004.7 - VCE150 Session 7 Cabin Lift
004.7 - VCE150 Session 7 Cabin Lift
ACH
U10 S71
Accumulators
B5
M3
S70 S44
Y29 Y21
CABIN LIFT Session 7-1
_ A + _ S101
No feed back
ICP A16 = STOP
MCU A5 Battery -
Battery - ESO Cabin, Battery +
Battery - _ 40
X101:2 GND. POWER +15VDC X103:4
107 S101
28 28
CAN 1
B X131:6 INP. CHASSIS PWR RELAY STATUS
Direction and
1st speed
B6
76
P X130:17 INP. LIFT SUPP SYST PRESSURE
30
X130:29 GND ANALOGUE
16
X130:1 PIVOT POT. +5VDC SUPP
S71 A
66
X130:15 INP. CABIN < REF HEIGHT
29 ESO Cabin, Battery +
X130:37 +15VDC SUPP
U10
99
X130:12 INP. CAB HEIGHT PULSE A
100
X130:26 INP. CAB HEIGHT PULSE B
FCU A4
ACH A2
220 24 80
8 F2 125A X130:8 CAN 2L 001 INP. +48VDC ESO CABIN GND 015
B+ CAN 2L 11 Battery -
40
M3 ACTUAL SPEED M3, SPEED REQUEST
X130:22 CAN 2H
_ 40
029 GND OUT. +15VDC SUPP 028
15
B- CAN 2H 10 S87 S88
118 141
X130:20 GND 026 INP. GATES CLOSED INP. SAFETY RELAY 041 U9
GND. CAN 13
9 INV ID CAN 2 119 INP. HEIGHT COUNT INI LIFT PULSE A 012
63
B3 55 027 CAN 1H
7 64
INP. HEIGHT COUNT INI LIFT PULSE B 011
52 M3 FORKS IN HOME? YES, IN HOME POS R109
4 GND. SENS 9 120
51 042 CAN 1L
3 +12VDC U
10 S50
53 CHOPPER V 103
5 11 INP. TURRET UNIT IN END POS 010
U12 REGULATION
54 60% W
6
26 Y21 39
1 +48VDC ESO 73 OUT. +5VDC SUPP 002
OUT. CABIN LOWER VALVE 1&2 X131:8
Y29
28 65
INP. FORK ROT ANGLE 007 R8
B
Cabin lift 1
Session 7-2
_ A + _ S101
No feed back
ICP A16 = STOP
MCU A5 Battery -
Battery - ESO Cabin, Battery +
Battery - _ 40
X101:2 GND. POWER +15VDC X103:4
107 S101
28 28
CAN 1
B X131:6 INP. CHASSIS PWR RELAY STATUS
2nd speed
B6
76
P X130:17 INP. LIFT SUPP SYST PRESSURE
30
X130:29 GND ANALOGUE
16
X130:1 PIVOT POT. +5VDC SUPP
S71 Reference height S71 A
66
X130:15 INP. CABIN < REF HEIGHT
Cabin floor 29
X130:37 +15VDC SUPP ESO Cabin, Battery +
(Parameter 103) U10
99
X130:12 INP. CAB HEIGHT PULSE A
100
X130:26 INP. CAB HEIGHT PULSE B
FCU A4
ACH A2
220 24 80
8 F2 125A X130:8 CAN 2L 001 INP. +48VDC ESO CABIN GND 015
B+ CAN 2L 11 Battery -
40
M3 ACTUAL SPEED HIGH SPEED REQUEST
X130:22 CAN 2H
_ 40
029 GND OUT. +15VDC SUPP 028
15
B- CAN 2H 10 S87 S88
118 141
X130:20 GND 026 INP. GATES CLOSED INP. SAFETY RELAY 041 U9
GND. CAN 13
9 INV ID CAN 2 119 INP. HEIGHT COUNT INI LIFT PULSE A 012
63
B3 55 027 CAN 1H
7 64
INP. HEIGHT COUNT INI LIFT PULSE B 011
52 M3 FORKS IN HOME? GATES CLOSED? YES R109
4 GND. SENS 9 120
51 042 CAN 1L
3 +12VDC U
10 S50
53 CHOPPER V 103
5 11 INP. TURRET UNIT IN END POS 010
U12 REGULATION
54 100% W
6
26 Y21 39
1 +48VDC ESO 73 OUT. +5VDC SUPP 002
OUT. CABIN LOWER VALVE 1&2 X131:8
Y29
28 65
INP. FORK ROT ANGLE 007 R8
B
Cabin lift 2
Session 7-3
_ A + _ S101
No feed back
ICP A16 = STOP
MCU A5 Battery -
Battery - ESO Cabin, Battery +
Battery - _ 40
X101:2 GND. POWER +15VDC X103:4
107 S101
28 28
CAN 1
B X131:6 INP. CHASSIS PWR RELAY STATUS
B6
76
P X130:17 INP. LIFT SUPP SYST PRESSURE
30
X130:29 GND ANALOGUE
Cabin lift 3
Lift blocked
Session 7-4
MAST
Accumulator pressure
220 bar
B A C
B6
M
CE
M C1 C2 R
250 bar
2
Y21 Y29 1
R1 R2
P1 P2
250 bar
The counter balance cylinder
carries in the lower lift zone
P
1/3 of the dead weight of the
Cabin and Auxilliary mast.
M3
Session 7-5
MAST
Accumulator pressure
almost “ZERO” at top
B A C
B6
M
CE
M C1 C2 R
250 bar
2
Y21 Y29 1
R1 R2
P1 P2
250 bar
M3
Session 7-6
_ A + _ S101
No feed back
ICP A16 = STOP
MCU A5 Battery -
Battery - ESO Cabin,
Battery - _ 40 107 S101
Battery + VBattery + 40
X131:14 INP. GND POWER Battery + F67 21
X101:2 GND. POWER +15VDC X103:4
109
F61
36
+ F68
X101:3 +48VDC POWER GND X103:5
X131:1 INP. +48VDC POWER K17 60 108
V 26
X101:1 OUT. (NPN) SET
KEY RELAY
INP. RIGHT DEADM HANDLE X103:6
S100
X131:5 INP. ESO IN 111
24 S22 S23 K10 +15VDC X100:4
37
X131:7 OUT. (NPN) MAIN CONT/CHASSIS REL 113
GND X100:5
F62 112
38 INP. LEFT DEADM HANDLE X100:6
8 V X131:15 INP. MAIN CONT/CAP. CHARGE
23
X101:6 INP. +48V KEY IN 133
V
28 28
CAN 1
B X131:6 INP. CHASSIS PWR RELAY STATUS
Direction and
V B6
1st speed
76
P X130:17 INP. LIFT SUPP SYST PRESSURE
V 30
X130:29 GND ANALOGUE
16
X130:1 PIVOT POT. +5VDC SUPP
S71 A
66
X130:15 INP. CABIN < REF HEIGHT
29 ESO Cabin, Battery +
X130:37 +15VDC SUPP
U10
99
X130:12 INP. CAB HEIGHT PULSE A
100
X130:26 INP. CAB HEIGHT PULSE B
FCU A4
ACH A2
220 24 80
8 F2 125A X130:8 CAN 2L 001 INP. +48VDC ESO CABIN GND 015
V V
B+ CAN 2L 11 Battery -
40
M3 ACTUAL SPEED M3, SPEED REQUEST
X130:22 CAN 2H
_ 40
029 GND OUT. +15VDC SUPP 028
15
B- CAN 2H 10 S87 S88
118 141
X130:20 GND 026 INP. GATES CLOSED INP. SAFETY RELAY 041 U9
GND. CAN 13
9 INV ID CAN 2 119 INP. HEIGHT COUNT INI LIFT PULSE A 012
63
B3 55 M3 027 CAN 1H
7 64
reversed INP. HEIGHT COUNT INI LIFT PULSE B 011
52 M3 speed FORKS IN HOME? YES, IN HOME POS R109
4 GND. SENS 9 120
51 042 CAN 1L
3 +12VDC U
10 S50
53 CHOPPER V
Valve 103
5 11 INP. TURRET UNIT IN END POS 010
U12 REGULATION negative
54 70% W out
6
26 Y21 39
1 +48VDC ESO 73 OUT. +5VDC SUPP 002
OUT. CABIN LOWER VALVE 1&2 X131:8
Y29
28 65
INP. FORK ROT ANGLE 007 R8
B
Cabin lower 1
Session 7-7
_ A + _ S101
No feed back
ICP A16 = STOP
MCU A5 Battery -
Battery - ESO Cabin,
Battery - _ 40 107 S101
Battery + VBattery + 40
X131:14 INP. GND POWER Battery + F67 21
X101:2 GND. POWER +15VDC X103:4
109
F61
36
+ F68
X101:3 +48VDC POWER GND X103:5
X131:1 INP. +48VDC POWER K17 60 108
V 26
X101:1 OUT. (NPN) SET
KEY RELAY
INP. RIGHT DEADM HANDLE X103:6
S100
X131:5 INP. ESO IN 111
24 S22 S23 K10 +15VDC X100:4
37
X131:7 OUT. (NPN) MAIN CONT/CHASSIS REL 113
GND X100:5
F62 112
38 INP. LEFT DEADM HANDLE X100:6
8 V X131:15 INP. MAIN CONT/CAP. CHARGE
23
X101:6 INP. +48V KEY IN 133
V
28 28
CAN 1
B X131:6 INP. CHASSIS PWR RELAY STATUS
2nd speed
V B6
76
P X130:17 INP. LIFT SUPP SYST PRESSURE
V 30
X130:29 GND ANALOGUE
16
X130:1 PIVOT POT. +5VDC SUPP
S71 A
66
X130:15 INP. CABIN < REF HEIGHT
29 ESO Cabin, Battery +
X130:37 +15VDC SUPP
U10
99
X130:12 INP. CAB HEIGHT PULSE A
100
X130:26 INP. CAB HEIGHT PULSE B
FCU A4
ACH A2
220 24 80
8 F2 125A X130:8 CAN 2L 001 INP. +48VDC ESO CABIN GND 015
V V
B+ CAN 2L 11 Battery -
40
M3 ACTUAL SPEED LOW SPEED REQUEST
X130:22 CAN 2H
_ 40
029 GND OUT. +15VDC SUPP 028
15
B- CAN 2H 10 S87 S88
118 141
X130:20 GND 026 INP. GATES CLOSED INP. SAFETY RELAY 041 U9
GND. CAN 13
9 INV ID CAN 2 119 INP. HEIGHT COUNT INI LIFT PULSE A 012
63
B3 55 M3 027 CAN 1H
7 64
reversed INP. HEIGHT COUNT INI LIFT PULSE B 011
52 M3 speed FORKS IN HOME? GATES CLOSED? YES R109
4 GND. SENS 9 120
51 042 CAN 1L
3 +12VDC U
10 S50
53 CHOPPER V
Valve 103
5 11 INP. TURRET UNIT IN END POS 010
U12 REGULATION negative
54 25% W out
6
26 Y21 39
1 +48VDC ESO 73 OUT. +5VDC SUPP 002
OUT. CABIN LOWER VALVE 1&2 X131:8
Y29
28 65
INP. FORK ROT ANGLE 007 R8
B
Cabin lower 2
Session 7-8
MAST
B A C
B6
M
CE
M C1 C2 R
250 bar
2
Y21 Y29 1
R1 R2
P1 P2
250 bar
M3
Session 7-9
MAST
B A C
B6
M
CE
M C1 C2 R
250 bar
2
Y21 Y29 1
R1 R2
P1 P2
250 bar
M3
Session 7-10
Let’s go to the
truck
! To load accumulator pressure
Related parameters
Parameter 101: Max cabin height
Effect on truck: Limits the maximum cabin floor lift height electrically
Code: 4:002
Abstract: ACH, temperature warning
Description: The temperature in the ACH is too high, the temperature in the
capacitors of the ACH is too high or the temperature sensor in
the ACH is defective.
What to do: Check the ACH temperature.
Check for correct operation of the M10 cooling fan.
Inspect the ACH connection plug.
Inspect the cabling connecting the ACH.
Code: 4:003
Abstract: ACH offset warning
Description: ACH current calibration error.
What to do: Check the ACH LED.
Inspect the ACH connection plug.
Inspect the cabling connecting the ACH.
Code: 4:005
Abstract: Narrow aisle identification, sensor warning
Description: One of the narrow aisle identification sensors is defective.
What to do: Check the inputs X130:41, X131:2 and X131:16
Check corresponding wiring and connectors
Checkaisle identification sensors
Code: 4:101
Abstract: ACH CPU or memory error
Description: Internal ACTL error.
What to do: Inspect the voltage feed to the ACH.
Code: 4:102
Abstract: Pump motor, overheating
Description: The temperature in the AC pump motor is too high
or the temperature sensor is defective.
What to do: Check the pump motor M3 temperature.
Check for correct operation of the M10 cooling fan.
Inspect the temperature sensor B3 in the pump motor M3.
Inspect the temperature sensor connection plug.
Inspect the cabling between M3 and ACH.
Code: 4:103
Abstract: ACH, capacitor temperature
Description: The temperature in the ACH capacitors is too high.
What to do: Check the ACH temperature.
Check for correct operation of the M12 cooling fan.
Inspect the ACH connection plug.
Inspect the cabling connecting the ACH.
Code: 4:104
Abstract: ACH, cooling unit temperature
Description: The temperature in the ACH cooling unit is too high.
What to do: Check the ACH temperature.
Check for correct operatio of the M12 cooling fan.
Inspect the ACH connection plug.
Inspect the cabling connecting the ACH.
Code: 4:105
Abstract: ACH, current limit
Description: The ACH is constantly above the current limit.
What to do: Inspect the power cables ACH/M3.
Inspect the M3 windings.
Check for mechanical seizure in M3.
Check for mechanical seizure in the hydraulic pump.
Code: 4:106
Abstract: ACH, over-voltage
Description: DC-voltage has been detected as too high by the hardware.
What to do: This may happen when regenerating to an overcharged battery.
Check the battery voltage.
Code: 4:107
Abstract: ACH, over-voltage
Description: DC-voltage has been detected as too high by the firmware.
What to do: This may happen when regenerating to an overcharged battery.
Check the battery voltage.
Code: 4:108
Abstract: ACH, under voltage
Description: DC-voltage has been detected too low by firmware.
What to do: Check the battery voltage.
Inspect the K10 contactor tips.
Code: 4:112
Abstract: Error in cabin lowering function
Description: This error is generated if the hydraulic pressure does not
increase within 2 seconds after receiving the cabin lowering
command.
What to do: Inspect the ACH, the ball bearing sensor in the cabin lift motor
and the wiring.
NOTE!
If this error code is generated, it may become necessary to manually lower the cabin
using the emergency lowering valve.
Code: 4:113
Abstract: B-cylinder pressure, error
Description: The sensor signal for the hydraulic pressure in the B-cylinder
is outside the allowed limits.
What to do: Inspect MCU input X130:17.
Inspect the sensor B6.
Check the voltage feed.
Code: 4:114
Abstract: Height sensor error
Description: No signals received from the height measuring sensor during cabin lift.
What to do: Verify voltage feed to U10.
Verify the U10 pulses.
Check MCU inputs X130:12 and 130:26.
Code: 4:115
Abstract: Incorrect measuring of the height sensor
Description: The current height value does not correspond with
height reference signa.l
What to do: Check to make sure that the reference sensor S71 is operating.
Verify the voltage feed to S71.
Inspect MCU input X130:27.
Also check parameter 102, i.e. The predefined cabin floor height at
which the reference sensor should switch operating status.
Code: 4:116
Abstract: Digital output 6 short-circuited
Description: The circuit for the cabin lowering valves Y21//Y29 has short circuited.
What to do: Inspect the valve (Y21/Y29) coils.
Inspect the connection plugs and cabling.
Check voltage feed.
Inspect MCU output X131:8.
The MCU could be defective.
Code: 4:117
Abstract: Digital output 6 interruption
Description: Interruption of the circuit for the cabin lowering valves Y21/Y29.
What to do: Inspect the valve (Y21/Y29) coils.
Inspect the connection plugs and cabling.
Check voltage feed.
Inspect MCU output X131:8.
The MCU could be defective.
Code: 4:500
Abstract: Regeneration error, lowering
Description: The lowering speed is too high (speed limit 0.45 m/s)
What to do: Inspect the speed sensor U12 in M3.
Check the LED status on the ACH.
Inspect the power cabling ACH - M3.
Inspect the pump motor M3.