Transcription
SCHAEFFProviding VALUE eff Inc.9655 Industrial DriveBridgeview, Il 60455, USTel: (708) 430 - 5301Fax: (708) 430 - 5331E-Mail: Mailbox@SchaeffInc.comwww.SchaeffInc.com Schaeff Inc. 10/03Part Number 6840005Printed in U.S.A.QUICK REFERENCE GUIDEarehousingSeries Lift Trucks
NotesServiceAlertOverTemperatureAlertLED DisplayOver-WeightAlertRight FootAlertWheel PositionIndicatorAux SwitchBattery Stateof-ChargeLight SwitchKey SwitchSpeed IndicatorOPERATOR'S DISPLAY
SYSTEM FAULT CODES /R14L/R151617FAULT CONDITION & DISPLAYED TEXTResulting EffectENGAGE BRAKE TO CONTINUE POSTPOSt will not continue until the brake pedal is releasedRELEASE THROTTLE TO RESUME OPERATIONTRACTION SYSTEM shutdown, until condition is clearedQUICKREFERENCEGUIDERELEASE CONTROL HANDLE TO RESUME LIFTINGLIFT SYSTEM shutdown, until condition is clearedDISCONTINUE REVERSE TRAVEL TO RESUME LIFTINGLIFT SYSTEM shutdown, until condition is clearedTRACTION SYSTEM PMI NECESSARYTRACTION SYSTEM derated based on SpeedLimLIFT SYSTEM PMI NECESSARYarehousingSeries Lift TrucksLIFT SYSTEM derated to 50% speedSTEER SYSTEM PMI NECESSARYTRACTION SYSTEM derated based on SpeedLimPOSITION HOLD DISABLEDMessage onlyLIFT MOTOR HOTMESSAGE ONLY, until condition is clearedElectricStand-upCounterbalanceLIFT CONTROL HOTMESSAGE ONLY, until condition is clearedLEFT/RIGHT TRACTION MOTOR HOTMESSAGE ONLY, until condition is clearedLEFT/RIGHT TRACTION CONTROL HOTSoftware Version 3.25APPLIES TO VERSIONS 3.00 - 3.2510/27/00MESSAGE ONLY, until condition is clearedLEFT/RIGHT TRACTION MOTOR TEMPERATURE IMBALANCEMESSAGE ONLY, until condition is clearedLEFT/RIGHT TRACTION CONTROL TEMPERATURE IMBALANCEMESSAGE ONLY, until condition is clearedREPOSITION RIGHT FOOT TO RESUME OPERATIONTRACTION SYSTEM shutdown, until condition is clearedPOWER DOWN REQUEST WHILE TRAVELINGHarsh plug, then power down when forklift has stoppedBATTERY GATE NOT PRESENTTRACTION SYSTEM shutdown, until condition is clearedTHIS REFERENCE GUIDE IS INTENDED AS A REPAIR AIDONLY. IT DOES NOT REPLACE THE SERVICE MANUAL.FOLLOW ALL INSTRUCTIONS AND PROCEDURES IN THESERVICE MANUAL (68 400 03). FAILURE TO DO SO CANRESULT IN PERSONAL INJURY AND PROPERTY DAMAGE.All information, specifications, and illustrations in thismanual are based on the latest available data at the timeof publication. SCHAEFF is constantly striving to improveits products and, therefore, reserves the right to changedesign, materials, and/or specifications without noticeand without incurring obligation or liability.SCHAEFF and each are registered trademarks of Schaeff Inc.
PERFORMANCE & DIAGNOSTICS MENUSOFTWARE VERSION 3.2510/27/00SYSTEM FAULT CODES (ERRORS)ERRORNO.78C798081828384L/RFAULT CONDITION & DISPLAYED TEXTResulting EffectSYSTEM CONTROL CONFIGURATION FAILURETOTAL shutdownDISPLAY CONTROL CONFIGURATIONFAILURETOTAL shutdownLIFT CUTOUT DUE TO LOW BATTERY STATE OF CHARGELIFT system, except lower, shutdownEACH BUTTON STUCKLIFT SYSTEM, except lower, shutdownOPERATIONAL PARAMETERS INVALIDTOTAL shutdownNot usedLEFT/RIGHT TRACTION MOTOR TEMPERATURE IMBALANCE EXCEEDEDTRACTION SYSTEM shutdown8586L/RNot usedLEFT/RIGHT TRACTION CONTROL TEMPERATURE IMBALANCEEXCEEDEDTRACTION SYSTEM shutdown87L/RLEFT/RIGHT TRACTION DIODE FAILURETRACTION SYSTEM shutdown8889L/RLIFT MOTOR CURRENT NOT PRESENT / DIODE FAILURELIFT SYSTEM shutdownLEFT/RIGHT TRACTION CONTROL HARDWARE FAILURETOTAL SYSTEM shutdown and open MAIN POWERCONTACTOR9091929394LIFT/STEER CONTROL HARDWARE FAILURETOTAL SYSTEM shutdown and open MAIN POWERCONTACTORSTEER ENCODER FAILUREHARSH PLUG then TRACTION and STEER SYSTEMshutdownSTEER ROTATION FAILUREHARSH PLUG then TRACTION and STEER SYSTEMshutdownKEYSWITCH CIRCUIT FAILUREDISPLAY MESSAGE until battery is disconnectedBOOST LIFT PUMP CONTACTOR WELDEDOpen MAIN POWER CONTACTOR
Pre-OperationalInformationSYSTEM FAULT CODES (ERRORS)ERRORNO.60FAULT CONDITION & DISPLAYED TEXTResulting EffectSTEER MOTOR CURRENT HIGHTOTAL shutdown61L/RLEFT/RIGHT MOTOR BRUSH WEAR FAILURE62L/RLEFT/RIGHT TRACTION MOTOR FIELD CURRENT HIGHSPEED limitedTRACTION SYSTEM shutdown63L/RLEFT/RIGHT TRACTION MOTOR FIELD CURRENT NOT PRESENT64L/RLEFT/RIGHT TRACTION MOTOR ARMATURE HIGHTRACTION SYSTEM shutdownTRACTION SYSTEM shutdown65L/RLEFT/RIGHT TRACTION MOTOR ARMATURE CURRENT NOT PRESENT66L/RLEFT/RIGHT TRACTION - NO MOVEMENT DETECTEDTRACTION SYSTEM shutdownOperationalInformationTRACTION SYSTEM shutdown67L/RLEFT/RIGHT DRIVE ROTATION DIRECTION FAILURE68L/RLEFT/RIGHT BRAKE INOPERABLE OR NOT PROPERLY ADJUSTEDTRACTION SYSTEM shutdownTOTAL shutdown697071L/RSYSTEM CONTROL 5 VOLTAGE OUT OF RANGETOTAL shutdownSYSTEM CONTROL 15 VOLTAGE OUT OF RANGETOTAL shutdownLEFT/RIGHT TRACTION CONTROL 5 VOLTAGE OUT OF RANGETOTAL shutdown72L/RLEFT/RIGHT TRACTION CONTROL 15 VOLTAGE OUT OF RANGETOTAL shutdown73L/RLEFT/RIGHT TRACTION CONTROL -15 VOLTAGE OUT OF RANGETOTAL shutdown7475767778A78BLIFT CONTROL 5 VOLTAGE OUT OF RANGEMENU CONVENTION1. MOVE through the menu using:TOTAL shutdownto move UP and DOWN, andLIFT CONTROL 15 VOLTAGE OUT OF RANGEto move LEFT and RIGHT.TOTAL shutdownLIFT CONTROL -15 VOLTAGE OUT OF RANGETOTAL shutdownSYSTEM CONTROL HARDWARE FAILURETOTAL shutdownSYSTEM CONTROL SOFTWARE FAILURETOTAL shutdownDOWNLOAD BACKUP SOFTWARE FAILURETOTAL shutdown2. ENTER alphanumerics using:to CYCLE letters/numbers, andto MOVE between character positions, thento ACCEPT.3. SELECT options by pressing.
DIAGNOSTIC MODE INPUT TESTSTESTNO.I 01I 02TEST NAMENORMAL OPERATION DISPLAYI 01 - OFF (Pos I) or I 01 - ON (Pos II)Brake Limit SwitchI 03 - VOLTAGEI 06I 04 - VOLTAGEI 05 - VOLTAGEI 08I 09I 10I 11I 12I 13I 14I 150642C42D073.1 - 4.6 Full Lift1.9 - 3.1 Neutral0.4 - 1.9 Full Lower09450819255051L/R521053I 08 - OFF or I 08 - ON24I 09 - OUT or I 09 - INAuxiliary Direction B Push Button4849I 07 - OFF or I 07 - ONAuxiliary Direction A Push Button464718Lift Limit SwitchI 10 - OUT or I 10 - INWeight Pressure Transducer VoltageI 11 - VOLTAGE 0.5 - 4.5NOT USED (CG Transducer)112nd Stage Sensor5455L/RI 13 - OFF (2nd) OR I 13 ON (1st)Floorpad Switch16569157I14 - OFF or I14 - ONElectric Steer EncoderI 15 - NUMBERFAULT CONDITION & DISPLAYED TEXTResulting EffectW2X LIFT SOLENOID DRIVER OVERHEATEDLIFT SYSTEM, except lower, shutdown, until cond. clearW2X LIFT SOLENOID SHORTED TO SUPPLYLIFT SYSTEM, except lower, shutdownW2X LIFT SOLENOID SHORTED TO GROUNDLIFT SYSTEM, except lower, shutdownW2X LIFT SOLENOID DISCONNECTEDLIFT SYSTEM, except lower, shutdown, until cond. clearTILT LIMIT REACHEDSPEED limited until condition is clearedTILT AND LIFT LIMITS REACHED3.1 - 4.6 Full Reverse1.9 - 3.1 Neutral0.4 - 1.9 Full ForwardTilt Limit Switch43440.4 - 1.9 Full Left (-90o)1.9 - 3.1 Straight (0o)3.1 - 4.6 Full Right (90o)Auxiliary Multi-lever PotentiometerVoltageI 06 - VOLTAGEI 0742B3.1 - 4.6 Full Forks First1.9 - 3.1 Neutral0.4 - 1.9 Full Tractor FirstSteer Position Potentiometer VoltageI 0517I 02 - UP or I 02 - DOWNLift/Lower Potentiometer VoltageI 04ERRORNO.42AStart SwitchTravel Potentiometer VoltageI 03SYSTEM FAULT CODES (ERRORS)FAULTDISPLAY000 - 255Some Input and Output tests shown will only be present in the menulist when the option is installed and enabled.5859SPEED limited and LIFT SYSTEM, except tilt back andlower, shutdown, until condition is clearedLIFT SPEED LIMIT REACHEDSPEED limited until condition is clearedLIFT HEIGHT LIMIT REACHEDLIFT SYSTEM, except lower, shutdown until cond. clearIMPACT THRESHOLD EXCEEDEDLIFT and TRACTION SYSTEM derationNot usedLIFT MOTOR OVERHEATEDLIFT SYSTEM, except lower, shutdownNot usedLEFT/RIGHT TRACTION MOTOR OVERHEATEDTRACTION SYSTEM shutdownNot usedLIFT CONTROL OVERHEATEDLIFT SYSTEM, except lower, shutdownNot usedLEFT/RIGHT TRACTION CONTROL OVERHEATEDTRACTION SYSTEM shutdownSTEER MOTOR BRUSH WEAR FAILURETRACTION SYSTEM deration to 1 mphLIFT MOTOR CURRENT NOT PRESENTLIFT SYSTEM shutdownLIFT MOTOR CURRENT HIGHLIFT SYSTEM shutdownSTEER MOTOR CURRENT NOT PRESENTTOTAL shutdown
SYSTEM FAULT CODES (ERRORS)ERRORNO.36C36D37AFAULT CONDITION & DISPLAYED TEXTResulting EffectSIDE SHIFT RIGHT VALVE SOLENOID SHORTED TO GROUNDLIFT SYSTEM, except lower, shutdownSIDE SHIFT RIGHT VALVE SOLENOID DISCONNECTEDLIFT SYSTEM, except lower, shutdown, until cond. clearAUXILIARY DIRECTION A VALVE SOLENOID DRIVEROVERHEATEDDIAGNOSTIC OUTPUT TESTSWARNING JACK THE TRUCK AND BLOCK THE WHEELSBEFORE PERFORMING ANY MAINTENANCE OUTPUT TESTSO 01O 02O 03LIFT SYSTEM, except lower, shutdown, until cond. clear37B37C37D38AAUXILIARY DIRECTION A VALVE SOLENOID SHORTED TO SUPPLYLIFT SYSTEM, except lower, shutdownAUXILIARY DIRECTION A VALVE SOLENOID SHORTED TO GROUNDLIFT SYSTEM, except lower, shutdownAUXILIARY DIRECTION A VALVE SOLENOID DISCONNECTEDLIFT SYSTEM, except lower, shutdown, until cond. clearAUXILIARY DIRECTION B VALVE SOLENOID DRIVEROVERHEATEDLIFT SYSTEM, except lower, shutdown, until cond. clear38B38C38D39A39B39C39D4041A41B41C41DO 04O 05O 06O 07O 08AUXILIARY DIRECTION B VALVE SOLENOID SHORTED TO SUPPLYLIFT SYSTEM, except lower, shutdownO 09AUXILIARY DIRECTION B VALVE SOLENOID SHORTED TO GROUNDLIFT SYSTEM, except lower, shutdownO 10Main Power ContactorO 01 - OPEN27A-FO 01 - CLSDSteer MotorO 02 - OPENXX AMPSLower Solenoid30A-DO 03 - OPENO 03 - CLSDLift Solenoid31A-DO 04 - OPENO 04 - CLSDNOT USEDTilt Forward SolenoidO 06 - OPEN33A-DO 06 - CLSDTilt Back Solenoid34A-DO 07 - OPENO 07 - CLSDSide Shift Left SolenoidO 08 - OPEN35A-DO 08 - CLSDSide Shift Right SolenoidO 09 - OPENAuxiliary Direction A SolenoidO 10 - OPENLIFT SYSTEM, except lower, shutdown, until cond. clearAuxiliary Direction B SolenoidBACKUP ALARM DRIVER OVERHEATEDDISPLAY MESSAGE, until condition is clearedBACKUP ALARM SHORTED TO SUPPLYDISPLAY MESSAGEO 12O 13BACKUP ALARM SHORTED TO GROUNDDISPLAY MESSAGEO 14BACKUP ALARM DISCONNECTEDDISPLAY MESSAGE, until condition is clearedO 15COIL DRIVER HARDWARE FAILURETOTAL shutdownO 16W2X STEER SOLENOID DRIVER OVERHEATEDTRACTION SYSTEM shutdown, until cond. is clearedW2X STEER SOLENOID SHORTED TO SUPPLYO 17O 18TRACTION SYSTEM shutdownO 10 - CLSDO 11 - OPEN38A-DO11 - CLSDImpact Sensor15, 47O 12 - X.XVO 12 - X.XVNot UsedLift/Lower Proportional SolenoidO 14 - OPEN29A-DO 14 - CLSDHorn26O 15 - OFFO 15 - ONDisplayO 16 - OFFO 16 -Left Traction MotorO 17 - OFFFXX/AXXXX.XX51L, 61-68L,84L, 87LRight Traction MotorO 18 - OFFFXX/AXXXX.XX51R, 61-68R,84R, 87RMPHW2X STEER SOLENOID DISCONNECTEDTRACTION SYSTEM shutdown, until cond. is cleared37A-DMPHTRACTION SYSTEM shutdownW2X STEER SOLENOID SHORTED TO GROUND36A-DO 09 - CLSDAUXILIARY DIRECTION B VALVE SOLENOID DISCONNECTEDO 1141A-D, 56,59, 60O 19Lift MotorO 19 - OFFXX.XAMP49, 57, 58,88
Battery DisconnectBattery GatesBattery RollersBrakesBrake Pedal/LinkageBrake SwitchCarriage / LoadBackrest / ForksContactor TipsControl HandleDecalsGearboxHydraulic SystemLift ChainsLightsMastMotor BrushesSteeringTires /WheelsStatic RSDAYSXCheck for leaksCheck level and fill (as needed)Change hydraulic oil and filterBreather cap - check and cleanIn place and touches the floorInspect tires for cracks, gouges, and wearLubricate wheel and final drive pinion bearingsLubricate final drive gearsTurns without binding - no excess playCheck for wear and proper seating. Replace as neededTexaco 32 / Tellus 32 / Mobil DTE 24McCollister Arctic Blue Hydraulic Oil 3028Mobil SHC 50 Synthetic Gear Lubricant or equivalentSAE J-1703 Brake Fluid DOT 3ABCDHGFEXXXXXXXX405XXXXXXXMobilith SHC 007 Synthetic Grease NLGI 00 or equivalentSAE 40W Motor OilSAE 20W Motor OilXXXXXEHFBBCCEDEHGAACCED-40oF 32oF350 2000 toto60 360 32oF 120oFMobilith SHC 220 Synthetic Grease NLGI 2 or equivalentInspect for damage and Check for cotter pins in place on tilt cylinder pinsFunction when switched onXXCheck operationCheck fluid level and fill (as needed)Change fluid at first 100 hours, then:Check for wear, damage, and cotter pins in place on connector pins at anchor boltsLubricate and adjustXXXXXXXXXX81Check operational, safety, and warning decals. Replace if missing or unreadableCheck for smooth and full movement forward, reverse, lift, and lower; check horn, tilt, and all auxiliaryfunctions for operation. Do Not LubricateCheck condition, inspect for pitting, adequate tip contact surface, signs of burningInspect for cracks, bends, and damageLubricate sideshift carriageLocks out travel capability when pedal is upCheck for smooth operation, no binding, and pedal comes up when foot is removed. Do Not LubricateReleased when pedal depressed and stops unit within specified distance when pedal releasedBrake pads - inspect and replace (as needed)Brake fluid - check level and add (as needed)Do Not Lubricate Plastic RollersCheck that they are securely in placeCheck for free movement of the lever and lever disconnects battery. Do Not LubricateCharge - NormalCharge - EqualizingCheck water level and cleanlinessConnector in good condition, bolt installedLUBRICATION REFERENCE TABLEBattery1COMPONENTSCHEDULED MAINTENANCE AND INSPECTION TABLE
Battery DisconnectBattery GatesBattery RollersBrakesBrake Pedal/LinkageBrake SwitchCarriage / LoadBackrest / ForksContactor TipsControl HandleDecalsGearboxHydraulic SystemLift ChainsLightsMastMotor BrushesSteeringTires /WheelsStatic RSDAYSXCheck for leaksCheck level and fill (as needed)Change hydraulic oil and filterBreather cap - check and cleanIn place and touches the floorInspect tires for cracks, gouges, and wearLubricate wheel and final drive pinion bearingsLubricate final drive gearsTurns without binding - no excess playCheck for wear and proper seating. Replace as neededTexaco 32 / Tellus 32 / Mobil DTE 24McCollister Arctic Blue Hydraulic Oil 3028Mobil SHC 50 Synthetic Gear Lubricant or equivalentSAE J-1703 Brake Fluid DOT 3ABCDHGFEXXXXXXXX405XXXXXXXMobilith SHC 007 Synthetic Grease NLGI 00 or equivalentSAE 40W Motor OilSAE 20W Motor OilXXXXXEHFBBCCEDEHGAACCED-40oF 32oF350 2000 toto60 360 32oF 120oFMobilith SHC 220 Synthetic Grease NLGI 2 or equivalentInspect for damage and Check for cotter pins in place on tilt cylinder pinsFunction when switched onXXCheck operationCheck fluid level and fill (as needed)Change fluid at first 100 hours, then:Check for wear, damage, and cotter pins in place on connector pins at anchor boltsLubricate and adjustXXXXXXXXXX81Check operational, safety, and warning decals. Replace if missing or unreadableCheck for smooth and full movement forward, reverse, lift, and lower; check horn, tilt, and all auxiliaryfunctions for operation. Do Not LubricateCheck condition, inspect for pitting, adequate tip contact surface, signs of burningInspect for cracks, bends, and damageLubricate sideshift carriageLocks out travel capability when pedal is upCheck for smooth operation, no binding, and pedal comes up when foot is removed. Do Not LubricateReleased when pedal depressed and stops unit within specified distance when pedal releasedBrake pads - inspect and replace (as needed)Brake fluid - check level and add (as needed)Do Not Lubricate Plastic RollersCheck that they are securely in placeCheck for free movement of the lever and lever disconnects battery. Do Not LubricateCharge - NormalCharge - EqualizingCheck water level and cleanlinessConnector in good condition, bolt installedLUBRICATION REFERENCE TABLEBattery1COMPONENTSCHEDULED MAINTENANCE AND INSPECTION TABLE
SYSTEM FAULT CODES (ERRORS)ERRORNO.0102FAULT CONDITION & DISPLAYED TEXTResulting EffectUSER PROFILES INOPERABLEMESSAGE ONLY, at power-upNot usedREAR VIEWEXCEEDED WEIGHT LIMIT OF VEHICLE03LIFT SYSTEM, except lower, and TRACTION shutdownuntil condition is cleared04Not used0506The numbers in this drawing correspond to thenumbers in the first column of the SCHEDULEDMAINTENANCE & INSPECTION TABLE.TOP VIEWwith Overhead Guard removed070809101112BATTERY VOLTAGE OUT OF RANGETOTAL shutdownTRAVEL POTENTIOMETER VOLTAGE OUT OF RANGETRACTION SYSTEM shutdownLIFT/LOWER POTENTIOMETER VOLTAGE OUT OF RANGELIFT SYSTEM shutdownAUXILIARY MULTI-LEVER POTENTIOMETER VOLTAGE OUT OF RANGELIFT SYSTEM shutdownSTEER POSITION POTENTIOMETER VOLTAGE OUT OF RANGETRACTION SYSTEM shutdownW EIGHT PRESSURE SENSE VOLTAGE OUT OF RANGELIFT SYSTEM, except lower, shutdownCENTER-OF-GRAVITY PRESSURE SENSE VOLTAGE OUT OF RANGELIFT SYSTEM, except lower, shutdownLIFT CONTROL TEMPERATURE SENSE VOLTAGE OUT OF RANGELIFT SYSTEM, except lower, shutdownLEFT/RIGHT TRACTION CONTROL TEMPERATURE SENSE VOLTAGE13L/ROUT OF RANGESPEED limited14151617181920LIFT MOTOR TEMPERATURE SENSE VOLTAGE OUT OF RANGELIFT SYSTEM, except lower, shutdownACCELEROMETER VOLTAGE OUT OF RANGELIFT and TRACTION SYSTEM derationFLOORPAD SWITCH VOLTAGE OUT OF RANGETRACTION SYSTEM shutdownBRAKE PEDAL SWITCH FAILURETOTAL shutdownTILT LIMIT SWITCH FAILURELIFT SYSTEM shutdownLIFT LIMIT SWITCH FAILURELIFT SYSTEM shutdownSIDE SHIFT RIGHT SWITCH VOLTAGE OUT OF RANGELIFT SYSTEM shutdown
RIGHT SIDE VIEWFRONT VIEWwith Mast removed
RIGHT SIDE VIEWFRONT VIEWwith Mast removed
SYSTEM FAULT CODES (ERRORS)ERRORNO.0102FAULT CONDITION & DISPLAYED TEXTResulting EffectUSER PROFILES INOPERABLEMESSAGE ONLY, at power-upNot usedREAR VIEWEXCEEDED WEIGHT LIMIT OF VEHICLE03LIFT SYSTEM, except lower, and TRACTION shutdownuntil condition is cleared04Not used0506The numbers in this drawing correspond to thenumbers in the first column of the SCHEDULEDMAINTENANCE & INSPECTION TABLE.TOP VIEWwith Overhead Guard removed070809101112BATTERY VOLTAGE OUT OF RANGETOTAL shutdownTRAVEL POTENTIOMETER VOLTAGE OUT OF RANGETRACTION SYSTEM shutdownLIFT/LOWER POTENTIOMETER VOLTAGE OUT OF RANGELIFT SYSTEM shutdownAUXILIARY MULTI-LEVER POTENTIOMETER VOLTAGE OUT OF RANGELIFT SYSTEM shutdownSTEER POSITION POTENTIOMETER VOLTAGE OUT OF RANGETRACTION SYSTEM shutdownW EIGHT PRESSURE SENSE VOLTAGE OUT OF RANGELIFT SYSTEM, except lower, shutdownCENTER-OF-GRAVITY PRESSURE SENSE VOLTAGE OUT OF RANGELIFT SYSTEM, except lower, shutdownLIFT CONTROL TEMPERATURE SENSE VOLTAGE OUT OF RANGELIFT SYSTEM, except lower, shutdownLEFT/RIGHT TRACTION CONTROL TEMPERATURE SENSE VOLTAGE13L/ROUT OF RANGESPEED limited14151617181920LIFT MOTOR TEMPERATURE SENSE VOLTAGE OUT OF RANGELIFT SYSTEM, except lower, shutdownACCELEROMETER VOLTAGE OUT OF RANGELIFT and TRACTION SYSTEM derationFLOORPAD SWITCH VOLTAGE OUT OF RANGETRACTION SYSTEM shutdownBRAKE PEDAL SWITCH FAILURETOTAL shutdownTILT LIMIT SWITCH FAILURELIFT SYSTEM shutdownLIFT LIMIT SWITCH FAILURELIFT SYSTEM shutdownSIDE SHIFT RIGHT SWITCH VOLTAGE OUT OF RANGELIFT SYSTEM shutdown
SYSTEM FAULT CODES AFAULT CONDITION & DISPLAYED TEXTResulting EffectSIDE-SHIFT LEFT SWITCH VOLTAGE OUT OF RANGELIFT SYSTEM shutdownTILT FORWARD SWITCH VOLTAGE OUT OF RANGELIFT SYSTEM shutdownTILT BACK SWITCH VOLTAGE OUT OF RANGELIFT SYSTEM shutdownAUXILIARY DIRECTION A SWITCH VOLTAGE OUT OF RANGELIFT SYSTEM shutdownAUXILIARY DIRECTION B SWITCH VOLTAGE OUT OF RANGELIFT SYSTEM shutdownHORN SWITCH VOLTAGE OUT OF RANGEDISPLAY MESSAGEMAIN POWER CONTACTOR DRIVER OVERHEATEDTOTAL shutdown, until condition is clearedMAIN POWER CONTACTOR SHORTED TO SUPPLYTOTAL shutdownMAIN POWER CONTACTOR SHORTED TO GROUND29C29D30A30B30Cbottom halfTOTAL shutdownMAIN POWER CONTACTOR DISCONNECTEDTOTAL shutdown, until condition is clearedMAIN POWER CONTACTOR WELDEDTOTAL shutdownMAIN POWER CONTACTOR OPENTOTAL shutdownNot UsedLIFT/LOWER PROPORTIONAL VALVE SOLENOID DRIVEROVERHEATEDLIFT SYSTEM shutdown, until condition is cleared29BScheduled Maintenance andInspection TableLIFT/LOWER PROPORTIONAL VALVE SOLENOID SHORTED TO SUPPLYLIFT SYSTEM shutdownLIFT/LOWER PROPORTIONAL VALVE SOLENOID SHORTED TO GROUNDLIFT SYSTEM shutdownLIFT/LOWER PROPORTIONAL VALVE SOLENOID DISCONNECTEDLIFT SYSTEM shutdown, until condition is clearedLOWER VALVE SOLENOID DRIVER OVERHEATEDLIFT SYSTEM shutdown, until condition is clearedLOWER VALVE SOLENOID SHORTED TO SUPPLYLIFT SYSTEM shutdownLOWER VALVE SOLENOID SHORTED TO GROUNDLIFT SYSTEM shutdown - - -up
SYSTEM FAULT CODES (ERRORS)ERRORNO.30D31A31B31C31D3233AScheduled Maintenance andInspection TableTop Half33B33C - - -up33D34A34B34C34D35A35B35C35D36A36BFAULT CONDITION & DISPLAYED TEXTResulting EffectLOWER VALVE SOLENOID DISCONNECTEDLIFT SYSTEM shutdown, until condition is clearedLIFT VALVE SOLENOID DRIVER OVERHEATEDLIFT SYSTEM, except lower, shutdown, until cond. clearLIFT VALVE SOLENOID SHORTED TO SUPPLYLIFT SYSTEM, except lower, shutdownLIFT VALVE SOLENOID SHORTED TO GROUNDLIFT SYSTEM, except lower, shutdownLIFT VALVE SOLENOID DISCONNECTEDLIFT SYSTEM, except lower, shutdown, until cond. clearNot UsedTILT FORWARD VALVE SOLENOID DRIVER OVERHEATEDLIFT SYSTEM, except lower, shutdown, until cond. clearTILT FORWARD VALVE SOLENOID SHORTED TO SUPPLYLIFT SYSTEM, except lower, shutdownTILT FORWARD VALVE SOLENOID SHORTED TO GROUNDLIFT SYSTEM, except lower, shutdownTILT FORWARD VALVE SOLENOID DISCONNECTEDLIFT SYSTEM, except lower, shutdown, until cond. clearTILT BACK VALVE SOLENOID DRIVER OVERHEATEDLIFT SYSTEM, except lower, shutdown, until cond. clearTILT BACK VALVE SOLENOID SHORTED TO SUPPLYLIFT SYSTEM, except lower, shutdownTILT BACK VALVE SOLENOID SHORTED TO GROUNDLIFT SYSTEM, except lower, shutdownTILT BACK VALVE SOLENOID DISCONNECTEDLIFT SYSTEM, except lower, shutdown, until cond. clearSIDE SHIFT LEFT VALVE SOLENOID DRIVER OVERHEATEDLIFT SYSTEM, except lower, shutdown, until cond. clearSIDE SHIFT LEFT VALVE SOLENOID SHORTED TO SUPPLYLIFT SYSTEM, except lower, shutdownSIDE SHIFT LEFT VALVE SOLENOID SHORTED TO GROUNDLIFT SYSTEM, except lower, shutdownSIDE SHIFT LEFT VALVE SOLENOID DISCONNECTEDLIFT SYSTEM, except lower, shutdown. until cond. clearSIDE SHIFT RIGHT VALVE SOLENOID DRIVER OVERHEATEDLIFT SYSTEM, except lower, shutdown, until cond. clearSIDE SHIFT RIGHT VALVE SOLENOID SHORTED TO SUPPLYLIFT SYSTEM, except lower, shutdown
SYSTEM FAULT CODES (ERRORS)ERRORNO.36C36D37AFAULT CONDITION & DISPLAYED TEXTResulting EffectSIDE SHIFT RIGHT VALVE SOLENOID SHORTED TO GROUNDLIFT SYSTEM, except lower, shutdownSIDE SHIFT RIGHT VALVE SOLENOID DISCONNECTEDLIFT SYSTEM, except lower, shutdown, until cond. clearAUXILIARY DIRECTION A VALVE SOLENOID DRIVEROVERHEATEDDIAGNOSTIC OUTPUT TESTSWARNING JACK THE TRUCK AND BLOCK THE WHEELSBEFORE PERFORMING ANY MAINTENANCE OUTPUT TESTSO 01O 02O 03LIFT SYSTEM, except lower, shutdown, until cond. clear37B37C37D38AAUXILIARY DIRECTION A VALVE SOLENOID SHORTED TO SUPPLYLIFT SYSTEM, except lower, shutdownAUXILIARY DIRECTION A VALVE SOLENOID SHORTED TO GROUNDLIFT SYSTEM, except lower, shutdownAUXILIARY DIRECTION A VALVE SOLENOID DISCONNECTEDLIFT SYSTEM, except lower, shutdown, until cond. clearAUXILIARY DIRECTION B VALVE SOLENOID DRIVEROVERHEATEDLIFT SYSTEM, except lower, shutdown, until cond. clear38B38C38D39A39B39C39D4041A41B41C41DO 04O 05O 06O 07O 08AUXILIARY DIRECTION B VALVE SOLENOID SHORTED TO SUPPLYLIFT SYSTEM, except lower, shutdownO 09AUXILIARY DIRECTION B VALVE SOLENOID SHORTED TO GROUNDLIFT SYSTEM, except lower, shutdownO 10Main Power ContactorO 01 - OPEN27A-FO 01 - CLSDSteer MotorO 02 - OPENXX AMPSLower Solenoid30A-DO 03 - OPENO 03 - CLSDLift Solenoid31A-DO 04 - OPENO 04 - CLSDNOT USEDTilt Forward SolenoidO 06 - OPEN33A-DO 06 - CLSDTilt Back Solenoid34A-DO 07 - OPENO 07 - CLSDSide Shift Left SolenoidO 08 - OPEN35A-DO 08 - CLSDSide Shift Right SolenoidO 09 - OPENAuxiliary Direction A SolenoidO 10 - OPENLIFT SYSTEM, except lower, shutdown, until cond. clearAuxiliary Direction B SolenoidBACKUP ALARM DRIVER OVERHEATEDDISPLAY MESSAGE, until condition is clearedBACKUP ALARM SHORTED TO SUPPLYDISPLAY MESSAGEO 12O 13BACKUP ALARM SHORTED TO GROUNDDISPLAY MESSAGEO 14BACKUP ALARM DISCONNECTEDDISPLAY MESSAGE, until condition is clearedO 15COIL DRIVER HARDWARE FAILURETOTAL shutdownO 16W2X STEER SOLENOID DRIVER OVERHEATEDTRACTION SYSTEM shutdown, until cond. is clearedW2X STEER SOLENOID SHORTED TO SUPPLYO 17O 18TRACTION SYSTEM shutdownO 10 - CLSDO 11 - OPEN38A-DO11 - CLSDImpact Sensor15, 47O 12 - X.XVO 12 - X.XVNot UsedLift/Lower Proportional SolenoidO 14 - OPEN29A-DO 14 - CLSDHorn26O 15 - OFFO 15 - ONDisplayO 16 - OFFO 16 -Left Traction MotorO 17 - OFFFXX/AXXXX.XX51L, 61-68L,84L, 87LRight Traction MotorO 18 - OFFFXX/AXXXX.XX51R, 61-68R,84R, 87RMPHW2X STEER SOLENOID DISCONNECTEDTRACTION SYSTEM shutdown, until cond. is cleared37A-DMPHTRACTION SYSTEM shutdownW2X STEER SOLENOID SHORTED TO GROUND36A-DO 09 - CLSDAUXILIARY DIRECTION B VALVE SOLENOID DISCONNECTEDO 1141A-D, 56,59, 60O 19Lift MotorO 19 - OFFXX.XAMP49, 57, 58,88
DIAGNOSTIC MODE INPUT TESTSTESTNO.I 01I 02TEST NAMENORMAL OPERATION DISPLAYI 01 - OFF (Pos I) or I 01 - ON (Pos II)Brake Limit SwitchI 03 - VOLTAGEI 06I 04 - VOLTAGEI 05 - VOLTAGEI 08I 09I 10I 11I 12I 13I 14I 150642C42D073.1 - 4.6 Full Lift1.9 - 3.1 Neutral0.4 - 1.9 Full Lower09450819255051L/R521053I 08 - OFF or I 08 - ON24I 09 - OUT or I 09 - INAuxiliary Direction B Push Button4849I 07 - OFF or I 07 - ONAuxiliary Direction A Push Button464718Lift Limit SwitchI 10 - OUT or I 10 - INWeight Pressure Transducer VoltageI 11 - VOLTAGE 0.5 - 4.5NOT USED (CG Transducer)112nd Stage Sensor5455L/RI 13 - OFF (2nd) OR I 13 ON (1st)Floorpad Switch16569157I14 - OFF or I14 - ONElectric Steer EncoderI 15 - NUMBERFAULT CONDITION & DISPLAYED TEXTResulting EffectW2X LIFT SOLENOID DRIVER OVERHEATEDLIFT SYSTEM, except lower, shutdown, until cond. clearW2X LIFT SOLENOID SHORTED TO SUPPLYLIFT SYSTEM, except lower, shutdownW2X LIFT SOLENOID SHORTED TO GROUNDLIFT SYSTEM, except lower, shutdownW2X LIFT SOLENOID DISCONNECTEDLIFT SYSTEM, except lower, shutdown, until cond. clearTILT LIMIT REACHEDSPEED limited until condition is clearedTILT AND LIFT LIMITS REACHED3.1 - 4.6 Full Reverse1.9 - 3.1 Neutral0.4 - 1.9 Full ForwardTilt Limit Switch43440.4 - 1.9 Full Left (-90o)1.9 - 3.1 Straight (0o)3.1 - 4.6 Full Right (90o)Auxiliary Multi-lever PotentiometerVoltageI 06 - VOLTAGEI 0742B3.1 - 4.6 Full Forks First1.9 - 3.1 Neutral0.4 - 1.9 Full Tractor FirstSteer Position Potentiometer VoltageI 0517I 02 - UP or I 02 - DOWNLift/Lower Potentiometer VoltageI 04ERRORNO.42AStart SwitchTravel Potentiometer VoltageI 03SYSTEM FAULT CODES (ERRORS)FAULTDISPLAY000 - 255Some Input and Output tests shown will only be present in the menulist when the option is installed and enabled.5859SPEED limited and LIFT SYSTEM, except tilt back andlower, shutdown, until condition is clearedLIFT SPEED LIMIT REACHEDSPEED limited until condition is clearedLIFT HEIGHT LIMIT REACHEDLIFT SYSTEM, except lower, shutdown until cond. clearIMPACT THRESHOLD EXCEEDEDLIFT and TRACTION SYSTEM derationNot usedLIFT MOTOR OVERHEATEDLIFT SYSTEM, except lower, shutdownNot usedLEFT/RIGHT TRACTION MOTOR OVERHEATEDTRACTION SYSTEM shutdownNot usedLIFT CONTROL OVERHEATEDLIFT SYSTEM, except lower, shutdownNot usedLEFT/RIGHT TRACTION CONTROL OVERHEATEDTRACTION SYSTEM shutdownSTEER MOTOR BRUSH WEAR FAILURETRACTION SYSTEM deration to 1 mphLIFT MOTOR CURRENT NOT PRESENTLIFT SYSTEM shutdownLIFT MOTOR CURRENT HIGHLIFT SYSTEM shutdownSTEER MOTOR CURRENT NOT PRESENTTOTAL shutdown
Pre-OperationalInformationSYSTEM FAULT CODES (ERRORS)ERRORNO.60FAULT CONDITION & DISPLAYED TEXTResulting EffectSTEER MOTOR CURRENT HIGHTOTAL shutdown61L/RLEFT/RIGHT MOTOR BRUSH WEAR FAILURE62L/RLEFT/RIGHT TRACTION MOTOR FIELD CURRENT HIGHSPEED limitedTRACTION SYSTEM shutdown63L/RLEFT/RIGHT TRACTION MOTOR FIELD CURRENT NOT PRESENT64L/RLEFT/RIGHT TRACTION MOTOR ARMATURE HIGHTRACTION SYSTEM shutdownTRACTION SYSTEM shutdown65L/RLEFT/RIGHT TRACTION MOTOR ARMATURE CURRENT NOT PRESENT66L/RLEFT/RIGHT TRACTION - NO MOVEMENT DETECTEDTRACTION SYSTEM shutdownOperationalInformationTRACTION SYSTEM shutdown67L/RLEFT/RIGHT DRIVE ROTATION DIRECTION FAILURE68L/RLEFT/RIGHT BRAKE INOPERABLE OR NOT PROPERLY ADJUSTEDTRACTION SYSTEM shutdownTOTAL shutdown697071L/RSYSTEM CONTROL 5 VOLTAGE OUT OF RANGETOTAL shutdownSYSTEM CONTROL 15 VOLTAGE OUT OF RANGETOTAL shutdownLEFT/RIGHT TRACTION CONTROL 5 VOLTAGE OUT OF RANGETOTAL shutdown72L/RLEFT/RIGHT TRACTION CONTROL 15 VOLTAGE OUT OF RANGETOTAL shutdown73L/RLEFT/RIGHT TRACTION CONTROL -15 VOLTAGE OUT OF RANGETOTAL shutdown7475767778A78BLIFT CONTROL 5 VOLTAGE OUT OF RANGEMENU CONVENTION1. MOVE through the menu using:TOTAL shutdownto move UP and DOWN, andLIFT CONTROL 15 VOLTAGE OUT OF RANGEto move LEFT and RIGHT.TOTAL shutdownLIFT CONTROL -15 VOLTAGE OUT OF RANGETOTAL shutdownSYSTEM CONTROL HARDWARE FAILURETOTAL shutdownSYSTEM CONTROL SOFTWARE FAILURETOTAL shutdownDOWNLOAD BACKUP SOFTWARE FAILURETOTAL shutdown2. ENTER alphanumerics using:to CYCLE letters/numbers, andto MOVE between character positions, thento ACCEPT.3. SELECT options by pressing.
PERFORMANCE & DIAGNOSTICS MENUSOFTWARE VERSION 3.2510/27/00SYSTEM FAULT CODES (ERRORS)ERRORNO.78C798081828384L/RFAULT CONDITION & DISPLAYED TEXTResulting EffectSYSTEM CONTROL CONFIGURATION FAILURETOTAL shutdownDISPLAY CONTROL CONFIGURATIONFAILURETOTAL shutdownLIFT CUTOUT DUE TO LOW BATTERY STATE OF CHARGELIFT system, except lower, shutdownEACH BUTTON STUCKLIFT SYSTEM, except lower, shutdownOPERATIONAL PARAMETERS INVALIDTOTAL shutdownNot usedLEFT/RIGHT TRACTION MOTOR TEMPERATURE IMBALANCE EXCEEDEDTRACTION SYSTEM shutdown8586L/RNot usedLEFT/RIGHT TRACTION CONTROL TEMPERATURE IMBALANCEEXCEEDEDTRACTION SYSTEM shutdown87L/RLEFT/RIGHT TRACTION DIODE FAILURETRACTION SYSTEM shutdown8889L/RLIFT MOTOR CURRENT NOT PRESENT / DIODE FAILURELIFT SYSTEM shutdownLEFT/RIGHT TRACTION CONTROL HARDWARE FAILURETOTAL SYSTEM shutdown and open MAIN POWERCONTACTOR9091929394LIFT/STEER CONTROL HARDWARE FAILURETOTAL SYSTEM shutdown and open MAIN POWERCONTACTORSTEER ENCODER FAILUREHARSH PLUG then TRACTION and STEER SYSTEMshutdownSTEER ROTATION FAILUREHARSH PLUG then TRACTION and STEER SYSTEMshutdownKEYSWITCH CIRCUIT FAILUREDISPLAY MESSAGE until battery is disconnectedBOOST LIFT PUMP CONTACTOR WELDEDOpen MAIN POWER CONTACTOR
SYSTEM FAULT CODES (WARNINGS)WARNNO.0102030405060708151
Series Lift Trucks. ELECTRIC STAND-UP COUNTERBALANCE. SCHAEFFProviding VALUE Solutions. Schaeff Inc. 9655 Industrial Drive Bridgeview, Il 60455, US Tel: (708) 430 - 5301 Fax: (708) 430 - 5331 E-Mail: Mailbox@SchaeffInc.com www.SchaeffInc.com Schaeff Inc. 10/03 Part Number 6840005 Printed in U.S.A.
