BP 249

44158 ANCENIS CEDEX - FRANCE

TEL : 33 (0)2 40 09 10 11

YOUR DEALER

REF : 547957 EN (11 / 12 / 2007)

ME 425
ME 430

REPAIR MANUAL
1st DATE OF ISSUE 11 / 12 / 2007

DATE OF ISSUE OBSERVATION

11 / 12 / 2007 - 1st ISSUE

THE TEXTS AND PICTURES IN THIS DOCUMENT CANNOT BE REPRODUCED EITHER TOTALLY OR PARTLY.
 CONTENTS
Groups Chapters

-0- - General -

0-1-M133 EN Lift truck characteristics

- 20 - - Transmission -

20-03-M133 EN Transmission components position

20-04-M133 EN Transmission control and adjusting
20-06-M133 EN Transmission removal
20-08-M133 EN Transmission troubleshooting

- 30 - - Axle -

30-03-M133 EN Axle components position

30-04-M133 EN Axle control and adjusting
30-05-M133 EN Axle components diagrams and sections

- 40- - Brake system -

40-01-M133 EN Brake system characteristics and specifications

40-03-M133 EN Brake system components position
40-04-M133 EN Brake system control and adjusting
40-08-M133 EN Brake system troubleshooting

- 60 - - Mast -

60-06-M133 EN Mast removal

60-08-M133 EN Mast troubleshouting

- 70 - - Hydraulic -

70-01-M133 EN Hydraulic characteristics and specifications

70-04-M133 EN Hydraulic control and adjusting
70-6-M133 EN Hydraulic diagrams
70-08-M133 EN Hydaulic troubleshooting

- 80 - - Electric -

80-01-M133 EN Electric characteristics and specifications

80-03-M133 EN Electric components position
80-04-M133 EN Electric control and adjusting
80-6-261248 EN Electric diagrams
80-08-M133 EN Electric troubleshooting
 00
GENERAL

20
TRANSMISSION

30
AXLE

40
BRAKE SYSTEM

60
MAST

70
HYDRAULIC

80
ELECTRIC
 00
GENERAL

- LIFT TRUCK CHARACTERISTICS

 00
LIFT TRUCK CHARACTERISTICS

0-1-M133EN (05/11/2007)
 2
Lift truck characteristics
00
00

CHARACTERISTICS

BATTERY

COMPARTMENT DIMENSIONS (MM) WEIGHT OF

BATTERY TYPE BATTERY
BATTERY +
CAPACITY
a b c d h1 h2 h3 COMPARTMENT
STANDARD 48V-320A-700Ah 1154 kg
EXIDE FULMEN
HIGH CAPACITY 48V-320A-775Ah 1174 kg
STANDARD 48V-320A-700Ah 1155 kg
HOPPECKE
HIGH CAPACITY 48V-320A-775Ah 1155 kg
ME 425 570 1028 280 4 580 400 780
STANDARD 48V-320A-700Ah 1160 kg
MIDAC
HIGH CAPACITY 48V-320A-775Ah 1207 kg
STANDARD 48V-320A-700Ah 1162 kg
HAWKER
HIGH CAPACITY 48V-320A-775Ah 1187 kg
STANDARD 80V-320A-500Ah 1284 kg
EXIDE FULMEN
HIGH CAPACITY 80V-320A-560Ah 1528 kg
STANDARD 80V-320A-560Ah 1483 kg
HOPPECKE
HIGH CAPACITY 80V-320A-620Ah 1483 kg
ME 430 710 1028 296 4 580 400 780
STANDARD 80V-320A-560Ah 1580 kg
MIDAC
HIGH CAPACITY 80V-320A-620Ah 1607 kg
STANDARD 80V-320A-560Ah 1480 kg
HAWKER
HIGH CAPACITY 80V-320A-620Ah 1572 kg
c

h3

h2
a

h1

(05/11/2007) 0-1-M133 EN
 3
Lift truck characteristics

00
TRANSMISSION ELECTRIC MOTOR

- Type DANAHER
- Number 1
- Control By electronic speed controller
- Rated power
ME 425 10,5 kW
ME 430 10,6 kW
- Rated current 181 A
- Rated voltage V
- Rated speed rpm

TRANSMISSION
- Type HDCS20
ShaoXing Qian Jin Chi Lun Xiang.

TRANSMISSION (CONTROL)
- Type ZAPI
- Reversing gear Electronic
. Number of forward speeds 1
. Number of reverse speeds 1
- Speed limiter (slow/fast) Electric

BRAKE
- Service brake Foot pedal. Hydraulic brake, applied on the front wheels.
. Type Drum.
- Parking brake Mechanical hand lever applied on the front wheels.
. Type Drum.

HYDRAULIC PUMP ELECTRIC MOTOR

- Type DANAHER
- Rated power
ME 425 11 kw
ME 430 12,8 kw
- Rated current A
- Rated voltage 48 V
- Rated speed 1774 rpm
- Max. speed rpm

0-1-M133EN (05/11/2007)
 4
Lift truck characteristics
00
00

CHARACTERISTICS ME 425

FRONT TYRES

PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE

DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
23 X 9 - 10 FRONT UNLADEN KG KG/CM2 CM2
SOLID
EUROSOFT W.P. FRONT LADEN KG KG/CM2 CM2

CAUTION : Drive wheeel tighten torque : 441 - 558 Nm

REAR TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
18 X 7 - 8 FRONT UNLADEN KG KG/CM2 CM2
SOLID
EUROSOFT W.P. FRONT LADEN KG KG/CM2 CM2

CAUTION :Rear wheel tighten torque : 157 - 176 Nm

HYDRAULIC CIRCUIT

- Type of pump Gear pump

. Capacity cm3
. Flow rate at full speed L/mn
- Pressure
. Lifting, tilting, attachment circuit Bar
. Steering circuit Bar
- Filtration
. Return μm
. Suction μm

(05/11/2007) 0-1-M133 EN
 5
Lift truck characteristics

00
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)

- Level of sound power in the LwA environment dB

(according to directive 2000/14 CE guaranteed)

- Speed of movement of lift truck in standard configuration on horizontal

ground
(except particular conditions)
. Forward unladen 14 km/h
. Reverse unladen 14 km/h

- Standard lift height 3300 mm

- Rated capacity with standard mast 2500 kg

- Load center 500 mm

- Weight of forks (each) 44,5 kg

- Lifting motions with standard mast

. Unladen lifting 0,24 m/s
. Rated load lifting 0,24 m/s
. Unladen lowering 0,36 m/s
. Rated load lowering 0,44 m/s

- Lift truck weight with standard mast

. Unladen 4285 kg
. Rated load 6785 kg

- Axle weight with standard mast (transport position)

. Front unladen kg
rated load kg
. Rear unladen kg
rated load kg

- Tensible strain at coupling hook

. Unladen 1150 daN
. Rated load 1110 daN

0-1-M133EN (05/11/2007)
 6
Lift truck characteristics
00
00

CHARACTERISTICS ME 430

FRONT TYRES

PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE

DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
23 X 9 - 10 FRONT UNLADEN KG KG/CM2 CM2
SOLID
EUROSOFT W.P. FRONT LADEN KG KG/CM2 CM2

CAUTION : Drive wheeel tighten torque : 441 - 558 Nm

REAR TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
18 X 7 - 8 AFRONT UNLADEN KG KG/CM2 CM2
SOLID
EUROSOFT W.P. FRONT LADEN KG KG/CM2 CM2

CAUTION :Rear wheel tighten torque : 157 - 176 Nm

HYDRAULIC CIRCUIT

- Type of pump Gear pump

. Capacity cm3
. Flow rate at full speed L/mn
- Pressure
. Lifting, tilting, attachment circuit Bar
. Steering circuit Bar
- Filtration
. Return μm
. Suction μm

(05/11/2007) 0-1-M133 EN
 7
Lift truck characteristics

00
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)

- Level of sound power in the LwA environment dB

(according to directive 2000/14 CE guaranteed)

- Speed of movement of lift truck in standard configuration on horizontal

ground
(except particular conditions)
. Forward unladen 14 km/h
. Reverse unladen 14 km/h

- Standard lift height 3300 mm

- Rated capacity with standard mast 3000 kg

- Load center 500 mm

- Weight of forks (each) 71 kg

- Lifting motions with standard mast

. Unladen lifting 0,4 m/s
. Rated load lifting 0,25 m/s
. Unladen lowering m/s
. Rated load lowering m/s

- Lift truck weight with standard mast

. Unladen 5400 kg
. Rated load 8400 kg

- Axle weight with standard mast (transport position)

. Front unladen kg
rated load kg
. Rear unladen kg
rated load kg

- Tensible strain at coupling hook

. Unladen daN
. Rated load daN

0-1-M133EN (05/11/2007)
 8
Lift truck characteristics
00
00

CHARACTERISTICS OF MASTS ME 425

DOUBLE MAST WITH ALL-ROUND VISION

MAST h3 α β h2 h1 h4
2m50 2500 5° 10° 140 1786 3556
2m70 2700 5° 10° 140 1886 3756
3m00 3000 5° 10° 140 2006 4056
3m30 3300 5° 10° 140 2186 4356
3m50 3500 5° 10° 140 2286 4556
3m60 3600 5° 10° 140 2336 4656
4m00 4000 5° 6/10° 140 2586 5056
4m30 4300 5° 6° 140 2751 5356
4m50 4500 5° 6° 140 2861 5556

DOUBLE MAST WITH TOTAL FREE-ACTING LIFT

MAST h3 α β h2 h1 h4 h4*
2m50 2500 5° 10° 3556 3185
2m70 2700 5° 10° 3756 3385
3m00 3000 5° 10° 1966 4056 3685
3m30 3300 5° 10° 4356 3985
3m60 3600 5° 10°
4m00 4000 5° 6/10°

TRIPLE MAST WITH TOTAL FREE-ACTING LIFT

MAST h3 α β h2 h1 h4 h4*
4m30 4300 5° 6° 1267 1976 5356 5019
4m50 4500 5° 6° 1387 2096 5556 5219
4m80 4800 5° 6° 1487 2196 5856 5519
5m00 5000 5/3° 6° 1552 2261 6056 5719
5m50 5500 3° 6° 1717 2426 6556 6219
6m00 6000 3° 6° 1932 2641 7056 6719

h3 : Lift height in mm
α : Forward tilting
β : Backward tilting
h2 : Free-acting lift in mm
h1 : Overall height with folded mast in mm
h4 : Overall height with spreaded out mast in mm with load back rest
h4* : Overall height with spreaded out mast in mm with without load back rest

(05/11/2007) 0-1-M133 EN
 9
Lift truck characteristics

00
CHARACTERISTICS OF MASTS ME 430

DOUBLE MAST WITH ALL-ROUND VISION

MAST h3 α β h2 h1 h4
2m50 2500 5° 10° 145 1786 3652
2m70 2700 5° 10° 145 1886 3852
3m00 3000 5° 10° 145 2036 4152
3m30 3300 5° 10° 145 2186 4452
3m50 3500 5° 10° 145 2286 4652
3m60 3600 5° 10° 145 2336 4752
4m00 4000 5° 6/10° 145 2586 5152
4m30 4300 5° 6° 145 2751 5452
4m50 4500 5° 6° 145 2861 5652
4m80 4800 5° 6° 145 3026 5952
5m00 5000 5/3° 6° 145 3136 6152

DOUBLE MAST WITH TOTAL FREE-ACTING LIFT

MAST h3 α β h2 h1 h4 h4*
2m50 2500 5° 10° 1089 1826 3652 3247
2m70 2700 5° 10° 1189 1926 3852 3447
3m00 3000 5° 10° 1299 2036 4152 3747
3m30 3300 5° 10° 1449 2186 4452 4047

TRIPLE MAST WITH TOTAL FREE-ACTING LIFT

MAST h3 α β h2 h1 h4 h4*
4m30 4300 5° 6° 1268 2041 5452 5083
4m50 4500 5° 6° 1348 2121 5652 5283
4m80 4800 5° 6° 1448 2221 5952 5583
5m00 5000 5/3° 6° 1514 2287 6152 5783
5m50 5500 3° 6° 1878 2451 6652 6283
6m00 6000 3° 6° 1844 2617 7152 6783

h3 : Lift height in mm
α : Forward tilting
β : Backward tilting
h2 : Free-acting lift in mm
h1 : Overall height with folded mast in mm
h4 : Overall height with spreaded out mast in mm with load back rest
h4* : Overall height with spreaded out mast in mm with without load back rest

0-1-M133EN (05/11/2007)
 10
Lift truck characteristics
00
00

DIMENSIONS AND LOAD CHART ME 425

(WITH STANDARD MAST)

Ast 4010 mm
b1 1265 mm
b3 1060 mm
b10 1058 mm
b11 960 mm
c 500 mm
e 130 mm
h1 2186 mm
h2 140 mm
h3 3300 mm
h4 4356 mm
h6 2165 mm
h10 250 mm
l 1070 mm
l1 3395 mm
l2 2325 mm
m1 98 mm
m2 120 mm
Q 2500 kg
s 40 mm
Wa 2090 mm
x 455 mm
y 1485 mm
α 5 °
β 10 °

CAPACITE NOMINALE
RATED CAPACITY
RATED CAPACITY NENNKAPAZITÄT
CAPACIDAD NOMINAL 2500 kg
CAPACITÀ NOMINALE

CAPACITES EFFECTIVES
ACTUAL CAPACITIES ACTUAL CAPACITIES
EFFEKTIVE KAPAZITÄT SUIVANT NORME EN 1726-1 (ISO 1074)
CAPACIDAD EFECTIVA
(according to standard EN 1726-1) CAPACITÀ EFFETTIVA

1- Jusqu'à hauteur de levée

Up to height of

1 - Up to height of Bis zur hubhöhe

Hasta altura de elevación
- mm
Sino ad altezza di sollevamento
2- Pour hauteur maximale de
For maximum height of

2 - For maximum height of Für maximale Höhe

Para altura máxima de
3300 mm
Per altezza massima di

MAT VERTICAL
VERTICAL MAST
- -
VERTIKALER MAST
1 -
VERTICAL MAST MASTIL VERTICAL
RAMPA VERTICALE 2500 2260
Q : kg 2 1535

D
D : mm
500 600 1100

EQUIPEMENT
-
ATTACHMENT -
ZUBEHÖR
ATTACHMENT EQUIPO
ATTREZZATURA
-
-
CAPACITES EFFECTIVES
ACTUAL CAPACITIES
- -
EFFEKTIVE KAPAZITÄT 1 -
ACTUAL CAPACITIES CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA - -
2 -
n°: 258205

(05/11/2007) 0-1-M133 EN
 11
Lift truck characteristics

00
DIMENSIONS AND LOAD CHART ME 430
(WITH STANDARD MAST)

Ast 4170 mm
b1 1260 mm
b3 1060 mm
b10 1058 mm
b11 960 mm
c 500 mm
e 130 mm
h1 2186 mm
h2 145 mm
h3 3300 mm
h4 4452 mm
h6 2165 mm
h10 255 mm
l 1070 mm
l1 3560 mm
l2 2490 mm
m1 102 mm
m2 125 mm
Q 3000 kg
s 45 mm
Wa 2230 mm
x 475 mm
y 1625 mm
α 5 °
β 10 °

CAPACITE NOMINALE
RATED CAPACITY
RATED CAPACITY NENNKAPAZITÄT
CAPACIDAD NOMINAL 3000 kg
CAPACITÀ NOMINALE

CAPACITES EFFECTIVES
ACTUAL CAPACITIES ACTUAL CAPACITIES
EFFEKTIVE KAPAZITÄT SUIVANT NORME EN 1726-1 (ISO 1074)
(according to standard EN 1726-1) CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA

1- Jusqu'à hauteur de levée

Up to height of
1 - Up to height of Bis zur hubhöhe
Hasta altura de elevación
- mm
Sino ad altezza di sollevamento
2- Pour hauteur maximale de
For maximum height of
2 - For maximum height of Für maximale Höhe
Para altura máxima de
3300 mm
Per altezza massima di

MAT VERTICAL
VERTICAL MAST
- -
VERTICAL MAST VERTIKALER MAST
1 -
MASTIL VERTICAL
RAMPA VERTICALE 3000 2720
Q : kg 2 1857

D
D : mm
500 600 1100

EQUIPEMENT
-
ATTACHMENT -
ATTACHMENT ZUBEHÖR
EQUIPO -
ATTREZZATURA
-
CAPACITES EFFECTIVES
ACTUAL CAPACITIES
- -
ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT 1 -
CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA - -
2 -
n°: 258214

0-1-M133EN (05/11/2007)
 12
Lift truck characteristics
00
00

FILTER ELEMENTS

HYDRAULI
HYDRAULIC RETURN OIL FILTER
Part number: 824074
Change: 1000 H

SUCTION STRAINER FOR HYDRAULIC OIL TANK

Part number: 824571
Clean: 1000 H

(05/11/2007) 0-1-M133 EN
 13
Lift truck characteristics

00
LUBRICANTS

USE LUBRICANTS.
- For topping up, oils may not be miscible.
- For oil changes, MANITOU oils are perfectly appropriate.

DIAGNOSTIC ANALYSIS OF OILS

If a service or maintenance contract has been organized with the dealer, a diagnostic analysis of engine, transmission and axle
oils may be requested depending on the rate of use.

TRANSMISSION
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBER
1 L. 62148
MANITOU Oil 20 L. 546332
TRANSMISSION Liter
Mechanical transmission 55 L. 546217
209 L. 546195

MAST
ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBER
MANITOU Lubricant
MAST LIFTING CHAINS 400 Ml. 554271
Chain special (aerosol)
400 g. 545996
MANITOU Grease
GREASING OF THE MAST 1 Kg. 161590
Multipurpose NLGI 2
50 Kg. 499235

HYDRAULIC
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBER
5 L. 545500
HYDRAULIC OIL TANK
MANITOU Oil 20 L. 582297
ME 425 25 Liters
Hydraulic ISO 46 55 L. 546108
ME 430 30 Liters
209 L. 546109

BRAKE
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBER
0,5 L. 473013
MANITOU fluid 1 L. 473014
BRAKE CIRCUIT 1,5 Liters
DOT 4 brake fluid 5 L. 486363
30 L. 486364

REAR AXLE
ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBER
400 g. 161589
1 Kg. 554973
SWIVEL PINS MANITOU Grease
5 Kg. 554974
STEERING CONNECTING ROD Multipurpose HD NLGI 2
20 Kg. 499233
50 Kg. 489670

0-1-M133EN (05/11/2007)
 14
Lift truck characteristics
00
00

(05/11/2007) 0-1-M133 EN
 TRANSMISSION

- TRANSMISSION COMPONENTS POSITION

20
- TRANSMISSION CONTROLE AND
ADJUSTING

- TRANSMISSION REMOVAL

- TRANSMISSION TROUBLESHOOTING
 20
TRANSMISSION COMPONENTS POSITION

20-03-M133 EN (03/12/2007)
 2
Transmission components position

Transmission gear box Parts

4
5
9 41
6 9 1
7
38 23
20

37 18
14 17
18
34
28 12 13
33 33 23 12
31 32 35
12
14
26 32 11
40 36
30 31 27 15
30 8 7
29 10
2 32 24 22
3 33 16
32 34 19
33 22 21
20
2
39

25
FRONT OF
THE MACHINE

1 Transmission gear box house 21 Bolt M12x1.25x100

2 Cap, bearing 22 Washer 12
3 Bolt 23 Pin B10x28
4 Cap, bearing 24 Gearwheel
5 O ring 80x3.1 25 Bolt
6 Bolt M10x1.25x25 26 Nut M10x1.25
7 Washer 10 27 Case, cross R.H.
8 Gear, Counter 28 Case, cross L.H.
9 Bearing 6206 29 Gear shaft (I)
10 Bearing 6307 30 Gear, side
11 Gear, Counter 31 Washer
12 Bearing 6305 32 Gear, pinion
13 Shaft 33 Washer, thrust
14 O ring25x2.4 34 Bearing 6211
15 Board 35 Pin B6x28
16 Bolt M10x1.25x15 36 Gear shaft (II)
17 Pinion 37 Gasket
18 Bearing 6208 38 Pin B8x30
19 Cover 39 Lock washer
20 Bolt M12x1.25x55 40 Washer, locker

(03/12/2007) 20-03-M133 EN
 20
TRANSMISSION CONTROL AND ADJUSTING

20-04-M133 EN (25/10/2007)
 2
Transmission control and adjusting

Disassembly the transmission Gear Box - HDCS (20A)

1. Remove the Differential Carrier first. Use a screwdriver

knock the 4 washers to be a plate surface.
And loosen the 4 bolts as shown. Remove the differential
carrier as an assy’.
20

Bolt

Washer

2. Make a remark on the bearing supports each side.

When assembling the carrier, do not make the wrong side
for bearing support.
Otherwise, it may cause the differential carrier noisy.
Then remove the assy’ carefully, do not damage the
bearings.

3. Remove the anti-loosen gaskets and bolts.

4. Detach the Main gear and you can get the differential.

(25/10/2007) 20-04-M133 EN
 3
Transmission control and adjusting

5. Remove the 4 bolts as shown. And remove the bearing seat.

Be careful do not damage the O ring

on it.

20
6. Remove the 8 bolts which fixed on the gear box cover as shown.

7. Remove the 2 bolts of pin board and remove the main shaft of
the pinion.

Use a copper bar to knock the shaft out, be

careful not to damage the O ring on it.

8. Remove the cover of the gear box. Use a stick bar if necessary.

9. When remove the cover you can use a copper stick to knock the
bearing as shown.

10. To assemble the cover, scratch the old glue on the

surface and paint new glue on it.

11. Then you can inspect the bearings, shaft, pinions and
so on inner side.

Paint glue
on this
surface

12. To assemble, reverse the order of disassemble.

20-04-M133 EN (25/10/2007)
 4
Transmission control and adjusting
20

(25/10/2007) 20-04-M133 EN
 20
TRANSMISSION REMOVAL

20-06-M133 EN (25/10/2007)
 2
Transmission removal

CONTENTS

Transmission ..........................................................................................................3

Transmission type ...................................................................................................3

Remove Front Axle from chassis body ......................................................................3

20

Remove Drive Motor ................................................................................................5

Remove Drive Motor in the truck ..............................................................................6

Remove the Transmission Gear Box - HDCS20(A) ......................................................7

(25/10/2007) 20-06-M133 EN
 3
Transmission removal

Transmission
• 4 wheel forklift truck use one drive motor, axle with differential and “L” shape transmission. Offering outstanding
acceleration, climbing ability and traction power.
• E.g. CPD30JD1: Gradeability 20% (laden, S2 5 min); Max drawbar pull force 22000 N
(laden, S2 5 min).

Transmission type

20
• System solution for Battery lift trucks

• Axle with Differential and “L” shape transmission,

with one drive motor.

Remove Front Axle from chassis body

In most conditions, you do not need to remove the

transmission, front axle and drive motor assy’. Usually
you can only remove drive motor, or only remove the
transmission gear box, or only remove the parts of front
axle by itself. Here we will explain the step of remove the
assy’ as one part.

1. Stop the truck on a level ground, and cut off the power
of battery. Lifting down the mast make the fork lowered
to ground, and tilting mast forward to max. angle.

2. Disconnect the accelerator and horn connector and

then remove the front floor mat and front floor.
6-M20°1.5
3. Remove the tilting cylinder cover hood and cylinder
pivot pin of chassis body.

4. Put a tough wooden block under the chassis body until

the truck wheel leave ground.

5. Unscrew the 6 wheel nut.

20-06-M133 EN (25/10/2007)
 4
Transmission removal

6. Remove the drive wheel.

7. Unscrew the two bolt of mast half caps each side.

8. Remove the half caps of the mast.

9. Remove the pivot pin of the tilting cylinder to mast & oil
pipes then remove the cylinder away.
A
Caution: When remove the cylinder pin, hoist the mast
20

with a rope and take care of the mast, make sure do not
make the mast drop forward.

10. Remove the high pressure oil pipe from control valve
to mast. B

11. Hoist the mast and remove it.

12. Loosen the Bolt of overhead guard (A) and remove it.

13. Detach the instrument panel assy’ and steering

wheel.

14. Detach the Parking brake lever, Control valve levers

pin, bendy weld pipe of brake booster, universal joint and
remove all of them.

15. Loosen the front guard bolts (B & C)

and remove it as an assy’.

16. Loosen the fixed bolt (A) of Gear Box to chassis.

17. Loosen the fixed bolt (D) of the plate bracket to chassis C
and remove the plate bracket.

18. Hoist the ASSY’, use a rope.

Plate bracket
(25/10/2007) 20-06-M133 EN
 5
Transmission removal

19. Loosen the front axle fixed nut (C) of the chassis
carefully.
C
20. Detach the assy’ from upside and front side.

21. To assembly the assy’, reverse the order of

disassembly.

20
Remove Drive Motor

1. Loosen the 5 Bolts M14°1.5°155 (A), and remove the drive motor from the gear mounting surface.

2. Be careful not damage the O ring 95°3.1 on the slot of motor shaft. If damaged, replace a new one.

3. If it is hard to remove the motor, please rotate the wheel hub and use a wooden hammer to strike the motor
mounting surface.
Use a rope through the hoist hook of motor and lift the motor, move the motor horizontal as a assy’.

NOTICE:
Also you can detach the motor as an assy’ in the truck.
You need not to disassemble the motor like this step.
Refer as follow.
A
More details about SEM DC/AC motor refers to electrical system.

20-06-M133 EN (25/10/2007)
 6
Transmission removal

Remove Drive Motor in the truck

1. Loosen the connector and remove the high pressure

pipe (A & B) to control valve.

2. Unscrew the clamp bolt (C) and remove the clamp. B

20

3. Loosen the 5 Bolts M14°1.5°155 of motor-to-gearbox,

and remove the drive motor from the gear mounting
surface.

4. Be careful not damage the O ring 95°3.1 on the slot of C

motor shaft. If damaged replace a new one.
A B

5. If it is hard to remove the motor, please rotate the

wheel hub and use a wooden hammer to strike the motor
mounting surface.
Use a rope through the hoist hook of motor and lift the
motor, move the motor horizontal as a assy’.

6. Be careful not to scratch the axle right supporter of

chassis when remove the motor.

(25/10/2007) 20-06-M133 EN
 7
Transmission removal

Remove the Transmission Gear Box - HDCS20(A)

1. Unscrew the drain plug at the bottom of front axle house
and drain the waste oil.
Use a pail and collect the waste oil. Collect it and take care
of an adequate disposal in compliance with the disposal
regulations of your company.

20
2. Unscrew the half axle nut and remove the half axle
from the axle house. Be careful do not damage the axle
oil seal.

2.5~3.0t

3. Remove the mast assy’ if necessary.

4. Unscrew the 10-M10°35 Bolts as shown.

5. Use a rope surround the gear box, and hoist it upward,

until the front wheel axle rotate to about 20~30 degree upward. Then remove the gear box as an assy’.

6. Discard the gasket between gear box and front wheel axle house. Always use a new one. When assembly, lubricate
LOCTITE glue on the mounting surface.

Note:
Also you can disassembly the gear box and motor as an assy’ from the front axle.

20-06-M133 EN (25/10/2007)
 8
Transmission removal
20

(25/10/2007) 20-06-M133 EN
 20
TRANSMISSION TROUBLESHOOTING

20-08-M133 EN (25/10/2007)
 2
Transmission troubleshooting

Gear carrier failures can be classified as oil leakage, seizure, unusual noise, noisy operation, and damage, according
to phenomena. Shown below are the trouble phenomena, their possible causes, and remedies to be taken.

Trouble Probable cause Corrective action

Distinguish between oil staining and oil leakage, and locate the point of leak, then take
proper corrective action.

Worn, faulty, or improperly installed oil seal. Replace the oil seal.
20

Loose gear carrier mounting bolts. Retighten, or replace gasket.

Oil leakage Faulty gasket. Replace gasket.
Loose filler plug or drain plug. Retighten.
Clogged or faulty air breather. Replace or repair.
Faulty axle housing O ring. Replace.
Worn, faulty, or improperly installed axle shaft oil
Replace oil seal.
seal.

Replace any seized or damaged parts. Check related parts for condition.
Repair or replace them if necessary.

Seizure Bearing seizure. Replace

Too large preload. Disassemble and readjust.
Too small backlash. Disassemble and readjust.
Insufficient oil, or use of improper oil. Add or replace oil as specified.
Before disassembling the gear carrier, make sure that the noise is not being produced
in transmission or wheel bearing.

Unusually Noise Improper hypoid gear backlash. Readjust

When starting off of Improper differential gear backlash. Readjust
shifting gears.
Too small drive pinion bearing preload. Readjust
Pitted or worn gear tooth surface, or broken tooth. Replace
Insufficient oil, or use of improper oil. Add or replace oil as specified.
Abnormally worn or broken differential gear. Replace
Abnormally worn or broken thrust washer. Replace
Unusually Noise
Broken pinion mate shaft. Replace
When making a turn.
Seized or broken side bearing. Replace
Insufficient oil, or use of improper oil. Add or replace oil as specified.

Perform test carefully as gear noise is often mistaken for motor noise, transmission
noise, or wheel bearing noise.
Test method: Check for gear noise in coating, accelerating, or in constant-speed driving,
or by jacking up the front wheels.

Improper contact of hypoid gear teeth. Adjust, or replace as a gear test.

Improper hypoid gear backlash. Readjust
Unusually Noise Worn, or broken hypoid gear tooth surface. Replace as a gear set.
When making a turn.
Seized hypoid gear. Replace as a gear set.
Improper pinion bearing preload. Readjust
Seized, or broken side bearing. Replace
Differential case run out. Replace
Seized, or broken pinion bearing. Replace
Loosen bolts and nuts. Retighten
(25/10/2007) 20-08-M133 EN
 AXLE

- AXLE COMPONENTS POSITION

- AXLE CONTROL AND ADJUSTING

- AXLE COMPONENTS DIAGRAMS AND

SECTIONS

30
AXLE COMPONENTS POSITION

30

30-03-M133 EN (20/11/2007)
 2
Axle components position

180° Drive motor

FRONT
30

Front of the
machine

REAR
180°

Front of the
machine

(20/11 /2007) 30-03-M133 EN

AXLE CONTROL AND ADJUSTING

30

30-04-M133 EN (04/12/2007)
 2
Axle control and adjusting

Front Axle Disassembly

1. Hoist the front axle on a work desk and remove the 6
wheel nuts each side.

2. We will shown the right side of wheel axle as follow, the

left side is same to right side.
30

3. Use a M12x40 bolt, tighten in the half axle surface

as shown, tighten the bolt to push the half axle out and
remove it.

4. Remove the green gasket of half axle.

5. Loosen the bolt as shown.

Then use a tool loosen the bush locker.

(04/12/2007) 30-04-M133 EN
 3
Axle control and adjusting

6. Use your hand push the wheel hub out, and remove it.

Be careful do not drop the inner support bearing.

7. Remove the inner support bearing as shown.

30
8. Remove the wheel brake & LEFT/RIGHT axle support
seat as an assy’.

Brake Drum
& wheel hub assy’

9. Loosen the 8 bolts of wheel brake bracket, you can

detach the wheel brake assy’.

10. Then loosen the brake drum 6 bolts as shown.

(Before you detach, loosen the 6-M6 bolts at first)

30-04-M133 EN (04/12/2007)
 4
Axle control and adjusting

11. Use a copper stick to knock the 6 bolts out or by

hands.

CAUTION:
Do not let the grease painted on the inner surface of brake
drum. Otherwise, clean it and dry it.

D=310mm
30

Wheel Bolt
Wheel Hub Brake Drum

12. Use a copper stick to knock the inner ring of the hub
bearing and let the Oil seal & Bearing down.

13. Use a copper stick to knock the outer ring of the hub
bearing.

14. To assemble the Outer ring of the hub bearing, use a

hydraulic machine to press it into the wheel hub because
they are interference fitting.

CAUTION:
• To assemble the Front Axle, reverse the order to
disassemble.
• Lubricate bearings when mounting them.

(04/12/2007) 30-04-M133 EN
 5
Axle control and adjusting

Rear Axle Disassemble

1 Remove the cap of wheel hub.

30
2. Loosen the bolts as shown and remove the
washer locker.

3. Remove the wheel hub.

Be careful not drop the inner race of bearing.

30-04-M133 EN (04/12/2007)
 6
Axle control and adjusting

Rear Axle Disassemble

4. Loosen grease nipple of the king pin.

5. Loosen the pin as shown and remove the Tir-

rod bar, up and down.
30

6. Use a copper bar to knock the king pin out

carefully.

7. Remove the other side king pin and steering

knuckle.

8. Loosen the steering cylinder fixed bolts, and

remove the cylinder out.

9. Then you can inspect the cylinder and king

pin, steering knuckle, etc.

Oil Seal

Needle Bearing

10. To assemble, reverse the order of

disassemble.
Note: When assemble, paint grease on all the
bearings if necessary.
(04/12/2007) 30-04-M133 EN
AXLE COMPONENTS DIAGRAMS AND SECTIONS

30

30-05-M133 EN (03/12/2007)
 2
Axle components diagrams
and sections

Front axle : transmission gear box Parts

1 2
3
13 4

9
8

12

1
30

5
10
35 6 17, 18

19
20

21
22
28
23 24 27
23
25
34
26
27
30 28
29 33

31 32

FRONT OF THE
MACHINE

1 Pipe 19 Washer 14
2 Vented plug 20 Bolt M14x1.5x30
3 Plug 21 Brake drum
4 Washer 22 22 Oil seal
5 Washer 20 23 Bearing 7815
6 Plug 24 Wheel hub
7 Axle house 25 Lock nut
8 Washer 12 26 Locking shim
9 Bolt M12x40 27 Washer 6
10 Washer 16 28 Bolt M6x12
11 Bolt 29 Oil seal PD45x62x12
12 Plate, Left 30 Gasket
13 Plate, Right 31 Half shaft
14 Shim 32 Pin D12x35
15 Washer 20 33 Wheel hub nut
16 Nut M20x1.5 34 Wheel hub bolt
17 Brake assy, Left 35 Plug M16x1.5
18 Brake assy, Right

(03/12/2007) 30-05-M133 EN
 3
Axle components diagrams
and sections

Front axle : transmission gear box sections

30

30-05-M133 EN (03/12/2007)
 4
Axle components diagrams
and sections

Rear axle : steering system

12
1 11
3 2
13 12
5 1
2 21
18
7 4 14
35 4

6 15 22
16 23
19 17
20
19
20
36
30

6 8 9 10

24
25
26
27
30
31
32
18
33
34

29 28
7
FRONT OF THE 18
MACHINE

1 Bolt 19 Nut
2 Washer 20 Pin
3 Bracket Right 21 Pin
4 Adjusitng shim 22 Snap ring
5 Bracker Left 23 Bearing
6 Rubber 24 Oil seal
7 Washer 25 Bearing
8 Bolt 26 Bolt
9 Washer 27 Wheel hub
10 Axle body 28 Nut
11 Cylinder 29 Steering wheel
12 Nipple 30 Bearing
13 Pin 31 Lock nut
14 Tir-rod bar, up 32 Washer
15 Snap ring 33 Gasket
16 Bearing 34 Cover
17 Tir-rod bar, down 35 Cover
18 Bolt 36 Stub axle

(03/12/2007) 30-05-M133 EN
 BRAKE SYSTEM

- BRAKE SYSTEM CHARACTERISTICS AND

SPECIFICATIONS

- BRAKE SYSTEM COMPONENTS POSITION

- BRAKE SYSTEM CONTROL AND

ADJUSTING

- BRAKE SYSTEM TROUBLESHOOTING

40
BRAKE SYSTEM CHARACTERISTICS AND
SPECIFICATIONS

40

40-01-M133 EN (22/10/2007)
 2
Brake system characteristics
and specification

Inspection and adjustment

Item Data

Pedal Free play (mm) 1-3

Brake pedal Pedal height (mm) 110 - 125

Depressed height (mm) More than 60

Allowable clearance
Master cylinder Les than 0,15
between cylinder and piston (mm)

Master cylinder type is Single conventional

40

Parking brake pulling force (N) 200 - 300

Service brake Brake drum / shoe type

(22/10/2007) 40-01-M133 EN
BRAKE SYSTEM COMPONENTS POSITION

40

40-03-M133 EN (04/12/2007)
 2
Brake system components position

a. Parking brake

Drum brake

Brake system

a. Parking brake: Toggle Lock.

Pull force is about 200~300N.
40

b. Service brake: Front wheel

brake drum & shoes type.

c. Regenerate brake is detailled

in Electric.

Parking brake lever assy’

b. Service brake
Tighten or Loosen the parking brake steel-cable, you can adjust
the Screw here clockwise or
anti-clockwise.

Return springs

Tighten torque:
19 - 25 Nm

Micro switch: signal ON/OFF

to control the travelling motor.
Protection
rubber hose
(04/12/2007) 40-03-M133 EN
 3
Brake system components position

35 36
28
27 33

24 26
38
25
37
39
19
31 30
30
29
34

8 7 6
32 10 9 5
1
15
21 26 16
23 14
22

40
13
12
18 20 11
2
3
4* 4

17

Legend : 19 - Screw
20 - Nut
1 - Body of master cylinder 21 - Pin
2 - Stopper ring 22 - Washer
3 - Stopper plate 23 - Pin
4 - Piston cup 24 - Tank
4*- Piston 25 - Hose
5 - Spacer 26 - Circlip
6 - Piston cup 27 - Bracket
7 - Spring seat 28 - Screw
8 - Return spring 29 - Brake pedal
9 - Spring seat 30 - Bushing
10 - Spacer 31 - Spring
11 - Dust cover 32 - Cover pedal
12 - Push rod 33 - Nut
13 - Fork joint 34 - Screw
14 - Nut 35 - Nut
15 - Connection 36 - Brake switch
16 - Seal 37 - Pin
17 - Hydraulic tube 38 - Screw
18 - Hydraulic tube 39 - Greaser

40-03-M133 EN (14/12/2007)
 4
Brake system components position
40

(14/12/2007) 40-03-M133 EN
BRAKE SYSTEM CONTROL AND ADJUSTING

40

40-04-M133 EN (04/12/2007)
 2
Brake system control and adjusting

Service brake pedal

40

H : 110 - 125 mm

Adjusting bolt of the brake pedal assy’, and

make sur the clearance from pedal to floor-mat
is about 125 mm.

After installation brake pedal, adjust it and make

sure pedal travels smoothly over its entire stroke
without binding, twisting, etc. and makes no
contacting noise.

(04/12/2007) 40-04-M133 EN
 3
Brake system control and adjusting

Air bleed of Brake pipe

When the brake fluid is filled up bleeding of the brake

system is required : T :12 - 16 Nm

STEP :

• Remove the protection cap from the bleeder and

connect a suitable hose with collecting tank

• Press the braking pedal by actuating the brake pedal

and keep this position

• With an open wrench loosen the bleeder approx. half

a turn and have the air escape

40
• Upon tighten of the bleeder release the brake pedal

This procedure has to be repeated until bubble-free

brake fluid comes out. In the meantime the fluid level
in the compensating tank is to be checked and refilled
if necessary.

40-04-M133 EN (04/12/2007)
 4
Brake system control and adjusting

Booster explosion view

Dust cover

Stopper ring

Stopper plate

Piston cup

Piston

Spacer

Piston cup

Spring seat

Return spring

Push rod
40

Spring seat

Cylinder body

Disassembly

Discard piston cup after removal; instal new one.

When disassembling parts, select a place that is clean and free from dust, and arrange all parts orderly to
facilitate reassembly.

Inspection :

Clean all parts in brake fluid and check their condition.

Do not use any other cleaning solvent to clean parts.

Assembly :

To assemble, reverse the order of disassembly. Observer the following :

• Clean all parts in clean brake fluid.
• Apply coat of brake fluid to frictional surfaces of piston and cylinder.
• Be careful not to scratch them when assembling.
• Instal a new piston cup; discard old ones.

(04/12/2007) 40-04-M133 EN
BRAKE SYSTEM TROUBLESHOOTING

40

40-08-M133 EN (23/10/2007)
 2
Brake system troubleshooting

Master cylinder booster

Trouble Probable cause Corrective action

Insufficient or heavy braking force Faulty brake booster Replace

Improper valve operating rod

Adjust
adjustment
Brake dragging
Faulty brake booster Replace

Poor pedal return Faulty brake booster Replace

Parking brake

Trouble Probable cause Corrective action

Open or elongated wire Replace

40

Water or oil on linings. Clean or replace.

Insufficient braking force
Uneven wear or contact
Grind or replace.
of brake linings.

Worn linings. Replace

(23/10/2007) 40-08-M133 EN
 3
Brake system troubleshooting

Service brake

Condition Probable cause Corrective action

Oil leakage in brake lines. Correct and replenish.

Air in brake lines. Bleed air.

Water or oil on linings. Clean or replace.

Insufficient or heavy Uneven wear or contact of braking linings. Grind or replace.

braking force Worn linings. Replace.

Improper functioning of master cylinder or wheel cylinder. Correct or replace.

Clogged oil lines. Clean

Improper functioning of brake booster Correct or replace.

Uneven tire pressure. Adjust

Brake out of adjustment. Adjust

40
Water or oil on brake linings. Clean or replace.

Deteriorated lining surfaces. Grind or replace.

Improper contact of linings. Grind or correct.

Unequal
braking. Worn lining. Replace
(Lift truck veers to Worn, warped, rusted or damaged brake drums. Correct or replace.
one side)
Improper sliding of shoes. Adjust

Loosen back plate bolts. Tighten or replace.

Warped back plate. Replace.

Improper adjusted wheel bearings. Adjust or replace.

Clogged oil lines. Clean

No free play of brake pedal. Adjust

Improper shoe sliding. Adjust

Improper operation of wheel cylinder. Adjust

Brake dragging.
Faulty piston cup. Adjust

Weak or broken return springs. Adjust

Clogged master cylinder return port. Clean

40-08-M133 EN (23/10/2007)
 4
Brake system troubleshooting

Service brake

Condition Probable cause Corrective action

Clogged oil lines. Clean

Brake dragging. Wheel bearing out of adjustment. Adjust or replace.

Improper functioning of brake booster. Correct or replace.

Brake drag. Refer to above

Improper returning of piston. Replace

Worn linings. Replace

Deteriorated lining surfaces. Grind or replace.

Improper contact of shoes with linings. Replace

Clean and apply brake
Excessively worn shoes or back plates.
grease.
Brake
40

squeaking Foreign particles on frictional surfaces of drums. Clean

Frictional surfaces of drums worn run out. Replace

Deformed or improperly installed shoes. Replace or correct.

Loose back plate bolts. Tighten

Worn anchors. Replace

Improper contact of linings. Correct or replace.

Improperly installed anti-rattle springs. Correct.

Rough frictional surfaces of drums Grind or replace.

Brake noise Drum out of center or excessively warped drum Replace.

Rough lining surfaces. Grind or replace.

Brake out of adjustment. Adjust

Air in oil lines. Bleed air

Excessive Oil leakage or insufficient oil. Check and correct.

pedal stroke Worn linings. Replace

Dislocation or improper returning of shoes. Correct.

Improper contact of linings. Correct.

(23/10/2007) 40-08-M133 EN
 MAST

- MAST REMOVAL

- MAST TROUBLESHOOTING

60
MAST REMOVAL

60

60-06-M133 EN (22/10/2007)
 2
Mast removal

Mast removal and installation

WARNING !

Be careful when removing and installing the forks, carriage and mast as they are heavy.
60

1. Remove forks

Unlock fork lock pins by pulling them and move forks to cutout portion in the middle of carriage bracket assembly.

Pull lower portion of fork to remove its lower jaw and lift it out.

Caution

Keep hands and feet away from forks. When removing and installing forks carefully, keep feet and hands clear.

Do not remove forks from the end of the fork bar.

Severe injury can result if the fork is dropped.

(22/10/2007) 60-06-M133 EN
 3
Mast removal

STEP :

2. Attach wire ropes to carriage bracket assembly and lift

carriage bracket assembly up with a lifting device.

3. Remove chain attaching nuts, and detach chains from

carriage bracket assembly

4. Remove carriage bracket assembly from inner mast.

5. Detach high pressure hose, lift hose and low pressure

hose.

6. Support mast assembly with wire ropes.

7. Pull out tilt cylinder pivot pin.

8. Remove mast support pins.

9. Remove mast assembly.

10. To install mast assembly, reverse order of removal.

60

60-06-M133 EN (22/10/2007)
 4
Mast removal

Disassembly
Remove lifting jack

Place mast flat on ground. Remove lifting jack attaching

U-bolts and tighten screw.

Remove rollers

Slide inner mast out until rollers are exposed and remove
little rollers with bearing puller. Unclench rollers carefully if
no bearing puller or rollers would be damaged.

Remove inner mast

Attach wire rope to middle of inner mast and slide it out

with a lifting device.

INSPECTION

1. Check lift rollers, roller shafts, and associated parts for

wear or damage.

2. Replace damaged parts as required.

60

(22/10/2007) 60-06-M133 EN
 5
Mast removal

Assembly and adjustment

Lift roller

Slide inner mast into outer mast and securely attach lift
rollers.

Clearance of back up metal and mast steel

Adjust clearance «B» to 0,1 - 0,8 mm with shims, which may not
use. Thickness of shim is 0,5 mm or 1 mm.

60
Lifting chain adjustment

• Install fork arm carrier on inner mast, and install lifting

chain, then install two nuts on end of every side. With mast
set straight up, lower carriage completely. Temporarily adjust
clearance of carriage to 74 mm above ground. If necessary,
adjust with chain adjusting nut.

• To adjust tension of lift chain, lower lifting jack until fork is on

the ground, and adjust chain adjusting nut (three every side) so
that dimension C will be as listed below whn the middle portion
of chain is pressed by a finger.
Dimension C : 25 - 30 mm.

60-06-M133 EN (22/10/2007)
 6
Mast removal

Tilt Cylinder removal and installation

WARNING!
When removing the tilt cylinder carefully
pay attention to the following:
Support the mast with a chain
and block to keep it from falling.
Keep hands and body
as far from equipment as possible.

STEP
1. Lower fork fully.
2. Remove bolt from joint at outer mast, and pull out pivot pin.
3. Disconnect two pipes connected to tilt cylinder at pipe connector.
4. Remove key plate from joint at body frame, pull out pivot pin
and dismount tilt cylinder.
5. To install, reverse the order of removal.

Disassembly (Use care do not

damage O ring)
1. Hold cylinder in vice, apply compressed air
alternately to two ports and actuate piston
60

to discharge oil from cylinder.

2. Loosen cylinder head screw, and remove
cylinder head from cylinder tube.
3. Remove piston rod assembly from cylinder
tube.
4. Loosen bolt 2 on piston rod head and
remove rod head from piston rod assembly.
5. Remove cylinder head 3.
6. Remove O ring and backup ring from piston
4.

Cylinder head
1. Remove O ring by pinching with fingers as shown.
2. Remove U ring and wiper ring with a screwdriver.
Note: Discard and removed U ring and wiper ring.

Assembly
To assembly, reverse the order of disassembly procedures,
noting the following:
1. Lubricate each parts with clean Hydraulic oil.
2. Never allow dust to enter the cylinder.
3. Use care not to twist or otherwise damage O ring.
4. When inserting cylinder head on piston rod,
use care not to damage O ring
and wiper ring with threaded portion of piston rod.

(22/10/2007) 60-06-M133 EN
MAST TROUBLESHOOTING

60

60-08-M133 EN (22/10/2007)
 2
Mast troubleshooting

Master cylinder booster

Condition Probable cause Corrective action

Adjust clearance at carriage side

roller, thrust metal and carriage
Carriage bracket assembly out of
roller to insideof inner mast.
adjustment.
Replace worn or faulty parts with
new ones as required.
Insufficient clearance between inner Adjust clearance with shims and
and outer mast or rollers and mast. side thrust metal.
Forks are lifted or lowered un- Apply grease on contact surfaces of
smoothly. Insufficient lubrication.
sliding parts.
Biting foreign materials between
Remove foreign materials.
moving parts.

Skew inner mast. Repair.

Bent carriage bracket assembly. Replace or repair.

Forks are lifted unevenly. Lift chains out of adjustment. Adjust lift chains.

Grease stiffened or dirt accumulated

on lift roller and mast sliding Clean and lubricate lift rollers.
Lift roller does not rotate. surfaces.
60

Improperly adjuster lift roller. Adjust.

Insufficient lubrication. Lubricate.

Improperly adjuster lift roller, side

Excessive mast noise. Adjust.
roller and back up metal.
Worn chain wheel, lift roller, side
Replace.
roller and back up metal.

(22/10/2007) 60-08-M133 EN
 HYDRAULIC

- HYDRAULIC CHARACTERISTICS AND

SPECIFICATIONS

- HYDRAULIC CONTROL AND ADJUSTING

- HYDRAULIC DIAGRAMS

- HYDRAULIC TROUBLESHOOTING

70
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS

70

70-01-M133 EN (05/12/2007)
 2
Hydraulic characteristics and
specifications

Oil pump

Tonnage Unit 2.5t 3t

Model / CBTDH-F416-ALH4 CBTDH-F420-ALH4

Power take off type / Gear to pump motor

Max. Pressure Mpa 25

Rated pressure / Rated speed Mpa / rpm 20 / 2000

Max. speed rpm 3000

Displacement ml/r 16 20

Control valve

Tonnage Unit 2.5 - 3.0t

Valve model (2 spools) / CDB2-F15DC-00

Main relief valve set pressure Mpa 17.5

Relief valve type / Cartridge type

Plunger type / Cylinder type, spring return system

70

Normal flow rate L/m 60 - 65

Ra ted flow rate L/m 62

Type Double-slide valve, with overflow and tilting-lock valve

(05/12/2007) 70-01-M133 EN
 3
Hydraulic characteristics and
specifications

Tilt cylinder (2.5t - 3t)

Type Piston type

Lifting height ≤ 4m 4m<Lifting height ≤ 5m 5m<Lifting height ≤ 6m

/
Tilting angle (5°/10°) Tilting angle (5°/6°) Tilting angle (3°/6°)

Stroke (mm) 120 88 72

Cylinder inner diameter (mm) 70

Cylinder outer diameter (mm) 85

Piston rod diameter (mm) 32

Duplex and Triplex mast lift cylinder (2.5t - 3t)

2 - stage wide view mast 3 - stage full lifting mast

(DUPLEX) (TRIPLEX)

Tonnage 2.5t 3t 2.5t 3t

J25M300 J30M300 J25N450 J30M450

Model
(Lifting height 3000 mm) (Lifting height 4500 mm)

Stroke (mm) 1505 1505

70
Cylinder inner diameter (mm) 50 56 50 56

Cylinder outer diameter (mm) 60 65 60 65

Piston rod diameter (mm) 40 45 40 45

Free-lift mast lift cylinder (2.5t - 3t)

Tonnage 2.5t 3t 2.5t 3t

J25U300 J30U300 J25U300 J30U300

Model
(Lifting height 3000 mm)

Stroke (mm) 1456 775 777

Cylinder inner diameter (mm) 50 90

Cylinder outer diameter (mm) 60 63.5 102 108

Piston rod diameter (mm) 35 40 75 85

70-01-M133 EN (05/12/2007)
 4
Hydraulic characteristics and
specifications

Power Steering Device — Pump Motor

A single large hydraulic motor provides flow for steering and all hydraulic functions, thus eliminating
the need for a separate power steering motor further reducing maintenance.
Today, most of Battery forklifts all adopt this technology.

More details about Pump motor refers to

Electrical system.

XCEL45 with VLC Priority Valve (BOPV)

EF Port

Priority valve P Port

(BOPV)
70

Tank port
V2

Cylinder Cylinder
Port R Port L

V1

LS
Steering
Column
Mount face Steering
Control unit
L: Steering Left input orifice XCEL45
R: Steering right input orifice
P: High Pressure Oil input orifice, about 8 - 10 MPa normally
T: Oil outlet orifice ➩ to oil tank
EF : Priority valve ➩ to control valve
LS : Hydraulic switch Pressure testing orifice, Screw : M12x1.25
V1 : Main relief valve - adjustable
V2 : Priority relief valve - adjustable

(05/12/2007) 70-01-M133 EN
 5
Hydraulic characteristics and
specifications

Data of Steering Unit and BOPV

Specification Data

• Steering unit model.............................................. 423-7982-15

• VLC Priority valve (BOPV) model ............................ 880-1580

Displacement ......................................................... 50 ml/r

Max. system pressure ............................................. 190 Bar

Max. back pressure................................................. 21 Bar

Rated flow :
50-125 cc/r ......................................................... 7,5 - 15 LPM

Input torque
Powered standard ................................................... 1,7 - 2,8 Nm
Powered low torque ................................................. 1,3 - 2,2 Nm
Non powered 136 Nm

Max. system operating temperature ......................... 93°C

Max. differential between steering unit and
other system temperature ...................................... 28°C

70
Fluid..............................ATF Type A and most petroleum based fluids
Recommended filtration........................ ISO 18/13 cleanliness level

Combination of valves

• Cylinder Relief Valve : .......................................... Included

• Anti-cavitations Valve : ......................................... Included
• Inlet check valve : ................................................ NONE
• Manual steering Chack Valve : .............................. Included

70-01-M133 EN (05/12/2007)
 6
Hydraulic characteristics and
specifications

Hydraulic Circuit Explanation

Load Sensing Dynamic Signal Non Load Reaction

Load sensing dynamic steering unit offers following advantages

- Provides smooth pressure compensated steering because load variations in the steering circuit do not affect axle
response or maximum steering rate.

- Provides true power beyond system capability by splitting the system into two independent circuits.
Pressure transients are isolated in each circuit.
Only the flow required by the steering maneuver goes to the steering circuit.
Flow not required for steering is available for use in the auxiliary circuits.

- Provides reliable operation because the steering circuit always has flow and pressure priority.

Dynamic Signal provides the following additional advantages

- Faster steering response.

- Improved cold weather start-up performance.

- Increased flexibility to solve problems related to system performance and stability.

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(05/12/2007) 70-01-M133 EN
 7
Hydraulic characteristics and
specifications

Additional EHPS

Electrical Hydraulic Powering Steering (EHPS) system.

More details please refers hydraulic system principle diagram.

This is a trend which more and more battery FLT adopt this technology in steering system. Like LINDE, JUNGHEINRICH,
SHINKO, TOYOTA, TCM electrical counterbalanced or reach truck.

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70-01-M133 EN (05/12/2007)
 8
Hydraulic characteristics and
specifications

Steering Unit Valve explanation

Inlet Relief Valve Inlet Check Valve

Or LS Relief Valve

Cylinder Relief Valve Anti-cavitations Valves

for cylinder ports
70

Inlet check valve - prevent oil from returning through the steering unit when pressure on the cylinder side is greater
than pressure on the inlet side, to prevent steering wheel kick.

Inlet relief valve - limits maximum pressure drop across the steering unit protecting the steering circuit

Internal check valve - converts the unit to a hand operated pump for limited manual steering. Included in all units.
Steering units with displacement larger than 200 cc/r may require a separate power source for limited operation.

Cylinder port shock valve - protect hoses against vacuum (cavitations) conditions.

Load sensing relief valve - limits inlet pressure from the priority valve.

(05/12/2007) 70-01-M133 EN
HYDRAULIC CONTROL AND ADJUSTING

70

70-04-M133 EN (22/10/2007)
 2
Hydraulic control and adjusting

Adjusting the pressure of the main relieve valve

The pressure of the main relieve valve is all ready adjusted in the factory, usually you do not need
adjust. The following is an example of 1.5t truck to specify how to adjust the pressure.

1. Put 125% of the rated load (1875kg) on the fork stable.

2. Pull up the parking brake lever and stop the truck on a level ground. Pill the lifting pole, if the
forklift can lift to the height of 300mm, the main relieve valve is all right. Otherwise, adjust it as
step 3.

3. If the forklift can’t lift, enhance the pressure main relieve valve, remove the front soleplate,
loosen the tightening nut of the main relieve valve, screw the adjusting nut clockwise to enhance
the pressure of the main relieve valve. If the height of lift is higher than 300mm, screw the adjust
nut anti-clockwise to reduce the pressure.

4. Make sure the forklift can lifting cargo to the height range of 0~300 mm. Otherwise, adjust it
as step 3.

5. Retighten the tightening nut, fix on the front soleplate.

Warning:
The load should be put stably.
Don’t adjust if the pressure is already adjusted correctly.
70

(22/10/2007) 70-04-M133 EN
 3
Hydraulic control and adjusting

Oil Pump Disassembly

1. When disassembling, clean pump surface and drive shaft. Place disassembled parts on clean
cloth or clean sheet of paper. Be careful not to stain, scratch or damaged parts.

2. Secure pump in vice with pump mounting flange facing down. Apply soft material such as wood
plate, aluminum plate, or copper plate to vice jaws.

3. Remove hexagon socket head bolts and plain washers.

4. Remove cover by pulling in a straight axial direction. Tap cover with wood hammer if hard to
remove. Remove plate seals and backing ring.

5. Remove pressure plate. This can be removed easily by slightly lifting up drive gear/ driven gear
shaft.

6. Make a match mark at the shaft ends of drive gear and driven gear, and remove the gears.

7. Remove pressure plate from under gear plate, taking care not to tilt the pressure plate.

8. Before removing, scribe a marking on the gear plate so as to identify the cover side and
mounting flange side of the gear plate.

9. Remove plate seal and backing ring from mounting flange. Remove snap ring, and then remove
oil seal. To remove seal, drive it from the inside using a standard screwdriver. At this time, be
careful not to damage oil seal fitting hole or bearing hole

10. Arrange the disassembled parts in order so that the original location and orientation of each

70
part can be understood.

Caution on use & mounting (Pump)

1. Check oil ports carefully before starting and ensure that pump’s rotation direction should be in
concordance with the label. Otherwise it will cause damage.

2. Use flexible coupling between pump’s shaft and drivine’s. The misalignment should be less
than 0.1mm.

3. The pump’s shaft should not with stand any axial, and radial force. Mount pump smoothly to
prevent damage.

4. Suction height should be less than 0.5 m.

5. Oil port flange should be free from damage. The suction jointing should be sealed strictly to
avoid air suction, which could cause noise vibration, bubble and volumetric efficiency decline.

6. Suction pipe should be ensure the fluid speed inside is less than 1.5m/s.

70-04-M133 EN (22/10/2007)
 4
Hydraulic control and adjusting
70

(22/10/2007) 70-04-M133 EN
HYDRAULIC DIAGRAMS

70

70-6-M133 EN (22/10/2007)
 2
Hydraulic diagrams

- LEGEND -
CA - Suction strainer

D - Valve 3 bank
EDL - Lateral moving section
EE - Inlet section
EI - Tilting section
EL - Lifting section

DD - Steering valve bank

FR - Return filter

MP - Electrical engine pump

Power (ME425) ...............11 Kw
Power (ME430) ...............12,8 Kw

P - Hydraulic pump
Volume of charge (ME425) ....... 16 cm3/rev.
Volume of charge (ME430) ....... 20 cm3/rev.

R - Hydraulic tanker

RD - Flow reducer

VD - Steering cylinder

VDDP - Priority flow dividing valve

VI - Tilting cylinder

VL - Lifting cylinder
70

VDL - Lateral moving cylinder

MAST 2T5 MAST 3T

DVT DLL TLL DVT DLL TLL
Valve bank taring
ø rod ø 40 ø 35 ø 45 ø 40
cylinder
Lateral

ø body int. ø 50 ø 50 ø 56 ø 50
throttle flow ± 10%
Free lifting

ø rod ø 75 ø 85
cylinder

ø boby int. ø 90 ø 90

(22/10/2007) 70-6-M133 EN
 3
Hydraulic diagrams
MAST : VL
TLL VERSION MAST D VT VERSION MAST

RD RD
RD
A1
A1

D 62l/min

B3 A4 B4
VDL
EA
OPTION

EDL

VI B2 A3
A2
A1 EI

A1
EL

EE

T 175b P

FRONT AXLE

70
L
Ø 350 REAR AXLE
125 cm3
R

DD
190b LS P
T CF
EF VD
VDDP
P

250b MP
FR FR P
M

CA
R
70-6-M133 EN (22/10/2007)
 4
Hydraulic diagrams
70

(22/10/2007) 70-6-M133 EN
HYDRAULIC TROUBLESHOOTING

70

70-08-M133 EN (22/10/2007)
 2
Hydraulic troubleshooting

Main Oil Pump

Condition Probable cause Corrective action

Low oil level in tank Add oil to specified level

No oil from oil pump

Clean oil line and tank.
Clogged suction pipe or strainer
If oil is dirty, change

Worn bearing faulty backup ring,

Repair faulty parts
O ring or pressure plate

Readjust to specified pressure using

Maladjusted relief valve
Low discharge pressure pressure gauge
on oil pump
Retighten suction side piping.
Add oil.
Air in the system Check pump oil seal.
Do not operate pump until bubbles
in tank disappear.

Cavitations due to crushed suction Clean strainer and repair crushed

hose or clogged strainer hose.

Air being sucked from loose suction

Retighten each joint
side joint

Noisy oil pump Replace with new oil having proper

Cavitations due to too high oil
viscosity for temperature at which
viscosity
70

pump is to be operated

Determine cause of bubbles and

Bubbles in hydraulic oil remedy such as air bleeding and
replace oil.

Faulty oil seal on pump, faulty O ring

Oil leacking from oil pump on body, faulty plate seal or worn Replace faulty parts
sliding surfaces on pump

(22/10/2007) 70-08-M133 EN
 3
Hydraulic troubleshooting

Control Valve

Trouble Probable cause Corrective action

Loose of pressure-adjust screw Readjusted and retighten

Distorted or damaged pressure-

Replace
Pressure of relief valve is not adjust spring
steady or too low
Worn or blocked relief valve core Replace or clean

Pump abated Examine and repair pump

Replace valve core and tilt lock

Worn or damaged tilt lock valve
valve as an assemble
Fork tilt forward when control
lever is used while engine is off Broken tilt lock spring Replace spring

Damaged tilt valve plunger O-ring Replace O-ring

Mast is unstable when tilting

Malfunctioning tilt relief valve Replace tilt relief valve assembly
forward

Valve body and spool valve is worn

Replace spool valve with specified
and clearance between them is too
clearance
great

Lowering distance of mast is big Spool valve is not in centre Keep being in the centre
when spool valve is in the center

70
Cylinder seal abated Examine and repair cylinder

Taper valve is worn or blocked by

Replace or clean taper valve
dirt

Damaged or distorted reposition-

Replace spring
spring

Dirt exist between valve body and

Spool valve is not return neutral Clean
spool valve
position

Blocked control device Adjusted

Not coaxial parts at reposition Reinstall. Be coaxial.

Damaged O-ring Replace

Faulty seal of joint Check and retighten

Leakage
Loose seal plate Clean seal plate and retighten blots

Loosed lock-nut of relief valve and

Tighten
connect-nut between plate and plate

70-08-M133 EN (22/10/2007)
 4
Hydraulic troubleshooting

Steering System

Condition Probable cause Corrective action

Tighten nuts or
1. Oil leakage occurs between sections
replace seals

2. Damage of seal in shift necking Replace

Leaking in steering
device
3. Damage of seal in safety valve Replace

Grinding shim or
4. Not flat of shim in limiting position bolt
replace it

1. Not enough oil supported by pump Adjust control valve

2. Air enters in the line of steering gear Bleed the air

3. Not enough oil in tank Fill oil

4. Too low pressure setting of the relief valve in the dividing Adjust pressure or
valve or blocking in valve clean dirt

5. Too high viscosity oil Replace wrong oil

High effort for steering
of failure to rotate 6. The steering fails to return to its natural position due to
steering system Replace wrong spring
breakage of locking spring or insufficient spring pressure
70

7. Break or deform of swivel pin Replace it

8. Break or deform of coupling Replace coupling

9. Wrong in spring or safety valve Replace spring

10. Too much internal leakage in the steering cylinder Replace seal or cylinder

11. Deform of steering axle Repair it

1. Damage of bearing fitted in swivel pin Replace bearing

Free play in hand 2. Too much clearance in rim bearing Adjust

wheel and wobble in
wheels
3. Too much clearance between steering rotator and stator Replace rotator or
and descend of volume efficiency stator

Front left and right

wheel does not match Controller parameter is not correct Adjust
to rear wheel

(22/10/2007) 70-08-M133 EN
 ELECTRIC

- ELECTRIC CHARACTERISTICS AND

SPECIFICATIONS

- ELECTRIC COMPONENTS POSITION

- ELECTRIC CONTROL AND ADJUSTING

- ELECTRIC DIAGRAMS

- ELECTRIC TROUBLESHOOTING

80
ELECTRIC CHARACTERISTICS AND SPECIFICATIONS

80

80-01-M133 EN (05/12/2007)
 2
Electric characteristics and
specifications

Component Representation Characteristics

Voltage : 24 V
Life-span : 500 h (continuous)
Front head lamp
Standard : JB/T7694
Power : 70 W

Voltage : 24 V
Life-span : 500 h (continuous)
Front side lamp
Standard : Q/321283TJA02-2005
Power : 8 W + 21 W

Voltage : 24 V
Rear combined lamp Life-span : 500 h (continuous)
Standard : Q/321283TJA02-2005

Voltage : 10 - 30 V
Warning lamp Life-span : more than 1 x 107 time
Standard : GB/T13954-92

Voltage : 24 V
Horn
105 - 125 db (A)
80

Voltage : 24 V
88 dB (A)
Buzzer
70 - 90 / MIN
< 60 mA

(05/12/2007) 80-01-M133 EN
 3
Electric characteristics and
specifications

ACS VMC 20

TYPE Component Part N° Original SW

VMC 20 83U03529A 69U03529C01

OPT 10 83Y26025A 41790V201

ME4
2,5t
ACS 4815 83Y05199A 69Y05199C01

ACS 4810 83Y05200A 69Y05199C01

VMC 20 83U03530A 69U03530C01

OPT 10 83Y26024A 41790V201

ME4
3t
ACS 4815 83Y05201A 69Y05199C01

ACS 4815 83Y05201A 69Y05199C01

80

80-01-M133 EN (05/12/2007)
 4
Electric characteristics and
specifications

VMC 20 Specifications:

Supply voltage

Nominal value (VDC) 24 - 80

Operating range (VDC) 16,8 - 104
Peak transient (<100us) (VDC) 120
Absolute min (<100ms) (VDC) 16,8

Environmental Limits Temperature

Operational (°C) -40 - +55

Storage (°C) -40 - +70

Mechanical Sealing IP54

ME4 General architecture:

80

(05/12/2007) 80-01-M133 EN
ELECTRIC COMPONENTS POSITION

80

80-03-M133 EN (06/12/2007)
 2
Electric components position

ACS 1 ACS 2

n
V
bl

n
U

n
r

j
W

r
r
j
V
bl r
bl r
j
U

j VMC 20

bl/ro
80

PUMP MOTOR
(MT1 -> ACS1)

U
U
V
W

DRIVE MOTOR
(MT2 -> ACS2)

(06/12/2007) 80-03-M133 EN
 3
Electric components position

80

80-03-M133 EN (06/12/2007)
 4
Electric components position
80

(06/12/2007) 80-03-M133 EN
 ELECTRIC CONTROL AND ADJUSTING

TABLE OF CONTENTS
Pages
– OPT 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– Control panel adjusting and operating. . . . . . . . . . . . . . . . . . . . . . . . .5

– ACS operating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

– Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
– Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
– Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
– Start up and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
– Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
– Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

80

80-04-M133 EN (06/12/2007)
 2
Electric control and adjusting

OPT 10

Supply voltage : 24 - 80 V DC
P
Current : 90 mA (at 24V DC)
Temperature : -30 / +55°
D 12 k m/h (operational)
B AT% 80 -30 / +70° (storage)
Protection class : IP65 (front)
1 2 3 4 5 Connector : AMPSEAL 8-pin

1 - Wide operating voltage from 24V to 80V with built-in under voltage, Over-voltage and reverse
polarity protection.
2 - Standard can open interface for simple and reliable communication.
3 - Two-level functionnality for normal user or service user.
4 - Configurable menu system for diagnostic and parameter setup.
5 - Performance mode handling connected to user.
6 - Password handling.
7 - Buzzer.

Press «*» key twice, the phrase

* «INPUT PASSWORD» will appear,
* Key in password
80

PASSWORD : 55555

(06/12/2007) 80-04-M133 EN
 3
Electric control and adjusting

SET MENU

1 INPUT DIAGNOSTIC 1.1 KEY SWITCH

1.2 SEAT SWITCH

1.3 FORWARD SWITCH

1.4 REVERSE SWITCH

1.5 PEDAL SWITCH

1.6 PARKING SWITCH

1.7 LIFT SWITCH

1.8 PUMP SWITCH 1
1.9 PUMP SWITCH 2 Diagnostic parameter
1.10 PUMP SWITCH 3

1.11 PUMP SWITCH 4

1.12 ACCEL SWITCH 2

1.13 ACCEL POT

1.14 PUMP POT

2 OUTPUT DIAGNOSTIC 2.1 MAIN CONTACTOR

2.2 N/C

3 TEMPERATURE 3.1 DRIVE MOTOR TEMP

3.2 PUMP MOTOR TEMP

3.3 DRIVE ACS TEMP
3.4 PUMP ACS TEMP

4 TRACTION SETTING 4.1 MAX SPEED

4.2 MAX ACCEL

80
4.3 NEUTRAL BRAKE

4.4 REVERSE BRAKE

4.5 PEDAL BRAKE Configurable parameter

5 STORE PARAMETERS 5.1 MAX SPEED

5.2 MAX ACCEL
5.3 LIFT SPEED
5.4 CREEP SPEED

5.5 PUMP SPEED 1

5.6 PUMP SPEED 2
5.7 PUMP SPEED 3
5.8 PUMP SPEED 4

6 STORE PARAMETERS 5.1 MAX SPEED

5.2 MAX ACCEL

80-04-M133 EN (06/12/2007)
 4
Electric control and adjusting

The principle of BDI (3-wheel & 4-wheel):

Press green curve to judge BDI when key switch from OFF to ON, and the value of BDI as per
voltage. As follows: 51.0V --100%; 47.0V --0%. If the value played is not right, the one kept before
is chosen.
Press red curve to judge BDI when key switch ON. Check the voltage per second, and then take the
average value. Renew BDI per 5 seconds. If the BDI value is lower than actual one, please lower
5%, not over 5% every time. Lowering as per 5%, BDI value mustn’t be raised.
80

You’ll be reminded when discharging to 25%. The alarm works when that is 20%, meanwhile
running with speed down..

(06/12/2007) 80-04-M133 EN
 5
Electric control and adjusting

CONTROL PANEL ADJUSTING AND OPERATING

D 12 k m/h
B AT% 80

1 2 3 4 5

80

80-04-M133 EN (06/12/2007)
 6
Electric control and adjusting

Outside Drawing
M D
A B C E
F

D 12 k m/h
B AT% 80

1 2 3 4 5

G L
H J K
I

A : Communication LED G : Menu Key

B : Fault LED H : Slow Speed Shift Key
C : Low State of Battery LED I : Acceleration Shift Key
D : Limited Speed LED J : Backup Key
E : Acceleration LED K : Shift Key for Steering Angle Indicating
F : Parking LED L : Shift Key for Time Indicating
M : LCD

Regular Operation

The representation about six Indicators are following

80

LED A : Communication
It blinks just during a software is downloaded.

LED B : Fault
It is on when a wrong operation is done or there is something wrong with the
truck, and in the meantime, error codes with a short phrase are shown on
LCD.

LED C : Low State of Battery

It is on once the state of charge is less than 20% of full sate of charge, in the
meantime, buzzer sounds and Low Battery is showed on LCD. The battery
have to be charged.

LED D : Limited Speed

It is on, which denotes the truck works under the slow mode, that is the
maximum traveling speed of the truck is reduced. Using “1” key can shift
between slow mode and fast mode.

(06/12/2007) 80-04-M133 EN
 7
Electric control and adjusting

LED E : Acceleration
It is on, which denotes the truck works under the slow acceleration mode,
that is the maximum traveling acceleration of the truck is reduced. Using “2”
key can shift between slow acceleration mode and fast acceleration mode.

LED F : Parking
It is on during parking.
P
Key G : Menu
Just uses for diagnosis mode.

Key H : Slow Speed Shift

1
Using for shifting traveling speed
between fast and slow.

Key I : Acceleration Shift

Using for shifting acceleration 2
between fast and slow.

Key J : Backup
A spare key. 3
Key K : Shift for Steering Angle
Indicating
Using for shifting the menu of
steering angle indicating, the
4
following image can be shown on
LCD.

Diamonds in the first line represent the angle of the steering wheel, the black diamond moves
to the left when the steering wheel turn left, and the black diamond moves to the right when the

80
steering wheel turn right.

Shift Key for Time Indicating L

Using for displaying the total time
of KEY on, it is shown below after
5
press it once.

It is shown below after press it once again.

It turns to the original image after press it once again.

LCD M
When turn on KEY each time, the truck checks itself and the six LED from A to F blink in turn. The
traveling speed and BDI are shown on LCD after startup. You can know the operation situations
through LCD.
80-04-M133 EN (06/12/2007)
 8
Electric control and adjusting

Maintenance and parameters setup

Press “*” key twice, The phrase “INPUT PASSWORD” will appear, input password.

1 INPUT DIAGNOSTIC

Name Value Description

Is there KEY switch signal?
1.1 KEY SWITCH 1<<ON:1 OFF :0>>
The value is 1 if KEY switch is on.
1.2 SEAT SWITCH 1<<ON:1 OFF :0>> The value is 1 if a driver is seated.
The value is 1 if FWD/RVS lever is in the forward
1.3 FORWARD SWITCH 1<<ON:1 OFF :0>>
position.
The value is 1 if FWD/RVS lever is in the reverse
1.4 REVERSE SWITCH 0<<ON:1 OFF :0>>
position.
1.5 PEDAL SWITCH 1<<ON:1 OFF :0>> The value is 1 if the foot brake switch is on.
1.6 PARKING SWITCH 1<<ON:1 OFF :0>> The value is 0 if the parking brake is pulled.
1.7 LIFT SWITCH 1<<ON:0 OFF :1>> The value is 0 if the lift lever is pulled.
The value is 1 when steering wheel is turned.
1.8 PUMP SWITCH 1 1<<ON:0 OFF :1>>
Orbitrol p. sw activated
1.9 PUMP SWITCH 2 1<<ON:0 OFF :1>> The value is 1 if the tilt lever is pulled.
1.10 PUMP SWICHT 3
1<<ON:0 OFF :1>> The value is 1 if the side shift lever is pulled.
1.11 PUMP SWICHT 4 1<<ON:0 OFF :1>> The value is 1 if the 4th valve lever is pulled.
1.12 ACCEL SWITCH 1<<ON:1 OFF :0>> The value is 0 if the accelerator is pressed.
The accelerator potentiometer ranges from
1.13 ACCEL POT 000105
000070 to 000665.
The steering potentiometer ranges from 000208
1.14 PUMP POT 000288
to 000588.

2 OUTPUT DIAGNOSTIC
80

Name Value Description

2.1 MAIN CONTACTOR 1<<ON:1 OFF :0>> The value is 1 if it energized.
2.2 NC NC

3 TEMPERATURE

Name Value Description

3.1 DRIVE MOTOR TEMP 032 degree Shows drive motor temperature in celsius.
3.2 PUMP MOTOR TEMP 032 degree Shows pump motor temperature in Celsius
3.3 DRIVE ACS TEMP 032 degree Shows drive ACS temperature in Celsius
3.4 PUMP ACS TEMP 032 degree Shows pump ACS temperature in Celsius

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 9
Electric control and adjusting

4 TRACTION SETTING

Parameter Set Value Description

The maximum speed of the traction motor is 3500r/
4.1 MAX SPEED 003500
min
The maximum acceleration. The larger is the value, the
4.2 MAX ACCEL 023
faster is the acceleration.
Neutral regenerative brake. The larger is the value, the
4.3 NUTRAL BRAKE 015
stronger is the force of the regenerative brake.
Regenerative brake for changing into opposite moving
4.4 REVERSE BRAKE 030 direction. The larger is the value, the stronger is the
force of the regenerative brake.
Regenerative brake for foot brake. The larger is the
4.5 PEDAL BRAKE 020 value, the stronger is the force of the regenerative
brake.
4.6 TURTLE VALUE 002000 The maximum traveling speed is under Slow Mode.
The acceleration is under Power Mode (Low speed
4.7 POWER VALUE 000010
Mode).

5 PUMP SETTING

Parameter Original Value Description

The maximum speed of the pump motor is 1700
5.1 MAX SPEED 001700
rpm
The maximum acceleration. The larger is the value,
5.2 MAX ACCEL 070
the faster is the acceleration.
Maximum speed while operating the lifting is 1650
5.3 LIFT SPEED 001650
rpm
The pump motor runs at 350 rpm when the forward/
5.4 CREEP SPEED 000350 reverse lever is engaged for the steering standby
pressure.

80
Pump rpm when steering (orbitrol p. switch
5.5 P.PUMP SPEED 1 000600
activated)
5.6 P.PUMP SPEED 2 001000 Pump rpm when tilting
5.7 P.PUMP SPEED 3 001500 Pump rpm when side shifting
5.8 P.PUMP SPEED 4 001300 Pump rpm when operating 4 valve

6 STORE PARAMETERS

Parameter Original Value Description

It is only possible to save parameters after having
6.1 STORE PARAMETERS 000000
entered the value 000001.
It only is possible to operate in service mode to after
6.2 SET SERVICE MODE 000000
having entered the value of 000001.

80-04-M133 EN (06/12/2007)
 10
Electric control and adjusting

7 HOW TO SETUP PARAMETERS

No.1 Press key “*” twice, “INPUT PASSWORD” appears on LCD

No.2 Input the password
No.3 Press key “1” or key“2” to reach “4 TRACTION SETTING”
No.4 Press key “4” to enter
No.5 Press key “1” or “2” to reach any one parameter for example, “4.1 MAX SPEED”
No.6 Press key “4” one blinking cursor appears press key “3” or key “4”to reach the value you
want to modify for example, 003500 is in 003500;
No.7 Press key“1” or key “2” to change into 003505
No.8 Press key “*” to confirm
No.9 Press key “3” to exit
No.10 Turn to item 5 .1 STORE PARAMETERS
No.11 Change 000000 into 000001 then press key “*” to update (If you want store parameters
must do this step.)
No.12 Shut down…..
No.13 Turn on Parameters modifications are finished

8 CALIBRATE ACCELERATOR POTENTIOMETER

No.1 Enter item 5.2 SET SERVICE MODE

No.2 Change 000000 into 000001 then press key “*” to confirm
No.3 Press key “3” twice
No.4 Press key“3” once again “Push pedal slowly” appears
No.5 Push the accelerator easy to the end and hold on
No.6 Press key “3” then “Step pedal & push 3” appears;
No.7 Press key “3” while holding the accelerator on then “Min value is 169” appears;
No.8 Press key “3” once again then “Max value is 823” appears
No.9 Press key “3” then shut down
No.10 Turn on Calibrating the accelerator potentiometer is finished
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9 CALIBRATE LIFT POTENTIOMETER

No.1 Enter menu 6,2 SET SERVICE MODE

No.2 Change 000000 into 000001 then press key “*” to confirm
No.3 Press key “3” twice
No.4 Press key“4” once again “Push lift bar slowy” appears
No.5 Pull lift lever towards you, then press key “4” , “If OK, push key 4” appears
No.6 Press key “4” once again then “Min value is 266” appears
No.7 Press key “4” once again then “Max value is 736” appears
No.8 Press key “4” once again then shut down
No.9 Turn on Calibrating the steering potentiometer is finished

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ACS OPERATING

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TABLE OF CONTENTS

Table of Contents .......................................................................................12

Introduction ...............................................................................................13
ABOUT AC SUPERDRIVE DOCUMENTATION ................................................................. 13
ABOUT THE AC SUPERDRIVE ..................................................................................... 14
PRODUCT IDENTIFICATION......................................................................................... 14

Wiring ........................................................................................................16
WIRING THE AC SUPERDRIVE .................................................................................... 16
MOTOR AND BATTERY CONNECTIONS ........................................................................ 16
CONTROL AND I/O CONNECTIONS ............................................................................. 18
CAN BUS COMMUNICATIONS..................................................................................... 22

Start up and Commissioning .......................................................................23

GENERAL ................................................................................................................. 23
CHECKS PRIOR TO INITIAL POWER UP ........................................................................ 23
VERIFYING AC SUPERDRIVE READINESS FOR OPERATION ........................................... 23
CONFIGURING THE AC SUPERDRIVE FOR THE APPLICATION......................................... 24
FINAL OPERATIONAL CHECKS IN VEHICLE .................................................................. 24

Maintenance ..............................................................................................25
INTRODUCTION ........................................................................................................ 25
PERIODIC PREVENTIVE MAINTENANCE ....................................................................... 25
REPLACEMENT OF AC SUPERDRIVE ........................................................................... 26

Troubleshooting Guide ................................................................................27

SCOPE OF THE TROUBLESHOOTING GUIDE ................................................................ 27
USING THE TROUBLESHOOTING GUIDE ...................................................................... 27
OEMS USER DOCUMENTATION .................................................................................. 29
MAIN CONTACTOR DOESN’T CLOSE ........................................................................... 30
FUSE TO POWER STAGE IS BLOWN ............................................................................ 31
AC SUPERDRIVE STATUS INDICATOR IS BLINKING OR OFF ........................................... 32
MOTOR RUNS ONLY AT LOW SPEED ........................................................................... 33
SPEED FEEDBACK SENSOR NOT CONNECTED ............................................................ 34
MOTOR TEMPERATURE ERROR .................................................................................. 35
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POWER LIMITED DUE TO OVER TEMPERATURE ........................................................... 35

POWER REDUCTION DUE TO MOTOR OVER TEMPERATURE .......................................... 35
HEATSINK OVER TEMPERATURE ERROR ..................................................................... 36
POWER LIMITED DUE TO HEATSINK OVER TEMPERATURE 1, 2 > 85 OC ....................... 36
POWER REDUCTION DUE TO TEMPERATURE ............................................................... 36
AC CURRENT OVER CURRENT .................................................................................... 37
AC CURRENT SHORT CIRCUIT .................................................................................... 37
DC BUS HIGH - HARDWARE DETECTED ....................................................................... 38
DC BUS HIGH - SOFTWARE DETECTED ....................................................................... 38
DC BUS LOW ............................................................................................................ 39
NO CHARGING DC BUS ............................................................................................. 39
CAN –TIME OUT ........................................................................................................ 40
HEATSINK TEMPERATURE SENSOR 1,2 – OPEN CIRCUIT/SHORT CIRCUIT ..................... 41
MOTOR - TEMP < -50 °C ............................................................................................ 42
HEATSINK MOTOR- TEMP 1, 2< -20 °C ....................................................................... 42
POWER REDUCTION .................................................................................................. 42
MOTOR TEMPERATURE SENSOR OPEN CIRCUIT/SHORT CIRCUIT ................................. 43
15 V SUPPLY LOW VOLTAGE ...................................................................................... 44
15 V SUPPLY LOW OR HIGH VOLTAGE ........................................................................ 44
CURRENT CALIBRATION ERROR ................................................................................. 44
REVERTED TO DEFAULT PARAMETERS........................................................................ 45

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INTRODUCTION

ABOUT AC SUPERDRIVE DOCUMENTATION

THIS VERSION OF THE MANUAL

This version replaces all previous versions of this document. Danaher Motion Stockholm AB has made every effort
to insure this document is complete and accurate at the time of printing. In accordance with our policy of continuing
product improvement, all data in this document is subject to change or correction without prior notice.

COPYRIGHT

This manual is copyrighted 2004 by Danaher Motion Stockholm AB. All right reserved. This manual may not be copied
in whole or in part, nor transferred to any other media or language, without the express written permission of Danaher
Motion Stockholm AB.

SCOPE OF THIS MANUAL

This manual presents instructions, guidelines, diagram and other information relevant for installation and maintaining
the AC SuperDrive in an electrically powered vehicle utilizing the CAN Bus and CANopen protocol for communications
and control.

PRODUCT RANGE

This manual presents important information about the AC SuperDrive Product Generation (5) five.

RELATED DOCUMENTS

For comprehensive information on designing electric vehicle drive systems using the AC SuperDrive, refer to the AC
SuperDrive Designer’s Guide (document number 89Y05100A) and Object Dictionary (document number 89Y05110A).
The Designer’s Guide provides important information on configuring lift and traction drive systems using the AC
SuperDrive as well as details on sizing and selecting system components, options and accessories. The Object
Dictionary provides important information about CANopen communication with the AC SuperDrive.

WARNING, CAUTION AND INFORMATION NOTICES

80
Special attention must be paid to the information presented in Warning, Caution and information notices when they
appear in this manual. Examples of Caution, Warning and information notices along with an explanation of their
purposes follow.

WARNING
• A Warning informs the user of a hazard or potential hazard
that could result in serious of fatal injury if the precautions or
instructions given in the warning notice are not observed.

CAUTION
• A Caution informs the user of a hazard or potential hazard that could result
in injury or damage to the equipment if the precautions or instructions
given in the caution notice are not observed.

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i An Information Box contains supplemental information or references to

supplemental information on a topic.

Stop Box highlights important conceptual or procedural details that must be

understood and applied in order to successfully use the product.

ABOUT THE AC SUPERDRIVE

PERSONAL SAFETY
Danaher Motion Stockholm AB provides this and other manuals to assist manufacturers in using the AC SuperDrive in
a correct, efficient and safe manner. Manufacturers must insure that all persons responsible for the design and use
of equipment employing the AC SuperDrive have the proper professional skill and apparatus knowledge.

WARNING
• The high power levels and high torque available from a motor, AC SuperDrive
combination can cause severe or fatal injury.

CAUTION
• The AC SuperDrive is intended for connection only to DC battery power sources
and for use with low voltage asynchronous motors.
• Always verify before installation that the AC SuperDrive model is correct for
the vehicle’s battery supply voltage. The DC Supply nominal voltage is stated
on a label on the cover of each AC SuperDrive.

INTENDED USE OF THE AC SUPERDRIVE

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Our AC SuperDrive products are intended for controlling motors in battery powered electric vehicles. These drives
are supplied to original equipment manufacturers (OEMs) for incorporation into their vehicles and vehicle control
systems.

OEM’S RESPONSIBILITY

OEM’s are responsible for ensuring that AC SuperDrives are used for their intended purpose only, safe function of the
system and for compliance with all applicable regulations.Responsibility for the safe functioning of the system reverts
to the owner or user in all cases in which a non-professional has done installation, service or repair and when the
system is used for other than its intended purpose.

PRODUCT IDENTIFICATION
PACKAGING CONFIGURATIONS

The AC SuperDrive is manufactured in the following two configurations:

• Convection cooled models (see Figure 1) employing a heat sink with cooling fins that transfer heat to the surrounding
air by convection.
• Conduction cooled models (see Figure 1) with a flat heat sink and mounting surface that transfers heat into the
surrounding vehicle structure by conduction.

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PRODUCT IDENTIFICATION LABEL

A label, see Figure 1 for placement, and see Figure 2 containing pertinent product identification information is affixed
to the AC SuperDrive cover next to the B+ terminal post. The product label fields relevant to product identification are
described below. For AC SuperDrive expressions, see Table 1.

Product identification label

Figure 1. AC Superdrive with fins and flat Mounting Surface. Figure 2. AC SuperDrive Product Identification Label.

Field Description
Danaher Motion Unique part number assigned to AC SuperDrives with a specific
Stockholm AB hardware and software configuration. AC SuperDrives with the same
article number and revision code are identical.
Rev. Indicates the revision level of the article.
Type

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* Contact Danaher Motion Stockholm AB for further information.
Serie No. Production lot number (assigned by the factory). The production lot
number together with the sequence number yield a unique serial number
for each AC SuperDrive.
Serie No. Serial number within a production lot.
Manufacture date Year, month and day of manufacture.
Table 1. AC SuperDrive Product expressions.

TECHNICAL SUPPORT

For additional information on any topic covered in this document, or for additional information or applications assistance
on any Danaher Motion Stockholm AB product, contact an Danaher Motion Stockholm AB Applications Center listed
in the front of this manual.

PRODUCT WARRANTY

Refer to the sales agreement or contract under which the AC SuperDrive was purchased for a complete statement
of the product warranty.
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WIRING

WIRING THE AC SUPERDRIVE

This section provides schematic diagrams and related information for connecting AC SuperDrives into a vehicle
in a CAN Bus based application. These circuit diagrams present basic - but functional - general purpose wiring
configurations. AC SuperDrive users may choose to augment these generic-wiring configurations to fit their individual
requirements or conventions.

MOTOR AND BATTERY CONNECTIONS

GENERAL

Figure 9 shows the basic power-wiring diagram for the AC SuperDrive and it’s motor. This configuration utilizes an on-
board fuse and main contactor under direct control of the truck controller. Table 2 provides a description of the six
terminal post connections on the AC SuperDrive.
Terminal Description
B+ Provides a tie point for connection of battery power to the on-board fuse
(no connection to internal AC SuperDrive circuitry from this terminal).
+ Supplies fused battery power for the power stage that produces
threephase AC motor current.
B- This is the battery return connection.
U, V, W Phase currents for the three-phase induction motor.
Table 2. Motor and Battery Connections.

INRUSH CURRENT LIMITING RESISTANCE

CAUTION
• The battery wiring to AC SuperDrives must include a suitable PTC (positive
temperature coefficient) resistance or other provisions for limiting inrush
current to the drive’s filter capacitors during power up. Failure to limit inrush
current may damage the drive.

A PTC resistance (or suitable alternative resistance) limits inrush current to the AC SuperDrive’s filter capacitors
during their initial charging period when DC Supply voltage is first applied. A diode in series with the PTC resistance
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prevents the energy stored in the SuperDrive’s internal capacitors from powering the truck controller when the start
key is switched off. See Figure 9.
The configuration shown in Figure 8 is typically used for Inrush Current Limiting for one (1) up to four (4) AC Superdrive

Figure 8. Recommended Inrush Current Limiting Circuit.

MAIN CONTACTOR

The main contactor serves as both a power distribution component and key safety interlock. The truck controller
energizes the main contactor when the AC SuperDrives and motors are ready and available to execute motion. When,
as the result of some error/fault condition motion is not permitted, the truck controller opens the main contactor.

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KEY START INPUT

The KEY START input (see Table 3) supplies battery voltage to the AC SuperDrive for its internal processor and other
functions. Power to the KEY START input is generally controlled by the vehicle start key.

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Figure 9. Motor and Battery Wiring Diagram with on-board fuse.

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CONTROL AND I/O CONNECTIONS

GENERAL

Connector K1 (Plug AMPseal 23P 770680-1, Contact 770854-1) provides the electrical interface for all control and
I/O connections to an AC SuperDrive. Figure 10 illustrates wiring of the mating interface connector. Refer to Table 3
for a description of the control and I/O signals.

i Read AMP
instruction.
Application Specification 114-16016 for assembly

K1 (pin) Type Name Description

1 Input KEY START KEY START supplies battery voltage to the AC SuperDrive
for its internal processor and other functions. Applying
battery power initiates the drive powerup sequence. This
input should be fused for protection. Protected against
reverse polarity
2, 10 Output OPEN DRAIN One of the outputs may be utilized for controlling the main
OUTPUT1 Y 2 contactor in the system. ON (low) when AC SuperDrive is
in normal operating mode. OFF (high) when a fault/error
condition prevents normal operation. For inductive load,
an external free wheel diode shall be used.
Open Drain output, sinks 1A. The output is a PWM
Controlled at 1, 2, 4, 8 kHz, or an ON/OFF output.
3 Output ENCODER +12_ Supply for external motor pulse sensors. Diode in series
OUT for B+ protection. Output voltage 11V +-5% at 50mA
load.
4 Output ENCODER GND Ground reference for ENCODER, not B+ protected.
5 Input ENCODER CH 1 Phase 1 input from encoder (sensor bearing).
Internal 1 kΩ pull-up resistor to +12V_OUT
6 Input ENCODER CH 2 Phase 2 input from encoder (sensor bearing).
Internal 1 kΩ pull-up resistor to +12V_OUT
11 Input DIGITAL INPUT Low<2V, High>8V, Max B+
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12, 20 Output ACS ID 1 Y 2 Internal Pull up See Table 5

13, 21 Output ACS ID GND. Not B+ protected. Ground reference for ACS ID. Use in
first hand pin 13
16 Output MOTOR TEMP Sensor KTY 84 (Max 24V input).
17 Output MOTOR TEMP GND Not B+ protected. Ground reference for MOTOR TEMP
GND
18 - - -
19 - - -
14, 15 Output CAN_L One for IN and one for OUT to the next device.
22, 23 Output CAN_H One for IN and one for OUT to the next device.
7, 8 Output CAN GND. One for IN and one for OUT to the next device.
Optional from Q042
9 Output CAN 120R CAN 120 ohm termination resistor. To use the termination
connect pin 9 to 22.

Table 3. Interface Connector K1 Inputs and Outputs.

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120 OHM TERMINATION

Both physical ends of the CAN Bus network shall be terminated with 120 Ω between CAN_H and CAN_L to improve
noise immunity. Internally one end of the termination resistor is connected to CAN_L. The open end of the resistor is
connected to pin 9, see Table 3.

SENSOR BEARING SIGNALS

The sensor bearing that is integrated into the motor, provides speed and direction feedback for the AC SuperDrive.
The connector on the AC SuperDrive side is an AMP Superseal (282088-1). The standard sensor bearing produces a
two-phase square wave output (Example SKF P/N 6206/VU1028 gives 64 pulses/ revolution per phase). Other pulse
rates in the range 32 - 160 p/r can be selected in the Software. (Parameter accessible via CANopen).

AMP
K1 Signal name Wire color AMP Pin No
Connector
3 ENCODER + 12_OUT Red 1
4 ENCODER GND Black 4
5 ENCODER CH 1 Blue 1) 2
6 ENCODER CH 2 White 1) 3
Table 4. Standard Sensor Bearing Wiring Color-Codes.

1) These two wires are motor depending. If the motor does not turn (i.e. oscillates around zero speed) at the first
start up, these two wires have to be swapped. If the rotation direction is not correct, the SW parameter bit Inverted
Rotation Direction in Application Setup Word (2020h:10) shall be set.Sensor bearings are manufactured with a
small length of unterminated four conductor cable to which input and output connections are made. Table 4 lists the
color-coding and signals names for the standard sensor bearing. Figure 10 shows the wiring diagram.

i The motor connections (U, V, W) shall never be swopped.

The connector on the motor side is an AMP Superseal (282106-1) with integrated RC filter.

To minimize the possibility of electrical noise coupling into encoder lines, avoid routing encoder cables next to
conductors carrying high currents or high current pulses. Noise immunity may also be improved by using twisted
conductor cable for encoder to drive connections.

80
Contact the motor manufacturer to get the correct wiring; otherwise

i the characteristic for the sensor will be changed. There can be other
connectors at motor side depending on OEM

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Figure 10. AC SuperDrive Control and I/O Wiring Diagram for SKF P/N 6206.

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ACS ID1 AND ID2 INPUTS

The ACS ID1 and ID2 inputs are used in applications to inform the AC SuperDrive firmware of it’s function (i.e. whether
a traction or lift). Connector(s) K1 pins 12 & 20 are wired as indicated in Table 5 to assign the function of each drive.
The OEM can choose functions to adapt their own purpose. The CAN base address is default value 8 to 5, See Table
5. The ACS ID is accessible via CANopen
CANopen
ACS ID2 (K1:20) ACS ID1 (K1:12)
Default ID
8 1 (open) 1 (open)
7 1 (open) 0 (connected to ACS ID GND)
6 0 (connected to ACS ID GND) 1 (open)
5 0 (connected to ACS ID GND) 0 (connected to ACS ID GND)

Table 5. K1 Pin 12 & 20 Wiring verses AC SuperDrive Function.

TEMPERATURE SENSOR

Contact the motor manufacturer to get the correct wiring; otherwise

i the characteristic for the sensor will be changed. There can be other
connectors at motor side depending on OEM

A temperature sensor with positive temperature coefficient (Philips P/N KTY 84- 150) embedded in the motor winding
(by the motor manufacturer) provides a means for the AC SuperDrive to monitor motor temperature. The connector
on the AC SuperDrive side is an AMP Superseal (282080-1). Table 6 lists the color-coding and signal names for the
standard motor temperature sensor. Figure 10 shows the wiring diagram. The connector on the motor side is an AMP
Superseal 282104-1 with integrated RC filter as standard. The ACS temperature measurement has a constant current
source, which runs 1.8mA through the temperature sensor. This results in a voltage that reflects the temperature. The
motor temperature is accessible via CANopen.

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Figure 11. Characteristics of Temperature Sensor KTY-84.

AMP Pin AMP

K1 Signal name Wire color
No Connector
16 MOTOR TEMP Red 2
17 MOTOR TEMP GND Red with a longitudinal 1
black stripe.

Table 6. Standard Motor Temperature Sensor Wiring Color Codes.

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Electric control and adjusting

CAN BUS COMMUNICATIONS

For additional information on CAN Bus and CAN hardware, refer to the

i Standard ISO 11898. The AC SuperDrive conforms to the CANopen

software protocol

INTERFACING AC SUPERDRIVE IN A TRUCK CANNETWORK

The AC SuperDrive employs an isolated CAN bus interface. Figure 12 illustrates the wiring configuration for:
• AC SuperDrive on a CAN network.
• VMC20
The CAN Bus must be wired in a “Daisy chain” arrangement as shown in Figure 12. Twisted pair wiring is required for
the CAN_H and CAN_L signals. Both physical ends of the CAN Bus must be terminated with 120 ohm resistances.
A service device connector in a safe, convenient location should be included in the wiring configuration. Additionally,
CAN Bus wiring should be physically separated from conductors carrying high currents.
The CAN bus is often opto-isolated to get sufficient noise margins in units that are switching high currents (such as
ACS). In these units, CAN GND is a reference point for the CAN communication (CAN H and CAN L). CAN GND should
be connected to B- at one point, and preferably one point only. If all units on the CAN bus are isolated, CAN GND
should be externally connected to B- (see Figure 12).

Figure 12. AC SuperDrive and VMC20 Connection to a Truck CAN

Network (three isolated nodes).

If one unit on the CAN bus is non-isolated, no external

connection of CAN GND shall be made. If several units on
the CAN bus are non-isolated, these should all be grouped
together at one end on the CAN bus, and the GND connection
to these units should be taken from one common point
(star connection) if possible (see Figure 13). Under no
circumstances shall CAN GND be carrying supply current to any
of the units, nor be connected to Protective GND (chassis).
80

Figure 13. ACS SuperDrive

and VMC20 Connection
to a CAN Network (two
isolated and two non-
isolated nodes).

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START UP AND COMMISSIONING

GENERAL

The AC SuperDrive is a software configurable device. In a CAN (Controller Area Network) based system, all aspects of
AC SuperDrive setup and operation are managed by a truck controller communicating over the CAN Bus.

This section presents a general procedure for the startup and verification of an AC SuperDrive following installation
in an operational system (vehicle).

The initial startup and verification of an AC SuperDrive in a new application

i or new design requires additional steps which are detailed in the AC

SuperDrive Designer’s Guide.

Built-in diagnostic functions monitor battery voltage, heatsink temperature and motor temperature along with a
number of additional error conditions. Warning and error conditions are logged in Warning and Error status words,
which are accessible to the truck controller. The Troubleshooting Guide beginning on page 31 provides procedures for
pinpointing and eliminating the causes of warning and error conditions.

CAUTION
• Wiring errors, improper setup, drive faults and other conditions may cause the
vehicle to move in the wrong direction or at the wrong speed. Take necessary
precautions to prevent injury to personnel or damage to equipment prior to
applying power for the first time.
• Make sure that the motor and battery cables are connected correctly.
Incorrect motor or battery connections may destroy the AC SuperDrive.

CHECKS PRIOR TO INITIAL POWER UP

Perform the following before applying power to an AC SuperDrive for the first time:

1. Verify that the proper AC SuperDrive article number for the application has been installed. Verify that
the vehicle battery voltage matches the AC SuperDrive’s Nominal DC Supply Voltage rating listed on the product
identification label affixed to the AC SuperDrive (see Figure 2).

80
2. Verify that all power and signal wiring to the AC SuperDrive is correct.
3. Verify that the resistance (or other provisions) for limiting inrush current to the drive capacitors are properly
installed in the power wiring to the AC SuperDrive.
4. Verify that connections to battery and motor terminals are tight.
5. Verify that the control I/O connector is fully mated and latched into position with the mating connector (K1)
on the AC SuperDrive.
6. Verify that the AC SuperDrive is correctly fused for the application. Refer to the vehicle manufacturer’s
maintenance documentation for the correct fuse size
7. On a traction application, block up or otherwise disable drives wheels to prevent the possibility of unexpected
vehicle motion or motion in the wrong direction during initial checkout. On a lift application, open the valve to prevent
the possibility of excess pressure build-up (in the event of a pressure relief valve malfunction).

VERIFYING AC SUPERDRIVE READINESS FOR OPERATION

The following procedure is to verify that an AC SuperDrive is functional and able to communicate over the CAN Bus.

1. Apply battery power to the KEY START input. This applies logic power to the AC SuperDrives.
2. Verify that the green LED indicator on each AC SuperDrive is in the steady ON condition. If the indicator is
blinking or off, it indicates an error/warning or other fault condition exists within the AC SuperDrive.
3. Consult the Troubleshooting Guide, beginning on page 31 of this manual for possible causes and corrective
actions.

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CONFIGURING THE AC SUPERDRIVE FOR THE APPLICATION

As shipped from us in the beginning of a truck development project, the AC SuperDrive is pre configured with a set of
default parameters appropriate for the drive model and motor designated to be controlled by the AC SuperDrive. These
default parameters enable the Drive and it’s motor to operate at fraction of their potential during initial start-up and
checkout. A necessary step in the AC SuperDrive start-up procedure is to update those AC SuperDrive parameters
adjustable by the user to the values established for the application. The useradjustable parameters are specified in
the AC SuperDrive Designer’s Guide.

The general procedure for obtaining the correct configuration in the final product requires normally that the established
parameter values are used as default values in the from us shipped AC SuperDrives. The exceptions are the
following:

• The truck controller (or other device) downloads parameter values that are depending on the truck configuration
chosen in for example production and/or in the field (for example performance modes). In order to retain
a configuration, the parameters have to be stored in the AC SuperDrive’s non-volatile memory (EEPROM).
Thereafter the configuration is not changed until another configuration is downloaded and stored in the same
manner. Consult the vehicle manufacturer’s maintenance information for specific instructions for performing
this task.

• When parameters are continuously updated via the real time data exchange from the truck controller to the
ACS.

The truck controller, by – for example – reading the checksum for all parameters stored in the AC SuperDrive’s EEPROM,
can detect the situation where a drive’s configuration (set of parameter values) is not correct for the application and
normally prohibits vehicle operation until the AC SuperDrive has been correctly configured.

WARNING
• All AC SuperDrive parameter values established have to be verified and validated prior to
that the parameter values are used in the field by the end user.
• This must be done in order to establish that all safety critical functions in the truck, for
example braking, are working properly.
• The complete range of parameter values that are updated by the truck controller (or any
other device) has also to be verified and validated prior to that the parameter values are
used in the field by the end user.
• During the process when the parameter values are established it is of major importance
to take proper safety precautions when testing since wrong parameter values may
jeopardize the operation of the truck’s safety critical functions.
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FINAL OPERATIONAL CHECKS IN VEHICLE

CAUTION
• For lift applications, make sure the pump rotates in the proper direction. Rotation in the
wrong direction may damage the pump.
• Make sure that the motor and battery cables are connected correctly. Incorrect motor or
battery connections may destroy the AC SuperDrive.

1. With the main contactor open (not enabled), apply battery power to the AC SuperDrive’s B+ (or +) terminal
through the inrush current limiting resistance.

2. Before enabling the main contactor, verify that the AC SuperDrive’s filter capacitors have charged. The filter
capacitors are fully charged when the voltage measured between the AC SuperDrive’s + and B- terminals has
reached battery voltage level.

3. Enable the main contactor.

4. Verify that the AC SuperDrive and it’s associated motor start, stop and run properly at slow speed and at full
operational speed. Refer to Wiring/Control and I/O Connections/Sensor bearing Signals.
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MAINTENANCE

The AC SuperDrive contains no user adjustable or user replaceable components beneath it’s
protective cover. Do not remove the cover.

Do not clean the AC SuperDrive using high-pressure water.

INTRODUCTION
This section presents a list of periodic preventive maintenance items and procedures for replacing an AC
SuperDrive.

CAUTION
• If drive was recently in operation, heatsink may be too hot to touch. If necessary, allow the
heatsink to cool before attempting to remove drive.
• Before removing or installing an AC SuperDrive, disconnect battery power from B+, + and
KEY START inputs.
• Wait 5 minutes for internal filter capacitors to self-discharge, or apply a 100 ohm resistance
between + and B- terminals for 15 seconds to discharge the filter capacitors.
• To prevent personnel injury and protect the AC SuperDrive from possible damage due to
voltage transients, the AC SuperDrive’s internal filter capacitors must be discharged as
described in “Drive Removal” on page 30. Do not short the + to B- terminal.

PERIODIC PREVENTIVE MAINTENANCE

The recommended periodic preventive maintenance procedures for the AC SuperDrive are minimal. We recommends
the following items be performed every six months (or more frequently if necessary):

AC SUPERDRIVE WITH FINNED HEATSINK

1. Remove all power from the drive. Apply a 100 ohm resistance between + and B- terminals for 15 seconds to
discharge the filter capacitors.

2. Remove accumulated dust and debris from the heatsink and blades of the cooling fan (if applicable). If air is
used, use only air with low pressure.
80

80
3. Make sure nothing is obstructing the drive’s air circulation path.

4. Retighten the nuts on the AC SuperDrive to 10 Nm ± 1Nm.

5. Retighten the nuts on the motor and battery terminal posts to 15 (±2) Nm.

6. (If applicable) power up the AC SuperDrive and verify that the cooling fan is operational.

AC SUPERDRIVE FLAT HEATSINK

1. Remove all power from the drive. Apply a 100 ohm resistance between + and B- terminals for 15 seconds to
discharge the filter capacitors.

2. Remove accumulated dust and debris from the AC SuperDrive. If air is used, use only air with low pressure.

3. Retighten the nuts on the motor and battery terminal posts to 15 (±2) Nm.

4. Retighten the nuts on the AC SuperDrive to 23 (±2) Nm.

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REPLACEMENT OF AC SUPERDRIVE
DRIVE REMOVAL
1. Remove all power from AC SuperDrive’s B+, + and KEY START inputs.

2. Wait 5 minutes for internal filter capacitors to self-discharge, or apply a 100 ohm resistance between + and
B- terminals for 15 seconds to discharge the filter capacitors.

3. Remove nuts from battery and motor terminals and remove wires. Label the wires prior to removal if not already
labelled.

4. Depress locking latch on connector housing and remove mating connector from K1.

5. Remove on-board fuse (if applicable) for use in replacement drive.

6. • On units with fins, loosen four bolts securing drive to its mounting brackets.
• On units with a flat heat sink, remove bolts securing drive to the vehicle.
Remove drive from the vehicle.

DRIVE INSTALLATION

1. Verify that battery power to the B+, + and KEY START inputs has been removed.

2. • On units with fins, place the replaced drive to its mounting brackets.
See Mounting AC SuperDrive , on page 9
• On units with a flat heatsink, apply thermal grease on the unit before mounting. See Mounting AC SuperDrive,
on page 10.

3. Install the on-board fuse (if applicable), motor wires, battery wires and nuts.
Tighten the nuts to 15 (+3 –0) Nm.

4. Insert mating connector into K1.

5. Perform initial start-up per the procedure titled Start up and Commissioning.
80

(06/12/2007) 80-04-M133 EN
 27
Electric control and adjusting

TROUBLESHOOTING GUIDE

SCOPE OF THE TROUBLESHOOTING GUIDE

This troubleshooting guide presents procedures for diagnosing and eliminating the causes of faults and error conditions
affecting the AC SuperDrive. The AC SuperDrive is one component of a drive chain, which may include mechanical drive
components, a motor, hydraulics, electrical controls, wiring and battery. AC SuperDrive errors/faults may result from
condition external to the AC SuperDrive. This troubleshooting guide addresses causes internal as well as external to
the AC SuperDrive, which may produce fault or error conditions within the AC SuperDrive.

The Symptom, Emergency Error codes Errors and Warning bitfield codes

i and related troubleshooting charts presented in this section are utilizing

the CANopen communications protocol. For further information on the
CANopen object, see Object Dictionary documentation.

USING THE TROUBLESHOOTING GUIDE

CAUTION
• Do not manually operate main contactor or override system control of main
contactor without first isolating AC SuperDrive B+ (or +) terminal from main
contactor output.

ORGANIZATION OF TROUBLESHOOTING GUIDE

This troubleshooting guide is organized by visual symptoms and error/warning codes produced by the AC SuperDrive.
Error/warning codes are usually displayed or available on an operator display under jurisdiction of the truck controller.
For each visual symptom and error/warning code there is a troubleshooting chart that lists possible causes and
corrective actions.

ABOUT ERRORS

The AC SuperDrive continuously monitors its internal operation as well as it’s interaction with the motor and truck
controller. Errors are serious problem, which prohibit continued operation of the AC SuperDrive.

80
When an error is detected :

• The AC SuperDrive operating software immediately stops motion then shuts down the drive’s power output to the
motor.

• The error bit in the Status Word is set.

• The error bit GENERIC in the Error Register is set.

• The appropriate error bit in the Extended Error register is set.

• Sends out the high priority EMCY message with the Error Code.

• The Error Code and the time is saved to the Error Log.

• The Time is saved to the Operation Times.

• The LED indicator starts to blink fast (10Hz).

80-04-M133 EN (06/12/2007)
 28
Electric control and adjusting

ABOUT WARNINGS

Less serious problems, which permit continued AC SuperDrive operation, often at reduced capacity, produce warnings.
The AC SuperDrive’s internal warning status is updated to reflect the code(s) for existing warning conditions. Operating
with active warning conditions does affect the AC SuperDrive status LED indicator, which changes from steady on
to slow (1Hz) blinking. When the root cause of a warning is removed, the AC SuperDrive automatically removes any
reduced capacity restriction related to the warning condition.

When an warning is detected :

• The warning bit in the Status Word is set.

• The appropriate warning bit in the Extended Error register is set.

• The LED indicator starts to blink slowly (1Hz).

LED STATUS INDICATOR

The LED status indicator, shown in Figure 14, provides a visual identification of the AC SuperDrives operating status.

STATUS DESCRIPTION
Steady green light. The controller is ok.

Fast flashing light. (10Hz) An error is reported to the controller.

When an error occurs, the AC SuperDrive
immediately stops motion then shuts down the
drive’s power output to the motor.

Slow flashing light. (1Hz) A warning is active.

80

Figure 14. The LED status indicator placement.

USING THE TROUBLESHOOTING CHARTS

Each troubleshooting chart presents possible causes and relevant conditions (in oval blocks) with connections to
corrective actions (in rectangular blocks). Supplemental comments and explanations are enclosed in oval shaped
blocks constructed with dashed lines. When using a troubleshooting chart, one should investigate first those possible
causes, which seem most likely considering the recent history of the vehicle.

Locate the observed symptom(s) in Table 7, error code in Table 8 and warning code in Table 9, then refer to the
troubleshooting chart on the referenced chart. After performing a corrective action, restart the AC SuperDrive and
verify that the error/warning does not reoccur. If the error/warning does reoccur, proceed to the next corrective action
on the troubleshooting chart.

Symptom code
Main contactor doesn’t close within 10 seconds after switching on key switch.
Fuse to Power Stage is blown.
AC SuperDrive Status indicator is blinking or off.
Motor runs only at low speed, with a ticking sound.
Table 7. Symptom verses Troubleshooting Chart.
(06/12/2007) 80-04-M133 EN
 29
Electric control and adjusting

Extended
Emergency Errors bit field
Error
Error code code index
3010h,2
0x2310 0x2000 AC Current - Over current.
0x2340 0x0001 AC Current – Short circuit.
0x3120 0x0010 No Charging DC Bus.
0x3211 0x0004 DC Bus high – software detected.
0x3212 0x0008 DC Bus high – hardware detected.
0x3221 0x0002 DC Bus low.
0x4210 0x0020 Motor temperature high.
0x4310 0x0040 / 0x0080 Heatsink Over temperature.
0x5111 0x0400 15 V Supply low voltage
0x5113 0x0800 15 V Supply low or high voltage
0x5210 0x0200 Current sensors offset calibration error
0x5410 0x1000 Open Drain Output Current High
0x8100 0x0100 CAN Time Out.
Table 8. Error verses Troubleshooting Chart.

Extended Warning bit

field code Error
Index 3010h, 1
0x0001 Low voltage
0x0002 High voltage
0x0004 DC Bus calibration
0x0008 Motor temperature low, <-50°C
0x0010 Motor temperature high>145°C
0x0020 Motor temperature sensor not connected/short circuit
0x0040 Heat sink temperature 1 low<-20°C
0x0080 Heat sink temperature 1 high >85°C
0x0100 Heat sink temperature sensor 1 not connected/short circuit

80
0x0200 Heat sink temperature 2 low<-20°C
0x0400 Heat sink temperature 2 high >85°C
0x0800 Heat sink temperature sensor 2 not connected/short circuit
0x1000 Default parameters
0x2000 Power reduction due to temperature (motor or heatsink).
0x4000 Speed feedback sensor not connected/short circuit
0x8000 Current Measurement Calibration.
0x40000 Open Drain Output Current High Warning
0x80000 Open Drain Output Current High Error

Table 9. Warning verses Troubleshooting Chart.

OEMS USER DOCUMENTATION

The troubleshooting charts in this section are generic in nature and designed to stand alone in order that OEMs may
easily incorporate this information into the their documentation for the vehicle. We can provide this troubleshooting
information on electronic media in various formats for OEMs who wish to import it into their documentation.

80-04-M133 EN (06/12/2007)
 30
Electric control and adjusting

MAIN CONTACTOR DOESN’T CLOSE

Symptom

Start

When status is
off, SuperDrive is not
Is SuperDrive status yes operating
indicator off ?
Go to troubleshooting
no chart for «SuperDrive
Status Indicator is off»

The SuperDrive status

Is SuperDrive Stauts yes indicator blinking means an
indicator blinking ? error condition exists which
may have caused the main
no Go to troubleshooting chart contactor to be deenergised.
for «SuperDrive Status
Indicator is blinking»

Does SuperDrive yes

directly control the main
contactor ?
no
Check «Open Drain
Output» output (K1:2
or K1:10). Replace
SuperDrive if output is
Verify truck controller defective.
80

to SuperDrive
communications is okay.

Checktruck controller Truck contactor may be

circuit which operates failling to enable main
main contactor and repair contactor.
if defective.

After disconnecting fuse

or otherwise isolating
SuperDrive B+ terminal from
battery voltage, verify main
contactor is operational.
Replace if defective.

End

(06/12/2007) 80-04-M133 EN
 31
Electric control and adjusting

FUSE TO POWER STAGE IS BLOWN

Symptom

The most likely reasons

Start for a blown fuse are a
short circuit in the drive
power stage or the average
current drawn by the drive
Replace fuse and restart
exceeds the fuse rating.
drive.

Does fuse blow almost yes

immediately after main
contactor is closed ?
no Replace drive.

Place vehicle back into

normal operation.

Does fuse blow again yes

after vehicle has been in
operation for some time ?
no
Verify that correct size fuse
was used.

80
End

Look for defective

mechanical component in
drive train which is creating Increased friction, heavier
increased friction. load, high speed and rapid
start/stop all increase
average current drawn by the
if vehicle has been drive. Vehicle may have been
operating with heavy load, operating at power levels
at high speed or in a beyond it’s operating limit.
repetitive stop/start cycle,
or above recommended
limits, try reducing speed,
load, accel. and decel
rates.

80-04-M133 EN (06/12/2007)
 32
Electric control and adjusting

AC SUPERDRIVE STATUS INDICATOR IS BLINKING OR

Symptom

Start

A blinking status
Is status indicator indicator means the
yes SuperDrive has detected an
blinking ?
error or warning condition.

no Fast (10Hz)= Slow (1Hz)=

Error codes Warning codes
Determine active error/
warning code and consult
appropriate troubleshooting
chart

When the status indicator

is off, it usually means that
the SuperDrive internal
operating program is not
executing.

Is Vbatt present at
key start input (measure no
between K1 and B-)
yes
Check and correct power Key start input supplies
distribution problem in key power for all internal
start circuit. SuperDrive electronics.
80

yes
Battery voltage too low ?

no
Charge battery

Replace SuperDrive

End

(06/12/2007) 80-04-M133 EN
 33
Electric control and adjusting

MOTOR RUNS ONLY AT LOW

Symptom

Start

If motor drive or wiring

was replaced, look for
Verify drive to motor wiring. motor to drive or sensor
bearing to drive wiring error
If not, look for a loose or
broken connection.

Verify sensor bearing to

drive wiring.

Motor phase windings

may be labelled incorrectly.
Swap two motor phase
connections.

Contact an InMotion
Change specified direction
Applications Center for
in SuperDrive control
assistance in making this
program.
control program modification.

Replace drive.

Does motor run okay now ? yes

80
no
End

Replace motor.

End

80-04-M133 EN (06/12/2007)
 34
Electric control and adjusting

SPEED FEEDBACK SENSOR NOT

Warning Code 0x4000

Start
The SuperDrive is detecting
either an open circuit or
short circuit condition in
Turn on DC supply
sensor bearing circuit.
power and key start to
SuperDrive.

Verify contunity of 4 motor

to SuperDrive sensor
bearing connections.

This test checks the

supply voltage produced by
Is DC voltage at K1-3 and no the drive.
K1-4=12 VDC ?

yes
Replace drive.

Is DC voltage measured at This test checks for

K1-5 -K1-4 and K1-6-/ K1-4 no an output from the sensor
with the motor turning from 0 bearing with the motor
- 8 VDC. turning.
yes Replace motor.

Replace drive.
80

Does motor run okay now ? yes

no
End

Replace motor.

End

(06/12/2007) 80-04-M133 EN
 35
Electric control and adjusting

MOTOR TEMPERATURE ERROR

Error Code 0x4210

POWER LIMITED DUE TO OVER TEMPERATURE

Warning Code 0x2000

POWER REDUCTION DUE TO MOTOR OVER TEMPERATURE

Warning Code 0x0010

Start
Air flowing across the
surface of the motor helps to
remove accumulated heat.
Is something interfering yes
with motor cooling ?

no
Make sure nothing impeding If the motor is fan cooled,
air flow to the motor verify that fan and its control
circuit are working.
If the motor is dirty, clean
accumulated dust and debris Let vehicule in idle state with
from surface. fan running until motor temp.
is okay.

Is vehicule operating at yes

ambient temperature above its
specified operating range ?
no Let vehicule in idle state until
Operate vahicule at reduced
speed & reduced load when
motor temp is okay.

80
ambient temp. is high.

Is vehicule operating yes

outside its capacity ?
no Reduce load, operating
Let vehicule in idle state until
speed, acceleration/
motor temp is okay.
deceleration rate.

Is there execive yes

friction in drive train ?
no Let vehicule in idle state until Check drive train components
motor temp is okay. for proper operation.

End

80-04-M133 EN (06/12/2007)
 36
Electric control and adjusting

HEATSINK OVER TEMPERATURE ERROR

Error Code 0x4310

POWER LIMITED DUE TO HEATSINK OVER TEMPERATURE 1, 2 > 85 OC

Warning Code 0x0080 1
0x0400 2

POWER REDUCTION DUE TO TEMPERATURE

Warning Code 0x2000

Start

Does this error occur when Heatsink temp. sensor

yes
drive is cold (i.e. after vehicule Replace AC SuperDrive. in SuperDrive may be
has been off for some time) ? defective.
no

Air flowing across the

Is something interfering yes surface of the heatsink
with drive cooling ? removes accumulated heat.
no Make sure nothing is If the drive is fan cooled,
impeding air flow over the verify that fan and its control
drive heatsink. circuit are working.

If heatsink is dirty, clean Let vehicule in idle state with

accumulated dust and debris fan running until drive telp. is
from surface. okay.
80

Is vehicule operating at yes

ambient temperature above its
specified operating range ?
no Let vehicule in idle state until
Operate vahicule at reduced
speed & reduced load when
motor temp is okay.
ambient temp. is high.

Is vehicule operating yes

outside its capacity ?
no Reduce load, operating
Let vehicule in idle state until
speed, acceleration/
motor temp is okay.
deceleration rate.

Is there execive yes

friction in drive train ?
no Let vehicule in idle state until Check drive train components
motor temp is okay. for proper operation.

End
(06/12/2007) 80-04-M133 EN
 37
Electric control and adjusting

AC CURRENT OVER CURRENT

Error Code 0x2310

AC CURRENT SHORT CIRCUIT

Error Code 0x2340

Start

An overcurrent error occurs

when the SuperDrive’s load
Remove power from key start impedance falls below the
input, wait a few seconds, required minimun value. This
then reapply power. is usualy the result of a short
circuit in the drive power
stage, drive to motor wiring or
in the motor.

Error reoccurs after restarting no

and trying to run current in the
SuperDrive ?

yes End

Check drive to motor wiring

for phase to phase shorts
and phase to ground shorts.

Replace drive.

80
Error reoccurs after
yes
restarting and trying to run
current in the SuperDrive ?
no
End

Replace motor.

End

80-04-M133 EN (06/12/2007)
 38
Electric control and adjusting

DC BUS HIGH - HARDWARE DETECTED

Error Code 0x3212

DC BUS HIGH - SOFTWARE DETECTED

Error Code 0x3211

This error occurs when the

Start SuperDrive detects that Vbatt
is too high for safe operation
of the drive. This condition is
usually the result of too much
regenerated energy returned to
the battery or high resistance
between SuperDrive and
Commanded braking torque
yes battery. Vbat (measured
may be too high ? between + & B- terminals) for
AC SuperDrive models must
not exceed approximately :
no Reduce braking torque
amplitude commanded by ASC Model Max Supply
truck controler. ASC 36 50 VDC
Check motor to SuperDrive ASC 48 65 VDC
and SuperDrive to battery ASC 80 110 VDC
wiring and connections.
80

Check main contactor.

Replace drive.

Supply voltage measurement

Replace vehicule battery.
by SuperDrive may be
defective.

End

(06/12/2007) 80-04-M133 EN
 39
Electric control and adjusting

DC BUS LOW

Error Code 0x3221

NO CHARGING DC BUS

Error Code 0x3120

Start This error occurs when the

drive software detects that
yes the DC supply voltage (as
Is battery voltage low ? measured at + & B- terminals)
is too low to insure reliable
no operation.
Recharge battery.

Does error occur when yes

is supplying high current to
motor ?
no Check supply voltage at
drive + & B- terminals under
load conditions. If voltage ASC Model min Supply
is below ~70% of rated DC ASC 36 23 VDC
supply voltage (see chart ASC 48 30 VDC
Check DC Bus charging on right), look for source ASC 80 48 VDC
circuit. Verify that all of voltage drop in circuit
components are working. supplying battery voltage to
SuperDrive.

Check connections to drive

80
B+, + and B- terminals.
Tighten nuts to 10 Nm.

Check vehicule battery.

Replace drive.

End

80-04-M133 EN (06/12/2007)
 40
Electric control and adjusting

CAN –TIME OUT

Error Code 0x8100

Start This error occurs when the

SuperDrive has not received
a control message from the
Is the same error occuring on yes truck contrlleer for an interval
more than one SuperDrive on the exceeding 70 ms (default
CAN network ? value).

no

Check integrity of network

connections at all nodes.

Check integrity of truck

controller.
80

Replace SuperDrive(s).

Replace SuperDrive.

End

(06/12/2007) 80-04-M133 EN
 41
Electric control and adjusting

HEATSINK TEMPERATURE SENSOR 1,2 – OPEN CIRCUIT/SHORT CIRCUIT

Warning Code 0x100 1

0x800 2

Start

Remove power from key

Heatsink temperature sensor
start input. Wait a few
may be defective.
seconds, then reapply
power.

Warning code reoccurs after yes

restarting SuperDrive ?

no

Replace drive.

80
End

80-04-M133 EN (06/12/2007)
 42
Electric control and adjusting

MOTOR - TEMP < -50 °C

Warning Code 0x0008

HEATSINK MOTOR- TEMP 1, 2< -20 °C

Warning Code 0x0040 1

0x0200 2

POWER REDUCTION

Warning Code 0x2000

Start

Operate vehicule at
reduced speed with reduce
load until drive has warned
sufficiently for full power
operation.

Bring vehicule into a

heated building until drive
80

warms sufficiently for full

power operation.

End

(06/12/2007) 80-04-M133 EN
 43
Electric control and adjusting

MOTOR TEMPERATURE SENSOR OPEN CIRCUIT/SHORT CIRCUIT

Warning Code 0x0020

Start

Motor temp. sensor or it’s

wiring to SuperDrive may be
defective.

Verify continuity of motor

temp. sensor to SuperDrive
wiring.

Verify motor temp. sensor

is fonctional. Replace
motor if temp. sensor
defective.

Motor temp. measurement by

Replace AC SuprDrive. SuperDrive may be defective.

80
End

80-04-M133 EN (06/12/2007)
 44
Electric control and adjusting

15 V SUPPLY LOW VOLTAGE

Error Code 0x5111

15 V SUPPLY LOW OR HIGH VOLTAGE

Error Code 0x5113

CURRENT CALIBRATION ERROR

Error Code 0x5210

Start

Remove power from key

start input. Wait a few
seconds, then reapply
power.

Error code reoccurs after yes

restarting SuperDrive ?
80

no

Replace drive.

End

(06/12/2007) 80-04-M133 EN
 45
Electric control and adjusting

REVERTED TO DEFAULT PARAMETERS

Warning Code 0x1000

Start
This warning is given when
the SuperDrvie substitutes
its default parameters for the
user’s parameters.
Warning occurs on first yes
powerup following installation Default parameters are
of drive. substituted when a checksum
error is detected in the user
no Check vehicle parameter storage aera of
manufacturer’s instructions SuperDrive memory, or when
for drive replacement. the drive ID parameter value
A specific procedure for does not match the ID0 & ID1
downloading parameters to inputs (K1-8 & K1-9).
replacement drive may be
required.

Verify that drive is correct

Remove power from key for the application (i.e. lift,
start input. Wait a few tration).
seconds, then reapply
power.

80
End

Warning code reoccurs after yes

restarting drive ?

no EEPROM may be
Replace drive. defective.

End

End

80-04-M133 EN (06/12/2007)
 46
Electric control and adjusting
80

(06/12/2007) 80-04-M133 EN
ELECTRICAL DIAGRAMS

80

80-6-261248 EN (07/12/2007)
 2
Electrical diagrams

PRINCIPLE ELECTRIC CIRCUIT

1 - Battery G1 - Battery
2 - Emergency stop
3 - Rear left position light K1 - Start authorization relay
4 - Rear right position light K2 - Reverse gear sound alarm relay
5 - Front left position light K3 - Working head light relay
6 - Front right position light K4 - Warning centre
7 - Front working head light relay K5 - Line switch
8 - Front left working head light
9 - Front right working head light M1 - Reverse gear sound alarm
10 - Front left indicator M2 - Road sound alarm
11 - Rear left indicator M3 - Accelerator potentiometer
12 - Warning centre M4 - Lifting potentiometer
13 - Front right indicator
14 - Rear right indicator P1 - Diagnostic socket
15 - Road sound alarm
16 - Rear left reverse light S1 - Key switch
17 - Rear right reverse light S2 - Light switch (position light / working light)
18 - Left stoplight S3 - Forward / reverse reverser lever
19 - Right stoplight S4 - Blinker switch
20 - Reverse gear sound alarm S5 - Seat switch
21 - Reverse gear sound alarm relay S6 - Brake pedal switch
22 - Starter authorization relay S7 - Handbrake switch
23 - Revolving light S8 - Road sound alarm switch
24 - Bill-stick S9 - Revolving light switch
25 - Accelerator potentiometer S10- Steering pressure switch
26 - Steering potentiometer S11- Steering switch
27 - Controller S12- Tilting switch
28 - Pump motor variator S13- Dash panel lateral moving switch
29 - Drive motor variator S14- 4th element switch
S15- Emergency stop switch
COLOUR CODING
bc : white bl : blue g : grey j : yellow OPT10- Bill-stick
jvt : yellow/green m : brown n : black o : orange
r : red ro : pink vt : green v : purple ACS1 - Pump motor variator
ACS2 - Drive motor variator
ELECTRICS COMPONENTS MT1 - Pump motor
E1 - Rear left position light MT2 - Drive motor
E2 - Rear right position light
80

E3 - Front left position light VMC20 - Controller

E4 - Front right position light Acc - Accelerator
E5 - L.H. front working head light CC - Charge circuit
E6 - R.H. rear working tail light L - Lifting
E7 - L.H. front indicator
E8 - L.H. rear indicator
E9 - R.H. front indicator
E10 - R.H. rear indicator
E11 - L.H. rear reverse light
E12 - R.H. rear reverse light
E13 - R.H. stoplight
E14 - L.H. stoplight
E15 - Revolving light

FUSES
FP1 - Hydraulic control motor (425:355A-430:300A)
FP2 - Pump front wheel motor (425:300A-430:250A)
F1 - Control circuit (10A)
F2 - Main circuit (10A)
F3 - Control panel (10A)
F4 - Lighting (10A)
F5 - Lighting (10A)
F6 - Replacement fuses (10A)
(07/12/2007) 80-6-261248 EN
 3
Electrical diagrams
System assy

DIAGRAM SEE DIAGRAM

LAMP AND SOUND SYSTEM TRACTION AND PUMP SYSTEM

K5

vt/bc vt/bc vt/bc

15W /25W

F3 F2 F1
CC
j

r/m r/j S15

K1
bc/j r/vt

r/vt r/vt r/vt r/vt

2 14
Di1 B+
S5
3
vt Di2 Po1
42
FP1 FP2
M.av 4
m/bc Di3 Po2
1
S3 M.ar 5
m/n Di4 Po3
15
S6
16
bl Di5 Po4
29

17
vt/j Di6 Po5
13

S7 18 27 1 B+ 9 1 B+ 9
Di7 Po6 KEY NC KEY NC
S11 19 Motor temp
16
bl 1 Motor temp
16
bl 1
Di8 41 2 2
Po7 SO1 SO1
S12 30 Motor temp GND
17
bc/n 2 Motor temp GND
17
bc/n 2
Di9 12 10 10
Po8 SO2 SO2
S13 31 Encoder 12v
3
vt/r 1 Encoder 12v
3
vt/r 1
Di10 26 18 18
Po9

VMC20
12v out 12v out
S14 32 Encoder CH1
5
vt/j 2 Encoder CH1
5
vt/j 2

MT1
40
F5 Di11 Po10 11 11

MT2
DI 6 DI 6
33 11
Encoder CH2 vt/bc 3 Encoder CH2 vt/bc 3
Di12 Po11 19 19
DI_GND 4 DI_GND 4
38 25
Encoder GND vt/n 4 Encoder GND vt/n 4
F4 Di13 Po12
S10 K5 12 12
r/bc bl 9 39
ID1 ID1
Di14 Po13 r/bl 13 U 13 U
6 ID1_GND ID1_GND
r/bc r/bc r 8v DUT 10

ACS1

ACS2
Po14
max V V
Acc 21
vt Ain1 24 20 20
M3 Po15 ID2 ID2
35 W W
min Ain2 21 21
max ID2_GND ID2_GND
L 36
K4 K2 M4 vt/j Ain3
22 22 23 22 23
8
80V (ME430) S15 min 37 CAN_H vt CAN_H1 CAN_H2 vt CAN_H1 CAN_H2 bc
r/bc r/bc r/bc r/bc bl/o r/bc Ain4
120W
+ 48V (ME425)
4 20
Ain5
CAN_L
23
vt/bc
14
CAN_L1 CAN_L2
15
vt/bc
14
CAN_L1 CAN_L2
15
bc
n n n 8 7 8 7 8
34
Ain6
CAN_GND o CAN_GND1 B- CAN_GND2 o CAN_GND1 B- CAN_GND2

28
7 B-
n AGND
S2 K3
S4
S3 S6 K2 S8 S1

L 0 R
0 1 2

24V CAN_H
7
CAN_L
P1 2
CAN_GND
3

80
G1

m bl/bc r bl bc ro vt bc/n
120W

S9

bc/bl
B+
1
0v
2
CAN_GND
OPT10 3
CAN_L
E1 E2 E3 E4 K3 E5 E6 E7 E8 E9 E10 M1 E11 E12 E13 E14 M2 K1 E15 5
CAN_H
6

n n
n n n n n n n n n n n n n n n n n n n n

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

80-6-261248 EN (07/12/2007)
 4
Electrical diagrams
Traction and pump system

K5

vt/bc vt/bc vt/bc

15W /25W

F3 F2 F1
CC
j

r/m r/j S15

K1
bc/j r/vt

r/vt r/vt r/vt r/vt

2 14
Di1 B+
S5
3
vt Di2 Po1
42
FP1 FP2
M.av 4
m/bc Di3 Po2
1
S3 M.ar 5
m/n Di4 Po3
15
S6
16
bl Di5 Po4
29

17
vt/j Di6 Po5
13

S7 18 27 1 B+ 9 1 B+ 9
Di7 Po6 KEY NC KEY NC
S11 19 Motor temp
16
bl 1 Motor temp
16
bl 1
Di8 41 2 2
Po7 SO1 SO1
S12 30 Motor temp GND
17
bc/n 2 Motor temp GND
17
bc/n 2
Di9 12 10 10
Po8 SO2 SO2
S13 31 Encoder 12v
3
vt/r 1 Encoder 12v
3
vt/r 1
Di10 26 18 18

VMC20
Po9 12v out 12v out

MT1

MT2
S14 32 Encoder CH1
5
vt/j 2 Encoder CH1
5
vt/j 2
Di11 40 11 11
Po10
DI 6 DI 6
33 11
Encoder CH2 vt/bc 3 Encoder CH2 vt/bc 3
Di12 Po11 19 19
DI_GND 4 DI_GND 4
38 25
Encoder GND vt/n 4 Encoder GND vt/n 4
Di13 Po12
S10 K5 12 12
9 ID1 ID1
bl Di14 Po13
39
r/bl U U

ACS2
13 13
6 ID1_GND ID1_GND
r

ACS1
8v DUT 10
Po14
max V V
Acc 21
vt Ain1 24 20 20
M3 Po15 ID2 ID2
35 W W
min Ain2 21 21
max ID2_GND ID2_GND
L 36
M4 vt/j Ain3
22 22 23 22 23
min 37
Ain4
CAN_H vt CAN_H1 CAN_H2 vt CAN_H1 CAN_H2 bc
23 14 15 14 15
120W
20
Ain5
CAN_L vt/bc CAN_L1 CAN_L2 vt/bc CAN_L1 CAN_L2 bc
n n n 8 7 8 7 8
34 CAN_GND o CAN_GND1 B- CAN_GND2 o CAN_GND1 B- CAN_GND2
80

Ain6
28
7 B-
n AGND

CAN_H
7
CAN_L
P1 2
CAN_GND
3

120W

B+
1
0v
2
CAN_GND
OPT10 3
CAN_L
5
CAN_H
6

n n

24 25 26 27 28 29
(07/12/2007) 80-6-261248 EN
 Lamp and sound system

F5

F4
r/bc

r/bc r/bc

K4 K2

80V (ME430) S15

r/bc r/bc r/bc r/bc bl/o r/bc
+ 48V (ME425)

S2 K3 S3 S6 K2 S8 S1
S4
L 0 R
0 1 2

24V

G1

m bl/bc r bl bc ro vt bc/n

S9
-
bc/bl

E1 E2 E3 E4 K3 E5 E6 E7 E8 E9 E10 M1 E11 E12 E13 E14 M2 K1 E15

Electrical diagrams

80-6-261248 EN
n n n n n n n n n n n n n n n n n n n n

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

(07/12/2007)
5

80
 6
Electrical diagrams
80

(07/12/2007) 80-6-261248 EN
ELECTRIC TROUBLESHOOTING

80

80-08-M133 EN (16/10/2007)
 2
Electric troubleshooting

1.1.1 Errors detected by VMC20

Nr Source Condition When Tract Main Reset Remark

101 Switch startup error ACCEL switch active at startup KEY=ON OFF ON ACC SWITCH=OFF Tract setspeed=0

102 Switch startup error FW|REV switch active at startup FW=REV= OFF Tract setspeed=0

103 Direction switch error FW and REV ON at the same time KEY=ON OFF ON KEY=OFF Tract setspeed=0

Pot voltage > 95% or Pot voltage < 5%

104 Accel pot error KEY=ON ON ON KEY=OFF Tract setspeed=0
of VX_out

Voltage > 30% when ACC switch is not

105 Accel switch error KEY=ON ON ON KEY=OFF Tract setspeed=0
active

107 Battery under voltage 48V:Less than 28.2V/.8s KEY=ON OFF OFF KEY=OFF Detected by VMC20, not by ACS.

Voltage < limit (Parameter) for more than

108 ACS under voltage KEY=ON OFF OFF KEY=OFF Detected by VMC20, not by ACS.
0.8sec

109 Battery over voltage More than 98V/0.8s KEY=ON OFF OFF KEY=OFF Detected by VMC20, not by ACS.

Voltage > limit (Parameter) for more than

110 ACS over voltage KEY=ON OFF OFF KEY=OFF Detected by VMC20, not by ACS.
0.8sec

111 Communication error See 2.1.1 KEY=ON OFF ON KEY=OFF Tract speed=0

CHARGE A
114 Battery low voltage Battery LED = ON KEY=ON ON ON It should charge to the battery.
BATTERY

You should contact with

115 Startup error Communication failure when startup KEY=ON OFF ON KEY=OFF
Manitou engineer.

116 Lilt switch startup error LIFT switch active at startup KEY=ON OFF ON LIFT SWITCH=OFF Lift setspeed=0

Speed1 switch startup

117 Speed1 switch active at startup KEY=ON OFF ON TILT SWITCH=OFF Lift setspeed=0
error

Speed2 switch startup

118 Speed2 switch active at startup KEY=ON OFF ON TILT SWITCH=OFF Lift setspeed=0
error

Speed3 switch startup

119 Speed3 switch active at startup KEY=ON OFF ON TILT SWITCH=OFF Lift setspeed=0
error

Speed4 switch startup

120 Speed4 switch active at startup KEY=ON OFF ON TILT SWITCH=OFF Lift setspeed=0
error

Pot voltage > 95% or Pot voltage < 5%

121 Pump pot error KEY=ON OFF ON KEY=OFF Lift setspeed=0
of VX_out

Voltage > 30% when Lift switch is not

122 Pump switch error KEY=ON OFF ON KEY=OFF Lift setspeed=0
active
80

1.1.2 Errors detected by drive ACS (EMCY)

Nr Source Condition When Tract Main Reset Remark

ACS is shorted or motor terminals are ACS may be damaged if short circuit is
351 Short circuit KEY=ON OFF OFF KEY=OFF
shorted internal.

352 ACS over temperature ACS hs temp > 125 degC KEY=ON OFF ON KEY=OFF See 2.1.2.1

353 Motor over temperature Motor temp > 180 degC KEY=ON OFF ON KEY=OFF See 2.1.2.2

354 ACS current sensor error ACS current sensor error KEY=ON OFF ON KEY=OFF ACS must be repaired

ACS capacitors are not charged within

355 Charging timeout KEY= ON OFF ON KEY=OFF Check charging circuit
10sec from power on

356 ACS no response ACS does not respond at startup KEY=ON OFF ON KEY=OFF Check CAN bus wiring.

ACS CANopen timeout (detcted by

357 ACS PDO timeout KEY=ON OFF ON KEY=OFF Check CAN bus wiring.
VMC20)

358 ACS SDO error ACS SDO error (wrong SW virsion) KEY=ON OFF ON KEY=OFF Check SW version

ACS CANopen timeout (detected by

359 CANopen timeout KEY=ON OFF ON KEY=OFF Check CAN bus wiring
VMC20)

360 ACS low voltage trip ACS voltage <36V KEY=ON OFF ON KEY=OFF Instantaneous voltage

361 ACS high voltage trip ACS voltage > 112V (software) KEY=ON OFF ON KEY=OFF Instantaneous voltage

(16/10/2007) 80-08-M133 EN
 3
Electric troubleshooting

362 ACS high voltage trip ACS voltage >112V (hardware) KEY=ON OFF ON KEY=OFF Instantaneous voltage

364 Other error KEY=ON OFF ON KEY=OFF Any other EMCY form ACS.

1.1.3 Errors detected by drive ACS (Warning)

Nr Source Condition When Tract Main Reset Remark

KEY=OFF or Heat
301 ACS low temp warning ACS heat sink temp < -20 degC KEY=ON ON ON See 2.1.2.1 Lowest Accel will be used.
sink temp normal

KEY=OFF or Heat
302 ACS high temp warning ACS heat sink temp > 85 degC KEY=ON ON ON See 2.1.2.1 Lowest Accel will be used.
sink temp normal

303 Motor high temp warning Motor temp > 145 degC KEY=ON ON ON KEY=OFF See 2.1.2.2 Lowest Accel will be used.

Heat sink temp sensor

304 ACS heat sink temp sensor error KEY=ON ON ON KEY=OFF Lowest Accel will be used.
error

305 Motor low temp warning Motor temp < -50 degC KEY=ON ON ON KEY=OFF See 2.1.2.2 Lowest Accel will be used.

Motor temp sensor not connected or KEY=OFF or sensor

306 Motor temp sensor error KEY=ON ON ON Lowest Accel will be used.
short circuit connected

Speed feedback sensor Speed feedback sensor not connected / KEY=OFF or sensor ACS can not control speed correctly. No
307 KEY=ON ON ON
error short circuit connected driving allowed.

KEY=OFF or voltage
308 ACS high voltage warning ACS voltage > 112V KEY=ON ON ON Lowest Accel will be used.
back to normal

KEY=OFF or voltage
309 ACS low voltage warning ACS voltage < 46,8V KEY=ON ON ON Lowest Accel will be used.
back to normal

ACS default values

310 Default parameters are used in ACS KEY=ON ON ON KEY=OFF Lowest Accel will be used.
loaded

Power is reduced (by some warning

311 Power reduce KEY=ON ON ON KEY=OFF
condition)

312 Checksum error Calibration parameter checksum error KEY=ON ON ON KEY=OFF

316 DC bus calibration Current sensor default KEY=ON ON ON KEY=OFF

1.1.4 Errors detected by pump ACS (EMCY)

80
Nr Source Condition When Tract Main Reset Remark

ACS is shorted or motor terminals are ACS may be damaged if short circuit is
451 Short circuit KEY=ON OFF OFF KEY=OFF
shorted internal.

452 ACS over temjperature ACS hs temp > 125 degC KEY=ON OFF ON KEY=OFF See 5.2.2.1

453 Motor over temperature Motor temp > 180 degC KEY=ON OFF ON KEY=OFF See 5.2.2.2

454 ACS current sensor error ACS current sensor error KEY=ON OFF ON KEY=OFF ACS must be repaired

ACS capacitors are not charged within

455 Charging timeout KEY=ON OFF ON KEY=OFF Check charging circuit
10sec from power on

456 ACS no response ACS does not respond at startup KEY=ON OFF ON KEY=OFF Check CAN bus wiring.

ACS CANopen timeout (detcted by

457 ACS PDO timeout KEY=ON OFF ON KEY=OFF Check CAN bus wiring.
VMC20)

458 ACS SDO error ACS SDO error (wrong SW virsion) KEY=ON OFF ON KEY=OFF Check SW version

ACS CANopen timeout (detected by

459 CANopen timeout KEY=ON OFF ON KEY=OFF Check CAN bus wiring
VMC20)

460 ACS low voltage trip ACS voltage <36V KEY=ON OFF ON KEY=OFF Instantaneous voltage

461 ACS high voltage trip ACS voltage > 112V (software) KEY=ON OFF ON KEY=OFF Instantaneous voltage

462 ACS high voltage trip ACS voltage >112V (hardware) KEY=ON OFF ON KEY=OFF Instantaneous voltage

464 Other error KEY=ON OFF ON KEY=OFF Any other EMCY form ACS

80-08-M133 EN (16/10/2007)
 4
Electric troubleshooting

1.1.5 Errors detected by pump ACS (Warning)

Nr Source Condition When Tract Main PS Reset Remark

KEY=OFF or Heat
401 ACS low temp warning ACS heat sink temp < -20 degC KEY=ON ON ON ON See 1.2.2.1 Lowest Accel will be used.
sink temp normal

KEY=OFF or Heat
402 ACS high temp warning ACS heat sink temp > 85 degC KEY=ON ON ON ON See 1.2.2.1 Lowest Accel will be used.
sink temp normal

403 Motor high temp warning Motor temp > 145 degC KEY=ON ON ON ON KEY=OFF See 1.2.2.2 Lowest Accel will be used.

Heat sink temp sensor

404 ACS heat sink temp sensor error KEY=ON ON ON ON KEY=OFF Lowest Accel will be used.
error

405 Motor low temp warning Motor temp < -50 degC KEY=ON ON ON ON KEY=OFF See 1.2.2.2 Lowest Accel will be used.

Motor temp sensor not connected or KEY=OFF or sensor

406 Motor temp sensor error KEY=ON ON ON ON Lowest Accel will be used.
short circuit connected

Speed feedback sensor Speed feedback sensor not connected / KEY=OFF or sensor ACS can not control speed correctly. No
407 KEY=ON ON ON ON
error short circuit connected driving allowed.

KEY=OFF or voltage
408 ACS high voltage warning ACS voltage > 112V KEY=ON ON ON ON Lowest Accel will be used.
back to normal

KEY=OFF or voltage
409 ACS low voltage warning ACS voltage < 46,8V KEY=ON ON ON ON Lowest Accel will be used.
back to normal

ACS default values

410 Default parameters are used in ACS KEY=ON ON ON ON KEY=OFF Lowest Accel will be used.
loaded

Power is reduced (by some warning

411 Power reduce KEY=ON ON ON ON KEY=OFF
condition)

412 Checksum error Calibration parameter checksum error KEY=ON ON ON ON KEY=OFF

416 DC bus calibration Current sensor default KEY=ON ON ON ON KEY=OFF

80

(16/10/2007) 80-08-M133 EN
 5
Electric troubleshooting

2.1. Error details

2.1.1 Communication error

The VMC20 communicates with the ACS and with the optional service tools and displays over the CAN bus.
There are two basic kinds of communication errors : CAN bus errors and CANopen errors. The most common
reason for communication errors are wiring problems.

2.1.1.1. CAN error (111)

In this case the basic communication has failed on an electrical level. The reasons can be bad cabling, missing
termination resistors, bad connectors, or a faulty unit. It is normally impossible to get information from the VMC20
via the service interface, or via a display when there is a CAN bus error. This type of error will cause error 111. If it
is possible to connect to the VMC20 via the CAN bus, the reason can be that the KEY signal has not reached the
ACSes. In this case, 111 may not happen if the service interface is connected to the truck at KEY-on. Instead 309
and 409 will happen.

2.1.1.2. CANopen error (359 and 459)

There are three possible cause for the CANopen error :
1. The ACS does not respond when KEY is turned ON.
2. The VMC20 does not receive message from ACS for 70 ms after already started.
3. The ACS does not receive message from VMC20 for 70 ms after already started.
Depending on which ACS, error 359 or 459 will be caused. This error is most often caused by wiring problems, or
bad connections. Another possible cause is that the ACS does not have KEY voltage (the ACS LED will be OFF in
this case).

2.1.2 Temperature errors

2.1.2.1. ACS over temperature error (301, 302, 352, 401, 402, 452)
The ACS will reduce its maximum accelerating current when the temperature measured on the heat sink is too
high or too low. If the unit is allowed to cool down (or heat up in case the warning was for low temperature), the
warning will disappear, and the reduction as well. The maximum accelerating current for the 4810 is 350A, which
corresponds to 100% in Figure 1. If the sensor is found to be missing or shorted, the ACS will not reduce power,
but this will be done in the VMC20, by only allowing a limited max speed and acceleration.

Max accelerating current

Low temp 100%
warning
High temp
60% warning Sensor
Sensor High temp not connected
short circuit Error warning
warning

80
- 50 -20 0 ACS temperature 85 115
125 170

Figure 1 ACS temperature warnings, errors and reductions

2.1.2.2. Motor temperature dependent power reduction (303, 305, 353, 403, 405, 453)
The ACS will reduce its maximum accelerating current when the temperature measured inside the motor is
too high. No reduction of current will take place in the ACS when the temperature sensor is defective, or the
temperature is low. Power reduction in this case will be handled by the VMC20, which will limit the max speed
and acceleration rate. It should be noted that the motor characteristics is temperature dependent so in case the
sensor is defective, the motor might not run at optimum efficiency. Maximum accelerating current as a function of
motor temperature is shown in Figure 2.

Max accelerating current

100%

High temp
60% warning High temp Sensor
Sensor Error not connected
short circuit warning
warning

-50 0 Motor temperature 145 165 185 195

180 184

Figure 2 Motor temperature warnings, errors and reduction

80-08-M133 EN (16/10/2007)
 6
Electric troubleshooting
80

(16/10/2007) 80-08-M133 EN