Jungheinrich is one of the three largest forklift manufacturers in the world — alongside Linde and Toyota — headquartered in Hamburg. Jungheinrich EFG (electric counterbalance), ETV/ETM (reach trucks), ECE (compact counterbalance), ETR (three-wheel) and EJE (pallet trucks) are all equipped with proprietary electronic controllers: ATS (traction), MP 1506 FH / MP 1505 (fork hydraulics), LEM (mast module) and CANbus communication modules. An ECU failure means an immediate forklift stop — often with an error code on the ISM panel and no possibility of driving. Acore from Knurow repairs Jungheinrich controllers at component level: we replace MOSFET transistors, capacitors, EEPROM memory, Siemens SAB 80C535 processors and gate drivers — instead of replacing the entire module for PLN 6,000–18,000.
What We See in the Customer Photos — Jungheinrich MP 1506 FH (Mat-Nr. 50026752)
The controller in the customer photos is the Jungheinrich MP 1506 FH (Mat-Nr. 50026752, firmware V4.30, internal code 981005). It is the fork hydraulics controller (FH = Fork Hydraulics), used in Jungheinrich EFG, ETV and ETM forklifts from 2000–2008. Visible internal components: Siemens SAB 80C535-N processor (Intel 8051 compatible, 12 MHz), green terminal blocks X1/X2/X4, current shunt A2, power MOSFET array (IRF3710), and ATS 6/ATS 7 traction controllers in the electrical compartment.
Jungheinrich Forklift Models — Supported Controller Series
| Series | Models | Load Capacity | Voltage | Traction Controller (ATS) | Hydraulic Controller (MP) | Application |
|---|---|---|---|---|---|---|
| EFG — 3/4-wheel counterbalance | EFG 110–116, EFG 213–225, EFG 316–320, EFG 425/430, EFG S30/S40 | 1000–4000 kg | 24/48/80 V | ATS 4812 / ATS 4814H / ATS 6 / ATS 7 | MP 1506 FH / MP 1505 / MP 1508 | Logistics, production, cold stores |
| ETV — 4-wheel reach truck | ETV 110–116, ETV 208–216, ETV 320, ETV Q20 | 1000–2000 kg | 24/48 V | ATS 4812 / ATS 6 / ATS 7 | MP 1506 FH / MP 1505 | High-rack warehouses up to 13 m |
| ETM — 3-wheel reach truck | ETM 110–116, ETM 214/216 | 1000–1600 kg | 24/48 V | ATS 4812 / ATS 6 | MP 1506 FH / MP 1505 | Standard warehouses, AGV applications |
| ECE — compact counterbalance | ECE 220/225, ECE 316/320/325 | 2000–3250 kg | 48/80 V | ATS 7 / ATS 4814H | MP 1508 / MP 1506 FH | Small/medium warehouses, light outdoor |
| ETR — 3-wheel electric | ETR 225, ETR 320/325/330/335 | 2000–3500 kg | 48/80 V | ATS 6 / ATS 7 / ATS 4814H | MP 1506 FH / MP 1508 | Narrow aisles, distribution centres |
| EJE — electric pallet trucks | EJE 112–120, EJE C20/D20 | 1200–2000 kg | 24 V | Jungheinrich MC (small traction controller) | MP 1505 / MP 1503 | Commissioning, horizontal transport |
| EKS — order picker | EKS 108–112, EKS 208–210, EKS 312/314, EKS 412/513 | 800–1500 kg | 24/48 V | ATS 4812 / ATS 6 | MP 1505 / MP 1506 FH | High rack commissioning, VNA |
| EKX — very narrow aisle VNA | EKX 410/412, EKX 513/515 | 1000–1500 kg | 48 V | ATS 6 / ATS 7 | MP 1506 FH | VNA (<1.5 m), automation |
Jungheinrich Fault Codes — Complete Diagnostic Table
| Code | Description | Hardware Root Cause | Measurement | Repair Cost |
|---|---|---|---|---|
| 3.1 | EEPROM memory fault | Failed EEPROM AT24C256 or ST M95256 (256 kbit I2C/SPI). Loss of PIN codes, speed limits, operating hours. Causes: overvoltage >60 V, battery discharge to <10 V with logic powered on. | I2C scope on SDA/SCL: 100 kHz, address 0x50 acknowledge. No ACK = replace SOIC8 EEPROM. ISM Online backup before repair required. | 500–1,200 PLN |
| 8.1 / 8.3 | CAN bus failure / no telegrams | CAN termination resistance out of range — must be 60 Ω. Failed CAN transceiver (PCA82C251, TJA1050) on one of the modules. Break or short in CAN H/L wires. | Disconnect all CAN modules, measure CAN H to CAN L resistance: 60 Ω expected. Below 50 Ω = short, above 70 Ω = missing terminator or broken wire. | 400–900 PLN |
| 10 | Main contactor jammed or not closing | Failed contactor coil (Albright SW180 or Tyco LEV200) or mechanically welded contacts. Failed coil driver MOSFET (IRFZ44N) on ATS PCB. | Measure coil resistance: 12–22 Ω at 48 V. OL = blown coil. MOSFET G-S: 0 V inactive, 12 V active. D-S at conduction: <0.1 V. | 600–1,400 PLN |
| 108 | Internal controller fault (ATS or MP) | Failed power MOSFET (IRF3710, IRFB4110), burned DC bus capacitors, or failed MOSFET gate driver (IR2104, IR2113). Controller cannot drive motor. | MOSFET diode test: D-S forward 0.4–0.6 V, D-S reverse OL. 0 Ω D-S = shorted MOSFET. DC bus capacitors (100 µF/63 V): ESR <50 mΩ, capacitance ±20% nominal. | 1,200–3,500 PLN |
| 112 | Traction controller (ATS) fault or CAN loss | Internal ATS failure or loss of CAN communication. Blown IGBT/MOSFET traction phase, burned shunt resistor A2 on PCB, bad wheel speed sensor signal. | ISM Online: check ATS parameters — motor current, temperature. Measure shunt A2 resistance: typ. 0.5–2 mΩ (very low). MOSFET IRF3710/IRFB4110 diode test. | 1,500–4,000 PLN |
| 113 | Hydraulic controller (MP) or LEM fault | Failed MP module (hydraulic pump controller) or LEM (mast module). Blown pump MOSFET (IRF3710), failed shunt A2, no CAN communication with MP. | Check CAN NODE STATUS for MP module. Measure MP supply voltage (should be 45–52 V for 48 V truck). Measure pump power MOSFET: diode test as above. | 800–2,500 PLN |
| 115 | Main contactor — implausible state | ATS detects inconsistency between control signal and contactor feedback. Worn main contacts (resistance >50 mΩ) or failed feedback signal MOSFET. | Measure main contact resistance (closed): should be <10 mΩ. Above 50 mΩ = worn contacts, replace contactor. | 700–1,800 PLN |
Service Area — Europe and Poland
Poland: Gliwice and Knurow (base), Katowice (26 km), Wroclaw (190 km), Lodz (230 km), Warsaw (290 km), Krakow (100 km), Poznan (270 km), Gdansk (420 km), and all of Poland via DPD/DHL courier.
Germany (Jungheinrich home market — largest fleet in Europe): Berlin, Hamburg, Munich, Frankfurt, Stuttgart, Düsseldorf, Cologne, Leipzig, Hannover, Nuremberg. DHL Express 1–2 business days, flat rate approx. €35 both ways.
Czech Republic and Slovakia: Prague, Brno, Ostrava, Bratislava, Zilina — DPD 1–2 days. Austria, Switzerland: Vienna, Graz, Zurich, Basel — DHL 2–3 days. Netherlands, Belgium: Amsterdam, Rotterdam, Antwerp — DHL 2–3 days. France: Paris, Lyon, Marseille — DHL 3–4 days. Italy: Milan, Rome, Turin — DHL 2–3 days. UK: London, Manchester — DHL DDP 3–4 days. Scandinavia: Copenhagen, Stockholm, Oslo, Helsinki — DHL 3–5 days. Free shipping both ways for repairs above PLN 3,000 (approx. €700).
FAQ
- Jungheinrich EFG 220 shows fault 112 (traction controller fault) and will not drive. What to check?
- Fault 112 indicates internal ATS traction controller failure or loss of CAN communication with ATS. Procedure: (1) read full log via ISM Online — check if fault 112 is alone or with 8.x codes; (2) if CAN errors present — measure 60 Ω on CAN bus; (3) if only 112 with good battery — ATS controller needs MOSFET repair. Send ATS for diagnostics.
- MP 1506 FH (50026752, Siemens SAB 80C535, year 2003) — do you repair such old controllers?
- Yes — we specialise in older Jungheinrich controllers with Siemens MCS-51 processors (SAB 80C535, SAB 80C537). New controllers of this generation are unavailable or cost PLN 6,000–9,000 — component repair is the only economical option. We replace burned MOSFET IRF3710, capacitors, EEPROM AT24C256, repair shunt A2 and connectors X1/X2/X4. Cost: 900–2,500 PLN.
- Shipping from Germany — cost and turnaround time?
- DHL Express 1–2 business days from Germany to Knurow. Return shipping next business day. Flat rate 150 PLN (approx. €35) both ways, insured to PLN 50,000. Free shipping both ways for repairs above PLN 3,000. Total repair cycle: 4–8 business days.