 6 screws (4) that are used to secure the drive motor to the drive plate must be inserted and tightened diagonally in several passes. 0/0267

4

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

2-06

Chapter 2

Travel drive

Travel motor maintenance General Maintenance work between major overhauls should consist of the following: • • • • v

Cleaning General visual inspection Replacing damaged parts Checking the brush unit and commutator Replacing the carbon brushes (if necessary)

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

This work should be carried out at least every 500 operating hours or once a quarter. We recommend having major motor overhauls carried out by a specially equipped workshop, as special tools and specialized knowledge are required. Note: Before carrying out any work on the motor, always first pull out the battery plug to avoid short circuits or injury.

Cleaning

8/3001

• Remove the sealing tape and take out the brushes. • Clean the motor thoroughly using compressed air, taking care not to breathe in any dust (wear a protective mask). • Clean soiled commutators and brush unit using a clean cloth (not cotton wool) moistened with benzine and dry well. Remark:

Do not lift the brush springs more than is necessary and do not bend them to the side.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

2-07

Chapter 2

Travel drive

Travel motor maintenance Visual inspection, replacing damaged parts • Straighten or replace dented sealing tapes. • Check fan impellers for damage. Damaged fans (imbalance, reduced output) must be replaced.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Clean the ventilation channels at the gear (1). To do so, remove the travel motor and clean the channels using a vacuum cleaner (do not clean them with compressed air). Soiling reduces the air circulation, leading to increased temperatures in the motor and possibly to irreparable damage.

1

• Check field and armature windings for signs of overloading (overheating): dark coloration, brittle or burned insulation, unsoldered commutators. Motors bearing this kind of damage must be exchanged without delay. 5/0039

• If you discover oil or grease in the motor (usually an oil paste, oil vapour mixed with dust and carbon abrasions), investigate the cause immediately and remedy it. The motor must be cleaned extremely thoroughly.

Remark: Rapid carbon brush or commutator wear is generally due to the effect of oil. The oil/grease burns in the brush sparks, leaving a sharp-edged oil ash which has an abrasive effect. This can lead to inadmissibly high levels of carbon brush wear before the scheduled maintenance dates.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

2-08

Chapter 2

Travel drive

Travel motor maintenance Checking the brush unit, replacing the carbon brushes After the carbon brush unit has been replaced, it should be possible to move the carbon brushes (1) easily in their guides when the spring (2) is lifted.

If one or more of the carbon brushes jam, they must not be sanded down with emery paper or any other abrasive.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

In this case, the entire carbon brush unit must be replaced, as it is possible that the brushes have been thermally overloaded.

2

1

8/3002

It is also important that the carbon brushes are not broken or chipped at the running edges. Remarks: • Always replace the entire brush set, basing your assessment on the shortest brush. • Only use original spare carbon brushes (see spare parts list!) • Do not allow the carbon brush springs to hit the carbon brushes when the brushes are inserted. • If the minimum length has not quite been reached, replace the brushes anyway, as the remaining running time may be shorter than the next maintenance interval. • A maximum of 3 carbon brush sets should be replaced in succession before a general overhaul of the motor is carried out (by a specialised workshop).

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

2-09

Chapter 2

Travel drive

Travel motor maintenance Bearings The ball bearings are maintenance-free. If the bearings are removed during repair work, they must be replaced. Whenever sealing elements are removed, they must be replaced without fail! The bearings must be renewed after approx. 25,000 operating hours.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Only use the bearings specified in the spare parts lists.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

2-10

Chapter 3

Drive wheel

Replacing the drive wheel Dimensions of new wheel:

ø 400 x 160mm

Replace when diameter reaches:

ø 375mm

The drive wheel must be replaced when: • the running surface is badly pitted, • the running surface is out of round, • the running surface is cracked, • the minimum diameter has been reached.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Removing the drive wheel 0/0272

•

Pull out the battery plug.

•

Jack the vehicle securely on both sides.

•

Remove the crossbar (1).

•

Turn the steering until the drive wheel nuts (2) are accessible.

•

Slacken the 8 drive wheel nuts and unscrew them.

•

Remove the wheel.

1

Wheel screw tightening torque: 140Nm

0/0277

2

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

3-01

Chapter 4

Gear

Oil change 2

The oil should be changed for the first time after approx. 200 operating hours. All subsequent gear oil changes should be made at intervals of 2000 operating hours or once a year. Remark:

The gear oil must be drained off when it is at operating temperature. The maximum permissible operating temperature is 80°C.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Set an oil catchment vessel under the oil drainage screw (1) (it should have a capacity of at least 3.5l). • Unscrew the oil filler cap (2). • Unscrew the oil drainage screw and drain off the oil. Note: The oil temperature may be as high as 80°C!

0/0276

• Replace the oil drainage screw, inserting a new sealing ring.

1

• Fill the gear with new gear oil up to the bottom edge of the threaded hole for the oil filler cap (approx. 3.5l). • Insert the oil filler cap, using a new sealing ring.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

4-01

Chapter 4

Gear

Removing the gear Note:

Once the gear has been removed, the vehicle is no longer braked. For this reason, always secure the vehicle to prevent it rolling away before removing the motor!

• Pull out the battrey plug. 0/0272

1

• Remove the drive motor, see sheet no. 2-05. Remark: Depending on the work you are carrying out, either drain off the gear oil or cover the gear opening with the protective cap.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Remove the crossbar (1).

• Unscrew and remove the 6 gear screws (2).

• Unscrew the lubricating nipple (3).

2

0/0273

• Raise the vehicle slighly with a jack and chock it up with wood.

• Roll the gear with drive wheel out from under the motor plate (4).

Remark: Suspend the gear from a rope or chock it up from below with wood to prevent it tilting backwards or to one side.

3

0/0275

4 Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

0/0274

Sheet no.

4-02

Chapter 5

Brake

Electromagnetic brake Function The 2-stage electromagnetic brake consists of two independent electromagnetic circuits. This is necessary so that the braking force can be adapted for the vehicle requirements

1

2

5

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

When current is absent from the brake, the spring assemblies of the primary (1) and secondary stages (2) press against the armature disc (3). This in turn presses on the friction lining (4), which is now pressed in between the motor housing and the armature disc and therefore blocks the drive = braking initiated. If a current is now passed through the two magnet coils (5) and (6) they become magnetic and attract the armature disc (3) and the bell (7) against the spring force. This releases the brake disc (4) and the motor can turn = unbraked condition.

0/0294

4

3

7

6

If the braking force has to be reduced because of the cab height or load, the magnet coil of the 2nd stage (5) is supplied continuously with power and consequently loses its brake-assisting effect.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

5-01

Chapter 5

Brake

Electromagnetic brake 2

Removal

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Note: Once the brake has been removed, the vehicle is no longer braked. For this reason, the vehicle must be secured against rolling away.

•

Disconnect the electrical connection (1) (pull out connector X1).

•

Release the 3 hexagon socket screws (2).

•

The entire magnet unit (3) including the compression springs, armature disc and adjusting sleeves can now be lifted off.

•

The brake lining (7) and the flange (8) lie loosely on the motor pinion (9), which is screwed onto the armature shaft of the motor.

•

To replace the brake, follow the instructions above in reverse order.

Remark: When the electromagnetic brake has been reinstalled, it is absolutely essential to check the brake clearance and to adjust it if necessary (sheet no. 5-04).

0/0295

1

3

4

5

6/1041

6

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

5-02

Chapter 5

Brake

Electromagnetic brake Replacing the brake lining

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

The brake lining (1) must be replaced when it has worn down so far that it can no longer be adjusted (to approx. 7mm) with the adjusting sleeves (2). The brake lining must also be renewed if it is cracked or shows signs of non-radial wear. The electromagnetic brake must be removed in order to replace the brake lining.

3 1

Remark: The brake lining (1) must move freely in an axial direction on the motor pinion (3) when it is turned by hand. A brake lining which does not move freely will always crack and cause noise during operation. For this reason, you must check the motor pinion carefully for scratches or soiling. If necessary, ease the movement of the brake lining on the toothed wheel with copper paste.

Thickness of a new brake lining: Replace at thickness of:

8-0523

14mm 7mm

2

1

3

6/1041

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

5-03

Chapter 5

Brake

Electromagnetic brake Setting the brake clearance 1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

The electromagnetic brake must be active in order to measure the brake clearance (vehicle at a standstill and deadman's switch not actuated). •

Release the three fastening screws (1). Do not remove them.

•

Screw the adjusting sleeves (2) in or out with an open-ended spanner until there is a clearance of 0.3 mm between the magnet section (3) and the armature disc (4) (use a flat gauge for measurement).

•

Check the clearance at 3 different points close to the screws.

•

Tighten the fastening screws (1) again and check the clearance again. Readjust if necessary.

Issue: 02/01 Replaces issue:

Workshop Manual

3

0,3 mm 6/0148

4

MX15-3

2

Sheet no.

5-04

Chapter 5

Brake

Electromagnetic brake 1

Releasing the brake mechanically The brake must be released mechanically if: •

one of the brake coils or one of the components essential for releasing the brake is faulty and the vehicle must be brought out of aisle mode quickly.

•

the vehicle chassis has to be pushed during commissioning.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

0/0295

For this purpose, screw in the two hexagon socket screws M6x16 (1) as far as they go. This pulls the brake base-plate tightly against the body of the magnet and the brake disc is released.

Checking the brake coils Resistance measurement at terminal X1: Pins 1 und 2

Stage 2

90Ω

Pins 3 und 4

Stage

200Ω

90Ω Ω

1

2

4

3 5/0010

Ω

200Ω

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

5-05

Chapter 5

Brake

Electromagnetic brake Continuous release of the second stage The "Optispeed" program module is located in the vehicle control system. Optispeed adapts the acceleration and deceleration parameters for the travel function and the ramps for the hydraulic functions to suit the lift height. Optispeed calculates the overall lift height from the main lift and additional lift. The main lift is valued at 100% and the additional lift 50%.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

E.g.:

The main lift is raised to 5m and the additional lift to an additional 2m. This gives: 1 x 5m + 0,5 x 2m = 6m

The 2nd braking stage is released continuously when the entire height exceeds 6,5m according to the Optispeed calculation.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

5-06

Chapter 5

Brake

Electromagnetic brake Measuring the brake deceleration General The brake deceleration value is measured with the dynometer, Id. no. W8 050 605.

6

This works on the principle of the pendulum, which registers irregular movements with great precision.

2

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

During travel at a steady speed over an even surface, the pendulum always hangs vertically and shows zero on the dial (4). On acceleration, the pointer deflects to the right (clockwise) and on braking (deceleration), it moves to the left.

1 5/0115

Preparations for measurement Moisten the rubber sucker on the underside of the measuring instrument, then use the lever (1) to fasten the dynometer onto a horizontal surface. The dial must face towards the driver's seat and be mounted in the direction of travel.

4

Before every deceleration measurement, the measuring case (2) must be tipped to move the measuring pointer (4) to zero.

5

The dynometer has been set correctly to the zero position when the measuring pointer can move almost a full turn to the left from zero and almost half a turn to the right when the case is tipped.

3

5/0116

The maximum pointer (3) must be moved to the measuring pointer from the right using the knob at the centre of the dial (6). During the braking process, the maximum pointer moves to the maximum deflection point together with the measuring pointer and remains there when the measuring pointer moves back to the zero position.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

5-07

Chapter 5

Brake

Electromagnetic brake Checking the braking deceleration The braking deceleration of the electromagnetic brake must be checked so that: • the vehicle is not braked too hard (stability of the vehicle must be guaranteed in every situation), • but the vehicle still brakes to a standstill within the shortest possible braking distance.

The electromagnetic brake is activated:

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• when the deadman switch is released and the vehicle is at a standstill (no impulses from the impulse transmitter), • manually (EMERGENCY-STOP switch) or if an EMERGENCY stop is initiated as the result of a malfunction. When the vehicle is braked in normal operation (drive lever is released and deadman switch is actuated) or during reversing, only the generator brake system is active. The easiest way to test the braking deceleration of the electromagnetic brake is to accelerate the vehicle to maximum speed and then press the EMERGENCY-STOP switch (1) on the operating console (main contactors become inoperative, electromagnetic brake becomes operative).

1

Q

Q

PSA

PSA Fehler

0/0001

The electromagnetic brake has two separate braking stages: Stage 1: 62W Stage 2: 26W If, when the additional lift is fully lowered, the main lift is below 6.5 m (see sheet no. 5-06), both braking stages are activated in an emergency braking situation, and contribute to braking of the vehicle. If, when the additional lift is fully lowered, the main lift is above 6.5 m (see sheet no. 5-06), the 2nd braking stage is supplied continuously with power and only the 1st braking stage contributes to the braking operation. For this reason, the maximum deceleration of both braking stages must be checked. Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

5-08

Chapter 5

Brake

Electromagnetic brake Checking the braking deceleration Testing braking stages 1 and 2 together • Drive the vehicle into an aisle with its maximum load, fully lower the main and additional lifts. • Check that it is possible to drive at full speed (tortoise symbol (5) on operating console deactivated). • Mount a dynometer (1) where it can be seen clearly and calibrate (see sheet no. 5-07). • Accelerate the vehicle and from maximum speed initiate an emergency braking operation by pressing the EMERGENCY STOP switch (2) on the operating console. • Read the deceleration value off the dynometer: The permissible value is 9% +2%, which represents a deceleration of approx. 0.9m/sec2.

1

5/0115

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

2 Testing the 1st braking stage • Drive the vehicle into an aisle with its maximum load, raise the main lift above 6.5 m and fully lower the additional lift. Remark: The operating buttons (3) on the operating console can be used to switch over the operating console display (4) between operating hours, speed in km/h and the current lift height in mm. • Check that it is possible to drive at full speed (tortoise symbol (5) on operating console deactivated).

5

Q

Q

PSA

PSA Fehler

0/0001

4

3

• Mount a dynometer (1) where it can be seen clearly and calibrate (see sheet no. Bl. 5-07). • Accelerate the vehicle and from maximum speed initiate an emergency braking operation by pressing the EMERGENCY STOP switch (2) on the operating console. • Read the deceleration value off the dynometer. The permissible value is 5.5% +1.5%, which represents a deceleration of approx. 0.6m/sec2. Remark: If the required braking deceleration readings are not reached the brake must be adjusted (see sheet no. 5-10). Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

5-09

Chapter 5

Brake

Electromagnetic brake Adjusting the braking deceleration 3

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Important: The braking deceleration of the 1st stage must be adjusted before the 2nd stage. • Drive the vehicle into an aisle with its maximum load, move the fork into the vehicle contour, raise the main lift to above 6.5 m and fully lower the additional lift (see sheet no. 5-06). Remark: The operating buttons (1) on the operating console can be used to switch over the operating console display (2) between operating hours, speed in km/h and the current lift height in mm. • Accelerate the vehicle to maximum speed. • Actuate the EMERGENCY-STOP switch (3) on the operating console and measure the max. braking deceleration (see sheet no. 5-09).

Q PSA

Q

PSA Fehler

0/0001

2

1

4

• If the braking deceleration is less than 5.5%, the adjusting ring (4) must be turned slightly to the right with a hook spanner. • Measure the deceleration again and if necessary repeat the adjustment until the required deceleration of 5.5%+1.5% is reached. • Keep the vehicle in the aisle with its maximum load. Fully lower the main lift and additional lift and check that the fork is inside the vehicle contour.

0/0295

6

5

• Accelerate the veicle to maximum speed. • Actuate the EMERGENCY-STOP switch (3) on the operating console and measure the max. braking deceleration (see sheet no. 5-09). • If the braking deceleration is below 9%, the locking screw (5) must be released and the adjusting screw turned to the right by a quarter turn with a hexagon socket screw key. • Measure the deceleration again and if necessary repeat the adjustment until the required deceleration of 9%+2% is reached.

0/0296

• Tighten the locking screw (5).

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

5-10

Chapter 6

Steering

Adjusting the steering General Manual steering As long as there is a difference between the set and actual values, the steering motor is driven, to regulate the difference to "zero". For this purpose, the motor is driven in either a right or left-hand rotary direction. The max. steering motor current is limited internally to 100A. Remark: The continuous current is approx. 30A. If 100A flows for longer than 100ms, a short-circuit is identified and the steering controller switches off.

Q PSA

Q

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

PSA Fehler

Driving onto the rail guidance system If both the rail switches or photoreflective cells for aisle recognition are actuated and the handwheel remains in the centre position for 2 seconds, the vehicle switches over to rail travel (manual steering inactive). Two-handed operation is needed to enable travel.

0/0001

1

Remark: The output for "straight-on take-over (rail travel)"of the vehicle control system (X1:24) switches to 24V once the signals "Ral switch LE" (X1:12) and "Rail switch DE" (X1:34) are applied to the vehicle control and the drive wheel is set to the straight on position. Finally, deceleration to v=2.5km/h is lifted. Rail travel The steering controller is switched internally to 7.5V (setpoint for straight on travel) and holds the drive wheel continuously in the position for straight-on travel, on condition that the steering is adjusted correctly. If the actual value deviates from the straight-on position (smaller or larger than 7.5V), it is regulated accordingly. Remark: If deviation from the setpoint is >5° during straight on travel in the aisle, the vehicle is decelerated to v= 2.5km/h and the LED for manual steering (1) on the operating console flashes. Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

6-01

Chapter 6

Steering

Adjusting the steering Adjusting sequence 1. Switch off the vehicle (key switch, EMERGENCYSTOP) and secure it to prevent it rolling away. Jack up the vehicle so that the drive wheel is free. 2. Check all the electrical connections at the potentiometers for actual and set values, steering motor and steering controller. 3. Check the toothed gear ring of the travel drive and steering motor for damage or wear.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

4. Turn the service switch of the steering controller to position "C" (30% drive power) (see sheet no. 6-12). Remark: This is only necessary when a new steering controller or a new actual value or setpoint potentiometer has been installed! (safety measure against incorrect wiring). 5. Turn the offset potentiometers of the steering controller (setpoint, actual value and steering angle limitation) to approximately the centre position (see sheet no. 6-12). Remark: This is only necessary if the steering is to be completely readjusted or if it is found during adjustment of the steering that a potentiometer is right at an end stop. 6. Check the rotary force at the handwheel and adjust if necessary (see sheet no. 6-04). 7. Set the retaining force in the straight-on position (see sheet no. 6-04). 8. Set potentiometers RT1 and RT2 on the operating console to standard values (see sheet no. 6-05). 9. Set the setpoint potentiometer (see sheet 6-06) 10. Set the actual value potentiometer (see 6-07). 11. Set the max. steering angle (see sheet no. 6-08). 12. Lower the vehicle from the jack again. 13. Correct the straight-on position with actual value and setpoint offset potentiometers (see 6-09). 14. Teaching-in for wheel position display (see 6-10). Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

6-02

Chapter 6

Steering

13

X1

8

9 3

4 2

X2

Remark: This is only necessary if the steering is to be completely readjusted or if it is found during adjustment of the steering that a potentiometer is right at an end stop.

1

1

2

3

4

5

6

7

Potentiometers (1) to (3) of the steering controller should be moved to their central position before the steering is adjusted. This is a precaution for fine adjustment, so that a potentiometer does not reach its end stop too soon, where it cannot be turned any further.

1

The potentiometers can be set to approximately the centre as follows:

If there is no audible click at the end, the potentiometer must be turned in one direction by 20 revolutions. Then turn the potentiometer back in the opposite direction by approx. 10 revolutions.

2

I

3

4 2

6

9 8 7

green

OK

S

red

8

red

4 2

5

X4

I

6

Turn it back clockwise by half the number of revolutions.

3 4 5

6

3

5

X3

F 0 12

1

Turn the potentiometer until you hear a quiet clicking sound.

Remark:

•

E D C B A

7

•

Turn potentiometer anti-clockwise until it reaches the end stop, counting the turns as you do so.

3

•

90°

S

1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

10

11

12

Setting the steering controller potentiometer to the central position

14

Adjusting the steering

5/0123

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

6-03

Chapter 6

Steering

Adjusting the steering Adjusting the turning force of the handwheel 1 In order to prevent the handwheel (1) turning accidentally when it is touched, there must be a certain amount of friction between the handwheel axis (2) and the guide. This degree of friction can be altered by turning the adjusting screw (4).

7

4

3

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

5 6

Adjusting the retaining force in the straight on position A spring-loaded ball centres the handwheel in the straight-on position (notch in the handwheel axle). The retaining force is increased by turning the adjusting screw (5) to the right. Lock with nut (6).

8 2

End stop 6/0175

The mechanical end stop functions when a vertical pin (7) hits a horizontal pin (8).

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

6-04

Chapter 6

Steering

Adjusting the steering Adjusting potentiometers RT1/ RT2

2

1

5

There are 2 potentiometers (1, 2) on the operating console board. These potentiometers limit the power supply of steering potentiometer 3R8. If they are turned fully to the left, the potentiometer resistance is 0Ω. • Potentiometers must always be set symmetrically on rail guided vehicles, i.e. the resistance value must be equal for both potentiometers, otherwise the steering angle is asymmetrical.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Remark: The resistance value of RT1 can be measured at plug-in contacts X55.1 and X55.2 (3). The resistance value of RT2 can be measured at plug-in contacts X56.1 and X56.2 (4). Connector X7 (5) must be disconnected for the resistance measurement!

0/0278

3

• The resistance values must be set so that when the drive wheel is turned to 90°, the handwheel for the steering on the operating console is at the mechanical end stop.

.

X56.1

. Standard value for RT1 (1) and RT2 (2) on rail guided 2KΩ Remark: You can also check that the potentiometers are set correctly by taking a voltage measurement. When the vehicle has just been switched on, the setpoint should be at approx. 2.5V, and the max. setpoint should be at approx. 12.5V. It is important to ensure that both potentiometers are set the same. If the resistance is set too low, the drive wheel turns by more than 90°, and if the resistance value is set too high, the 90° steering angles are not reached. Remark:

If the setpoint or actual value is less than 2.2V or if the setpoint or actual value exceeds 12.8V, the steering controller fails (see sheet no. 6-12).

.

3R8 5KΩ

.

X55.1

.2

vehicles: 1600Ω

RT2

4

Ω

Ω

. RT1

.

.

X56.2

. .

X55.2 6/0183

Resistance measurement

. 2KΩ .

.

X56.1

3R8 5KΩ

.

X55.1

.2

RT2 V

. RT1

V

≈12,5V

≈2,5V

.

.

. .

6/0183.1

Voltage measurement

Issue: 02/01 Replaces issue:

Workshop Manual

2KΩ

MX15-3

Sheet no.

6-05

2KΩ

Chapter 6

Steering

Adjusting the steering 1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Adjusting the setpoint potentiometer •

Switch on the vehicle

•

Allow the handwheel (1) to engage in the central position.

•

Release the threaded pins (2) with a 1.5mm hexagon socket screw key.

•

Prepare the voltage measurement against 7.5Vref. (steering controller terminal X1:14) at the steering controller terminal X3:2 (steering setpoint).

•

Turn the shaft of the setpoint potentiometer (3) until the measuring device shows exactly 0V. The arm of the potentiometer is now in the central position.

•

Tighten threaded pin (2) again.

•

Check the setting again. 2

6/0175

3

3R8 5KΩ 2KΩ

2KΩ

.

RT1

RT2

15V (X3:1)

. .

Sollwert (X3:2)

. 0V

V 0V Vref = 7,5V

(X3:3)

6/0183.2

(X1:14)

Issue: 02/01 Replaces issue:

8-0219

Workshop Manual

MX15-3

Sheet no.

6-06

Chapter 6

Steering

Adjusting the steering Adjusting the actual value potentiometer Remark: If a new actual value potentiometer or a new steering controller has been installed, the output power should be reduced at the service switch (see sheet no. 6-12), to prevent damage to the steering in the event of reverse voltage. • Set the drive wheel to the straight-on position. • Switch off the vehicle. • Release the two nuts from the flange (1) to remove the actual value potentiometer (2) from the steering motor.

1 2

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Set the 10KΩ actual value potentiometer exactly to the centre position (ohmically). • Screw on the potentiometer with the flange with holes (3) so that is has to be adjusted as little as possible. Remark: The holder for the actual value potentiometer must be mounted loosely, for the event that the shaft does not run concentrically.

0/0315

Note:

Take care with the cable guide for the connecting cable of the actual value potentiometer. The connecting cable must be secured to the chassis so that it does not get caught in the steering mechanism! • Switch on the vehicle.

3

• Actuate the deadman switch. Remark: If the max. current has previously been limited at the service switch, the switch must be reset to its normal position "7" after approximate adjustment of the drive wheel has been carried out. • The drive wheel must be set exactly to straight on by adjusting the threaded rod (3). If the deviation from the ideal centre position is large, the threaded rod must be adjsted along the fastening rail (4). If the deviation is minimal, the threaded rod can be turned accordingly.

0/0336

4

• Check the function. Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

6-07

Chapter 6

Steering

Adjusting the steering

12 10

11

8

9

6

7

4

5

2

3 4 2

1 3 1

I S 1

Remark: If a steering angle of 90° cannot be reached even by adjusting the potentiometer, proceed as follows: - Move the potentiometer into the central position (see sheet 6-03). - Switch off the vehicle. - Decrease potentiometers RT1 and RT2 on the operating console by approx. 100Ω (see sheet 6-05). - Turn the handwheel into the central position. - Switch on the vehicle. - Proceed as described above.

9 8 7

4 2

5

X3

green

OK

red

S

red

8

I

4 2

6

X4

3 4 5

6

6

E D C B A

F 0 12

3

•

90°

1

•

2

7

•

X2

5

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

•

Press the deadman's switch. Carefully turn the handwheel on the operating console to the right or left-hand stop. The max. steering angle must be 90° on both sides. The drive wheel must not hit the mechanical steering stop. If the steering angle is too small, the potentiometer for the max. steering angle (2) must be turned to the left, to increase the steering angle. If the steering angle is too large, the potentiometer for the max. steering angle (2) must be turned to the right, to decrease the steering angle. The steering angle is set correctly when a steering movement of max. right to max. left and back can be made in service position "7".

3

• •

If a new actual value potentiometer or a new steering controller has been installed, the output power should be reduced at the service switch (1) (see sheet no. 6-12). This prevents damage to the steering in the event of reverse voltage.

1

Remark:

13

X1

14

Setting the maximum steering angle

5/0123

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

6-08

Chapter 6

Steering

13

X1

10

11 3

4 2

X2

1

1

2

3

4

5

6

7

8

9

• Activate both rail switches. • Use a straight line on the floor or a point in the distance as a guide for checking straight-on travel. • Drive the vehicle straight on forwards. • If the vehicle moves sideways by less than 0.5m over a distance of 10 m, the straight-on setting is in order. • If the deviation is larger, it must be corrected with the actual value offset potentiometer (1). • Straight on movement must be checked in forwards and reverse travel. • Preparation for steering adjustment "Free travel": - Take a voltage measurement between the steering actual value (X2:2) and reference voltage 7.5V (X1:14) at the steering controller. - Make a note of the voltage reading on the display (e.g. 0.085V)

90°

1

I

2

S E D C B A

F 0 12

3 4 5

6 9 8 7

3

4 2

5

X3

1

• Enable one rail switch. If the steering is not yet set correctly, this will cause the drive wheel to turn or jerk slightly. • Set the offset potentiometer for the setpoint (2) so that the voltage measurement between the actual value and reference voltage produces exactly the same value as that previously measured in the rail guide (in our example this was 0.085V). • The steering is now set correctly. When the rail switch is activated and subsequently enabled, the drive wheel should not jerk. If it does, the actual value and setpoint must be reset again correctly.

6

Free travel

green

OK

red

3

4

6

8

S

7

red

5

X4

I

2

b)

12

Rail travel

1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

a)

14

Adjusting the steering

5/0123

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

6-09

Chapter 6

Steering

Adjusting the steering Teaching-in the wheel position display The wheel position display (1) on the operating console represents the position of the drive wheel (actual value). In the event that the green LED (2) on the wheel position display does not light up, although the steering has been set exactly with the drive wheel and handwheel in the centre position, but instead one of the yellow LEDs lights up, a teaching-in process must be carried out for the wheel position display.

PSA

PSA Fehler

0/0001

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

2

1

Teaching-in the wheel position display: • Switch on the vehicle. • Switch the vehicle control to USER mode (see sheet no. 21-01). • Actuate the deadman switch. • Set the steering to straight on. • Press the button for 2-handed travel in an aisle (3) and at the same time briefly press the acknowledgement key (4). Remark 1:

Remark 2:

When the two buttons for "2-handed travel in an aisle and "acknowledgement" are pressed at the same time, the sound emitter on the operating console emits a brief tone and the green LED (2) on the wheel position display lights up.

Q PSA

Q

PSA Fehler

0/0001

3

4

When the vehicle control system is in USER mode, the maintenance LED flashes. The vehicle can be operated in this mode without any limitations. When the vehicle is switched off and then on again, the system is switched back from USER mode to normal operation.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

6-10

Chapter 6

Steering

Steering controller

12

3

4 2

X2

1

1

2

3

4

5

6

7

8

9

10

11

The steering controller must be isolated from the vehicle chassis when it is fitted.

Safety test After a supply voltage of 1+24V has been applied to X1.1 and 2+48V to X1.10, a safety test is carried out. The error memory checks the opened contact of the steering contactor 3K1 via the R, L and + terminals. If the result of this safety test is positive, the "Safety relay" output (X1:9) is set and the relay 3K1 picks up. 3K1 closes its contact and 48V are applied to R, L and +. A green LED OK (1) indicates that the error memory has sent an enable signal. The enable signal is removed (green LED goes off) if: • Signal 2+48V is missing at X1.10

90°

• There is a power supply error (internal 15V/7.5V)

S

I

• The external power supply is missing • The steering contactor contact is not open before the test

E D C B A

F 0 12

3 4 5 6

9 8 7

3

4

1

2

5

X3

• There is a setpoint error (red LED (3)), e.g. cable to setpoint potentiometer is broken

6

• There is an actual value error (red LED (2)) e.g. cable to actual value potentiometer is broken

• There is an output stage error

1

• There is a controller error

2

I

red

3

S

red

8 4 2

6

3

5

X4

7

External enable The output stage is enabled internally via input X1.3 (deadman's switch). This causes the "Steering OK" output (X1.8) to be set. Via this output, the vehicle control system (FZS) is informed that the steering is ready for operation. If this does not occur, the brake is not released! The steering remains active for about 2 seconds after X1.3 (enable) is switched off. Remark:

green

OK

• There is a short-circuit error

1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

13

X1 Remark:

14

Description

The error memory also switches the "Steering OK" output (X1.8) if errors occur.

Issue: 02/01 Replaces issue:

Workshop Manual

5/0123

MX15-3

Sheet no.

6-11

Chapter 6

Steering

Steering Controller

(4)

Service switch

(5)

LED for "Steering OK" enable

(6)

LED for actual value error (faulty potentiometer, cable breakage, contact weakness, Actual value <2,2 or actual value >12,8V)

12

Setpoint offset potentiometer

10

(3)

8

Actual value offset potentiometer

11

(2)

9

Adjusting potentiometer for max. steering angle

2

3 4 2

1 3 1

X2

1

LED for setpoint error (faulty potentiometer, cable breakage, contact weakness, setpoint <2,2V or setpoint >12,8V)

90°

2

I

3

S 4 E D C B A

Switch position

Output

Normal operation

7

100%

Max. reduction of the output stage

C

30%

Reduction of the

D

40%

3

4 2

I

red

7

S

red

4

5

60%

6

X4

8

50%

2

F

6

7

Min. reduction of the output stage

green

OK

3

E

9 8 7

5

output stage Reduction of the output stage

5

X3

3 4 5

6

1

The service switch can be used to reduce the output of the steering output stage for steering adjustment. The service switch may only be turned to a maximum setting of "F" (not a continuous switch).

F 0 12

6

Service switch

1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

(7)

4

5

6

7

(1)

13

X1

14

Guide to potentiometers and LEDs

After adjustment work, the switch must be reset to its normal operating position "7". Issue: 02/01 Replaces issue:

Workshop Manual

5/0123

MX15-3

Sheet no.

6-12

Chapter 6

Steering

Steering controller

X2

4

1

2

3

4

5

6

7

8

9

10

11

12

13

X1

2

Description 1+24V supply voltage not occupied Enable (deadman switch) Actual value, straight on (FZS, X1:24) not occupied not occupied Setpoint > 5° Steering OK Safety relay (selection of 3K1) EMERGENCY-STOP chain closed not occupied not occupied not occupied not occupied, 7,V reference voltage

3

Signal 24V 24V 24V 24V 24V 24V 2+batt. 7.5Vref

1

Type Input Input Input Output Output Output Input Output

90°

Pin assignment X2

0V

4 5 6

Output

24V

X4

Pin assignment X4 Remark: Connector X4 is only required for inductive wire guidance (LR80). The steering controller is used as a steering output stage with inductive wire guidance systems.

6 4 2

green

OK I

red

S

red

8

Input Output

6

2 3

Description 15V supply voltage, setpoint potentiometer (approx. 14.6V with load) Setpoint 7.5V± 5V 0V supply voltage, setpoint potentiometer (approx. 0.4V with load) not occupied not occupied take-over, straight on (FPS, X11:13)

4

Signal 15V

9 8 7

2

Pin Type 1 Output

3 4 5

6

5

X3

Pin assignment X3

F 0 12

3

-

E D C B A

1

-

0V

S

7

4

Input Output

I

Description 15V supply voltage, actual value potentiometer (approx. 13.7V with load) Actual value 7.5V± 4.5V 0V supply voltage, actual value potentiometer (approx. 1.3V with load) not occupied

5

2 3

Signal 15V

3

Pin Type 1 Output

1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14

14

Pin assignment X1

5/0123

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

6-13

Chapter 6

Steering

Steering controller Main current connections, steering controller

2+80V 3K1

(1) + 80V supply via contactor 3K1 (2) Steering motor field connection (left) (3) Steering motor field connection (right) (4) 0V

3

1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

2

5/0510

4

+ 80V

4

3

2

1

L

R

0V

5/0505

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

6-14

Chapter 6

Steering

Steering motor General The servo unit is made up of an electric motor and a flange-mounted gear (1) and (2). The motor is fitted with two separate series field windings, so that clockwise and anti-clockwise rotation are possible without changing the polarity. The ball bearings are maintenance free. If the ball bearings are removed when repairs are carried out, they must be replaced. The bearings must also be replaced after about 25,000 operating hours. The gear is greased for the duration of its operating life and is therefore maintenance free.

2 4 3

1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Terminal markings on terminal board A1 = Armature Dr/D1 = Field 1 for clockwise rotation Dl/D2 = Field 2 for anti-clockwise rotation

9/0021a

Replacing the carbon brushes The carbon brushes must be replaced when they have worn down by 50% of the original length. A complete set of carbon brushes must always be replaced (4 brushes). Carbon brush (3) Brush spring (4) Length of a new carbon brush: Replace at residual length:

28mm 14mm

Emergency steering When the vehicle is switched off, a hexagon socket screw key (5) can be used to turn the axis of the steering motor, so that the drive wheel can be set to the required position. Remark: In order to make this adjustment to the drive wheel when the vehicle is switched off, the vehicle must be raised slightly with a jack or similar tool.

Maintenance For instructions on maintenance, please refer to the description of the drive motor (see sheet no. 2-07).

0/0314

5

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

6-15

Chapter 7

Mast

Removing the mast Remark: When the mast is installed or removed, the attachment, including the support, must be mounted or removed. The lowest crossbar (1) of the almost vertically positioned mast can then be guided more easily round the oil tank (2). 0/0317

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

1

2

• Raise the cab by approx. 10 cm and support the attachment from below (3). Height: approx. 6cm

Height: approx. 20cm

0/0321

3 • Disconnect the electrical (4) and hydraulic (5) connections from the attachment.

0/0337

4 Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

5 Sheet no.

7-01

Chapter 7

Mast

Removing the mast • Release the locking screw (1) that secures the support on the underside of the cab.

0/0323

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Releae the hexagon socke screws (2) that secure the support on the underside of the cab.

1

0/0322

2 • Unscrew the support from the cab (3).

0/0324

3 • Use a low lifter to raise the attachment with the support by about 16mm and pull it out at the front (4)

0/0325

4 Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

7-02

Chapter 7

Mast

Removing the mast • Lower the cab entirely. • Close the mechanical stop valves (1) of the main lift cylinders.

• Remove the battery. 0/0327

2

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Disconnect the electrical connections (2) and hydraulic connections (3) for the attachment on the mast.

0/0326

3 • Disconnect the hydraulic supply lead to the main lift cylinders (4).

4

1

0/0320

• Ensure that the hydraulic supply leads to the main lift cylinders are pulled out taut through the opening in the chassis so that the hydraulic leads are not damaged when the mast is removed. Remark: Alternatively, the hydraulic supply leads to the main lift cylinders can be drawn back into the battery compartment while the mast is being removed or installed. 0/0342

3 Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

7-03

Chapter 7

Mast

Removing the mast 1 • Release the electrical connection to the reference switch (1) for the main lift function and draw it back to the battery compartment.

0/0319

4

3

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Open the mast bearing (2), first checking that it is clearly marked.

• Remove both the mast clamps (3). Remark: Do not confuse the shims with one another (4).

0/0318

2 • Attach lifting gear to the mast.

• Lift the mast vertically upwards until the lowest mast strut (5) of the outer mast is just below the lower edge of the tank (6). Important: Ensure that the hose connection points on the tank are not damaged!

0/0317

5

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

6

7-04

Chapter 7

Mast

Removing the mast • Lift the mast horizontally forwards and out of the chassis.

• Lay the mast on 2 squared timbers (1) to lay it down. 1

0/0329

• Carefully lay down the mast.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Also support the upper part of the mast with 2 pieces of wood (2).

0/0328

1

Installing the mast To install the mast, follow the instructions for removal in reverse order (see sheet no. 7-01). Note:

On installation of the mast, the hydraulic leads to the main lift cylinders must be pushed through the opening in the chassis (3) to the outside, otherwise there is a risk that the hydraulic leads may be damaged. Alternatively, the hydraulic supply leads to the main lift cylinders can be drawn back into the battery compartment while the mast is being removed or installed.

0/0330

2

Remark: Do not reconnect the electrical and hydraulic connections until the mast is fully installed. 0/0342

3 Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

7-05

Chapter 7

Mast

Mast table

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Mast type Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele Tele

Issue: 02/01 Replaces issue:

Height (mm) 2500 2600 2700 2800 2900 3000 3100 3200 3300 3400 3500 3600 3700 3800 3900 4000 4100 4200 4300 4400 4500 4600 4700 4800 4900 5000 5100 5200 5300 5400 5500 5600 5700 5800 5900 6000 6100 6200 6300 6400

Cylinder diam. max. lift height (mm) (mm) 55 2470 55 2670 55 2870 55 3070 55 3270 55 3470 55 3670 55 3870 55 4070 55 4270 55 4344 55 4544 55 4744 55 4944 55 5144 55 5344 55 5544 55 5744 55 5944 55 6144 55 6344 55 6544 55 6744 55 6944 55 7144 65 7330 65 7480 65 7630 65 7780 65 7980 65 8180 65 8380 65 8580 65 8780 65 8980 65 9180 65 9380 65 9585 65 9795 65 10000

Workshop Manual

MX15-3

Sheet no.

7-06

Chapter 7

Mast

Mast table

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Mast type Triplex Triplex Triplex Triplex Triplex Triplex Triplex Triplex Triplex Triplex Triplex Triplex Triplex Triplex Triplex Triplex Triplex Triplex Triplex Triplex Triplex Triplex Triplex Triplex Triplex Triplex

Issue: 02/01 Replaces issue:

Height (mm) 2450 2800 2900 3000 3100 3200 3300 3400 3500 3600 3700 3800 3900 4000 4100 4200 4300 4400 4500 4600 4700 4800 4900 5000 5100 5200

Cylinder diam. max. lift height (mm) (mm) 65 3610 65 4330 65 4630 65 4930 65 5230 65 5530 65 5780 65 6030 65 6280 65 6530 65 6780 65 7030 65 7280 65 7530 65 7780 65 8030 65 8280 65 8530 65 8780 65 8930 65 9080 65 9180 65 9480 65 9780 65 10000 65 10380

Workshop Manual

MX15-3

Sheet no.

7-07

Chapter 8

Vehicle control system

General The vehicle control system (FZS) 8U60 (1) is the "headquarters" of the vehicle. The vehicle control system is connected via the CAN bus to the operating console, the travel and pump control (FPS) and the load handling controls (LAS) in the attachment. All input signals are connected to the vehicle control either directly or via the CAN bus. The vehicle control system contains the entire vehicle program.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

If the parameters need adjusting or a new vehicle program is to be loaded, this work must be carried out with a notebook computer. The notebook can be connected at one of the two diagnosis points in the driver's cab or in the controls compartment.

Description

0/0285

• The input signals and linked input signals are processed in real time. • Operation under extreme conditions is possible (temperature range from -40°C to +80°C). • All inputs and outputs are resistant to excess voltage and short circuits. In addition, all the outputs can be diagnosed, i.e. the diagnosis software can determine whether there is a short circuit or lead interruption at an output. Remark: All the outputs except the select signals for the brake, the select signals for the safety relays K33 and K34 and the acknowledgement signal are supplied with 2+24V. If a malfunction occurs in the vehicle, all the outputs except those specified above are switched off by an internal safety relay. • There is a high degree of protection against electromagnetic interference.

1

• Parameters and configuration of the vehicle are stored in a non-volatile memory (EEPROM). 0/0284

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

8-01

Chapter 8

Vehicle control system

Pin assignment

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Pin Type 1 Output 2 3 4 5 6

Output Output Input

7

Input

8 9

Input Input

10

Output

11 12 13

Input Input

14 15

Input Input

16 17 18 19 20

Input Input Input Input Input

21

Input

22 23

Output

24 25 26 27 28 29 30

Output Output Input Input Input

Issue: 02/01 Replaces issue:

Signal 0V

Description 0V supply voltage, potentiometer, height measurement of main lift 0.1A Travel direction LE (forwards) 0.1A Aisle recognition LR80 not occupied not occupied 0-8.5V Setpoint potentiometer, height measurement of main lift 24V Chain monitoring switch, right (NO contact) 24V Steering lock LR80 24V Setpoint, steering >5° ---> deceleration LR80 0-20mA Selection of electromagnetic brake (2nd stage) not occupied 24V Rail switch LE (actuated = 24V) 24V Aisle recognition - outside (actuated = 0V) 24V Act. val, steering >3° (actuated = 0V) 24V Chain monitoring switch, left (NC contact) 24V EASS, Input 2 24V EASS, Input 4 24V EASS, Input 6 24V EASS, Input 8 0-10V Incremental encoder, drive motor (Signal B) 0-24V Incremental enc, height measurement main lift (Signal B) not occupied 8.5V/1A 8.5V supply voltage, potentiometer, height measurement main lift 0.1A Take-over, straight-on (rail travel) 0.1A Travel direction DE (reverse) CAN bus (low) CAN bus (high) 20mA Control on/off at key switch 0-8.5V Adapted actual value, steering 24V Chain monitoring switch, left (NO contact)

Workshop Manual

MX15-3

0/0253

Sheet no.

8-02

Chapter 8

Vehicle control system

Pin assignment

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Pin Type 31 Input 32 Input

33 34 35

Input Input

36

Input

37

Input

38 39 40 41 42

Input Input Input Input Input

43

Input

44 45

Output

46 47 48 49 50

Output Output Output Output

51

Output

52

Output

53

Input

54

Input

55 56

Input Input

57

Input

Issue: 02/01 Replaces issue:

Signal Description 24V Automatics LR80 4.5/6.5V Selection USER/SUPERUSER mode (rotary knob on A13, supplied with 1+24V via fuse F11, see sheet no. 13-01) not occupied 24V Rail switch DE (actuated = 24V) 24V Aisle recognition - inside (actuated = 0V) 24V Ref. switch, height measurement main lift (actuated = 24) 24V Chain monitoring switch, right (NC contact) 24V EASS, Input 1 24V EASS, Input 3 24V EASS, Input 5 24V EASS, Input 7 0-10V Incremental encoder, drive motor (Signal A) 0-24V Incremental enc, height measurement main lift (Signal A) not occupied 0.1A Acknowledgement, mobile personal safety eqipment 1A Selection of valve, lift main lift 1A Selection of valve, lower main lift 1A Selection of valve, ancill. movements not occupied 0.1A EMERG-STOP circuit 1(0V selection relay K34) 0.1A EMERG-STOP circuit 2 (0V selection relay K33) 0-20mA Selection of electromagnetic brake (stage 1) 0V 0V supply voltage for expansion module 1 of the vehicle control sys. 24V/1A 1+24V supply voltage for vehicle control system (buffered via 7A22) 0V 0V supply voltage for vehicle control 24V 2+24V supply voltage for outputs of vehicle control system 24V 2+24V supply voltage for outputs of the vehicle control system

Workshop Manual

MX15-3

0/0253

Sheet no.

8-03

Chapter 8

Vehicle control system

Pin assignment

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Pin Type 58 Input

Signal 24V

59 60 61 62 63

Output Output Output

2A 1A 2A

64 65

Input

0V

66

Input

0V

67

Input

24V

68

Input

24V

Description 2+24V supply voltage for outputs of the vehicle control system not occupied not occupied Horn Warning light Selection of motor for steering angle limitation, LR80 not occupied 0V supply votlage for expansion module 1 of vehicle control system 0V supply voltage for expansion module 2 of vehicle control system 1+24V supply voltage for outputs of expansion module 2 of vehicle control system 1+24V supply voltage for outputs of expansion module 2 of vehicle control system

0/0253

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

8-04

Chapter 9

FPS

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

General The travel and pump controller A10 (1) contains the control and regulating electronics and the ouput electronics for the travel and pump motor. The travel and pump controller (FPS) is installed in the top right-hand corner of the controls compartment. The connections for the control and regulating electronics, the CAN bus connection and the connections for the field coil of the travel and pump motor are located to the right-hand side of the FPS. The main current connections for the battery and the armature coil connections of the travel and pump motor are located to the left-hand side of the FPS. The base plate of the control unit is made of aluminium and is fastened to the chassis with 6 screws. Mounted to the left of the FPS on the base plate, there is always a fan (5) and an additional electronics unit, the negative feeder module A14 (6) (see sheet no. 14-01).

0/0246

1

3

4

Remark: The housing of the FPS is potential free.

0/0247

2

Terminals

5

Control and logic unit

6

(2) 42 pin connector X11 (control and logic leads) (3) CAN bus interface connector X18 (4) Terminal strip X17 for the field coil of the drive and pump motors X17.1 F1 (drive motor 1M3) X17.2 F2 (drive motor 1M3) X17.3 F1 (pump motor 2M1) X17.4 F2 (pump motor 2M1)

Power section 1 2 3 4 5 6 7 8

Battery not occupied not occupied not occupied A1 drive motor 1M3 A2 pump motor 2M1 A2 drive motor 1M3 Battery + / negative feeder module

Issue: 02/01 Replaces issue:

Workshop Manual

0/0297

5 1

6 2

3 7 4 8 8/3066

MX15-3

Sheet no.

9-01

Chapter 9

FPS

Pin assignment X11

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Pin Type 1 Input

Signal +Batt.

2

Input

+Batt.

3 4

Input Output

24V PWM

5 6 7

Input Input Input

24V 24V 0V

8

Input

0V

9 10

Output

24V

11

Output

10V

12

Input

10V

13

Input

24V

14

Input

24V

15 16 17

Input Input

+Batt. +Batt.

18 19 20 21

Input

24V

22

Output

23 24

Input Input

10V 10V

25

Input

10V

26

Input

24V

27

Input

24V

Issue: 02/01 Replaces issue:

1.3mA

Description 80V supply voltage for the control and logic section of the FPS 1+80V voltage to closed relay contacts K33 and K34 Status negative feeder module A14 Clocked 0V power supply for main contactors K1 and K2 Deadman switch signal Steering OK 0V supply voltage for control and logic section of the FPS 0V supply voltage for control and logic section of the FPS not occupied 1+24V supply voltage for electronics of the negative feeder module A14 10V supply voltage for the incremental encoder of drive and pump motors Incremental encoder signal, drive motor (channel A) Actual value, straight on (steering controller takes over rail travel) Inductive wire guidance OK (24V = Inductive wire guidance is OK) 1+80V after key switch not occupied Carbon brush monitor, pump motor (80V = carbon brushes OK) not occupied not occupied not occupied Steering angle limiter locked (3S34) (24V = locked) + supply for temperature sensor of drive and pump motors Temperature monitor, drive motor Incremental encoder signal, pump motor (Channel A) Incremental encoder signal, drive motor (Channel B) Steering angle limiter unlocked (3S33) (24V = unlocked) Mobile personal safety equipment travel cutout

Workshop Manual

MX15-3

8/0123

Sheet no.

9-02

Chapter 9

FPS

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Pin assignment X11 Pin Type 28 Input

Signal 24V

29

Input

+Batt.

30 31 32 33 34 35 36 37 38 39

Ausgang Input Input

24V 10V 10V

40 41

Input

24V

42

Input

24V

Description Mobile personal safety equipment deceleration Carbon brush monitor, drive motor (80V = carbon brushes OK) not occupied not occupied not occupied not occupied Activate negative feeder module A14 not occupied not occupied not occupied Temperature monitor, drive motor Incremental encoder signal, pump motor (Channel B) not occupied Mobile personal safety equipment error Mobile personal safety equipment mode 8/0123

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

9-03

Chapter 9

FPS

Block diagram +Batt. +Batt. K36

+Batt.

K33

Key switch K34

Deadman switch

2+24V

X11:15 X11:5

X11:1

X11:2 X18:1

Vehicle control

CAN bus

X18:2

Ind. wire guid. OK

LR80

X11:14 X11:6 X11:13

PSA - stop

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

PSA - error

FPS

•

Signal N1

X11:26

Control und logic unit

X11:42

+10V

X11:25

2M1 X11:17

CBM pump motor

X11:29

CBM drive motor

K X11:4

0V

X11:24

Negative feed

X11:34

1+24V

X11:10

Status

X11:3

X11:38

X11:22 X11:7 X11:8

K1

1+Batt.

K2

Temp. mon. 2M1

υ

Temp. mon. 1M3

υ

2+Batt.

•

Sensor + 0V 0V

1M3

+ •

•

K2

X17:1

1V21

•

8

FPS power section

Neg. feeder module

X17:2 X17:3

2M1

X17:4

1 5

6

Issue: 02/01 Replaces issue:

K1

X11:39

Signal N1 0V

X11:23

Battery 80V

1+Batt.

Main contactors

Signal N2

1V04

Steering angle limiter

Unlocked (3S33)

1M3

X11:12

+10V

Negative feeder module

Locked (3S34)

X11:11

Signal N2 0V

Speed sensor, pump motor

X11:21

X11:28 X11:41

PSA - mode

Speed sensor, drive motor

Str. controller output stage

Actual val., straight on

X11:27

PSA - deceleration

PSA

Steering OK

7

M

M 2M1

Workshop Manual

1M3

MX15-3

Sheet no.

9-04

Chapter 9

FPS

Signal processing The following signals are sent from the vehicle control system (FZS) via the CAN bus to the travel and pump controller (FPS): • Travel setpoint • Hydraulics setpoint • Travel direction signal LE or DE • Maximum speed (depends on situation) • Deceleration (depends on situation) • Acceleration and delay values (lift height dependent)

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

The following signals are sent from the FPS via the CAN bus to the FZS: • Control system OK • Actual speed • Actual speed of the pump motor The following signals are connected to the FPS and are sent via the CAN bus to the FZS: • Mobile personal safety equipment - stop • Mobile personal safety equipment deceleration • Mobile personal safety equipment - error • Mobile personal safety equipment - mode • Steering OK • Actual value, straight on (rail travel) • Steering angle limiter locked (3S34) • Steering angle limiter unlocked (3S33) Remark: These signals are not evaluated by the FPS. The following signals are connected to the FPS and are evaluated by the FPS: • Deadman switch signal • Temperature monitor, travel motor • Temperaturr monitor, pump motor • Carbon brush monitor, drive motor • Carbon brush monitor, pump motor • Incremental encoder signal, drive motor • Incremental encoder signal, pump motor

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

9-05

Chapter 9

FPS

Response of the main contactors General Main contactors K1 and K2 are connected directly to the FPS in series. The main contactors cannot pick up unless the vehicle is switched on, the EMERGENCY-STOP chain is closed and no errors have occurred in the FPS.

+Batt.

7A22

K36

1+Batt

. K33

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Description When the battery plug is plugged into the vehicle, +Batt. is applied to pin X11:1 of the FPS. If the key switch is turned on, 1+batt is applied to X11:15. If the EMERGENCY-STOP chain has been closed and 1+Batt is applied at X11:2 to relay contacts K33 and K34, an internal K-relay of the FPS is selected. The NO contact of the internal K-relay causes a pulsed "0V" signal from the FPS to be applied to the main contactors (X11:4) so that they can become operative.

K34

.

.

A13

X11:1

X11:2

X11:15

0V

FPS K

Remark: All 3 voltages (+Batt., 1+Batt. and 1+Batt to K33 and K34) must be applied in order for the main contactors to pick up and remain operative. If this is not the case or if the FPS has detected an error internally, the internal K-relay of hte FPS is not selected and the main contactors do not pick up or drop out.

X11:4 K1 K2

The main contactors are selected by means of current regulation. The pick-up current is approx. 1.1A and the holding current 0.55A.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

9-06

Chapter 9

FPS

Control OK The "Control OK" signal from the FPS is needed by the vehicle control system (FZS) for the travel function. The following conditions must be met in order for the "Control OK" signal to be sent from the FPS to the FZS via the CAN bus: • the main contactors must have picked up (see sheet no. 9-06) and • no internal errors may have occurred in the FPS and • the deadman switch must be actuated

1+Batt.

7A22 K33 K34

2+24V

.

Deadman switch

X11:2

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

X11:5

0V

FPS K

Control OK (via CAN bus)

X11:4 K1 K2

FZS

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

9-07

Chapter 9

FPS

Temperature monitor for the drive and pump motors General A temperature sensor is built into the carbon brush yoke of the drive and pump motors as a temperature detector. The temperature sensors are temperaturedependent resistors. As the temperature increases, the resistance of the sensor also increases. As the resistance increases, the voltage drop over the sensor increases. If the voltage drop of a temperature sensor exceeds a specified value, the relevant motor is switched to emergency operation.

1M3

2M1 υ

υ

• 1.3mA

U1M3

X11:22

U2M1 X11:23

1.3mA X11:38

FPS

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Description A continuous current of 1.3mA flows through the temperature sensors that are connected in series. At a motor temperature of approx. 20°C, the voltage drop over the temperature sensors of U1M3 and U2M1 is about 0.7V each. If the temperature of a motor increases significantly and the voltage drop exceeds 2V, the relevant motor is switched to emergency operation. The armature current is reduced to about 25% of the maximum armature current. The following error codes appear on the operating console display (1): "FE2197" for excess temperature in the drive motor, "FE2198" for excess temperature in the pump motor. Remark: A voltage drop of about 2V by a temperature sensor represents a temperature in the motor between the carbon brushes and stator of about 160°C.

Testing the temperature sensors To test the temperature sensors, the plug-in connection X15 to the motor in question is disconnected. The resistance is then measured at the sensor end between pins X15:4 and X15:1. Finally, the temperature at the motor housing must be measured. The measured values must correspond with those shown in the table to the right ±20Ω. Remark: The temperature sensor is mounted in the carbon brush yoke. If the sensor is faulty, the entire carbon brush yoke must be replaced

Issue: 02/01 Replaces issue:

Workshop Manual

Q PSA

PSA Fehler

0/0001

1

Temperature °C

Resistance Ω

25

600

50

720

70

840

100

1020

130

1220

150

1360

160

1450

MX15-3

Sheet no.

9-08

Chapter 9

FPS

Temperature monitor for the FPS General A temperature sensor is mounted on the power unit in the FPS. The output power of the drive and pump motors is reduced according to the temperature of the power section. The reduction in output begins at approx. 60°C. At the same time, the error code "FE2053", appears on the operating console display (1), see sheet no. 35-18.

Q PSA

PSA Fehler

0/0001

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

1

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

9-09

Chapter 9

FPS

Carbon brush monitor for the drive and pump motors 1

General

2

The carbon brush yokes (1) in the drive and pump motors are fitted with monitoring switches (normally closed contacts) (2). When the brushes are shorter than the permissible remaining brush length, the switch is opened by the brush springs. This switching signal is sent on to the FPS via signal leads (3) and (4). Remark: There are double sets of carbon brushes (5) fitted in the pump motor.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Description

3 4 New carbon brush

6/0172

2

1

If the carbon brush monitor for the drive motor is triggered, error code "FE2195" appears on the operating console display, see sheet no. 35-21. If the carbon brush monitor for the pump motor is triggered, error code "FE2196" appears on the operating console display, see sheet no. 35-21. Remark: Carbon brush errors "FE2195" and "FE2196" do not have any effect on the range of functions that can be carried out with the vehicle. Once the carbon brushes have been replaced, the error code on the operating console display is deleted after a delay of about 20 - 40 seconds. Note:

Worn carbon brush

5

When the brush spring comes to rest on the monitoring switch, the spring pressure on the worn carbon brush is significantly reduced. As a result, the carbon brush begins to spark and there is a risk that the commutator may be damaged. For this reason, it is absolutely essential to replace the carbon brushes immediately when the error codes "FE2195" or "FE2196" appear. The entire set of carbon brushes must always be replaced.

Issue: 02/01 Replaces issue:

Workshop Manual

6/0173

0/0249

MX15-3

Sheet no.

9-10

Chapter 9

FPS

Carbon brush monitor for the drive and pump motors

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

EMERGENCY operation If the carbon brushes are not replaced within 10 operating hours of error code "FE2195" or "FE2196" appearing, the affected motor is switched over to emergency operation. The armature current of the affected motor is reduced to approx. 25% of the maximum armature current. If the drive motor is switched to emergency operation because the carbon brushes have not been replaced within 10 operating hours, error code "FE2203" appears on the operating console display (1), see sheet no. 35-22. If the pump motor is switched to emergency operation because the carbon brushes have not been replaced within 10 operating hours, error code "FE2204" appears on the operating console display, see sheet no. 35-22.

Q PSA

PSA Fehler

0/0001

1

Important: The entire set of carbon brushes must always be replaced. Remark:

Once the carbon brushes have been replaced, the error code on the operating console display (1) and emergency operation of the affected motor are deleted after a delay of about 20 - 40 seconds.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

9-11

Chapter 9

FPS

Incremental encoder monitor General 1

There is an incremental encoder mounted on the drive motor and one on the pump motor. These incremental encoders are designed with two channels, for measurement of the speed and of the direction of rotation of the motor. The supply voltage for the incremental encoders comes from the FPS. The output signals of the incremental encoders are connected directly to the FPS, which monitors the motors for their speed and direction of rotation. In the event of an error, the affected motor is switched to idle by the FPS.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

0/0250

Remark: On the drive motor, the incremental encoder (1) is mounted on the counter wheel. On the pump motor, the incremental encoder is mounted on the rotary shaft of the motor. The incremental encoder for the drive and pump motors are not compatible.

2

Description The incremental encoders of the drive and pump motors are supplied with 10V by the FPS. Each incremental encoder supplies voltage signals of approx. 1V or approx. 9V at its outputs, depending on the switching status. These signals are phase shifted by 90°. U(V)

0/0251

Phase shift 90° Channel A

U(V)

t(s)

Channel B t(s)

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

9-12

Chapter 9

FPS

Incremental encoder monitor Description The output signals of both incremental encoders are connected directly to the FPS and are monitored for the following criteria: • that the incremental encoders supply correct signals on both channels • that the phase shift of both channels of each incremental encoders is 90° • that the phase shift between the two channels of an incremental encoders corresponds with the direction specified by the FPS • that the number of impulses on each channel of the incremental encoder corresponds with the speed specified by the FPS.

A

0V

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

N1

If the FPS detects a fault in one of the incremental encoders, the affected motor is immediately switched to idle. At the same time, one of the following error codes appears on the operating console display (see sheet no. 35-22):

Incremental encoder, drive motor

Incremental encoder, pump motor

X11:24

B

+10V +10V

N2 X11:39

.

+10V X11:11

A

B

. . . .

N2

N1

X11:12

X11:25

FPS Switch relevant drive to idle

Monitor

Internal error memory

FE2206: Error, incremental encoder of drive motor 1M3 FE2208: Error, model calculation of drive motor 1M3 FE2207: Error, incremental encoder of pump motor 2M1 FE2209: Error, model calculation of pump motor 2M1 Remark:

The speed sensor signals from the drive motor are also connected to the vehicle control system (FZS) and to 7A22. The FZS monitors the actual speed and the actual travel direction, which are transmitted from the FPS to the FZS via the CAN bus with the original speed sensor signals. If an error is detected, the FZS reacts and displays the appropriate error code on the operating console display, see sheet no. 35-02) In the 7A22, the speed sensor signals are adapted for the inductive wire guidance (LR80).

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

0V

9-13

7A22 FZS

Chapter 9

FPS

Incremental encoder monitor Incremental encoder terminals, drive motor X12:1 X12:2 X12:3 X12:4

+10V supply voltage Channel A 0V supply voltage Channel B

Incremental encoder, drive motor Signal A

10V

Signal B

X12 2

X12 1

0V

X12 4

X12 3

. . . . approx. 9V

approx.9V

V

10V

Testing the incremental encoder of the drive motor Note: Secure the vehicle to prevent it rolling away!

V

V

X11:11

X11:12

X11:25

FPS

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Jack up the vehicle far enough to free the drive wheel. • Switch on the vehicle. • Check the power supply of the incremental encoder (1) between X12:1 (10V) and X12:3 (0V). • Actuate the deadman switch. • Accelerate the drive wheel. If this is not possible, turn the drive wheel by hand with the magnetic brake released (deadman switch). • Check the sensor signals. The voltage between X12:2 (Signal A) and X12:3 (0V), and the voltage between X12:4 (Signal B) and X12:3 (0V) should be approx. 9V. If there is significantly less or no voltage applied, the incremental encoder is faulty.

0/0266

1

Remark: The mounting distance for the incremental encoder in the drive motor between the counter wheel and the sensor should be between 1 and 2mm.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

9-14

Chapter 9

FPS

Incremental encoder monitor Incremental encoder terminals, pump motor X1:1 X1:2 X1:3 X1:4

+10V supply voltage Channel A 0V supply voltage Channel B

Incremental encoder, pump motor 10V

Signal A

Signal B

X1:1

X1:2

X1:4

0V X1:3

. . . . approx. 9V

V

approx. 9V

V

10V

Testing the incremental encoder of the pump motor

V

X11:11

• Switch on the vehicle.

X11:24

X11:39

FPS

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Check the power supply of the incremental encoder between X1:1 (10V) and X1:3 (0V). • Select the hydraulics. If this is not possible, remove the incremental encoder from the rotary shaft of the motor and turn the shaft of the incremental encoder by hand. Remark: In order to remove the incremental encoder from the rotary shaft of the motor, the fastening screw (1) must be released. • Check the sensor signals. The voltage between X1:2 (Signal A) and X1:3 (0V) and the voltage between X12:4 (Signal B) and X12:3 (0V) should be approx. 9V.

1

If there is significantly less or no voltage applied, the incremental encoder is faulty.

Issue: 02/01 Replaces issue:

Workshop Manual

0/0252

MX15-3

Sheet no.

9-15

Chapter 10

Operating console

Operating elements 1

2

3

4

5

6

7

8

9

10

11

12

Q PSA

Q

PSA Fehler

0/001

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

20

19

18

17

16

15

14

13

(1) (2) (3) (4) (5) (6)* (7)* (8)* (9) (10) (11) (12) (13)

2-handed operation, aisle travel 2-handed operation, synchronous swivel-shift movement 180° (SSSB 180°) Steering wheel (setpoint generator) EMERGENCY-STOP button Manual/auto switch, inductive wire guidance (LR80) 2-handed operation, fork adjustment, 1 cylinder 2-handed operation, fork adjustment, 2 cylinders 2-handed operation, reduced extension Horn 2-handed operation, side shift 2-handed operation, additional lift 2-handed operation, reduced extension Operating lever for travel (setpoint for travel and forward and reverse travel directions) (14) 2-handed operation for simultaneous lowering of main lift and additional lift (button is on the underside of the operating lever) (15) 2-handed operation for swivelling (16) Operating console display (17)* 2-handed operation for synchronous swivel-shift movement 90° (SSSB 90°) (18) Acknowledgement key (19)* This button does not currently have a function (the button is on the underside of the operating lever) (20) Operating lever for hydraulics (setpoint for hydraulics and lifting or lowering direction of mast) These buttons may have different functions, depending on the customer order. Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

10-01

Chapter 10

Operating console

Block diagram

Keyboard board 2

S12

S5

S13

Keyboard board 3 S6

S7

S11 S10

S8 X3

S9 X4

10V

10V

Travel potentiometer

X4

X3

X5

Add-on board for CAN bus X2

10V Hydraulics potentiometer

(option)

X4 X1 X7

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

X1

X6

LR80 board

X1

X8

X9

Operating console board

X11

Display board

X2 X2

10V

• 0V

15V Steering potentiometer

EM. STOP

Man./auto switch

X2

S2

S14

Keyboard board 1

S4

S3

S1 S10

Select extension reduction

S1

2-handed operation

S2

Select SSSB 180°

S6

Select additional lift

S11 Select fork adj. 1 cylinder

S3

Select SSSB 90°

S7

Select shifting

S12 Select fork adj. 2 cylinder

S4

Acknowledgement

S8

Select swivelling

S13

S5

Select main lift

S9

Select horn

Issue: 02/01 Replaces issue:

Workshop Manual

Select simultaneous lowering main lift and add. lift S14 No function

MX15-3

Sheet no.

10-02

Chapter 10

Operating console

Operating console board

16

1 2

3

4

5

15 6 14 7 13

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

8

0/0286

12 11 10 9

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Potentiometer RT1 (potentiometer for 90° steering angle to the left) Potentiometer RT2 (potentiometer for 90° steering angle to the right) Connector X1 --> Display board Connector X8 --> Plug-in connection X21 (behind driver's seat) Connector X7 --> Steering, EMERGENCY-STOP switch, MAN/AUTO switch Connector X2 --> Keyboard board 1 Test contacts X56 for measuring resistance of potentiometer R12 Connector X6 --> Setpoint and direction for hydraulic movements Connector X9 --> Plug-in connecors X28 (CAN bus) Buzzer Connector X11 --> LR80 board in operating console (option) Measuring contacts X55 for measuring resistance of potentiometer R11 Additional board for CAN bus Connector X5 --> Setpoint and direction for travel Connector X3 --> Keyboard board 2 Connector X4 --> Keyboard board 3

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

10-03

Chapter 10

Operating console

Pin assignment Connector X8, 18-pin (1)

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Pin Assignment 1 1+24V supply voltage 2 0V supply voltage 3 EMERGENCY-STOP chain starting from EMERGENCY-STOP switch --> 4 Barrier switch LHS 5 Barrier switch RHS 6 Deadman switch 7 Not occupied 8 Not occupied 9 Not occupied 10 Not occupied 11 Roof switch (option) 12 Chain monitoring switch, LHS (triple mast) 13 Chain monitoring switch, RHS (triple mast) 14 Not occupied 15 Not occupied 16 12V LR80 17 Sout LR80 18 Sin LR80

0/0278

1

2

Connector X9, 14-pin (2) Pin Assignment 1 2 3 4 5 6 7 8 9 10 11 12 13 14

CAN high CAN low 0V supply voltage for CAN bus 0V supply voltage for CAN bus (diagnosis interface, driver's cab) 1+24V supply voltage (diagnosis interface, driver's cab) Not occupied Not occupied Not occupied Not occupied Not occupied Not occupied Not occupied Not occupied Not occupied

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

10-04

Chapter 10

Operating console

Keyboard board 1

0V 2-handed button, travel 2-handed button, SSSB 180° 2-handed button SSSB 90° Acknowledgement key Not occupied

X2:1) X2:2) X2:3) X2:4) X2:5) X2:6) 0/0287

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Keyboard board 2

0V 2-handed button, main lift 2-handed button, additional lift 2-handed button, side shifting 2-handed button, swivelling 2-handed button, simultaneous lowering, main lift and additional lift

X3:1) X3:2) X3:3) X3:4) X3:5) X3:6) 0/0288

Keyboard board 3 0V X4:1) Button for the horn X4:2) Button for extension reduction X4:3) Button for fork adj. 1 cyl. X4:4) Button for fork adj. 2 cyl. X4:5) 0/0289

Not occupied X4:6)

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

10-05

Chapter 10

Operating console

Operating console display General The purpose of the display printed circuit board is to show the operating modes of the vehicle. Information from various sources is evaluated and displayed in the form of status displays, maintenance instructions and pieces of service information. 1

2

3

4

5

6

7

8

Q

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

PSA

9

14

PSA Fehler

15 9/0169

13

(1) (2) (3) (4) (5) ( 6) (7) (8) (9) (10) (11) (12) (13) (14) (15)

12

11

10

Red display "Dead man switch not actuated" Display field not used (with optional mobile personal safety equipment, yellow display "MPSE op. mode") Red display "2-handed operation not actuated" Red display "Barrier open" Red display "LR80 self-test" and "LR80 error" (central control unit LR80) - optional Red display "Acknowledgement required" Yellow display "Deceleration active" or or the maximum speed is limited to v=2.5km/h, Display field for LR80 operating modes and error messages Display field for operating hours and error codes (see sheet 10-07) Operating keys Battery discharge display Constant red display: "Maintenance interval has expired" Display filed not occupied (with optional mobile personal safety equipment, yellow display "MPSE error") Wheel position display LR80 status display

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

10-06

Chapter 10

Operating console

Operating console display Basic display If the vehicle is fully operational without errors, the so-called basic display appears when the vehicle is switched on. The following display elements are active in the basic display: • Operating hours • Remaining battery capacity • Wheel position display • Selected statuses

Operating hours

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

This 6-figure operating console display (1) shows the operating hours. The operating hours are updated every 6 minutes (1/10 hr.). Error codes are also displayed in the operating console display (see sheet no. 35-01).

8/3044

1

Remaining battery capacity The 8 LEDs (5 green, 2 yellow and 1 red) are used to indicate the current remaining capacity of hte battery. If only the red LED (2) lights up, the remaining capacity is 30%. When the remaining capacity drops to 20%, the red LED flashes synchronously with the display position (1). At the same time, the "lift main lift" function is deactivated. Remark: It is essential to recharge the battery when it is in this condition.

red yellow

green

8/3044

2

Wheel position display The wheel position display indicates the approximate position of the drive wheel. The information for the wheel position display is derived from the actual value potentiometer of the steering. Remark: If the steering is correctly adjusted and the drive wheel is set exactly to the straight-on position, the green LED (3) in the wheel position display should light up (see sheet no. 6-10).

Issue: 02/01 Replaces issue:

Workshop Manual

8/3044

3

MX15-3

Sheet no.

10-07

Chapter 10

Operating console

Operating console display Display LED for manual steering

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

If the LED for manual steering (1) is lit up, manual steering is possible. If the vehicle is in an aisle (steering is fixed automatically to the straight-on position) or the vehicle is guided inductively (LR80), the LED is off and manual steering is not possible. Remark: If the LED for manual steering (1) flashes, this means the vehicle is in an aisle but the handwheel (2) for the steering is not set to the engaged centre position. In this case, the vehicle only travels at a speed of v=2.5km/h. When the handwheel is returned to the centre position, the LED goes out and the deceleration constraint is lifted.

3

2

4 5

1

8/3044

1

2

Status and maintenance symbols Status and maintenance symbols are activated by the FZS and can occur in various combinations with other symbols. Application of the input conditions is static, i.e. the relevant symbol lights up for as long as the information from the FZS is transmitted via the CAN bus.

Q PSA

Q

PSA Fehler

8/3044

"Deadman switch not actuated" display The "Deadman switch not actuated" display (3) flashes when a setpoint for travel of >3V is applied to the FPS and the "Enable travel" signal is missing. 4

3

"Creep speed" display (4) This display lights up when the maximum speed is limited to v=2.5km/h. The display flashes when the maximum speed is limited to v=1km/h.

Q PSA

PSA Fehler

9/0169

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

10-08

Chapter 10

Operating console

Bedienpultanzeige "2-handed operation not actuated" display (1)

2

This display flashes when the vehicle is in an aisle and the "2-handed operation for travel in aisle" (2) has not been actuated.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

"Barrier open" display (3) This display lights up as soon as one or both of the barriers is opened. The display flashes if the following functions are selected when a barrier is open: lift/lower main lift, lift/lower additional lift or travel. These functions are blocked when a barrier is open. Remark: The side shift and swivel functions are possible throughout the entire lifting height even when a barrier is open.

Q 8/3044

7

3

1

"Maintenance" display (4)

Q

This display lights up as soon as the service interval programmed in the FPS comes to an end. The display flashes as soon as an error message appears on the operating console display (5). The information that drives this display is formed in the operating console.

PSA

PSA Fehler

9/0169

"LR80 error" display (6)

6

4

5

This display is only used on vehicles with inductive wire guidance (LR80). The display lights up during the self-test carried out by the LR80 central control unit when the vehicle is switched on. The display also lights up when the LR80 has initiated an EMERGENCY-stop. In the event of an EMERGENCY-stop by the LR80 central processing unit, a flow text is displayed on the display field of the LR80 (7), which describes the reason for the EMERGENCY-stop.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

10-09

Chapter 10

Operating console

Operating console display

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

"Acknowledgement required" display (1) This display lights up: • When an intermediate lift cut-out is active. When the acknowledgement key (2) is pressed once, the intermediate lift cut-out is lifted . • On an absolute stop. If you wish to continue travel in the direction in which the absolute stop took place, the acknowledgement key (2) must be pressed and held down, so that the vehicle can be driven at a speed of v = 2.5km/h. If the direction is changed (towards the centre of the aisle), the vehicle can be driven immediately at a speed of v = vmax. • In the event of an LR80 error. If an inductively guided vehicle (LR80) is switched over to MANUAL when it is in an aisle and over the wire, and the vehicle comes to a standstill, a travel stop is initiated immediately. The vehicle can be driven at v = 2.5km/h by pressing the acknowledgement key. When the vehicle is switched back to AUTO, the error status is automatically lifted.

1

Q PSA

Q

PSA Fehler

8/3044

2

Q PSA

"Reserve1" display (3)

PSA Fehler

This display is not used on standard vehicles. On vehicles fitted with with mobile personal safety equipment, the display is used to indicate the status of this equipment: • Illuminated: PSA active • Flashing (1Hz): PSA not active • Flashing (4Hz): Cycle test • Off: PSA not fitted

9/0169

4

3

"Reserve2" display (4) This display is not used on standard vehicles. On vehicles fitted with with mobile personal safety equipment, the display is used to indicate the error status of this equipment: • Illuminated: Error (PSA has detected an error internally) • Flashing (1Hz): Alarm (the PSA brakes the vehicle, further travel is only possible by pressing the acknowledgement key (5))

Issue: 02/01 Replaces issue:

Workshop Manual

Q PSA

Q

PSA Fehler

8/3044

5

MX15-3

Sheet no.

10-10

Chapter 10

Operating console

Operating console display Error display The vehicle has an on-board diagnosis system. If the on-board diagnosis system detects an error, this error is displayed in the form of an error code on the operating console display. The two letters "FE" are always placed at the beginning of the code, so that it is immediately obvious that the message on the operating console display is an error code, e.g. "FE304". Remark: If several errors occur at the same time, the operating keys (1) and (2) can be used to display the other error codes.

F E

3 0 4 8/3044

Q

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

The error code is displayed on the operating console display as long as the error is present. For a guide to all the error codes, see sheet no. 35-01.

PSA

PSA Fehler

Remark: As long as an error code is displayed, it is not possible to switch the operating console display over to operating hours, travel speed in km/h or lift height in mm (height of top edge of fork) (see sheet no. 10-12).

9/0169

1

2

Information display The operating console display can also be used to convey other important information to the driver, apart from the operating hours, the travel speed, the lift height and error codes. The two letters "In" are always placed at the beginning of the code, so that it is immediately obvious that the message on the operating console display is an information message, e.g. "In 4". At the moment, it is possible that the following information can appear on the operating console display: In 1: The battery needs charging In 2: EMERGENCY-STOP switch actuated In 3: Traction cut-out activated In 4: Fork outside the vehicle contour Remark: As long as an information message is displayed, it is not possible to switch the operating console display over to operating hours, travel speed in km/h or lift height in mm (height of top edge of fork) (see sheet no. 10-12). Issue: 02/01 Replaces issue:

Workshop Manual

I n

4 8/3044

MX15-3

Sheet no.

10-11

Chapter 10

Operating console

Operating console display Switching-on test An automatic self-test of the display elements on the operating console can be carried out by pressing operating keys (1) and (2) when the vehicle is switched on. All LEDs, symbols and the sound transmitter are triggered in sequence.

Q PSA

PSA Fehler

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Switching over the operating console display As long as there is no error code displayed on the operting console display, (3), it can be switched between operating hours, travel speed in km/h and lift height in mm (height of top edge of fork) by pressing the right-hand key (1) or left-hand key (2) once. If there is an error displayed on the operating console display, the operating console display cannot be switched over between operating hours, travel speed and lift height. If several errors have occurred at the same time, the operating keys (1) and (2) can be used to display the other error codes.

9/0169

3

4

Display for the operating status of the inductive wire guidance (LR80 option)

1

2

5

Automatic operation is divided into 3 successive operating statuses. The LEDs (4)-(7) and text messages on the LR80 display (8) indicate which of the 3 operating statuses the vehicle is currently in:

8

Q PSA

PSA Fehler

Wire search:

Preparatory aisle travel:

Yellow LED (4) flashes alternately with the red LED (6).

Both green LEDs (5) and (7) flash.

9/0169

7 Aisle travel:

Issue: 02/01 Replaces issue:

6

Both green LEDs (5) and (7) are lit up continuously.

Workshop Manual

MX15-3

Sheet no.

10-12

Chapter 10

Operating console

Replacing the setpoint potentiometer Removing the setpoint potentiometer • Switch off the vehicle. • Unscrew the operating console from its support (1).

1/0023

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

1

• Disconnect the electrical leads (2).

1/0024

2

3

• Unscrew the lower section of the operating console (3).

1/0025

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

10-13

Chapter 10

Operating console

Replacing the setpoint potentiometer Removing teh setpoint potentiometer Remark: (1) Travel setpoint potentiometer (2) Hydraulics setpoint potentiometer

1/0026

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

1

2

3 • Disconnect the electrical connection of the setpoint potentiometer (3) on the operating console board. Remark: So that the new potentiometer can be adjusted more quickly after it has been installed, it is helpful to mark the current position of the nut (4) on the threaded rod. • Release the nut (4) so that the adjusting plate (5) can be removed from the threaded rod.

1/0027

4

• Release the hexagon socket screw (6).

• Remove the setpoint potentiometer from the mechanical elements in the direction of the arrow.

1/0028

6 Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

5 Sheet no.

10-14

Chapter 10

Operating console

Replacing the setpoint potentiometer Installing the setpoint potentiometer • Prepare the setpoint potentiometer before installation so that the flat side of the rotary shaft (1) faces upwards.

1/0029

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

1

• Push the potentiometer into the mechanical elements in the direction of the arrow.

1/0030

• Hook the adjusting plate (2) onto the threaded rod and screw up the nut (3) to the position you marked previously.

• Tighten the hexagon socket screw (4) securely.

1/0031

4

Issue: 02/01 Replaces issue:

Workshop Manual

2

MX15-3

3

Sheet no.

10-15

Chapter 10

Operating console

Replacing the setpoint potentiometer

1

Installing the setpoint potentiometer • Screw the lower section of the operating console (1) in place.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

1/0023

• Make the electrical connection (2) to the vehicle.

1/0024

2

• Screw the operating console securely in place on the vehicle (3). Important: After a new setpoint potentiometer has been installed, the potentiometer must be readjusted and teaching-in carried out (see sheet no. 10-17)!

1/0025

3

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

10-16

Chapter 10

Operating console

Replacing the setpoint potentiometer

2

Rough adjustment of the potentiometer • Hold down both operating keys (1) and horn (2) at the same time and then switch on the vehicle. • The following appears on the operating console display (3): BPS • To adjust the travel setpoint potentiometer, briefly press operating key 2 (4) once. The operating console display shows: 1_

PSA

PSA Fehler

B PS

0/0001

or, to adjust the hydraulics setpoint potentiometer, briefly press operating key 2 (4) twice. The operating console display shows: 2_ Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Q

• Press the operating key 2 (4) once for longer (approx. 3 sec.). The following appears on the operating console display for adjustment of the travel setpoint potentiometer: 10 XXX and for adjustment of the hydraulics setpoint potentiometer: 20 XXX . Remark: XXX stands for the current setpoint in volts. In the example shown here (5), a setpoint of 0.11V is displayed.

3

1

Q PSA

PSA Fehler

0/0001

• When the operating lever is in neutral, the setpoint should be "2". If this is not the case, the setpoint potentiometer must be moved mechanically into the correct centre position with the adjusting plate. To do so, proceed as follows: - Switch off the vehicle. - Remove the operating console. - Release the electrical connections. - Correct the position of the adjusting plate with an open-ended spanner (6). - Make the electrical connection to the vehicle. - Mount the operating console. - Repeat the process from the start of the section "Rough adjustment of the potentiometer". Remark: This process must be repeated until the setpoint is indicated as "2" on the operating console display.

5

Workshop Manual

4

1/0032

Important: The adjusting process must be continued at "Fine adjustment of the potentiometer" (see sheet no. 10-18). Issue: 02/01 Replaces issue:

1 1

1 0

6

MX15-3

Sheet no.

10-17

Chapter 10

Operating console

Replacing the setpoint potentiometer Fine adjustment of the potentiometer Remark: For fine adjustment of the setpoint potentiometer, rough adjustment must first be carried out (see sheet no.10-17). • Move operating lever to one side until a " " (1) appears in the operating console display in front of the the setpoint (signal from direction switch).

Q PSA

PSA Fehler

1 0

1 4 3

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Move the lever to the other side until a " " appears on the operating console display in front of the setpoint (signal from the direction switch). 0/0001

• The amount by which the operating lever is deflected in order for the direction signal to appear must be symmetrical to the centre position of the lever in both directions (approx. 5° deflection of lever until direction signal appears). If this is not the case, the setpoint potentiometer must be moved mechanically into the correct centre position with the adjusting plate (2). To do so, proceed as follows: - Switch off the vehicle. - Remove the operating console. - Release the electrical connections. - Correct the position of the adjusting plate with an open-ended spanner (3). - Make the electrical connection to the vehicle. - Mount the operating console. - Press and hold down the horn and operating keys 1 and 2 at the same time and then switch on the vehicle. - To adjust the travel setpoint potentiometer, briefly press operating key 2 (4) once. To adjust the hydraulics setpoint potentiometer, briefly press operating key 2 twice. - Press op. key 2 once for longer (approx. 3 sec.) Remark:

1

4

1/0031

2

This process must be repeated until the two direction switches of the setpoint potentiometer switch symmetrically to the centre position of the operating lever.

1/0032

3

Important: The adjusting process must be continued at "Teaching-in the setpoint potentiometer" (see sheet no. 10-19). Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

10-18

Chapter 10

Operating console

Replacing the setpoint potentiometer

2

Teaching-in the setpoint potentiometer Remark: In order to "teach in" the setpoint potentiometer, its mechanical adjustment must be correct (see sheet no. 10-17). • Hold down both operating keys (2) and horn (1) at the same time and then switch on the vehicle.

Q PSA

• The following appears on the operating console display (3): BPS • To teach in the travel setpoint potentiometer, briefly press operating key 2 (4) once. The operating console display shows: 1_

PSA Fehler

B PS

0/0001

3

1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

or, To teach in the hydraulics setpoint potentiometer, briefly press operating key 2 (4) twice. The operating console display shows: 2_ • Press the operating key 2 (4) once for longer (approx. 3 sec.). The following appears on the operating console display for adjustment of the travel setpoint potentiometer: 10 2, and for adjustment of the hydraulics setpoint potentiometer: 20 2 • Press both operating keys (1) and the acknowledgement key (5) at the same time (maintenance LED (6) on the operating console flashes).

Q PSA

Q

PSA Fehler

0/0001

6

5

• Move the operating lever slowly in one direction until the direction signal " " (7) appears on the operating console display. • Hold the lever in this position and press the acknowledgement key. • Move the operating lever further in the same direction to the mechanical end stop and hold it in this position for approx. 2 secs.

Q PSA

PSA Fehler

1 0

1 4 3

• Slowly move the operating lever in the other direction until the direction signal " " appears on the operating console display.

0/0001

• Hold the lever in this position and press the acknowledgement key.

Issue: 02/01 Replaces issue:

Workshop Manual

7

MX15-3

4

Sheet no.

10-19

Chapter 10

Operating console

Replacing the setpoint potentiometer Teaching-in the setpoint potentiometer • Move the operating lever further in the same direction to the mechanical end stop and hold it in this position for approx. 2 secs • Press both the operating keys (1) and the acknowledgement key (2) at the same time to save the values from the teaching-in press (maintenance LED (3) on the operating console is off).

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Remark:

If you wish to end this process without saving the new teaching-in values, press both operating keys (1) at the same time (maintenance LED (3) on the operating console is off).

Important: The voltage value during teaching-in of the min. value (direction signal active) should be between 0.25V and 2.0V.

Q PSA

Q

PSA Fehler

0/0001

3

2

Q PSA

PSA Fehler

1 4 3

1 0

The voltage value during teaching-in of the max. value (operating lever fully deflected) should be between 6.0V and 9.5V.

0/0001

4

If this is not the case, the error message "Error" appears on the operating console display during teaching-in. The tought-in value is limited to the relevant key value. Remark:

1

(4) represents the current setpoint. In the example shown here, the setpoint is 1.43V.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

10-20

Chapter 10

Operating console

LR80 board (option) Description

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

This board is only required if the vehicle is fitted with an inductive wire guidance system. It is used to control the display field for the LR80 operating statuses (1), the display for the "LR80 self-test" and "LR80 error" (2) and the LEDs for the operating status display of the LR80 central operationg unit (3). The MANUAL/AUTO signal is also transmitted through this board. The LR80 board is screwed onto the operating console board with spacers. It is electrically connected at the front to the display board (connector X2) with a ribbon cable (4) and to the operating console board (connector X11) with a second ribbon cable (5) (see sheet no. 10-02).

Q PSA

PSA Fehler

8/3044

3

1

2

There are two connectors at the back of the LR80 board. They are connector X1 (6) and the connector labelled (7) in the diagram. Neither of these connectors are used on this vehicle.

0/0340

4

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

6

7

5

Sheet no.

10-21

Chapter 10

Operating console

LR80 board (option) Pin assignment Connector X11 (10-pin) connected to connector X2 of the LR80 board, which is needed on vehicles with inductive wire guidance Pin Description 1 2 3 4 5

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

6 7

8 9 10

+12V from LR80 central processing unit not occupied not occupied not occupied Input for control of the buzzer (clocked 0V signal from the LR80 board) Output for steering setpoint to LR80 board +10V supply voltage for steering potentiometer (12V from LR80 central processing unit are converted to 10V on the LR80 board) 0V supply voltage for steering potentiometer not occupied Output for MANUAL/AUTO switch (MANUAL = no potential, AUTO = 0V)

0/0340

Connector X11

Connector X4 (20-pin) on the LR80 board, connected to the display board connector X2 Pin Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

12V supply voltage from LR80 central process. unit 0V supply voltage from LR80 central processing unit Data lead 6 0V supply voltage from LR80 central processing unit Data transfer signal 1 Addressing lead 1 Addressing lead 2 Data transfer signal 2 Output for sound transmitter (0V active) Test LED (red) Wire search LED (red) Auto LED (green) Data lead 5 Data lead 4 Data lead 2 Data lead 3 Data lead 1 Data lead 0 Manual LED (yellow) 5V (are generated on the board from the 12V)

Issue: 02/01 Replaces issue:

Workshop Manual

0/0340

Connector X2

MX15-3

Sheet no.

10-22

Chapter 11

LHC

General • Die load handling control (LHC) 8U61 is built into an aluminium housing (1) that is sealed against water splashes. • The housing must not be opened. • If a fault is ascertained in the LHC, the entire unit must always be replaced. • The LHC is suitable for use in cold stores and in alternate cold and warm environments. • The LHC has a 42-pin connector (2). • The LHC does not have any display elements.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Remark: The housings of the LHC and the 7A22 are exactly the same. The two components can only be distinguished by their factory nameplate (3).

Description The LHC (4) is located in the attachment of the vehicle. The LHC is connected to the vehicle control system, the operating console and the travel and pump control (FPS) via the CAN bus. All the switching and proportional valves in the attachment are controlled by the LHC. In addition, all the sensors for the different position sensing systems on the attachment are connected to the LHC.

0/0242

1

2

3

Important: If the LHC is replaced because of a fault, a teaching-in process must be carried out for the following hydraulic functions: • Additional lift • Swivelling • Side shifting (see sheet no. 22-01).

0/0243

0/0290

4

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

11-01

Chapter 11

LHC

Pin assignment

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Pin Type 1 Input 2

Output

3 4

Output

5

Output

6

Output

7

Output

8

Output

9

Output

10

Output

11

Output

12

Output

13

Output

14

Input

15 16

Input

17 18

Input

19

Input

20 21

Input Input

22 23 24 25

Output

Issue: 02/01 Replaces issue:

Signal 0V

Description 0V supply voltage for LHC and screening for CAN bus 1A Control of valve for lifting add. lift (B/W valve 2Y23) not occupied 1A Control of valve for side shift, right (proportional valve 2Y25) 1A Control of valve for side shift, left (proportional valve 2Y26) 1A Control of valve for fork adjustment with 1 cylinder (B/W valve 2Y30) 1A Control of valve for fork adjustment with 1 cylinder (B/W valve 2Y31) 1A Control of valve for side shift (proportional valve 2Y18) 1A Control of valve for lowering add. lift (proportional valve 2Y43) 1A Control of valve for fork adjustment with 2 cylinders (B/W valve 2Y34) 1A Control of valve for fork adjustment with 2 cylinders (B/W valve 2Y35) 1A Control of valve for swivelling right (proportional valve 2Y27) 1A Control of valve for swivelling left (proportional valve 2Y28) 0V 0V supply voltage for swivelling and shifting potentiometer CAN bus (low) 24V/0.5A 24V supply voltage for internal electronics of the LHC not used 24V Contour switch, side shift 2B56 (actuated = 24V) 24V Load sensor (option) (load = 24V) 24V Pos. switch for prong adjustment 1 24V Magnetic sensor for additional lift (Channel A) not occupied not occupied not occupied 0.1A 10V supply voltage for shifting and swivelling potentiometer

Workshop Manual

MX15-3

8/0123

Sheet no.

11-02

Chapter 11

LHC

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Pin assignment Pin 26 27 28 29

Type Input Input Input

Signal 0-10V 24V 0V

30 31 32 33

Input Input

24V 24V

34

Input

24V

35

Input

24V

36

Input

24V

37 38 39 40 41

Input Input

0-10V 0-10V

42

Input

24V

Issue: 02/01 Replaces issue:

Description Setpoint potentiometer for swivelling not occupied 2+24V supply voltage for LHC 0V supply voltage for outputs of the LHC CAN bus (high) notused Identification pin Limit switch for swivelling 2B57 (actuated = 24V) Reference switch 2B63 for add. lift (actuated = 24V) Position switch for fork adjustment with 2 cylinders Magnetic sensor for add. lift (Channel B) not used not used not used Setpoint potentiometer for shifting Setpont potentiometer for fork adjustment 2+24V supply voltage for outputs of the LHC

Workshop Manual

MX15-3

8/0123

Sheet no.

11-03

Chapter 12

NAV

General • The EMERGENCY-STOP and amplifier module 7A22 (NAV) is built into an aluminium housing (1) that is sealed against water splashes. • The housing must not be opened. • If a fault is ascertained in the NAV, the entire unit must always be replaced. • The NAV is suitable for use in cold stores and in alternate cold and warm environments. • The NAV has a 42-pin connector (2). • The NAV does not have any display elements.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Remark: The housing of the NAV and the housing of the LAS CAN bus module (see sheet no. 11-01) are exactly the same. The two components can only be distinguished by their factory nameplate (3). 0/0242

1

2

3

Description The NAV (4) is mounted at the right-hand side of the controls compartment next to the vehicle control system (5). It contains the following components/ functions: • • • • • • • • •

0/0243

Safety relays K33, K34 Safety relay K35 Key switch relay K36 Relay K37 (steering error) "Enable hydraulics" signal Chain monitoring Adaptation of the actual steering value Selection of the electromagnetic brake Adaptation of incremental encoder signals

0/0285

4 Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

5 Sheet no.

12-01

Chapter 12

NAV

Pin assignment

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Pin Type 1 Input 2 Output

Description 0V supply voltage for NAV 0V supply voltage for B/W valve for lifting main lift 2Y20 3 Output 0V/1A 0V supply voltage for B/W valve for lowering main lift 2Y21 and B/W valve for ancilliary movements 2Y22 4 Input +Batt. Battery voltage 5 Output +Batt. 1+Batt. supply voltage for the 2nd stage of the electromagnetic brake 6 Output +Batt. Battery voltage after key switch 7 Output +Batt. 2+Batt. supply voltage for the 1st stage of the electromagnetic brake 8 Input +Batt. 2+Batt. for control of relay K35 9 Output 0V/1A Control of the 1st stage of the electromagnetic brake (0V = braking stage released) 10 Output 0V/1A Control of the 2nd stage of the electromagnetic brake (0V = braking stage released) 11 Input +Batt. 1+Batt. for control of the DC/DC converter (ON signal) 12 Output +Batt. 1+Batt. for control of the DC/DC converter (ON signal) Remark: Pins 11 and 12 are directly connected with each other in the NAV. 13 Output +Batt. 1+Batt. to closed contacts of safety relays K33 and K34 14 Input +Batt. +Batt. supply voltage for the DC/DC converter 15 Output 24V 1+24V supply voltage for distributor board A13 16 Input 24V "Enable hydraulics" signal from the operating console 17 Input 24V Chain monitoring switches, left (24V = switches are not actuated) 18 Input 24V Chain monitoring switches, right (24V = switches are not actuated) 19 Input 24V EMERGENCY-STOP chain from the operating console 20 Input 24V 0V supply voltage for safety relay K34 21 Input 20mA Clocked signal for releasing brakes (1st stage)

Issue: 02/01 Replaces issue:

Signal 0V 0V/1A

Workshop Manual

MX15-3

8/0123

Sheet no.

12-02

Chapter 12

NAV

Pin assignment

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Pin Type 22 Input

Signal 20mA

23

Input

10V

24

Input

10V

25

Output

12V

26

Output

12V

27 28

Output Output

+Batt. +Batt.

29

Input

24V

30 31 32

Input Output Input

15V 10V 0V

33

Input

0V

34

Input

24V

35

Output

24V

36

Input

24V

37

Output

24V

38

Input

24V

39

Input

10V

40 41 42

Input

24V

Issue: 02/01 Replaces issue:

Description Clocked signal for releasing brakes (2nd stage) Increm. encoder signal, drive motor (Channel A) Increm. encoder signal, drive motor (Channel B) Adapted incremental encoder signal Drive motor for LR80 (Channel A) Adapted incremental encoder signal Drive motor for LR80 (Channel B) Key switch on/off for FZS +Batt. supply voltage for DC/DC converter 1+24V output voltage from DC/DC converter Actual value, steering Adapted actual value, steering for FZS 0V supply voltage for internal electronics for adaptation of the actual value for steering 0V reference voltage for adaptation of the actual value for steering 1+24V supply voltage for relay K37 (inductive wire guidance OK) 1+24V to relay contact K37 (contact closed = inductive wire guidance OK) Error in inductive wire guidance (0V = OK) Buffered voltage for the FZS, so that parameters can be stored when the key switch is turned off 0V supply voltage for safety relay K33 Setpoint potentiometer for main lift position sensor not occupied not occupied 2+24V supply voltage for outputs of the NAV

Workshop Manual

MX15-3

8/0123

Sheet no.

12-03

Chapter 12

NAV

Safety relays K33 and K34 General Safety relays K33 and K34 must prevent the main contactors from becoming operative up or must cause them to drop out in the following cases: • If there is a fault in the vehicle control system (FZS), (e.g. the main processor is no longer functioning correctly) • If the FZS detects a malfunction that results in an EMERGENCY stop • If the EMERGENCY-STOP chain is opened • If either one or both the relay coils of K33 and K34 are faulty • If the relay contacts of K33 and/or K34 are melted or faulty When the main contactors have dropped out, the vehicle cannot be driven and none of the hydraulic functions can be carried out.

Battery G2

1+24V Internal relaycontact EM.STOP button

Distributor board A13

PSA

(option)

F6

EM.-STOP chain

NAV 7A22 K37

K36 Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Op.console 8U62

•

Description If the EMERGENCY-STOP chain is closed, there are no faults in the FZS and the FZS cannot detect any malfunctions, relays K33 and K34 pick up via their NC contacts (1). Remark: Relay contact K37 is always closed on vehicles with standard steering. On vehicles with inductive wire guidance, relay contact K37 is closed as long as there are no faults in the central processing unit of the LR80 or an EMERGENCY-STOP has been initiated (see sheet no. 12-07).

K34

K33

•

•

K33

K34

• FZS 8U60 FPS A10 0V

When relays K33 and K34 become operative, this causes the normally open contacts (2) that are connected in series to close. The normally closed and normally open contacts in a relay are connected to each other mechanically so that both cannot be open or closed at the same time (selfmonitoring). The main contactors receive the supply voltage they need to become operative via 2 other normally open contacts of K33 and K34 (3). Remark: Relay contact K36 is closed immediately when the vehicle is switched on. 12-06).

Issue: 02/01 Replaces issue:

Workshop Manual

0V

K1

K2

MX15-3

Sheet no.

12-04

Chapter 12

NAV

Safety relay K35 General Safety relay K35 guarantees that the 2+24V supply voltage is not applied until after the main contactors pick up, and that the 2-24V supply voltage is switched off immediately if the main contactors drop out.

1 1+24V

•

K33

Remark: Safety relays K33 and K34 alone are not adequate for this function. Safety relays K33 and K34 can have picked up, but the main contactors still do not pick up or may already have dropped out (FPS error, main contactors faulty).

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Description If main contactors K1 and K2 pick up, the 2+battery voltage is applied to the transistor (1) in the NAV via fuse 3F1 and F3. The transistor switches through and the safety relay K35 can pick up. The 2+24V supply voltage is enabled by relay contacts K33, K34 and K35, which are connected in series. If the main contactors drop out, no voltage is applied to the transistor. Safety relay K35 drops out and opens its contact. This causes the 2+24 supply voltage to be switched off.

NAV 7A22

K35

K35

K34

0V

•

2+24V

Distributor board A13

FPS A10

F3 K1

3F1 •

K2

Remark: Switching off of the 2+24V supply voltage has the following effects: - no enable signal for the FPS, operating console and steering controller can be sent via the deadman switch, - all outputs of the LHC are switched off, - all outputs of the vehicle control system except "Acknowledge PSA" and "Selection of the 2nd braking stage" are switched off.

Issue: 02/01 Replaces issue:

Workshop Manual

Battery G2

MX15-3

Sheet no.

12-05

Chapter 12

NAV

Key switch relay K36 General Thanks to the key switch relay K36, savings can be made on leads over the mast. After the operating console, the 1+battery voltage is not sent to the controls compartment via the mast, but is rather generated by key switch relay K36 directly in the controls compartment.

S1

Batt

U30

1+Batt

NAV 7A22 K36

K36

• K33 K34

Remark: In contrast to previous definitions, there are two different 1+battery voltages in this vehicle: - after the key switch - after relay contact K36

Workshop Manual

converter 1+24V

When the key switch is switched on, 1+battery voltage is applied at the ON input of the DC/DC converter and at the transistor in the NAV. The transistor switches through and the DC/DC converter supplies 1+24V supply voltage at its output. The key switch relay K36 can then pick up. Through the normally open contact of K36, the battery voltage from the distributor board A13 is converted into 1+battery voltage. This 1+battery voltage is sent back to distributor board A13.

Issue: 02/01 Replaces issue:

Distributor board A13

DC/DC •

Description

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Key switch

0V

MX15-3

Sheet no.

12-06

Chapter 12

NAV

Relay K37 (steering error) General Relay K37 is used to monitor the inductive wire guidance system. The EMERGENCY-STOP chain may only be closed if there are no faults at the LR80 central processing unit and the LR80 central processing unit has not initiated an EMERGENCYSTOP.

1+24V

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Description When the vehicle is switched on, 1+24V are applied to relay K37. If there are no faults at the LR80 central processing unit and if the LR80 central processing unit has not initiated an EMERGENCYstop, the LR80 central processing unit delivers a "0V" signal (pin X8:4) to the "Steering error" output for relay K37. Relay K37 can pick up and both relay contacts are closed. One normally open contact (1) is positioned directly in the EMERGENCY-OFF chain. The other normally open contact (2) is connected at the FPS. The switching status of the contact is transmitted to the FZS via the FPS. Only if the contact is closed can the FZS deliver the 0V signal for safety relays K33 and K34 (see sheet no. 12-04). Remark: The FPS only serves as a terminal point for the FZS in this case. The information is transmitted from the FPS to the FZS via the CAN bus and is not actually evaluated by the FPS itself.

EM.-STOP chain

NAV 7A22 1+24V

1+24V K37

K37

1 • K33

2

K34

•

•

K33

K34

• 0V

FPS A10

A13 (Standard steering)

oder

CAN bus

LR80

FZS 8U60

(option)

If there is a fault at the LR80 central processing unit or if the LR80 central processing unit has initiated an EMERGENCY-stop, the voltage potential of the "Steering error" output changes from 0V to 24V. As a result, relay K37 either cannot pick up or drops out. The EMERGENCY-STOP chain is interrupted and safety relays K33 and K34 drop out. When the safety relay drops out, this also causes the main contactors to drop out (see also sheet no. 12-04). When the main contactors have dropped out, the vehicle cannot be driven and none of the hydraulic functions can be carried out.

0V

0V

Remark: On vehicles with standard steering, relay K37 is supplied with 0V by the distributor board A13. Relay K37 picks up immediately when the vehicle is switched on. Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

12-07

Chapter 12

NAV

"Enable hydraulics" signal General The "Enable hydraulics" signal is generated in the operating console and evaluated in the NAV. The enable signal causes 0V to be applied to the switching valves in the chassis valve block. The relevant switching valve is selected by the FZS.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Description If one of the following hydraulic functions is selected on the operating console: • Lifting • Lowering • SSSB90° • SSSB180°, the "Enable travel" signal changes from 0V to 24V. The "Enable travel" signal is connected to logics in the NAV. When this signal changes to 24V, both transistors are switched through and supply 0V to the following switching valves: • 2Y20 for lifting main lift • 2Y21 for lowering main lift • 2Y22 for ancilliary movements and the proportional valve • 2Y02 for fine control, lowering main lift.

Op. console 8U62

NAV 7A22 Logic 0V

0V

•

•

2Y02

2Y22

2Y21

2Y20

FZS 8U60

Remark: SSSB = Synchronous swivel-shift movement Depending which hydraulic function is selected, the FZS selects the relevant switching valve with a 24V signal. When the hydraulic movement is complete, the "Enable hydraulics" signal changes from 24V to 0V after a delay of approx. 1.5 seconds, so that hydraulic ramps can be completed. Remark: A slack chain and chain breakage have an effect on the logic in the NAV and also on the 0V supply voltage of the switching valves (see sheet no. 12-11).

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

12-08

Chapter 12

NAV

Chain monitoring Block diagram

1+24V

1+24V

•

•

2S61

2S60

Triplex

Op.console 8U62

CAN bus

1+24V

1+24V

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Enable hydraulics

Tele NAV 7A22

2S62

2S63

• Logic

•

0V

0V

•

•

2Y02

2Y22

2Y21

2Y20

FZS 8U60

Remark: On triplex masts, the normally closed contacts 2S60 and 2S62 on the righthand side of the mast and the normally closed contacts 2S61 and 2S63 on the left-hand side of the mast are connected in series. Normally open contacts 2S61 and 2S60 are connected at the operating console. In this case, the operating console only acts as a terminal point for the FZS. The information is transmitted from the operating console to the FZS via the CAN bus and is not actually evaluated by the operating console itself.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

12-09

Chapter 12

NAV

Chain monitoring General The chain tension of the load chains on the mast is monitored by chain monitoring switches (1). If a chain slackens, the relevant chain monitoring switch is actuated. The chain monitoring switches have a normally open contact and a normally closed contact which are connected to each other mechanically so that both contacts cannot be open or closed at the same time.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

The normally closed contacts of the chain monitoring switches are evaluated by the NAV and the FZS. The normally open contacts of the chain monitoring switches are only evaluated by the FZS.

0/0244

1

Remark: The FZS monitors the normally closed contact and the normally open contact of each chain monitoring switch. If the normally closed contact and the normally open contact are both closed or opened at the same time, all the hydraulic functions are inactivated by the FZS and the vehicle can only be driven at a speed of v = 1km/h.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

12-10

Chapter 12

NAV

Chain monitoring

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Chain breakage If a chain monitoring switch is actuated while a hydraulic function is selected, the FZS regulates the pump speed down to "0" within 1 second via the FPS. In this way, an abrupt stop, which would cause an additional jolt, is prevented. If still only 1 chain monitoring switch is actuated after 1 second, the FZS initiates a chain breakage status. The error code "FE308" appears on the operating console display. In the event of chain breakage, all the hydraulic functions are inactivated and the vehicle can only be driven at a speed of v = 1km/h. The chain breakage status can only be reset by switching the vehicle off and then on again. Remark: As an additional safety feature in the event of chain breakage, the 0V supply voltage for switching valves 2Y20 (lifting main lift), 2Y21 (ancilliary movements) and 2Y22 (lowering main lift) and the proportional valve 2Y02 (fine control for lowering main lift) is switched off by the logic of the NAV.

Slack chain If a chain monitoring switch is actuated while a hydraulic function is selected, the FZS regulates the pump speed down to "0" within 1 second via the FPS. If the second chain monitoring switch of the inner or outer mast is actuated within this 1 second, an immediate lowering stop and slack chain status is initiated by the FZS. The error code "FE309" appears on the operating console display. If a chain is slack, the only hydraulic function that remains active is lifting the main lift, and the vehicle can only be driven at a speed of v = 1km/h. A slack chain status can be reset by selecting the lift main lift function. Remark: As an additional safety feature in the event of a slack chain, the 0V supply voltage for switching valves 2Y21 (ancilliary movements) and 2Y22 (lowering main lift) and the proportional valve 2Y02 (fine control for lowering main lift) is switched off by the logic of the NAV. Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

12-11

Chapter 12

NAV

Adaptation of the steering setpoint General The steering setpoint from the steering controller or from the inductive wire guidance system is processed by the vehicle control system (FZS). In order for the FZS to process the voltage value, an adaptation of the level and impedance is necessary. Adaptation of the steering setpoint takes place in the NAV.

Inductive wire guidance

Standard steering

• 0V

Description Adaptation with standard steering:

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

7.5V ± 4.5V

Adaptation

4.5V ± 2.7V

Impedance and level adaptation NAV 7A22

Adaptation with inductive wire guidance:

5V ± 4V

Adaptation

3V ± 2.4V AGND

Remark 1: The wheel position display on the operating console indicates the position of the drive wheel. Once the steering has been adjusted, it is necessary to teach in the straighton position for the wheel position display on the operating console (see sheet no. 6-10)

FZS 8U60

CAN-Bus

Op.console 8U62 (wheel pos. display)

Remark 2: AGND (analogue ground) and 0V are connected to each other in the vehicle control system. As well as for impedance adaptation, the AGND is also used for the supply voltage of the actual value potentiometer for height measurement of the main lift.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

12-12

Chapter 12

NAV

Control of the electromagnetic brake General Both brake coils of the electromagnetic brake (1st stage and 2nd stage) are connected at the NAV. In the NAV there is a power output for each brake coil. These are controlled by the FZS. Both brake coils must always be supplied with power for the travel function. The electromagnetic brake is active when: • the EMERGENCY-STOP chain is interrupted • the vehicle is at a standstill (parking brake) • a malfunction is detected by the FZS.

FZS 8U60

NAV 7A22 0V

0V

2+Batt.

1+Batt.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Description When the deadman switch is actuated, both power stages for the brake coils are selected by the FZS. If the EMERGENCY-OFF chain is interrupted, the FZS detects a malfunction or if the vehicle has been braked to a standstill with the generator brake, both braking stages immediately become operative when the cab is at a height of < 6.5m (see sheet no. 5-06). If the cab is above 6.5m, only the 1st stage becomes operative. The 2nd braking stage continues to be controlled by the FZS. As a result, the stability of the vehicle is not endangered during an emergency braking operation.

Brake 1Y44 1st stage

Brake 1Y44 2nd stage

Remark: The 2nd brake coil is supplied with 1+battery voltage so that the 2nd stage remains operative in the event of an emergency braking operation.

The FZS monitors the brake coils continuously for interruptions and short circuits. If a short circuit or interruption is detected, the FZS causes the safety relays K33 and K34 to drop out and the FPS switches the travel drive to idle. Depending on the cause of the error, one of the following error codes appears on the operating console display: "FE100", "FE101", "FE102" or "FE103" (see sheet no. 35-02).

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

12-13

Chapter 12

NAV

Control of the electromagnetic brake Description

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

The safety relays dropping out also causes the main contactors to drop out (see sheet no. 12-04). When the main contactors are inoperative, all the hydraulic functions are inactive and the vehicle cannot be driven.

Evaluation of the setpoint potentiometer for the main lift The analogue setpoint (X1:39) of the height measuring system for the main lift is evaluated as follows in the NAV: • If the setpoint is ≤ 2.9V (equivalent to a cab height of approx. <5m), both braking stages are switched off in the event of an EMERGENCY-STOP, irrespective of whether they are selected by the FZS. • If the setpoint is ≥ 4.0V (equivalent to a cab height of approx. > 7m), the 2nd stage of the electromgnetic brake continues to be supplied with power in the event of an EMERGENCY-STOP, irrespective of whether it is selected by the FZS.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

12-14

Chapter 12

NAV

Adaptation of incremental encoder signals General Incremental encoder, drive motor 1M3

In vehicles with wire guidance, incremental encoder signals from the drive motor incremental encoder must be adapted for the LR80 central processing unit.

A

B

Description

NAV 7A22

The incremental encoder of the drive motor supplies a 9V signal on both channels with every impulse:

0V

0V

9V

V Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

t Impulse

Impulse

• A

B

12V

12V

Impulse

e.g. 24V

The central processing unit of the LR80 needs a 0V signal to detect the impulses:

Central processing unit LR80 3A21

e.g. 24V

0V t Impulse

Impulse

Impulse

Adaptation of the incremental encoder signals is carried out by the NAV. Remark: In order to measure the incremental encoder signal between the NAV and the LR80, the incremental encoder signal must be measured against a positive voltage, e.g. 24V.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

12-15

Chapter 13

Distributor board

General

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Distributor board A13 is located on the right-hand side in the controls compartment, underneath the vehicle control system (FZS). Distributor board A13 is used in this vehicle as a voltage distributor. All the supply voltages, from battery voltage and 1+battery voltage to 2+24V are connected to distributor board A13. If power is required for supplying components or sensors, this power can be picked off a suitable connector of distributor board A13. The voltages that can be picked off: • battery voltage • 1+24V • 2+24V are protected with a total of seven fuses (1). Each fuse is fitted with an LED (2). If an LED is not lit up, this means that the corresponding fuse is faulty or the voltage which is protected is not being applied.

0/0233

1

2

There is a multiple switch on distributor board A13 (3). This multiple switch must always be set to position "1". If the switch position is any other than position "1", the error code "FE1011" appears on the operatign console display and the components that are connected to the vehicle control system are no longer supplied with 2+24V.

0/0233

3

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

13-01

Chapter 13

Distributor board

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Structure

0/0240

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

13-02

Chapter 14

Negative feeder module

General The negative feeder module (1) is mounted next to the travel and pump control system (2) on the cooling plate of the latter. The negative feeder module only works in combination with the travel and pump control (2). Together with the armature actuator of the pump, it forms a half H-bridge for the armature actuator in the FPS. This means that the field actuator can be used to control an externally excited d.c. motor in 4-quadrant operation for the pump drive.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Description

0/0297

When the lower main lift function is selected, the travel and pump control unit receives a lowering command from the vehicle control system via the CAN bus. So that the cab does not drop immediately with a sudden jolt, the area between the pump and the chassis valve block must be filled with oil by means of a so-called "initial movement". During the initial movement, the pump is briefly controlled by the FPS with the valves closed. Finally, the FPS regulates the hydraulic motor to the speed of the vehicle control system that is specified via the CAN bus. The power released from the lowering process is channelled back to the consumers in the vehicle or to the battery.

1

2

Terminals (3)

Connector X1 (communication between FPS and negative feeder module) 2+Batt. 0V A2 pump motor

(4) (5) (6)

0/0298

3

4

5

6

Pin assignment X1 Pin 1 2 3 4

Type Output Input Input Input

Issue: 02/01 Replaces issue:

Signal 34V 0V 24V 24V

Description Status (lower main lift = 0V, otherwise ca. 34V) 0V supply voltage. 24V supply voltage Control command (lower main lift = 0V) Workshop Manual

MX15-3

Sheet no.

14-01

Chapter 15

Main contactors

General

FPS A10

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

The purpose of the main contactors K1 and K2 (1) is to ensure that the power supply for the drive, pump and steering motors is switched off safely in the event of an error.

0V

Two 24V main contactors are used in this vehicle. These are connected in series, so that if one contactor fails, both drop out immediately. The main contactors receive a pulsed 0V signal (PWM signal) from the travel and pump controller (FPS). The FPS monitors the pick-up current (approx. 1.1A) and the holding current (0.55A) of the contactors. In the event of an error, the 0V signal is switched off by the internal K relay in the FPS for the main contactors and the contactors drop out. The main contactors are located above the pump unit

K

X11:4 K1 K2

2+Batt.

1

Coil holder suppression There is a suppression at the coil holder which consists of a diode 1N4005 (2) and a 47Ω/24V resistor (3). The purpose of the suppression is to reduce the induction voltage on switching off. Remark: Because of the permanently installed diode, the positive and negative connections are fixed. Reverse voltage connection causes a short circuit.

0/0245

3 2

Spacing distance 9/0060

When the contactor has picked up, there must be a distance of between 1.8 and 3.2mm (4) between the contact bridge and the support finger.

Contact pressure The contact pressure of the contactor when fully actuated: 11-14N per contact, based on the centre of the contact.

4 8/3032

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

15-01

Chapter 16

DC/DC-Converter

General The DC/DC converter is used for the entire 24V power supply in the vehicle. The DC/DC converter is located in the controls compartment between the negatve feeder module A14 and the main contactors K1 and K2.

2

1

3

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Description When the battery plug is plugged in, the DC/DC converter is supplied with power from the battery. When the vehicle is switched on, the orange LED (1) lights up and the DC/DC converter supplies an output voltage of 24V. The converter is protected against reverse voltage and has thermal overload protection. Remark: The output voltage of the DC/DC converter is protected on the distributor board A13 by a suppressor diode. When the DC/DC converter delivers an output voltage of >24V, a high current flows through the suppressor diode at the output to 0V. In the same way, if the input voltage of the DC/DC converter increases, fuse F4 (5A) is tripped. This means that the 24V components connected to the DC/DC converter are protected from excess voltage.

6/0020

4

Battery G2 Key switch S1 •

•

F4 SUPPLY-

Electrical connections The converter does not deliver a 24V output voltage until 1+battery voltage (vehicle switched on) is applied to this terminal (3) SUPPLY + 0V battery voltage (4) SUPPLY - Battery voltage (5) OUTPUT + 24V output voltage (6) OUTPUT - 0V output voltage

6

5

SUPPLY+

ON

DC/DC converter U30

(2) ON

OUTPUT-

OUTPUT+

Distributor board

A13

Technical data Input voltage: Output voltage: Nominal output voltage: Operating temp. range:

Issue: 02/01 Replaces issue:

28V - 110V 24V 14A -20°C - +85°C

Workshop Manual

MX15-3

Sheet no.

16-01

Chapter 17

Distance sensor/main lift

General A distance sensor (1) is used to detect the lift height. It includes an incremental encoder and a potentiometer. The incremental encoder is monitored by the potentiometer, which is mechanically fixed to it. This is done by evaluating and comparing the two measured values in the vehicle control system. The distance sensor is actuated by a highly flexible steel wire that is held taut along the entire extension length by a spring motor. 1/0033

Location

1

In the cab behind the driver's seat (2).

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Identification Screw-fitted aluminium housing with cable conducting tube. Type: WDS-15000-P501-S-P-E-STW

Technical data Measuring range: Resolution: Potentiometer, 10-speed: Incremental encoder nom. voltage:

15,000mm 1 impulse/mm 1 kOhm / 1W 24V DC 0/0236

2

3

Pin assignment Terminal (3) on the housing, viewed from exterior: Pin 1: Pin 2: Pin 3: Pin 4: Pin 5: Pin 6: Pin 7: Pin 8:

24V supply, incremental encoder 0V supply, incremental encoder Channel A, incremental encoderer Channel B, incremental encoder 8.5V supply, potentiometer 0V supply, potentiometer not occupied Potentiometer arm 0/0234

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

17-01

Chapter 17

Distance sensor/main lift

Monitoring The vehicle control monitors the incremental encoder, the potentiometer and the reference switch for the main lift function. If an error occurs in this measuring system, a suitable error code (see sheet no. 35-05) appears on the operating console display (1).

Q PSA

Q

PSA Fehler

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Important: After repair work has been carried out on the distance sensor, a teaching-in process must be carried out on the measuring system (see sheet no. 22-04).

0/0001

1

The reference switch (2) is fastened to the mast and is actuated by a switching plate (3) that is mounted on the rear of the cab. The distance sensor is checked by the reference switch. Every time the cab is raised above the reference switch, the measured height is compared to the stored value in the vehicle control system. The mounting height of the reference switch is set during the teaching-in process (see sheet no. 22-04), for this reason the position must not subsequently be changed again.

Issue: 02/01 Replaces issue:

Workshop Manual

0/0235

2

MX15-3

3

Sheet no.

17-02

Chapter 17

Distance sensor/main lift

Safety instructions The housing of the distance sensor may only be opened by trained personnel. Remark:

Damage to the measuring cable Damage to the distance sensor

Do not let the measuring cable snap and do not pull it out over the given measuring range.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Caution:

Risk of injury from whipping effect of the cable

Damage to the distance sensor

When opening the spring motor, please follow the working instructions precisely. Danger:

Issue: 02/01 Replaces issue:

Risk of injury from pre-tensioned spring motor

Workshop Manual

MX15-3

Sheet no.

17-03

Chapter 17

Distance sensor/main lift

Description of errors Error

Cause

Rectification

Mechanically in order, no incremental encoder signal (FE 311, 314, 315)

Supply voltage faulty

Check

Cable/connector damaged

Visual inspection

Encoder faulty

Replace encoder, first determine cause (excess voltage, wiring error, or similar)

3, (2, 1)

Supply voltage faulty

Check

1

Cable, connector damaged

Check, replace

Potentiometer faulty

Replace potentiometer, check toothed belt, possibly below measuring range, excess voltage, short circuit, wiring error

Infeed stuck

Clean infeed (with alcohol)

Sheath damaged

Determine the cause, 2, (1) new cabl, possibly new infeed

Cable jammed

Release carefully, if damaged then new cable

2, (1)

Belt faulty

Check spring and potentiometer, new belt

4, (3,2,1)

Spring faulty

Check belt and potentiometer, new spring

5, (4,3,2,1)

Mechanical effect

Check spring and belt

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Mechanically in order, no potentiometer signal (FE 314, 315)

Cable loose, does not return (FE 312, 314, 315)

Cable or cable fixture torn (FE 312, 313, 315)

Work

New cable, new potentiometer, (new spring)

2, 1, (5)

Work Replacement of: 1 = potentiometer, 2 = cable, 3 = incremental encoder, 4 = belt, 5 = spring. If work is in (), only carry out the work - replace parts only if necessary!

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

17-04

Chapter 17

Distance sensor/main lift

Removal and installation

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Removal: • Switch the vehicle control to user mode (1) (see sheet no. 21-01). • Delete the teach-in values for the main lift (see sheet no. 22-03). • Raise the cab and chock it up from below. • Extend the measuring cable at the cable pull eye by approx. 0.5m with wire or string. • Disengage the cable pull eye at the vehicle frame and slowly pull the measuring cable through the cab floor with the extension. • Lower the cab • Remove the driver's seat • Remove the distance sensor (2) (4 x hexagon screws M6).

Installation: • Insert the extension of the measuring cable through the hole in the cab floor from above and screw the distance sensor securely in place. • Raise the cab and chock it up from below. • Pull the measuring cable out at the extension and engage the cable pull eye in the holder on the vehicle frame. Remove the extension from the measuring cable. • Teach in the main lift again (see sheet no. 22-04).

Issue: 02/01 Replaces issue:

Workshop Manual

Q PSA

Q

PSA Fehler

0/0001

1

0/0236

2

MX15-3

Sheet no.

17-05

Chapter 17

Distance sensor/main lift

Repair instructions 1. Replacing the potentiometer The potentiometer (1kOhm, 10 revolutions) must be adjusted close to the internal mechanical end stop with the measuring cable fully wound (resistance approx. 0-30 Ohm between terminal pins 2 and 3), increasing proportionally as the cable is pulled out). The spring motor is still pre-tensioned here with approx. 20 revolutions here.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Remark: In the event that a cable snaps, the belt snaps or the belt tension slackens, the spring motor overwinds the potentiometer and damages it mechanically. For this reason, always disconnect the potentiometer from the spring motor before making all other adjustments. Assembly: • Open the sensor housing (10 screws, hexagon head spanner size 5) • Loosen the grub screw in potentiometer adjusting ring (2) • Reconnect the connector from the old potentiometer in the new one (1=white, 2=green, 3=black). If necessary, bend the contacts slightly together. • Turn the potentiometer clockwise (viewed towards the axis) as far as it goes. • Push the potentiometer axis into the adjusting ring so that the leg of the wire eye (1) is positioned slightly clockwise from the hexagon bolt (3). • Tighten the adjusting ring and check the position of the potentiometer stop. • Engage the leg of the wire eye (1) in the slot (4). The potentiometer is now fixed approx. 2-3 degrees from its internal stop when the cable is fully wound. • Check the function and screw the housing shut. Remark: If the potentiometer is supplied without a wire eye (1) mount the old wire eye on the new potentiometer and secure the screw with locking compound (not Loctite).

Issue: 02/01 Replaces issue:

Workshop Manual

1/0001

1

2

1/0002

1/0003

1

3

MX15-3

4

Sheet no.

17-06

Chapter 17

Distance sensor/main lift

Repair instructions

1

2. Replacing the cable Remark:

Uncontrolled releasing of the cable drum makes the spring motor overwind the potentiometer and cause mechanical damage to it.

• Open the housing, release the connector from the cover plate if necessary. • Remove the potentiometer as described under point 1.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Tension the housing vertically in a vice so that the cable conducting tube points horizontally to the side.

1/0004

• If the measuring cable has not snapped, pull the cable right out, jam an electric screwdriver onto the shaft end and leave it there to block the cable drum. • If the old cable has snapped, the potentiometer must also always be replaced. If the cable has overwound, the spring may also be damaged. Remove all remains of the old cable and check manually that the spring is disengaged. Tighten the cable drum 49...51 turns clockwise with an electric screwdriver until the 0.6mm hole of the cable drum is close to the cable inlet (1).

1/0005

• Pull out the Cu sleeve and pinch it off, then remove the old cable. • Push the new cable without forming loops through the cable inlet and hole into the drum base. • Swage on the Cu sleeve with wire end sleeve crimping pliers, laying the cable double; do not let the loop protrude.

1/0006

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

17-07

Chapter 17

Distance sensor/main lift

Repair instructions Replacing the cable • Push the crimped sleeve into the 1.9mm hole (1) in the drum. • Hold the cable and cable drum tight and remove the electric screwdriver. • Wind the cable evenly onto the cable drum using the tension of the spring motor. On the first few turns, push the cable right to the edge of the drum in the direction of the 0.6mm hole (2).

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Let the cable run right in. Do not let it run through your hand.

1/0007

2

1

• Check: Pull the cable out by 15.0 m (exactly 30 turns) and then release it again; do not interfere with the winding process here. The coils should lie adjacent to one another. The cable pull must be even. • Install the potentiometer as described under point 1.

1/0008

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

17-08

Chapter 17

Distance sensor/main lift

Reparair instructions 3. Replacing the incremental encoder Remark: The incremental encoder is also the belt tensioning device. When the fastening screws are released, the spring motor may unwind.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

When the incremental encoder is replaced, either the cable must be removed carefully or a new cable must be used. The tension must be released from the spring motor for this purpose. 1/0009

• Open the housing and pull out the potentiometer, as described under point 1. • Clamp the housing vertically in a vice so that the cable conducting tube points horizontally to the side. • Pull the cable right out and lay it down without any loops in it. • Jam the electrical screwdriver onto the drum shaft to block the spring motor. • Pinch off the cable close to the Cu sleeve. Pull out the Cu sleeve and carefully let the cable drum run back until the tension is fully released from the spring motor. • Unscrew the incremental encoder. • Mount a new incremental encoder, insert the fastening screws without tightening fully. The belt should lie neatly in the teeth. • Tension the belt by moving the incremental encoder, check the belt tension: it should be possible to move the belt 2-3 mm when gentle pressure is applied with the thumb. As a check, lay a 300g hammer on the centre of the belt (it should sag by about 2-3 mm). (belt tension measuring device: 215Hz ± 15 Hz) • Tighten the screws and fix the screw heads on the encoder with compound (not Loctite or similar attacks plastic).

Issue: 02/01 Replaces issue:

Workshop Manual

1

1/0010

MX15-3

Sheet no.

17-09

Chapter 17

Distance sensor/main lift

Repair instructions 3. Replacing the incremental encoder

• Fasten the leads again with cable binders. • Mount the potentiometer as described under point 1.

• If the unwound coil is still in good condition (no

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

kinks), it can be used again. It does not matter that the piece of cable that has been cut off at the Cu sleeve is lost. If the cable is not in good condition, a new cable must be installed as described under point 2.

1

4. Replacing the belt If a torn belt (1) needs replacing the potentiometer, the cable and possibly also the spring are usually also damaged. If a belt is replaced without the components named above being damaged, these can be used again if they are handled carefully during the replacement work. The working sequence is the same as that described in points 1,2,3,(5). 1/0010

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

17-10

Chapter 17

Distance sensor/main lift

Repair instructions 5. Replacing the spring The spring may bend due to wear, breakage or unbraked drawing in of the cable in the opposite direction to the the winding direction. If the potentiometer and cable are also faulty in a case like this, it is a good idea to replace the entire distance sensor. Most faults to the spring are caused when a cable breaks or through incorrect handling (wrong rotary direction) during installation where the spring hangs out of the spring driver. 1/0011

Checking the spring: Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Remark:

1

Remove the cable from the cable drum.

• Open the housing and remove the potentiometer as described under point 1 1. • Clamp the housing in a vice and mark the cable drum at the edge (1). • Jam an electric screwdriver onto the drum shaft and carefully wind up the spring motor in a clockwise direction until it reaches the mechanical stop (count approx. 68...84 revolutions of the cable drum). • Now unwind the drum shaft by about 3/4 of the revolutions in a clockwise direction, remove the electric screwdriver and slowly let the drum run right back by hand (count the revolutions).

1/0004

The drum must turn back by ±4 revolutions. • Repeat the press. No extreme noises should be produced and the force on the drum must be relatively even, otherwise the spring must be replaced.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

17-11

Chapter 17

Distance sensor/main lift

Repair instructions Replacing and engaging the spring: • Release the screws (1) that secure the distance plate (2) (3xM5 Phillips screws). Caution: Lift the distance plate and the spring out carefully - the spring may already spring out!! • Secure the spring in the spring housing with a wooden strip or something similar. • Lay the distance plate flat on a suitable surface with the spring facing up. • If the spring is in good condition but is unhooked from the driver, it does not need to be replaced. If this is not the case, the spring must be replaced.

1/0017

1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Danger:

The spring may uncoil! Before removing the old spring, always be sure to bind it up into a roll with 3 strong cable binders or wire and then remove it with a pair of universal pliers. Always wear protective gloves!

Installing a new spring:

1/0020

2 Remark: Do not release the spring securing element (3) until the spring is inside the steel pins and correctly positioned. Once the tension on the spring has been released it can no longer be moved or turned! If the spring has been released by accident, the spring can be rewound in the spring housing with the help of an electric screwdriver. Always wear protective gloves!

1/0012

3 Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

17-12

Chapter 17

Distance sensor/main lift

Repair instructions Installing a new spring: • Lay the housing ring (1) over the hand you are going to use to press the new spring firmly onto the distance plate. • Hold the spring around its circumference with your fingers (winding direction clockwise) and insert it between the steel pins and the spring driver. • Keep hold of the spring and release about 6cm of the outer end of the spring. • Carefully nip off the wire securing element with a pair of side cutting pliers so that the outer end of the spring projects.

1/0015

1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

2 • Turn the tensioned spring so that the outer end of the spring (2) can pass around the outside past one steel pin and be engaged at the next steel pin. • Hook the end of the spring on the steel pin. • Push the housing ring off your wrist and over the spring. • Use your free hand to press the spring down with a piece of wood or something similar and then carefully release it. The spring relaxes and sits tightly against the steel pins and the spring housing on the inside.

1/0013

• Check the bent leg of the spring in the spring driver. While doing so, hold down the spring with a wooden strip or something similar • If necessary, smear a little grease (3) onto the free spring coils.

1/0014

3

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

17-13

Chapter 17

Distance sensor/main lift

Repair instructions Installing a new spring • Lay the plastic disc (1) in the centre over the spring and check the bearing (2). • Carefully lay the distance plate on the base plate and push the axis into the bearing.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

1

2

1/0022

• Screw the plates together. Do not forget the two spacer sleeves (3). • Conduct a function test. See the section entitled "Checking the spring". • Secure the screws with screw locking compound. • Continue as described under point 2.

1/0018

3

1/0019

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

17-14

Chapter 18

Distance sensor/add. lift

General A two-channel magnetic sensor (1) is used for height measurement of the additional lift. It scans a magnetic strip (2) along the entire length of the additional lift mast. Output signals:

A, B, square wave signals, in quadrature Resolution: 1 pulse/mm Power supply: 24Vdc Distance from sensor strip: 0.1 - 4.0mm 0/0238

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Remark: The magnetic strip (2) is protected by a metal strip that lies over it.

A magnetic switch (reference switch) is used for continuous monitoring of the lift height. The magnetic switch is mounted on the lift carriage next to the magnetic sensor (1) and is actuated by a short piece of magnetic strip (4) when the additional lift is fully lowered. On every negative-going edge of the magnetic switch (additional lift is raised), the counter in the vehicle control system is checked. The distance between the magnetic switch and the magnetic strip must not exceed 8mm. Remark:

1

3

0/0200

2

4

The magnetic strip (4) is protected by a metal strip that lies over it.

Important: The magnetic strips for the magnetic sensor and the magnetic switch are not interchangeable! The magnetic sensor and the magnetic switch are connected to the CAN bus module LAS (see sheet no. 11-01).

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

18-01

Chapter 18

Distance sensor/add. lift

Monitoring The vehicle control system monitors the 2-channel magnetic sensor and the magnetic switch. If an error occurs in this measuring system, the relevant error code (see sheet no. 35-07) appears on the operating console display (1).

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Remark:

Q

Q

PSA

PSA Fehler

When the additional lift is fully lowered, the magnetic switch (2) should be actuated. When the magnetic switch is actuated the LED on the encoder housing lights up.

0/0001

1

Important: When repair work has been carried out on the sensors, a teaching-in process must be carried out on the measuring system (see sheet no. 22-05).

0/0238

2

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

18-02

Chapter 19

Distance sensor/swivelling

General

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

A 1kΩ potentiometer (1) is used for distance measurement of the swivel function. The end position of the swivel function is monitored by a limit switch (inductive encoder) (2). The potentiometer and the limit switch are connected to the LHC. When installing the potentiometer, it is important to ensure that: • The potentiometer value increases from right to left during swivelling, • The setpoint at the right-hand swivelling end position is no less than 0.15V, • The setpoint at the left-hand swivelling end position is no more than 9.85V, • The potentiometer does not pass through zero during swivelling from left to right and vice versa.

0/0239

1

Remark: Move the fork into the front position and set the potentiometer to half the total resistance (500Ω) (see sheet no. 31-16). When the end position for swivelling right (swivelling angle <3°) or the end position for swivelling left (swivelling angle >177°) is reached, the limit switch should be actuated (red LED on encoder lights up). 0/0223

Monitoring

2

3

The vehicle control system monitors the potentiometer value and the limit switch for the swivel function. If an error occurs in this measuring system, the relevant error code (see sheet no. 35-09) appears on the operating console display (4). Important: When repair work has been carried out on the sensors, a teaching-in process must be carried out on the axis (see sheet no. 22-06).

Q

Q

PSA

PSA Fehler

0/0001

4

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

19-01

Chapter 20

Distance sensor/side shifting

General

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

A 1kΩ potentiometer (1) is used for distance measurement of the side shift function. The end position of the side shift function is monitored by a contour switch (inductive encoder) (2). The potentiometer and the contour switch are connected to the LHC. When installing the potentiometer, it is important to ensure that: • The potentiometer value increases from right to left during side shifting, • The setpoint at the left-hand side shifting end position is no less than 0.15V, • The setpoint at the right-hand side shifting end position is no more than 9.85V, • The potentiometer does not pass through zero during shifting from left to right and vice versa.

0/0215

1

Remark: Move the side shift carriage into exactly the centre position and set the potentiometer to half the total resistance (500Ω) (see sheet no. 31-14). There are two different end positions for side shifting to the left and right: • The fork is swivelled into the end position and the fork prongs do not point in the selected side shift direction or the fork is not swivelled into its end position In this position, it is not possible to shift the fork beyond the normal end position. • The fork is swivelled into the end position and the fork prongs point in the selected side shift direction. In this position, the normal end position can be exceeded and the fork moved as far as the overshift function (if fitted) allows.

0/0220

2

When the end position for side shifting to the left or to the right (side shift carriage closes flush with the fork holder) is reached, the contour switch should be actuated (red LED on the encoder lights up).

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

20-01

Chapter 20

Distance sensor/side shifting

Monitoring The vehicle control system monitors the potentiometer value and the contour switch for the side shift function. If an error occurs in this measuring system, the relevant error code (see sheet no. 35-08) appears on the operating console display (1).

Q

Q

PSA

PSA Fehler

Important: When repair work has been carried out on the sensors, a teaching-in process must be carried out on the axis (see sheet no. 22-07).

0/0001

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

1

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

20-02

Chapter 21

USER mode

Description In order for parameters to be stored in the vehicle control system (FZS), the vehicle control system must be switched over from normal mode to USER mode.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

This switch-over of the control system to USER mode is necessary when: • Hydraulic functions need teaching in (see sheet no. 22-01), • Parameters needs to be changed and saved using diagnosis software, • Options need to be set or deleted using diagnosis software, • A complete vehicle program is to be loaded into the vehicle control system.

1

To switch the FZS into USER mode, proceed as follows: • Actuate the EMERGENCY-STP button (1) on the operating console. • Press both operating keys (2) and the acknowledgement key (3) on the operating console at the same time. • The maintenance LED (4) flashes. • Release the EMERGENCY-STOP button. Remark: When the vehicle control system is in USER mode, the maintenance LED flashes. The vehicle can be operated without limitations in this mode. To switch back from USER mode to normal mode, switch the vehicle off and then on again.

Issue: 02/01 Replaces issue:

Workshop Manual

Q PSA

Q

PSA Fehler

0/0001

3

MX15-3

4

Sheet no.

2

21-01

Chapter 22

Teaching-in process

General

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

During the teaching-in process, parameters are stored in the vehicle control system that send each distance sensor of a hydraulic function to the mechanical end stop: • Main lift distance sensor (see sheet. 17-01) • Add. lift distance sensor (see sheet. 18-01) • Swivelling distance sensor (see sheet. 19-01) • Side shift distance sensor (see sheet. 20-01). The vehicle control system uses the parameters that are programmed with the diagnosis software during initial commissioning (e.g. max. lift height, distance between top edge of fork and floor, standing height of the driver in the cab, fork holder width, etc.. ..., see sheet no. 22-02) to calculate the values required for the start of the ramp function, the ramp speed, etc... . Teaching-in of the hydraulic functions is only necessary on initial commissioning of the vehicle (this is alredy carried out in the factory), see sheet no. 22-02. Important: If a component is replaced on a distance sensor or the position of a sensor is changed, a new teaching-in process must be carried out on the axis in question! If a hydraulic function is not taught in, it can be executed at a "commissioning speed" without automatic speed reduction before the mechanical end stops. The "commissioning speed" is set so that the mechanical end stops are not damaged. The vehicle control system (FZS) must be set to USER mode for teaching in (see sheet no. 21-01). The switch-over into USER mode and teaching-in is carried out on the operating console.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

22-01

Chapter 22

Teaching-in process

Initial commissioning During initial commissioning, the following parameters must be checked and entered correctly using diagnosis software: • Main lift function - Maximum lift height in mm (see sheet 7-06). - Measurement from the floor to the top edge of the fork when the lift carriage is fully lowered and the cab is lowered, in mm (standard setting: 60mm). - Measurement from the floor to the standing height of the driver in the cab, in mm (standard setting: 435mm).

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Additional lift function - Lift limitation before mechanical end stop, in mm (standard setting: 10mm). • Side shift function - Width of fork holder in mm (from mechanical end stop to mechanical end stop). - Home position (fork in contour) to mechanical end stop, in mm (standard setting: 65mm). - Overshift position to mechanical end stop in mm (standard setting: 10mm)

1/0059

1

Remark: The overshift position to the mechanical end stop only needs to be set if the trilateral head is fitted with the option of shifting the side shift carriage beyond the fork frame (1).

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

22-02

Chapter 22

Teaching-in process

Deleting the teaching-in values If a hydraulic function has been incorrectly taught in, the stored values can be deleted by pressing the key for the hydraulic function (1), both the operating keys (2) and the acknowledgement key (3) all at the same time. The vehicle control system must first be switched over to USER mode (see sheet no. 21-01). Remark: When all 4 keys are pressed at the same time to delete the stored value for a hydraulic function in the FZS, a short tone is emitted by the sound transmitter on the operating console.

Q PSA

Q

PSA Fehler

0/0001

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

The hydraulic function can then be taught in again. After a hydraulic function has been taught in, the speed setting and the ramp function before the mechanical end stop are displayed immediately.

3

2

1

If several or all of the axes are to be deleted in succession, it is extremely important to do this in the following order: 1. Main lift 2. Additional lift 3. Swivelling 4. Side shifting After teaching in, the rotary knob (4) on the distributor board A13 must be reset to position "1" (basic position). 0/0233

Remark1: Not until all the hydraulic functions have been correctly taught in are the following limitations lifted: deceleration to a speed of v = 2.5km/h and reduced speed for lifting and lowering the main lift.

4

Remark2: After teaching-in values have been deleted, the vehicle should not be switched off until the hydraulic function has been taught in again.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

22-03

Chapter 22

Teaching-in process

Preparation for teaching in • Check or enter the parameters during initial commissioning (see sheet no. 22-02). • Switch the FZS to USER mode (see sheet no. 21-01) • Preset the parameters in the FZS. • Move the trilateral head into its home position, i.e. the fork must be shifted fully to the left and swivelled fully to the right (1). • During referencing work, the rotary knob (2) on the distributor board A13 must be set to position "2" (USER mode) or position "4" (SUPERUSER mode). • Raise the additional lift by at least 10cm.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

1

Teaching in the main lift distance sensor • Prepare for the teaching-in process (see sheet no. 22-04). • Fully lower the main lift and with "Lower main lift" selected, press the acknowledgement key (3) on the operating console once. Remark: When the acknowledgement key is pressed, the sound transmitter on the operating console emits a sound at intervals. If this is not the case, the system has been incorrectly operated, and the teaching-in process has not been started.

0/0233

2

• Select "lift main lift" and raise to the max. lifting height of the cab. With "lift main lift" selected, press the acknowledgement key (3) on the operating console once. Remark: Once the acknowledgement key has been pressed, the sound transmitter in the operating console is switched off.

Q PSA

Q

PSA Fehler

• The axis is now taught in.

0/001

3

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

22-04

Chapter 22

Teaching-in process

Teaching in the additional lift distance sensor • Prepare for the teaching-in process (see sheet no. 22-04).

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Fully lower the additional lift. The reference switch (1) must be pressed during this process (yellow LED lights up). Important: The reference switch (1) must send a positive-going edge to the vehicle control system once after the vehicle is switched on, in order for teaching-in of the height measuring system for the additional lift to be possible at all. For this purpose, the lift carriage must be raised until the reference switch (1) is no longer actuated (LED on the sensor goes out). The lift carriage must then be fully lowered (LED on the sensor lights up).

0/0224

1

• With "lower additional lift" selected, press the acknowledgement key (2) on the operating console once. Remark: When the acknowledgement key is pressed, the sound transmitter on the operating console emits a sound at intervals. If this is not the case, the system has been incorrectly operated, and the teaching-in process has not been started.

Q PSA

Q

PSA Fehler

0/001

2

• Carefully raise the additional lift until it reaches the mechanical end stop. With "lift additional lift" selected, press the acknowledgement key (2) on the operating console once. Remark: Once the acknowledgement key has been pressed, the sound transmitter in the operating console is switched off. • The axis is now taught in.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

22-05

Chapter 22

Teaching-in process

Teaching in the swivelling distance sensor • Prepare for the teaching-in process (see sheet no. 22-04). • Carefully swivel the fork to the mechanical end stop at the right. With "swivel right" selected, press the acknowledgement key (2) on the operating console once.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Remark: When the acknowledgement key is pressed, the sound transmitter on the operating console emits a sound at intervals. If this is not the case, the system has been incorrectly operated, and the teaching-in process has not been started.

Q PSA

Q

PSA Fehler

0/001

2

• Carefully swivel to the mechanical end stop at the left. With "swivel left" selected, press the acknowledgement key (2) on the operating console once. Remark: Once the acknowledgement key has been pressed, the sound transmitter in the operating console is switched off. • The axis is now taught in.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

22-06

Chapter 22

Teaching-in process

Teaching in the side shift distance sensor • Prepare for the teaching-in process (see sheet no. 22-04). • Carefully side shift the fork to the mechanical end stop at the left. With "side shift left" selected, press the acknowledgement key (1) on the operating console once.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Remark: When the acknowledgement key is pressed, the sound transmitter on the operating console emits a sound at intervals. If this is not the case, the system has been incorrectly operated, and the teaching-in process has not been started.

Q PSA

Q

PSA Fehler

0/001

1

• Carefully side shift to the mechanical end stop at the right. With "side shift right" selected, press the acknowledgement key (1) on the operating console once. Remark: Once the acknowledgement key has been pressed, the sound transmitter in the operating console is switched off. • The axis is now taught in.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

22-07

Chapter 23

Reference sequence

General The two distance sensors for the main lift and additional lift have, among other features, a digital measuring system. If the vehicle is switched off when it should not be and the vehicle control system does not have enough time to store the information about the present position of the cab and the lift carriage, or if the cab is lowered using the emergency release screw when the vehicle is switched off, it is necessary to carry out a reference sequence. Remark: It is not necessary to carry out reference movements for the analogue measuring systems for side shifting and swivelling.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Reference sequence, main lift An inductive switch (1) that is located on the rear wall of the cab is used for referencing the digital measuring system for the main lift (incremental encoder) Conducting the reference sequence: • Lower the cab fully (LED on the inductive encoder lights up). • Raise the cab. • When the inductive encoder is no longer actuated by a switching plate on the rear wall of the cab (2) (LED on inductive encoder goes out) the axis for the main lift is referenced.

0/0235

1

2

Reference sequence, additional lift A magnetic switch (3) that is mounted on the lift carriage is used for referencing the digital measuring system for the additional lift (magnetic sensor). Conducting the reference sequence: • Lower the lift carriage fully (LED on magnetic sensor lights up). • Raise the lift carriage. • When the magnetic switch is no longer actuated by the short magnetic strip on the additional lift mast (LED on the magnetic switch goes out), the axis for the additional lift is referenced. Issue: 02/01 Replaces issue:

Workshop Manual

0/0224

3

MX15-3

4 Sheet no.

23-01

Chapter 24

Chassis valve block

Functional elements Presure relief valve (1) This limits the excess pressure that comes from the hydraulic unit. The pressure is set to 250 bar (see sheet no. 24-02). Important: The hydraulic components are designed for a maximum system pressure of 250 bar!

Test connection (2) Manometer connection for pressure adjustment.

1 4

3

5

Emergency release screw (3)

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

2

6

This allows you to open the oil return feed to the tank and in this way lower the cab manually in an emergency. Remark: The hexagon socket screw key needed for this purpose must be attached to the valve block at all times.

7

8

B/W valve, lifting main lift (4) Blocks the oil flow to the main lift when ancilliary movements are selected. This valve must be supplied with power in order for the main lift to rise.

0/0300

B/W valve, lowering main lift (5) Load retaining valve for the main lift. This valve must be supplied with power in order for the main lift to be lowered.

2

1

4

3

B/W valve, ancilliary movements (6) Blocks the oil flow to the ancilliary movements when "lift main lift" is selected. This valve must be supplied with power when an ancilliary movement is selected .

Mechanical soiling indicator (7) If the colour of the mechanical soiling indicator (7) changes from green to red, the filter element must be replaced (see sheet no. 24-04).

High pressure filter (8) The high pressure filter cleans the oil before it enters the hydraulic system. The mechanical soiling indicator shows when the filter needs changing.

Issue: 02/01 Replaces issue:

Workshop Manual

8

MX15-3

6

Sheet no.

5

24-01

Chapter 24

Chassis valve block

Setting the maximum pressure • The vehicle must be fully operational. • The axes must be taught in (see sheet no. 22-01). • The maximum parameter for the pump speed must be active. • Lower the driver's cab fully so that the inductive encoder (1) on the rear wall of the cab is actuated by the switching plate. • Close the stop valves for the main cylinder (2). 0/0235

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Connect pressure measuring device at the test connection (3).

1

• At the maximum setpoint for lifting the main lift, set the pressure to 250 bar with the maximum pressure valve (4). Remark1:

Remark2:

Only operate the pump at a full load for a short time . If the pump is run for an extended time for setting the maximum pressure, the error message "FE312" is displayed. This can be deleted by switching the key switch off and then on again once the correct maximum pressure has been set.

0/0302

The circulation pressure to the valve block for the attachment is approx. 10 bar.

2

3

4

Parameterising the main lift The lifting/lowering speed and the ramp function for the main lift can only be set with parameters, using the diagnosis software. For a guide to the lifting and lowering speeds that should be set, please refer to sheet no. 1-02.

0/0303

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

24-02

Chapter 24

Chassis valve block

Soiling indicator

1

The chassis valve block has a mechanical soiling indicator (1) with an inspection window (2) for the screw-mounted high-pressure filter (1).

2

If green is visible in the inspection window, the filter is in good order and the mechanical soiling indicator has not been triggered. If red is visible in the inspection window, the mechanical soiling indicator has been triggered and the filter must be replaced.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

The mechanical soiling indicator is triggered when a pressure drop of >7bar occurs over the filter.

0/0304

Once the filter has been replaced, the mechanical soiling indicator must be reset manually by pushing in the direction of the arrow (3), so that the inspection window (2) is filled with green again.

3

Remark: The soiling indicator may also be triggered by high pressure peaks. In order to ascertain whether the soiling indicator has been actuated by a soiled filter or a pressure peak, proceed as follows: • Reset the mechanical soiling indicator by pushing in the direction of the arrow (3).

0/0304

• Raise the main lift at 1/2 speed. • If the soiling indicator responds immediately, the filter needs replacing. • If the soiling indicator does not respond, a pressure peak has caused the soiling indicator to trigger early, and the filter does not need to be replaced.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

24-03

Chapter 24

Chassis valve block

High pressure filter Changing the filter - removal • Unscrew the filter cup (1). • Pull off the filter cup vertically downwards. • Remove the filter element (2) vertically from the bottom. • Clean the filter cup (empty out the hydraulic oil and clean off all dirt).

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Remark: The filter cup must be screwed back in place when the filter element has been removed, otherwise hydraulic oil runs out of the tank. (This is because the gear pump leaks. The pump is only sealed when it is under pressure and is the only component between the tank and the filter).

0/0305

1

Changing the filter - installation Remark: Before installation, fill the filter cup about 3/4 full with hydraulic oil so that not too much air enters the hydraulic system. • To install, follow the instructions for removal in reverse order.

0/0306

• Tighten the filter cup up to the block with an open-ended spanner and then make a 1/4 turn back again so that any thermal strain does not have negative effects.

2

Remark: After replacing the filter, bleed all air from the hydraulic system. The easiest way to bleed the system is to select the side shift hydraulic function for approx. 15 seconds. Do not select the main lift, additional lift or swivelling functions, otherwise the air can be "locked" in the cylinders. 0/0307

2

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

24-04

Chapter 24

Chassis valve block

Removing the chassis valve block • Drain off al the hydraulic oil. Remark: When the valve block is removed, hydraulic oil runs out continuously because the pump is not sealed unless it is under pressure. • If the hydraulic oil cannot be drained off completely, it is possible, as an alternative, to push the battery half way out of the battery compartment to the side and to block the suction hose with a suitable tool (1). 0/0338

• Release the 4 screws (2) to unscrew the chassis valve block from the pump.

1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Remove the chassis valve block (3). • Release all the hydraulic connections.

0/0332

2

0/0334

3 Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

24-05

Chapter 24

Chassis valve block

Fine control of lowering main lift When the lower main lift function is selected with a setpoint specification of ≤ 10%, the flow of oil is fed back into the oil tank through a proportional valve (1) that is located underneath the battery. The maximum throughflow volume when the valve is fully open is approx. 3l/min. The effect of this is that the lowering movement can be very accurately dosed when making small lowering movements. If the lowering speed is increased and the oil volume exceeds approx. 3l/min, the switching valve for lowering the main lift opens - some of the oil flows through the fully opened proportional valve and some of it through the pump and back to the tank (power recovery).

0/0308

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

1

0/0309

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

24-06

Chapter 25

Attachment valve block

Functional elements B/W valve for side shift right (1) This valve controls the side shift movement to the right.

1

3

2

4

Proportional valve for side shift (2) Controls the speed for the left/right side shift functions and the lifting additional lift function.

B/W valve for lifting additional lift (3) This valve has to be supplied with power for the lift additional lift function to the executed. During all other ancilliary movements, this valve blocks the flow of oil to the additional lift cylinder.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Proportional valve for swivelling right This proportional valve (4) controls the speed for the swivelling right function.

B/W valve for side shift left (5) This valve controls the side shift movement to the left.

0/0313

5

7

6

Proportional valve for lowering additional lift This proportional valve (6) controls the speed for the lowering additional lift function.

Proportional valve for swivelling left This proportional valve (7) controls the speed for the swivelling left function.

1

0/0312

4 Issue: 02/01 Replaces issue:

7

3

6 Workshop Manual

2

5

MX15-3

Sheet no.

25-01

Chapter 25

Attachment valve block

Adjusting work The valve block on the attachment (1) is preset in the factory and does not require any adjusting work.

Parameterising the ancilliary movements

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

The lifting and lowering speed for the additional lift, the speed for side shifting, swivelling and for synchronous swivel-shift movements, and the ramp functions of all ancilliary movements can only be set with parameters, using the diagnosis software. For a guide to the speeds that should be set, please refer to sheet no. 1-02.

0/0310

1

Remark: The values that should be set for the proportional valves in the diagnosis software are approximately equivalent to the current that flows through the proportional valve: Proportional valve current, swivelling: Imin: approx. 350mA - 470mA Imax: approx. 650mA - 750mA Proportional valve current, side shift: Imin: approx. 200mA - 300mA Imax: approx. 620mA - 720mA

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

25-02

Chapter 26

Pump motor

General The pump motor is made up of the following components:

2

Field coil (1) Armature coil (2)

Technical data for the pump motor Model:

GP 164-M2

Motor type:

Shunt motor

Nominal current:

320A

Voltage:

80V

0/0281

1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Revolutions max.: 2000 r.p.m. Output:

21KW

Protection class:

IP23

4

Pump motor terminals Armature coil

A2

(3)

Armature coil

A1

(4)

Field coil

F1

(5)

3

Field coil F2 (6) Block connector X15 Carbon brush monitoring and (7) temperature sensor (7) 0/0281

7

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

6

Sheet no.

5

26-01

Chapter 26

Pump motor

Temperature sensor integrated in the carbon brush yoke

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

If the temperature in the pump motor between the carbon brushes and stator of the pump motor rises to 160°C, the output of the pump motor is reduced by the travel and pump controller (emergency operation). The error code "FE2198" appears on the operating console display, see sheet no. 35-21. Remark: In the first series manufactured vehicles, an error message does not appear on the operating console display in the event of excess temperature in the pump motor. To check the temperature sensor, the connector X15 to the pump motor must be disconnected. The resistance is then measured at the sensor end between pins X15:4 and X15:1. Finally, the temperature at the motor housing must be measured.

Temperature °C

Resistance Ω

25

600

50

720

70

840

100

1020

130

1220

150

1360

160

1450

The measured values must correspond with those shown in the table to the right ±20Ω. Remark:

The temperature sensor is mounted in the carbon brush yoke. If the sensor is faulty, the entire carbon brush yoke must be replaced.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

26-02

Chapter 26

Pump motor

Carbon brush monitoring The carbon brush yoke (1) in the pump motor is fitted with a monitoring switch (normally closed contact) (2). When the residual brush length is reached, this switch is opened by the brush spring (3). The switching signal is transmitted to the travel and pump controller via signal leads (4) and (5). The error code "FE2196" appears on the operating console display, see sheet no. 35-21. There are double sets of carbon brushes (6) fitted in the pump motor. 0(0283

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Note:

When the brush spring comes to rest on the monitoring switch, the spring pressure on the carbon brush is significantly reduced. As a result, the carbon brush begins to spark and there is a risk that the commutator may be damaged. For this reason, it is absolutely essential to replace the carbon brushes. The entire set of carbon brushes (6) must always be replaced (8 brushes)!

6

1

3

2

4 5 Carbon brush, new

1

2

Carbon brush, worn

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

6/0172

Sheet no.

6/0173

26-03

Chapter 26

Pump motor

Replacing the carbon brushes The carbon brushes must be replaced when the brushes reach a residual length of 20mm (1).

1

Length of a new carbon brush: 34mm The entire set of brushes (8 brushes) must always be replaced at once: • Pull out the battery plug. • Remove the tensioning belt of the pump motor. • Lift the brush spring withthe help of a wire clip. • Pull the carbon brushes out at the connecting cable (2). • Disconnect the connecting cable. • Clean the commutatorcompartment (blow out with air).

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Caution:

Do not breathe in carbon dust.

• Mount the new carbon brushes.

6/0163

Remark: The motor must not be run at full load after the carbon brushes have been replaced. The carbon brushes run in relatively quickly when they are not subjected to a heavy load.

1

Checking the brush springs Brush springs that are not pre-tensioned adequately can cause the commutator to burn. Check that the carbon brushes run smoothly in the shaft. 0(0283

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

26-04

Chapter 26

Pump motor

Pump motor maintenance

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

For further details on this subject, please refer to the description of the drive motor (see sheet no. 2-07).

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

26-05

Chapter 27

Hydraulic motor

Function The hydraulic motor (1) is the drive unit for the side shifting function. It is mounted on the side shift carriage (2) underneath the cover (3). Its drive shaft is connected directly to the toothed shaft (4) in the side shift carriage.

1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Depending in which direction the oil flows through the hydraulic motor, it rotates either clockwise or anticlockwise and drives the toothed shaft. The toothed shaft runs on the two toothed rods of the holder and pushes the side shift carriage to the left or right. The hydraulic motor is connected to the valve block of the attachment with two hydraulic leads. This valve block contains the switching valves for the direction of oil flow through the hydraulic motor (side shifting to the left or right) and the proportional valve for side shifting, with which the volume of oil that passes through the hydraulic motor can be altered (shifting speed). The volume of oil also depends on the pump speed for shifting that is set in the vehicle control system.

0/0291

2 3

Commissioning • Start up the motor gently. • Run the motor for 15 to 30 minutes with a moderate load and at a moderate speed. • Do not run the motor with a full load until all air has been bled out of the system and the dirt particles have been filtered out. 0/0293

4

Technical data • Maximum pressure (duration): 140bar • Maximum pressure (peak):

160bar

Remark: Do not subject the motor to loads that exceed the maximum values.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

27-01

Chapter 27

Hydraulic motor

Checking for leaks • Clean all oil off the connectors of the hydraulic motor and off the hydraulic motor itself.

2

• Shift the side shift carriage out of the ramp area. • Block the side shift function with a piece of wood. • Select the side shift function and apply the max. setpoint for shifting for approx. 10 seconds. • Look to see if any oil has emerged from the connectors (1) of the hydraulic motor. If it has, the leaking connectors must be inspected and replaced if necessary • Look to see if oil has emerged from the B-end shield (2).

0/0291

1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

If it has, the hydraulic motor must be replaced. Remark: The A-bearing of the hydraulic motor (3) is not visible when the motor is installed in the vehicle. If the A-bearing leaks, the oil that escapes runs over the toothed shaft bearing (4) onto the gearwheel of the toothed shaft (5). In this case, the hydraulic motor must be replaced.

3

0/0293

4

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

5

Sheet no.

27-02

Chapter 27

Hydraulic motor

Removal Remark: As soon as either of the two hydraulic connectors is disconnected, hydraulic oil leaks out. The oil that emerges must be caught in a suitable container. • Release the pressure on the hydraulic leads to the hydraulic motor. Remark: The pressure can be released from the hydraulic leads to the hydraulic motor by selecting the side shift function without a load.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

If the hydraulic axes have been correctly taught in, the hydraulic supply leads to the hydraulic motor are free of pressure in both end positions of the side shift function.

0/0291

1

• Remove the cover of the side shift carriage. • Release the hydraulic leads to the hydraulic motor (1). • Release both screws (2) on the hydraulic motor. • The hydraulic motor can be released by lifting the toothed shaft vertically upwards.

0/0292

2

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

27-03

Chapter 28

Pump

Removing the pump • Push the battery half way out of the battery compartment so that the suction hose can be removed from the battery compartment side. • Drain off the hydraulic oil completely. • If the hydraulic oil cannot be drained off completely, the alternative is to block off the suction hose with a suitable tool (1). • Remove the chassis valve block (2) (see sheet no. 24-05).

0/0338

1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Disconnect the suction hose (3) from the pump from the battery compartment side. • Release the pump from the pump motor at both screws (4).

0/0333

3

2

0/0335

4

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

28-01

Chapter 29

Oil level indicator

Oil level indicator On the right-hand side of the vehicle there are 2 inspection glasses on the oil tank. When the vehicle is filled with hydraulic oil, the oil level should be visible in the upper inspection glass (4). If the oil level in the lower inspection glass is no longer visible, the hydraulic oil must be topped up without fail. Important: The hydraulic oil level must be measured with the cab fully lowered and the addtional lift also fully lowered.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Remark:

0/0299

4

When the oil level can be seen in the centre of the upper inspection glass, there are approx. 47.5l of hydraulic oil in the tank. When the oil level can be seen in the centre of the lower inspection glass, there are approx. 43l of hydraulic oil in the tank.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

29-01

Chapter 30

Ventilation filter

Function In order to prevent inadmissible changes in pressure occurring inside the hydraulic tank, an exchange of air with the air outside the system must take place with a ventilation filter (1). Air from the outside, which is often very heavily soiled, would cause additional soiling of the oil if there were not a suitable filter fitted. The consequences would be negative side effects like increased wear, premature ageing of the oil and shortening of the operational life of the pressure filter. 0/0409

4

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Structure The ventilation filter consists of an oil-resistant, noncorrosive plastic housing in which a wide-surface filter is inserted.

Maintenance It should not be necessary to replace the ventilation filter for at least 5 years.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

30-01

Chapter 31

TLH

Adjusting work on the trilateral head The following conditions must be met before the trilateral head (TLH) can be adjusted: • All the necessary parameters must be programmed in the vehicle control system (FZS). The following list of adjusting work is a logical sequence for complete basic setting of the TLH. This list should be followed as closely as possible: • Adjustment of the tooth profile play • Adjustment of the eccentric rollers for the overshift function

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Adjustment of the swivel shaft for the additional lift • Removal of the lift carriage • Adjustment work on the lift carriage • Adjustment of the potentiometer for side shifting • Adjustment of the potentiometer for swivelling • Adjustment of the 90° swivelling range • Adjustment of the switching lugs for side shifting • Adjustment of the limit switches for swivelling • Adjustment of the magnetic sensors

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

31-01

Chapter 31

TLH

Adjusting work on the trilateral head

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Adjusting the tooth profile play The following preparations must be made for adjustment of the tooth profile play on the TLH and for checking that the side shift carriage (1) is at right angles to the fork holder (2): • Swivel the fork to 90° (front position). • Shift the side shift carriage into centre position. • Remove side covers from the pulling cylinders. • Release the lock nuts from all 12 eccentric rollers (without the overshift there are 8 eccentric rollers) at the top and bottom on the shift carriage (1). Remark: To release the lock nuts on the large centre eccentric roller at the bottom (3), the pulling cylinders (4) must be unscrewed. Every time the pulling cylinders have been adjusted, the 90° swivelling range must be checked and readjusted if necessary. For this reason, it is helpful to measure the distance X (5) on both pulling cylinders before unscrewing the cylinders. If the pulling cylinders are screwed on again to the measured dimension X when the adjustment work is complete, the 90° swivelling range either does not need to be corrected at all or just minimally.

2

3

1

0/0195

0/0196

4

Note:

When the pulling cylinders are unscrewed, no hydraulic functions may be selected! Before a pulling cylinder is unscrewed, the hydraulic pressure must be released by carefully unscrewing the hydraulic screw connection on the cylinders. • Entirely remove the small eccentric rollers from the top and bottom of the side shift carriage. • If there is a large eccentric roller at the centre top and bottom, remove these too. • Entirely remove the large rollers from the bottom so that the gearwheel lies on the toothed rack. • Raise the side shift carriage with a hand lifting truck or hydraulic jack (6) so that the upper gearwheel of the toothed shaft fits tightly against the upper toothed rack. Remark: Ensure when jacking up the side shift carriage that pressure is not applied to the small eccentric rollers, but that the toothed shaft lies directly against the toothed rack. Issue: 02/01 Replaces issue:

Workshop Manual

X

5

0/0197

6

MX15-3

0/0213

Sheet no.

31-02

Chapter 31

TLH

Adjusting work on the trilateral head

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Adjusting the tooth profile play First the right angle between the side shift carriage and the fork holder must be set with the eccentric rollers on the upper guide block of the side shift carriage. Then the tooth profile play between the toothed shaft and the upper toothed rack must be set to 0.5mm: • The right angle between the side shift carriage and the fork holder must be set with the 2 large upper eccentric rollers. During this process, the two eccentric rollers should only be applied gently to the guide rail (so that the idler rollers can still be turned by hand). Important: All the eccentrics (1) must be tightened from the outside (marking points must be on the outside) in order to achieve the largest possible distance from the pressure points. Remark: If there is no large angle steel available to measure the right angle, proceed as follows: • Shift the side shift carriage exactly into the centre position (same measure ment from both ends of the holder to the side shift carriage). • Pick a prominent point on the shift carriage that is fitted symmetrically on both sides, e.g. the end of the lower bumper (2). • If the distance from this prominent point to the end of the holder is equal (3) in both directions, the side shift carriage is at right angles to the fork holder. • Apply both the small eccentric rollers (3) gently to the guide rail (so that the idler rollers can still be turned by hand). • Lower the hand lifting truck or hydraulic jack that was used to jack up the side shift carriage. • Release the two large eccentric rollers (4) evenly by approx. 1/8 of a turn. • Use an angle steel to check that the angle between the toothed rack and the side shift carriage is a right angle. • Use a feeler gauge to check the distance between the small eccentric rollers and the guide rail. The tooth profile play should be set to 0.5mm ±0.1mm. Issue: 02/01 Replaces issue:

Workshop Manual

0/0198

1

0/0199

2

3

0/0195

4

MX15-3

3

Sheet no.

31-03

Chapter 31

TLH

Adjusting work on the trilateral head Adjusting the tooth profile play

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Once the small eccentric rollers (3) have been applied to the guide rail (so that the idler rollers can just be turned by hand, max. distance 0.1 mm), the upper guide block not including the overshift function is pre-adjusted. Now the lower guide block must be adjusted: • Ensure that the lower gearwheel is applied to the toothed rack (the hand lifting truck or hydraulic jack must be lowered). • Apply the two outer smaller eccentric rollers (1) evenly to the guide rail. • Turn these small eccentric rollers evenly back by approx. 1/8 of a turn. • Use a feeler gauge to check the distance between the small eccentric rollers and the guide rail. The distance for each should be set to 0.5mm ± 0.1mm. • Tighten the two larger outer eccentric rollers (2) evenly until the small eccentric rollers opposite are applied lightly (the idler rollers can still be turned by hand, max. distance 0.1mm). In order to tighten the rollers evenly, each roller should only be tightened so far that the other roller can still just be turned by hand. Now tighten this roller, etc...

1

0/0196

2

Both the guide blocks are now pre-adjusted. The tooth profile play must be checked by selecting the hydraulic functions for side shifting and swivelling. The tooth profile play is set too large: • if the mast tilts too much during swivelling from left to right or vice versa. The tooth profile play is set too small: • if "rattling" noises occur when the hydraulic side shifting function is selected • if the side shift carriage rises vertically when it is unloaded and the hydraulic side shifting function is selected, or if the side shift carriage no longer seated on the rail with the large vertical roller at any point across the width of the holder.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

31-04

Chapter 31

TLH

Adjusting work on the trilateral head

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Adjusting the tooth profile play Remark: The tooth profile play should be set equally on the lower and upper guide blocks. To check, brush some grease onto a few cm width of the toothed racks with a brush and run the side shift carriage over then. The grease should now be squeezed out evenly from the top toothed end to the bottom toothed end. If the tooth profile play needs readjusting, the small, outer eccentric rollers at the top and bottom of the side shift carriage should first be removed. Then the large, outer eccentric rollers at the top and bottom of the side shift carriage should be adjusted minimally (by approx. 1/16 revolution). Ensure during this operation that the eccentric rollers are adjusted equally at the top and bottom guide blocks, otherwise the right angle between the side shift carriage and the fork holder will be put out of adjustment. Next, all 4 small eccentric rollers must be applied again (so that the idler rollers can still be turned by hand, max. distance 0.1mm) and then the tooth profile play must be checked again. Once the eccentric rollers are set correctly, the lock nuts of the eccentrics must be tightened. When tightening the lock nuts, ensure that the eccentric shaft is held steady (with the assistance of a second person). It is best to do this with a 14mm hexagon socket screw key that is shortened by 30mm. Otherwise the puller cylinders must be dismantled. Remark: Adjustment of the rollers is extremely important, since if the rollers are set incorrectly, the rotary shaft may be damaged. Tightening torque for the lock nuts of the small eccentric rollers: 120Nm. Tightening torque for lock nuts of the large eccentric rollers: 450Nm when the centre rollers are mounted, 300Nm when no centre rollers are mounted. Finally, replace the side covers on the pulling cylinders.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

31-05

Chapter 31

TLH

Adjusting work on the trilateral head

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Adjusting the eccentric rollers for the overshift function In order to adjust the eccentric rollers for the overshift function, the following preparation work must be carried out: • The tooth profile play must already be adjusted. • Release the lock nuts of the centre guide rollers at the top and bottom on the side shift carriage (1). Remark: To release the lock nuts on the large centre eccentric roller at the bottom (1), the pulling cylinders (2) must be unscrewed. Every time the pulling cylinders have been adjusted, the 90° swivelling range must be checked and readjusted if necessary. For this reason, it is helpful to measure the distance X (3) on both pulling cylinders before unscrewing the cylinders. If the pulling cylinders are screwed on again to the measured dimension X when the adjustment work is complete, the 90° swivelling range either does not need to be corrected at all or just minimally.

0/0196

1

2

Note:

When the pulling cylinders are unscrewed, no hydraulic functions may be selected! Before a pulling cylinder is unscrewed, the hydraulic pressure must be released by carefully unscrewing the hydraulic screw connection on the cylinders! • Screw on both pulling cylinders. Adjustment of the small, centre eccentric rollers at the top and bottom of the side shift carriage: • The two eccentric rollers must be applied so that they only just touch the guide rail. Adjustment of the large, centre eccentric rollers at the top and bottom of the side shift carriage: • Shift the side shift carriage in the direction of the overshift position (fork is swivelled into end position and the fork prongs point in the selected shift direction) until the large, outer guide rollers (4) at the top and bottom of the side shift carriage only just come into contact with the guide rail of the holder. Issue: 02/01 Replaces issue:

Workshop Manual

X 0/0213

3

0/0201

4

MX15-3

Sheet no.

31-06

Chapter 31

TLH

Adjusting work on the trilateral head Adjusting the eccentric rollers for the overshift function • In this position the two large, centre eccentric rollers (1) should be applied gently to the stopping cam (2). • Swivel the fork prongs around 180° and move the side shift carriage to the other side in overshift position. Check the adjustment of the centre eccentric rollers.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

The eccentric roller (1) is applied too tightly if: • there is a an impact when it hits the stopping cam.

0/0201

2

1

The eccentric roller is not applied tightly enough: • if the side shift carriage moves out of 90° alignment angle to the fork holder when it is in the overshift position. If the two cams (2) at the left and right-hand sides of the side shift carriage are different sizes, the large centre eccentric rollers should be adjusted to the larger cam. Remark: If the difference in size between the two cams is so large that the centre eccentric rollers cannnot be adjusted satisfactorily for both sides, the larger stopping cam can be ground down on the mounting side by the difference in size.

Issue: 02/01 Replaces issue:

Workshop Manual

0/0202

2

MX15-3

Sheet no.

31-07

Chapter 31

TLH

Adjusting work on the trilateral head Adjusting the eccentric rollers for the overshift function

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Once the eccentric rollers are set correctly, the lock nuts of the eccentrics must be tightened. When tightening the lock nuts, ensure that the eccentric shaft is held steady. Remark: To release the lock nuts on the large centre eccentric roller at the bottom, the pulling cylinders must be unscrewed. Every time the pulling cylinders have been adjusted, the 90° swivelling range must be checked and readjusted if necessary. For this reason, it is helpful to measure the distance X (1) on both pulling cylinders before unscrewing the cylinders. If the pulling cylinders are screwed on again to the measured dimension X when the adjustment work is complete, the 90° swivelling range either does not need to be corrected at all or just minimally. Note:

X 0/0213

1

When the pulling cylinders are unscrewed, no hydraulic functions may be selected!

Tightening torque for the lock nuts of the small eccentric rollers: 120Nm. Tightening torque for lock nuts of the large eccentric rollers: 450Nm.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

31-08

Chapter 31

TLH

Adjusting work on the trilateral head Adjusting the swivel shaft for the additional lift • Shift the side shift carriage into the centre position. • Swive the fork into the straight-on position. • Measure the height of the fork prong back. Remark: If the two fork prongs are not set to exactly the same height, the mean value should be calculated.

0/0208

1

2

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Measure the height of the fork prong tip (2). Remark: If the two fork prong tips are not set to exactly the same height, the mean value should be calculated. The fork prong tips should be 5mm higher than the fork prong backs. If this is not the case, proceed as follows: 0/0209

7

3

4

• Release the threaded pin (3) at the left and right of the fork holder. • Release the clamping screw (4) at the left and right of the fork holder. • Release the screw (5) at the left and right of the fork holder. • Use a screw (M20) to push the TLH away from the cab at the bottom (6). Remark: If there is no forcing screw available, the TLH can also be lifted with a hydraulic jack (see point 1, sheet no. 31-10).

0/0210

5

• If the fork prong tips are too low in relation to the fork prong backs, the TLH should be lifted using a forcing screw (or hydraulic jack), until the required 5mm difference is reached. Finally, shims must be inserted (see point 2, sheet no. 31-10) between the TLH and the fork holder (7). Remark: In order to insert the shims, the TLH must be raised higher than is finally necessary. Issue: 02/01 Replaces issue:

Workshop Manual

0/0211

6

MX15-3

Sheet no.

31-09

Chapter 31

TLH

Adjusting work on the trilateral head Adjusting the swivel shaft for the additional lift • If the tips of the fork prongs are too high in relation to the backs of the fork prongs, shims must be removed from between the TLH and the holder until the required 5mm difference is reached. If there are no shims between the TLH and the fork holder, the fork prong tips cannot be lowered any further.

0/0197

1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Remark: The shims (2) are available in the following thicknesses: • 2mm, Id. no. W8 270 115 • 3mm, Id. no. W8 270 116 • Release the forcing screw (or lower the hydraulic jack) and check the difference between the fork prong tips and the fork prong backs. If necessary, adjust as described.

0/0212

2

• Tighten the screws (3) at the left and right of the fork holder. • Tighten the clamping screws (4) at the left and right of the fork holder. • Tighten the threaded pins (5) at the left and right of the fork holder.

0/0210

3

5 Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

0/0209

4 Sheet no.

31-10

Chapter 31

TLH

Adjusting work on the trilateral head Removing the lift carriage The lift carriage must be removed completely in order to make adjustments to the radial and axial play of the lift carriage: • Lower the additional lift completely. • Remove the fork prong securing elements from the left and right of the lift carriage.

0/0203

1

• Disengage the fork prongs. • Remove the upper mechanical end stop (1) for the lift carriage. • Unscrew the cover.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Disconnect the electrical connection (2). • Unscrew the cable clip (3) from the lift carriage. • Use a crane or similar equipment to lift the lift carriage up and out over the return roller (4) on the additional lift cylinder. • Unscrew the screw on the chain securing element (5). 0/0204

• Disengage the chain from the bottom.

5

3

2

• The lift carriage can now be lifted completely out of the profile of the additional lift mast.

0/0205

4

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

31-11

Chapter 31

TLH

Adjusting work on the trilateral head Adjusting work on the lift carriage The lift carriage must be removed completely in order to make adjustments to the radial and axial play of the lift carriage.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Adjusting the radial play on the lift carriage • Measure the narrowest point of the right and left additional lift mast profile over the entire height. • Select idling rollers (1) of a suitable size, so that they do not jam at the narrowest point of the profile of the additional lift mast. Remark: The idling rollers are available in 3 different diameters: • 89.9mm, Id. no. W8 424 223 • 90.2mm, Id. no. W8 424 224 • 90.5mm, Id. no. W8 424 225

0/0206

1

Adjusting the axial play on the lift carriage • The 4 idling rollers on the lift carriage must be underlaid with shims until all the idling rollers run smoothly along the additional lift mast profile. If necessary, the left hand idling roller can, for example, be underlaid with one shim more than the idling roller on the right hand side Remark: The shims are available in the following thickness: • 0.5mm, Id. no. W8 413 890 • The idling rollers are underlaid correctly when the lift carriage has an axial play of max. 0.6mm in the profile at the narrowest point, and when the entire lift carriage is positioned vertically.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

31-12

Chapter 31

TLH

Adjusting work on the trilateral head Adjusting work on the lift carriage Adjusting the height of the lift carriage with the additional lift fully lowered • When a new lifting chain has just been installed, it must be pre-tensioned: Raise the lift carriage with a full load about 3-4 times and place a load on the chain by stopping the lowering movement several times with a jolt.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Release the lock nut (1) on the chain tensioner (2) for the additional lift. • Turn the adjusting nut (3) so that when the forks are in the front position, the fork prong tips are 60 - 80mm above the ground when the additional lift cylinder is fully lowered.

0/0207

2

3

1

• This height must also be checked in both home positions (fork swivelled to the left and to the right. 31-09). • Tighten the lock nut.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

31-13

Chapter 31

TLH

Adjusting work on the trilateral head Adjusting the potentiometer for side shifting

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

A 1KΩ potentiometer (1) is used for path measurement of the side shifting hydraulic function. When the side shift carriage is positioned in the centre of the fork holder, the resistance of the potentiometer should be 500Ω ± 10Ω. Remark: The resistance value is measured on the potentiometer between pin 1 (white connecting wire) and pin 2 (orange connecting wire). 0/0215

If the resistance value of the potentiometer deviates from the specified value in this position, the potentiometer must be readjusted: Remark: So that the potentiometer does not have to be readjusted every time the side shift carriage is removed and reinstalled, the side shift carriage should always be installed on the side of the holder on which it was removed. • Raise the cab until the potentiometer for side shifting (1) is easily accessible.

1

• Support the cab safely from below at this height. • Remove the side covers from the side shift carriage over the pulling cylinders. • Release the pulling cylinders (2).

0/0214

2

Remark: Every time the pulling cylinders have been adjusted, the 90° swivelling range must be checked and readjusted if necessary. For this reason, it is helpful to measure the distance X (3) on both pulling cylinders before unscrewing the cylinders. If the pulling cylinders are screwed on again to the measured dimension X when the adjustment work is complete, the 90° swivelling range either does not need to be corrected at all or just minimally.

Issue: 02/01 Replaces issue:

Workshop Manual

X 0/0213

3

MX15-3

Sheet no.

31-14

Chapter 31

TLH

Adjusting work on the trilateral head Adjusting the potentiometer for side shifting Note:

When the pulling cylinders are unscrewed, no hydraulic functions may be selected! Before a pulling cylinder is unscrewed, the hydraulic pressure must be released by carefully unscrewing the hydraulic screw connection on the cylinders!

• Unscrew the potentiometer holder (torque converter bearing for the potentiometer). 0/0215

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Release the plate with holes (1). • Set the resistance value of the potentiometer to 500Ω ± 10Ω by turning the plate with holes (2) (the side shift carriage must be positioned exactly in the centre).

1

• Secure the plate with holes using 2 screws, so that the potentiometer is only moved minimally, i.e. the plate with holes must be turned until the next two easily accessible threads on opposite sides are positioned under the holes • Secure the potentiometer holder with the screws. • Screw up the pulling cylinder to the previously measured dimension X (3).

0/0216

2

• Screw on the side covers of the side shift carriage over the pulling cylinders.

X

0/0213

3

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

31-15

Chapter 31

TLH

Adjusting work on the trilateral head Adjusting the potentiometer for swivelling A 1KΩ potentiometer (1) is used for path measurement of the swivelling hydraulic function. When the fork is swivelled to straight on, the resistance of the potentiometer should be 500Ω ± 10Ω. If the resistance value of the potentiometer deviates from the specified value in this position, the potentiometer must be readjusted: • Raise the cab until the potentiometer for swivelling (1) is easily accessible.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Support the cab safely from below at this height.

• Swivel the fork into the straight-on position.

0/0217

1

• Disconnect the plug-in connectors (2). • Unscrew the fastening screws from the potentiometer holder (3). • Remove the potentiometer from below with its holder. • Set the resistance value of the potentiometer to 500Ω ± 10Ω by turning the toothed wheel (4) (the fork must be swivelled into the straight-on position). • Secure the potentiometer and holder in this position with screws. • Make the electrical connection with the potentiometer.

Issue: 02/01 Replaces issue:

Workshop Manual

0/0218

4

3

MX15-3

2

Sheet no.

31-16

Chapter 31

TLH

Adjusting work on the trilateral head Adjusting the 90° swivelling range • Remove the shims (1) • Swivel the lifting mast right to the side. • Adjust the fully retracted cylinder with the screw (2), so that there is a distance of 5 - 10mm (4) between the rear back of the fork and an angle steel that is applied to the toothed rack and the front back of the fork. The fork holder now has a swivelling angle of just more than 90°.

0/0219

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Screw on several shims. Remark: The shims are available in the following thickness: • 1mm, Id. no. W8 313 255

1

• Use an angle steel to check that the fork backs form a 90° angle with the toothed rack. Check the adjustment by adding or removing shims. • Follow the same procedure on the other side. • Measure the length of each extended piston rod. The length must not exceed 162 mm. Note:

5-10mm

This step is important, because the cylinders will be damaged if the piston reaches the mechanical end stop during swivelling!

4

0/0353

• Finally measure the screw length "X" on both pulling cylinders and check for the limit values (2). Remark: Xmax = 95mm Xmin = 71mm

X 0/0213

2

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

3

Sheet no.

31-17

Chapter 31

TLH

Adjusting work on the trilateral head Adjusting the switching lug for side shifting Remark: In order for the switching lug to be set correctly, the parameters for the TLH in the vehicle control system must be programmed. • Shift the forks very slowly to the left until the side shift carriage comes to a halt by itself. • Move the switching lug (1) on the left hand side so that it is directly above the contour switch (2) (inductive encoder) for side shifting.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• The switching distance between the contour switch and the switching lug should be 5 ± 2mm.

0/0220

2

1

• When the contour switch is actuated, the red LED (3) in the threaded section of the contour switch lights up. • Shift the forks very slowly to the right until the side shift carriage comes to a halt by itself. • Move the switching lug on the right hand side so that it is directly above the contour switch for side shifting. • The switching distance between the contour switch and the switching lug should be 5 ± 2mm.

0/0221

3

• When the contour switch is actuated, the red LED (3) in the threaded section of the contour switch lights up. Remark: The LED on the contour switch (3) is not always visible, depending on how the element is installed.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

31-18

Chapter 31

TLH

Adjusting work on the trilateral head Adjusting the limit switches for swivelling Remark: In order for the limit switch (inductive encoder) for swivelling to be set correctly, the 90° swivelling range to the left and right must be set correctly. • Swivel the fork to the mechanical end stop at the left or right.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• The distance between the limit switch (1) and the fixed switching lug (2) should be 5 ± 2mm.

0/0222

1

2

• When the limit switch is actuated, the red LED (3) in the threaded section of the contour switch lights up. Remark: The LED on the limit switch (3) is not always visible, depending on how the element is installed.

0/0223

3

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

31-19

Chapter 31

TLH

Adjusting work on the trilateral head Adjusting the magnetic sensors

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Magnetic switch for referencing • The switching distance between the magnetic switch (1) and the magnetic strip for referencing (2) should be <8mm. Remark: The distance between the magnetic switch and the magnetic strip can be adjusted with longitudinal slots. • The magnetic strip for referencing (2) is glued into the profile of the additional lift mast and covered with a protective strip. • When the lift carriage is fully lowered, the magnetic switch should be positioned over the magnetic strip for referencing. Remark: When the magnetic switch (1) recognises the magnetic strip, the LED on the sensor lights up.

0/0224

1

3

4

Magnetic sensor for height measurement, additional lift • The switching distance between the magnetic sensor (3) and the magnetic strip (4) that is applied along the entire length of the additional lift should be <4mm. The standard distance setting is 2mm. Remark: The distance between the magnetic switch and the magnetic strip can be adjusted with longitudinal slots. 0/0200

• The magnetic strip for height measurement (4) is glued into the profile of the additional lift mast and covered with a protective strip.

2

Remark1: The magnetic sensor should not be turned, otherwise the height measurement does not function properly. Remark2: The magnetic strip loses its magnetism if it comes into contact with strong magnets.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

31-20

Chapter 35

Error codes

General The vehicle is fitted with an onboard diagnosis system. All errors that can be read out over the diagnosis software are shown on the operating console display in the form of an error code. The possible errors are divided into groups according to the affected function:

Q PSA

PSA Fehler

FE1XX: FE2XX: FE3XX: FE4XX: FE5XX: FE6XX: FE7XX:

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

FE8XX: FE9XX: FE10XX: FE11XX: FE12XX: FE2XXX:

Remark:

Travel, see sheet no. 35-02 Steering, see sheet no. 35-03 Main lift, see sheet no. 35-05 Additional lift, see sheet no. 35-07 Side shifting, see sheet no. 35-08 Swivelling, see sheet no. 35-09 SSSB180° (Synchronised side shift movement 180°), see sheet no. 35-10 SSSB 90° (Synchronised side shift movement 90°), see sheet no. 35-11 CAN bus, see sheet no. 35-12 General errors, see sheet no. 35-13 Automatic braking at end of aisle (EASS), see sheet no. 35-16 Options, see sheet no. 35-17 Travel and pump controller ( FPS), see sheet no. 35-18

0/0001

1

The error code on the operating console display also indicates in which group of errors the error can be found in the PC diagnosis system. E.g.: FE310 - Error group 03, error number 10

Important: If a component is changed on one of the distance measuring systems listed below or if the position of a sensor is changed, a teaching-in process must be carried out on the relevant axis (see sheet no. 22-01): - Height measuring system, main lift - Height measuring system, add. lift - Distance measuring system for side shifting - Distance measuring system for swivelling.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-01

Chapter 35

Error codes

Travel function • FE100 Error occurred on measurement of "Brake selection brake 1" The brake amplifier for the 1st stage of the electromagentic brake cannot be selected. • FE101 Error in brake coil, 55W The brake amplifier of the 1st stage of the electromagnetic brake can no longer be actuated (brake is not released). If this error occurs, the FPS is switched to idle. The brake amplifier of the 1st stage of the electromagnetic brake can no longer be deactivated (brake is not applied). If this error occurs, an EMERGENCY-stop is initiated. This error code is also displayed if the steering fuse (3F1) is faulty.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• FE102 Error occurred on measurement of "Brake selection brake 2" The brake amplifier for the 2nd stage of the electromagnetic brake cannot be selected. • FE103 Error in brake coil, 25W The brake amplifier of the 2nd stage of the electromagnetic brake can no longer be actuated (brake is not released). If this error occurs, the FPS is switched to idle. The brake amplifier of the 2nd stage of the electromagnetic brake can no longer be deactivated (brake is not applied). If this error occurs, an EMERGENCY-stop is initiated. • FE112 Comparison of travel speed FPS - FZS is not plausible The speed specified by the FPS does not match the speed that the vehicle control system receives from the speed sensor. The max. travel speed is limited to v=2.5km/h. • FE113 Comparison of travel direction FPS - FZS is not plausible The travel direction specified by the FPS does not match the travel direction that the vehicle control system receives from the speed sensor. The max. travel speed is limited to v=2.5km/h. • FE114 Travel speed too high The travel speed is too high. Deceleration is activated. • FE115 Brake deceleration is too weak The amount by which the travel speed is decreased on braking is too small. If this error occurs, an EMERGENCY stop is initiated to switch the FPS to idle.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-02

Chapter 35

Error codes

Steering function

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• FE205 LR80: distance monitoring A/B reflector on/off signal Distance measurement monitoring is carried out between the "inside" and "outside" signals of the reflective light barrier and vice versa. The error occurs when no pulses or too many pulses are measured by the incremental encoder between the two signals. The max. travel speed is limited to v=2.5km/h and diagonal travel is not possible.

•

FE206 LR80: "outside" reflective light barrier switches in the wrong area The "inside" reflective light barrier is actuated before the "outside" reflective light barrier as the vehicle enters the aisle. The max. travel speed is limited to v=2.5km/h and diagonal travel is not possible.

•

FE207 LR80: "inside" reflective light barrier switches in the wrong area The "outside" reflective light barrier is actuated before the "inside" reflective light barrier as the vehicle enters the aisle. The max. travel speed is limited to v=2.5km/h and diagonal travel is not possible.

• FE208 LR80: Timeout steering lock off On a vehicle with inductive wire guidance, switch 3S33 (unlocked) must be actuated within 1.1 second after the "steering lock" signal has gone (0V). If this is not the case, an EMERGENCY stop is initiated. • FE209 LR80: Timeout steering lock on On a vehicle with inductive wire guidance, switch 3S34 (locked) must be actuated within 2 seconds after the "steering lock" has been applied (24V). If this is not the case, an EMERGENCY stop is initiated. • FE210 LR80: steering angle >3° in an aisle On a vehicle with inductive wire guidance, the ±3° switch for the steering angle limiter has been actuated. If this error occurs, an EMERGENCY-stop is initiated. • FE211 LR80: "Deceleration" output for LR80 implausible The "deceleration" output signal of the LR80 central processing unit is behaving implausibly in relation to other signals. The max. travel speed is limited to v=2.5km/h. • FE212 LR80: switched over to manual steering in an aisle The driver has switched the inductively guided vehicle (LR80) over to manual steering inside an aisle when this is not permissible. As a result, a travel stop is initiated. This error can be rectified by switching back to AUTO.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-03

Chapter 35

Error codes

Steering function • FE213 LR80: error message from LR80 If the inductive wire guidance system (LR80) initiates an EMERGENCY-stop, this error appears on the operating console display. • FE214 No "steering OK" signal from the steering amplifier Within 0.5 seconds of the deadman switch being actuated, the "Steering OK" signal should be applied at the output of the steering controller. If this is not the case, the vehicle cannot be moved.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• FE215 No "Straight-on actual value" from the steering amplifier Within 3 seconds of the vehicle entering an aisle, the "Straight-on actual value" signal should be applied at the output of the steering controller. If this is not the case, the max. travel speed is reduced to v=2.5km/h.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-04

Chapter 35

Error codes

Main lift function • FE307 Roof switch actuated The roof switch has been actuated. The electromagnetic brake becomes operative and all the hydraulic functions except the main lift lowering function are deactivated.

•

FE308 Chain breakage All the hydraulic functions except the main lift lifting function are deactivated. The max. travel speed is limited to v=1km/h.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• FE309 Slack chain All the hydraulic functions except the main lift lifting function are deactivated. The max. travel speed is limited to v=1km/h. • FE310 The inductive encoder does not switch within its range The inductive encoder (reference switch) does not switch within the specified range for the potentiometer. The main lift lifting and lowering functions can only be executed at a reduced speed. The max. travel speed is limited to v=2.5km/h. • FE311 Lifting speed monitor movement without selection The incremental encoder for the height measuring system of the main lift is delivering pulses although the main lift function has not been selected and no valves have been triggered for this function. If this error occurs, an EMERGENCY-stop is initiated, so that the valves and pump motor can be switched off safely. • FE312 "Wire terminal monitor" lifting and lowering or cable breakage The incremental encoder for the height measuring system of the main lift is not delivering any pulses, although the pump motor is running and the relevant valves for this hydraulic function have been triggered. The main lift lifting function is only possible if the reference switch at the rear of the cab is actuated. The main lift lowering function can only be executed at a reduced speed and with the acknowledgement key pressed and held down on the operating console. The max. travel speed is limited to v=2.5km/h. This error code can also be displayed with the maximum pressure setting (see sheet no. 24-02). • FE313 Lifting speed monitor or cable breakage The speed for the main lift lifting and lowering functions (e.g. cable breakage in the height measuring system) is too high. The main lift lifting function is only possible if the reference switch at the rear of the cab is actuated. The main lift lowering function can only be executed at a reduced speed. The max. travel speed is limited to v=2.5km/h.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-05

Chapter 35

Error codes

Main lift function • FE314 Counter comparison, potentiometer and incremental encoder A difference of > 20cm has occurred between the two measuring systems (incremental encoder and potentiometer), which monitor each other, for the main lift function. The main lift lifting function is only possible when the reference switch at the rear of the cab is actuated. The main lift lowering function can only be executed at a reduced speed. The max. travel speed is limited to v=2.5km/h. In order to rectify this error, a reference sequence must be carried out, in which the cab is fully lowered and then raised until the inductive encoder (reference switch) at the rear of the cab is no longer actuated.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• FE315 Wire breakage and short circuit monitoring There is a short circuit (voltage signal >9.3V) or an interruption (voltage signal < 0.15V) of the analogue setpoint (potentiometer). The main lift lifting and lowering functions can only be executed at a reduced speed. The max. travel speed is limited to v=2.5km/h.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-06

Chapter 35

Error codes

Additional lift function • FE412 The axis moves without being selected or the measuring system is faulty The incremental encoder for the height measuring system of the additional lift is delivering pulses although the additional lift function has not been selected and no valves have been triggered for this function. If this error occurs, an EMERGENCY-stop is initiated, so that the valves and pump motor can be switched off safely.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• FE413 Axis does not move although it has been selected or the measuring system is faulty. The magnetic sensor of the height measuring system of the additional lift is not delivering any pulses, although the pump motor is running and the relevant valves for this hydraulic function have been triggered. The additional lift lifting and lowering functions can only be executed at a reduced speed. The max. travel speed is limited to v=2.5km/h. • FE414 Lifting and lowering speed too high The speed for the additional lift lifting and lowering functions is too high. The additional lift lifting and lowering functions can only be executed at a reduced speed. The max. travel speed is limited to v=2.5km/h. • FE415 No reference signal in the target window The reference switch does not switch within the specified range. The additional lift lifting and lowering functions can only be executed at a reduced speed. The max. travel speed is limited to v=2.5km/h.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-07

Chapter 35

Error codes

Side shift function • FE513 Measuring range exceeded or not reached There is a short-circuit (voltage signal >9.3V) or an interruption (voltage signal < 0.15V) of the analogue setpoint (potentiometer). The main lift lifting and lowering and side shift functions can only be executed at a reduced speed. The max. travel speed is limited to v=2.5km/h. • FE514 Reference signal not in target window The potentiometer value does not match the switching signal of the contour switch. The main lift lifting and lowering and side shift functions can only be executed at a reduced speed. The max. travel speed is limited to v=2.5km/h.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• FE515 No reference signal in target window The switching signal of the contour switch does not match the potentiometer value. The main lift lifting and lowering and side shift functions can only be executed at a reduced speed. The max. travel speed is limited to v=2.5km/h.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-08

Chapter 35

Error codes

Swivel function • FE613 Measuring range exceeded or not reached There is a short-circuit (voltage signal >9.3V) or an interruption (voltage signal < 0.15V) of the analogue setpoint (potentiometer). The main lift lifting and lowering and side shift functions can only be executed at a reduced speed. The max. travel speed is limited to v=2.5km/h. • FE614 Reference signal not in target window The potentiometer value does not match the switching signal of the limit switch. The main lift lifting and lowering and side shift functions can only be executed at a reduced speed. The max. travel speed is limited to v=2.5km/h.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• FE615 No reference signal in target window The switching signal of the limit switch does not match the potentiometer value. The main lift lifting and lowering and side shift functions can only be executed at a reduced speed. The max. travel speed is limited to v=2.5km/h.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-09

Chapter 35

Error codes

Synchronous swivel shift movement 180°

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• FE715 Fork outside contour In the synchronous swivel shift movement, the side shift function is too fast or slow in relation to the swivel function (trailing error).

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-10

Chapter 35

Error codes

Synchronous swivel shift movement 90°

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Remark: At the time of compiling this workshop handbook, no error codes were yet known.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-11

Chapter 35

Error codes

CAN bus error • FE900 General CAN bus error A general error has occurred in the CAN bus communication system. • FE901 Time window of LHC (PDO1) has been exceeded Communication with the LHC has been interrupted. The max.travel speed is limited to v = 1km/h and all hydraulic movements are deactivated. • FE902 Time window of BPS (PDO1) has been exceeded Communication with the operating console has been interrupted. The max. travel speed is limited to v = 0km/h and all the hydraulic functions are deactivated.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• FE903 Time window of FPS (PDO1) has been exceeded Communication with the travel and pump controller has been interrupted. If this error occurs, an EMERGENCY-stop is initiated.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-12

Chapter 35

Error codes

General errors • FE1000 Check sum error in EEPROM when the vehicle is switched on An error in the check sum for the changeable parameters has occurred when the vehicle is switched on. The max. travel speed is limited to v=2.5km/h. All the hydraulic functions can only be executed at a reduced speed. The red LED on the operating console that indicates "Maintenance interval expired" also flashes. This error can be rectified by switching the vehicle off and then on again. • FE1001 Check sum error in EEPROM when the vehicle is switched on An error in the check sum for the changeable parameters has occurred when the vehicle is switched on. The max. travel speed is limited to v=2.5km/h. All the hydraulic functions can only be executed at a reduced speed.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

This error can be rectified by switching the vehicle off and then on again. • FE1002 Check sum error in EEPROM when the vehicle is switched on An error in the check sum for the options has occurred. The max. travel speed is limited to v=2.5km/h. All the hydraulic functions can only be executed at a reduced speed. Also, all the options are blocked. • FE1003 Access to EEPROM faulty This error occurs when the vehicle control system (FZS) is faulty or there is a program error. The standard parameter set is automatically loaded. In this case, the FZS must be replaced. • FE1004 The last access was not a writing process When the vehicle was switched off, the vehicle control system did not have enough time to save all the data in the height measuring system for the main lift and the additional lift. These two axes must be newly referenced (see. FE1008 and FE1009). • FE1005 Implausible axis selection This error occurs when several functions are selected at the same time but these may not be executed at the same time, e.g. the driver selects side shift and wants to drive the vehicle at the same time, or side shifting and swivelling are selected at the same time. If this error occurs, the vehicle can only be driven at a speed of v = 1km/h and all the hydraulic functions are blocked. When the functions are selected correctly, the error is deleted automatically.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-13

Chapter 35

Error codes

General errors

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• FE1006 On switching on or EMERGENCY-STOP, operating console not at home settings or deadman switch actuated This error occurs if a travel direction or a hydraulic function is selected when the vehicle is switched on or after an EMERGENCY-STOP has been initiated with the deadman switch (e.g. a button is jammed on the operating console). If this error is delivered, the vehicle cannot be driven and all the hydraulic functions are blocked. When the acknowledgement key is pressed once, the vehicle can be driven at a speed of v= 1km/h. This error must be deleted by switchin the vehicle off and then on again or by actuating/releasing the EMERGENCY-STOP button. • FE1008 Reference sequence required for additional lift The height measuring system for the additional lift has not been referenced. The additional lift lifting and lowering functions can only be executed at a reduced speed. A reference sequence must be carried out (see sheet no. 18-01) in which the lift carriage is fully lowered and then raised until the magnetic switch (reference switch) is not longer acuated. • FE1009 Reference sequence requirement for main lift The incremental encoder for the height measuring system for the main lift has not been referenced. The main lift lifting and lowering functions can only be executed at a reduced speed. A reference sequence must be carried out (see sheet no. 18-01) in which the cab is fully lowered and then raised until the inductive encoder (reference switch) on the rear wall of the cab is no longer actuated. • FE1010 No calculation for teaching-in process The vehicle control system has not be switched over to USER mode during work with the diagnosis software (see sheet no. 21-01). The new settings made with the diagnosis software have not been saved. • FE1011 Sensor system power supply faulty The rotary knob on the distributor board A13 (see sheet no. 13-01) is not set to position "1". The components connected to the vehicle control system (FZS) are no longer supplied with 2+24V. The max. travel speed is limited to v=1km/h. • FE1012 EMERGENCY-STOP chain cannot be closed On activation of the outputs for safety relays K33 and K34 (pin 50 and pin 51 of the vehicle control system) the voltage of one or both outputs has remained at <0.5V. The consequence is that the vehicle control system can no longer make the safety relay drop out reliably. If this error occurs, the electromagnetic brake becomes operative and all the hydraulic functions are deactivated.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-14

Chapter 35

Error codes

General errors • FE1013 EMERGENCY-STOP chain not closed on switching on This error occurs if the EMERGENCY-STOP chain is not closed 15 seconds after the vehicle is switched on. When the EMERGENCY-STOP chain is not closed, travel is not possible and none of the hydraulic functions can be carried out.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• FE1014 Faulty selection of safety relays K33 and K34 When the outputs for safety relays K33 and K34 (pin 50 and pin 51 of the vehicle control system) are switched off, the voltage of one or both outputs remains at >1V. The consequence is that the vehicle control system can no longer make the safety relay pick up reliably. If this error occurs, the electromagnetic brake becomes operative and all the hydraulic functions are deactivated. • FE1015 Relay contact K37 does not close If an error occurs in the steering of a vehicle with inductive wire guidance, relay K37 drops out. Relay contact 3K37 is opened and interrupts the EMERGENCY-STOP chain. The main contactors drop out - travel is not possible and none of the hydraulic functions can be exectuted.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-15

Chapter 35

Error codes

Automatic braking at end of aisle (EASS) • FE1108 EASS magnetic switches are not switching in pairs - reverse The magnetic switches in the EASS magnetic system do not switch in pairs when reverse (DE) travel is selected. The max. travel speed is limited to v=2.5km/h. • FE1109 EASS megnetic system: implausible magnetic switch statuses outside aisle Implausible magnetic switch statuses have occurred in the EASS magnetic system when the vehicle is outside the aisle. The max. travel speed is limited to v=2.5km/h.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• FE1110 ASS megnetic system: implausible magnetic switch statuses inside aisle Implausible magnetic switch statuses have occurred in the EASS magnetic system when the vehicle is inside the aisle. The max. travel speed is limited to v=2.5km/h. • FE1111 ASS megnetic system: magnetic switches are not switching in pairs - forwards The magnetic switches in the EASS magnetic system do not switch in pairs when forward (LE) travel is selected. The max. travel speed is limited to v=2.5km/h. • FE1112 EASS inductive system: 2nd inductive encoder does not switch after 0.5m The signal from the 2nd inductive encoder is not removed after 0.5m when the vehicle leaves the braking plates or the signal from the 2nd inductive encoder is not received after 0.5m when the vehicle drives onto the braking plates. The max. travel speed is limited to v=2.5km/h. • FE1113 2nd rail switch does not switch after 2m When the vehicle drives into the aisle, the 2nd rail switch must be actuated after a stretch of 2m at the latest. If this is not the case, the max. travel speed is limited to v=2.5km/h. The EASS inductive system does not work in this case and diagonal travel is not possible. • FE1114 EASS inductive system: signal from inductive encoder is applied for >2m outside aisle In the EASS inductive system, an inductive encoder continues to be actuated for a stretch of at least 2m outside the aisle. The max. travel speed is limited to v=2.5km/h. • FE1115 At least 1 rail switch or aisle recognition missed in the fast travel zone In connection with the EASS, the "In aisle" signal (vehicle with inductive wire guidance) or "Straight-on" signal (mechanical rail guidance) must be applied permanently in the fast travel zone, otherwise the EASS is not active. If this is not the case, the max. travel speed is limited to v=2.5km/h.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-16

Chapter 35

Error codes

Option errors

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Remark: At the time of compiling this workshop handbook, no error codes were yet known.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-17

Chapter 35

Error codes

Travel and pump controller errors (FPS) • FE2014 Short-circuit in supply, external A short-circuit has occurred in the 10V supply voltage (X11:11) for the drive motor and pump motor speed sensors. The travel and hydraulic drives are switched to idle. • FE2024 Undervoltage UC1 (intermediate circuit) The main contactors drop out. The battery voltage is too low. • FE2025 Main contactor stuck The main contactor contacts are already closed when the vehicle is switched on (main contactor contacts are welded together). The travel and hydraulic drives are switched to idle.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• FE2026 Loading error in intermediate circuit • FE2027 Invalid "vehicle type" parameter An unknown standard parameter set is loaded in the vehicle control system. The main contactors drop out or do not pick up. It may be possible to rectify this error by loading the right standard parameter set. • FE2028 FPG parameter error One of the travel parameters is outside the permissible range of values. The FPs limits the speed to the internally fixed limit value. • FE2051 Short circuit, FPS temperature sensor The measuring circuit for temperature measurement of the FPS has short-circuited. This error does not have any effect on the range of functions that can be carried out with the vehicle. • FE2052 Cable breakage, FPS temperature sensor The measuring circuit for FPS temperature measurement has been interrupted. This error does not have any effect on the range of functions that can be carried out with the vehicle. • FE2053 Excess temperature, FPS The operating temperature at the power section of the FPS has exceeded 60°C. The output power for the drive and pump motors is reduced by the same amount, according to the operating temperature.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-18

Chapter 35

Error codes

Travel and pump controller errors (FPS) • FE2054 Temperature sensor failure, FPS An error has occurred in the measuring circuit for the FPS temperature measurement . This error does not have any effect on the range of functions that can be carried out with the vehicle. • FE2057 Excess voltage, UC1-Max The protective excess voltage suppression in the FPS has responded. The travel drive is switched to idle and the vehicle is braked to a standstill. This error can occur if the vehicle is switched off during generator braking or if the battery is not in order. • FE2063 Active lowering blocked

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• FE2106 CAN bus error • FE2107 CAN bus error • FE2108 CAN bus error • FE2109 CAN bus error • FE2110 General error in the CAN bus • FE2114 ERror in e CAN bus network • FE2159 Short-circuit, drive motor temperature sensor The measuring circuit for temperature measurement of the drive motor has shortcircuited between X11:22 and X11:23 of the FPS. This error does not have any effect on the range of functions that can be carried out with the vehicle.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-19

Chapter 35

Error codes

Travel and pump controller errors (FPS) • FE2161 Short circuit, pump motor temperature sensor The measuring circuit for temperature measurement of the pump motor has shortcircuited between X11:23 and X11:38 of the FPS. This error does not have any effect on the range of functions that can be carried out with the vehicle. • FE2162 Cable breakage, drive motor temperature sensor The measuring circuit for temperature measurement of the drive motor has been interrupted between X11:22 and X11:23 of the FPS. This error does not have any effect on the range of functions that can be carried out with the vehicle.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• FE2164 Cable breakage, pump motor temperature sensor The measuring circuit for temperature measurement of the pump motor has been interrupted between X11:38 der FPS unterbrochen. This error does not have any effect on the range of functions that can be carried out with the vehicle. • FE2165 Earth contact, drive motor temperature sensor Test input X11:22 of the FPS has a direct connection with 0V. This error does not have any effect on the range of functions that can be carried out with the vehicle. • FE2167 Earth contact, pump motor temperature sensor Test input X11:38 of the FPS has a direct connection with 0V. This error does not have any effect on the range of functions that can be carried out with the vehicle. • FE2168 Earth contact, reference point temperature sensor Test input X11:23 of the FPS has a direct connection with 0V. This error does not have any effect on the range of functions that can be carried out with the vehicle. • FE2169 Collective error, temperature sensor A short circuit, an interruption or an earth contact has occurred in one of the 3 temperature measuring circuits (drive motor, pump motor and FPS). This error does not have any effect on the range of functions that can be carried out with the vehicle. • FE2173 Monitoring of drive motor armature regulator A current that is too high has occurred in the armature regulator of the drive motor. The travel drive is switched to idle. The cause may be an internal or an external shortcircuit.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-20

Chapter 35

Error codes

Travel and pump controller errors (FPS) • FE2174 Monitoring of drive motor field regulator A current that is too high has occurred in the field regulator of the drive motor. The travel drive is switched to idle. The cause may be a short-circuit or because a main contactor has opened during normal travel. • FE2176 Monitoring of pump motor field regulator A current that is too high has occurred in the field regulator of the pump motor. The hydraulic drive is switched to idle. The cause may be a short-circuit or because a main contactor has opened during a hydraulic function.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• FE2177 Monitoring of pump motor armature regulator A current that is too high has occurred in the armature regulator of the pump motor. The hydraulic drive is switched to idle. The cause may be an internal or an external short-circuit. • FE2195 Carbon brush error, drive motor At least one of the 4 carbon brushes in the drive motor is shorter than the permissible residual length or an interruption has occurred between the carbon brush monitor switches and test input X11:29 of the FPS. In the event that the carbon brushes are worn, all 4 carbon brushes in the drive motor must be replaced. This error does not have any effect on the range of functions that can be carried out with the vehicle. • FE2196 Carbon brush error, pump motor At least one of the 4 carbon brushes in the pump motor is shorter than the permissible residual length or an interruption has occurred between the carbon brush monitor switches and test input X11:17 of the FPS. In the event that the carbon brushes are worn, all 4 carbon brushes in the pump motor must be replaced. This error does not have any effect on the range of functions that can be carried out with the vehicle. • FE2197 Excess temperature, drive motor The operating temperature inside the drive motor has exceeded 160°C (voltage drop between X11:22 and X11:23 of the FPS is ≥ 2V). The armature current for the drive motor is limited to approx. 25% of the max. armature current (emergency operation). • FE2198 Excess temperature, pump motor The operating temperature inside the pump motor has exceeded 160°C (voltage drop between X11:23 and X11:38 of the FPS is ≥ 2V). The armature current for the pump motor is limited to approx. 25% of the max. armature current (emergency operation).

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-21

Chapter 35

Error codes

Travel and pump controller errors (FPS) • FE2199 Temperature sensor failure, drive motor A short-circuit, an interruption or a ground contact has occurred in the temperature measuring circuit for the drive motor.This error does not have any effect on the range of functions that can be carried out with the vehicle. • FE2200 Temperature sensor failure, pump motor A short-circuit, an interruption or a ground contact has occurred in the temperature measuring circuit for the pump motor.This error does not have any effect on the range of functions that can be carried out with the vehicle.

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• FE2203 Carbon brush error, drive motor, emergency operation The carbon brushes for the drive motor have not been replaced within 10 operating hours of the error message "FE2195" occurring. The armature current for the drive motor is limited to approx. 25% of the max. armature current (emergency operation). • FE2204 Carbon brush error, pump motor, emergency operation The carbon brushes for the pump motor have not been replaced within 10 operating hours of the error message "FE2196" occurring. The armature current for the pump motor is limited to approx. 25% of the max. armature current (emergency operation). • FE2205 Speed change in drive motor too large The speed of the drive motor has changed too much in too short a time. The travel drive is switched to idle. The cause may be a faulty speed sensor. • FE2206 Error in the drive motor speed sensor The speed sensor of the drive motor is not supplying the correct increments on one or both channels. The travel drive is switched to idle. • FE2207 Error in the drive motor speed sensor The speed sensor of the pump motor is not supplying the correct increments on one or both channels. The hydraulic drive is switched to idle. • FE2208 Error in model calculation for drive motor The FPS uses a model calculation to monitor the drive motor. The measured speed, the motor voltages or motor currents do not match the characteristic data for the drive motor. The travel drive is switched to idle. The cause may be a faulty drive motor or speed sensor.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-22

Chapter 35

Error codes

Travel and pump controller errors (FPS)

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• FE2209 Error in model calculation for pump motor The FPS uses a model calculation to monitor the pump motor. The measured speed, the motor voltages or motor currents do not match the characteristic data for the pump motor. The hydraulic drive is switched to idle. The cause may be a faulty pump motor or speed sensor.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

35-23

Chapter 36

Troubleshooting guide

Power supply function General In this chapter, the reader is taken through the "Power supply" function step by step with a troubleshooting guide. In order to keep the structure of the troubleshooting guide clear, the power supply function has been divided up into several inter-related sub-functions:

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

• Battery voltage • 1+battery voltage after key switch • 1+24V • 1+battery voltage after 1+24V • EMERGENCY-STOP chain • 2+battery voltage • 2+24V If an error occurs in the power supply, the sequence shown above and the sequence within these subdescriptions must be maintained during troubleshooting without fail. Remark: A large number of potential errors are identified by the vehicle control system (FZS) and shown on the display in the form of an error code. The possible cause of the error can be determined very quickly from an error description (see sheet no. 35-01). At the beginning of every sub-function, a list is provided of which voltages should be applied to which components/pins. If these voltages are measured at all the listed components/pins, you can move on immediately to the next sub-function. More detailed information about components and their function can be found very easily by using the cross references to the relevant chapters in the guide to components.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

36-01

Chapter 36

Troubleshooting guide

Voltage supply function Battery voltage When the battery plug is inserted, the battery voltage should be applied at the following components/pins: • NAV, pin X1:4 • FPS, pin X11:1 • Key switch S1, terminal P • DC/DC converter, pin IN+

Battery G2

F1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Remark: If battery voltage is applied at all the listed components/pins, troubleshooting can be continued at 1+battery voltage. If no battery voltage is measured at the NAV, pin X1:4, check the following: • Connecting lead between battery plug and fuse F1 of the main current circuit (355A) • Fuse F1 of the main current circuit • Connecting lead between fuse F1 of the main current circuit and main contactor contacts of K1 • Connecting lead between main contactor contacts of K1 and fuse F2 • Fuse F2 (10A) • Connecting lead between fuse F2 and distributor board A13, plug-in contact X3 • Fuse F6 (5A) on distributor board A13 • Connecting lead between distributor board A13, pin X13:2 and NAV, pin X1:4

•

Main contactor contacts of K1

• •

F2

F6

F5

F4

Distributor board A13

FPS A10

NAV 7A22

•

DC/DC converter U30

If no battery voltage is measured at the FPS, pin X11:1, check the following: • Fuse F5 (5A) on distributor board A13 • Connecting lead between distributor board A13, plug-in contact X17 and FPS, pin X11:1

Key switch S1

If no battery voltage is measured at the key switch, terminal P, check the following: • Connecting lead between distributor board A13, pin X16:9 and key switch S1, terminal P

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

36-02

Chapter 36

Troubleshooting guide

Power supply function Battery voltage

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

If no battery voltage is measured at the DC/DCconverter, terminal IN+, check the following: • Connecting lead between main contactor contacts of K1 and fuse F4 • Fuse F4 (5A) • Connecting lead between fuse F4 and NAV, pin X1:14 • Internal connection in the NAV between pin X1:14 und X1:28 (protector diode for DC/DCconverter) Remark: If an interruption is found between these two pins in the NAV, the entire NAV must be replaced. • Connecting lead between the NAV, pin X1:28 and DC/DC-converter, terminal IN+

Battery G2

F1 •

Main contactor contacts of K1

• •

F2

F6

F5

F4

Distributor board A13

FPS A10

NAV 7A22

•

DC/DC converter U30 Key switch S1

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

36-03

Chapter 36

Troubleshooting guide

Power supply function Battery voltage after key switch When the vehicle is switched on, the 1+battery voltage after the key switch should be applied to the following components/pins: • DC/DC-converter, ON terminal • FZS, pin X1:28

Key switch S1

Remark: If 1+battery voltage is applied at all the listed components/pins, troubleshooting can be continued at 1+24V.

DC/DC converter U30

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

NAV 7A22

If no 1+battery voltage is measured at the DC/DCconverter at the ON terminal, check the following: • Connecting lead between key switch S1, terminal 14 and NAV, pin X1:11 Remark: If this is a standard vehicle, there is a wire jumper between pins X99:13 and X99:14. If this is a cold store version vehicle, the pilot contacts of the battery plug are connected between pins X99:13 and X99:14. This means that the vehicle cannot be moved during the loading process. • Internal connection in the NAV between pins X1:11 and X1:12 Remark: If an interruption is found between these two pins in the NAV, the entire NAV must be replaced. • Connecting lead between the NAV, pin X1:12 and DC/DC-converter, ON terminal

Issue: 02/01 Replaces issue:

Workshop Manual

FZS 8U60

MX15-3

Sheet no.

36-04

Chapter 36

Troubleshooting guide

Power supply function 1+battery voltage after key switch

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

If no 1+battery voltage is measured at the FZS, pin X1:28, check the following: • Internal connection in the NAV between pins X1:11 and X1:27 Remark: If an interruption is found between these two pins in the NAV, the entire NAV must be replaced. • Connecting lead between the NAV, pin 1:27 and FZS, pin 1:28 Remark: The 1+battery voltage on distributor board A13 is not available until relay contact K36 has closed. Relay K36 is supplied with 1+24V, i.e. the 1+battery voltage is not available on the distributor board until the 1+24V has been applied.

Issue: 02/01 Replaces issue:

Workshop Manual

Key switch S1

DC/DC converter U30 NAV 7A22 FZS 8U60

MX15-3

Sheet no.

36-05

Chapter 36

Troubleshooting guide

Power supply function 1+24V When the vehicle is switched on, the 1+24V output voltage of the DC/DC-converter should be applied at the following comonents/pins: • Distributor board A13, plug-in contact X1 • NAV, pin X1:34 • FZS, pin X1:54

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Remark: If 1+24V is applied at all the listed components/pins, troubleshooting can be continued at the EMERGENCYSTOP chain. If no 1+24V is measured at distributor board, plugin contact X1, check the following: • Connecting lead between DC/DC-converter OUT+ terminal and NAV, pin X1:29 • Internal connection in the NAV between pins X1:29 and X1:15 Remark: If an interruption is found between these two pins in the NAV, the entire NAV must be replaced. • Connecting lead between the NAV, pin X1:15 and distributor board A13, plug-in contact X1

DC/DC converter U30

NAV 7A22 K37

FZS 8U60

F7

Distributor board A13

If no 1+24V is measured at the NAV, pin X1:34, check the following: • Fuse F7 (5A) on distributor board A13 • Connecting lead between distributor board A13, pin X7:11 and NAV, pin X1:34

If no 1+24V is measured at the FZS, pin X1:54, check the following: • Internal connection in the NAV between pins X1:29 and X1:37 Remark: If an interruption is found between these two pins in the NAV, the entire NAV must be replaced. • Connecting lead between the NAV, pin X1:37 and the FZS, pin X1:54

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

36-06

Chapter 36

Troubleshooting guide

Power supply function 1+battery voltage after 1+24V After the NAV has been supplied with 1+24V, 1+battery voltage should be applied at the following comonents/pins: • FPS, pin X11:15

NAV 7A22 K36

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Remark: If 1+battery voltage is applied at all the listed components/pins, troubleshooting can be continued at the EMERGENCYSTOP chain. If no 1+battery voltage is measured at the FPS, pin X11:15, check the following: • Relay contact K36 in the NAV between pins X1:4 and X1:6 Remark: If an interruption is found between these two pins in the NAV, the entire NAV must be replaced. • Connecting lead between the NAV, pin X1:6 and distributor board A13, plug-in contact X4 • Internal connection on distributor board A13 between plug-in contact X4 and pin X14:1 Remark: If an interruption is found between these two pins on distributor board A13, distributor board A13 must be replaced. • Connecting lead between distributor board A13, pin X14:1 and FPS X11:15

Issue: 02/01 Replaces issue:

Workshop Manual

Distributor board A13

FPS A10

MX15-3

Sheet no.

36-07

Chapter 36

Troubleshooting guide

Power supply function EMERGENCY-STOP chain The fllowing conditions must be met for the EMERGENCY-STOP chain to close: • BPS OK • EMERGENCY-STOP switch not actuated • PSA OK (option) • STeering OK • FZS OK • NAV OK

Op. console 8U62

FZS 8U60

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

If the EMERGENCY-STOP chain is closed, 2+battery voltage is applied at the following components/pins: • NAV, pin X1:13 Remark: If 2+battery voltage is applied at all the listed components/pins, troubleshooting can be continued at 2+battery voltage. If no 2+battery voltage is measured at the NAV, pin X1:13, check the following: • Signal voltage at BPS, pin X8:3 Remark: A "24V" signal should be applied at this pin. If there is no "24V" signal applied, either the EMERGENCY-STOP switch is actuated or a fault has occurred in the vehicle control system or the operating console. • Connecting lead between BPS, pin X8:3 and plug-in connector X99, pin 3 Remark: If this is a standard vehicle there is a wire jumper between pins X99:3 and X99:4. If the vehicle is fitted with mobile personal safety eqipment, there is a normally open contact connected between pins X99:3 and X99:4. The contact is open when the PSA detects a malfunction or there is a fault at the PSA.

PSA (Option)

NAV 7A22 K33

K37

K34

A13 (Standard steering)

or

LR80 (option)

• Connecting lead between plug-in connector X99, pin 3 and NAV, pin X1:19

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

36-08

Chapter 36

Troubleshooting guide

Power supply function EMERGENCY-STOP chain • Signal voltage at the NAV, pin X1:36 Remark: A "0V" signal should be applied at this pin. If there is no "0V" signal applied, a fault has occurred in the LR80 central processing unit. If no potential is measured, the connecting lead between the NAV, pin X1:36 and distributor board A13, pin X11:8 (standard steering) or the connecting lead between the NAV, pin X1:36 and LR80 central processing unit, pin X8:4 (inductive wire guidance) must be checked.

Op. console 8U62

FZS 8U60

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

PSA

• Voltage measurement at the FZS, pin X11:14 Remark: A "24V" signal should be applied at this pin. If there is no "24V" signal applied, the connecting lead between the FZS, pin X11:14 and NAV pin X1:35 must be checked. If this connecting lead is OK, the NAV must be replaced. • Voltage measurement at the FZS, pins X1:50 and X1:51 Remark: A "0V" signal should be applied at these pins. If no "0V" signal is applied at either one or both the pins, there is a fault at the FZS that does not allow the EMERGENCYSTOP chain to close. • Connecting lead between FZS, pin X1:50 and NAV, pin X1:20

(Option)

NAV 7A22 K33

K37

K34

A13 (Standard steering)

or

LR80 (option)

• Connecting lead between FZS, pin X1:51 and NAV, pin X1:38 • Internal connection in the NAV between pins X1:4 and X1:13 Remark: If an interruption is found between these two pins in the NAV, the entire NAV must be replaced.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

36-09

Chapter 36

Troubleshooting guide

Power supply function 2+battery voltage After the EMERGENCY-STOP chain has closed, the 2+battery voltage after the NAV should be applied at the following components/pins: • FPS, pin X11:2 • Main contactor K1, terminal A1

NAV 7A22 K33

If no 2+battery voltage is measured at the FPS, pin X11:2, check the following: • Connecting lead between the NAV, pin X1:13 and FPS, pin X11:2

FPS A10

If no 2+battery voltage is measured at main contactor K1, terminal A1, check the following: • Connecting lead between the NAV, pin X1:13 and main contactor K1, terminal A1

Distributor board A13

K34

•

Negative feeder module A14

F3 K1

3F1

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

•

If the main contactors K1 and K2 do not pick up, check the following: • Main contactors K1 and K2 • Connecting lead between the main contactors • Connecting lead between main contactor K2, terminal A2 and the FPS, pin X11:4 • Signal voltage at the FPS, pin X11:4 Remark: A "50V" signal should be applied at this pin. The main contactors are supplied with a clocked "0V" signal by the control system via this pin. If no "50V" signal is applied, a fault has occurred at the FPS (see sheet no. 35-18).

K2

Battery G2

After the main contactors K1 and K2 pick up, 2+battery voltage should be applied at the following components: • FPS, connecting terminal 8 • Negative feeder module A14, terminal X10.1 • NAV, pin X1:8 Remark: If 2+battery voltage is applied at all the listed components/pins, troubleshooting can be continued at 2+24V.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

36-10

Chapter 36

Troubleshooting guide

Power supply function 2+battery voltage If no 2+battery voltage is measured at the FPS, connecting terminal 8, check the following: • Connecting lead between the main contactor contacts of K1 and K2 • Connecting lead between the main contactor contact K2 and the FPS, connecting terminal 8.

NAV 7A22 K33

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

If no 2+battery voltage is measured at the negative feeder module A14, terminal X10.1, check the following: • Connecting lead between the FPS, connecting terminal 8 and negative feeder module A14, terminal X10.1

FPS A10

Workshop Manual

•

Negative feeder module A14

F3

If no 2+battery voltage is measured at the NAV, pin X1:8, check the following: • Connecting lead between the main contactor contact K2 and fuse 3F1 • Fuse 3F1 (50A) • Connecting lead between fuse 3F1 and fuse F3 • Fuse F3 (5A) • Connecting lead between fuse F3 and distributor board A13, plug-in contact X5 • Internal connection on distributor board A13 between plug-in contact X5 and pin X15:2 Remark: If an interruption is found between these two pins on the distributor board, distributor board A13 must be replaced. • Connecting lead between distributor board A13, pin X15:2 and NAV, pin X1:8

Issue: 02/01 Replaces issue:

Distributor board A13

K34

K1

3F1 •

K2

MX15-3

Battery G2

Sheet no.

36-11

Chapter 36

Troubleshooting guide

Power supply function 2+24V After 2+battery voltage is applied to the NAV, pin X1:8, 2+24V should be applied at the following components: • Distributor board A13, plug-in contact X2

NAV 7A22 K33

K34

K35

Copyright protected. No part of this manual may be reproduced in any form. Copyright reserved.

Remark: If 2+24V is applied at all the listed components/pins, the power supply function is OK.

Distributor board A13

If no 2+24V is applied at distributor board A13, plug-in contact X2, check the following: • Internal connection in the NAV between pins X1:29 and X1:42 Remark: If an interruption is found between these two pins in the NAV, the entire NAV must be replaced. • Connecting lead between the NAV, pin X1:42 and distributor board A13, plug-in contact X2.

Issue: 02/01 Replaces issue:

Workshop Manual

MX15-3

Sheet no.

36-12