CTM/CEM 10-20

Version. 2.0 Service Training

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K.E. 15.1.2001
Functions
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Mechanic

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Brake Function
 Error memory traction control

CTM/CEM 10-20 Error Memory Drive Controller 19.3.1999

Fehlerliste
 Error memory traction control

CTM/CEM 10-20 Error Memory Drive Controller

Description Code
20.10.1999
Tip:
Accelerator pedal, Interruption in accelerator circle A50 If the accelerator voltage is
higher than 1,5V after
switching the key-operated
switch, the drive functions
are blocked.
„ACCELERATOR“
appears on the display. No
error is entered in the fault
memory.
An error is indicated, if the power-circuit of the accelerator-power supply
is disturbed.
The +12V supply voltage runs from the drive control, plug TG3, to the
drive pedal F1-1 via the wire 78A. The current runs back from the drive
pedal F1-3 via wire 13F to the drive control, plug TG1
There is a diode in the drive control, between TG1 and battery minus.
When a current is flowing a voltage arises at this diode (0,6 to 0,7V). This
voltage is measured by the control.
 Error memory traction control

CTM/CEM 10-20 Error Memory Drive Controller 20.10.1999

Description Code
Accelerator pedal, Interruption in accelerator circle A50
Shunt value incorrect A 51

An error is indicated, if the control recognises current

while the truck stands still or if no current is measured
during operation (faster than 65% speed).
 Error memory traction control

CTM/CEM 10-20 Error Memory Drive Controller 20.10. 1999

Description Code
Accelerator pedal, Interruption in accelerator circle A50
Shunt value incorrect A 51
Steering potentiometer out of range <0,8V or >4,2V A 52

The steering potentiometer provides voltage proportional to

the actual steering angle. If the voltage is lower then 0,8V or
higher then 4,2V, an error is indicated.
 Error memory traction control

CTM/CEM 10-20 Error Memory Drive Controller 20.10.1999

Description Code
Accelerator pedal, Interruption in accelerator circle A50
Shunt value incorrect A 51
Steering potentiometer out of range <0,8V or >4,2V A 52
Watchdog timer or MOSFET-driver A 53

Software monitoring:
The software (the programme) is processed step by step by the
microprocessor.
A counter runs in parallel to this. Each time the programme is run, it
reaches a point at which this counter is set to zero. If the programme
does not run properly, the counter is not set to zero, leading to the
achievement of a defined numerical value at which the programme
is interrupted.
 Error memory traction control

CTM/CEM 10-20 Error Memory Drive Controller 20.10.1999 If this failure

Description Code
Accelerator pedal, Interruption in accelerator circle A50 appears, the total
Shunt value incorrect A 51
Steering potentiometer out of range <0,8V or >4,2V A 52
parameter list has to
Watchdog timer or MOSFET-driver A 53 be loaded again. If
EEPROM-Checksumme A 54
the failure appears
repeatedly, the
electronic card has
to be changed.

The EEPROM is a memory for changeable data, i.e. parameters, failures,

etc., which must not get lost after turning of the supply voltage.
If a value of the memory is changed, the software inquires a checksum
out of the present index. This checksum is memorised. Every time the
machine is turned on, the checksum is inquired again and compared with
the memorised checksum. If the checksums are not identical, one or more
values must have been changed.
 Error memory traction control

CTM/CEM 10-20 Error Memory Drive Controller 20.10.1999

Description Code
Accelerator pedal, Interruption in accelerator circle A50
Shunt value incorrect A 51
Steering potentiometer out of range <0,8V or >4,2V A 52
Watchdog timer or MOSFET-driver A 53
EEPROM-Checksum A 54
Theramal protection (>75°C) contin. Speed reduction A 55

The temperature sensor is located directly on the transistors.

At temperatures above 75°C, the control system regulates the speed.

If no cooling is reached with power decrease, the motor is switched

off, at a temperature of 80°C.
 Error memory traction control

CTM/CEM 10-20 Error Memory Drive Controller 20.10.1999

Description Code
Accelerator pedal, Interruption in accelerator circle A50
Shunt value incorrect A 51
Steering potentiometer out of range <0,8V or >4,2V A 52
Watchdog timer or MOSFET-driver A 53
EEPROM-Checksum A 54
Theramal protection (>75°C) contin. Speed reduction A 55
Voltage at VMN(R)-(L) not between 30% - 70% A 56

If the transistors are not controlled, the voltage between battery

negative and and VMN(R) and (L) is half the battery voltage.
 Error memory traction control

CTM/CEM 10-20 Error Memory Drive Controller 20.10.1999

Description Code
Accelerator pedal, Interruption in accelerator circle A50
Shunt value incorrect A 51
Steering potentiometer out of range <0,8V or >4,2V A 52
Watchdog timer or MOSFET-driver A 53
EEPROM-Checksum A 54
Theramal protection (>75°C) contin. Speed reduction A 55
Voltage at VMN(R)-(L) not between 30% - 70% A 56
No UB- connection; delay detective (F or R don´t switch on) A 57

The direction-contactors are switched on, before the drive-brake-

contactor is activated. After switching on, the software has to change the
voltage potential at V MN (R) and (L) to 0V within a given time.
 Error memory traction control

CTM/CEM 10-20 Error Memory Drive Controller 20.10.1999

Description Code
Accelerator pedal, Interruption in accelerator circle A50
Shunt value incorrect A 51
Steering potentiometer out of range <0,8V or >4,2V A 52
Watchdog timer or MOSFET-driver A 53
EEPROM-Checksum A 54
Theramal protection (>75°C) contin. Speed reduction A 55
Voltage at VMN(R)-(L) not between 30% - 70% A 56
No UB- connection; delay detective (F or R don´t switch on) A 57
No UB+ connection; delay detective (relais not correct) A 58

If the direction-coils and the brake-coil is switched on, the potential at

VMN(R) and (L) battery has to be +.

After switching on the coil, the voltage potential has to be reached

within a given time, built into the software.
 Error memory traction control

CTM/CEM 10-20 Error Memory Drive Controller 20.10.1999

Description Code
Accelerator pedal, Interruption in accelerator circle A50
Shunt value incorrect A 51
Steering potentiometer out of range <0,8V or >4,2V A 52
Watchdog timer or MOSFET-driver A 53
EEPROM-Checksum A 54
Theramal protection (>75°C) contin. Speed reduction A 55
Voltage at VMN(R)-(L) not between 30% - 70% A 56
No UB- connection; delay detective (F or R don´t switch on) A 57
No UB+ connection; delay detective (relais not correct) A 58
Problem with contactor coils A 59

The contactor-coils are checked from the control,that there is no

interruption and short circuit in winding (to high current).
 Error memory pump control

CTM/CEM 10-20 Error Memory Drive Controller 20.10.1999

Description Code The power circuit is
Accelerator pedal, Interruption in accelerator circle A50
Shunt value incorrect A 51
connected with the
Steering potentiometer out of range <0,8V or >4,2V A 52 battery (+) from the
Watchdog timer or MOSFET-driver A 53
EEPROM-Checksum A 54 exit of the control
Theramal protection (>75°C) contin. Speed reduction A 55
Voltage at VMN(R)-(L) not between 30% - 70% A 56
(M-) via motor coil.
No UB- connection; delay detective (F or R don´t switch on) A 57
No UB+ connection; delay detective ( relais not correct) A 58 If this connection
Problem with contactor coils A 59
does not exists, the
CTM/CEM 10-20 Error Memory Pump Controller power circuit must be
Description Code
Power circuit open, tested on M- A 60 disturbed.
 Error memory pump control

CTM/CEM 10-20 Error Memory Drive Controller 20.10.1999 The temperature sensor
Description Code is located directly on
Accelerator pedal, Interruption in accelerator circle A50
Shunt value incorrect A 51 the transistors.
Steering potentiometer out of range <0,8V or >4,2V A 52 At temperatures above
Watchdog timer or MOSFET-driver A 53 75°C, the control
EEPROM-Checksum A 54
Theramal protection (>75°C) contin. Speed reduction A 55 system regulates the
Voltage at VMN(R)-(L) not between 30% - 70% A 56 speed.
No UB- connection; delay detective (F or R don´t switch on) A 57
No UB+ connection; delay detective (relais not correct) A 58
Problem with contactor coils A 59 If no cooling is
reached with power
CTM/CEM 10-20 Error Memory Pump Controller
Description Code
decrease, the motor is
Power circuit open, tested on M- A 60 switched off, at a
Thermal protection close to the transistors (>75°C) A 61 temperature of 80°C.
 Error memory pump control

CTM/CEM 10-20 Error Memory Drive Controller

Description Code
20.10.1999 A failure is
Accelerator pedal, Interruption in accelerator circle A50 indicated, if the
Shunt value incorrect A 51
Steering potentiometer out of range <0,8V or >4,2V A 52 control registers
Watchdog timer or MOSFET-driver A 53 current at the still
EEPROM-Checksum A 54
Theramal protection (>75°C) contin. Speed reduction A 55 standing motor or
Voltage at VMN(R)-(L) not between 30% - 70% A 56
No UB- connection; delay detective (F or R don´t switch on) A 57 no current at the
No UB+ connection; delay detective (relais not correct) A 58 running motor.
Problem with contactor coils A 59

CTM/CEM 10-20 Error Memory Pump Controller

Description Code
Power circuit open, tested on M- A 60
Thermal protection close to the transistors (>75°C) A 61
Shunt value incorrect A 62
 Error memory pump control
Software monitoring:
The software (the
CTM/CEM 10-20 Error Memory Drive Controller 20.10.1999
programme) is
Description Code processed step by step
Accelerator pedal, Interruption in accelerator circle A50 by the microprocessor.
Shunt value incorrect A 51
Steering potentiometer out of range <0,8V or >4,2V A 52
A counter runs in
Watchdog timer or MOSFET-driver A 53 parallel to this. Each
EEPROM-Checksum A 54 time the programme is
Theramal protection (>75°C) contin. Speed reduction A 55
Voltage at VMN(R)-(L) not between 30% - 70% A 56
run, it reaches a point at
No UB- connection; delay detective (F or R don´t switch on) A 57 which this counter is set
No UB+ connection; delay detective (relais not correct) A 58 to zero. If the
Problem with contactor coils A 59
programme does not run
CTM/CEM 10-20 Error Memory Pump Controller properly, the counter is
Description Code not set to zero, leading
Power circuit open, tested on M- A 60 to the achievement of a
Thermal protection close to the transistors (>75°C) A 61
Shunt value incorrect A 62 defined numerical value
Watchdog timer or MOSFET-driver A 63 at which the programme
is interrupted.
 Error memory pump control

CTM/CEM 10-20 Error Memory Drive Controller 20.10.1999 The value of the
Description Code
Accelerator pedal, Interruption in accelerator circle A50 EEPROM memory
Shunt value incorrect A 51 cells is not equal to
Steering potentiometer out of range <0,8V or >4,2V A 52
Watchdog timer or MOSFET-driver A 53 the EEPROM
EEPROM-Checksum A 54 checksum.
Theramal protection (>75°C) contin. Speed reduction A 55
Voltage at VMN(R)-(L) not between 30% - 70% A 56
No UB- connection; delay detective (F or R don´t switch on) A 57
No UB+ connection; delay detective (relais not correct) A 58
Problem with contactor coils A 59

CTM/CEM 10-20 Error Memory Pump Controller

Description Code
Power circuit open, tested on M- A 60
Thermal protection close to the transistors (>75°C) A 61
Shunt value incorrect A 62
Watchdog timer or MOSFET-driver A 63
EEPROM-Checksum A 64
 Check point traction control

CTM/CEM 10-20 Check Points Traction Controller

All important test items can be called up with the

diagnosis.
The use of measuring devices is therefore minimised.
The values are "measurement values" and can only be
read off, not changed.
checkliste
 Check point traction control

CTM/CEM 10-20 Check Points Traction Controller

Description Code Demand Act.
Software - Version C 54

The software version of the drive control system is displayed!

 Check point traction control
Tip: At older trucks the 0V-supply of the drive pedal can take place directly from the
battery-minus. At newer trucks, the minus-supply comes from the drive control (TG1). If
there is the older version, the accelerator voltage has to be 0,2V-0,4V while switching on
MS1.
CTM/CEM 10-20 Check Points Traction Controller Tip: Before
Description Code Demand Act.
Software – Version C 54 MS1is switched,
Acceleration pedal value, MS1 switched on. C 55 0,8 - 1,2 V the display
Maximal value. > 4,3V + 0,7V
changes between
the actual
voltage value
and 0. After
MS1 is switched,
the actual value
The value shown indicates the voltage (V), which is given to the
control, depending on the position of the accelerator pedal. is continually
The voltage during the closing of MS1 is decisive for the starting shown.
speed of the truck. If the value is too high, the truck starts
jerkily. The voltage reaches its maximum value before the end of
pedal movement.
 Check point traction control
As both wheels have their own drive motor, it is necessary to rebuild the
differential gear unit. The value of the steering poti corresponds to the
steering corner. At straight-ahead position it should have a value of
2,5V.
CTM/CEM 10-20 Check Points Traction Controller
Description Code Demand Act.
Software – Version C 54
Acceleration pedal value, MS1 switched on. C 55 0,8 - 1,2 V
Maximal value. > 4,3V + 0,7V
Steering potentiometer straight. C 56 2,5V +/-0,1V
Steering max. right. 4,0V + 0,1V
Steering max. left. 1,0V – 0,1V

With increasing steering angle, the speed of the inside turn wheel is at first
reduced. If the steering angle keeps increasing, the speed of the wheel is
again raised in the opposite direction.
 Check point traction control

CTM/CEM 10-20 Check Points Traction Controller

Description Code Demand Act.
Software – Version C 54
Acceleration pedal value, MS1 switched on. C 55 0,8 - 1,2 V
Maximal value. > 4,3V + 0,7V
Steering potentiometer straight. C 56 2,5V +/-0,1V
Steering max. right. 4,0V + 0,1V
Steering max. left. 1,0V – 0,1V
Direction switch forward. C 57 on / off
Direction switch reward. C 58 on / off

The function of the direction switch can only be read, if

MS1 is shut and the handbrake is off.
 Check point traction control

CTM/CEM 10-20 Check Points Traction Controller

Description Code Demand Act.
Software – Version C 54
Acceleration pedal value, MS1 switched on. C 55 0,8 - 1,2 V
Maximal value. > 4,3V + 0,7V
Steering potentiometer straight. C 56 2,5V +/-0,1V
Steering max. right. 4,0V + 0,1V
Steering max. left. 1,0V – 0,1V
Direction switch forward. C 57 on / off
Direction switch reward. C 58 on / off
Brake switch. C 59 on / aoff

The switch of the brake is a pressure switch. It is located in the

hydraulic circuit of the braking system. Its response pressure
is 2 bar.
 Check point traction control

Tip: The seat switch is actuated due to a mechanism within

the seat. If your seat has a weight adjustment, it has to be
set correctly for the driver‘s weight.
CTM/CEM 10-20 Check Points Traction Controller
Description Code Demand Act.
Software – Version C 54
Acceleration pedal value, MS1 switched on. C 55 0,8 - 1,2 V
Maximal value. > 4,3V + 0,7V
Steering potentiometer straight. C 56 2,5V +/-0,1V
Steering max. right. 4,0V + 0,1V
Steering max. left. 1,0V – 0,1V
Direction switch forward. C 57 on / off
Direction switch reward. C 58 on / off
Brake switch. C 59 on / off
Seat switch. C 60 on / off

The entrance of the seat switch has a switch off delay of

1 sec. This means, that a short switch off has no effect
(e.g. on rough ground).
 Check point traction control

CTM/CEM 10-20 Check Points Traction Controller

Description Code Demand Act.
Software – Version C 54
Acceleration pedal value, MS1 switched on. C 55 0,8 - 1,2 V
Maximal value. > 4,3V + 0,7V
Steering potentiometer straight. C 56 2,5V +/-0,1V
Steering max. right. 4,0V + 0,1V
Steering max. left. 1,0V – 0,1V
Direction switch forward. C 57 on / off
Direction switch reward. C 58 on / off
Brake switch. C 59 on / off
Seat switch. C 60 on / off
Actual controller temperature. C 61 <80°C

If the control reaches a temperature of 75°C, the electronic starts to limit

the power. If a further increase of the temperature can not be prevented,
the function is stopped at a temperature of 80°C. After the temperature
has decreased again, the function is switched on.
 Check point pump control

CTM/CEM 10-20 Check Points Traction Controller

Description Code Demand Act.
Software - Version C 54
Acceleration pedal value, MS1 switched on. C 55 0,8 - 1,2 V
Maximal value. > 4,3V + 0,7V
Steering potentiometer straight. C 56 2,5V +/- 0,1V
Steering max. right. 4,0V + 0,1V
Steering max. left. 1,0V – 0,1V
Direction switch forward. C 57 on / off
Direction switch reward. C 58 on / off
Brake switch. C 59 on / off
Seat switch. C 60 on / off
Actual controller temperature. C 61 <80°C

CTM/CEM 10-20 Check Points Pump Controller

Description Code Demand Act.
Software – Version. C 50
 Check point pump control

CTM/CEM 10-20 Check Points Traction Controller

Description Code Demand Act.
Software - Version C 54 The dash board
Acceleration pedal value, MS1 switched on. C 55 0,8 - 1,2 V
Maximal value. > 4,3V + 0,7V gives a voltage
Steering potentiometer straight.
Steering max. right.
C 56 2,5V +/- 0,1V
4,0V + 0,1V
(intended value) to
Steering max. left. 1,0V – 0,1V the pump control.
Direction switch forward. C 57 on / off
Direction switch reward. C 58 on / off The amount of the
Brake switch. C 59 on / off
Seat switch. C 60 on / off
voltage depends
Actual controller temperature. C 61 <80°C on the activated
CTM/CEM 10-20 Check Points Pump Controller dash board
Description Code Demand Act. entrance (function
Software - Version C 50
Lift potentiometer, range minimal to maximal. C 51 >4,3V - <0,8V entrance).
Micro switch corresponding to dash board adjustment. <4,0V - >1,0V

The voltage for lifting corresponds to the lift lever position

(analogue value of the potentiometer).
The voltages for all other functions correspond to each
separately programmed for the respective micro switches.
 Check point pump control

CTM/CEM 10-20 Check Points Traction Controller

Description Code Demand Act.
Software - Version C 54
Acceleration pedal value, MS1 switched on. C 55 0,8 - 1,2 V
Maximal value. > 4,3V + 0,7V
Steering potentiometer straight. C 56 2,5V +/- 0,1V
Steering max. right. 4,0V + 0,1V
Steering max. left. 1,0V – 0,1V
Direction switch forward. C 57 on / off
Direction switch reward. C 58 on / off
Brake switch. C 59 on / off
Seat switch. C 60 on / off
Actual controller temperature. C 61 <80°C

CTM/CEM 10-20 Check Points Pump Controller

Description Code Demand Act.
Software - Version C 50
Lift potentiometer, range minimal to maximal. C 51 >4,3V - <0,8V
Micro switch corresponding to dash board adjustment. <4,0V - >1,0V
Actual controller temperature. C 52 <80°C
 Parameter-list pump control

The parameters are compiled into lists.

Within the list, each parameter has a fixed address.
The address begins with the letter "L".
Parameter Pump Control standard 22.11.2000
Software Version: 1.3
Listplace Parameter Standard Min. Max. Release-
L code
50
51
52
53
54
55
56
57
58

Parameter Pumpe
 Parameter-list pump control

The designation of the parameter is found in the "parameter" column.

The smallest value which can be set is found in the "min." column.
The largest value which can be set is found in the "max." column.
The value set in the factory is found in the "standard" column.
Whether, and by whom, the parameter can be changed is entered in the
"release code" column.
Parameter Pump Control standard 22.11.2000
Software Version: 1.3
Listplace Parameter Standard Min. Max. Release-
code
 Parameter-list pump control

To change the unit features some parameters must be changed.

To simplify these changes 3 preset lists exist.
List No. 1 contains standard sets.
List No. 2 contains “gentle, economical” behaviour.
List No. 3 contains “hard, aggressive” behaviour.
The number of the actual selected list exists on address “L50”.

Parameter Pump Control standard 22.11.2000

Software Version: 1.3
Listplace Parameter Standard Min. Max. Release-
L Designation Value Value Value code
50 List-no. 001 001 003 Service
 Parameter-list pump control

Parameter L51 specifies the speed of the

hydraulic motor for the power steering.

Parameter Pump Control standard 22.11.2000

Software Version: 1.3
Listplace Parameter Standard Min. Max. Release-
L Designation Value Value Value code
50 List-no. 001 001 003 Service
51 RPM steering (%) 016 010 040 Service
 Parameter-list pump control
Change of the floor condition, e.g. while leaving a factory hall, the current of the
motor increases, the RPM decreases.
The control recognises this change of the motor current and reacts on it with the
increase of the motor RPM (increase of voltage).
The size of the increase is determined by parameter L 52. The smaller the factor,
the smaller the increase.

Parameter Pump Control standard 22.11.2000

Software Version: 1.3
Listplace Parameter Standard Min. Max. Release-
L Designation Value Value Value code
50 List-no. 001 001 003 Service
51 RPM steering (%) 016 010 040 Service
52 Compensat. Steering 004 000 009 Service
 Parameter-list pump control

Parameter L53 influences hydraulic pump “after-

running” following the termination of the travel
functions.

The actual value is the “after-running” time in

seconds.
Parameter Pump Control standard 22.11.2000
Software Version: 1.3
Listplace Parameter Standard Min. Max. Release-
L Designation Value Value Value code
50 List-no. 001 001 003 Service
51 RPM steering (%) 016 010 040 Service
52 Compensat. Steering 004 000 009 Service
53 Steering delay (s) 004 000 020 Service
 Parameter-list pump control
The speed of the hydraulic motor changes depending on the voltage at
the nominal value input (plug PC pin 1).

The speed which applies at the corresponding input voltage can be set
with parameters L54,56 and 57.

Note:
The preset parameters reveal an approximately linear course. Set value in Volt
If the parameters are readjusted, the course becomes non linear.
4,0
Parameter Pump Control standard 22.11.2000
Point 1
Software Version: 1.3
Listplace Parameter Standard Min. Max. Release-
L Designation Value Value Value code
Point 2
50 List-no. 001 001 003 Service
51 RPM steering (%) 016 010 040 Service
52 Compensat. Steering 004 000 009 Service Point 3
53 Steering delay (s) 004 000 020 Service
54 RPM Point 1 (%) 020 010 040 Service RPM in %

56 RPM Point 2 (%) 037 020 070 Service

57 RPM Point 3 (%) 050 030 090 Service 100
 Parameter-list pump control
If the RPM of the hydraulic motor reduces because of load (increase of power),
the control can correct the RPM with an increase of voltage. The dimension of the
increase is determined by parameter L55. The smaller the factor, the smaller the
increase.
Tip: With high compensation factor, the regulation might „swing“. (The voltage is
increased, the power decreases, the voltage is decreased again, etc.).

Parameter Pump Control standard 22.11.2000

Software Version: 1.3
Listplace Parameter Standard Min. Max. Release- Example of compensation:
L Designation Value Value Value code
50 List-no. 001 001 003 Service
51 RPM steering (%) 016 010 040 Service Factor Motor-current Motor-voltage
52 Compensat. Steering 004 000 009 Service 5 65A 5,88V
53 Steering delay (s) 004 000 020 Service 5 150A 9,33V
54 RPM Point 1 (%) 020 010 040 Service 5 185A 10,8V
55 Compens. hydraulic 004 000 009 Service
56 RPM Point 2 (%) 037 020 070 Service
6 65A 6,18V
57 RPM Point 3 (%) 050 030 090 Service 6 150A 10,2V
6 185A 11,6V
 Parameter-list pump control
The pump control system measures the battery charge status. Following measurement, the information
is forwarded to the dash board. The dash board displays the information which has been received.
If the value which is displayed does not correspond to the actual conditions, the value can be
"readjusted".
In order to readjust this, measure the battery voltage, add approximately 1.2V to this, and write the
value which is achieved in list space L58. The value which is input must be in tenths of volts, e.g.
41.2V corresponds to 412.
Note:
A higher charge status than before is only displayed if the new value is at least 30% higher than the
previously displayed value!
Parameter Pump Control standard 22.11.2000
Software Version: 1.3
Listplace Parameter Standard Min. Max. Release-
L Designation Value Value Value code
50 List-no. 001 001 003 Service
51 RPM steering (%) 016 010 040 Service
52 Compensat. Steering 004 000 009 Service
53 Steering delay (s) 004 000 020 Service
54 RPM Point 1 (%) 020 010 040 Service
55 Compens. hydraulic 004 000 009 Service
56 RPM Point 2 (%) 037 020 070 Service
57 RPM Point 3 (%) 050 030 090 Service
58 Battery character Measuring * 390 600 Service
 Parameter-list pump control

The maximum RPM of the hydraulic Tip: If a limitation of the

motor is fixed on 100%. max. RPM is needed, list no.
2 can be loaded. Here the
Parameter Pump Control standard 22.11.2000 RPM is limited to 80%. The
Software Version: 1.3
Listplace Parameter Standard Min. Max. Release-
other parameters can be
L Designation Value Value Value code regulated separately to their
50 List-no. 001 001 003 Service
51 RPM steering (%) 016 010 040 Service respective values.
52 Compensat. Steering 004 000 009 Service
53 Steering delay (s) 004 000 020 Service
54 RPM Point 1 (%) 020 010 040 Service
55 Compens. hydraulic 004 000 009 Service
56 RPM Point 2 (%) 037 020 070 Service
57 RPM Point 3 (%) 050 030 090 Service
58 Battery character Measuring * 390 600 Service
Max RPM (%) 100 Fix.
 Parameter-list pump control
Parameter Pump Control economy 22.11.2000
Software Version: 1.3
Listplace Parameter Standard Min. Max. Release-
L Designation Value Value Value code
50 List-no. 002 001 003 Service
51 RPM steering (%) 013 010 040 Service
52 Compensat. Steering 004 000 009 Service
53 Steering delay (s) 004 000 020 Service The lists “economic” and
54 RPM Point 1 (%) 010 010 040 Service
55 Compens. hydraulic 004 000 009 Service
“aggressive” contain
56 RPM Point 2 (%) 025 020 070 Service prefixed parameters.
57 RPM Point 3 (%) 037 030 090 Service
58 Battery character Measuring * 390 600 Service These parameters are not
Max RPM (%) 100 Fix. the possible smallest and
Parameter Pump Control hard 22.11.2000 biggest but the most
Listplace Parameter Standard
Software Version:
Min. Max.
1.3
Release-
needed values, as shown
L Designation Value Value Value code through experience. Of
50 List-no. 003 001 003 Service
51 RPM steering (%) 019 010 040 Service course the single
52
53
Compensat. Steering
Steering delay (s)
004
004
000
000
009
020
Service
Service
parameters within this list
54 RPM Point 1 (%) 030 010 040 Service can be fixed individually.
55 Compens. hydraulic 004 000 009 Service
56 RPM Point 2 (%) 042 020 070 Service
57 RPM Point 3 (%) 063 030 090 Service
58 Battery character Measuring * 390 600 Service
Max RPM (%) 100 Fix.
 Parameter-list drive control
Parameter Pump Control standard 22.11.2000
Software Version: 1.3
Listplace Parameter Standard Min. Max. Release-
L Designation Value Value Value code
50 List-no. 001 001 003 Service
51 RPM steering (%) 016 010 040 Service
52 Compensat. Steering 004 000 009 Service
53 Steering delay (s) 004 000 020 Service
54 RPM Point 1 (%) 020 010 040 Service
55 Compens. hydraulic 004 000 009 Service
56 RPM Point 2 (%) 037 020 070 Service
57 RPM Point 3 (%) 050 030 090 Service
58 Battery character Measuring * 390 600 Service
Max RPM (%) 100 Fix.

CTM/CEM 10-20 Parameter Traction controller standard 1.12.2000

Software Version : 1.4
Listplace Parameter Standard Min. Max. Release
L Description Value Value Value Code
60 List-no. 001 001 003 Service

Fahrparameter
 Parameter-list drive control

The acceleration (aggressiveness) of the unit can be set in

10 stages.
The value 0 is the "most gentle" setting, the value 9 the
most aggressive setting.

CTM/CEM 10-20 Parameter Traction controller standard 1.12.2000

Software Version : 1.4
Listplace Parameter Standard Min. Max. Release
L Description Value Value Value Code
60 List-no. 001 001 003 Service
61 Acceleration 006 000 009 Service
 Parameter-list drive control

Braking behaviour on reversal of the direction of

travel and on actuation of the foot brake can be set
at list space L62.
CTM/CEM 10-20 Parameter Traction controller standard 1.12.2000
Software Version : 1.4
Listplace Parameter Standard Min. Max. Release
L Description Value Value Value Code
60 List-no. 001 001 003 Service
61 Acceleration 006 000 009 Service
62 F/R & Footbrake 045 015 070 Service
 Parameter-list drive control

The time taken from a momentary speed to a lower speed

depends on the braking force.
This force also determines the distance which the unit rolls
before coming to a stop.
CTM/CEM 10-20 Parameter Traction controller standard 1.12.2000
Software Version : 1.4
Listplace Parameter Standard Min. Max. Release
L Description Value Value Value Code
60 List-no. 001 001 003 Service
61 Acceleration 006 000 009 Service
62 F/R & Footbrake 045 015 070 Service
63 Rolling brake 025 000 050 Service
 Parameter-list drive control

Here, the maximum current available at the motor is set.

CTM/CEM 10-20 Parameter Traction controller standard 1.12.2000

Software Version : 1.4
Listplace Parameter Standard Min. Max. Release
L Description Value Value Value Code
60 List-no. 001 001 003 Service
61 Acceleration 006 000 009 Service
62 F/R & Footbrake 045 015 070 Service
63 Rolling brake 025 000 050 Service
64 I-max. (A) 550 470 650 Service
 Parameter-list drive control

The maximum drive speed can be regulated in both

directions.

CTM/CEM 10-20 Parameter Traction controller standard 1.12.2000

Software Version : 1.4
Listplace Parameter Standard Min. Max. Release
L Description Value Value Value Code
60 List-no. 001 001 003 Service
61 Acceleration 006 000 009 Service
62 F/R & Footbrake 045 015 070 Service
63 Rolling brake 025 000 050 Service
64 I-max. (A) 550 470 650 Service
65 Max. speed 100 % 050 % 100 % Service
 Parameter-list drive control

With increasing steering angle, the speed of the inside turn wheel is at first
reduced.If the steering angle keeps increasing, the speed of the wheel is again
raised in the opposite direction.
The drive speed of the inside turn wheel is reduced in proportion to the steering
angle. If the inside turn wheel stand still while the steering angle is still
increased, the wheel is accelerated into the opposite direction. The maximum
drive speed of the outside turn wheel is regulated on 50%.

CTM/CEM 10-20 Parameter Traction controller standard 1.12.2000

Software Version : 1.4
Listplace Parameter Standard Min. Max. Release The speed limit of the inside
L Description Value Value Value Code
60 List-no. 001 001 003 Service turn wheel serves the
61 Acceleration 006 000 009 Service
62 F/R & Footbrake 045 015 070 Service
stability in small corners.
63 Rolling brake 025 000 050 Service
64 I-max. (A) 550 470 650 Service
65 Max. speed 100 % 050 % 100 % Service
Curve speed max. 50% Fix
 Parameter-list drive control

If there is a failure in the pump control, the signal PA1

appears. (entrance drive control TL9).
Potential: without failure >10V; with failure <3V.

CTM/CEM 10-20 Parameter Traction controller standard 1.12.2000

Software Version : 1.4
Listplace Parameter Standard Min. Max. Release As the steering help is not
L Description Value Value Value Code
60 List-no. 001 001 003 Service
activated in the case of a
61 Acceleration 006 000 009 Service failure at the pump
62 F/R & Footbrake 045 015 070 Service
63 Rolling brake 025 000 050 Service control or at the pump
64 I-max. (A) 550 470 650 Service
65 Max. speed 100 % 050 % 100 % Service motor, the drive speed is
Curve speed max. 50% Fix reduced to max. 30%.
Pump fail.speed max. 30% Fix
 Parameter-list drive control
CTM/CEM 10-20 Parameter Traction controller economyc 1.12.2000 The lists “economic” and
Software Version : 1.4
Listplace Parameter Standard Min. Max. Release “aggressive” contain
L Description Value Value Value Code
60 List-no. 002 001 003 Service prefixed parameters.
61
62
Acceleration
F/R & Footbrake
002
033
000
015
009
070
Service
Service
These parameters are not
63 Rolling brake 015 000 050 Service the possible smallest and
64 I-max. (A) 490 470 650 Service
65 Max. speed 80 % 050 % 100 % Service biggest but the most
Curve speed max.
Pump fail.speed max.
50%
30%
Fix
Fix
suitable values, as shown
through experience. Of
CTM/CEM 10-20 Parameter Traction controller aggressive 1.12.2000
Software Version : 1.4 course the single
Listplace Parameter Standard Min. Max. Release
L Description Value Value Value Code
parameters within this list
60 List-no. 003 001 003 Service can still be fixed
61 Acceleration 008 000 009 Service
62 F/R & Footbrake 063 015 070 Service individually.
63 Rolling brake 030 000 050 Service
64 I-max. (A) 610 470 650 Service
65 Max. speed 100 % 050 % 100 % Service
Curve speed max. 50% Fix
Pump fail.speed max. 30% Fix
 Plug-connection pump control

Connector Pumpensteuerung CTM/CEM 10-20

Description Pin active
24.6.99
Inactive
Description of the plug pins
PA 01 (pump control system) and
PB 01
PB 02 the expected voltages.
PB 04
PB 05 "Active" means: The signal
PB 06
PB 07 at the relative input or
PB 08
PC 01
output is active e.g. advance
PC 02 direction switch engaged.
PC 03
PD 01
PD 02 Accordingly, "inactive" is
PE 04
PE 07
the non-activated input or
PF 01 output.
PF 02/03
PF 05/06

Pumpenstecker
 Plug-connection pump control

Connector Pump controller CTM/CEM 10-20 24.6.99

The shown voltages are
Output pump failure
Description Pin
PA 01
Activ
>10V
Inactiv
<3V
measured against battery
Output mode signal PB 01 (V inactiv) -2V 12V +/-1V minus.
Input mode signal PB 02 (V inactiv) -2V 12V +/-1V
Output release data communication PB 04 <3V >10V
Battery minus
Output supply (not used)
PB 05
PB 06
< 0,5V
The note (V-inactive), -
Not used
Input diagnosis to dash board activ
PB 07
PB 08 <0,5V > 0,5V
2V means:
Input PC 01 >4,3V
Lift poti in the range min-max >4,3V-<0,8V 2V have to be subtracted
Microswitchfunction 1 <4,1V->0,9V
Microswitch function 2 <4,1V->0,9V from the voltage, which is
Microswitch function 3 <4,1V->0,9V
Battery minus (not used) PC 02 <0,5V measured in inactive state
Curent generator max 35mA (not used) PC 03
Input key switch Battery + PD 01 U Battery at this plug-pin.
Output key switch Battery + (not used)
Input steering request
PD 02
PE 04 >8V <0,5V
The required voltage is
Input data request from traction control
Output hour meter request
PE 07
PF 01
>8V
<1V
<0,5V
>4V
then measured at the same
Output data driver PF 02/03 <0,5V >4V plug-pin, when it’s in an
Output clock driver PF 05/06 <0,5V >4V
active state.
 Plug-connection
PE9 o
PE8 o
PE7 o Input data request pump from traction control
PE6 o
PE5 o
PE4 o Input steering request
B+ PE (9pol.) PE3 o
PE2 o
PE1 o
M+ PD (2pol.) PD2 o
Pump-Controller PF PD1 o Input key switch UB+
PC (3pol.) 6 pol. PC3 o
B- PC2 o
PC1 o Input demand value h hydraulic
PB (8pol.)
PB8 o Input diagnostic to dash board activ
PB7 o
M- PA (2pol.)
PB6 o
PB5 o Output UB-
PB4 o Output release data communication
PB3 o
PB2 o Input mode signal (RXD)
PB1 o Output mode signal (RXD for traction controller)
PA2 o
PA1 o Output pump failure
 Plug-connection
TL9 o Input pump failure TA1 o
+SHL TL (9pol.) TA (2pol.) VMNL
TL8 o TA2 o Output steering request
TL7 o TB (8pol.)
-SHL TJ (2pol.) -B TB1 o Input supply opto coupler
TL6 o
Traction-Controller TC (3pol.) TB2 o Input mode signal
TL5 o Input release data communic. TH (3pol.) TB3 o Output data request to pump
TL4 o Output 8.5V 40mA steer.pot.
-SHR TD (2pol.) +B
TB4 o
TL3 o TG (8pol.)
TB5 o Output battery minus
TL2 o Input steering angle +SHR TF (2pol.) TE (9pol.) VMNR TB6 o Output supply opto coupler
TL1 o Output battery minus
TB7 o Checkpoint supply 5V
TJ2 o TB8 o Input diagnostic to dash board
TJ1 o
TC1 o
TH3 o TC2 o
TH2 o Output data TC3 o
TH1 o
TD1 o
TG8 o Input FWD switch TD2 o
TG7 o Input REV switch
TE1 o Input key switch
TG6 o Input food brake switch
TE2 o Output UB+ to contactor coils
TG5 o Output UB+ to switches
TE3 o Output clock
TG4 o
TE4 o Output contactor REV right
TG3 o Output 12V max. 25mA
TE5 o Output contactor FWD right
TG2 o Input accelerator pedal
TE6 o Output contactor REV left
TG1 o Output UB- to accel. pedal
TE7 o Output contactor FWD left
TF2 o TE8 o Output UB+ to contactor regen
TF1 o Input seat switch TE9 o Output UB- to contactor regen
 Plug-connection drive control
Connector Traction Controller CTM/CEM 10-20 24.6.99
Description Pin Activ Inactiv
TA 01 Description of the plug pins
TA 02
TB 01 (pump control system) and
TB 02
TB 03 the expected voltages.
TB 05
TB 06
TB 07
TB 08
TE 01
"Active" means: The signal
TE 02
TE 03
at the relative input or output
TE 04
TE 05 is active e.g. advance
TE 06
TE 07 direction switch engaged.
TE 08
TE 09
TF 01
TG 01
TG 02
Accordingly, "inactive" is
TG 03
TG 05
the non-activated input or
TG 06
TG 07
output.
TG 08
TH 02
TL 01
TL 02
TL 04
TL 05
TL 09

Fahrstecker
 Plug-connection drive control
Connector Traction Controller CTM/CEM 10-20 24.6.99
Description Pin Activ Inactiv
Output UB- (not used) TA 01 <0,5V
Output steering request
Output supply opto coupler
TA 02
TB 01
>8V
12V+/-1V
< 0,5V
<10V
The shown voltages are
Input MODE signal (Data RxD)
Output data request to pump controller (RTS)
TB 02
TB 03
(V-inactiv)-2V
>8V
12V+/-1V
<0,5V
measured against battery
Output UB-
Output supply opto coupler
TB 05
TB 06
<0,5V
12V+/-1V
minus.
Chekpoint supply 5V TB 07 >4,7V <5,5V
Input diagnostic to dash board TB 08 <0,5V >0,5V
Input key switch UB+
Output key switch UB+, supply contactor coils
TE 01
TE 02
U Battery
U Battery
The note (V-inactive)-2V
Output clock
Output contactor coil REV right
TE 03
TE 04
<0,5V
<0,5V
>4V
U Battery means:
Output contactor coil FWD right TE 05 < 0,5V U Battery
Output contactor coil REV lefzt TE 06 <0,5V U Battery
Output contactor coil FWD left TE 07 < 0,5V U Battery 2V have to be subtracted
Output contactor regen UB+ about Diod from TG7 or TG8 TE 08 U Battery Open
Output contactor regen(-) TE 09 <0,5V U Batt. / open from the voltage, which is
Input seat switch TF 01 >U Batt. – 2V <0,5V
Output UB- accel.pedal (not used in older machines) TG 01 <0,5V measured in inactive state
Accelerator value, MS1 closing TG 02 0,8V – 1,2V
Max. range
Output 12V max. 25mA to accelerator pedal TG 03
>4,3V + 0,7V
12V+/-1V
at this plug-pin.
Output UB+, supply micro switches
Input foot brake switch
TG 05
TG 06
U Battery
>U Battery –2V <0,5V
The required voltage is
Input direction switch REV
Input direction switch FWD
TG 07
TG 08
>U Battery –2V
>U Battery –2V
<0,5V
<0,5V
then measured at the same
Output Daten
Output UB- to steering potentiometer
TH 02
TL 01
<0,5V
<0,5V
>4V
plug-pin, when it’s in an
Steering max left TL 02 1,0V – 0,1V
Left reversal 1,3V – 0,2V active state.
Left cut off 1,9V – 0,2V
Steering straight 2,5V +/- 0,1V
Right cut off 3,1V + 0,2V
Right reversal 3,7V + 0,2V
Steering max right 4,0V + 0,1V
Output 8,5V 40mA steering potentiometer TL 04 8V – 9V
Input release data communication (CTS) TL 05 <3V >10V
Input speed reduction in case of pump failure TL 09 <3V >10V
 Function blocks

Dashboard

Direct current
Pump control Pump motor

Battery Direct current

Direct current
Driving
Drive motor
control
 Position of the main components

Dash board

Controller 2 drive axles with

own motor each

Steering
axle Motor to work
hydraulic and
Battery power steering

Frame
Hydraulic

Hauptkomponenten
 Hydraulic motor
Hydraulic pump

Direct current drive motor for the hydraulic pump.

The control of the motor is independent of the drive
motor.
The RPM of the motor is regulated corresponding to the
functions wanted.
The necessary RPMs can be regulated.
 Pump control in counter weight

Steuerung
Microprocessor-Card

Pump Controller

Software
(EPROM)
Dash board
Dash board display
Dash board open

Plug printed board

Microprocessor
printed board (PROM
for Software on the
back)

Control LCD-
display
 Dash board with additional printed board

3 Relay socket for: Standard relay

1. Front lights
2. Rear lights
3. Flasher during reversing
Dash board with additional printed board

Connection
cable

Relay for
separating dash
board electronics
and external wiring.
Battery
 Models and Batteries
Modell Loading Battery size Battery capacity Battery type Battery capacity Ah Batteriy type
capacity Length / High mm Ah normal powerd up powerd up
CTM 10 1000 421/627 300 3 PZS 300 360 3 PZSH 360
CTM 10X 1000 421/784 360 3 PZS 360 440 3 PZSH 440
CTM 12S 1250 421/627 300 3 PZS 300 360 3 PZSH 360
CTM 12SX 1250 421/784 360 3 PZS 360 440 3 PZSH 440
CTM 12 1250 529/627 400 4 PZS 400 480 4 PZSH 480
CTM 12X 1250 529/784 480 4 PZX 480 600 4 PZSH 600
CTM 16S 1600 529/627 400 4 PZS 400 480 4 PZSH 480
CTM 16SX 1600 529/784 480 4 PZS 480 600 4 PZSH 600
CTM 16 1600 637/627 500 5 PZS 500 600 5 PZSH 600
CTM 16X 1600 637/784 600 5 PZS 600 720 5 PZSH 720
CTM 20 2000 637/627 500 5 PZS 500 600 5 PZSH 600
CTM 20X 2000 637/784 600 5 PZS 600 720 5 PZSH 720

CEM 12S 1250 529/627 400 4 PZS 400 480 4PZSH 480
CEM 12SX 1250 529/784 480 4 PZS 480 600 4 PZSH 600
CEM 12 1250 637/627 500 5 PZS 500 600 5 PZSH 600
CEM 12X 1250 637/784 600 5 PZS 600 720 5 PZSH 720
CEM 16S 1600 637/627 500 5 PZS 500 600 5 PZSH 600
CEM 16SX 1600 637/784 600 5 PZS 600 720 5 PZSH 720
CEM 16 1600 745/627 600 6 PZS 600 720 6 PZSH 720
CEM 16X 1600 745/784 720 6 PZS 720 860 6 PZSH 860
CEM 20S 2000 745/627 600 6 PZS 600 720 6 PZSH 720
CEM 20SX 2000 745/784 720 6 PZS 720 860 6 PZSH 860
 Axle

Each side has a separate drive

motor, transmission and disc
brake.

The motors have an tin cover to

prevent dust from being sucked in.
The cooling air is sucked in from
the backside of the covers.
 Axle
Connection motor-armature
Connection brush wear
and temperature sensor

Connection motor-field
 Frame

Frame for 3-wheel trucks

Frame for 4-wheel trucks

 Steering axle
3-wheel-steering axle

4-wheel-steering axle
Steering axle

3-wheel-steering
axle for dual
drive
 Current and magnetic field
If an electric current is flowing through a conductor e.g. a cable, a magnetic
field is created around this conductor.
This magnetic field requires energy, which is taken from the energy of the
electrical current.
If the current is shut off, the collapsing magnetic field returns its energy to
the conductor.
In turn, the returning energy generates an electrical current in the conductor.

Lines of
magnetic field
Current

Contactor
 Electro-dynamical principle
Permanent Magnet /
North Pole
If a conductor is
moved via a
magnetic field
(or if a magnetic
Lines of
magnetic field field moves
around a
Contact
conductor), an
brushes electrical voltage
is "induced" in
the conductor.

Permanent Magnet / Armature

South Pole turn
 Principe of function direct current (DC) motor

a) b) c) d)

Nord Nord Nord Nord

N N
Magnetic
pole of
Stator

N N

The current through the armature is mechanically switched

over (collector). As a result of this, the polarity of the
armature-magnetic field is also changed.
 Direct current (DC) motor

Brushes

Collector
(Commu-
tator)

Field coil
Dash board functions

Normal working

Diagnose Hydraulic
(F1-button)
Diagnose-Periphery
(Light-button)
Diagnose Controller
(M-button)

Failure display

Main menu
 Dash board functions

After switching on
the key-operated
switch, the
operating time
WORKH. 181.1H counter and the
SERVICE 250H time remaining
until the next
service are
displayed for a few
seconds.
The operating time
counter cannot be
adjusted.
Dash board functions

After a few seconds, the

display changes to the
"operating screen".
Here, the battery charge
status, the status of the
parking brake, the
direction of travel and
information regarding
any possible
malfunctions are
displayed.
 F1-Diagnose

On the display
following information is
shown:
ST = voltage of steering
angle (optional)
LI = voltage of lift
potentiometer
TV; A1 ; A2 = 0 or 1
Condition of hydraulic
micro switch

Actuate F1 button
whilst switching on.
 F1-Diagnose
Diagnostic display with button “F1”
ST 2,5 TILT AUX 1 AUX 2
LI 2,8 0 0 0
LI = LIFT - Potentiometer input voltage 2,8 V (Neutral).
ST = Steering - Potentiometer input voltage 2,5 V.

TILT (Function 1-button) 0 = Off; 1 =On

AUX1= Auxiliary function 1 (Function 2-button) 0 = Off; 1 = On
AUX2= Auxiliary function 2 (Function 3-button) 0 = Off; 1 = On
This diagnostic serves for the fast display of the actual values.
Turn on diagnose:
1. Switch off key switch.
2. Press F1-button and keep pressed.
3. Turn on key switch.
Input of codes are necessary.
 Diagnose with the light-button

In order to access the

diagnosis for general
information and
settings (languages,
n
oil filter...) the light
button must be
actuated whilst
switching on the key-
operated switch.

Actuate light button whilst switching

on.
 Diagnose with the light-button

The access code is input

from back to front.

The F1 (+) button or the

F2 (-) button are required
ENTER CODE 0000
for inputting a digit.

In order to move to the

next position, actuate the
M button.

If the code has been input

completely, actuate the
light button.

After inputting the code, actuate the

light button again.
 Diagnose with the light-button

After inputting the access

code, a menu is accessed.

The menu can be scrolled

SET LANGUAGE through using the F1 (+)
and F2 (-) buttons.

F1 (+) for the next menu item.

 Diagnose with the light-button

After inputting the access

code, a menu is accessed.

The menu can be scrolled

SERVICE TIMER
through using the F1 (+)
and F2 (-) buttons.

F2 (-) for the previous menu item.

 Diagnose with the light-button

If the displayed menu item

is to be activated, the
illuminated button must be
actuated.
Each menu item may
SET LANGUAGE
contain a sub-menu, a
status display or an input
request.

Light button to actuate the

activated menu item
 Diagnose with the light-button

With the F1 button, the

next item of a menu is
accessed, or the value
which is to be changed is
SET SPRACHE
LANGUAGE
increased.
ENGLISH

F1-button (+) for next language

 Diagnose with the light-button

With the F2 button, the

previous menu is accessed,
or the value which is to be
changed is reduced.
SET SPRACHE
LANGUAGE
FRANCE

F2-button (-) back to previous language

Diagnose with the light-button
Back counter
In order to store the
changed value or the new
menu item, actuate the M
button for 10 seconds.
SET SPRACHE
LANGUAGE
ENGLISH 10
After this period of time,
the new information is
adopted in the memory.

If the displayed language is to be

adopted, keep the M button depressed
for 10 seconds.
 Diagnose with the light-button
Further menu items:
PUMOT SENSOR RPM hydraulic pump motor
RPM% (only activ during running)
STEERPOTI Steering angle voltage
LIFTPOTI Lifting potentiometer voltage
TILT AUX1 AUX2 Microswitch display
Note: The three previous items can also be called up with the "F1" diagnosis, but in
this diagnosis, the values can be displayed during operation, with the result that the
cause of sporadically occurring errors can be found.
RESET Countdown timer reset in the event of the following
TIMER FAULT messages: Change hydraulic filter or motor brushes.
SET COUNT DOWN Set the service counter in 10h stages.
SOFTWARE VERSION Version of the software in the DASH BOARD.
 Diagnose with the light-button

Further menu items:

RESET TRAMOT TEMP The time during which the travel motor was
00 MIN overheated for longer than 5 minutes is displayed.

RESET HYMOT. TEMP As above, but for the pump motor

00 MIN
V-TILT Adjustment of the nominal voltage which the
dash board transfers to the control system on
actuation of the tilt lever.
V-AUX1 As above, but for the 1st auxiliary function.
V-AUX2 As above, but for the 2nd auxiliary function.
 Diagnose motor control

If a parameter is to be
checked or changed, the M
button must be actuated.
The M button must also be
actuated in order to return
n to the menu.

Actuate the M button in order

to call up the parameter.
 Diagnose motor control

The first digit after the H

designates the position of the 4-
digit code. The left digit has the 0
column, the next digit the 1
column, etc.
The second digit after the H is the
ENTER CODE code which is to be input in the
H00 column.
After this has been input, input is
confirmed with the M button.
Example of a code: 3456.
0123 column
3456 Code

H03
H14
H25
H36
Actuate the M button
whilst switching on.
 Diagnose motor control

If the Code is put in successfully,

the parameter list of hydraulic-
pump control is accessed.
The parameter lists can be
scrolled through using the F1 (+)
PARAMETER PUMP and F2 (-) buttons.

Scrolling can be carried out with the

F1 (+) and F2 (-) buttons.
 Diagnose motor control

If a parameter is to be
checked or changed, the M
button must be actuated.
The M button must also be
actuated in order to return
RPM STEERING
to the menu.

Actuate the M button in order

to call up the parameter.
 Diagnose motor control

The parameter values

can be changed with the
F1 (+) and F2 (-)
buttons.
RPM STEERING
20
In order to store the
changed parameter,
actuate the M button
twice within 1 second.

Actuate the M button in order

to call up the parameter.
 Diagnose motor control
Back counter
In the right lower
corner, a reverse
counter from 10 to 0
appears. Following the
expiry of the counter,
RPM STEERING
20 10
the new value is
adopted in the memory.

During this period, it is

possible to interrupt the
procedure by actuating
the M button.

Actuate the M button in order

to call up the parameter.
 Failure display
There are two types of fault.
1. Faults which are recognised by
the dash board electronics.
2. Faults which are recognised by
the motor control systems.

The LED illuminates in the case

(P) PUSH MODE
Û Û Û Û Û Û Û 100% of both types of fault.
In the case of dash board errors,
the request "PUSH MODE"
appears after a short time; this
means that the fault is displayed
following actuation of the MODE
(M) button.
If more than one fault is present,
these can be scrolled through via
further actuation of the M button.

LED illuminates in the event of a fault

 Failure display

If the hydraulic filter is

blocked, a corresponding
symbol and a text appear.
The maximum travel time
which remains until the filter
FILTER BLOCK is replaced is displayed in the
60 HRS. REST second line. This counter
counts backwards with the
operating time counter signal.
If the filter has not been
changed by the time counter
status 0 has been reached,
counting is carried out
forwards with a negative
prefix.

So that the counter status is not lost when the operating voltage is switched
off, it is stored in the memory. For this reason, the filter must be manually
reset after the filter has been replaced. Diagnosis menu "RESET FAULT
MEMORY".
 Failure display

If one of the brushes of the drive

motor is worn out, so that the
brush sensor reacts, respective
symbol and text appear on the
dash board.
In the second line the max.
FAMOT BUERST remaining driving time is shown
150 STD. REST before the change of the brushes.
This timer counts with the signal
of the hourmeter backward.

If the brushes are not changed

after the timer reached 0, the
timer counts upwards in negative
range.

The value of the timer is stored in the memory, after turning of the operating
voltage. Therefore the memory has to be manually reset in the diagnose menu
“RESET FAULT MEMORY” after changing the brushes.
 Failure display

If the temperature sensor in

the drive motor changes its
value from 50Ω to 2500 Ω,
a warning message is
displayed.
TEMP DRIVEMOT
PLEASE STOP The switching point
corresponds to a motor
temperature of approx..
150°C.

The time during which the travel motor was overheated for more than
5 minutes is stored in the memory. The memory can be manually
reset in the "TRAVEL MOTOR TEMP" diagnosis.
 Failure display

If the temperature sensor in

the pump motor (in the
field winding) changes its
value from 50Ω to 2500 Ω,
a warning message is send
TEMP PUMPMOT out.
AUTO COULING
At the same time, the
motor speed is raised in the
case of all hydraulic
functions.

The time during which the pump motor was overheated for more than
5 minutes is stored in the memory. The memory can be manually
reset in the "HYDR.MOTOR TEMP" diagnosis.
 Failure display

A switch is located in the

foot brake fluid reservoir
cover.
This switch is actuated if
the fluid level is too low.
BR-LIQUIDE
( ) CALL SERVICE In the display, a droplet is
displayed in the form of a
symbol. In addition, the
request that a service
technician be called is
displayed.
 Search for failures
Have fault described by driver, subsequently check if possible.

In which situation did the fault occur?

E.g. whilst driving? Was the travel pedal still actuated?
Did the fault occur on actuation or on release of the travel pedal?

Is a fault present in the travel control system or in the hydraulic

control system?

Does the failure occur only occasionally?

If yes: Try to find the failure conditions, e.g. dependent on
temperature, after cleaning the truck or after rain, while
temperature changes (e.g. running in a cold-storage depot)
 Insulating test 1
3. The insulating should be
tested with a voltage
corresponding at least
minimum to the battery
voltage.

1. Pull out If the insulating should be

battery plug tested with a voltage more
after pushing then 100V, the inner control
the emergency components have to be
switch. protected against overvoltage.

Therefore the power wires

have to be separated from
the control or short-
circuited.
2. Discharge the capacitors with
pushing the horn for 10 seconds.
 Insulating test 2
If there should not be an adequate
insulating meter at your disposal, the
battery of the truck can be used as the
voltage source.

The test is made in three steps.

1. After disconnecting the battery plugs,

connect the battery minus pole with the
conductive truck frame.

2. Therefore you need a “thin” lead (safety

function)or a lead with fuse, e.g. 1A. One
end of this lead is connected with the
battery plus pole. With the other end tip
on the power connections. No spark must
be seen.
 Insulating test 3
3. If no sparking could be recognised, a
mA-meter in the testline is laid to the
battery plus pole. mA

The loose end is again connected one after

the other with all power connections. The
current can be read on the mA-meter. The
value of the current should not extend 1
mA.
Tip: This test can be made on all electric
trucks independent of the battery voltage.
The current, max. allowed, has to be
always 1mA.
 General measurement
Basically there are two kinds of meters.
1. Analogue meters (pointer meter)
2. Digital meters (with dial display).
Analogue meters are suitable for measurements, which can slowly change, e.g.capacitor charges.
Digital meters are suitable to measure constant values, e.g. battery voltage.

All meters have a connection for the „minus-instrument lead“. This connection is signed with
„COM“ or the symbol “ Á “.
The connection for the „plus-instrument lead“ is signed, depending on the meter, with “U“; “ê“;
“U- ê“ or “U-I-ê“.

The meters need their own power supply for measuring the resistance, mostly from built in
batteries. For some measurements (e.g. of diodes) the polarity of this voltage is important. The
positive meter voltage of digital meters lays mostly next to the „plus-instrument lead“. At
analogue meters the positive meter voltage lays next to the „minus-instrument lead“!!
 Measurement braking diodes

Both braking diodes lay with their

cathodes at battery plus.
The anode for the right drive motor
lay at +SHR and -SHR.The anode for
the left drive motor lays accordingly ê
at +SHL and -SHL.

If the instrument-lead with the

positive voltage (analogue and
digital meters differ) is connected
with -SH or +SH and the negative
side with B+, the resistance must be
measurable.
If the polarity is vice versa, the
resistance has to be higher than
100Mê .
 Measurement capacitor

The capacitor are measured in two steps:

1. Discharge capacitors.
For discharge use emergency-switch (lock)
and push horn for ca. 10-20 seconds.
ê

2. Connect an ohmmeter between battery-

minus and battery-plus at the control. Pay
attention to polarity and meter voltage!
The resistance has to increase slowly.
If the resistance does not change, the
capacitors respectively the connection to
the capacitors are defective.
 Transistors
The used power transistors are MOSFET
types (Metal Oxide Semiconductor Field
Effect Transistor).
Due to the fabrication there is a diode
behaviour between the drain- and the Parasitically
source-connection. Diode
This means, current can run through the Transistor
transistor in direction of the interlock
system. This apparently diode is so called
„parasitically diode“.
This diode has the positive effect to
protect the transistor against voltages
with opposite polarity.

The existence of the diode has to be

considered for measurement.
 Measurement transistors, diodes

If the resistance is measured between the battery-

minus and the connector VNML(R) two currents
are flowing (positive side of meter voltage at
VMNR respectively L).
1. From the meter through the freewheel diode
back to the meter. This current charges the 1,2kê
capacitor. With increasing capacitor voltage the
current decreases and therefore the resistance in
this circuit increases.
2. From the meter to the lower resistance Rx. This D1
resistance has 1,2 kOhm.

So two parallel resistances are measured, once D2

1,2kOhm and the resistance, which comes up from
the series connection between diode D1 and the ê 1,2kê
capacitor. The meter shows a value lower then 1,2
kOhm.
 Measurement transistors, diodes

If the capacitor is short-circuited with a

bridge between connection B+ and B-, the
diode 1 is directly parallel to the lower
resistance Rx. The capacitor is not
charged.

1,2kê
Capacitor
bridge
If the resistance reaches almost 0 Ohm with
short-circuited capacitor, the free-wheel D1
diode D1 has a short circuit.
If the resistance with capacitor and with
short-circuited capacitor is almost 0 Ohm,
the transistors are defective. D2

ê 1,2kê
 Measurement transistors, diodes

If the polarity of the meter is changed, the test

current flows through diode D2 and a second test
current through the lower resistance Rx.
As also the resistance lays parallel to the diode,
the same result is achieved as earlier with bridged
capacitor. 1,2kê

D1

If the transistor or the transistor-internal diode D2

D2
should have a short-circuit, the resistance is very
low. ê 1,2kê
 Measurement transistors, diodes

For the explanation of the D1

functions the components are
D1 shown here in a slightly
different way. D2

D2

The measurements at the pump control are identical to the

measurements of the drive control. Though the pump control has
no braking diode.
 Drive Failure 1
The hydraulic functions are functioning normally, but travel is not
possible (not even slowly):

Appear symbols for drive directions in display?

No Yes
Is manual braking switch Acceleration value (C55) in
HBS1 switched on? order?
Yes
Yes
One direction switch
actuated? Is seat-switch (Seat-SW)
switched on?
Yes
Yes
Does MS1 switch?
Do direction- and braking
Yes contactors switch?
Check supply voltage at
TG5.
 Drive Failure 2

You can only drive slowly or the drive motor and the
drive control report overtemperature.

Possible reason:
Defective function of brake.
Brake does not release. Pins of the manual brake are stuck or brake
is not sufficiently (in the middle) adjusted.

Required value of acceleration reaches not the max. value.

 Control of motor circuits 1
Drive control:

Do insulating test, as described in chapter “insulating test”.

Switch on key switch.

Check the voltage between battery minus and VMN(R) resp. (L).
Here half battery voltage has to be seen.

Unplug the connections between the coils and the direction contactors.
Provide he contactor coils with battery voltage, so the contacts for one drive
direction are closed.
The voltage between battery minus and VNMR(L) must now be almost 0V. If
the voltage on both connections (VMNR and VMNL) is still half battery
voltage, the connection between the plus-connections (L+ and R+) of the
drive contactors and the battery-minus connection does not exist. This
connection runs over the TFR-contact (opener). See also sheet “Switch test 2”
 Control of motor circuits 2
Drive control:

If the voltage at one of both connection is not correct, the failure is to be

found at the power wires between the control and the direction contactor, at a
disturbance in the motor-anchor-circuit or at the direction contactor.

If no failure occurred during above mentioned measurement, unplug the

connection of the coil at the TFR-contactor and also provide it with battery
voltage.

The voltage at VMN(L) resp. (R) now must have a positive battery voltage.
If the voltage is incorrect, check the TFR-coil and the connections up to the
battery-plus-pole including the fuse.
 Control of motor circuits 3
Drive control:

The components described before, can also be tested in the power circuit without
voltage.

For this:
1. Push emergency-switch.
2. Discharge capacitors (Push horn up to 10 seconds.).
3. Unplug battery plug.
4. Separate all power wires form the control.
5. Unplug the connectors from the coils of the direction contactors and connect the
coil for one direction with additional leads (e.g. 1mm) with the battery voltage.
6. Measure resistance between end of wire +SH(L) or (R) and the end of wire B-.

The resistance should be lower then 100 Ohm.

If the value it too high, the resistances of the power wires, the contactor contacts
and the motor-armature each has to be measured.
 Control of motor circuits 4
Drive control:

7. Supply the coil of the TFR-contactor with voltage.

8. Measure the resistance at the TFR contact. It should be almost 0 Ohm.

For the measurement of the motor fields, measure the resistance between V
MNR and -SHR at the right drive motor.
For the left drive motor, measure the resistance between V MNL and -SHL.
The resistances must be lower then 100 Ohm.
 Control of motor circuits 5
Pump control:

Without voltage:
Measure connection between B+ connection of control and fuse F1.
Measure connection between B- connection and emergency switch.

Disconnect M+ and M1 at the control.

Measure resistance between the end of wires M+ and M-.
The resistances must be lower then 100 Ohm.
 Hydraulic failure 1
The hydraulic motor constantly turns over at excessive speed.

Is the hydraulic nominal value at PC1 (C51) less than 4.0V?

Yes No
Activate diagnosis "F1" Check steering speed and
after-running setting.

Are all microswitch inputs = 0?

Yes

Is the lift potentiometer voltage

above 2,7V?
 Hydraulic failure 2
The hydraulic motor does not turn over when requested via lever or joystick

Is the hydraulic nominal value at PC1 (C51) less than 4.0V on

activation of a lever?
No Yes
Activate diagnosis "F1" Pump electronics defective.

Yes
Does the corresponding
microswitch switch?

Set corresponding nominal

value with "light diagnosis".
Does the lift potentiometer
Lower voltage = higher speed.
voltage sink below 2.8V on
actuation?
 Hydraulic failure 3

On request, the hydraulic motor

turns over at excessive speed.

"Pump motor temperature" input is activated,

or nominal speed value is set too high (with
"light diagnosis")
 Hydraulic failure 4

The drive control requires steering RPM if:

The truck is driven, the foot pedals are pushed and if a curve-
dependent shift point for one motor is reached.

The reason might be, that the pump control

does not react on the demand of the drive
control.
 Hydraulic failure 5

Control the voltage at the input PE4 of the pump control.

If no steering speed is required, the voltage has to be lower then 0,5V.
With steering demand the voltage is higher than 8V.
In the failure case, check lead 50 for disturbances and short circuit to the close
leads or to the frame.

The braking pedal is pushed, but the pressure-button does not switch.
Check the switch with the diagnose menu, point C59

After releasing the drive pedal, the hydraulic motor stops too soon.
Check the adjustment of the delay time with parameter L 53.

The steering is too hard or the motor speed for the steering is too high.
Check the adjustment of the motor speed with parameter L 51.
 Battery display 1

The pump control system tests the battery.

This test is only possible when the motor is stationary.
If, immediately after switching on, a travel or hydraulic function is
started, the battery cannot be tested, the display does not receive any
information, and will display "BATTERY CLARK".

In the event of data transmission problems (data or clock lead

damaged, dash board negative supply, insulation fault, etc.),
"BATTERY CLARK" is also displayed.
 Battery display 2

If, e.g. a charge of 80% is displayed, and the unit is then used intensively over a
longer period of time (the pump motor runs continuously due to the steering after-
running period), energy is constantly withdrawn from the battery, but the battery
is not measured.
When all motors are stationary for the first time following use, further
measurement may reduce the 80% display to what is now the current value of e.g.
30%.
This great difference is not an error, but is based on the measurement principle.

Note: Theoretically, a battery may be discharged to below 20% in

this manner.
As the output of the machine is reduced if the battery charge is so
low, the driver notices the change.
 Battery display 3

The battery display value decreases during operation.

After turning off and on, the value might lay above the previous value.
The reason is an increase of the battery voltage (e.g. because of cooling down
during breaks).

Tip: As long as the key switch is not turned on or off, no higher value then
before will be shown.
 Current failure 1
For each motor the current is measured separately

The measurement is made indirect with a magnetic sensor.

The output voltage of each sensor can be adjusted with 2 potentiometers each.

The sensors and accompanying circuits are located on the power component.
A gap is built into the microprocessor-card to enable the adjustment of the
sensor. Because of this gap the potis can be reached.

The zero point is set up with the potentiometer „OFFSET“. This means:
There is no signal of current circuit to the microprocessor if the motor stands
still. With the second potentiometer „GAIN“ the intensification is set up, this
means, the current which is signalled to the processor while the motor is running,
is compared to the actual current.
 Current failure 2
To set up the current zero point, the value of each motor has to be measured and
adjusted.

For the drive motors the value is measured in the drive control.
For the right drive motor connect one voltmeter (with mV-range) between
battery-minus and the anode of diode D19.
For the left drive motor between battery-minus and the anode of diode D55.
For the hydraulic motor the voltage is measured between battery-minus and the
right connection of the resistance R14 (lead to PIN 14 of the flatwireband).

With potentiometer T1 for the right drive motor, T3 for the left drive motor and
T1 at the hydraulic control set up the values at the smallest value possible.
 Current failure 3
Diode D19 Q12 Set up right
motor

Set up left
Diode D55 motor
 Current failure 4
Drive control
T1 T2

Offset Gain
D19
Anode
D55

Q12

Offset Gain

T3 T4
Diode-connections

Cathode Anode
 Current failure 5
Pump control

Flatwireband

R14

Q5
T1 (Offset)

Test point 1
 Use work-hydraulic

Conventional All hydraulic functions and travel

operation via easy- direction preselection in one
running levers operating lever.
Option MegaValve

All hydraulic functions and

travel direction preselection in
one operating lever.
 Option MegaValve

The security function

Function release only

following actuation of the
activation switch
 Option MegaValve
Functions
Lift Lower

Push Joystick to the right Push Joystick to the left

 Option MegaValve
Functions
Tilt forward Tilt backward

Push Joystick to the front Pull Joystick to the back

 Option MegaValve

Functions
1. Additional function Shift for driving
direction

2. Additional function
 Joystick electronic

Cover plate

Electronic box

Fastner
Cover plate
 Joystick electronic

Plug connector S2
to Joystick

Plug connector S1
to main harness
Hydraulic valve with joystick (MegaValve)

Electrically controlled hydraulic

valve (Joystick).
It has both functions:
Main overpressure valve,
analogue valve for pressure,
switch valve for lift functions,
pre-controlled analogue valve for
lower function, exit for switch on
of valve for tilt- and auxiliary
functions.
 Option pedals

• Automotive pedal layout or

• Unitrol
Power supply
Power part
Drive
Hydraulic motor
Data transmission

The data transmission from

Dash board to the controllers
appears through the Mode-lead.
Because each message starts
with an adress, it is possible to
contact the right controller.
Data transmission hydraulic

Data is exchanged from the control

system to the dash board in a
"synchronous" manner. One lead with
even impulses exists for
synchronisation purposes (clock) and
a second lead exists for the data
(data).
The pump control system is the
superordinate (master) control system.
It takes precedence over the travel
control system.
Data transmission drive

Data are transmitted from the travel control system to the dash
board via the same leads as in the case of data exchange from the
pump control system. So that clear transmission is guaranteed,
only one control system may transmit at once.
Before the travel control system transmits data, it outputs a
request signal (RTS) to the pump control system, and waits for a
release signal (CTS). Only then are data transmitted.
Data from the dash board to the control system are passed along
the same lead (MODE) via the pump control system to the travel
control system.
Hour meter
Periphery signals
Complete wiring diagram
Capacitor charge
The battery is connected.
The emergency-switch is unlocked.
The battery voltage runs directly to the capacitors.
If the capacitors have no restcharge, the charge-
current is very high at the beginning. With increasing
charge the current decreases.

The battery-plug must only be plugged in resp. plugged or

if the emergency switch is locked.
Capacitors of the drive control

If the battery-plug would be connected though the

emergency-switch is unlocked, the contactfields can
be destroyed because of very hig charge current at
the beginning!

Capacitors of the pump control

 TFR-contactor

The TFR-contactor gets only positive voltage if there is a respective

voltage at one of both direction inputs.
To avoid re-effects between both direction inputs two diodes are switched
in serial.
 Contactor-coil-test
The pump control sends positive
voltage. The drive control gets this
voltage via contactor-coil. Example: coil “FR“

TE2 TE5

Shunt Power
value
The drive control switches to minus.
Now power runs through the Internal switch
contactor-coil. The power is
controlled with a power measure link
(shunt).
Self-diagnose 1

After turning on the emergency

switch the drive control gives
battery (+).
Because of internal resistances RX
in the control the battery voltage is
divided into halves (measurable at
point V MNR and V MNL).

The first step of the self-diagnose is

VMNR and VMNL = 1/2 battery
voltage.
Self-diagnose 2

If the result of the test is positive, the

control switches on the direction-
contactors (F or R).
Besides this the battery (-) is switched
to VMNR resp. VMNL via TFR-
contact, motor-armature, shunts and
field coils.

In the second step of the self-diagnose

battery (-) is at VMNR and VMNL.
Self-diagnose 3

If the result of the second test is

positive, the control switches on the
drive-brake-contactor (TFR).

Besides this the battery (+) is

switched to VMNR resp. VMNL via
TFR-contact, motor-armature, shunts
and field coils.

In the third step of the self-diagnose

battery (+) is at VMNR and VMNL.
Self-diagnose 4

If the third test is positive the control

heads for the transistors.
Besides this the field-coils of the
motors (VMNR resp. VNML) are
switched against battery (-). The
motors start running.

In the fourth step of the self-diagnose

the transistors start to pulse. - Drive
operation!
Self-diagnose 5

During the pulse brakes (transistors

lock) the motor acts like a
generator. The generator power
runs into the same direction as
before the motor power, thought
it’s turned back to the motor-
armature via the free wheel diodes
(below).

Free wheel diodes

Self-diagnose 6
If the truck (motor) shall slow down (e.g.
change of direction) the TFR-contactor
switches over.
Because of this switch over the motor-
armature change poles. The motor still acts
as generator but the transistors are pulsing
to create a magnetic field in the field coils
(“brake power” can therefore be dosed)
The battery serves as a buffer
(accumulator) and is charged via generator
voltage (power recycling). Here the power
runs via brake diodes (upside).
 Curve drive 3-wheel

3-wheel-truck Reducing the

at simple drive acceleration of the
turn inside wheel

1 2

Switching of the Change over of the

turn inside drive turn inside wheel, at
the same time the
chosen acceleration of
the outside wheel is
3 4 reduced.
Curve drive 3-wheel

Potentiometer
for the
steering corner
 Curve drive 4-wheel

4-wheel-truck Reducing of
at simple drive the turn-inside
wheel

1 2

Switching off the

turn-inside wheel

3
 Harness
In the harness there is at each
connection a cable-number.

A-End Wire B-End mm2

No.
TA-10 6 R 1
TA-2 8 F 1
Verb. 10C 10 KS 1
CON I-35 10A KS 1
KS 10B CON DCDC-1 1,5
TA-1 10C PA1 1 In the harness-lists
The connections are PA-6 10E MC+COIL 1
TA-6 10F MC+COIL 1 the source and the
shown in the harness- HBS 1 10G MC+COIL 1
R 11 F 1 end of the cable is
plan. 2FU 12 KS-BAT. 1,5
2FU 12A HRN SW 1 described for each
BAT 12B CON I1-18 1
PA-15 12C R-LOAD 1 number.
UB NEG 13 HRN NEG 1
UB NEG 13A CON I4-8 1
CON I4-8 13B CON I3-8 1
CON I3-8 13C HYD PRS 1
HYD PRS 13D BR LLS 1
BR LLS 13E HBS 2 1
UB NEG 13F CON I1-17 1
UB NEG 13G CON DCDC-2 1,5
UB NEG 13H TVS 1
TVS 13I AUX 1 1
 Harness diagram
CON I3R CON I3L

RR
15 21
GREEN
BLU CON G
27/27A CON PA
HBS1 GRN EG
N
34 28C UB
13F/13G
BLU 13/13A
I TVS
63L /13
13H
BRN BLK 13L/13W TFR CON PE
HBS2 57
13L BLU
BRN 28D BLACK
AUX 1
RL 58
13K
13I/ 27C CON PD
CON LK BLK
YELLOW
15A
RED 2FU
E 23
28 CON PC 10B
AUX 2

13A/1
3K
BLK CON TE
25
27B/27C 27/27A CON PB
HORN
13 YELLOW GREEN 10B
22 SPL1
20
CON DCDC
CON TB
CON I1

SPL2

13D,13E CON TG
GRN CON TA
81 CON F2
BR LLS 30 CON PF
CON F1
GRN CON I4
BR SW CON TF

82/82B
10C
10/10A CON TH
KS 13C/13D (BROWN)
12/12B
CON S-A CON S-B
12A 11 HYD PRS
HRN SW 25 R CON TL CON S
6/46 63H (BROWN)
8/45
F 11/15

10
CON DCDC-1 (10B) CON I1-1 CON I1-26 (28D) CON I4-1 (63E) CON PD-1 (10E) CON TB-1 (55) CON TG-1
SPL1 10E-B
CON DCDC-2 (13M9 CON I1-2 (45) CON I1-27 (28C) CON I4-2 (13B/13H) CON PD-2 CON TB-2 (53) CON TG-2 (29)
CON DCDC-3 (15A) CON I1-3 (46) CON I1-28 (63H) CON I4-3 (143) CON TB-3 (51) CON TG-3 (78A) 10D
CON PE-1
CON I1-4 (44) CON I1-29 (30) CON I4-4 (27D) CON TB-4 CON TG-4
CON PE-2
CON F1-1 (78A) CON I1-5 (43) CON I1-30 (63L) CON I4-5 (27B) CON TB-5 (54) CON TG-5 (82)
CON PE-3 82A
CON F1-2 (29) CON I1-6 (63M) CON I1-31 (63C) CON I4-6 (27F) CON TB-6 (55) CON TG-6 (81)
CON PE-4 (50)
CON F1-3 (13F) CON I1-7 CON I1-32 (63E) CON I4-7 CON TB-7 CON TG-7 (6) SPL2 82
CON F1-4 (10C) CON PE-5
CON I1-8 CON I1-33 (142) CON I4-8 CON TB-8 (54) CON TG-8 (8) 82C
CON PE-6
CON F1-5 (34) CON I1-9 (27D) CON I1-34 (143) CON I4-9
CON PE-7 (51)
CON F1-6 (82B) CON I1-10 CON I1-35 (10A)
CON PE-8 CON TE-1 (10D) CON TH-1
CON I1-11 (14A) CON PA-1 (59)
CON F2-1 (78) CON PE-9 CON TE-2 (27) CON TH-2 (43A)
CON I1-12 CON I3L-1 CON PA-2
CON F2-2 (29A) CON TE-3 (44A) CON TH-3
CON I1-13 (27F) CON I3L-2 (141) CON PF-1 (63M)
CON F2-3 (79) CON PB-1 (53) CON TE-4 (21)
CON I3L-3 CON PF-2 (43)
CON I1-14 (28A) CON PB-2 (26) CON TE-5 (20)
CON F2-4 CON TL-1 (79)
CON I1-15 CON I3L-4 (63C) CON PF-3 (43A)
CON PB-3 CON TE-6 (23) CON TL-2 (29B)
CON I1-16 (13L) CON I3L-5 (63D) CON PF-4
CON G-A (14A) CON PB-4 (52) CON TE-7 (22) CON TL-3
CON I1-17 (13G) CON I3L-6 CON PF-5 (44)
CON G-B (28B) CON PB-5 (56) CON TE-8 (57) CON TL-4 (78)
CON G-C (28A) CON I1-18 (12B) CON PF-6 (44A)
CON I3R-1 CON PB-6 CON TE-9 (58) CON TL-5 (52)
CON I1-19 (28) CON PB-7
CON I3R-2 (141/142) CON S-A (82A) CON TL-6
CON I1-20 (28B) CON PB-8 (56
CON I3R-3 )
CON S-B (14E) CON TF-1 (14E) CON TL-7
CON I1-21 (29A,29B)
CON I3R-4 (63D) CON TF-2 CON TL-8
CON S-C
CON I1-22 CON I3R-5 (13B/13C) CON PC-1 (28)
CON TL-9 (59)
CON I1-23 (26) CON PC-2
CON I3R-6 CON TA-1
CON I1-24 (27E) CON PC-3
CON TA-2 (50)
CON I1-25 (28E)
 Harness-list
A-End Wire B-End mm2 A-End Wire B-End mm2
No. No.
CON T-G7 6 R 1 CON I1-11 14A CON G-A 1
CON T-G8 8 F 1 CON S-B 14E CON IF-1 1
SPL1 10 KS 1 F 15 HBS 1 1
CON I-35 10A KS 1 DCDC 3 15A LK 1,5
2FU 10B CON DCDC-1 1,5 CON TE-5 20 FR 1
CON F1-4 10C KS 1 CON TE-4 21 RR 1
CON T-E1 10D SPL1 1 CON TE-7 22 FL 1
CON P-D1 10E SPL1 1 CON TE-6 23 RL 1
R 11 F 1 HRN SW 25 HRN POS 1
2FU 12 KS-BAT. 1,5 CON PB-2 26 CON I1-23 1
2FU 12A HRN SW 1 CON TE-2 27 FR 1
KS BAT 12B CON I1-18 1 FR 27A RR 1
UB NEG 13 HRN NEG 1 RR 27B FL 1
UB NEG 13A AUX 2 1 FL 27C RL 1
CON I4-2 13B CON I3R-5 1 CON I1-9 27D CON I4-4 1
CON I3R-5 13C HYD PRS 1 CON I1-24 27E CON I4-5 1
HYD PRS 13D BR LLS 1 CON I1-13 27F CON I4-6 1
BR LLS 13E HBS 2 1 CON P-C1 28 CON I1-19 1
UB NEG 13F CON F1-3 1 CON I1-14 28A CON G-C 1
UB NEG 13G CON I1-17 1 CON I1-20 28B CON G-B 1
TVS 13H CON I4-2 1 CON I1-27 28C TVS 1
AUX 1 13I TVS 1 CON I1-26 28D AUX 1 1
AUX 2 13K AUX 1 1
UB NEG 13L CON I1-16 1
UB NEG 13M CON DCDC-2 1,5
 Harness-list
A-End Wire B-End mm2 A-End Wire B-End mm2
No. No.
CON I1-25 28E AUX2 1 CON TE-9 58 TFR 1
CON TG-2 29 CON F1-2 1 CON TL-9 59 CON PA-1 1
CON I1-21 29A CON F2-2 1 CON I3L-4 63C CON I1-31 1
CON TL-2 29B CON I1-21 1 CON I3L-5 63D CON I3R-4 1
CON I1-29 30 BR LLS 1 CON I4-1 63E CON I1-32 1
CON F1-5 34 HBS 1 1 HYD PRS 63H CON I1-28 1
CON PF-3 43 CON I1-5 1 HBS 2 63L CON I1-30 1
CON T-H2 43A CON PF-2 1 CON P-F1 63M CON I1-6 1
CON PF-5 44 CON I1-4 1 CON TL-4 78 CON F2-1 1
CON TE-3 44A CON PF-6 1 CON TG-3 78A CON F1-1 1
CON I1-2 45 F 1 CON TL-1 79 CON F2-3 1
CON I1-3 46 R 1 CON TG-6 81 BR SW 1
CON TA-2 50 CON PE-4 1 CON TG-5 82 SPL2 1
CON TB-3 51 CON PE-7 1 SPL2 82A CON S-A 1
CON TL-5 52 CON PB-4 1 BR SW 82B CON F1-6 1
CON PB-1 53 CON TB-2 1 BR SW 82C SPL2 1
CON TB-5 54 CON TB-8 1 CON I3L-2 141 CON I3R-2 1
CON TB-6 55 CON TB-1 1 CON I3R-2 142 CON I1-33 1
CON PB-8 56 CON PB-5 1 CON I4-3 143 CON I1-34 1
CON TE-8 57 TFR 1
Hydraulic Components

Hydraulic valve with levers

 Hydraulic Components
Hydraulic valve with levers
Potentiometer
for lift function

Switch for tilt

function and
auxiliary
function
 Hydraulic adjustments
Standard factory settings
Oel pressure:
Auxiliary 2: 90 bar +/- 10 bar
Auxiliary 1: with side shifter: 120 - 140 bar (look for flow noise).

Type Triplex Std. & Hilo Average

in bar in bar adjustment
in bar
10 135 110 155
12 155 125 180
16 190 160 205
20 220 190 235

Tilt speed reduction dependent on maximum lift hight.

Lift hight Set value Set value Set value List-No. Parameter Parameter Parameter
tilting auxiliary 1 auxiliary 2 L54 L56 L57
(Dash board) (Dash board) (Dash board)
<3600 3,5V 3,5V 3,5V 1 20 37 50
<4800 3,7V 3,7V 3,7V 1 20 25 40
>4800 1,0t-1,6t 3,8V 3,8V 3,8V 1 10 20 30
>4800 2,0t 3,6V 3,8V 3,8V 1 10 20 30
Hydraulic adjustments
Standard factory settings

Speed reduction with CTM-machines (L65):

Type up to lift Speed in %

hight
10 ever 66
10X ever 66
12S 3560mm 66
12SX 3560mm 66
12 3560mm 66
12X 3560mm 66
16S 3560mm 72
16SX ever 66
16 3560mm 87
16X 3560mm 87
20 3560mm 72
20X 3560mm 72
Hydraulic pump

The used pump has a supply

capacity of 16ccm per turn.
16ccm means 0,016 liters.
Therefore the theoretically supply
value is 16 liter per minute with a
motor speed of 1000U/min .
As there are losses in any system,
the actual supplied amount is
about 2% - 4% smaller.
 Hydraulic control valve
Entrance
of the
pump Exit to the tank

Constant oil-quantity

Residue of
oil(Arrival of oil-
quantity - constant
oil-quantity).

Additional Tilt Lift

Testing point
functions function function
 Hydraulic Excess pressure valve
Pressure relief valve
for adjusting the
maximum pressure.

Note:
The maximum pressure is
adjusted by moving the lift
or the tilt function to stop.
Hydraulic function lift

Slide in
position
“LIFT”

Exit lift
Hydraulic function lower

Slide in position
“LOWER”

Exit lift
Hydraulic tilt-function

Slide “TILT”

This valve prevents the

load-influence on the
forward tilt.

Exit tilt
Hydraulic additional functions

Slide additional function

Maximal pressure-Adjustment
of auxiliary function
 Hydraulic MegaValve

Connection point Function

M1
B1 Lifting/Lowering
T L Steering
PZ Load-Sensing
LS PDH LS
M1 Measuring connection
B

0.5
O/
P Pressure input
0.5

DB10
Pressure output
O/

PZ
Y1.3 For FLCN-CE...
P

T Tank
Y1.2 RVS
0.8

PV
O/

Y1.1
L
P B1
 Hydraulic MegaValve
Nozzle M6 O/ 2
LS

PZ
L T

Inscription field
Flutec Mat.-No.
Ident number
Clark PN

M1

P B1

Y1.1 Measuring point G1/8

Precontrol PDH

SW32mm 70+5Nm

Y1.3
RVS SW24mm 25 +5Nm
To get out the valve
use a suitable catch
or similar tool.

PV Y1.2 DB10 PDH

SW32mm 70 +5Nm SW27mm 25 +5Nm
SW8mm
SW2.5mm
 Hydraulic MegaValve
P

Y2.1 Y2.2 Y3.1 Y3.2 Y4.1 Y4.2

Tilt and
B1 auxiliary
O/ 2mm
functions
DBA3 DBA4
SBV DBB3 DBB4

200bar+10

B2 A2 B3 A3 B4 A4

Tilting Auxiliary function 1 Auxiliary function 2

 Hydraulic MegaValve
SW4mm
Y2.2 Y3.2 Y4.2
SW13mm SBV

SW24mm
30+5 Nm

A2 B3 B4
P

Valve unit for tilt and 2

T A3 A4 B2 auxiliary functions.

4+1Nm

Y2.1 Y3.1 Y4.1

After loosing is The coil
SBV is to turn for 360°
SW2.5mm
SBV SW8mm and to remove
DBB3 DBB4
SW13mm 12 +3Nm

B2

DBA3 DBA4
 Hydraulic MegaValve
Complete MegaValve hydraulic
M1

T PZ P

LS PDH
T
B

O/ 0.5
Y2.1 Y2.2 Y3.1 Y3.2
0.5

DB10
O/

Y1.3
P

Y1.2 RVS
B1
PV
0.8

/ 2mm
O
O/

Y1.1
DBA3
L DBB3
SBV
P B1 200bar
+10

B2 A2 B3 A3
 Hydraulic MegaValve
A c t i v a te o f h y d r a u l i c M e g a -V a l v e

Valve no.: 1.1 1.2 1.3 2.1 2.2 3.1 3.2 4.1 4.2
Digital Analog Analog digital digital digital digital digital Digital
Lift 1 X 0
Lower 0 X
Tilt forw. X 1 0
Tilt rew. X 0 1
AUX1 (1) X 1 0
AUX1 (2) X 0 1
AUX2 (1) X 1 0
AUX2 (2) X 0 1

Digital means: Valve has only two positions, open and closed.
Analog means: It is possible the valve position to change by changing the voltage.
1 means: Valve activated
0 means: Valve not activated
X means: Valve the valve position is selected by a corresponding voltage.
 Hydraulic Plan
MAIN HYDRAULIC VALVE 4-SPOOL
HYDRAULIK VENTIL 4 FUNKTIONEN

4 3 2 1

P T

LS T P

HYDRAULIC
PUMP & MOTOR
HYDRAULIK
PUMPE & MOTOR

M A3 B3 B2 PUMP SENSOR
A4 B4 A2 A1 B1 STEERING CONTROL
CHECK POINT PUMPENSENSOR
VALVE
MAIN HYDRAULIC
LENKVENTIL
ME?PUNKT HYDRAULIK

PRESSURE SWITCH
DRUCKSCHALTER

TILT CYLINDER
NEIGEZYLINDER

RETURN LINE
FILTER
RÜCKLAUFFILTER
FFL TSU

PRIMARY
PRIMÄR

SECONDARY SECONDARY
STD HIVI SEKUNDÄR SEKUNDÄR

POWER STEERING
CYLINDER
LENKZYLINDER

SUCTION BREATHER FILTER

FILTER BELÜFTUNGSFILTER
SAUGFILTER
 Steering

Powersteering
 Steering

Driveshaft of steering
wheel

Lower propeller shaft,

connection power
steering

Steering
sensor
 Function steering
Steering wheel shaft
Exit tank Input pressure
Request lead

Exit to steering cylinder

 Hydraulic plan steering
To Mainvalve

Priority Valve

From Mainvalve

LS T P

HYDRAULIC
PUMP & MOTOR
HYDRAULIK
PUMPE & MOTOR

PUMP SENSOR
STEERING CONTROL
PUMPENSENSOR
VALVE
LENKVENTIL

PRESSURE SWITCH
DRUCKSCHALTER Power steering

RETURN LINE
FILTER
RÜCKLAUFFILTER

POWER STEERING
CYLINDER
LENKZYLINDER

SUCTION BREATHER FILTER

FILTER BELÜFTUNGSFILTER
SAUGFILTER
Brake system

Brake discs
 Brake system
Control pin Bleeding nipple
Manual brake

Brake pads
 Brake system

Main brake Brake pedal Microswitches Storage for braking fluid

cylinder
1.Symbol for
manual brake
Storage for braking fluid
2.Release drive
 Parking brake
Control pin Control pin

Cam

Lever is activated by
push-pull cable. Disc for use of
pin
Parking brake

Microswitches
HBS1 and HBS2

Push-pull cable
 Foot brake
Brake-shoe

Spacer
Brake piston
 Foot brake

Pedal stop

Main braking
cylinder
 Foot brake
Left side Right side

Storage for brake

Oil hoses for use of brake liquid
Brake pedal

Master cylinder
Options

Mega Valve Overview

Megavalve Hardware

Megavalve Hydraulic

Megavalve Wiring Diagram

Megavalve Harness

Accelerator Pedals
 Mega Valve Harness
314-B 301-B
CAN-L CAN-H
C

Auxi liary 1 (28D)

Auxiliary 2 (28E)
A

Electronic

Tilting (28C)
C A B
3 305-B COM
02
PL-

Minus
302-B

303-B

315-B

335-B
336-B
312-B B

MegaValve
2 306-B Rev.
3
4 SO-01 1 304-B Fwd.
-0
PL

313-B
Lifting (28B)

S1
326-B
322-B

320-B
328-B

332-B
317-B
Y4.1

Y3.1

Y2.1
A uxil iary 2-B

A uxil iary 1-B

Tilt Rev. A

1.2

Y1
B Y
5-

.1 3
33 4 -B
32 23- B

3 -B , 33
3
3 Pin Wire End
1 301-A CAN-H
2 302-A Output Tilting 28C

7-A
3 303-A Output Aux 1 28E
4 304-A Output Fwd. 8
5 305-A Supply Dir.Switches 11

Valve

Y1
6 306-A Output Rev.. 6

.3 3
7

3 3 1-B
8

7-B
3
9
10

Tilting / Auxiliary
11

Valve Lifting
12 312-A Input Key Switch. 10C
Auxili ary 2-A

Tilti ng Fwd. A
Auxiliary 1-A

13 313-A Analogic Outp. Hyd.28B

14 314-A CAN-L
15 315-A Output Aux. 1 28D
16
17 317-A Valve Tilting Fwd.
18 318-A Valve Tilting Rev.
Y4.2 327-B

Y3.2

Y2.2 332-B

19 319-A
20 320-A Valve Aux 1-B
21 321-A Valve Aux 2-A
319-B
329-B
321-B

317-B

22 322-A Valve Aux 2-B

23 323-A Valve Bypass
24 324-A
25 325-A Valve Bypass
26 326-A Valve Aux 2-B
27 327-A Valve Aux 2-A
28 328-A Valve Aux 1-B
29 329-A Valve Aux 1-A
30 330-A Valve Tilting Fwd.
31 331-A
32 332-A Valve Tilting Rev.
33 333-A Valve Lifting
34 334-A Valve Lifting +12V
35 335-A 0V
36 336-A 0V
 Mega Valve Harness
Wiring Mega-Valve CTM/CEM 10-20
A-End Wire no. B-End A-End Wire no. B-End
Con S1-01 301 Con PL03-A Con S1-22 322 Aux 2 Y 4.1
Con S1-02 302 Tilt Con S1-23 323 Uml.Vent. Y 1.2
Con S1-03 303 Aux 2 Con S1-25 325 Uml.Vent. Y 1.2
Con S1-04 304 Con S01-1 Con S1-26 326 Aux 2 Y 4.1
Con S1-05 305 Con S01-3 Con S1-27 327 Aux 2 Y4.2
Con S1-06 306 Con S01-2 Con S1-28 328 Aux 1 Y 3.1
Con S1-12 312 Con PL03-B Con S1-29 329 Aux 1 Y3.2
Con S1-13 313 Con 02-B Con S1-30 330 Tilt REV Y 2.1
Con S1-14 314 Con PL03-C Con S1-31 331 Lowering Y 1.3
Con S1-15 315 Aux 1 Con S1-32 332 Tilt FWD Y 2.2
Con S1-17 317 Tilt FWD Y 2.2 Con S1-33 333 Lift Y 1.1
Con S1-18 318 Tilt REV Y 2.1 Con S1-34 334 Lift Y 1.1
Con S1-19 319 Aux 1 Y 3.2 Con S1-35 335 UB-
Con S1-20 320 Aux 1 Y 3.1 Con S1-36 336 UB-
Con S1-21 321 Aux 2 Y 4.2 Lift Y 1.1 337 Lowering Y 1.3
 Mega Valve Wiring Diagram
Joystick Side Harness Side
Shield
S2 S1
30 White / Yellow
0V 9
29 Brown / Green CAN-H
Lift Neutral-Switch 1
8 Output Tilting
36 White / Green 2 Wire 28C CON I1-27
Tilt Neutral_Switch 7 Output Auxiliry 2
3 Wire 28E CON I1-25
17 White Direction Forw.
Auxiliary. 1 left 11 4 Wire 8
16 Green Input Supply Direction Switches
5 Wire 11
Auxiliary 1 right
12 Grey
12
Mega Valve 6
Direction Rev.
Wire 6
Auxiliary. 2 left 13
7
Auxiliary 2 right
10 Yellow
14 Control 8
11 Pink
M1
9
Activation-Switch 18
19 Red 10
Poti +4.5V 4
11
24 Violet Input Key Switch
Poti Lifting / Lowering 5 Wire 10C KS 48/80V
12
Black Analogic-Output Hydraulic
20 13 Wire 28B CON I1-20 (CON C-B)
Poti Tilting Forw. / Rev. 6
CAN-L
18 Blue 14
Poti 0V 10 Output Auxiliary 1
15 Wire 28D CON I1-26
38 Yellow / Brown
Supply Direction Switches 2 16
Grey / Pink 12V-Output
39 17
Direction Switch Rev. 1 12V-Output
41 Red / Blue 18 F Y 2.1
Direction Switch Forw. 3 12V-Output Tilting R Y 2.2
19
12V-Output
15 20 A Y 3.1
12V-Output Aux. 1 B Y 3.2
21
16 12V-Output
22
17 12V-Output A Y 4.1
23 Aux. 2 B Y 4.2
24 1.2 4.1 4.2 3.1 3.2 2.2 2.1
Bypass-Valve
25
Auxiliary Function 2
26
Auxiliary Function 2
27 Valve
Auxiliary Function 1
28
Auxiliary Function 1
29
18 13 Tilting Forw. Y 1.1
30 Lifting
Tilting Rev.
12 7 31
Lowering
32 Lowering Y 1.3

6 1 33
Lifting
1.1 1.3
12 V-Output Bypass
34 Y 1.2
0V
35 UB- Harness Minus
0V
36 UB- Harness Minus
 Help

This presentation was designed interactive, therefore the

user can easily determine the presentation due to the
cursors. The functions of the green buttons are:

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 Structure
Main menu
Motor - Basics Symbols

Functions Components Dash Board Mechanic Options

Dash Board Hydr. comp.

Diagn.Control. Normal use
Axle Hydr. function
Wiring diagr. Diagn. Hydr.
Hydr. motor Hydr. plan

Harness Frame Diagn.Periph. Steering comp.

Single function Control Diagn.Control. Steering funct.

Search failure Steering axle Failure display Brake comp.

Battery Brake function

Hydraulic
 Index
Axle Food brake Search for failures
Basic DC-motor Harness Steering functions
Battery Hydraulic functions Test items drive control
Brake functions Hydraulic plan Test items pump control
Capacitor test Hydraulic use Turn on TFR-contactor

Contactor-coil test Parameter drive control Voltage test

Dash board functions Parameter pump control Wiring diagram complete
Diagnose “F1” Wiring diagram drive
Parking brake
Diagnose “LIGHT” Wiring diagram hydraulic functions
Plug arrangement
Diagnose “M” Plug drive control Wiring diagram power circle
Failure drive control Plug pump control Wiring diagram power supply
Failure pump control
 Diagnose Controller
L 50 = List Number (001...003)
A=Alarms L 51 = RPM steering (%)(010...040)
C=Check Parameter L 52 = Compensat. steering (000...009)
L=List parameter L 53 = Steering delay (s)(000...020)
L 54 = RPM point 1 (%)(010...040)
L 55 = Compens. hydraulic (000...009)
L 56 = RPM point 2 (%)(020...070) C 50 = Software version
L 57 = RPM point 3 (%)(030...090) C 51 = Lifting, Tilting, AUX 1, AUX 2
Pump Controller L 58 = Battery character (V:10)(404...600) C 52 = Actual controller temperature
Measuring !!!
L50 - L58 + L12
C50 - C52
A59 - A65 L12 = Separate in both controllers.
On- off switching of test circle
Dash board current measuring.

Traction Controller

L60 - L65 + L12 C 54 = Software version L 60 = List Number (001...003)

C 55 = Accelerator value, MS1 L 61 = Acceleration (000...009)
C54 - C61 C 56 = Steering potentiometer value L 62 = F/R & Footbrake (015...070)
A50 - A58 C 56 = Direction switch forward L 63 = Rolling-Brake (000...050)
C 57 = Direction switch reward L 64 = I-Max. (A)(470...650)
C 59 = Brake switch L 65 = Max. speed (%)(050...100)
C 60 = Seat switch
C 61 = Actual controller temperature
 Presentation
Clark Material Handling GmbH
Karl Eckholt
Product Marketing / Product Specialist

Tel. +49 0208 588 1497

Fax +49 0208 588 1370
For criticism and e-mail keckholt@clarkmhe.com
suggestion please
contact Thomas Jennen
Product Marketing / Product Specialist

Tel. +49 0208 588 1590

Fax +49 0208 588 1370
e-mail tjennen@clarkmhe.com