Service Manual J 3001 06.

04 1
MULTIPILOT, Adjustment and Repair

Index
Index .......................................................................................... 1
Multipilot Disassembly ............................................................... 2
Grip Disassembly .................................................................. 2
Switch/Rocker Disassembly .................................................. 3
Assembly ............................................................................... 3
Sensor System Adjustment ....................................................... 4
Rocker Replacement ............................................................. 4
Switch Replacement .............................................................. 4
Activating and Deactivating External Switches ...................... 4
MULTIPILOT parameters ...................................................... 5
Error messages ......................................................................... 6
Range readings ......................................................................... 8
Connector Layout ...................................................................... 9

Used before safety instructions which must be observed to avoid

danger to personnel.
Used before notices which must be observed to avoid material
damage.
Used before explanations.
 Service Manual J 3001 06.04 2
Multipilot Disassembly .
1
Grip Disassembly
3
1. Remove the cover (1) from the "travel direction" switch and 4
remove screw (2).
2. Remove screws (5+6) and take the grip (4) away from the 2
housing
3. Remove the 6 pole electronic connector (3) 5

4. Remove the screws (7), bellow (9) from the housing and pull
the connector through the housing opening.
6
9 7
Assembly
8
1. Guide the connector through the housing opening and push
the housing onto the lower section.
2. Press the bellows (9) into the housing groove and make sure
the sealing lip is well secured.
3. Insert and tighten the screws (7)
4. Refit the electronic connector, place the grip (4) on the
housing (3), insert screws (2, 5+6) and tighten them. Clip the Item Description Item Description
cover onto the travel direction switch.
1 Cover 6 Screw MA=0.7±0.1 Nm
2 Screw MA=0.7±0.1 Nm 7 Screw MA=2.2±0.15 Nm
3 Electronic connector 8 Housing
4 Grip 9 Bellow
5 Screw MA=0.7±0.1 Nm
 Service Manual J 3001 06.04 3
Switch/Rocker Disassembly
1. Remove the tilt rocker (1) from the axle in the direction of the 2
arrow. 1

2. Remove the travel direction switch (4) from the axle in the 4
direction of the arrow, from the narrow side.
3. Remove the sideshift rocker (2) from the axle in the direction
of the arrow.
4. Remove the horn switch (3) from the axle in the direction of
the arrow.

Assembly
1. Push the tilt rocker and the sideshift rocker initially with a
right turn onto the respective axles until the left spring leg is
resting on the stud of the grip shell.
Continue to push up onto the axle with a left turn until the
right spring leg is resting on the stud of the grip shell and then 3
the rocker engages in the clip.
2. Insert the travel direction switch in the top left-hand stop of
the grip shell; the compound spring should now rest in the
grip shell. Now clip it onto the axle.
3. Remove the horn switch and place it on the axle until the clip
engages. The compound spring should now rest on the grip Item Description
shell.
1 Tilt rocker
2 Sideshift rocker
3 Horn switch
4 Travel direction switch
 Service Manual J 3001 06.04 4
Sensor System Adjustment
After replacing the Multipilot head in full there is no requirement Switch Replacement
for calibration. Calibration should however be performed if the
When the switches are adjusted the zero position and limit values
analog function actuators have been replaced.
are calibrated.
Rocker Replacement 1. Select servicemode on the driver’s display panel or the on-
board computer.
After replacing a rocker the zero position and end stops should be
re-calibrated. 2. Select parameters in accordance with the MULTIPILOT
parameter table.
Three rocker positions must be calibrated for a full adjustment.
3. Set switch to starting position (zero position or end stop)
1. Select servicemode on the driver’s display panel or the on-
board computer. 4. After calibration of all three positions turn the keyswitch off to
save.
2. Select parameters in accordance with the MULTIPILOT
parameter table. When you switch it on again the Multipilot will be initialised with the
new values.
3. Set the rocker to its starting position (e.g. zero position, left or
right stop) For calibration with JUDIT: In the zero position, a "0” should
appear in the CAN telegram and in the end stop the value "1”. If
4. After calibration of all three positions turn the keyswitch off to
this is the case, the rocker has been successfully adjusted.
save.
When you switch it on again the Multipilot will be initialised with the Activating and Deactivating External Switches
new values.
The external switches (parameters 539, 540, 543) are activated
For calibration with JUDIT: In the zero position, a "0” should and deactivated via the CAN telegrams. The current status is
appear in the CAN telegram and in the end stops an analog value initially transfered to the RAM. The set parameters are written to
of "0xFF”. If this is the case, the rocker has been successfully the EEPROM via the last CAN telegram.
adjusted.
If this is not the case, the settings must be repeated.
 Service Manual J 3001 06.04 5
MULTIPILOT parameters

Para- Parameter description/ Setting Description

meter Display range
137 Travel direction change sensor_Min Minimum Hall – travel direction change sensor
138 Travel direction change sensor_Max Maximum Hall – travel direction change sensor
139 Horn sensor_MIN Minimum Hall – horn sensor
140 Horn sensor_MAX Maximum Hall – horn sensor
530 Tilt sensor_Zero Tilt sensor neutral position
531 Tilt sensor_Fwd._Max Tilt sensor forward max. level
532 Tilt sensor_Rev_Max Analog value Tilt sensor reverse max. level
533 Sideshift sensor_Zero Sideshift sensor neutral point
534 Sideshift sensor_Fwd_Max Sideshift sensor forward max. level
535 Sideshift sensor_Rev_Max Sideshift sensor reverse max. level
536 ZH2Sensor_Zero ZH2 sensor neutral position
537 ZH2Sensor_Fwd_Max ZH2 sensor forward max. level
538 ZH2Sensor_Rev_Max ZH2 sensor reverse max. level
539 Horizontal switch Horizontal switch present
0 = deactivated;
540 Centre shift switch Centre shift switch present
1 = activated
543 180°/360° steering switch Steering mode switch present
 Service Manual J 3001 06.04 6
Error messages
As only a limited number of error numbers are available, a The following error messages have been defined for the Multipilot.
recorded error may have several causes.
Error Error description Error cause
no.
22 Warning 22 "No steering” Steering telegram timeout exceeded.
The timeout for both steering telegrams "CMD_STEER ANGLE” and "CMD_STEER
In earlier software versions issued as a
MODE” is five seconds.
normal error.
If either of the telegrams is not received by the Multipilot within this time, the warning
is triggered.
26 Lift nominal value transmitter error There are a variety of causes of nominal value transmitter errors:
• Faulty sensor signal (e.g. through short circuit, wire breakage)
29 Reach nominal value transmitter error
• Faulty mechanics
30 Tilt nominal value transmitter error • Faulty sensor adjustment
• Hardware error
31 ZH1 nominal value transmitter error • Zero or faulty connection to processor in grip (internally, nominal value transmitter
32 ZH2 nominal value transmitter error errors are then set for all grip functions, but only error 30 is generated)
• Invalid adjustment data
• Incorrect item no. (function available according to Multipilot item no., but in fact not
available)
34 CAN Bus faulty Generated if the CAN module of the processor has switched to error status. Errors
caused by:
Removed again as it was never sent, but
• Faults on the CAN Bus
possibly present in error logbook
• CAN Bus connection interruption
• No terminal resistance
36 No lift zero position Generated when the main lift function is applied via the Multipilot.
39 Improbable truck type Generated if the truck type login procedure does not match its own.
• Components connected to the CAN Bus with different truck type
 Service Manual J 3001 06.04 7

Error Error description Error cause

no.
50 Horizontal tilt wire breakage "Wire breakage" error messages may have the following causes:
• The respective switch was pressed when the Multipilot was applied.
65 Centre shift wire breakage
• A wire breakage was detected in the respective switch
66 180/360 degree steering change wire breakage • A short circuit was detected in the respective switch
• The flags for the external switches are incorrectly set (flag set although no switch
present)
• Switch signal line faults
67 Travel direction nominal value transmitter error There are a variety of causes of nominal value transmitter errors:
• Faulty sensor signal (e.g. through short circuit, wire breakage)
• Faulty mechanics
• Faulty sensor adjustment
• Hardware error
• Invalid adjustment data
The travel direction switch also has the anomaly that a nominal value transmitter error
is recorded if the switch is already pressed when the truck is powered up.
96 No zero position for hydraulics One or more of the following Multipilot functions are already activated when the
Multipilot was applied.
• Reach
• Tilt
• Sideshift
• ZH2
100 Improbable software version for internal Replace the Multipilot head section or the Multipilot in full
component parts
 Service Manual J 3001 06.04 8
Range readings
Voltage recorded in DC, reference potential against PIN 10
Pin Pin Function Voltage Voltage
Component Fz Multipilot nominal recorded
X1_1 X500_1 GND 0V 0V
X1_2 X500_2 GND 0V 0V
X1_3 X500_3 CAN High out:2.75V - 4.5V; in: -0.5 - 15.5V 2.6 V
X1_4 X500_4 CAN Low out: 0.5V - 2.25V; in: -0.5V - 15.5V 2.4 V
X1_5 X500_5 CAN High out:2.75V - 4.5V; in: -0.5 - 15.5V 2.6 V
X1_6 X500_6 CAN Low out: 0.5V - 2.25V; in: -0.5V - 15.5V 2.4 V
X1_7 X500_7 GND 48V 0V
X1_8 X500_8 GND 0V 0V
X1_9 X500_9 Supply 48V 49.6 V
X1_10 X500_10 Supply 0V 0V
X1_11 X500_11 Forks horizontal invers 0V (inactive). 5V (active) 0V
X1_12 X500_12 Forks horizontal 5V (inactive). 0V (active) 4.8 V
X1_13 X500_13 Sideshift centre invers 0V (inactive). 5V (active) 0V
X1_14 X500_14 Sideshift centre 5V (inactive). 0V (active) 4.8 V
X1_15 X500_15 180° / 360° invers 0V (inactive). 5V (active) 0V
X1_16 X500_16 180° / 360° 5V (inactive). 0V (active) 4.8 V
 Service Manual J 3001 06.04 9
Connector Layout

PIN No. Function Voltage Current 8 7 6 5 4 3 2 1

1
0 V (for switches) 0V
2
3 CAN High
4 CAN Low
0V-5V
5 CAN High
6 CAN Low
7
0 V (for switches) 0V
8 16 15 14 13 12 11 10 9
9 48 V supply 16.8 - 104 V 70 -200 mA
10 0 V supply 0V
11 Horizontal tilt invers 0 V (inactive) 5 V (active)
12 Horizontal tilt 5 V (inactive) 0 V (active)
13 Sideshift centre invers 0 V (inactive) 5 V (active)
0.2-4mA max.
14 Sideshift centre 5 V (inactive) 0 V (active)
15 180°/ 360° change invers 0 V (inactive) 5 V (active)
16 180° / 360° change 5 V (inactive) 0 V (active)