Jungheinrich Forklift Truck Fault Codes DTC

õUNGHEINRICH

Event Messages

03.15

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G

Event Messages

Z This display units shows a four-digit event message for every event. Trucks that only use one luminous display (e.g. LED) show the event through a flashing code (see "Display System”).

Each event message is also stored in the master logbook. The master logbook describes the event in more detail through the sub index behind the event message (FEXX).

Event numbering display

F	E XX S
F	Function group;	E	Event group
XX	Event number	S	Sub index

Z The first two characters “F, E” refer to the category. The middle two digits “XX” refer to the event. From these two digits the range:

•1 to 50 describes standard events (uniform basic events) which can occur in any function group.

•51 to 99 describes specific events.

The event is described in further detail through the last characters “S” (single digit / multi-digit).

This process ensures that a unique number is assigned to each event. Example:

F Function group

E Event group XX Event number S Sub-index

ï í ð ë ï

Sub-division of function group "F"

		System:
	0	Overlapping functions that cannot be assigned to any other
		function group)
		Example: seat switch / deadman switch or master controller
	1	Travel
	2	Hydraulics (load handling)
	3	Steering and travel
	4	Displays/controls, interface
	5	Charger (either on-board or external charger)
	6	Reserved
	7	Reserved
	8	Reserved
	9	Special functions
		Example: ISM

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Event Messages

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Sub-division of event group “E”

	0	Fault reset or
		no fault
		General fault / additional functions
	1	Example:
		Logic error, e.g. both directions selected simultaneously
	2	Current
		(input interface, device-internal, output interface)
	3	Voltage
		(input interface, device-internal, output interface)
	4	Temperature
		Hardware
	5	Example: Output transformer short circuit, EEPROM not
		responding, …
		Software
	6	(internal software, application software, data record /
		parameters)
		Example: EEPROM data error
	7	Additional modules
	8	CAN monitoring
	9	External fault
		Example: ISM

Display system

The system distinguishes between:

•event messages caused by operator errors.

•event messages caused by truck errors.

For operator errors there are three versions that can be displayed in the truck depending on the display unit options.

•Event number display (e.g. CANDIS)

•Pictogram display

•Text message display

For truck errors the event number and possibly a fault graphic icon (e.g. service key) will also be displayed.

Trucks that only use one luminous display (e.g. LED) use the following flashing code:

•Each character of the four-digit event number is shown with a 2 Hz / 0.5 sec frequency (flashing).

Z The figure “zero” is displayed by flashing ten times.

•After each character of the four-digit event message there is a pause (LED off) of one second.

•After the complete four-digit event message a 3 second pause (LED off) is set.

https://www.truck-manuals.net/

	õUNGHEINRICH			Event Messages	03.15	3	G
Description / cause / action and effects
Z		The following table lists the event message with a description / cause / action and effect.
		Each event group (E) with the corresponding event number (XX) can be combined with different function groups (F), hence in the following
		table the placeholder “F” is used for the first character “F” of the four-digit event number.
		It also shows the operating status when the event occurred:
		Operating status		Explanation
				Occurs during / directly after truck power up
		Bootloader		(basic initialisation of components, possible change to flash mode).
				Example: Checking the RAM / ROM (memory check)
		System start		Occurs during installation of operating software of individual components.
				Example: correct hardware installed, ...
		Self test		Occurs during the self-test of each component, as coordinated by the master
				The main contactor is then closed
		Operation		Occurs during operation
		System end		Occurs during truck power-down (correct powering down of components, …)
		Undefined		Can occur at any time

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Event Messages

03.15

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“Event messages” table

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

Supply via unexpected key

Evaluation of three key switch inputs. Possible

- Check key switch input connection against the

_

1

01

1

System start

encodings are 1, 2 or 4, otherwise the event message is

wiring diagram;

switch input

triggered.

- Replace controller;

Contact closed instead of

On power-up the capacitor voltage should be one volt

- Test the main contactor output of the controller;

_

1

1

Self test

- Check wire connection;

open

(1 V) below the battery voltage.

- Replace contactor;

Contact open instead of

When the main contactor has switched on the capacitor

- Test the main contactor output of the controller;

_

1

2

Self test

voltage should be the same as the battery voltage (within

- Check wire connection;

closed

500 msec.), otherwise the event message is produced.

- Replace contactor;

- Replace controller;

02

An attempt is being made to open the main contactor.

Lithium-ion battery 24V/110Ah (in the case of

repeated faults):

Main contactor permanently

The event message is triggered if the monitoring system

_

1

3

Self test

- Check the harness of the lithium-ion battery and

on

detects that the main contactor has not opened after T >

replace if necessary;

time limit.

- Replace battery contactor;

- Replace battery management system (BMS);

Self test

Main contactor feedback

Feedback signal from main contactor status implausible

- Test the main contactor output of the controller;

_

1

4

with main contactor control (error activated after limit

- Check wire connection;

Operation

input implausible

time)

- Replace contactor;

1

Self test

Output transformer faulty

The semi-jumpers 1, 2 and 3 are controlled in turned for

- Replace controller;

(phase U)

50 msec at 25% PWM (pulse width modulation) when

the output transformer is closed (“Output transformer

2

Self test

Output transformer faulty

_

1

03

deactivated” signal).

(phase V)

The event message is issued if at the end of the 50 msec

3

Self test

Output transformer faulty

period of the respective phase the following applies:

VPhase_X < (Vcapacitor / 2) - 25%

(phase W)

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

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F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

1

Self test

Output transformer faulty

Semi-jumpers 1, 2 and 3 are controlled in turn for

- Replace controller;

(phase U)

50 msec at 25% PWM (pulse width modulation).

_

1

04

2

Self test

Output transformer faulty

The event message is issued if at the end of the 50 msec

(phase V)

period of the respective phase the following applies:

VPhase_X > (Vcapacitor / 4) 25% or

Output transformer faulty

3

Self test

VPhase_X < (Vcapacitor / 4) - 25%

(phase W)

"Error, power stage ID : The power card of the power

- Replace controller;

Error bit set for power

stage can only obtain faulty information (ID) about the

_

1

04

4

Operation

identity and hence suitability of the card for the intended

stage ID

powering of the operating system when the error bit is

set"

Semi-jumpers 1, 2 and 3 are controlled in turn for

- Check motor connection wire (wire breakage);

50 msec at 25% PWM (pulse width modulation).

- Replace motor;

The event message is issued if at the end of the 50 msec

_

1

05

1

Self test

Motor cutout

period of at least one of the two non-controlled phases

the following applies:

VPhase > (Vcapacitor / 4) 25% or

VPhase < (Vcapacitor / 4) - 25%

Semi-jumpers 1, 2 and 3 of a combi controller power

- Switch the truck off and on again;

part are controlled in turn for 50 msec at 25% PWM

- Check the motor connections;

"Combi controller behaviour

(pulse width modulation).

- Check for a short between two power stages

The event message is issued if at the end of the 50 msec

or motors;

_

1

05

2

Self test

for non-controlled power

period of at least one of the semi-jumpers of the other

- Replace signal-evaluating controller;

stages" logic implausible

power part the following applies:

VPhase_X > (Vcapacitor / 2) + 15% or

VPhase_X < (Vcapacitor / 2) - 15%

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

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F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

The safety switch consists of a NC and a NO contact.

- Check safety switch wire connection;

When the button is pressed both contacts connect

- Check safety switch;

simultaneously. As a result, only the 0/1 and 1/0

- Replace safety switch;

combinations should occur.

Z

Safety switches can include:

Safety switch inputs

During operation combinations 0/0 and 1/1 (500 msec.)

_

1

06

1

Operation

- Deadman (foot switch),

implausible

trigger the event message.

- Seat switch,

For a valid combination (0/1 or 1/0, 500 msec) the event

- Tiller switch.

message and the truck response are reset. For an

implausible condition the seat switch is considered to

be open (-> the truck brakes with the coasting ramp).

- Check wiring with multimeter;

Deadman switch inputs

During operation combinations 0/0 and 1/1 trigger the

- Check sensor system with multimeter;

_

1

06

2

Operation

event message. The event message can only be reset

- Check computer component inputs;

implausible

by resetting the truck. The activation limit is 2000 msec.

- Repair faulty components and replace if

necessary;

During operation combinations 0/0 and 1/1 trigger the

- Check wiring with multimeter;

- Check sensor system with multimeter;

Slack-chain switch inputs

event message. For a valid combination (0/1 or 1/0),

_

1

06

3

Operation

- Check computer component inputs;

implausible

the event and the truck response are reset. The

- Repair faulty components and replace if

activation limit is 1000 msec.

necessary;

During operation combinations 0/0 and 1/1 trigger the

- Check wiring with multimeter;

- Check sensor system with multimeter;

Cabin gate inputs

event message. For a valid combination (0/1 or 1/0),

_

1

06

4

Operation

- Check computer component inputs;

implausible

the event and the truck response are reset. The

- Repair faulty components and replace if

activation limit is 2000 msec.

necessary;

During operation combinations 0/0 and 1/1 trigger the

- Check wiring with multimeter;

- Check sensor system with multimeter;

Optional cabin gate inputs

event message. For a valid combination (0/1 or 1/0),

_

1

06

5

Operation

- Check computer component inputs;

implausible

the event and the truck response are reset. The

- Repair faulty components and replace if

activation limit is 2000 msec.

necessary;

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

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F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

During operation combinations 0/0 and 1/1 trigger the

- Check wiring with multimeter;

- Check sensor system with multimeter;

Sideshift index inputs

event message after a traverse path of more than 30mm.

_

1

06

6

Operation

- Check computer component inputs;

implausible

For a valid combination (0/1 or 1/0), the event and the

- Repair faulty components and replace if

truck response are reset. The activation limit is 0 msec.

necessary;

During operation combinations 0/1 and 1/0 trigger the

- Check wiring with multimeter;

- Check sensor system with multimeter;

Aisle recognition right inputs

event message after the truck has travelled more than

_

1

06

7

Operation

- Check computer component inputs;

implausible

100mm. The event message can only be reset by

- Repair faulty components and replace if

resetting the truck. The activation limit is 100 msec.

necessary;

During operation combinations 0/1 and 1/0 trigger the

- Check wiring with multimeter;

- Check sensor system with multimeter;

Aisle recognition left inputs

event message after the truck has travelled more than

_

1

06

8

Operation

- Check computer component inputs;

implausible

100mm. The event message can only be reset by

- Repair faulty components and replace if

resetting the truck. The activation limit is 100 msec.

necessary;

- Check wiring with multimeter;

Load handling inputs: no

During operation combinations 0/0 and 1/1 trigger the

- Test sensor system with multimeter;

_

1

06

9

Operation

event message. The event message can only be reset

- Check computer component inputs;

signal

by resetting the truck. The activation limit is 2000 msec.

- Repair faulty components and replace if

necessary;

- Check wiring with multimeter;

Load sensing inputs: no

If the weight display > 300 kg the load sensors must be

- Test sensor system with multimeter;

_

1

06

10

Operation

applied. The event message can only be reset by

- Check computer component inputs;

signal

resetting the truck. The activation limit is 2000 msec.

- Repair faulty components and replace if

necessary;

- Check wiring with multimeter;

Logic test: signal at working

During operation combinations 0/0 and 1/1 trigger the

- Test sensor system with multimeter;

_

1

06

11

Operation

platform raised inputs

event message. The event message can only be reset

- Check computer component inputs;

improbable

by resetting the truck. The activation limit is 2000 msec.

- Repair faulty components and replace if

necessary;

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õUNGHEINRICH

Event Messages

03.15

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F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

- Check wiring with multimeter;

Logic test: signal at left/right

During operation combinations 0/1 and 1/0 trigger the

- Test sensor system with multimeter;

_

1

06

12

Operation

- Check computer component inputs;

gate lock inputs improbable

event message. The activation limit is 2000 msec.

- Repair faulty components and replace if

necessary;

- Check wiring with multimeter;

Logic test: No signal for gate

During operation no feedback triggers the message

- Test sensor system with multimeter;

_

1

06

13

Operation

lock despite gate lock being

- Check computer component inputs;

when applied. The activation limit is 2000 msec.

applied

- Repair faulty components and replace if

necessary;

- Check wiring with multimeter;

Logic test: Signal for gate

During operation a feedback triggers the message

- Test sensor system with multimeter;

_

1

06

14

Operation

lock present despite gate

- Check computer component inputs;

without being applied. The activation limit is 2000 msec.

lock not being applied

- Repair faulty components and replace if

necessary;

Logic test: No signal for gate

- Check wiring with multimeter;

During operation no feedback triggers the message

- Test sensor system with multimeter;

lock despite the lift

_

1

06

15

Operation

when lift mechanism is above the set height. The

- Check computer component inputs;

mechanism being above the

activation limit is 2000 msec.

- Repair faulty components and replace if

set height

necessary;

The body protection switch consists of a NC and a NO

- Check wire connections;

contact. When the button is pressed both contacts

- Check operator protection switch;

connect simultaneously. As a result, only the 0/1 and 1/0

- Replace operator protection switch;

_

1

07

1

Operation

Operator protection switch

combinations should occur.

inputs implausible

During operation combinations 0/0 and 1/1 (500 msec.)

trigger the event message.

For a valid combination (0/1 or 1/0, 500 msec) the event

message and the truck response are reset.

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

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F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

During operation combinations 0/0 and 1/1 (500 msec.)

- Check wire connections;

_

1

07

2

Operation

Acknowledge button inputs

trigger the event message.

- Check button;

implausible

For a valid combination (0/1 or 1/0, 500msecs) the event

- Replace button;

and the truck response are reset.

The touch mode button consists of a NC and a NO

- Check wire connection;

contact. When the button is pressed both contacts

- Check touch mode button;

connect simultaneously. As a result, only the 0/1 and 1/0

- Replace touch mode button;

_

1

08

1

Operation

Touch mode switch inputs

combinations should occur.

implausible

During operation combinations 0/0 and 1/1 (500 msec.)

trigger the event message.

For a valid combination (0/1 or 1/0, 500 msec) the event

message and the truck response are reset.

The "inching" button consists of a NC and a NO contact.

- Check wire connections;

When the button is pressed both contacts switch

- Check crawl speed button;

simultaneously. As a result, only the 0/1 and 1/0

- Replace crawl speed button;

combinations should occur.

During operation the combinations

_

1

08

2

Operation

"Crawl speed redundant

0/0 and 1/1 (switched for 500 msec.) activate the event

inputs" logic implausible

message.

For a valid combination (0/1 or 1/0, switched for 500

msec.)

the event and truck response are reset. The status is

assessed as an actuated status (adjustable inching

speed active)

The "Stop" button consists of an NC and an NO contact.

- Check parameter reading (side pedestrian mode

When the button is pressed both contacts switch

activated?);

simultaneously. As a result, only the 0/1 and 1/0

- Check wire connections;

_

1

08

3

Operation

“Stop" button redundant

combinations should occur.

- Press "Stop" button;

inputs” logic improbable

During operation the combinations

- Replace "Stop" button;

0/0 and 1/1 (500 msec) trigger the event message.

For a valid combination (0/1 or 1/0, 500 msec) the event

message and the truck's response are reset.

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

10

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

The "handbrake lever" switch consists of a NC and a NO

- Check wire connections;

contact. When the button is pressed both contacts switch

- Check “handbrake lever” switch;

simultaneously. As a result, only the 0/1 and 1/0

- Replace “handbrake lever” switch;

combinations should occur.

_

1

08

4

Self test

“Handbrake lever redundant

During operation the combinations

Operation

inputs” logic implausible

0/0 and 1/1 (switched for 500 msec.) activate the event

message.

For a valid combination (0/1 or 1/0, switched for

500msec) the event message and the truck's response

are reset.

The "parking brake" switch consists of a NC and a NO

- Check wire connections;

contact. When the button is pressed both contacts switch

- Check options keypad;

simultaneously. As a result, only the 0/1 and 1/0

- Replace options keypad:

“Parking brake switch

combinations should occur.

Self test

During operation the combinations

_

1

08

5

redundant inputs” logic

Operation

0/0 and 1/1 (switched for 500 msec.) activate the event

implausible

message.

For a valid combination (0/1 or 1/0, switched for 500

msec.) the event message and the truck's response are

reset.

The weigher button consists of a NC and a NO contact.

- Check wire connection;

When the button is pressed both contacts connect

- Check weigher button;

simultaneously. As a result, only the 0/1 and 1/0

- Replace weigher button;

_

1

09

1

Operation

Weigher button inputs

combinations should occur.

implausible

During operation combinations 0/0 and 1/1 (500 msec.)

trigger the event message.

For a valid combination (0/1 or 1/0, 500 msec) the event

message and the truck response are reset.

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

11

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

During operation the combination 1/1 for both buttons

- Check wire connection;

pressed simultaneously for 500 msec triggers the

- Check button;

_

1

10

1

Operation

Lift/lower digital setpoints

following event message.

- Replace button;

are invalid

For a valid combination (0/0, 0/1 or 1/0 [button not

pressed / only one button pressed]; 500 msec) the event

message and the truck response are reset.

During operation the limits for 1/1 [both buttons pressed

- Check wire connection;

Lift/lower analog setpoints

simultaneously] for 500 msec have been exceeded.

- Check button;

_

1

10

2

Operation

For a valid combination (0/0, 0/1 or 1/0 [button not

- Replace button;

are invalid

pressed / only one button pressed]; 500 msec) the event

message and the truck response are reset.

The event message is triggered if the following applies

- Check wire connection;

_

1

11

1

Operation

Braking setpoint and release

for T = 250msec:

- Check pedal power supply;

contact implausible

Vbrake pedal < 12.5% and

- Replace pedal;

Logic signal release contact = 1

- Replace signal-evaluating controller;

The event message is triggered if the following applies

- Check wire connection;

_

1

11

2

Operation

Braking setpoint and release

for T = 250msec:

- Check pedal power supply;

contact implausible

Vbrake pedal > 25% and

- Replace pedal;

Logic signal release contact = 0

- Replace signal-evaluating controller;

The event message is triggered if the following applies

- Check wire connection;

_

1

11

3

Operation

Braking setpoint and full

for T = 250msec:

- Check pedal power supply;

brake contact implausible

Vbrake pedal < 65% and

- Replace pedal;

Logic signal full brake contact = 1

- Replace signal-evaluating controller;

The event message is triggered if the following applies

- Check wire connection;

_

1

11

4

Operation

Braking setpoint and full

for T = 250msec:

- Check pedal power supply;

brake contact implausible

Vbrake pedal > 80% and

- Replace pedal;

Logic signal full brake contact = 0

- Replace signal-evaluating controller;

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

12

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

Combination "brake

The event message is triggered

- Check brake fluid level;

setpoint" against brake

- Check proximity sensor;

_

1

11

5

Operation

if for T = 250 ms the following applies:

pressure invalid (movement

- Check pressure sensors;

• Vbrake pedal > 80% and brake pressure < 40 bar

without brake pressure)

Combination "brake

The event message is triggered

- Check brake fluid level;

_

1

11

6

Operation

setpoint" against brake

if for T = 250 ms the following applies:

- Check proximity sensor;

pressure invalid (brake

• Vbrake pedal < 20% (> 7 volt ) and brake pressure

- Check pressure sensors;

pressure without movement)

> 20 bar

- Check the cable connection;

Sum of the voltages

The event message is triggered

- check accelerator-pedal power supply /

if for T = 250 ms the following applies:

tiller head power supply;

_

1

11

7

Operation

"Braking 1 setpoint" to

• Vbrake pedal1 + Vbrake pedal 2 > 5.5 V or

- replace accelerator pedal / tiller arm;

"Braking 2 setpoint" invalid

• Vbrake pedal1 + Vbrake pedal 2 < 4.5 V

- replace the controller that is evaluating the

signal;

The event message is triggered if the following applies

- Check wire connection;

_

1

12

1

Operation

Travel setpoint and release

for T = 250msec:

- Check accelerator pedal/tiller arm power supply;

contact invalid

Vaccelerator pedal < 12.5% and

- Replace accelerator pedal / tiller arm;

Logic signal release contact = 1

- Replace signal-evaluating controller;

The event message is triggered if the following applies

- Check wire connection;

_

1

12

2

Operation

Travel setpoint and release

for T = 250msec:

- Check accelerator pedal/tiller arm power supply;

contact invalid

Vaccelerator pedal > 25 % and

- Replace accelerator pedal / tiller arm;

Logic signal release contact = 0

- Replace signal-evaluating controller;

Total voltage "Travel1

The event message is triggered

- Check wire connection;

if for T = 250 ms the following applies:

- Check accelerator pedal/tiller arm power supply;

_

1

12

3

Operation

setpoint" to "Travel2

• Vbrake pedal1 + Vbrake pedal 2 > 5.5 V or Vbrake pedal1 +

- Replace accelerator pedal / tiller arm;

setpoint" invalid

Vbrake pedal 2 < 4.5 V

- Replace signal-evaluating controller;

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

13

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

During operation the combination 1/1 [both travel

- Check wire connection;

direction switch / button / twin pedal pressed] for 500

- Check travel direction switch/button/twin pedal;

Travel direction 1 and travel

msec triggers the following event message.

- Check travel direction switch/button/twin pedal;

_

1

13

1

Operation

For a valid combination (0/0, 0/1 or 1/0 [travel direction

- Replace signal-evaluating controller;

direction 2 invalid

switch/button/twin pedal not pressed or only one travel

direction switch/button/twin pedal pressed]; 500 msec)

the event message and the truck response are reset.

- Check parameter settings;

If more than one direction sensor is installed:

- Check installed accelerator (hardware);

Direction setting signal

While the truck is travelling, the system monitors if by

- Check installed Pilots (hardware);

_

1

13

2

Operation

improbable (direction

mistake more than one direction sensor (travel direction

- Check travel direction switch / button / twin

sensor)

switch on pilot, external direction sensor or twin pedal) is

pedal;

installed. If this is the case, the event is triggered

- Replace travel direction switch / button / twin

pedal;

- Rectify mechanical blockage of drive system;

Motor speed signal

Logic test: after a short period of motor control, the

- Check speed sensor power supply;

_

1

14

1

Self test

- Check wire connection;

implausible

speed sensor does not supply any signals

- Replace speed sensor;

- Replace signal-evaluating controller;

_

1

15

1

Operation

Motor powers without

Motor powered for 500 msec without setpoint.

- Check motor connections;

setpoint

Logic: implausible status in controller

- Check motor model, replace if necessary;

_

1

15

2

Operation

Motor powers without

Convergence problem in monitor for the motor speed

- Check motor connections;

setpoint

Logic: implausible status in monitor

- Check motor model, replace if necessary;

- Check speed sensor power supply;

_

1

16

1

Operation

Irregular speed signal

Jump from n_motor > 10% to n_motor < 1% and for

- Check wire connection;

T = 80 msec. the following applies: n_motor < 1%

- Replace speed sensor;

- Replace signal-evaluating controller;

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

14

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

Incrementer damaged

- Check incrementer signals with multimeter;

The AC-3 Power Control (U8) has identified the sensor

- Check speed sensor power supply;

bearing as being damaged. The AC-3 Power Control

- Check wire connection;

(U8) monitors sensor to ensure the impulse wires are

- Replace speed sensor;

single-channel, and to check for sudden changes in the

- Replace signal-evaluating controller;

pulse rate and for constant power supply.

Sensor is damaged (broken wire, short circuit, incorrect

pulses);

Operating system wrongly flags a fault;

AC-3 Power Control component (sensor bearing control)

Irregular speed signal (large

is faulty

Jump from n_Motor> 10 % to n_Motor< 1 % and

_

1

16

2

Operation

jump in evaluated speed

For T = 80 msec.:

signal)

n_motor< 1%

- Manually move the shuttle to the channel start,

remove any blockage (use recovery vehicle);

- Reduce load on shuttle;

- Drive: check setpoint specification, motor

No signals from incremental transmitter 1B5.

controller 9U19 and drive motor including

carbon brushes and incremental transmitter

1B5;

- Check wire connection;

- If the shuttle is overloaded, increase the travel

speed;

- Check speed-sensor power supply;

Implausible value for the

Engine control unit is sending an incorrect value for the

- Check the wiring;

_

1

16

3

Operation

- Replace speed sensor;

engine-speed signal

engine-speed signal.

- Replace the controller that is evaluating the

signal;

Both speed sensor tracks are counted. When the first

- Check speed sensor incrementer channels;

_

1

17

1

Operation

A speed sensor channel

deviation limit is reached the system waits for a feasible

- Replace speed sensor;

does not pulse

signal from the suspected broken track. When the

- Replace signal-evaluating controller;

second limit is reached the event message is generated.

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

15

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

Incrementer damaged

- Check incrementer signals with multimeter;

The AC-3 Power Control (U8) has identified the sensor

- Check speed sensor power supply;

bearing as being damaged. The AC-3 Power Control

- Check wire connection;

(U8) monitors sensor to ensure the impulse wires are

- Replace speed sensor;

single-channel, and to check for sudden changes in the

- Replace signal-evaluating controller;

pulse rate and for constant power supply.

A speed sensor channel

Sensor is damaged (broken wire, short circuit, incorrect

_

1

17

2

Operation

pulses);

does not pulse

Operating system wrongly flags a fault;

AC-3 Power Control component (sensor bearing control)

is faulty

Both sensor tracks are counted. When the first deviation

limit is reached the system waits for a feasible signal

from the suspected broken track. When the second limit

is reached the event is generated.

No speed signal from the

The counts for both incrementers are compared.

- Check incrementer signals with multimeter;

travel impulse sensor

If the travel incrementer supplies a speed signal of

- Check wiring with multimeter;

_

1

17

3

Operation

although travel sensor

> 0.05 km/h and the travel pulse contact controller

- Replace speed sensor;

indicates greater than

incrementer a speed signal of 0 km/h, the event is

0.5 km/h.

triggered. The activation limit is 100 msec.

No speed signal from travel

The counts for both incrementers are compared. If the

- Check incrementer signals with multimeter;

travel incrementer supplies a speed signal of 0 km/h and

- Check wiring with multimeter;

sensor although travel

_

1

17

4

Operation

the travel pulse contact controller incrementer a speed

- Replace speed sensor;

impulse sensor indicates

signal of > 0.05 km/h, the event is triggered. The

greater than 0.5 km/h.

activation limit is 100 msec.

Deviation of more than

The counts for both incrementers are compared. If the

- Check incrementer signals with multimeter;

_

1

17

5

Operation

0.25 km/h between travel

speed signals of both incrementers differ by more than

- Check wiring with multimeter;

impulse sensor and travel

0.025 km/h, the event is triggered. The activation limit is

- Replace speed sensor;

sensor

100 msec.

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

16

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

Directions obtained from

The counts for both incrementers are compared. If the

- Check incrementer signals with multimeter;

speed of both incrementers > 0.01 km/h and the

- Check wiring with multimeter;

travel sensor and travel

_

1

17

6

Operation

directions of the speed signals for both incrementers are

- Replace speed sensor;

impulse sensor are

contradictory, the event is triggered. The activation limit

contradictory

is 100 msec.

One incremental track

Both sensor tracks are counted. When the first deviation

- Check incrementer signals with multimeter;

_

1

17

7

Operation

height measurement of the

limit is reached the system waits for a feasible signal

- Check wiring with multimeter;

proportional lift pulses, the

from the suspected broken track. When the second limit

- Replace speed sensor;

other does not

is reached the event is generated.

One incremental track

Both sensor tracks are counted. When the first deviation

- Check incrementer signals with multimeter;

_

1

17

8

Operation

height measurement of the

limit is reached the system waits for a feasible signal

- Check wiring with multimeter;

free lift pulses, the other

from the suspected broken track. When the second limit

- Replace speed sensor;

does not

is reached the event is generated.

One incremental track

Both sensor tracks are counted. When the first deviation

- Check incrementer signals with multimeter;

_

1

17

9

Operation

height measurement of the

limit is reached the system waits for a feasible signal

- Check wiring with multimeter;

auxiliary lift pulses, the other

from the suspected broken track. When the second limit

- Replace speed sensor;

does not

is reached the event is generated.

The counts for both incrementers are compared. If the lift

- Check incrementer signals with multimeter;

Main lift does not lower

controller incrementer supplies a speed signal, but the lift

- Check wiring with multimeter;

_

1

17

10

Operation

despite the hydraulic motor

height measurement incrementer does not supply a

- Replace speed sensor;

turning

signal after one second, the event is triggered. The

activation limit is 20 msec.

The counts for both incrementers are compared. If the lift

- Check incrementer signals with multimeter;

Main lift lowers despite the

height measurement incrementer supplies a speed

- Check wiring with multimeter;

_

1

17

11

Operation

signal, but the lift controller incrementer does not supply

- Replace speed sensor;

hydraulic motor not turning

a signal after one second, the event is triggered. The

activation limit is 20 msec.

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

17

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

The counts for both incrementers are compared. If the

- Check the hydraulic system for leaks;

Excessive deviation

incrementers for the lift control and lift height

- Check incrementer signals with multimeter;

_

1

17

12

Operation

between lift speed and pump

measurement are not synchronised within three

- Check wiring with multimeter;

speed

seconds, the event is triggered. The activation limit is

- Replace speed sensor;

100 msec.

Proportional lift incrementer

- Check incrementer signals with multimeter;

_

1

17

13

Operation

Channel A or channel B are defective on the incrementer

- Check wiring with multimeter;

1: One channel defective

- Replace speed sensor;

Proportional lift incrementer

- Check incrementer signals with multimeter;

_

1

17

14

Operation

Channel A or channel B are defective on the incrementer

- Check wiring with multimeter;

2: One channel defective

- Replace speed sensor;

Free lift incrementer 1:

- Check incrementer signals with multimeter;

_

1

17

15

Operation

Channel A or channel B are defective on the incrementer

- Check wiring with multimeter;

One channel defective

- Replace speed sensor;

Free lift incrementer 2:

- Check incrementer signals with multimeter;

_

1

17

16

Operation

Channel A or channel B are defective on the incrementer

- Check wiring with multimeter;

One channel defective

- Replace speed sensor;

Aux. lift incrementer 1:

- Check incrementer signals with multimeter;

_

1

17

17

Operation

Channel A or channel B are defective on the incrementer

- Check wiring with multimeter;

One channel defective

- Replace speed sensor;

The counts for both incrementers are compared.

- Check incrementer signals with multimeter;

Logic test: Main lift does not

If the lift controller incrementer supplies a speed signal,

- Check wiring with multimeter;

_

1

17

18

Operation

but the lift height measurement incrementer does not

- Replace speed sensor;

lower despite pump rotating

supply a signal after one second, the event is triggered.

The activation limit is 20 msec.

_

1

17

19

Operation

LH load wheel sensor

Incorrect counting detected between ChA and ChB.

- Check mounting position of sensor to magnet;

incrementer deviation

- Replace sensor;

_

1

17

20

Operation

RH load wheel sensor

Incorrect counting detected between ChA and ChB.

- Check mounting position of sensor to magnet;

incrementer deviation

- Replace sensor;

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

18

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

LH load wheel sensor

Incorrect counting detected between LH load wheel

- Check mounting position of sensor to magnet;

_

1

17

21

Operation

excessive deviation from

- Check tyre quality;

sensor and drive wheel incrementer.

reading to drive wheel

- Replace sensor;

RH load wheel sensor

Incorrect counting detected between RH load wheel

- Check mounting position of sensor to magnet;

_

1

17

22

Operation

excessive deviation from

- Check tyre quality;

sensor and drive wheel incrementer.

reading to drive wheel

- Replace sensor;

Three channel incrementer

The sensor bearing and three channel incrementer are

- Test the electrical function of the sensor bearing

synchronised with respect to each other every 120 mm.

- Test the mechanical function of the sensor

_

1

17

23

Operation

comparison with sensor

The error is generated if the sensor bearing deviates

bearing

bearing incrementer

from the three channel sensor by >= 5 mm.

- Check speed sensor power supply;

_

1

18

1

Undefined

Speed sensor in load wheel

This event message is not currently used.

- Check wire connection;

sensor damaged

- Replace speed sensor;

- Replace signal-evaluating controller;

The event message is triggered

- Check wiring from controller to platform lower

if for T >= time limit the following applies:

limit sensor;

_

1

19

1

Operation

Cabin position implausible

• A change in status of the platform lower-limit sensor

- Check / replace lower limit sensor;

from the neutral position into the "Platform raised"

- Check lift motor power cables;

position is detected while driving

- Replace the signal-generating controller;

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

19

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

Excessive slip / drive has probably been tipped

- Check motor connection wire (wire breakage);

The AC-3 Power Control (U8) has detected excessive

- Check motor model, replace if necessary;

deviation (slip) between the phase current frequency and

- Check motor and replace if necessary;

the speed.

The activation limit is 20 msec.

More torque is required from / placed on the motor than it

_

1

20

1

Operation

Drive wheel slip excessive

can provide / accept;

Field current is reduced excessively;

Error accompanying sensor bearing control or output

stage protection;

Operating system does not allow enough slip for the

driven motor;

AC-3 Power Control component is damaged

The lift actuator jumper is controlled for max. 40 msec at

- Check motor connection wire (wire breakage);

100 % PWM (pulse width modulation).

- Check motor model, replace if necessary;

_

1

21

1

Self test

Output stage faulty

The event message is triggered if the pump voltage

- Replace controller;

drops within this time below 10% of the capacitor

voltage: Vpump > Vcapacitor / 10.

_

1

22

1

“Digital signal” logic/signal

This event message is triggered if the signal shape or

- Replace tiller head;

shape implausible

modulation of a digital signal is implausible.

The event message is triggered if after the brake applies

- Remove physical blockage from the brake;

Brake response switch

- Check wire connection;

_

1

23

1

Operation

the feedback switch does not report this status (after

signal implausible (in idle)

- Check switch and replace if necessary;

1 sec.).

- Replace signal-evaluating controller;

The event message is triggered if after the brake is

- Remove physical blockage from the brake;

Brake response switch

- Check wire connection;

_

1

23

2

Operation

released the feedback switch does not report this status

signal implausible (in idle)

- Check switch and replace if necessary;

(after 300 msec.).

- Replace signal-evaluating controller;

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

20

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

Brake response switch

- Remove physical blockage from the brake;

This event message is triggered if the response switch

- Check wire connection;

_

1

23

3

Operation

signal implausible (speed >

signals applied status during travel.

- Check switch and replace if necessary;

1km/h)

- Replace signal-evaluating controller;

- Check brake wear, replace wear parts / brake if

The event message is triggered

necessary.

_

1

23

4

Operation

Brake does not hold on a

if for T > 250 ms the drive system

- Measure current through the magnetic coil (you

ramp (failsafe brake)

• reports an actual rotational speed > 20 rpm when the

should not be able to measure any current when

brake is applied.

the brake is applied).

- Replace signal-issuing controller;

- Check brake wear, replace wear parts / brake if

Failsafe brake does not hold

On system start or engine start, the traction drives are

necessary.

- Measure current through the magnetic coil (you

_

1

23

5

System start

(on system start or motor

subjected to a travel request for a test time. If a truck

should not be able to measure any current when

start)

actual speed is detected, this event will be triggered.

the brake is applied).

- Replace signal-issuing controller;

- Check wiring with multimeter;

Left load wheel brake not

Left load wheel brake not controlled but feedback signal

- Check sensor system with multimeter;

_

1

23

6

Operation

controlled but feedback

is still present

- Check computer component inputs;

signal present

The activation limit is 1000 msec.

- Repair faulty components and replace if

necessary;

- Check wiring with multimeter;

Left load wheel brake

Left load wheel brake controlled but feedback signal is

- Check sensor system with multimeter;

_

1

23

7

Operation

controlled although

not present

- Check computer component inputs;

feedback signal missing

The activation limit is 1000 msec.

- Repair faulty components and replace if

necessary;

- Check wiring with multimeter;

Right load wheel brake not

Right load wheel brake not controlled but feedback

- Check sensor system with multimeter;

_

1

23

8

Operation

controlled but feedback

signal is still present

- Check computer component inputs;

signal present

The activation limit is 1000 msec.

- Repair faulty components and replace if

necessary;

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

21

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

- Check wiring with multimeter;

Right load wheel brake

Right load wheel brake controlled but feedback signal is

- Check sensor system with multimeter;

_

1

23

9

Operation

controlled although

not present.

- Check computer component inputs;

feedback signal missing

The activation limit is 1000 msec.

- Repair faulty components and replace if

necessary;

- Listen to check if emergency stop mechanism

hydraulic fail-safe brake

for 500 msec.: brake energised and pressure on

switches:

_

1

23

10

System start

- If so, check the pressure sensor and replace if

cannot be released

emergency stop mechanism > 3 bar

necessary;

- If not, check the relay and replace if necessary;

- Check brake wear, replace wear parts / brake if

Parking brake feedback

If the combinations 0/0 and 1/1 appear for longer than

necessary;

_

1

23

11

Operation

- Check wire connection;

contacts implausible

the limit time, a message is activated.

- Check switch and replace if necessary;

- Replace signal-evaluating controller;

The lift height sensor sequence is implausible. This

- Check wire connection;

event message is triggered if the following applies for

- Check sensor and replace if necessary;

_

1

24

1

Operation

Lift height signal implausible

T => 500 msec:

- Replace signal-evaluating controller;

Sequence of 2 lift height signals is implausible, e.g.

Top lift height signal without Bottom lift height signal

“Stacking height redundant

The event message is triggered

- Check wire connection;

_

1

24

2

Operation

if for T = 100 ms the following applies:

- Check sensor and replace if necessary;

inputs” logic implausible

• NC and NO contacts have the same status

- Replace signal-evaluating controller;

The event message is triggered

- Check wire connection;

“Free lift sensor redundant

if for T = 250 ms the following applies:

- Check sensor and replace if necessary;

_

1

24

3

Operation

• NC and NO contacts have the same status

inputs” logic implausible

When the event occurs, the master assumes that the

truck is in the mast lift stage.

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

22

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

Lifting stroke greater than 2x

Integrated lift stroke is greater than 2x the set free lift

- Check wire connection;

height, however sensor indicates free lift. When the

- Check sensor and replace if necessary;

_

1

24

4

Operation

free lift, however mast lift

event occurs, the master assumes that the truck is in the

has not been detected

mast lift stage.

“Lift limit switch redundant

The event message is triggered

- Check wire connection;

_

1

24

5

Operation

if for T = 100 ms the following applies:

- Check sensor and replace if necessary;

inputs” logic implausible

• NC and NO contacts have the same status

- Replace signal-evaluating controller;

“Initial lowering limit

The event message is triggered

- Check wire connection;

_

1

24

6

Operation

redundant inputs” logic

if for T = 100 ms the following applies:

- Check sensor and replace if necessary;

implausible

• NC and NO contacts have the same status

- Replace signal-evaluating controller;

- If possible, do not use the lift system, as the lift

limit is deactivated. The lift mechanism could

move too far and be damaged;

- If absolutely necessary, carefully lower the

Logic: lift system limit

No positive signal at 7B38.1 - 7B38.4 during lifting or

platform manually. Note that lowering must end

_

1

24

7

Operation

as soon as the shuttle can move freely

switch faulty.

lowering.

underneath the pallets;

- Check limit switches 7B38.1–7B38.4; check

signal feedback at inputs R3–R6 of the main

controller 8U37;

- Check the wiring;

Integrated lift stroke is greater than 1.5x the set free lift

- Check free-lift sensor (position, contamination);

Lift stroke greater than 1.5x

height, however sensor indicates free lift.

- Check free-lift height setting (JUDIT);

_

1

24

8

Operation

free lift, however mast lift

When the event occurs, the master assumes that the

- Check pump drive (e.g. worn pump?);

has not been detected

truck is in the mast lift stage.

Event is reset when mast lift is detected.

- Check wiring with multimeter;

Signal on load sensing

During operation combinations 0/0 and 1/1 trigger the

- Check sensor system with multimeter;

_

1

25

1

Operation

event message. The event message can only be reset

- Check computer component inputs;

inputs is implausible

by resetting the truck. The activation limit is 2000 msec.

- Repair faulty components and replace if

necessary;

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

23

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

Plausibility test: If the weight display > 300 kg the load

- Check wiring with multimeter;

- Check sensor system with multimeter;

No load sensing signal when

sensors must be applied. The event message can only

_

1

25

2

Operation

- Check computer component inputs;

weight > 300 kg

be reset by resetting the truck. The activation limit is

- Repair faulty components and replace if

2000 msec.

necessary;

Feedback from a main

Feedback from a main contactor contact or the

- Check wiring with multimeter;

contactor contact or the

- Check computer component inputs;

emergency stop relay although the Emergency

emergency stop relay

- Repair faulty components and replace if

_

1

26

1

Operation

Disconnect switch is not activated. The event message

although the Emergency

necessary;

can only be reset by resetting the truck. The activation

Disconnect switch is not

limit is 100 msec.

activated.

Feedback from the

- Check wiring with multimeter;

Emergency Disconnect

Feedback from the Emergency Disconnect switch at

- Check computer component inputs;

switch at channel 1 of the

channel 1 of the Safe computer although the Emergency

- Repair faulty components and replace if

_

1

26

2

Operation

Safe computer although the

Disconnect switch has not been activated. The event

necessary;

Emergency Disconnect

message can only be reset by resetting the truck. The

switch has not been

activation limit is 100 msec.

activated

Feedback from the main

Feedback from the main contactor level 1 control at

- Check wiring with multimeter;

contactor level 1 control at

- Check computer component inputs;

channel 1 of the Safe computer although contactor level

channel 1 of the Safe

- Repair faulty components and replace if

_

1

26

3

Operation

1 has not been activated. The event message can only

computer although contactor

necessary;

be reset by resetting the truck. The activation limit is

level 1 has not been

100 msec.

activated.

Feedback from the main

Feedback from the main contactor level 2 control at

- Check wiring with multimeter;

contactor level 2 control at

- Check computer component inputs;

channel 1 of the Safe computer although contactor level

channel 1 of the Safe

- Repair faulty components and replace if

_

1

26

4

Operation

1 has not been activated. The event message can only

computer although contactor

necessary;

be reset by resetting the truck. The activation limit is

level 1 has not been

100 msec.

activated.

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

24

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

Feedback from the

- Check wiring with multimeter;

Emergency Disconnect

Feedback from the Emergency Disconnect switch at

- Check computer component inputs;

switch at channel 2 of the

channel 2 of the Safe computer although the Emergency

- Repair faulty components and replace if

_

1

26

5

Operation

Safe computer although the

Disconnect switch has not been activated. The event

necessary;

Emergency Disconnect

message can only be reset by resetting the truck. The

switch has not been

activation limit is 100 msec.

activated

Feedback from the main

Feedback from the main contactor level 1 control at

- Check wiring with multimeter;

contactor level 1 control at

- Check computer component inputs;

channel 2 of the Safe computer although contactor level

channel 2 of the Safe

- Repair faulty components and replace if

_

1

26

6

Operation

1 has not been activated. The event message can only

computer although contactor

necessary;

be reset by resetting the truck. The activation limit is

level 1 has not been

200 msec.

activated.

No feedback from the

- Check wiring with multimeter;

Emergency Disconnect

No feedback from the Emergency Disconnect switch at

- Check computer component inputs;

_

1

26

7

Operation

switch at channel 1/2 of the

channel 1/2 of the Safe computer, although activated

- Repair faulty components and replace if

Safe computer although the

The event message can only be reset by resetting the

necessary;

Emergency Disconnect

truck. The activation limit is 200 msec.

switch has been activated

No feedback from relay K1

No feedback from relay K1 although the Safe computer

- Check wiring with multimeter;

has been activated. The event message can only be

- Check computer component inputs;

_

1

26

8

Operation

despite Safe computer

reset by resetting the truck. The activation limit is

- Repair faulty components and replace if

activation

200 msec.

necessary;

No feedback from relay K2

No feedback from relay K2 although the Safe computer

- Check wiring with multimeter;

has been activated. The event message can only be

- Check computer component inputs;

_

1

26

9

Operation

despite Safe computer

reset by resetting the truck. The activation limit is

- Repair faulty components and replace if

activation

200 msec.

necessary;

No feedback from relay K3

No feedback from relay K3 although the Safe computer

- Check wiring with multimeter;

has been activated. The event message can only be

- Check computer component inputs;

_

1

26

10

Operation

despite Safe computer

reset by resetting the truck. The activation limit is

- Repair faulty components and replace if

activation

200 msec.

necessary;

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

25

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

No feedback from relay K4

No feedback from relay K4 although the Safe computer

- Check wiring with multimeter;

has been activated. The event message can only be

- Check computer component inputs;

_

1

26

11

Operation

despite Safe computer

reset by resetting the truck. The activation limit is

- Repair faulty components and replace if

activation

200 msec.

necessary;

No feedback from main

No feedback from main contactor 1 although the Safe

- Check wiring with multimeter;

computer has been activated. The event message can

- Check computer component inputs;

_

1

26

12

Operation

contactor 1 despite "main

only be reset by resetting the truck. The activation limit is

- Repair faulty components and replace if

contactor 1" signal activation

200 msec.

necessary;

No feedback from main

No feedback from main contactor 2 although the Safe

- Check wiring with multimeter;

computer has been activated. The event message can

- Check computer component inputs;

_

1

26

13

Operation

contactor 2 despite "main

only be reset by resetting the truck. The activation limit is

- Repair faulty components and replace if

contactor 2" signal activation

200 msec.

necessary;

Test routine for emergency

Power up test for emergency stop circuit by the Safe

- Check wiring with multimeter;

computer has failed The event message can only be

- Check computer component inputs;

_

1

26

14

System start

stop circuit by the Safe

reset by resetting the truck. The activation limit is

- Repair faulty components and replace if

computer has failed

20 msec.

necessary;

Different input statuses

Redundant controllers of the Safe computer have

- Check wiring with multimeter;

detected different input statuses. The event message

- Check computer component inputs;

_

1

26

15

Operation

between the two Safe

can only be reset by resetting the truck. The activation

- Repair faulty components and replace if

computers

limit is 100 msec.

necessary;

Comparison of channel A /

- Check information in the truck display;

_

1

26

16

System start

channel B of external

The error is triggered for the combination 1/0 or 0/1.

- Assess wiring;

Emergency Disconnect of

Activation limit 100 ms.

- Check CAN-Bus;

APM + PLC for diversity

Monitoring of APM+

The Emergency Stop request is withdrawn via the

- Check information in the truck display;

Emergency Stop cancel

- Assess wiring;

_

1

26

17

System start

CanBus, however there is no corresponding Emergency

request and the

- Check CAN-Bus;

Disconnect feedback.

power supply.

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

26

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

Monitoring of APM+

The Emergency Stop request is set via the CanBus,

- Check information in the truck display;

Emergency Stop cancel

- Assess wiring;

_

1

26

18

System start

however there is no corresponding Emergency

request and the

- Check CAN-Bus;

Disconnect feedback.

power supply.

Main Lift lowers without

Main Lift stage has lost height without request. The

- Check mast mechanics;

_

1

27

1

Operation

event message appears as soon as the lift height lowers

- Check mast hydraulics;

activation signal

by more than 50 mm without request.

_

1

28

1

Operation

Main lift: free lift has lowered

The free lift stage has moved hydraulically although the

- Check mast mechanics;

before proportional lift

proportional lift stage was not fully retracted.

- Check mast hydraulics;

_

1

28

2

Operation

Main lift: proportional lift has

The proportional lift stage has moved hydraulically

- Check mast mechanics;

lowered before free lift

although the free lift stage was not fully retracted.

- Check mast hydraulics;

_

1

29

1

Operation

Main lift: Permissible

The permissible lowering speed has been exceeded.

- Check mast mechanics;

lowering speed exceeded

- Check mast hydraulics;

_

1

29

2

Operation

Aux. lift: Permissible

The permissible lowering speed has been exceeded.

- Compare actual speed with data sheet values;

lowering speed exceeded

- If it is too high, adjust to data sheet value;

- Compare the actual sideshift speed with the

_

1

29

3

Operation

Sideshift: Permissible speed

The permissible sideshift speed has been exceeded.

data sheet values;

exceeded

- If the sideshift speed has been exceeded, set it

to the data sheet values;

- Compare the actual rotating speed with the data

_

1

29

4

Operation

Rotate: Permissible speed

The permissible rotating speed has been exceeded.

sheet values;

exceeded

- If the rotating speed has been exceeded, set it

to the data sheet values;

Main lift does not reach pre-

- Check the pre-tension torque with JUDIT and

The pre-tension moment could not be established in the

adjust if necessary;

_

1

30

1

Operation

tension moment in

set time.

- Check mechanical system of the mast;

prescribed time

- Check mast hydraulics;

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

27

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

Aux. lift does not reach pre-

- Check the pre-tension torque with JUDIT and

The pre-tension moment could not be established in the

adjust if necessary;

_

1

30

2

Operation

tension moment in

set time.

- Check mechanical system of the mast;

prescribed time

- Check mast hydraulics;

Pallet clamp does not reach

- Check the hydraulic setpoint and adjust if

The pallet clamp "CLOSED" end position could not be

necessary;

_

1

30

3

Operation

the "CLOSED" end position

reached in the set time.

- Check the pallet clamp mechanisms for

in the prescribed time

sluggishness;

Pallet clamp does not reach

- Check the hydraulic setpoint and adjust if

The pallet clamp "OPEN" end position could not be

necessary;

_

1

30

4

Operation

the "OPEN" end position in

reached in the set time.

- Check the pallet clamp mechanisms for

the prescribed time

sluggishness;

Emergency stop circuit

CAN-BUS status damaged during booting. The event

- Check wiring with multimeter;

power-up test: Emergency

- Check computer component inputs;

_

1

31

1

System start

message can only be reset by an Emergency Stop reset.

Stop switch activated, but

- Repair faulty components and replace if

The activation limit is 1000 msec.

CAN-BUS not OK

necessary;

Emergency stop circuit

No pulse contact controller has reported charge circuit

- Check the charging voltage on the controllers;

_

1

31

2

System start

power-up test: no activation

activation. The charging of the pulse contact controllers

- Check wiring;

of any pulse contact

must be finished within 10 seconds. The activation limit

controllers

is 1000 msec.

Emergency stop circuit

The hydraulic controller has not reported charge circuit

- Check the charging voltage on the controllers;

activation. The charging of the pulse contact controllers

- Check wiring;

_

1

31

3

System start

power-up test: no lift

must be finished within 10 seconds. The activation limit

controller activation

is 1000 msec.

Emergency stop circuit

The traction controller has not reported load circuit

- Check the charging voltage on the controllers;

activation. The charging of the pulse contact controllers

- Check wiring;

_

1

31

4

System start

power-up test: no traction

must be finished within 10 seconds. The activation limit

controller activation

is 1000 msec.

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

28

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

Emergency stop circuit

The steering controller has not reported load circuit

- Check the charging voltage on the controllers;

activation. The charging of the pulse contact controllers

- Check wiring;

_

1

31

5

System start

power-up test: no steering

must be finished within 10 seconds. The activation limit

controller activation

is 1000 msec.

Emergency stop circuit

Feedback contact of second main contactor level not

- Check the charging voltage on the controllers;

_

1

31

6

System start

power-up test: no release of

closed within 10 seconds. The activation limit is

- Check wiring;

main contactor level 2

1000 msec.

Emergency stop circuit

Other non-separated event message in main contactor

Z

The event message should not

occur.

_

1

31

7

System start

power-up test: non-defined

circuit. This event message does not occur in normal

Otherwise contact troubleshooting specialists;

EMERGENCY STOP error

operation. The activation limit is 1000 msec.

Charge

- Check power cables (main current connections,

The AC-3 Power Control (U8) has been activated while

integrated charging circuit wiring,...);

its internal capacitors were charging.

- Check main current fuses and replace if

The main contactor was opened during active control.

necessary;

Power circuit activated during charging. The activation

- Replace AC-3 Power Control interface card;

limit is 20 msec.

power circuit activated

The main contactor was disconnected during active

_

1

32

1

System start

control;

during charging

The control system was activated before the main

contactor was closed and the internal capacitors were

charged;

Installation of the AC-3 Power Control component is

damaged;

AC-3 Power Control component (voltage measurement)

is damaged;

Capacitor pre-charge cannot

The capacitor voltage should reduce by at least 1 V

- Replace controller;

_

1

32

2

Self test

within 750 msec. of the pre-charge circuit being switched

be switched off

off.

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

29

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

- Check battery voltage;

Capacitor pre-charge

- Check key switch voltage;

The condition (V-key - V-cap.) < limit voltage is not met

- Check controller power connections for short

_

1

32

3

Self test

(output stage pre-charge)

within a fixed time after activating the pre-charge circuit.

circuits;

not complete

- Check harness for short circuit;

- Replace component;

Ground system track 1 left

- Check wiring with multimeter;

- Check sensor system with multimeter;

actual value sensor system:

Switch status of ground sensors unequal. The activation

_

1

33

1

Operation

- Check computer component inputs;

invalid channel A / channel

limit is 20 msec.

- Repair faulty components and replace

B value relationship

if necessary;

Ground system track 2 left

- Check wiring with multimeter;

- Check sensor system with multimeter;

actual value sensor system:

Switch status of ground sensors unequal. The activation

_

1

33

2

Operation

- Check computer component inputs;

invalid channel A / channel

limit is 20 msec.

- Repair faulty components and replace

B value relationship

if necessary;

Ground system track 3 left

- Check wiring with multimeter;

- Check sensor system with multimeter;

actual value sensor system:

Switch status of ground sensors unequal. The activation

_

1

33

3

Operation

- Check computer component inputs;

invalid channel A / channel

limit is 20 msec.

- Repair faulty components and replace if

B value relationship

necessary;

Ground system track 1 right

- Check wiring with multimeter;

- Check sensor system with multimeter;

actual value sensor system:

Switch status of ground sensors unequal. The activation

_

1

33

4

Operation

- Check computer component inputs;

invalid channel A / channel

limit is 20 msec.

- Repair faulty components and replace if

B value relationship

necessary;

Ground system track 2 right

- Check wiring with multimeter;

- Check sensor system with multimeter;

actual value sensor system:

Switch status of ground sensors unequal. The activation

_

1

33

5

Operation

- Check computer component inputs;

invalid channel A / channel

limit is 20 msec.

- Repair faulty components and replace if

B value relationship

necessary;

https://www.truck-manuals.net/

õUNGHEINRICH

Event Messages

03.15

30

G

F

E

XX

S

Operational

Description

Cause / Triggering Event

Action

Status

Ground system track 3 right

- Check wiring with multimeter;

- Check sensor system with multimeter;

actual value sensor system:

Switch status of ground sensors unequal. The activation

_

1

33

6

Operation

- Check computer component inputs;

invalid channel A / channel

limit is 20 msec.

- Repair faulty components and replace if

B value relationship

necessary;

Brake force governor: invalid

Analog sensor value relationship deviates by more than

- Check sensor wiring;

_

1

34

1

Operation

channel A / channel B value

- Measure sensor signals with multimeter;

2.5°. The activation limit is 100 msec.

relationship

- Replace sensor;

Traverse sensor system:

Analog sensor value relationship deviates by more than

- Check sensor wiring;

_

1

34

3

Operation

invalid channel A / channel

- Measure sensor signals with multimeter;

2.5°. The activation limit is 100 msec.

B value relationship

- Replace sensor;

Rotate sensor system:

Analog sensor value relationship deviates by more than

- Check sensor wiring;

_

1

34

5

Operation

invalid channel A / channel

- Measure sensor signals with multimeter;

2.5°. The activation limit is 100 msec.

B value relationship

- Replace sensor;

Left hand support

- Check sensor wiring;

_

1

34

7

Operation

mushroom: invalid channel

Analog sensor value relationship deviates by more than

- Measure sensor signals with multimeter;

A / channel B value

2.5°. The activation limit is 100 msec.

- Replace sensor;

relationship

Right hand support

- Check sensor wiring;

_

1

34

9

Operation

mushroom: invalid channel

Analog sensor value relationship deviates by more than

- Measure sensor signals with multimeter;

A / channel B value

2.5°. The activation limit is 100 msec.

- Replace sensor;

relationship

Steering actual value sensor

Analog sensor value relationship deviates by more than

- Check sensor wiring;

_

1

34

11

Operation

systems: invalid channel A /

- Measure sensor signals with multimeter;

2.5°. The activation limit is 100 msec.

channel B value relationship

- Replace sensor;

Steering setpoint device:

Analog sensor value relationship deviates by more than

- Check sensor wiring;

_

1

34

13

Operation

invalid channel A / channel

- Measure sensor signals with multimeter;

2.5°. The activation limit is 100 msec.

B value relationship

- Replace sensor;

https://www.truck-manuals.net/