LPE200 LPE220 LPE250 (Levio AC) RM7572514-040 From 63045331 (Updated 2018)

Repair manual 7572514 en
LPE200
LPE220
LPE250
Translation of the original instruction
Publication No.: 7572514-040

Translation of the original instruction
List of models:
Model T-Code Valid from serial number

LPE200 1010 6304531-
LPE220 1010 6304531-
LPE250 1010 6304531-
Change history:
Date Change Change description

2017-11-01 Various updates
2018-01-01 Periodic maintenance, page 6 - 5 Updated maintenance list.
Table of contents
General introduction 1
General safety rules 2
Operating principle 3
Parameters 4
Installation 5
Maintenance 6
Troubleshooting 7
Chassis C0000 8
Motors C1000 9
Transmission/Drive gear C2000 10
Brake/wheel/track system C3000 11
Steering system C4000 12
Electrical system C5000 13
Hydraulics/Pneumatics C6000 14
Work function - lifting masts C7000 15
Auxiliary equipment, installation equipment C8000 16
Optional equipment/Extra equipment C9000 17
Instructions for disposal 18
Wiring diagram 19
Hydraulics schematics 20
Tools 21
Service data and grease specifications 22
Technical data 23
Index 24

Table of contents

General introduction 1
1.1 Pictograms ......................................................................................................................................................... 1 - 1
1.2 Abbreviations ..................................................................................................................................................... 1 - 1
Repair manual 7572514-040

1 General introduction

Pictograms
1
General introduction
1.1 Pictograms 1
1.1
Pictograms
Symbol Procedure Symbol Procedure

Visual inspection of condition, wear and loose
Component replacement.
connections.
Cleaning Measurement
Check that screws, nuts, etc. are tightened to

Checks for leaks.
torque.
Listening for noise. Lubrication, application.
Check of functions. Calibration
Adjustment Welding
Disassembly/removal Assembly/installation
Open Close
Refilling Emptying
Update Charging
Lift Lower
An example of another type of pictogram is “Cut cable ties”:
Additional information under the pictogram can, for example, indicate the number of cable ties to be cut.
1.2 Abbreviations
1.2
Abbreviations
Abbrevi- Meaning Explanation

ation
ACC Alternate Current Combi Motor control, hydraulics and drive.
ACH Alternate Current Hydraulic Motor control, hydraulics.
ACT Alternate Current Traction Motor control, drive.
BCU Onboard system
BDI Battery Discharge Indicator Unit indicating the state of battery charge.
CAN Controller Area Network A standardised interface that enable communication between different
electrical units.
1-1 Repair manual 7572514 en

Abbreviations
Abbrevi- Meaning Explanation

ation
CID Central Information Display Display with menu-based information system that is used as the
primary communication tool between operator and truck.
DX Duplex Mast with two sections.
EPS Electronic Power Steering Complete steering servo with its own motor control.
ESO Emergency Switch Off Emergency stop switch.
FCM Fuse Central Module Fuse panel.
FCU Fork Control Unit Unit for fork functions.
GFU General Function Unit Unit for general functions.
HPS Height Pre-Select Height pre-selection
ICH Integrated Control Handle
IPM Intelligent Power Module Power control unit
LID Load Information Display Display that provides the operator information such as lift height, load
weight and height preselection.
MCU Main Control Unit Main control unit.
PDA Personal Digital Assistant A compact, portable handheld computer.
PPS Personal Protection System Personal protection system.
PTC Positive Temperature Coefficient Electrical property that causes resistance to increase with temperature.
SCU Secondary Control Unit Secondary control unit
SEU Spider Expansion Unit
SF Shuttle Forks Telescoping fork unit.
TBD To Be Defined Means that the instruction/chapter will be supplemented at a later date.
TH Turret Head Turret head fork unit
I-Site T.W.I.S. – Toyota Wireless Inform-
ation System
TX Triplex Mast with three sections.
VNA Very Narrow Aisle Narrow aisles
VRE Very narrow aisle Rider Electric
Repair manual 7572514 en 1-2

General safety rules 2
2.1 Authorised personnel ......................................................................................................................................... 2 - 1
2.2 Work safety ........................................................................................................................................................ 2 - 1
2.3 Electrical system ................................................................................................................................................ 2 - 2
2.3.1 Electrostatic risks................................................................................................................................. 2 - 2
2.3.2 Battery handling................................................................................................................................... 2 - 2
2.4 Safe lifting .......................................................................................................................................................... 2 - 3
2.5 Product modification .......................................................................................................................................... 2 - 4
2.6 Software............................................................................................................................................................. 2 - 4
2.7 Hydraulic system................................................................................................................................................ 2 - 4

2 General safety rules

Authorised personnel

2
General safety rules
2.1 Authorised personnel

2.1
Authorised personnel
Only personnel trained in servicing and repair of this type of product are authorised to carry out service and repair activit-
2
ies.
2.2 Work safety

2.2
Work safety
For safe work, always remember:
▷ Always disconnect the battery when carrying out maintenance or repair work, unless otherwise stated in this re-
pair manual.
▷ always disconnect the battery when performing welding work.
▷ Make sure that the place where service work is performed is a safe place. Follow the regulations.
▷ Keep the maintenance work site clean. Oil and water on the floor will make it slippery.
▷ Use the correct working posture. Service work often involves sitting on your knees or bending over forwards. Try
sitting on a toolbox, for example, to relieve the strain on your knees and back.
▷ Loose items and jewellery can get caught in moving parts. So never wear loose articles or jewellery when per-
forming maintenance or repairs.
▷ Exercise caution and always follow applicable local regulations when working at high heights.
▷ Use the correct tools for the work you are carrying out.
▷ Keep all tools well maintained.
▷ Make sure that all safety equipment including guards and covers are properly secured and that they work as in-
tended before starting the repair work. If a guard or cover must be removed in order to perform the repair work,
extra care must be taken, and when the repair work is finished the guard or cover must be refitted.
▷ Use paper or a stiff piece of cardboard when checking for possible oil leaks. Do not use your hands.
▷ The drive unit oil may be hot.
▷ Use only new and clean oil for the drive gear.
▷ Store and transport changed oil according to applicable local directions.
▷ Do not flush solvents, etc. down the drain unless they are intended to be disposed of in this way. Follow local dis-
posal regulations.
▷ Prior to welding or grinding on painted surfaces, be sure to remove the paint at least 100 mm around the welding/
grinding area by using sandblasting equipment or paint remover.
▷ To maintain a high level of product safety and to minimise downtime, all current maintenance instructions must
be carried out.
▷ Always keep fire-fighting equipment close at hand, and do not use an open fire to check fluid levels or when
searching for leaks

Electrical system
2.3 Electrical system

2.3
Electrical system
When working on the electric system, keep the following in mind:
WARNING Short-circuiting/Burn injuries

Loose items and jewellery can get caught in moving parts. So never wear loose articles or jewellery when performing
maintenance or repairs.
► Remove any jewellery and loose items before starting work.
▷ Always use insulated tools when working on the electrical system.
▷ Always disconnect the battery before opening any covers to drive units or the electrical system.
▷ Always disconnect the battery prior to welding work using an electric welding unit. The welding current may dam-
age the battery.
▷ Never remove the warranty seals on the electronic cards.
2.3.1 Electrostatic risks

2.3.1
Electrostatic risks
Purpose
These work instructions describe how to work in a safe manner with components that are sensitive to electrostatic
chocks.
Scope
These work instructions apply to all that work with component or units that are sensitive to electrostatic chocks.
Procedure
Electrostatic discharges from people may destroy sensitive equipment. For this reason, one must follow the instructions
for packaging and earthing. Always pay attention to these precautionary instructions.
Electronic card are supplied in electrostatically protected packages or envelopes.
These packages carry the following symbol:
▷ Leave electrostatically sensitive equipment in their respective packaging until you can place them on an electro-
statically protected work area.
▷ Electrostatically sensitive equipment should only be handled when they are properly earthed.
▷ Use electrostatically protected footwear!
▷ Store electrostatically sensitive equipment in their protective packaging or on electrostatically protected surfaces.
▷ Use an antistatic surface: Anti-static carpet 148115, page 21 - 7.
2.3.2 Battery handling

2.3.2
Battery handling
When working on the battery, keep the following in mind:
▷ Working with and charging batteries should always be performed in accordance with the safety instructions
provided by the battery manufacturer.
▷ Always use safety equipment to protect the eyes, face and skin while checking or handling batteries.

Safe lifting
▷ Do not place any electrically conductive items on the battery terminals or their connections.
▷ Ensure there is a shower and an eye bath nearby in case an accident happens.
▷ Batteries generate explosive gases. Never use an open flame or other sources of ignition in close vicinity to a 2
battery.
▷ Do not place tools or other metal objects on the battery. This can cause a short-circuit and even an explosion.
▷ The battery must be used according to the battery manufacturer's instructions regarding ambient and working
temperatures. Otherwise there is a large risk that the battery is damaged and that it will soon have to be re-
placed.
▷ Spilled electrolyte must be neutralised at once using a lot of water.
NOTICE Changing to the correct battery type

Only change to a battery that meets the data given on the product identification plate. The weight of the battery affects
the stability and braking capacity of the truck. Information on the minimum permitted battery weight is on the product
identification plate.
WARNING Risk of centre of gravity shifting

A battery weight that is too low gives impaired stability and braking capacity.
► The battery weight must be in accordance with the data on the truck’s identification plate.
WARNING Battery acid may cause burns

Battery acid may cause burns.
► If battery acid gets onto your skin or clothes, flush immediately with cold water.
► If you get battery acid in the face or in the eyes, immediately flush the area with cold water and seek medical as-
sistance.
2.4 Safe lifting

2.4
Safe lifting
When lifting the product, remember that:
▷ All lifting must be carried out on a level, non-slip and stable surface. Asphalt surfaces should be avoided if pos-
sible.
▷ To prevent the product moving while it is being lifted, it must not be lifted with anyone on the platform or with the
tiller arm in the lowered position.
▷ If the drive wheel which is braked, is being lifted, the other wheels must be blocked to stop the product from mov-
ing.
▷ Select the lifting point so that the lift is as light as possible, for example one corner at a time. If there are lifting
points indicated on the lower part of the chassis, these must be used to ensure balanced lifting.
▷ Make sure the surface where the jack is placed is clean and free of oil and grease.
▷ Make sure your hands and the jack lever are free of grease and oil.
▷ Only use the lever supplied with the jack. If the lever is too short, more exertion than is necessary will be re-
quired. If the lever is too long, there is a risk that the jack will be overloaded.
▷ Never work under a product that is not supported by trestles and secured by a lifting device.
▷ Never work under a raised product without it being properly supported on trestles.
▷ Never support the jack on trestles to achieve a higher lift.
Put trestles:

Product modification
▷ as close to the lifted part of the chassis as possible in order to reduce the falling height if the product should col-
lapse.
▷ so that no wheels may turn causing the product to move.
2.5 Product modification

2.5
Product modification
Any modification of the product must be approved beforehand. No modification of product may be performed that may in-
fluence the capacity, stability and safety of the product without prior written approval from the manufacturer, its repres-
entative or successor.
In the case of the manufacturer no longer being in business and there being no successor, the user of the product may
arrange for modifications on the precondition that the user:
▷ makes sure that an engineer with expert knowledge of the product type and its safety designs, tests and imple-
ments the modification,
▷ files all documentation of the design, tests and implementation of the modification,
▷ approves and makes the applicable changes to the capacity plate, adhesive labels, markings and operator’s
manual,
▷ affixes a permanent and well visible sign to the product stating how the product has been modified, together with
the date of the modification and the name and address of the company that carried out the modification work.
2.6 Software
2.6
Software
Erroneous handling of the product systems and/or the external systems of the product may affect the safety of the
product and the environment.
1. Always make sure that the correct software is downloaded to the product.
2. In case of parameter adjustments, the recommended values must be respected.
3. Only adjust one parameter at the time when performing changes to the truck. Check the function after each ad-
justment.
4. Change the parameters in small increments.
2.7 Hydraulic system

2.7
Hydraulic system
When working on the hydraulic system, keep the following in mind:
▷ Lower the forks completely and keep pressing the button for another 5 - 10 seconds to relieve system pressure.
▷ The hydraulic oil may be hot.
▷ Only fill the hydraulic system with new and clean oil.

Operating principle 3
3.1 Description ......................................................................................................................................................... 3 - 1
3.1.1 Battery is connected ............................................................................................................................ 3 - 1
3.1.2 Login via keypad.................................................................................................................................. 3 - 1
3.1.3 Login via “ID key” option ...................................................................................................................... 3 - 1
3.1.4 Tiller arm lowered for driving ............................................................................................................... 3 - 1
3.1.5 Driving in fork direction ........................................................................................................................ 3 - 2
3.1.6 Driving in the drive wheel direction ...................................................................................................... 3 - 2
3.1.7 Braking in neutral................................................................................................................................. 3 - 2
3.1.8 Reverse braking .................................................................................................................................. 3 - 3
3.1.9 Mechanical braking.............................................................................................................................. 3 - 3
3.1.10 Emergency reversal............................................................................................................................. 3 - 3
3.1.11 Fork lifting ............................................................................................................................................ 3 - 4
3.1.12 Fork lowering ....................................................................................................................................... 3 - 4

3 Operating principle

Description
3
Operating principle
3.1 Description
3.1
Description
3.1.1 Battery is connected

3.1.1
Battery is connected
3
Event: 1 Battery is connected
Previous event -
Action(s) Battery [G1], page 19 - 2is connected
Influencing elements Main fuse [F1], page 19 - 2 OK
Power circuit fuse [F50], page 19 - 2[F51], page 19 - 2[F52], page
19 - 2[F53], page 19 - 2 OK
Resulting conditions Login possible
3.1.2 Login via keypad

3.1.2
Login via keypad
Event: 2 Login via keypad

Previous event Battery is connected, page 3 - 1
Action(s) Log in with a PIN code and press the ON button [S223], page 19 - 3
Influencing elements Emergency stop Nödstopp not activated
Drive mode sensor [B60], page 19 - 2 deactivated
Input T1:INP TILL. ARM IN DRIV. POS is {low}
Resulting conditions Battery indicator lamp is lit. The display [P6], page 19 - 3 shows the hour counter
for 5 seconds, followed by battery status (% of full charge)
The mechanical brake [Q1], page 19 - 3 must remain actuated
T1:OUT.BRAKE RELEASE {high}
3.1.3 Login via “ID key” option

3.1.3
Login via “ID key” option
Event: 3 Login via “ID key” option

Previous event Battery is connected, page 3 - 1
Action(s) Log in with an ID key and press the ON button [S223], page 19 - 3
Influencing elements Emergency stop Nödstopp not activated
Drive mode sensor [B60], page 19 - 2 deactivated
Input T1:INP TILL. ARM IN DRIV. POS is {low}
Resulting conditions Battery indicator lamp is lit. The display [P6], page 19 - 3 shows the hour counter
for 5 seconds, followed by battery status (% of full charge)
The mechanical brake [Q1], page 19 - 3 must remain actuated
T1:OUT.BRAKE RELEASE {high}
3.1.4 Tiller arm lowered for driving

3.1.4
Tiller arm lowered for driving
Event: 4 Tiller arm lowered for driving

Previous event Login via keypad, page 3 - 1
Login via “ID key” option, page 3 - 1

Description
Event: 4 Tiller arm lowered for driving

Action(s) Lower tiller arm
Influencing elements Sensor [B60], page 19 - 2 for tiller arm in drive mode
Resulting conditions Sensor [B60], page 19 - 2 for tiller arm in drive mode activated T1:INP.TILLER
ARM IN DRIVE POS {high}
Main contactor output goes {low} T1:OUT.MAIN CONTACTOR.
Main contactor [Q1], page 19 - 3 closes
3.1.5 Driving in fork direction

3.1.5
Driving in fork direction
Event: 5 Driving in fork direction

Previous event Tiller arm lowered for driving, page 3 - 1
Action(s) Move the speed control [L1] in the fork direction
Influencing elements Hall element in speed control [A5:S310-S318]
Parameter settings
Resulting conditions T1:OUT.BRAKE RELEASE goes {low}
Brake coil [Q1], page 19 - 3 is energised, mechanical brake is released
Pulsed current is fed to the drive motor in proportion to the position of the speed
control
3.1.6 Driving in the drive wheel direction

3.1.6
Driving in the drive wheel direction
Event: 6 Driving in the drive wheel direction

Previous event Tiller arm lowered for driving, page 3 - 1
Action(s) Move the speed control [L1] in the drive wheel direction
Influencing elements Direction indicator's Hall element [A5:S300-S308]
Parameter settings
Resulting conditions T1:OUT.BRAKE RELEASE goes {low}
Brake coil is energised, mechanical brake [Q1], page 19 - 3 released
Pulsed current is fed to the drive motor [M1], page 19 - 3 proportionally to the po-
sition of the speed control [L1]
3.1.7 Braking in neutral

3.1.7
Braking in neutral
Event: 7 Braking in neutral

Previous event Driving in fork direction, page 3 - 2
Driving in the drive wheel direction, page 3 - 2
Action(s) Allow the speed control [L1] to return to the neutral position
Influencing elements Parameter settings4, page 4 - 3

Description
Event: 7 Braking in neutral

Resulting conditions The drive motor [M1], page 19 - 3 works as a generator and converts the kinetic
energy of the truck into electrical energy via the transistor regulator [T1], page
19 - 3. This reduces the speed of the truck.
The excess energy is fed back to the battery [G1], page 19 - 2
3
The mechanical brake[Q1], page 19 - 3 is activated when the truck comes to a
complete stop
T1:OUT.BRAKE RELEASE goes {high}
3.1.8 Reverse braking

3.1.8
Reverse braking
Event: 8 Reverse braking

Action(s) The speed control [L1] is moved to the opposite driving direction
Influencing elements Parameter settings201, page 4 - 6
Resulting conditions The drive motor [M1], page 19 - 3 works as a generator and converts the kinetic
energy of the truck into electrical energy via the transistor regulator [T1], page
19 - 3. This reduces the speed of the truck.
The excess energy is fed back to the battery [G1], page 19 - 2
The mechanical brake[Q1], page 19 - 3 is activated when the truck comes to a
complete stop
3.1.9 Mechanical braking

3.1.9
Mechanical braking
Event: 9 Mechanical braking

Action(s) Raise or lower the tiller arm
Influencing elements Sensor [B60], page 19 - 2 for tiller arm in drive mode
Resulting conditions Input T1:INP TILL. ARM IN DRIV. POS goes {low}
Brake reduction until the truck is stationary
Brake coil is deactivated, mechanical brake[Q1], page 19 - 3 is applied
3.1.10 Emergency reversal

3.1.10
Emergency reversal
Event: 10 Emergency reversal

Previous event Driving in the drive wheel direction, page 3 - 2
Action(s) When driving in the drive wheel direction, the emergency reversal button is
pressed
Influencing elements Emergency reversal

Description
Event: 10 Emergency reversal

Resulting conditions The Hall sensor [A5:S317] is immediately activated. The card [A5], page 19 - 2
interprets this signal as a command to the transistor regulator [T1], page 19 - 3 to
run the drive motor[M1], page 19 - 3 at a reduced speed in the fork direction as
long as the button is pressed. The normal drive command signal received from [L1]
is blocked until [L1] is released and returns to neutral position.
3.1.11 Fork lifting

3.1.11
Fork lifting
Event: 11 Fork lifting

Action(s) Press the button for fork lift
Influencing elements Main contactor [Q10], page 19 - 3
Fuse [F1], page 19 - 2
Fork lifting button
Battery status OK (>20% capacity remaining)
Lift height limitation [B61], page 19 - 2
T1:INP.LIFT LIMIT not activated
Resulting conditions The pump motor [M3], page 19 - 3 starts
3.1.12 Fork lowering

3.1.12
Fork lowering
Event: 12 Fork lowering

Fork lifting, page 3 - 4
Action(s) Press the fork lowering button
Influencing elements Fork lowering button
Main contactor [Q10], page 19 - 3
Resulting conditions T1:OUT. LOWER VALVE goes {low}
The proportional valve [Q4], page 19 - 3 opens

Parameters 4
4.1 Software............................................................................................................................................................. 4 - 1
4.2 Display/change parameters ............................................................................................................................... 4 - 1
4.3 Parameters in general........................................................................................................................................ 4 - 1
4.4 Parameters on commissioning........................................................................................................................... 4 - 2
4.4.1 Setting parameters .............................................................................................................................. 4 - 2
4.4.2 Setting collision sensor parameters (option) ....................................................................................... 4 - 2
4.4.3 Setting battery parameters .................................................................................................................. 4 - 2
4.5 Parameter list..................................................................................................................................................... 4 - 2

4 Parameters

4 Parameters
Software
4 Parameters
4
Parameters
4.1 Software
4.1
Software
Erroneous handling of the product systems and/or the external systems of the product may affect the safety of the
product and the environment.
4
1. Always make sure that the correct software is downloaded to the product.
2. In case of parameter adjustments, the recommended values must be respected.
3. Only adjust one parameter at the time when performing changes to the truck. Check the function after each ad-
justment.
4. Change the parameters in small increments.
4.2 Display/change parameters

4.2
Display/change parameters
CAN key 7516707, page 21 - 7

1. Ensure that the truck is switched off. Connect the CAN key or enter the PIN code.
Do not press the ON switch.
Before any service parameter can be changed, the CAN service key must be connected to the contact [X41].
2. Press and then release the horn button. “Info“ is shown on the display.
3. Move between menus by turning the speed control several times.
4. “Par” is shown on the display.
5. Press the horn button to select. The parameter symbol lights up.
6. You move along in the parameter list by pressing the speed control repeatedly.
To show a parameter, release the speed control when the required parameter is shown on the display. Press the horn
button to change the parameter.
4.3 Parameters in general

4.3
Parameters in general
The control system can store a number of different parameters. These are used to configure the product according to the
task to be performed. The parameters are divided into groups:
• Operator parameters (1-100)

The operator parameters are used to adapt truck's characteristics to a specific operator or work task. A number of
sets of operator parameters can be stored.
Operator parameters are displayed and changed only for a selected operator, but if a CAN service key is connec-
ted, the parameters for all operators can be displayed and changed. Operator parameters can be changed by the
operator if the truck's program is set up for this.
• Service parameters (101-1000)
Used to adjust the functional performance of the truck. The service parameters can be changed once a suitable
CAN service key or TruckCom has been connected to the truck. Please note that the service parameters can be
checked without any need for plugging in a CAN service key; however it is then not possible to change the values.
• Factory parameters (1001-1250)
Truck-specific parameters pre-set at the factory. These can be changed by a service technician if special needs
arise.
The parameters specify e.g. the model and which controls to use for the hydraulic function. The factory paramet-
ers are changed via TruckCom and cannot be changed via the CAN service key.
• Calibration parameters (1251-1300)
Stores the value generated during calibration of valves, potentiometers, etc. These should not normally be
changed.
The parameters can be changed once a suitable CAN service key or TruckCom has been connected to the truck.
All parameters can be changed via TruckCom (refer to the separate TruckCom manual).

4 Parameters
Parameters on commissioning
4.4 Parameters on commissioning

4.4
Parameters on commissioning
4.4.1 Setting parameters

4.4.1
Setting parameters
1. This chapter covers only those parameters that need to be set when commissioning the truck and which, as a
result, require a more detailed description. For information about other parameters, see Parameters, page 4 - 1.
Check to make sure all parameters are set to the desired values in terms of
- speed
- acceleration
- deceleration
- collision sensor
- battery
When checking or setting parameters, remember to note down the truck's specific parameter values, for example
in a truck report. This separate information on truck-specific parameters can come in handy, e.g. in case of
downtime, since the information is not available elsewhere.
4.4.2 Setting collision sensor parameters (option)

4.4.2
Setting collision sensor parameters (option)
Collision sensitivity parameters must be set during truck installation.
1. If there is a collision sensor installed on the CAN bus, it registers when the truck bumps into something. If a colli-
sion exceeds a certain force, set by parameters Collision sensor sensitivity in X and Collision sensor sensitivity in
Y, it is interpreted as a collision, and the truck travel speed is reduced to creep speed, a signal is heard and error
code The collision sensor has registered a collision is displayed.
Information about the collision is stored in the truck's internal memory. The last ten registered collisions can be
read directly from the display together with operator identity via the PIN code. Additional information is available
via TruckCom, where collision levels and time indications can also be read.
4.4.3 Setting battery parameters

4.4.3
Setting battery parameters
1. Set or check parameter Battery size when installing the battery. See parameter 107 Battery size.
Even if the battery comes with the truck from the factory, the parameters must be set or checked.
4.5 Parameter list

4.5
Parameter list
Software: 7528678
4.5.1 Operator parameters
The operator parameters can be adjusted individually to the available log-in profiles. The parameter’s connection to the
operator is done by a combination of operator and parameter numbers where the single digit always corresponds to the
parameter.
Operator profile Parameter range

1 1-7
2 11-17
3 21-27
4 31-37
5 41-47
6 51-57
7 61-67
8 71-77

4 Parameters
Parameter list
9 81-87
10 91-97
Tab. 1: Connection to logged-in operator
The maximum travel speed can also be limited by factory parameter 1044, page 4 - 22 and it is always the lowest speed
for a parameter that is the limiting one.
No. Designation See section Valid for 4

1 Max. speed, in fork direction, page 4 - 3 4.5.1.1 General, page
4-3
2 Maximum speed, in drive wheel direction, page 4 - 3 4.5.1.1 General, page
4-3
3 Acceleration , page 4 - 3 4.5.1.1 General, page
4-3
4 Automatic speed reduction, page 4 - 3 4.5.1.1 General, page
4-3
5 Maximum speed, gates are down, page 4 - 3 4.5.1.1 General, page
4-3
6 Max. speed, walk-along mode, page 4 - 3 4.5.1.1 General, page
4-3
7 Maximum speed, forks above 1.8 m, page 4 - 4 4.5.1.1 General, page
4-3
4.5.1.1 General
No. Designation Min Std. Max Step Unit

1 Max. speed, in fork direction 30 100 100 5 %
Adjusts the maximum speed of the truck in the fork wheel direction, with gates up and operator on the platform

2 Maximum speed, in drive wheel direction 30 100 100 5 %
Adjusts the maximum speed of the truck in the drive wheel direction, with gates up and operator on the platform

3 Acceleration 10 100 100 5 %
The lower the parameter value, the more time is needed to accelerate to the maximum speed.

4 Automatic speed reduction 40 100 100 5 %
Defines plug braking force when the operating control [L1] returns to the neutral position. The lower the value of para-
meter, the longer it takes to reduce speed.

5 Maximum speed, gates are down 30 100 100 5 %
Adjusts the maximum speed of the truck for this application, with gates down and operator on the platform

6 Max. speed, walk-along mode 30 100 100 5 %

4 Parameters
Parameter list
Adjusts the truck’s maximum speed when the operator is not on the platform, platform is up and the gates down, i.e.
when the operator walks alongside the truck.

7 Maximum speed, forks above 1.8 m 30 100 100 5 %
Adjusts the maximum speed of the truck when the forks are above 1.8 m
Maximum travel speed" forks above 1.8 m is set as a % of the value of service parameter 203, page 4 - 6
4.5.2 Service parameters

Before any service parameter can be changed, the CAN service key must be connected to the truck.

4 Parameters
Parameter list
Changing specific truck parameters changes the truck's driving properties. Do not change any parameter values without
the necessary know-how.

4 Parameters
Parameter list
No. Designation See section Valid for

101 Service intervals, page 4 - 8 4.5.2.1 General, page
4-8
102 Operator access, page 4 - 8 4.5.2.1 General, page
4-8
103 Start-up display, page 4 - 8 4.5.2.1 General, page
4-8
104 Time to automatic log-out, page 4 - 9 4.5.2.1 General, page
4-8
105 Impact sensor sensitivity for X, page 4 - 9 4.5.2.1 General, page
4-8
106 Impact sensor sensitivity for Y, page 4 - 9 4.5.2.1 General, page
4-8
107 Battery size, page 4 - 9 4.5.2.1 General, page
4-8
109 Battery type, built-in charger, page 4 - 10 4.5.2.1 General, page
4-8
110 Battery size, built-in charger, page 4 - 11 4.5.2.1 General, page
4-8
111 Resetting procedure after collision, page 4 - 11 4.5.2.1 General, page
4-8
112 Erase application data, page 4 - 11 4.5.2.1 General, page
4-8
201 Deceleration when reversing, page 4 - 11 4.5.2.1 General, page
4-8
202 Maximum speed Turtle mode activated, page 4 - 12 4.5.2.1 General, page
4-8
203 Maximum speed, forks above 1.8 m, page 4 - 12 4.5.2.1 General, page
4-8
204 Maximum acceleration, forks above 1.8 m, page 4 - 12 4.5.2.1 General, page
4-8
205 Max. retardation on reversing, forks over 1.8 m, page 4 - 12 4.5.2.1 General, page
4-8
206 Automatic speed reduction, forks above 1.8 m, page 4 - 12 4.5.2.1 General, page
4-8
207 Deactivate the possibility to control the truck when walking 4.5.2.1 General, page
alongside it., page 4 - 12 4-8
208 Limitation of max. speed with forks fully lowered, page 4 - 12 4.5.2.1 General, page
4-8
208 Limitation of max. speed with support arms fully lowered, page 4.5.2.1 General, page
4 - 13 4-8
209 Minimum fork/support arm lifting height to exit limited speed set 4.5.2.1 General, page
with parameter 208, page 4 - 13 4-8
211 Automatic speed reduction (Built-in), page 4 - 13 4.5.2.1 General, page
4-8
212 Automatic speed reduction (Built-in), page 4 - 13 4.5.2.1 General, page
4-8

4 Parameters
Parameter list

220 Min. steering angle for initiation of speed limitation, page 4 - 13 4.5.2.1 General, page
4-8
222 Max. speed at full speed limitation, page 4 - 14 4.5.2.1 General, page
4-8
223 Max. steering angle for full speed limitation, page 4 - 15 4.5.2.1 General, page 4
4-8
250 Min. steering resistance (TFD) in drive wheel direction, page 4.5.2.1 General, page
4 - 15 4-8
251 Max. steering resistance (TFD) in drive wheel direction, page 4.5.2.1 General, page
4 - 15 4-8
252 Min. steering resistance (TFD) in fork direction, page 4 - 16 4.5.2.1 General, page
4-8
253 Max. steering resistance (TFD) in fork direction, page 4 - 16 4.5.2.1 General, page
4-8
304 Support arm lowering speed, page 4 - 16 4.5.2.1 General, page
4-8
307 Automatic support arm lowering (On/Off), page 4 - 16 4.5.2.1 General, page
4-8
311 Indication of load weight, page 4 - 16 4.5.2.1 General, page
4-8
312 Pressure equalization, page 4 - 17 4.5.2.1 General, page
4-8
313 Support arm lift speed, page 4 - 17 4.5.2.1 General, page
4-8
314 Deactivate lifting above 1.8 m, page 4 - 17 4.5.2.1 General, page
4-8
320 Reach speed, page 4 - 17 4.5.2.1 General, page
4-8
321 Maximum load, both forks, page 4 - 17 4.5.2.1 General, page
4-8
322 Option switch 1, page 4 - 17 4.5.2.1 General, page
4-8
4-8
4-8
4-8
4-8
4-8
329 Tilt speed , page 4 - 18 4.5.2.1 General, page
4-8
330 Sideshift, page 4 - 18 4.5.2.1 General, page
4-8

4 Parameters
Parameter list

331 Fork spread function , page 4 - 18 4.5.2.1 General, page
4-8
499 License key, page 4 - 18 4.5.2.1 General, page
4-8
501 Steering response, page 4 - 19 4.5.2.1 General, page
4-8
4.5.2.1 General

101 Service intervals 0 0 2000 50 h
This parameter determines the time value (in hours) to the next service from 0 to 2000 hours in increments of 50 hours.
Whenever this value is changed, the timer is reset and will start to count the truck activity time. On reaching the set
value, code “S - 0h” is shown on the display and the red LED flashes.
If the value is set as '0', no service interval is given.

102 Operator access 1 3 10 1
Specifies which login method should be used and if the operator will have the possibility of changing the operator para-
meter settings.
Values 1 and 2 = Key
Values 3 and 4 = Keypad with up to 100 PIN codes.
Values 5 and 6 = Keypad with DHU
Values 7 and 8 = ID unit
Values 9 and 10 = SA2
Odd values = Operator parameters are open and can be changed by the operator.
Even values = Operator parameters can only be changed with a CAN key connected.

103 Start-up display 1 2 5 1
Sets which value is shown on the display when the truck is started.
When the truck is started, one of the truck's 5 values is shown on the hour meter display "H" (hour meter display) for 5
seconds. After the menu has disappeared, the battery capacity is continuously shown in the numeric field at the same
time as the battery indicator is lit.
The truck control system stores five different time values. "Value 2 - Operating time" is the default value on the start-up
display.
Hour meter values Display

Value 1 = (A) Key time
The total time the truck has been in use.
Value 2 = (B) Operating time

Combined time during which the pump or drive motor
has been in operation. Default display.
Value 3 = (C) Drive motor time
The total time the drive motor has been in operation.

4 Parameters
Parameter list
Hour meter values Display

Value 4 = (D) Pump motor time
Total time the pump motor has been in operation.
Value 5 = (S) Remaining time until next service.

Parameter 101 controls the initial value.
4
104 Time to automatic log-out 0 20 20 1 min.
Gives the time, in minutes, before automatic log-out if the truck is inactive.
If the value is set as ‘0’, logout takes place after 4 hours.

105 Impact sensor sensitivity for X 0 0 100 1
Indicates the degree of sensitivity for what should be interpreted as a frontal/rear-end impact. 0 = Impact sensor not ac-
tivated.

106 Impact sensor sensitivity for Y 0 0 100 1
Indicates the degree of sensitivity for what should be interpreted as a side impact. 0 = Impact sensor not activated.

107 Battery size 1 12 27 1
Specifies what type of battery the truck is equipped with.

The parameter can be used to compensate for different ways of driving by:
• increasing the value to discharge the battery even more.
• reducing the value if the battery is discharged too much.
In order to set the meter for battery charge level, consideration must be given to the following:
• Electrolyte density when the battery is fully charged in order to check the quality of the battery. This value should be
between 1.27 and 1.29.
Please note that the acid density may vary between different types of battery.
• When the lifting capacity is disabled (battery 80% discharged), the value must be close to (but not below) 1.14.
Refer to the table below for recommended parameter settings.
Parameter 107 Lead/acid bat- Gel battery

tery
Slight discharge 1
2
3 581-650 Ah
4 480-580 Ah
5 381-480Ah
6 281-380 Ah
7 ≤280Ah
8
9
10

4 Parameters
Parameter list
Parameter 107 Lead/acid bat- Gel battery

tery
11 ≥601Ah
12 401-600Ah
13 210-400 Ah
14 ≤209Ah
15
16
17
18
19
20
21
22
23
24
25
26
Deeper discharge 27
Verifying parameter settings for freely ventilated batteries (lead-acid batteries)

1. Charge the battery.
2. Use the truck in its normal application until the battery indicator shows a discharged battery (0% on the display).
3. Disconnect the battery from the truck and allow it to rest for at least two minutes. Note: Do not charge or discharge
during this time.
4. Measure the specific gravity of the electrolyte at ambient temperature.
Reduce the parameter value if the specific gravity is below 1.15 g/cm3.
If the value is considerably higher than 1.15 g/cm3, the risk of damage to the battery is reduced. At the same time, the
operating time of the truck is reduced. If extended operating time is desired, then increase the parameter value by no
more than one unit.
Note: Each change should be followed up by a new verification of the parameter setting.
Verifying the parameter setting for valve-regulated batteries (Exide)
1. Charge the battery.
2. Operate the truck in its normal application until the battery indicator indicates a discharged battery (0% in the display).
3. Disconnect the battery from the truck and allow it to rest for at least two hours. Note: Do not allow any charging or dis-
charging during this time.
4. Measure the battery voltage at room temperature.
If the voltage is less than Uend (see the table below), the parameter value must be reduced. If the value exceeds Uend
considerably, the risk of causing damage to the battery is reduced. At the same time, however, the operating time of the
truck decreases. If extended operating time is desired, then increase the parameter value, but maximum by one unit.
Note: Each change should be followed up by a new verification of the parameter setting.
Battery type Battery voltage while resting,

Uend
Exide 24.24 V

109 Battery type, built-in charger 0 0 3 1
Repair manual 7572514 en 4 - 10

4 Parameters
Parameter list
Sets the type of battery in case of built-in charger. This parameter has no use unless there is a built-in charger.
#0 = No charging
#1 = Lead/acid battery
#2 = Hawker Evolution battery
#3 = Exide gel battery
4
110 Battery size, built-in charger 100 100 350 1 Ah
Sets the battery size used with the built-in charger so the correct charging current is used. For Hawker Evolution only the
sizes 134 Ah, 174 Ah and 201 Ah are approved. This parameter has no use unless there is a built-in charger.

111 Resetting procedure after collision 0 0 3 1
Specifies the condition for how the truck is to be taken into operation again after the impact sensors have been triggered.
Value 0 default = The horn sounds immediately in case of a collision, and then every 5 seconds until the truck is reset.
Value Function
0 Std. setting.
1 The operator can reset the truck; only if the impact
sensor is managed by the truck.
2 Deactivates the horn sounding every 5 seconds.
3 Options 1 and 2 combined
The PIN code to be activated for resetting can be found in operator profile 1 and special block 10. See section “6.6.1 Set-
ting impact sensor parameters (option)”.

112 Erase application data 0 0 2 1
Specifies whether information from the histogram/impact sensor is to be deleted at login.
Value Function
0 Do not clear
1 Clear histogram at start-up
2 Clear collision log at start-up
The histogram data consists of the logged motor temperature, motor control and steering motor in the form of a histo-
gram. You clear this data by setting parameter 112 =1. This is useful when transferring the truck from one client to an-
other.
The collision log is a log with the 10 latest collisions are stored together with the operator PIN code. You clear this data
by setting parameter 112 =2.

201 Deceleration when reversing 70 100 100 5 %
Sets how hard the truck will brake when the speed control is turned in the opposite direction, and used to get a smoother
deceleration where the application requires this for all operator profiles.
100% = 2.5 m/s2
Parameter 201 is set to 70% on all trucks with forks shorter than 1500 mm, and with a small battery compartment.
4 - 11 Repair manual 7572514 en

4 Parameters
Parameter list

202 Maximum speed Turtle mode activated 0.5 4.0 6.0 0.5 km/h
Sets the maximum speed when Turtle mode is activated.

203 Maximum speed, forks above 1.8 m 0.5 6.0 6.0 0.5 km/h
Not valid for LPE200, LPE220, LPE250
Sets the maximum speed when the forks are above 1.8 m.

204 Maximum acceleration, forks above 1.8 m 10 50 60 5 %
Sets the maximum acceleration when the forks are above 1.8 m. As a percentage of maximum acceleration for this ap-
plication.

205 Max. retardation on reversing, forks over 1.8 m 45 80 80 5 %
Sets the max. retardation on reversing when the forks are above 1.8 m. As a percentage of max. retardation on reversing
for this application.

206 Automatic speed reduction, forks above 1.8 m 45 60 80 5 %
Sets the automatic speed reduction when the forks are above 1.8 m. As a percentage of maximum speed reduction for
this application.

207 Deactivate the possibility to control the truck when walking 0 0 1 1
alongside it.
This parameter is used to deactivate the possibility of the operator operating the truck with the tiller arm while walking
alongside the truck (i.e. not standing on the platform).
Value Function
0 Activated
1 Deactivated

208 Limitation of max. speed with forks fully lowered 0.5 12.5 12.5 0.5 km/h
Limits the maximum speed when the forks are fully lowered. This option requires that a pressure sensor Load detection
is installed. This is helpful when you are operating on uneven floors and do not want excessive wear to the forks.

4 Parameters
Parameter list

208 Limitation of max. speed with support arms fully lowered 0.5 12.5 12.5 0.5 km/h
Limits the maximum speed when the support arms are fully lowered. This option requires that a sensor Support arm in
bottom position is installed. This is helpful when you are operating on uneven floors and do not want excessive wear to
the support arms. 4
209 Minimum fork/support arm lifting height to exit limited speed set 10 10 50 1 ms
with parameter 208
The required lifting time that the hydraulic pump must be active/lift the forks/support arms above the floor (in increments
of 20 ms) to exit limited speed set with parameter 208.

211 Automatic speed reduction (Built-in) 25 25 100 5 %
Specifies automatic speed reduction when the photocell [B124], page 19 - 2[B125], page 19 - 2 is broken for more
than 500ms. As a percentage of maximum speed reduction for this application.
The light beam must be broken for more than 500 ms in order for the feet to be detected as outside the platform.
Validity set using parameter 212, page 4 - 6.
0 Speed reduction, inactive if the travel speed is 6 km/h or

more.
1 Speed reduction, always active.
Tab. 4: 212

212 Automatic speed reduction (Built-in) 0 0 1 1 -
Automatic braking on trucks with fixed side guards when interrupting the beam of the photocell [B124], page
19 - 2[B125], page 19 - 2.
The photocell must be broken for more than 500 ms in order for the feet to be detected as outside the platform.
The speed reduction is set using parameter 211, page 4 - 6.
0 Speed reduction, inactive if the travel speed is 6 km/h or

more.
1 Speed reduction, always active.
Tab. 5: 212

220 Min. steering angle for initiation of speed limitation 1 5 10 1 °
Parameters 220, 222, 223 are used to adjust the maximum speed when taking corners.
This parameter is used to set when speed reduction during cornering should begin. Set in degrees between 1 and 10º
A lower angle produces a milder nature during cornering.
This parameter is set (default) to 10° on LPE.

4 Parameters
Parameter list
14
10°
12
5°
10
1°
8
Y
6
0
0 20 40 60 80 100
X
X Steering angle
Y Maximum speed

222 Max. speed at full speed limitation 2.5 See the 6.3 0.1 km/h
table
This parameter is used to determine the speed when full speed limitation is achieved during cornering. Set in km/h and is
dependent on the wheel base of the truck; see the table below.
A higher speed here produces gentler braking, but a higher curve speed.
dm
Wheel Parameter 222

base (dm) (km/h)
15 4.8
16 5.0
17 5.1
18 5.3
19 5.4
20 5.6
21 5.7
22 5.9
23 6.0
24 6.2
25 6.3

4 Parameters
Parameter list
14
6,3 Km/h
12
4,5 Km/h
2,5 Km/h
10
8
Y
6
4
4
0
0 20 40 60 80 100
X

223 Max. steering angle for full speed limitation 30 60 75 1 °
This parameter is used to set when speed reduction during cornering should end. Set in degrees between 30 and 75º
A higher value produces gentler braking, but allows a higher curve speed quote far into the turn.
This parameter is set (default) to 75° on LPE.
14
30°
12
50°
10 75°
8
Y
6
0
0 20 40 60 80 100
X

250 Min. steering resistance (TFD) in drive wheel direction 0 20 100 5 %
TFD (Tactile Feedback Device)

All trucks with power steering also have a TFD. The TFD is used to both measure the tiller arm angle and to produce res-
istance in the tiller arm. This resistance is set with parameters 250-253. 100% = 1000 mA, 0% = 0mA. If the minimum
parameters Min. steering resistance (TFD) in drive wheel direction or Min. steering resistance (TFD) in fork direction are
set to a higher value than the maximum parameters Max. steering resistance (TFD) in drive wheel direction or Max.
steering resistance (TFD) in fork direction, the lowest value will be used.
This parameter is used to set the minimum steering resistance in the drive wheel direction.

251 Max. steering resistance (TFD) in drive wheel direction 0 100 100 5 %

4 Parameters
Parameter list
For built-in (E-man steering arm) 60% is the standard value
This parameter is used to set the maximum steering resistance in the drive wheel direction.

252 Min. steering resistance (TFD) in fork direction 0 20 100 5 %

This parameter is used to set the minimum steering resistance in the fork direction.

253 Max. steering resistance (TFD) in fork direction 0 100 100 5 %

This parameter is used to set the maximum steering resistance in the fork direction.

304 Support arm lowering speed 10 45 60 5 %
This parameter controls how much the proportional valve opens when lowering the support arms, and thus controlling the
lowering speed.

307 Automatic support arm lowering (On/Off) 0 2 3 1
Controls whether the support arms should be lowered automatically when the forks reach the 1.8 m sensor.1.8 m sensor
Value Function
0 Inactivated
1 Activated = Fork lifting is temporarily stopped
2 Activated = Fork lifting continues
3 Activated = Support arms are automatically lowered
each time the forks are lifted even if the forks are below
the 1.8 m sensor.1.8 m sensor

311 Indication of load weight 0 0 2 1 Kg

4 Parameters
Parameter list
Indication of load weight in kg, based on hydraulic pressure

The display automatically shows the load weight in increments of,
1 = Weight indication on support arm lift, 100 kg.
2 = Weight indication on fork lift, 50 kg.
if the support arms/forks are lowered shorter than 300 ms. The load weight is shown on the display for four seconds.
Calibration sequence 13 must be run before you use “Weight indication on fork lift value 2” for the first time.
Value Function 4
0 No weight indication activated
1 Weight indication on support arm lift
2 Weight indication on fork lift

312 Pressure equalization 0 0 5 1 ms
Activates and controls a pressure equalization pulse after a lift. This is to equalize the pressure, and to get a better
measurement of the load weight. Is set to 0 to switch off the function (standard). If it is set to a higher value than 0, the
duration of the lowering pulse will be a multiple of the parameter value 20 ms. The truck must have a pressure sensor
Load detection to enable the function.

313 Support arm lift speed 10 40 40 5 %
Specifies the lift speed of the support arms.

314 Deactivate lifting above 1.8 m 0 0 1 1
Deactivate lifting above 1.8 m
0 Off
1 On

320 Reach speed 10 30 50 5
Adjusting the speed of the reach movement

321 Maximum load, both forks 500 1000 1200 50
Maximum load, the total for both forks

322 Option switch 1 0 0 4 1
Hydraulic function for option switch 1

4 Parameters
Parameter list






329 Tilt speed 5 30 50 5
Adjusting the tilt movement speed

330 Sideshift 5 10 50 5
Adjusting the side-shift movement speed

331 Fork spread function 5 10 50 5
Adjusting the fork spread movement speed.

499 License key
This parameter is only used for field test software

4 Parameters
Parameter list
Error code 2:012, page 7 - 13 is shown is case of erroneous license

501 Steering response 130 1280 1280 10
Adjusts the steering sensitivity. A higher value gives a faster steering reaction. (A more aggressive steering)
4.5.3 Factory parameters 4
WARNING Risk of personal injury or material and property damage.

All factory parameters affect the truck's configuration and performance. Changes may only be made by a person who
has undergone training concerning parameter setting and who can verify having a good knowledge of how the truck is
affected in the event of changes to the factory parameters and how changes to factory parameters are made.
Note:
The truck's factory parameters are preset in the truck during production at the factory. Factory parameters can only be
changed using the TruckCom software application. Changes to the factory parameters are registered in the truck's soft-
ware. The registration indicates the time of the change and the person who performed it.
Factory parameters # 1003 to 1042 - configurable optional functions
Parameters #1003 to #1042 are reserved in the truck’s control system for extra truck options and/or special product
modifications. The parameters configure and control the Spider expansion unit (SEU) that must be fitted to the truck, in
some cases it is enough to have an empty I/0 in the motor control. This method of implementation enables use of the
standard program. This eliminates the need for any special program. Normally, these parameters are configured by the
manufacturer when the truck is modified or customised. It is advisable to upload the parameter settings from the truck
when carrying out any modification. If the main control unit [A2] has been replaced, the original parameter settings can
be transferred to the new unit, thus ensuring that special options function correctly. Factory parameter no. #1003, #1008,
#1013, #1018, #1023, #1028, #1033 and #1038 can be adjusted to allow up to a maximum of 8 pre-programmed "Basic
options" to be activated and configured to suit a specific special option or customisation.
Activation of optional functions
The system can use up to eight configurable optional functions simultaneously. Each configurable function is controlled
by five factory parameters. During activation, an index parameter (#1003, #1008, #1013, #1018, #1023, #1028, #1033,
#1038) must first be set to a value equivalent to an optional function. Four parameters that can be modified to configure
the optional function are linked to each index parameter. The index parameter is allocated one optional function (optional
function is determined).

4 Parameters
Parameter list
Each optional function can have up to 4 arguments associated with it. Each argument holds a value which can be
changed to configure the function (optional function is configured). If the value of an argument is outside of the highest or
lowest permitted value, an error code is generated and the option cannot be used. The error code cannot be eliminated
until the argument is given a permissible value.

4 Parameters
Parameter list

1001 Truck type, page 4 - 24 4.5.3.1 General, page
4 - 24
1002 Non-configurable option, page 4 - 25 4.5.3.1 General, page
4 - 24
1003 Optional function 1, page 4 - 25 4.5.3.1 General, page 4
4 - 24
1004 Optional function 1 Arg1, page 4 - 25 4.5.3.1 General, page
4 - 24
4 - 24
4 - 24
4 - 24
1008 Optional function 2, page 4 - 25 4.5.3.1 General, page
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24

4 Parameters
Parameter list

4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
4 - 24
1043 Configuration of walkie buttons (operation from the side), page 4.5.3.1 General, page
4 - 28 4 - 24
1044 Master maximum speed, page 4 - 28 4.5.3.1 General, page
4 - 24
1045 Type of battery in the truck, page 4 - 28 4.5.3.1 General, page
4 - 24
1046 Used only with specially configured trucks, page 4 - 28 4.5.3.1 General, page
4 - 24

4 Parameters
Parameter list

1051 Inactivate hydraulic functions, page 4 - 28 4.5.3.1 General, page
4 - 24
1060 Wheelbase, page 4 - 29 4.5.3.1 General, page
4 - 24
1061 Tiller arm, page 4 - 29 4.5.3.1 General, page 4
4 - 24
1070 Hydraulic control (Min. rpm hydraulic motor), page 4 - 29 4.5.3.1 General, page
4 - 24
1071 Hydraulic control (Min. rpm hydraulic motor), page 4 - 29 4.5.3.1 General, page
4 - 24
1101 Built-in battery charger, page 4 - 29 4.5.3.1 General, page
4 - 24
1102 Controls for hydraulic function, page 4 - 30 4.5.3.1 General, page
4 - 24
1103 Safety gate, page 4 - 30 4.5.3.1 General, page
4 - 24
1106 Top position sensor, page 4 - 30 4.5.3.1 General, page
4 - 24
1107 Steering, page 4 - 30 4.5.3.1 General, page
4 - 24
1108 Truck type (version), page 4 - 30 4.5.3.1 General, page
4 - 24
1110 Reset voltage for BDI, page 4 - 31 4.5.3.1 General, page
4 - 24
1111 Platform, page 4 - 32 4.5.3.1 General, page
4 - 24
1113 Protective overhead guard, page 4 - 32 4.5.3.1 General, page
4 - 24
1115 Cooling fan, page 4 - 32 4.5.3.1 General, page
4 - 24
1116 Decompression locking, page 4 - 32 4.5.3.1 General, page
4 - 24
1117 Lifting height sensor 1.8 m, page 4 - 33 4.5.3.1 General, page
4 - 24
1119 Battery size, page 4 - 33 4.5.3.1 General, page
4 - 24
1120 Fork carriage, page 4 - 33 4.5.3.1 General, page
4 - 24
1122 Reach stop, page 4 - 33 4.5.3.1 General, page
4 - 24
1124 Steering arc, page 4 - 34 4.5.3.1 General, page
4 - 24
4 - 24
4 - 24

4 Parameters
Parameter list

4 - 24
1131 Reduction of lowering speed (Softstop), page 4 - 34 4.5.3.1 General, page
4 - 24
1132 Reducing speed and acceleration, page 4 - 34 4.5.3.1 General, page
4 - 24
1139 Horn signal for auto functions, page 4 - 35 4.5.3.1 General, page
4 - 24
1140 Motor controller:, page 4 - 35 4.5.3.1 General, page
4 - 24
1141 ANSI standard, page 4 - 35 4.5.3.1 General, page
4 - 24
4.5.3.1 General
General factory parameters are used to specify the truck type and how the truck is configured. Some of the parameters
can only be specified with a single value.

1001 Truck type 0 0 158 1
This parameter is used to set which truck type the program is to adapt operational data for.
Value Function
0 Unknown truck type
2 LPE200
3 LPE220
4 LPE250
5 LAE250
101 SPE120
102 SPE140
103 SPE160
104 SPE200
105 SPE120L
106 SPE140L
107 SPE160L
108 SPE200L
109 SPE140S
110 SPE200DN
111 SPE200D
112 SPE120XR
113 SPE120XRD
114 SAE160
151 SWE145
152 SWE160
153 SWE200
154 SWE145L
155 SWE160L
156 SWE200L
157 SWE140S

4 Parameters
Parameter list
Value Function
158 SWE120XR

1002 Non-configurable option 0 1 7 1
3 different functions are accessible via parameter 1002. These functions are either active or inactive. The functions do 4
not require any further adjustment and are thus referred to as non-configurable options.
Value Function
0 No optional function
1 CLICK-2-CREEP
2 TURTLE
3 CLICK-2-CREEP and TURTLE
4 HORN SIGNAL WHEN ERB IS ACTIVATED
5 HORN SIGNAL WHEN ERB IS ACTIVATED and CLICK-2-CREEP
6 HORN SIGNAL WHEN ERB IS ACTIVATED and TURTLE
7 HORN SIGNAL WHEN ERB IS ACTIVATED, CLICK-2-CREEP and
TURTLE

1003 Optional function 1 0 0 21 1
For further information, see the text for factory-standard

1004 Optional function 1 Arg1 0 0 255 1







4 Parameters
Parameter list
















4 Parameters
Parameter list


4













4 Parameters
Parameter list



1043 Configuration of walkie buttons (operation from the side) 0 0 1 1
This parameter is used to configure the controls for operating the truck while the operator walks alongside.
0 No walkie button selected

1 Walkie buttons connected to SEU 0

1044 Master maximum speed 0.5 12.5 12.5 0.5 km/h
Sets the maximum speed for the application. The speed can never exceed the value of this parameter, regardless of the
settings of the other parameters.

1045 Type of battery in the truck 0 0 1 1
Specifies the type of battery found in the application.
Value Function
0 Lead/acid battery
1 Li-ion battery from Hoppecke

1046 Used only with specially configured trucks 0 0 6 1

1051 Inactivate hydraulic functions 0 0 255 1
Block one or more hydraulic functions when the operator is not standing on the platform. The value is determined by the
binary number system and is primarily used by the manufacturer for different options.
To disable all hydraulic functions when the operator leaves the platform, enter the value 255.
Value Function
Bit 0 1st hydraulic function, lift
Bit 1 2nd hydraulic function, lift
Bit 2 3rd hydraulic function, lift
Bit 3 4th hydraulic function, lift
Bit 4 1st hydraulic function, lower
Bit 5 2nd hydraulic function, lower
Bit 6 3rd hydraulic function, lower
Bit 7 4th hydraulic function, lower

4 Parameters
Parameter list

1060 Wheelbase 15 15 25 1 dm
For SPE/ SWE the parameter is always read as std (150cm) irrespective of what the parameter value is.
This value is set based on the truck's wheel base (measured between the drive wheel and fork wheel) and controls the
deflection between the tiller arm position and the drive wheel position. It is progressive steering that is adapted to the
4
length of the truck.
The deflection is dependent on:

Tiller arm position
Truck's wheel base
Truck's current travel speed
As a result, steering is less sensitive at high travel speeds and/or with shorter wheel bases.

1061 Tiller arm 0 0 1 1
Specifies the type of tiller arm fitted on the truck.
Value Function
0 Short tiller arm (E-man), used in trucks with fixed side guards.
1 Standard tiller arm
2 Mechanical steering
3 Steering angle, configurable with parameters 1125-1127

1070 Hydraulic control (Min. rpm hydraulic motor) 20 25 100 1
Used to get the correct minimum rpm for the pump motor in case of no load on the forks.

1071 Hydraulic control (Min. rpm hydraulic motor) 20 85 100 1
Used to get the correct minimum rpm for the pump motor in case of maximum load on the forks.

1101 Built-in battery charger 0 0 2 1
Indicates if there is a battery charger on the application. If there is a battery charger, parameters 109 and 110 must also
be set.
Battery charger, special version with extra sensor:
Some countries have a breaker for each socket. If it is not switched on, the BCU will not detect whether it is connected or
not. To prevent the risk of the truck being started and driven off with the mains cable connected to the wall, the "UK" ver-
sion has an extra sensor that measures whether the mains cable is in its parked position in the battery compartment.
Value Function
0 No battery charger
1 Battery charger present
2 Battery charger, special version with extra sensor in truck:

4 Parameters
Parameter list

1102 Controls for hydraulic function 1 1 4 1
Value Function
1 The rear lifting and lowering control is connected to the second hydraulic function, while the front
control is connected to the first hydraulic function.
2 The rear lifting and lowering control is connected to the first hydraulic function, while the front con-
trol is connected to the second hydraulic function.
3 Both the lifting and the lowering controls are connected to the first hydraulic function. There is no
second hydraulic function.
4 The analogue lifting and lowering control is connected to the first hydraulic function, while the front
control is connected to the second hydraulic function.
The rear one means the control towards the operator

1103 Safety gate 0 0 1 1 Bool
Indicates if there is a safety gate on the application.
Value Function
0 There is no safety gate
1 Safety gate present

1106 Top position sensor 0 0 1 1
Indicates if there is a sensor for support arm/fork top position mounted at the top.
Value Function
0 The truck has no sensor for top position
1 The truck a top position sensor for support arms or forks

1107 Steering 0 0 1 1
Specifies what type of steering the truck is equipped with.
Value Function
0 Manual control
1 Power steering

1108 Truck type (version) 0 0 3 1
Indicates what type of truck (speed) is current for this application.
Value Function
0 6 km/h
1 8 km/h
2 10 km/h
3 12.5 km/h

4 Parameters
Parameter list
This parameter is set automatically for trucks types with only model. For trucks with several versions, this parameter
must agree with parameter 1001, page 4 - 21, otherwise error code 2.503 will be generated.
Value 1001 Model 1108

0 Unknown truck type
2 LPE200 0
1
2
4
3 LPE220 1
2
4 LPE250 3
5 LAE250
101 SPE120 0
1
102 SPE140 0
1
2
103 SPE160 0
1
104 SPE200 0
105 SPE120L 0
1
106 SPE140L 0
1
2
107 SPE160L 0
1
108 SPE200L 0
109 SPE140S 0
1
110 SPE200DN 2
111 SPE200D 2
112 SPE120XR 0
1
113 SPE120XRD 0
1
114 SAE160
151 SWE145 0
152 SWE160 0
153 SWE200 0
154 SWE145L 0
155 SWE160L 0
156 SWE200L 0
157 SWE140S 0
158 SWE120XR 0

1110 Reset voltage for BDI 24.8 25.2 27.0 0.1 V

4 Parameters
Parameter list
After the battery is charged to full capacity, BDI is reset to 100% provided that battery voltage comes up to the pre-pro-
grammed reset value. If the reset voltage value is not reached, it could be due to a voltage drop between the battery and
the logic card.
In case of reset problems:
• Charge the battery to full capacity following the instructions in the operator's manual.
• Then drive the truck for at least 25 seconds before logging out.
• BDI will only set to 100% if the battery has been disconnected/reconnected.
• Check the battery voltage and compare with the voltage between wires 20 and 40 on the tiller arm logic card (A5)
• A voltage drop between the battery and the logic card (A5) could be caused by poor contacts/connections or a loose
connection in the battery connector.

1111 Platform 0 0 4 1
Indicates the type of platform fitted to the application.
Value Function
0 No platform
1 Platform (folding up)
2 Platform (staying down)
3 Platform (backrest)
4 Platform (built in)

1113 Protective overhead guard 0 0 1 1 Bool
Indicates if there is a overhead guard on this application.
Value Function
0 No overhead guard
1 Protective overhead guard

1115 Cooling fan 0 0 1 1 Bool
Indicates if there is a cooling fan[M12], page 19 - 3[M13], page 19 - 3 on this application.
Value Function
0 No cooling fan
1 Cooling fan

1116 Decompression locking 0 0 1 1 Bool
Indicates whether there is decompression locking installed on this application.

The function locks spring decompression for the drive wheel if the truck tilts too much with the forks lifted, while speed is
below a certain limit value.
Value Function
0 No decompression locking installed
1 Decompression locking is installed

4 Parameters
Parameter list

1117 Lifting height sensor 1.8 m 0 0 1 1 Bool
Indicates a lifting height sensor1.8 m sensor fitted to this application.
Value Function 4
0 No lifting height sensor is fitted
1 Lifting height sensor is fitted

1119 Battery size 0 0 1 1
States what kind of battery the truck uses.
Value Function
0 197mm
1 294mm

1120 Fork carriage 0 0 2 1
States the kind of fork carriage the truck is using.
Value Function
0 Standard
1 Sideshift
2 Sideshift and fork spreading

1122 Reach stop 30 90 150 1
The parameter 1122 is used to determine how far from the mechanical stop the reach carriage stops. The lower the
value for the parameter, the further forward the reach carriage moves. After setting the parameter value you must check
that the reach carriage does not bump into the mechanical stop.
With forks
• XRD Fork Back Mono Mast: 5-15mm in FRONT of the support arms
• XR Fork Back: 10-20mm in FRONT of the support arms
Without forks

4 Parameters
Parameter list
• XR Fork Back of Side Shift Unit (at side shift) or yoke beam: 22-32 mm BEHIND the support arms

1124 Steering arc 0 0 1 1
Only valid for trucks with fixed side guards. Parameter 1061, page 4 - 23 set to "3"
Using parameters 1124-1127 it is possible configure the truck so that the steering reacts differently at higher speeds.
Sets the steering angle when the steering wheel is turned
Value Function
0 Standard
1 1:1 steering

1125 Steering arc 20 70 70 1
Sets the speed when the steering angle gets smaller with the same amount of movement of the tiller arm

1126 Steering arc 70 120 120 1
Maximum speed when the steering angle is as per parameter Steering arc

1127 Steering arc 50 80 90 1
Steering angle at maximum speed according to parameter Steering arc and the tiller arm is at the end position.

1131 Reduction of lowering speed (Softstop) 0 0 1 1
Reducing the lowering speed when the forks are near the floor if equipped with Softstop sensorSoft-stop sensor.
Value Function
0 No sensor
1 Sensor

1132 Reducing speed and acceleration 0 0 1 1
Reduction of speed and acceleration in the drive wheel direction when walking with the truck if truck is fitted with tall
coaming (higher ground clearance)
Value Function
0 No reduction of speed and acceleration in the drive wheel dir-
ection

4 Parameters
Parameter list
Value Function
1 Reduction of speed to (3 km/h) and the acceleration is reduced
to 0.4 km/h in the drive wheel direction

1139 Horn signal for auto functions 0 0 4 1
4
0 Not applicable
1 Not applicable
2 Not applicable
3 Not applicable
4 Not so loud a signal for automatic functions.

1140 Motor controller: 0 0 1 1
Type of motor control unit for LPE200LPE220LPE250
0 ACT
1 ACC

1141 ANSI standard 0 0 1 1
States if the truck is configured according to the ANSI standard.
0 Standard
1 ANSI

4 Parameters
Parameter list
4.5.4 Calibration parameters

These parameters manage calibration for the various truck functions. Based on the truck configuration, only those para-
meters that are valid for the truck model will be visible in the calibration menu..

1251 Steering motor calibration, page 4 - 36 4.5.4.1 General, page
4 - 36
1252 Steering motor potentiometer, page 4 - 36 4.5.4.1 General, page
4 - 36
1253 Steering offset, page 4 - 37 4.5.4.1 General, page
4 - 36
1254 Steering angle potentiometer, page 4 - 37 4.5.4.1 General, page
4 - 36
1261 Fork lowering speed, page 4 - 37 4.5.4.1 General, page
4 - 36
1262 Proportional valve - starting point, page 4 - 37 4.5.4.1 General, page
4 - 36
1271 Start value for load weight, page 4 - 37 4.5.4.1 General, page
4 - 36
1272 End value for load weight, page 4 - 37 4.5.4.1 General, page
4 - 36
1273 End value for load weight, page 4 - 37 4.5.4.1 General, page
4 - 36
1274 Maximum reach movement in, page 4 - 37 4.5.4.1 General, page
4 - 36
1275 Maximum reach movement out, page 4 - 37 4.5.4.1 General, page
4 - 36
1276 Load weight, secondary pressure sensor, without load., page 4.5.4.1 General, page
4 - 38 4 - 36
1277 Load weight, secondary pressure sensor, maximum load., page 4.5.4.1 General, page
4 - 38 4 - 36
1278 Load weight, secondary pressure sensor, maximum load., page 4.5.4.1 General, page
4 - 38 4 - 36
1281 Decompression locking zero position, page 4 - 38 4.5.4.1 General, page
4 - 36
1282 Zero point for tilt sensor, page 4 - 38 4.5.4.1 General, page
4 - 36
4.5.4.1 General

1251 Steering motor calibration -1000 0 1000 1 mV
Analogue offset/mV
Offset adjustment of analogue setpoint for steering. Value set during calibration.

1252 Steering motor potentiometer 4000 5000 6000 1 mV
Checksum/mV

4 Parameters
Parameter list
Sum of the analogue steering potentiometers' inputs. Value set during calibration.

1253 Steering offset -300 0 300 1 °/10
Calibration/(degrees/10)
Fine adjustment of steering (zero) 4
-300: 30 degrees to the left
300: 30 degrees to the right

1254 Steering angle potentiometer 2000 2500 3000 1 mV
The sum total of all the steering angle potentiometer inputs. Value set during calibration.

1261 Fork lowering speed 500 1200 1350 10 mA
Max. current for proportional valve. Indicates the maximum lowering speed of the forks. Value set during calibration.
Actual maximum voltage is parameter 1261 + 1262

1262 Proportional valve - starting point 150 400 900 10 mA
Indicates the starting point of the proportional valve. Value set during calibration.

1271 Start value for load weight 500 500 1499 1 mV
Indicates the start value for load weight in mV. Value set during calibration.

1272 End value for load weight 1500 1500 3500 1 mV
Indicates the end value for load weight in mV. Value set during calibration.

1273 End value for load weight 2500 2500 4200 1 mV
Indicates the end value for load weight in mV. Value set during calibration.

1274 Maximum reach movement in 500 500 2499 1 mV
Reach movement potentiometer voltage, reach movement in. Value set during calibration.

1275 Maximum reach movement out 2500 4500 4500 1 mV
Reach movement potentiometer voltage, reach movement out. Value set during calibration.

4 Parameters
Parameter list

1276 Load weight, secondary pressure sensor, without load. 500 500 1499 1 mV
The voltage from the secondary pressure sensor indicates the end value for the load weight in mV, without load

1277 Load weight, secondary pressure sensor, maximum load. 1500 1500 3500 1 mV
The voltage from the secondary pressure sensor indicates the end value for the load weight in mV, maximum load

1278 Load weight, secondary pressure sensor, maximum load. 2500 2500 400 1 mV
The voltage from the secondary pressure sensor indicates the end value for the load weight in mV, maximum load

1281 Decompression locking zero position 2000 2500 3000 1 mV
The value of this parameter produces zero tilt. Value set during calibration.

1282 Zero point for tilt sensor 50 127 200 1 mV
The value of this parameter produces zero tilt. Value set during calibration.

Installation 5
5.1 Transport............................................................................................................................................................ 5 - 1
5.1.1 Transporting the truck.......................................................................................................................... 5 - 1
5.1.2 Transporting the fork carriage ............................................................................................................. 5 - 1
5.2 Lifting the truck................................................................................................................................................... 5 - 2
5.2.1 Lifting the truck .................................................................................................................................... 5 - 2
5.2.2 Lift using a jack .................................................................................................................................... 5 - 2
5.3 Commissioning .................................................................................................................................................. 5 - 3
5.3.1 Battery ................................................................................................................................................. 5 - 3
5.3.1.1 Battery installation ................................................................................................................ 5 - 3

5 Installation

5 Installation
Transport
5 Installation
5
Installation
5.1 Transport
5.1
Transport
5.1.1 Transporting the truck

5.1.1
Transporting the truck
Use inserts and sheets of shock-absorbing material to prevent damage to the truck during lashing and transport.
5
1. Secure the truck properly with stopping (A).
A
5.1.2 Transporting the fork carriage

5.1.2
Transporting the fork carriage
Preparations
Removing the fork carriage, page 8 - 11
1. Cables and hoses must be secured so they cannot come loose or be damaged.
A 2. The entire fork carriage must then be anchored on a pallet or

some other suitable support for transport.

5 Installation
Lifting the truck
5.2 Lifting the truck

5.2
Lifting the truck
5.2.1 Lifting the truck

5.2.1
Lifting the truck
WARNING Risk of tipping

The truck may tip over if it is lifted in the wrong places.
► Always lift the truck from the marked lifting points.
WARNING Risk of rotation

The truck may start to rotate when hanging in the lifting eye.
► Make sure the truck cannot rotate.
Required special tools

• Eye bolt 7541426
1. Always remove the load before lifting the truck.
2. Open the cover marked with a lifting hook.
3. Attach the lifting eye. Eye bolt 7541426, page 21 - 6
4. Lift the truck with the lifting eye.
5.2.2 Lift using a jack

5.2.2
Lift using a jack
1. Place the jack, the whole rear frame can be used for lifting with
a jack.
2. Place blocks around the wheels to stop the truck from moving.
WARNING Risk of tipping

The truck may tip over if it is lifted in the wrong places.
► Always lift the truck from the marked lifting points.

5 Installation
Commissioning
5.3 Commissioning
5.3
Commissioning
5.3.1 Battery
5.3.1
Battery
5.3.1.1 Battery installation

5.3.1.1
Battery installation
WARNING Falling battery

The battery may fall if it is not securely supported to the correct height when you release the lifting hook.
► Check the height of the supporting material before releasing the lifting hook. 5
The battery to be installed in the truck must be the right size. If the battery is too small in terms of size and
weight, it can seriously affect the truck's braking ability and truck stability when lifting goods. See the truck's iden-
tification plate for the correct battery data.
1. Park the truck, and open the battery door.
2. Lift the battery into place using an approved lifting device and a
suitable battery lifting yoke or lifting loops.
Use a battery changing table if changing the battery from the
side.
Check that the cables are not pinched when the battery is lifted
into place.

5 Installation
Commissioning
3. Fit the battery lock.
4. Check the electrolyte level in the battery. Top up with deionized

water as necessary.
5. Connect the battery cables/battery connector.
NOTICE Risk of short-circuiting

An incorrectly connected battery may cause short-circuiting.
► The polarity must be correct. Compare the markings on
the cables with those on the battery terminals.
6. Close the battery compartment cover.
7. Check or set battery parameters, see parameter Battery size.

Maintenance 6
6.1 Introduction ........................................................................................................................................................ 6 - 1
6.2 Maintenance instructions ................................................................................................................................... 6 - 1
6.2.1 Cleaning .............................................................................................................................................. 6 - 1
6.2.2 High-pressure washers........................................................................................................................ 6 - 1
6.2.3 Degreasing agents .............................................................................................................................. 6 - 2
6.2.4 Cleaning the exterior ........................................................................................................................... 6 - 2
6.2.5 Cleaning the chain ............................................................................................................................... 6 - 2
6.2.6 Cleaning the motor compartment ........................................................................................................ 6 - 2
6.2.7 Electric components ............................................................................................................................ 6 - 2
6.2.8 Optical sensors and reflectors ............................................................................................................. 6 - 2
6.2.9 Hydraulic system ................................................................................................................................. 6 - 3
6.2.10 Signs, warnings and adhesive labels .................................................................................................. 6 - 3
6.2.10.1 Placement of signs ............................................................................................................... 6 - 3
6.3 Lubricants specification...................................................................................................................................... 6 - 4
6.4 Periodic maintenance ........................................................................................................................................ 6 - 5

6 Maintenance

6 Maintenance
Introduction
6 Maintenance
6
Maintenance
6.1 Introduction
6.1
Introduction
Follow the general safety regulations when performing maintenance work. General safety rules, page 2 - 1
▷ To maintain a high level of safety and to minimise downtime, all the points specified in the service programme
must be carried out.
▷ The set intervals of 1000 operating hours/12 months (whichever comes first) are those that meet the manufac- 6
turer's requirements for a product in standard applications. The local operating environment may require service
intervals that differ from those specified.
▷ The first service may occur after x operating hours to reduce wear during the run-in period. See the maintenance
schedule.
▷ Once the service intervals have been determined, the hour counter is primarily used for determining when servi-
cing is to be carried out.
▷ To maintain safety, only spare parts approved by the manufacturer may be used for servicing and repairs.
▷ Worn components on the truck must be replaced when discovered.
During the warranty-period:

If repairs/servicing have been carried out by non-authorised personnel, or if non-approved spare parts are used, the war-
ranty ceases to be valid.
6.2 Maintenance instructions

6.2
Maintenance instructions
6.2.1 Cleaning
6.2.1
Cleaning
Cleaning is an important factor in maintaining product reliability.
▷ Always clean the product when servicing it.

Risk of damage to the electrical system.
► Before washing, switch off the power supply to the truck by disconnecting the battery.
6.2.2 High-pressure washers

6.2.2
High-pressure washers
If using a high-pressure washer, remember that:
▷ High-pressure washing may only be performed on metal surfaces.
▷ Under no circumstances may high-pressure washers be used in the motor compartment.
▷ When using a high-pressure wash, the jet must be directed in such a way that it does not damage electric cables,
electric sensors, hydraulic hoses or decals.
▷ Lifting chains, piston rods and end pieces of hydraulic cylinders, ball and roller bearings – including those that are
fully enclosed – must not be exposed to the jet, as there is a risk that water may penetrate and cause corrosion.
▷ After performing a high-pressure wash, all bearings and chains must be lubricated/greased as specified in the
maintenance instructions.

► Do not wash electrical components with a high-pressure washer.

6 Maintenance
6.2.3 Degreasing agents

6.2.3
Degreasing agents
When using degreasing agents, only environmentally-friendly cold degreasing agents may be used, such as those that
are designed for general vehicle cleaning and do not damage paintwork, plastic components, cables, hydraulic hoses or
decals.
6.2.4 Cleaning the exterior

6.2.4
Cleaning the exterior
Always clean the outside of the truck when servicing it.
▷ Remove rubbish, etc. from the wheels
▷ Degreasing agents can be used as needed, in line with the previous section.
▷ Rinse off loose grime using tepid water.
NOTICE Seizing, corrosion

Risk of damage to mechanical parts.
► Lubricate the truck parts after washing the truck.
6.2.5 Cleaning the chain

6.2.5
Cleaning the chain
We recommend you to replace a chain that is very dirty.

Dirty chains should be cleaned before they are lubricated, e.g. by washing with solvent such as diesel or petrol.
The chain should be blown dry using compressed air and lubricated immediately after cleaning.
NOTICE Degreasing agents

Exercise care with degreasing agents as these can contain abrasives.
6.2.6 Cleaning the motor compartment

6.2.6
Cleaning the motor compartment
Always clean the motor compartment when servicing it.
▷ Cleaning is most suitably done using compressed air and/or a vacuum cleaner.

► Do not wash electrical components with a high-pressure washer.
6.2.7 Electric components

6.2.7
Electric components
Always clean electric components of the product when servicing it.
▷ Clean electric motors using vacuum cleaner or a rag.
▷ Clean electrical panels, electronic cards, contactors, connectors, solenoid valves, etc. with a dampened cloth and
a cleaning agent that will not damage the part.

Risk of damage to electrical components.
► Do not break off any warranty seals on the logic cards.
6.2.8 Optical sensors and reflectors

6.2.8
Optical sensors and reflectors
▷ Use a soft brush to remove dust from the units. Wipe the glass with a clean cloth moistened with anti-static fluid
without alcohol.

6 Maintenance
6.2.9 Hydraulic system

6.2.9
Hydraulic system
Follow the regulations concerning work with hydraulics when performing maintenance work. See Hydraulics/Pneumatics
C6000, page 14 - 1
6.2.10 Signs, warnings and adhesive labels

6.2.10
Signs, warnings and adhesive labels
Inspect all signs and labels when performing service on the truck.
6.2.10.1 Placement of signs

6.2.10.1
Placement of signs
6
WARNING Illegible warning and information signs
The warning and information signs on the truck contain important information about the truck and for personal safety. If
a warning and information sign is missing there is a risk of danger. The signs must always be legible.
► Replace broken or missing warning and information signs
a
b
c
d
e
f
g
h
i
j
k
g h
The figure shows the position and significance of the signs on the truck.
a) Modification plate (only for trucks adapted to customers or applications)
b) Maximum capacity
c) Identification plate
d) Radio transmitter (option)
e) The truck is equipped with a lithium-ion battery (option)
f) Adapted for cold storage environments (option)
g) Hydraulic oil filler neck cold store (option)

6 Maintenance
Lubricants specification
h) Hydraulic oil filler neck

i) Risk of crushing
6.3 Lubricants specification

6.3
Lubricant type Specification 10001 30002

B Hydraulic oil See table below. X
3
C Transmission oil Synthetic base hypoid oil F
SAE 75W-90
Class API-GL5
3
C Transmission oil Cassida Fluid GL 150 F
Approved for the Synthetic
food processing in- NSF H1
dustry
NSF ISO 21469
D Grease See table below. X
E Grease Grafloscon, A-G1 (Klüber) X
F Grease Gletmo 805 X X
F Grease Rembrandt EP2 X X
1. Every 1000 hours
2. Every 3000 hours
3. The drive gear oil is only replaced during the first 1000-hour service.
Pos. Ambient temperature Viscosity class Usage

B 0°C - 40° C ISO VG 32 Hydraulic system
ISO 6743-4 category HM
DIN 51524 part 2 = HLP
B -35 ° C - 40° C ISO VG 27.5 Hydraulic system
ISO 6743-4 category HV
DIN 51524 part 3 = HVLP
B 0°C – 40°C Cassida Fluid HF 32 / ISO VG 32 Hydraulic system
ISO 6743-4 category HM Approved for the food pro-
DIN 51524 part 2 = HLP cessing industry
NSF H1
NSF ISO 21469
Pos. Ambient temperature Viscosity class Recommended products*

D >-40°C VG 15 Klüberoil 4UH 1-15, Klüber Lubrication
<-30°C
D >-30°C VG 68 Klüberoil 4UH 1-68N, Klüber Lubrication
<+5°C Anticorit LBO 160 TT, Fuchs DEA
D >+5°C VG 150 Klüberoil 4UH 1-150N, Klüber Lubrication
<+45°C Anticorit LBO 160, Fuchs DEA
Rexoil, Rexnord Kette
D >+45°C VG 220 Klüberoil 4UH 1-220N, Klüber Lubrication
<+80°C

6 Maintenance
Periodic maintenance
6.4 Periodic maintenance

6.4
F First service.
X The set intervals are 1000 operating hours/12 months (whichever comes first)
S Safety-related service points.

6 Maintenance

Pos. Type Point Instruction Measure 250 500 750 1000 1500 2000 3000 4000 5000
Preparations Collect the truck
1 Drive motor bear- Drive the truck and listen for any ab- Check the drive motor fit- X
ings normal noise from the drive motor ting (1.8 and 2.5 kW), page
bearings. 9 - 18
Listen for any abnormal noise in the Check the drive motor fit-
drive motor bearings, page 9 - 17 ting (2.8 kW), page 9 - 18
Replacing the drive motor,
page 9 - 19
2 The drive gear Drive the truck and listen for any ab- Replacing the drive gear X
normal noise from the drive gear steering bearing , page
bearings. 10 - 13
Checking for noise in the drive gear,
page 10 - 4
3 Presence switch Drive the truck carefully (no faster X
function than 6 km/h), and check that the pho-
tocell (Built-in) disconnects if the foot
6-7
is outside the platform for longer than
500ms.
Checking the photocell, page 13 - 47
4 The function of the Inspect the platform for crack forma- Replacing the platform, X
platform switch tion and other damage. page 8 - 74
Checking the platform, page 8 - 66
5 Operating hours Inspect the error log and operating X
hours.
Checking error log and operating
hours, page 13 - 26
Preparations Raise the forks.
Lift the truck and support it on trestles
so that all wheels are in the air.
Switch off the truck and pull out the
battery connector.
Remove the platform
6 Maintenance

6
6 Electric panel Check the electric panel's attach- X
ment.
Checking the electric panel mounting,
page 13 - 31
7 Electric panel Inspect the cable connections on the Replacing the motor con- X
6 Maintenance
electric panel. Gently pull on all the trol panel, page 13 - 32

cable connections and copper plate.
Checking the cable connections, page

13 - 31
8 The contactors Check the contactor electrical con- Replacing the motor con- X
nections. Gently pull on all the cable trol panel, page 13 - 32
connections and copper plate.
Checking the contactors, page
13 - 31
9 Electric panel Clean the heatsink of the electric X
panel by blowing carefully with com-
pressed air
6-8
Cleaning the electric panel heatsink,
page 13 - 32
10 Steering motor Check the drive gear's attachment, X
+3
mount tightening torque 26 ⁄-3 N·m.
Check the drive gear's attachment,
page 9 - 8
11 Steering motor Inspect the electrical connections of X
the steering motor.
Checking the electrical connections,
page 9 - 8
12 Steering motor Check that the steering motor is not Replacing the steering mo- X
damaged. tor, page 9 - 8
Checking the steering motor, page
9-8
13 The parking brake Tighten the parking brake mounting X
+1.2
bolts to a torque of 11.3 ⁄-1.2 N·m.
Tighten the parking brake mounting
bolts, page 11 - 6
14 The parking brake Clean the inside of the brake. Use Replacing the parking X
compressed air to carefully blow brake, page 11 - 11
away the brake dust inside the brake. Fitting the parking brake,
Cleaning the parking brake, page page 11 - 13
11 - 3
15 The parking brake Use a feeler gauge to check that the Cleaning the parking brake, X
gap gap between the brake unit's magnet page 11 - 3
housing and the movable pressure Replacing the friction disc,
+0.25
disc is =0.4 ⁄-0.25 mm. page 11 - 8
Adjusting the parking brake gap, page
11 - 5
16 The parking brake Use a feeler gauge to check that the Cleaning the parking brake, X
gap gap between the brake unit's magnet page 11 - 3
6-9
housing and the movable pressure Replacing the friction disc,
+0.2
disc is =0.3 ⁄-0.15mm. page 11 - 8
Adjusting the parking brake gap, page
11 - 4
17 The drive motor Check the rotational speed sensor Replacing the rotational X
rpm-sensor [B11], page 19 - 2 fitting speed sensor, page 9 - 32
Check the rotational speed sensor fit-
ting, page 9 - 19
18 The drive motor Check that the drive motor is not Replacing the drive motor, X
damaged. page 9 - 19
Checking the drive motor, page
9 - 17
19 The drive motor Carefully pull at the electrical con- X
nectors to make sure they are fitted
properly.
Checking the electrical connections,
page 9 - 17
6 Maintenance

6
20 The drive motor fix- Check the screws to the drive motor X
ings (1,8 and 2,5 kW), torque the screws
in two stages crosswise, tightening
+1
torque 7 ⁄-1 N·m.
Check the drive motor fitting (1.8 and
2.5 kW), page 9 - 18
6 Maintenance

21 The drive motor fix- Check the screws to the drive motor
ings (2,8 kW), torque the screws in two

stages crosswise, tightening torque
9.5 N·m.
Check the drive motor fitting (2.8 kW),
page 9 - 18
22 The drive unit fix- Check for cracks and other damage X
ings on the motor mounts/PowerTrak.
Checking the motor mounts, page
8 - 31
23 The chassis Check for cracks and other damage X
on the rear chassis.
6 - 10
Inspection of the rear chassis, page
8-1
24 Wiring harness Check all wiring harnesses (including X
their attachment devices and con-
tacts) for wear, damage and proper
attachment.
Checking the wiring harnesses, page
13 - 35
25 DHU Check that the DHU's green LED is X
lit.
Checking DHU/I-site [K110], page
17 - 4
26 The mounting of Check the attachment of the lift cylin- Replacing the main lift cyl- X
the hydraulic cylinders. inders, page 14 - 32
ders Checking the attachment of the lift
cylinders, page 14 - 32
27 The hydraulic cylin- Inspect the lift cylinders for leaks. Replacing the main lift cyl- X
der Checking for leaks in the lift cylinder, inders, page 14 - 32
page 14 - 32
28 The integrity of the Check that there are no leaks from X
hydraulic system hydraulic hoses and hose couplings
around the hydraulic unit.
Checks for leaks from hydraulic con-
duits and connections, hydraulic unit,
page 14 - 31
29 The pump motor Change the hydraulic oil, Lubricant B, Draining oil, page 14 - 10 X
see Lubricants specification, page Topping up with oil, page
6 - 4. 14 - 10
Filling volume 1.8L
Oil change, page 14 - 10
30 The oil filter Change the oil filter at the same time X
you change the oil
Oil filter replacement, page 14 - 13
6 - 11
31 The oil strainer Use compressed air to clean the suc- Replacing the suction filter, X
tion filter. page 14 - 13
Cleaning the air filter, page 14 - 12
32 Tank Check the tank for cracks or other Replacing the tank, page X
damage. 14 - 11
Checking the tank, page 14 - 9
33 Tank Blow off any visible particles from the X
hydraulic system.
Rinse the tank with clean hydraulic
fluid.
Cleaning the tank, page 14 - 9
34 The drive gear Place a piece of cardboard or similar Replacing the wheel hub X
under the drive gear to check for seal , page 10 - 7
leaks.
Checking for leaks in the drive gear,
page 10 - 3
6 Maintenance

6
35 The drive gear fix- Check the drive gear's attachment. X
ings 23 N·m
Check the drive gear's attachment ,
page 10 - 3
36 Gear ring Carefully clean the ring gear (servo, X
6 Maintenance
option).

Cleaning the ring gear, page 9 - 7
37 Steering motor Inspect the steering motor pinion. Replacing the steering mo- X
Checking the steering motor gears, tor, page 9 - 8
page 9 - 8
38 The drive gear for Change the drive gear oil. Empty the drive gear oil, F
oil change The drive gear oil is only replaced page 10 - 10
during the first 1000-hour service. Empty the drive gear oil,
Drive gear oil change, page 10 - 9 page 10 - 11
Filling oil in the drive gear,
page 10 - 12
Filling oil in the drive gear,
6 - 12
page 10 - 13
39 The wear surface Measure the drive wheel tread. The Replacing the drive wheel, X
of the drive wheel tread must be D=250 ≥12.5 mm. page 11 - 17
Measuring the drive wheel tread, page
11 - 15
40 The wear surface Measure the drive wheel tread. The Replacing the drive wheel, X
of the drive wheel tread must be D=230 ≥15 mm. page 11 - 17
Measuring the drive wheel tread, page
11 - 16
41 The caster wheel Check that the castor wheel is prop- Replacing the castor wheel X
erly attached and that it rotates and assembly, page 11 - 25
pivots freely.
Checking the castor wheels, page
11 - 21
42 The wear surface Measure the castor wheel tread. The Replacing the castor wheel, X
of the caster tread must be D=125 ≥7.5mm. page 11 - 21
wheels Measuring the castor wheel tread,
page 11 - 21
of the caster tread must be D=150 ≥10mm. page 11 - 21
page 11 - 20
page 11 - 20
page 11 - 21
46 Gear ring Lubricate the ring gear (Servo, op- X
6 - 13
tion) Lubricant type E.
Lubricating the ring gear, page
9-8
47 The battery lock Check that the battery lock keeps the X
battery in place. This applies to bat-
teries that are permanently installed.
Checking the battery lock, page
8 - 30
48 The battery lock Check that the battery lock keeps the Adjusting the battery lock, X
battery in place. The recommended page 8 - 30
force required to close the battery
lock is 250-350 N.
Checking the battery lock, page
8 - 30
49 Battery Clean the battery. Use a cloth and a X
mild detergent.
Cleaning the battery, page 13 - 2
6 Maintenance

6
50 The battery cell and Verify that the cell and terminal pro- X
terminal covers tectors are not damaged.
Checking cell and terminal protectors,
page 13 - 4
51 Battery connections Inspect all connections to the battery, X
6 Maintenance
truck and charger

Checking the connections, page
13 - 3
52 Battery cables Check the battery cables/cable pro- X
tectors between the fork carriage and
the chassis, replace if too damaged.
Checking the battery cables, page
13 - 3
53 Battery Check that the battery data complies X
with the truck specification, see the
serial number plate. Signs, warnings
and adhesive labels, page 6 - 3
6 - 14
Checking the battery, page 13 - 3
54 Battery electrolyte Check electrolyte density and tem- X
density perature.
Checking the electrolyte density, page
13 - 4
55 Battery electrolyte Check the electrolyte level. Top up X
level with deionized water as necessary.
Checking the level of the electrolyte,
page 13 - 4
56 The fork carriage Check for cracks and other damage Replacing the fork carriage, X
on the fork carriage. page 8 - 11
Checking the fork carriage, page
8 - 26
57 The fork carriage Check the fork carriage for lateral X
play at the rollers.
Checking the fork carriage play, page
8 - 27
58 The fork carriage Check for cracks and other damage Replacing the torsion tube- X
on the linkage. linkage-wheel fork, page
Checking the linkage, page 8 - 26 8 - 18
59 The fork wheels Check the fork wheel mounting. Replacing a single wheel, X
Checking the fork wheel mounting, page 11 - 30
page 11 - 29 Replacing bogie wheels,
page 11 - 34
60 The fork wheels Measure the fork wheel tread. The Replacing a single wheel, X
tread must be D=85 ≥5 mm. page 11 - 30
Measuring the fork wheel tread, page Replacing bogie wheels,
11 - 29 page 11 - 34
61 The fork wheels Pull the wheel fork backward and for- Replacing the torsion tube- X
ward to ensure that it moves freely. linkage-wheel fork, page
Checking the wheel fork flexibility, 8 - 18
page 8 - 26 Replacing the torsion tube-
linkage-wheel fork, page
8 - 18
6 - 15
62 The fork wheels Check that the bushings in the wheel Replacing the wheel fork X
fork are not worn. There should be no bushing, page 8 - 9
play in the wheel shaft nor should it
be worn.
Checking the fork wheel bushings,
page 11 - 29
Resetting Lower the truck to the ground and
connect the battery connector.
Lower the forks and release the pres-
sure in the hydraulic system.
Install the platform.
63 Mast beams Lubricate the beams, lubricant type X
F. Lubricate from above downwards.
Lubricating the beams, page 8 - 27
6 Maintenance

6
64 The lift height limit Lift the fork carriage as far up as pos- X
function sible, and check that the fork carriage
lift height limitation is working prop-
erly.
Checking the fork lift height limitation,
page 8 - 27
6 Maintenance

65 The function of the Check the operation of the brake mi- Replacing the safety switch,
brake switch croswitch in the upper and lower page 12 - 37

brake positions. The lower position
means that you have to press down
to activate the switch.
Checking the brake microswitches,
page 12 - 28
66 The function of the Operate the truck and move the gate X
gate switches up and down to check the function of
the gate switches.
Checking the function of the gate
switches, page 8 - 87
6 - 16
67 The function of the Check the function of the platform Checking the position X
platform switch switches by attempting to drive the sensor [B119], page 8 - 72
truck with the platform down and up Replacing sensor [B119],
respectively.[B119], page page 8 - 73
19 - 2[B120], page 19 - 2
Checking the function of the platform
switches, page 8 - 65
68 Steering arm Drive the truck and move the tiller Replacing the steering X
arm fully in both directions, the tiller bearing, page 12 - 68
arm must move in both directions
without sticking.
Checking the play and the return
travel, page 12 - 29
69 The function of the Drive the truck and move the speed Fitting the lift/lower button, X
speed control control back and forth. It should page 12 - 6
spring back to the neutral position. Replacing the operating
Checking the speed control, page panel, page 12 - 12
12 - 13 Replacing the tiller arm
wiring harness, page
12 - 59
70 Hydraulic functions Check that the hoses and the wiring X
harness are not worn/squeezed and
that there is no noise, jerky move-
ment or vibration when running all the
hydraulic functions.
Checking the hydraulic functions,
page 12 - 4
71 The function of the Press the horn button to produce a X
horn signal.
Checking the horn function, page
13 - 11
6 - 17
72 Steering arm Check that the height adjuster runs Replacing a gas strut, page X
freely and the gas strut is able to 8 - 66
bear the weight of the tiller arm. Replacing the steering ad-
Checking the height adjuster, page apter, page 12 - 45
12 - 54
73 Steering arm Check that the tiller arm can be lifted X
and lowered and that the lock does
not seize in the steering adapter.
Checking the height adjustment lock,
page 12 - 55
74 The emergency Drive the truck carefully and press X
switch function the emergency switch.
Checking the emergency switch func-
tion, page 13 - 40
6 Maintenance

6
75 Stomach button Drive the truck carefully in both direc- Replacing the logic card, X
tions. Press the stomach button page 12 - 16
(safety reversing) and check that
power to the drive is cut.
Checking the stomach button, page
12 - 4
6 Maintenance

76 The parking brake Drive the truck at crawl speed and Emergency release of the
press the emergency stop switch. parking brake, page

Drive the truck carefully and move 11 - 6
the tiller arm up and down to test the Adjusting the parking brake
activation of the plug braking and the gap, page 11 - 4
parking brake. Adjusting the parking brake
Checking the parking brake, page gap, page 11 - 5
11 - 7 Replacing the friction disc,
page 11 - 8
77 Fire extinguisher If the machine is equipped with a fire X
extinguisher, its condition must be in-
spected
6 - 18
Inspection of fire extinguisher, page
17 - 7
Troubleshooting 7
7.1 Initial troubleshooting ......................................................................................................................................... 7 - 1
7.2 Concluding troubleshooting ............................................................................................................................... 7 - 2
7.3 Auxiliary functions .............................................................................................................................................. 7 - 3
7.3.1 Towing a defective truck ...................................................................................................................... 7 - 3
7.3.1.1 Towing and transporting a defective truck............................................................................ 7 - 3
7.3.1.2 Towing and transporting a defective truck............................................................................ 7 - 3
7.3.2 Emergency driving mode ..................................................................................................................... 7 - 4
7.3.2.1 Emergency driving mode...................................................................................................... 7 - 4
7.3.3 Error code history ................................................................................................................................ 7 - 4
7.3.3.1 Error code history ................................................................................................................. 7 - 4
7.3.4 Extended error log ............................................................................................................................... 7 - 4
7.3.4.1 Extended error log................................................................................................................ 7 - 4
7.3.5 Built-in test function for the tiller arm ................................................................................................... 7 - 5
7.3.5.1 General................................................................................................................................. 7 - 5
7.3.5.2 Display test........................................................................................................................... 7 - 5
7.3.5.3 Speed control ....................................................................................................................... 7 - 6
7.3.5.4 Safety reversing ................................................................................................................... 7 - 6
7.3.5.5 Controls for lifting/lowering ................................................................................................... 7 - 6
7.3.5.6 Sensilift................................................................................................................................. 7 - 7
7.3.5.7 Keypad ................................................................................................................................. 7 - 7
7.3.6 Digital input/output status .................................................................................................................... 7 - 8
7.3.6.1 Test mode "9" ....................................................................................................................... 7 - 8
7.3.6.2 Test mode “12” SEU expansion unit (option). ...................................................................... 7 - 8
7.3.7 Service information .............................................................................................................................. 7 - 9
7.3.7.1 Service information............................................................................................................... 7 - 9
7.3.8 Hydraulic pressure............................................................................................................................. 7 - 10
7.3.8.1 Erroneous hydraulic system pressure ................................................................................ 7 - 10
7.4 Troubleshooting using error codes .................................................................................................................. 7 - 11
7.4.1 List of error codes .............................................................................................................................. 7 - 11

7 Troubleshooting

7 Troubleshooting
Initial troubleshooting
7 Troubleshooting
7
Troubleshooting
7.1 Initial troubleshooting

7.1
Initial troubleshooting
Begin the troubleshooting
Eliminate improbable
Was an error code displayed? Follow the instructions in 7
errors
“Troubleshooting using error
Yes codes”
No
Select and prioritize the
Are there symptoms in Follow the instructions in most likely causes
“Troubleshooting based on “Troubleshooting based on
symptoms”? Yes symptoms”
No
What is the problem?
Collect as much information as When the error is
possible about the problem localized, see the

Where at the place of work did the instructions in the section
problem occur? for procedures
When did the problem occur?
Identify all parts that may have

caused the problem. Use the
wiring chart if needed Which functions are affected?
What conditions triggered

the problem?

7 Troubleshooting
Concluding troubleshooting
7.2 Concluding troubleshooting

7.2
Concluding troubleshooting
End the troubleshooting
Make sure all cables and hoses are refitted in Let the operator drive.
the correct manner. Verify that the problem does not occur again.
Make sure that parts that have been emptied of If you previously contacted the department for
fluids are refilled to the correct level. technical support to discuss the problem, we ask
you to please get in touch again to tell us how
the problem was resolved.
Recreate the same conditions as when the

problem first occurred
Sending feedback will add to the common
knowledge database.
This is important for the continued improvement
of the support to the service technicians in the
field.
Drive the truck in the same way it was driven

when the problem occurred.
Verify that the problem does not occur again.

7 Troubleshooting
Auxiliary functions
7.3 Auxiliary functions

7.3
Auxiliary functions
7.3.1 Towing a defective truck

7.3.1
Towing a defective truck
7.3.1.1 Towing and transporting a defective truck

7.3.1.1
Towing and transporting a defective truck
WARNING Personal injury

The truck can start to roll when the parking brake function is disabled.
► Never leave the truck with the parking brake released unless the wheels have been chocked in a satisfactory
manner.
Note: The towed truck shall always have an operator who can steer and apply the brake when towing using a tow-truck 7
and tow-rope.
▷ Always remove the load before towing or transporting the truck to the site of repair.
Tow or transport the defective truck according to the following procedure:
▷ Start the truck, move the tiller arm to the drive position and push the truck by hand.
Tow using a tow truck and tow wagon:
1. Lift the truck onto the tow wagon. See the instructions under Lifting a truck.
2. Connect the truck to the wagon.
3. Drive with care.
4. Lift off the truck according to the instructions under Lifting a truck.
7.3.1.2 Towing and transporting a defective truck

7.3.1.2
Towing and transporting a defective truck
WARNING Personal injury

The truck can start to roll when the parking brake function is disabled.
► Never leave the truck with the parking brake released unless the wheels have been chocked in a satisfactory
manner.
Note: The towed truck shall always have an operator who can steer and apply the brake when towing using a tow-truck
and tow-rope.
▷ Always remove the load before towing or transporting the truck to the site of repair.
Tow or transport the defective truck according to the following procedure:
▷ Start the truck, move the tiller arm to the drive position and push the truck by hand.
Tow using a tow truck and tow wagon:
1. Lift the truck onto the tow wagon. See the instructions under Lifting a truck.
2. Connect the truck to the wagon.
3. Drive with care.
4. Lift off the truck according to the instructions under Lifting a truck.

7 Troubleshooting
Auxiliary functions
7.3.2 Emergency driving mode

7.3.2
Emergency driving mode
7.3.2.1 Emergency driving mode

7.3.2.1
If the truck for some reason stops operating and remains immobile in an unsuitable place, it is possible to active the
emergency travel mode to move the truck out of the way (max. 1.3 km/h). In this mode, it is possible to lower and lift the
forks.
1. Ensure that the truck is switched off. Enter your PIN code.
3. Turn the speed control several times until “Ed” is shown on the display.
4. Press and then release the horn button to select.
5. All lamps flash and “SLO” is shown on the display.
It is now possible to drive the truck, but exercise extreme caution. It is not possible to brake suddenly by raising the
steering unit.
If the truck is on an incline, be even more careful when using the emergency travel mode. If you apply too much throttle,
there is a risk the truck will roll away. To stop the truck, turn the sped control in the opposite drive direction.
Some errors block emergency travel mode. You then cannot obtain information on the error.
7.3.3 Error code history

7.3.3
Error code history
7.3.3.1 Error code history

7.3.3.1
Error code history
Up to 50 of the most recent error code events can be stored in a log along with the hour meter reading when the error oc-
curred. The error code log displays error codes in chronological order starting with the most recent error code.
The 10 latest error codes show extended information if you look at them in TruckCom.Extended error log, page 7 - 4
1. Ensure that the truck is switched off. Connect the CAN key or enter the PIN code. Note: Do not press the ON
button.
3. Press and then release the horn button to select the "Info" menu.
4. Turn the speed control several times until “E” is shown on the display. The error code symbol lights up.
6. The most recent error is then displayed. The display alternates between the error code and the hour counter
reading when the error occurred. If the error code log contains more than one error code, the codes can be dis-
played by repeatedly pressing the speed control.
7. Switch off the truck by pressing the OFF button or return to the previous menu by selecting "ESC". The display of
error code history is now complete.
7.3.4 Extended error log

7.3.4
Extended error log
7.3.4.1 Extended error log

7.3.4.1
Extended error log
The 10 latest error codes in the error code log contain extended information. Data 1, 9-15 only for the manufacturer. Ac-
cess to the error log is through TruckCom.
Data Description Resolution Unit Standard value

1 Motor, hydraulics, steering and machine statuses - -
2 Battery voltage 1 mV
3 True speed 0.1 km/h
4 Motor temperature 1 °C

7 Troubleshooting
Auxiliary functions
5 Temperature [T1] ACT/ACC 1 °C

6 Signal from pressure sensor 1 mV
7 Signal from PowerTrack sensor 1 mV
8 Difference between the set angle of the servo and the true one 5.493E-3 ° Only for trucks with
servo
8 Signal from steering angle sensor 1 mV Only for trucks
without servo
9 Signal to [T1] ACT/ACC Only for factory data
10 Signal from [T1] ACT/ACC Only for factory data
11 Signal to servo Only for factory data 7
12 Signal from servo Only for factory data
13 Generic data depending on error type Only for factory data
7.3.5 Built-in test function for the tiller arm

7.3.5
Built-in test function for the tiller arm
7.3.5.1 General
7.3.5.1
General
1. Make sure the battery is connected.
2. Check that the truck is switched off. Press the OFF switch.
3. Connect the CAN key or enter the PIN code. Note: Do not press the ON button.
5. Press and release the horn button to select the "Info" menu.
6. Turn the speed control several times until “tESt” is shown on the display.
7. Press the horn button and release it to enter the test mode.
8. The first one you arrive at is the display test. Press on the button/function you want to test to proceed. In this
mode, the 2 LEDs on the keypad flash.
9. Switch off the truck by pressing the OFF button or return to the previous menu by pressing the horn button.
7.3.5.2 Display test

7.3.5.2
Display test
The digital display [A6] can be tested to verify all the segments of the display function correctly. A moving 8 tests all the
segments of the display.

7 Troubleshooting
Auxiliary functions
7.3.5.3 Speed control

7.3.5.3
Speed control
The Hall elements are tested by moving the speed control all the way back and forth. Follow these steps to test the Hall
elements:
Move the rocker from the neutral position to begin the test. This is visualised as number X Y when the rocker is moved in
the fork direction and X-Y when the rocker is moved in the drive wheel direction. X is the total number of Hall elements
that are affected by the magnet and Y is the number of existing Hall elements.
At full movement in both directions 9-9 or 9 9 is shown when all Hall elements are OK.
7.3.5.4 Safety reversing

7.3.5.4
Safety reversing
Press the button for safety reversing “Er 1” is shown in the display
7.3.5.5 Controls for lifting/lowering

7.3.5.5
Controls for lifting/lowering
Press a button for lifting / lowering in order to start the test. “L1”, “L2”, “L3” or “L4” is shown in the display depending on
which button has been pressed.

7 Troubleshooting
Auxiliary functions
7.3.5.6 Sensilift
7.3.5.6
Sensilift
Move the sensilift rocker from the neutral position to begin the test. The analogue value from the sensilift potentiometer is
shown in mV.
7.3.5.7 Keypad
7.3.5.7
Keypad
Press a number to start testing the keypad. “b1” up to “b11” is shown in the display depending on which button is
pressed. The numbers 0-9 are shown as “b0” to “b9”. The red button “b10” and the green button “b11”

7 Troubleshooting
Auxiliary functions
7.3.6 Digital input/output status

7.3.6
Digital input/output status
7.3.6.1 Test mode "9"

7.3.6.1
Test mode "9"
In this mode, the digital inputs and outputs are tested by checking specific segments on the display according to the fol-
lowing tables.
1
6 7 2
5 3
8
1 2 3 4 4
Position:
1) Digital input of A5 [A5]
2) Digital input/output of A5 [A5]
3) Transistor regulator inputs
4) Transistor regulator inputs
1 – 8: Reference to segment
Digit 1, A5 digital in Digit 2, A5 digital in/out

1 Segment Description 1 Segment Description
1 Option button 6 1 Rear button up
6 7 2 2 Option button 5 6 7 2 2 Rear button down
3 Option button 4 3 Front button up
5 3 4 Option button 1
5 3 4 Front button down
5 Option button 2 5 Main contactor
86 86
4 Option button 3 4 Horn input
7 A5 address (node ID) 7 Brake output
8 - 8 Pump
Digit 3, [T1] digital in Digit 4, [T1] digital in

1 Top position sensor not active 1 Input 9
6 7 2 (B61) 6 7 2
2 Steering arm active (B60) 2 Input 10
3 Operator on platform [B119] 3 Input 11
5 3 4 Input 4
5 3 4 Input 12
85 Input 5 85 Input 13
4 4
6 Platform up (B120) 6 Input 14
7 Gate up (121) 7 Motor encode, channel A
8 Gate down (B122) 8 Motor encode, channel B
7.3.6.2 Test mode “12” SEU expansion unit (option).

7.3.6.2
Test mode “12” SEU expansion unit (option).
In this mode, the digital inputs and outputs are tested by checking specific segments on the display according to the fol-
lowing tables.

7 Troubleshooting
Auxiliary functions
1
6 7 2
5 3
8
1 2 3 4 4
Position:
1) SEU 0 inputs
2) SEU 0 outputs
3) SEU 1 inputs
7
4) SEU 1 outputs
1 – 8: Reference to segment
Digit 1, SEU 0 digital in Digit 2, SEU 0 digital out

1 In 1 1 Out 1
6 7 2 2 In 2 6 7 2 2 Out 2
3 In 3 3 Out 3
4 In 4 4 Out 4
5 3 5 3
5 In 5 5
86 86
4 In 6 4
7 In 7 7
8 In 8 8
Digit 3, SEU 1 digital in Digit 4, SEU 1 digital out

1 In 1 1 Out 1
6 7 2 2 In 2 6 7 2 2 Out 2
3 In 3 3 Out 3
4 In 4 4 Out 4
5 3 5 3
5 In 5 5
86 86
4 In 6 4
7 In 7 7
8 In 8 8
7.3.7 Service information

7.3.7
Service information
7.3.7.1 Service information

7.3.7.1
Service information
The truck has a service information mode that is a useful aid for troubleshooting. To activate:
• Connect the CAN service key to [X41] and log in.

• The battery status symbol lights up.
8 4 2 1
• Press the horn button [S18] repeatedly to select the desired mode in the service information mode.
All truck functions work as normal when the service information mode is active. Care should be taken when operating the
truck and reading the display at the same time.

7 Troubleshooting
Auxiliary functions
Data Flashing symbol Description Resolution Unit Standard value

- BDI 10 % 0-100
1 Battery voltage 0.1 V Depending on battery type.
Compare with the real battery
voltage
2 Battery voltage, the value indic- 1 A 0-450A
ated in an approximate value of
motor and pump voltages.
3 Set speed sent to [T1] from A5. 0.1 km/h -12.5 - 12.5 km/h (depending
Positive value in the drive on truck type)
wheel direction. Negative value
in the fork direction.
4 Speed value from the speed 0.1 km/h -12.5 - 12.5 km/h (depending
sensor. Positive value in the on truck type)
drive wheel direction. Negative
value in the fork direction.
5 Forks or support arms, lifting or 1 % 0-100%
lowering command. 100%
shown for on/off checked sig-
nals
6 Pressure sensor 1 (hydraulic 0.001 V 0.5-4.5V
pressure). “nonE” is shown if no
pressure sensor exists.
7 Pressure sensor 2 (hydraulic 0.001 V 0.5-4.5V
pressure). “nonE” is shown if no
pressure sensor exists.
8 Sensor leaning angle. “nonE” is 0.1 ° ± 1,5 ° A higher value will activ-
shown if no sensor exists. ate the decompression locking
9 Digital I/0 for A5 and [T1]. See - - -

description in “Test mode “9”
10 - - -
11 Maximum value for collision 0.1 G 0 G - 10 G

sensor X and Y. “nonE” is
shown if no sensor exists.
12 SEU digital I/0. See description - - -
in “Test mode “12” – SEU ex-
pansion unit (option).” on page
77 “nonE” is shown if no SEU is
present.
13 Steering angle 7 ° 0-90°
14 Drive motor temperature 1 °C -
15 [T1] temperature 1 °C -
7.3.8 Hydraulic pressure

7.3.8
Hydraulic pressure
7.3.8.1 Erroneous hydraulic system pressure

7.3.8.1
Erroneous hydraulic system pressure

• Hydraulic pressure gauge (Manometer) 219730

7 Troubleshooting
Troubleshooting using error codes
1. If there is a suspicion of a wrong hydraulic system pressure, use the tool: Hydraulic pressure gauge (Manometer)
219730, page 21 - 6.
7.4 Troubleshooting using error codes

7.4
7.4.1 List of error codes

7.4.1
List of error codes
Software: 7528678
Error codes
7
No. Description Felorsak(er) Action
2:002 Parameters set to default val- • New software has been 1) Check parameters
ues. loaded in the truck, Check that factory para-
Inte påverkad. adding a new parameter, meters are set according
or it has changed the to the truck configura-
At start-up, it was detected that parameter limit values tion.
one or more parameters were Check that other para-
not within acceptable intervals; • Corrupt memory A5
meters are set correctly.
they have therefore been reset
to default values 2) Replace A5
See section Removing
the logic card, page
12 - 16
2:004 Backup copies do not match. • Hardware (T1 or A5) has 1) Copy the truck configura-
Inte påverkad. been replaced. tion using TruckCom
• Software has been up- See the separate manual
Backup copy in secondary unit for TruckCom.
(T1) does not match data in dated to an older version
primary unit (A5) • Corrupt memory T1 2) Copy the truck configura-
tion using TruckCom
• Corrupt memory A5 See the separate manual
for TruckCom.
3) Replace T1
See section “14.7.2 Re-
placing the motor con-
trol”.
4) Replace A5
placing the logic cards”.
2:005 Internal program error • Internal program error 1) Create a truck report.
Inte påverkad. A5 Send a report to the
manufacturer.
Internal program error
2) Update the truck soft-
ware to the latest ver-
sion.
2:006 Saving to memory failed. • Battery connector dis- 1) Connect the battery con-
Inte påverkad. connected from truck nector
that is started 2) Check battery voltage
Saving to memory failed be-
cause low battery voltage. Bat- • Voltage loss on supply to Check the voltage using
tery voltage below 15 V at the A5 the built-in test proced-
time of saving • The battery is defective ure and comparing with
value from external volt
• Battery parameter #107 meter
has an erroneous value Check connectors, joints

7 Troubleshooting

2:006 Saving to memory failed. and splices for damage
Inte påverkad. or corrosion.
Check fuses F1 and F50
Saving to memory failed be-
cause low battery voltage. Bat- 3) Check the battery.
tery voltage below 15 V at the 4) Check parameters
time of saving Check that factory para-
meters are set according
to the truck configura-
tion.
Check that other para-
2:007 Internal program error A5 • Internal program error 1) Create a truck report.
Inte påverkad. Send a report to the
manufacturer.
Internal program error A5
sion.
manufacturer.
sion.
manufacturer.
sion.
2:010 CAN communication warning • Error on CAN bus wiring 1) Check the CAN bus
Inte påverkad. or connections Check that CAN is intact
• Loose connections in terms of wiring har-
A5 has received too may erro- ness, resistance and
neous signals • CAN node defective connectors. Disconnect
• Software failure the battery. Check that
the resistance between
(X41:3) and (X41:4) is 54
- 66 ohms.
Check that the CAN wir-
ing harness is not
pinched. Measure resist-
ance between the
chassis and CAN con-
tact. Limit value >24
kOhm
2) Check for loose connec-
tions
Switch on the truck, and
pull carefully in the
branches of the wiring
harness to find any loose
connections, and note
when/if the error code
appears.

7 Troubleshooting

2:010 CAN communication warning 3) Check the CAN node
Inte påverkad. Deactivate and discon-
nect the option unit con-
A5 has received too may erro- nected to the CAN wiring
neous signals (e.g. K110,B90,T14 and
A36/A37). Activate and
then connect them one
by one to identify which
unit produces the com-
munication error. 7
ware
Update the truck soft-
ware package to the
latest available version.
2:011 New software. • New software installed 1) Logged in the error log to
Inte påverkad. see when the software
was updated
New software installed. In order
to look in the error code log to
see when new software was in-
stalled.
2:012 Wrong license key • Wrong license key para- 1) Enter the correct license
Inte påverkad. meter 499 key in parameter License
key
New software installed. In order
to look in the error code log to
see when new software was in-
stalled.
Kryphastighet, blockerad lyft/ • Manufacturing defect in Send a report to the
sänk rörelse. A5 manufacturer.
Internal program error ware to the latest ver-
sion.
2) Replace A5
See section Removing
the logic card, page
12 - 16
2:102 Configuration error. • Incorrect value for para- 1) Check parameters
Kryphastighet, blockerad lyft/ meter 1102 Check that factory para-
sänk rörelse. meters are set according
Truck configuration does not tion.
match parameter 1102 Check that other para-
Kryphastighet, blockerad lyft/ Send a report to the
sänk rörelse. manufacturer.
Internal program error 2) Update the truck soft-

sion.

7 Troubleshooting

2:181 Fault in height measuring • Logic error A5 1) Let the forks pass 1.8 m
one time
Truck behaviour
Creep speed
2:182 Missing signal • Defective component 1) Check the height sensor
from the 1.8 m sensor B129 B129
Check that B129 is se-
Truck behaviour curely fastened.
Creep speed, blocked lifting/ Check that the magnet is
lowering movement in place. If not, install a
new one.
If the magnet is in place:
Check that the lateral
distance and the dis-
tance between the
sensor and the magnet
is OK.
Perform the test of B129
TruckCom or Service In-
formation mode 9. Low
signal = actuated sensor;
High signal = unactuated
sensor
2:183 Missing signal B129 • Defective component 1) Check the height sensor
Expected signal from B129 not B129 B129
received during lifting or lower- Check that B129 is se-
ing movement curely fastened.
Check that the magnet is
Truck behaviour in place. If not, install a
Creep speed, blocked lifting/ new one.
lowering movement If the magnet is in place:
Check that the lateral
tance between the
is OK.
formation mode 9. Low
signal = actuated sensor;
High signal = unactuated
sensor
2:184 Signal from B129 • Defective component 1) Check the height sensor
Signal from B129 despite open B129 B129
main contactor • Broken wiring Check that B129 is se-
No test signal from B129 to T1 curely fastened.
when it is energised. Check that the magnet is
in place. If not, install a
Truck behaviour new one.
Creep speed, blocked lifting/ If the magnet is in place:
lowering movement Check that the lateral
tance between the
is OK.

7 Troubleshooting

2:184 Signal from B129 formation mode 9. Low
Signal from B129 despite open signal = actuated sensor;
main contactor High signal = unactuated
No test signal from B129 to T1 sensor
when it is energised. 2) Check wiring after the
Truck behaviour break.
Creep speed, blocked lifting/ Disconnect the battery
lowering movement Using instruments, check
that there is no break in
any wire. 7
Measure and check the
voltage with the func-
tions activated
2:281 Erroneous combination of sig- • High signal from both 1) Check the sensor signal
nals B119 and B120 Check that the distance
Incorrect signal combination • Constantly high signal at between the sensor and
from platform position sensor. inputs (T1:101) and the opposite part is cor-
(T1:97) rect.
Truck behaviour Check that there is no
Creep speed dirt or foreign objects on
the sensor
Inspect cabling.
Measure the signals
from the sensor with a
volt meter and verify us-
ing TruckCom or the
built-in test that the sig-
nal is correct
2) Check the signal to the
unit
Compare the signals
from the sensor with the
input signal (use a volt
meter and verify using
TruckCom or the built-in
test that the signals are
the same)
Check the pins on the
unit and in the connector
Replace the unit if you
cannot get it to work
properly
2:282 Platform sensor activated • Platform loaded 1) Handling error - no ac-
The platform sensor has been • Constantly high signal tion.
activated for more than 5 from B119 2) Check the sensor signal
minutes without any truck activ- • Constantly high signal at Check that the distance
ity. inputs T1:101 between the sensor and
Truck behaviour the opposite part is cor-
Creep speed rect.
Check that there is no
dirt or foreign objects on
the sensor
Inspect cabling.
Measure the signals

7 Troubleshooting

2:282 Platform sensor activated ing TruckCom or the
The platform sensor has been built-in test that the sig-
activated for more than 5 nal is correct
minutes without any truck activ- 3) Check the signal to the
ity. unit
Truck behaviour Compare the signals
Creep speed from the sensor with the
the same)
properly
2:284 Erroneous combination of sig- • High signal from both 1) Check the sensor signal
nals B121 and B122 Check that the distance
Incorrect signal combination • Constantly high signal at between the sensor and
from the gate position sensor inputs (T1:88) and the opposite part is cor-
(T1:96) rect.
Creep speed dirt or foreign objects on
the sensor
Inspect cabling.
Measure the signals
ing TruckCom or the
nal is correct
2) Check the signal to the
unit
Compare the signals
the same)
properly
3)
2:285 Incorrect signal combination • High signal from both 1) Check the sensor signal
from the support arm position B62 and B65 Check that the distance
sensor • Constantly high signal at between the sensor and
inputs (T1:95) and the opposite part is cor-
(T1:111) rect.
Creep speed, blocked lifting/ dirt or foreign objects on
lowering movement the sensor
Inspect cabling.
Measure the signals

7 Troubleshooting

2:285 Incorrect signal combination from the sensor with a
from the support arm position volt meter and verify us-
sensor ing TruckCom or the
nal is correct
Truck behaviour
Creep speed, blocked lifting/ 2) Check the signal to the
lowering movement unit
Compare the signals
input signal (use a volt 7
the same)
properly
2:501 Low battery voltage • The battery is dis- 1) Charge the battery.
Allt stoppas direkt, parkerings- charged 2) Check battery voltage
broms aktiveras och huvudkon- • Voltage loss on supply to Check the voltage using
taktor öppnas. A5 the built-in test proced-
Low battery voltage below 16.8 • The battery is defective ure and comparing with
Volts for more than 2 seconds value from external volt
• Battery parameter #107 meter
has an erroneous value Check connectors, joints
and splices for damage
or corrosion.
3) Check the battery.
4) Check parameters
Check that factory para-
tion.
2:502 Truck type not set • A5 is replaced and/or er- 1) Copy the truck configura-
Allt stoppas direkt, parkerings- roneous value for factory tion using TruckCom
broms aktiveras och huvudkon- parameters See the separate manual
taktor öppnas. • Incorrect value for para- for TruckCom.
Parameter 1001 is incorrectly meter 1001 2) Check parameters.

set Check that factory para-
tion.

7 Troubleshooting

2:503 Wrong truck model set. • A5 is replaced and/or er- 1) Copy the truck configura-
Parameter 1108 is wrongly set roneous value for factory tion using TruckCom
in combination with 1001 parameters See the separate manual
• Wrong value for para- for TruckCom.
Truck behaviour
Everything is stopped at once, meter 1108 and/or 1001 2) Check parameters.
the parking brake is activated, Check that factory para-
and the main contactor opens meters are set according
tion.
2:504 Low battery voltage • The battery is dis- 1) Charge the battery
The battery voltage to the capa- charged 2) Check the voltages in T1
citors in T1 is below 16.0 Volt • Voltage loss on pre-sup- Check fuses F50 and F1
when the main contactor must ply to T1 Check the voltage using
be closed • The battery is defective a volt meter (Measuring
Truck behaviour point F50 - B-) and com-
• Battery parameter #107 pare with the TruckCom
Everything is stopped at once, has an erroneous value
the parking brake is activated, value “Battery
and the main contactor opens Voltage” (Node:ACT,
Analogue I/O) (Limit val-
ues?) (TBD)
Check the voltage using
a volt meter (Measuring
point F1 - B-) and com-
pare with the TruckCom
value “Battery
Voltage” (Node:ACT,
ues?) If the contactor is
open, there is several
volts of difference -- nor-
mal. If the contactor is
closed, voltage should
match the point across
±XX
Check the connectors,
joints and splices
Check that any extra
equipment is connected
in accordance with our
recommendation.
3) Inspect the battery.
4) Check parameters
tion.

7 Troubleshooting

2:511 A5 has received too may erro- • Error on CAN bus wiring 1) Check the CAN bus
neous signals or connection Check that CAN is intact
Allt stoppas direkt, parkerings- • Loose connections in terms of wiring har-
broms aktiveras och huvudkon- ness, resistance and
• CAN node defective connectors. Disconnect
taktor öppnas.
• Software failure the battery. Check that
A5 has received too may erro- the resistance between
neous signals (X41:3) and (X41:4) is 54
- 66 ohms.
Check that the CAN wir- 7
ing harness is not
ance between the
kOhm
tions
appears.
3) Check the CAN node
Deactivate and discon-
nect the option unit con-
nected to the CAN wiring
(e.g. K110,B90,T14 and
A36/A37). Activate and
then connect them one
by one to identify which
unit produces the com-
munication error.
ware
sion.
2:515 No response is received from • Error on CAN bus wiring 1) Check the CAN bus
(DHU/TWIS) or connection Check that CAN is intact
Allt stoppas direkt, parkerings- • Wrong setting for para- in terms of wiring har-
broms aktiveras och huvudkon- meter 102 ness, resistance and
taktor öppnas. connectors. Disconnect
• No connection with K110 the battery. Check that
No return signal from K110 • Loose connections the resistance between
(DHU/TWIS) within 0.6 seconds (X41:3) and (X41:4) is 54
after logging on • Software failure
- 66 ohms.
ing harness is not
ance between the
kOhm

7 Troubleshooting

2:515 No response is received from 2) Check parameters.
(DHU/TWIS) Check that factory para-
Allt stoppas direkt, parkerings- meters are set according
broms aktiveras och huvudkon- to the truck configura-
taktor öppnas. tion.
No return signal from K110 meters are set correctly.
(DHU/TWIS) within 0.6 seconds
after logging on 3) Check K110 (DHU/
TWIS)
Check that the DHU's
green LED is lit. If the
LED is not lit: Check the
DHU's feed voltage =
battery voltage
Check that it is possible
to connect TruckCom to
the DHU. If it is possible
to connect them, check
the DHU's configuration.
If there is a power supply
but no communication,
check the CAN bus. If it
still not possible to com-
municate with the DHU,
replace the unit.
tions
appears.
ware
sion.
2:516 A5 has an incorrect box ad- • Box address error on A5 1) Check whether contact
dress. X203 is short circuited. If
Allt stoppas direkt, parkerings- a jumper is fitted, re-
broms aktiveras och huvudkon- move it.
taktor öppnas. 2) Replace A5
There is a jumper/short circuit in See section “13.1.6 Re-
contact X203 between pin 1 and placing the logic cards”.
0 V internally on the A5 card.
2:520 Parameter values do not match • Checksum error 1) Set new checksum
Allt stoppas direkt, parkerings- • New software has been If the problem with the
broms aktiveras och huvudkon- loaded in the truck, check sum occurs dir-
taktor öppnas. adding a new parameter, ectly in connection with
or it has changed the the software update, pro-
The checksum of the parameter ceed as follows:
values does not match the para- parameter limit values
Change the value of one
meter values. • Corrupt memory circuit parameter in each cat-
egory, operator paramet-

7 Troubleshooting

2:520 Parameter values do not match ers, service parameters
Allt stoppas direkt, parkerings- and calibration paramet-
broms aktiveras och huvudkon- ers.
taktor öppnas. Save the changes and
restart the truck.
The checksum of the parameter Reset the values you
values does not match the para- changed in the previous
meter values. step back to their original
values.
Restart the truck. 7
The program will have
performed a new check-
sum calculation.
2) Check parameters
tion.
3) Replace A5
2:522 Incorrect power supply to the • Incorrect power supply to 1) Check the Hall sensors
Hall sensors. the Hall sensors. Check with TruckCom or
Motorbromsning till stopp the built-in test that the
därefter aktiveras parkerings- Hall sensors work the
broms och huvudkontaktor way they should.
öppnas. A Hall sensor that is be-
ing influenced should
High (or low) signal from all Hall give a low signal.
sensors A5:S300-S318 Replace A5 if the Hall
sensors have an error
function. See section
“13.1.6 Replacing the lo-
gic cards”.
2:523 Internal memory (FRAM or • Corrupt memory circuit 1) Replace A5
RAM) is faulty See section “13.1.6 Re-
Allt stoppas direkt, parkerings- placing the logic cards”.
broms aktiveras och huvudkon-
taktor öppnas.
Reading from or writing to
memory failed
2:525 Truck software • Software download inter- 1) Update the truck soft-
A5 does not have any truck soft- rupted ware.
ware Update the truck entire
software package to the
Truck behaviour latest available version.
The truck cannot be started

7 Troubleshooting

2:540 Contactor points in the main • Contactor points in the 1) Check contactor
contactor fused main contactor are Check the function of the
High voltage over the capacitor fused. Q10:3, Q10:4 main contactor and that
bank internally in the motor con- there is no connection
trol unit on the secondary side between the points.
of the connector when it is open Check that there is no
short-circuit that can
Truck behaviour cause improper power
Everything is stopped at once, supply.
the parking brake is activated, If this voltage does not
and the main contactor opens increase when the main
contactor pulls and the
voltage is close to bat-
tery voltage (measured
via precharge in), it is a
sign that the contactor
points in the main con-
tactor are fused.
Replace the contactor.
2:541 Contactor points fused • Contactor points in the 1) Check contactor
Contactor points for steering main contactor are Check the function of the
servo and pump etc. in the main fused. Q10:1, Q10:2 main contactor and that
contactor are fused. Voltage on there is no connection
this side is measured through between the points.
the steering servo. Check that there is no
Truck behaviour cause improper power
Everything is stopped at once, supply.
the parking brake is activated, On this side of the main
and the main contactor opens contactor, there is no
PTC resistor that can
precharge any capacitor
bank. So, this voltage
drops towards zero when
the main contactor is
open. Check that the
voltage drops at least 1
V over 5 seconds before
trying to pull the main
contactor again.
2:560 Main contactor ordered to close • Fuse F1 defective 1) Check fuses
but stays open. • Poor or no connection Check if there is any
Low voltage on the secondary between the points. contact on the fuse. Re-
side of the contactor when it is place the fuse if it is de-
• Broken wiring fective.
closed
Truck behaviour 2) Check contactor
Everything is stopped at once, Check the contactor's
the parking brake is activated, function and that there is
and the main contactor opens a connection between
the points [Q10:3] and
[Q10:4].
cause improper power
supply.

7 Troubleshooting

2:560 Main contactor ordered to close 3) Check wiring after the
but stays open. break.
Low voltage on the secondary Disconnect the battery
side of the contactor when it is Using instruments, check
closed that there is no break in
any wire.
Truck behaviour Measure and check the
Everything is stopped at once, voltage for the activated
the parking brake is activated, functions
and the main contactor opens
7
2:561 Main contactor ordered to close • Fuse F53 defective 1) Check fuses
but stays open. • Poor or no connection Check if there is any
Low voltage on the secondary between the points. contact on the fuse. Re-
side of the contactor when it is place the fuse if it is de-
• Broken wiring fective.
closed
Truck behaviour 2) Check contactor
Everything is stopped at once, Check the contactor's
the parking brake is activated, function and that there is
and the main contactor opens a connection between
the points [Q10:1] and
[Q10:2].
cause improper power
supply.
3) Check wiring after the
break.
Disconnect the battery
Using instruments, check
any wire.
tions activated
2:580 Signal from Hall element • A5 defective 1) Check the Hall sensors
Motorbromsning till stopp Check with TruckCom or
därefter öppnas huvudkontaktor the built-in test for the
och parkeringsbroms aktiveras. Hall sensors that they
work the way they
The Hall element for the speed should. A Hall sensor
control gives a signal (active that is being influenced
low) when it should not should give a low signal.
Replace A5 if the Hall
gic cards”.
3:001 The speed control was not in • Control manipulated. 1) Let go of the control, and
the neutral position at start-up • The speed control does wait for four seconds
Trucken kan inte köras, övriga not spring back to neut- 2) Check the speed control
funktioner ok. ral position. Check the spring func-
One or more Hall elements for • A5 defective tion
the speed control give an active Check that the speed
signal at start control is not seized

7 Troubleshooting

3:001 The speed control was not in Check that the plastic
the neutral position at start-up cover where the spring is
Trucken kan inte köras, övriga attached is intact.
funktioner ok. 3) Check the Hall sensors
One or more Hall elements for Check with TruckCom or
the speed control give an active the built-in test for the
signal at start Hall sensors that they
work the way they
should. A Hall sensor
that is being influenced
should give a low signal.
Replace A5 if the Hall
gic cards”.
3:080 Temperature sensor out of • Cooling is reduced or the 1) Check the cooling
range temperature sensor is Check the cooling
Motorstyrningen begränsar defective. flanges of the transistor
strömmen. regulator, motor and
steering motor as well as
The temperature sensor in the the battery charger and
motor control power stage is fans and filters for accu-
outside the limit values. Above mulations of dirt and
130°C dust. Too much dust and
dirt cause the cooling not
to work properly.
Check that the fans work
when the speed control
is activated (fans behind
T1 and motor fan)
Check that the fan on
charger T14 works when
the charging begins, i.e.
when the mains cable is
connected
Check the signal from
the temperature sensors
for T1 and T13 and from
B1 using the built-in test
or TruckCom. Determine
if the temperature sig-
nals are plausible relat-
ive to the real temperat-
ures of the components.
If not, replace T1,T13 or
replace B1 with a repair
kit.
3:081 The motor temperature sensor • Cooling is reduced or the 1) Check the cooling
is outside of limit values. temperature sensor is Check the cooling
Kryphastighet och motorstyrnin- defective. flanges of the transistor
gen begränsar strömmen. regulator, motor and
Above 210°C. the battery charger and
fans and filters for accu-
mulations of dirt and
dust. Too much dust and

7 Troubleshooting

3:081 The motor temperature sensor to work properly.
is outside of limit values. Check that the fans work
Kryphastighet och motorstyrnin- when the speed control
gen begränsar strömmen. is activated (fans behind
T1 and motor fan)
Above 210°C. Check that the fan on
connected 7
kit.
3:100 Motor control warning. • Internal program error 1) Create a truck report.
Kryphastighet, blockerad lyft/ • Software failure Send a report to the
sänk rörelse. manufacturer.
Unknown warning 2) Update the truck soft-

sion.
3:120 Incorrect checksum • Motor control corrupt 1) Replace T1
Kryphastighet, blockerad lyft/ See section “14.7.2 Re-
sänk rörelse. placing the motor con-
trol”.
Incorrect checksum for the mo-
tor control parameters
3:127 Output current • Defective transistor on 1) Replace T1
The strength of the current the output See section “14.7.2 Re-
through the horn is more than placing the motor con-
200mA even though the output trol”.
is deactivated
Truck behaviour
Not influenced
The strength of the current the output See section “14.7.2 Re-
through the output to the fans is placing the motor con-
more than 200mA even though trol”.
the output is deactivated
Truck behaviour
Not influenced

7 Troubleshooting

3:140 Short circuit in horn output • High power consumption 1) Check for overcurrent or
Inte påverkad. or short circuit short circuit:
Check the ohms and the
Hardware protection in T1 de- amperes of the compon-
tects a short circuit in the output ent, compare them to the
for the horn. The current setpoint values if they
through the horn is above the outside the accepted
valid limit value. Maximum value range.
= 500mA, continuous value = Check the connections
300mA and wiring harness for
short-circuit.
Check that the compon-
ent does not seize or is
jammed.
If points 1-3 are OK, it in-
dicates that the output
stage is short circuited -
Replace the power-sup-
plying component
3:141 Short circuit in fan output. • High power consumption 1) Check for overcurrent or
Hardware protection in T1 de- or short circuit short circuit:
tects a short circuit in the output Check the ohms and the
for the fans. The current through amperes of the compon-
the fan is above the valid limit ent, compare them to the
value. Maximum value = 2.5A, setpoint values if they
continuous value = 1.5A outside the accepted
range.
Truck behaviour Check the connections
Not influenced and wiring harness for
short-circuit.
jammed.
plying component
3:225 High motor rpm • Defective component 1) Check the rotational
T1 detects to high speed for the speed sensor
motor, more than 5000 rpm Disconnect the B11.
Check that there are no
Truck behaviour metal fragments on B11
Creep speed sensor points.
Check that the toothed
wheel on the motor axle
is clean, intact and prop-
erly mounted.
3:303 Motor control start-up failed • Error on CAN bus wiring 1) Check the CAN bus
Trucken kan inte startas. or connection Check that CAN is intact
• Incorrect value for para- in terms of wiring har-
meter 1001 ness, resistance and
connectors. Disconnect
• No power supply the battery. Check that
• Wrong kind of motor the resistance between
control (X41:3) and (X41:4) is 54
- 66 ohms.

7 Troubleshooting

3:303 Motor control start-up failed Check that the CAN wir-
Trucken kan inte startas. ing harness is not
ance between the
kOhm
2) Check parameters.
meters are set according 7
tion.
3) Check wiring after the
break.
any wire.
voltage for the activated
functions
4) Replace T1
trol”.
3:500 Internal error in T1 • Internal program error 1) Create a truck report.
• Software failure Send a report to the
manufacturer.
Truck behaviour • Defective motor control
Everything is stopped at once, 2) Update the truck soft-
the parking brake is activated, ware to the latest ver-
and the main contactor opens sion.
3) Replace T1
trol”.
3:502 Error in T1 • Defective motor control 1) Replace T1
Allt stoppas direkt, parkerings- See section “14.7.2 Re-
broms aktiveras och huvudkon- placing the motor con-
taktor öppnas. trol”.
Error in T1 when saving para-

meters
3:505 Unknown error in T1 • No software compatibility 1) Update the truck soft-
Allt stoppas direkt, parkerings- ware
broms aktiveras och huvudkon- Update the truck entire
taktor öppnas. software package to the

7 Troubleshooting

3:506 Low battery voltage • Battery discharged 1) Charge the battery
Motor control detects excess- • Voltage loss on supply to 2) Check battery voltage
ively low battery voltage at start- T1 Check the voltage using
up. Battery voltage below 15.3V the built-in test proced-
after 10 seconds from power-on ure and comparing with
Truck behaviour value from external volt
The truck cannot be started meter
Check connectors, joints
or corrosion.
3:507 Internal error in T1 • Defective motor control 1) Replace T1
Allt stoppas direkt, parkerings- See section “14.7.2 Re-
broms aktiveras och huvudkon- placing the motor con-
taktor öppnas. trol”.
3:511 CAN communication problem • Error on CAN bus wiring 1) Check the CAN bus
Allt stoppas direkt, parkerings- or connection Check that CAN is intact
broms aktiveras och huvudkon- • CAN module in A5 de- in terms of wiring har-
taktor öppnas. fective ness, resistance and
CAN communication problem the battery. Check that
between T1 and A5, A5 gets no the resistance between
signals from T1 (X41:3) and (X41:4) is 54
- 66 ohms.
ing harness is not
ance between the
kOhm
2) Replace the A5, see sec-
tion “13.1.6 Replacing
the logic cards”.
Allt stoppas direkt, parkerings- or connection Check that CAN is intact
broms aktiveras och huvudkon- in terms of wiring har-
taktor öppnas. ness, resistance and
CAN communication problem the battery. Check that
between A5 and T1, T1 gets no the resistance between
signals from A5 (X41:3) and (X41:4) is 54
- 66 ohms.
ing harness is not
ance between the
kOhm

7 Troubleshooting

CAN communication problem, or connection Check that CAN is intact
A5 cannot send to T1 • CAN module in A5 de- in terms of wiring har-
fective ness, resistance and
Truck behaviour connectors. Disconnect
Everything is stopped at once, the battery. Check that
the parking brake is activated, the resistance between
and the main contactor opens (X41:3) and (X41:4) is 54
- 66 ohms.
ing harness is not
ance between the
kOhm
2) Replace A5
3:520 Signal earthing in T1 • The ground for speed
Signal earthing in T1 out of valid sensor and temperature
range (TBD) sensor is connected to
chassis, battery- or bat-
Truck behaviour tery+
Everything is stopped at once,
the parking brake is activated,
The amperage through the out- the output See section “14.7.2 Re-
put to the brake (Q1) is more placing the motor con-
than 200mA even though the trol”.
output is deactivated
Truck behaviour
The amperage through the out- the output See section “14.7.2 Re-
put to the main contactor (Q10) placing the motor con-
is more than 200mA even trol”.
though the output is deactivated
Truck behaviour
3:525 High motor rpm • Defective component 1) Check the rotational
T1 detects to high speed for the speed sensor
motor, more than 6000 rpm Disconnect the B11.
Truck behaviour metal fragments on B11
The drive is stopped immedi- sensor points.
ately with the parking brake Check that the toothed
erly mounted.

7 Troubleshooting

3:540 Short circuit in power stage • Short circuit in motor 1) Check the motor
Allt stoppas direkt, parkerings- • Short circuit in motor wir- Disconnect motor wiring
broms aktiveras och huvudkon- ing harness including sensor wires.
taktor öppnas. Insulation test.
• Short circuit in power Check that the coils are
Hardware in T1 detects a short stage not electrically connec-
circuit in the power stage and a ted to the chassis. Re-
phase-to-phase short circuit, place M1 if the motor is
phase B- and phase B+ not isolated
2) Check the motor wiring
harness
Visual check of the mo-
tor wiring harness.
contact between the pole
connections on the mo-
tor/motor control. Search
for contact and damaged
insulation on the wiring
harness.
Disconnect the motor
wiring harness at the
motor control and the
motor and measure the
ohms of the wiring har-
ness between the
phases and verify that
there is no contact.
3) Replace T1
trol”.
3:542 High current in speed sensor • High power consumption 1) Check for overcurrent or
Too many amperes to the or short circuit short circuit:
speed sensor, limit value 68 mA Check the ohms and the
amperes of the compon-
Truck behaviour ent, compare them to the
The drive is stopped immedi- setpoint values if they
ately with the parking brake outside the accepted
range.
Check the connections
and wiring harness for
short-circuit.
jammed.
plying component

7 Troubleshooting

3:545 Output short circuit • High power consumption 1) Check for overcurrent or
Allt stoppas direkt, parkerings- or short circuit short circuit:
broms aktiveras och huvudkon- Check the ohms and the
taktor öppnas. amperes of the compon-
ent, compare them to the
Hardware protection in T1 de- setpoint values if they
tects a short circuit in the output outside the accepted
to the brake (Q1) The current range.
through the brake exceeds the Check the connections
limit values. Maximum value =
5.95A, continuous value = 3A
and wiring harness for 7
short-circuit.
jammed.
plying component
3:546 Short circuit or current in main • High power consumption 1) Check for overcurrent or
contactor or short circuit short circuit:
Allt stoppas direkt, parkerings- Check the ohms and the
broms aktiveras och huvudkon- amperes of the compon-
taktor öppnas. ent, compare them to the
setpoint values if they
Hardware protection in T1 de- outside the accepted
tects a short circuit or current range.
through the main contactor Check the connections
(Q10) exceeds valid limit val- and wiring harness for
ues. Maximum value = 2.5A, short-circuit.
continuous value = 1.5A Check that the compon-
jammed.
plying component
3:547 Output short circuit • Components are using 1) Check components that
Allt stoppas direkt, parkerings- too much power or wiring are supplied with power
broms aktiveras och huvudkon- is short circuited. from the High Side Out
taktor öppnas. • No software compatibility (Main contactor, pump
contactor (if low-lifting),
Hardware protection in T1 de- • Short circuit in power brake coil and lowering
tects a short circuit in the output stage valve).
“High Side driver”
outside the accepted
range.
short-circuit.
jammed.

7 Troubleshooting

3:547 Output short circuit If points 1-3 are OK, it in-
Allt stoppas direkt, parkerings- dicates that the output
broms aktiveras och huvudkon- stage is short circuited -
taktor öppnas. Replace the power-sup-
plying component
Hardware protection in T1 de-
tects a short circuit in the output 2) Update the truck soft-
“High Side driver” ware
sion.
3) Replace T1
3:560 Low current • Broken wiring 1) Check wiring after the
The amperage to speed sensor • Defective component break.
(B11) is below the 6mA limit Disconnect the battery
value Using instruments, check
Truck behaviour any wire.
The drive is stopped immedi- Measure and check the
ately with the parking brake voltage for the activated
functions
2) Check the rotational
speed sensor
Disconnect the B11.
metal fragments on B11
sensor points.
erly mounted.
3:563 Low current • Low power consumption 1) Check wiring and com-
Allt stoppas direkt, parkerings- or break ponent after the break
broms aktiveras och huvudkon- Disconnect the battery
taktor öppnas. Visually check the wiring
harness
The amperage is below the limit Using instruments, check
value 100mA on the output to that there is no break in
brake (Q1) any wire
Check the Ohms and the
Amperes of the compon-
setpoint values, and re-
place the unit if they are
range.
Reconnect the battery.
functions.

7 Troubleshooting

Allt stoppas direkt, parkerings- or break ponent after the break
broms aktiveras och huvudkon- Disconnect the battery
taktor öppnas. Visually check the wiring
harness
The amperage is below the limit Using instruments, check
value 100mA on the output to that there is no break in
brake (Q10) any wire
Amperes of the compon- 7
range.
functions.
3:584 Power supply outside of valid • High power consumption 1) Check for overcurrent or
range or short circuit. short circuit:
Power supply to B11 out of valid • Defective motor control. Check the ohms and the
range. External 12V outside of amperes of the compon-
valid range: 10V - 14V ent, compare them to the
Truck behaviour outside the accepted
The drive is stopped immedi- range.
ately with the parking brake Check the connections
short-circuit.
jammed.
plying component
2) Replace T1
trol”.
3:586 High current • Short circuit in motor 1) Check the motor
Software in T1 detects too high • Short circuit in motor wir- Disconnect motor wiring
a current in the power stage and ing harness including sensor wires.
also high current phase-phase, Insulation test. Check
• Short circuit in power that the coils are not
phase B- and phase B+. The stage
current is 150% of maximum electrically connected to
current. the chassis. Replace M1
if the motor is not isol-
Truck behaviour ated
The drive is stopped immedi-
ately with the parking brake 2) Check the motor wiring
harness
Visual check of the mo-
tor wiring harness.
contact between the pole

7 Troubleshooting

3:586 High current connections on the mo-
Software in T1 detects too high tor/motor control. Search
a current in the power stage and for contact and damaged
also high current phase-phase, insulation on the wiring
phase B- and phase B+. The harness.
current is 150% of maximum Disconnect the motor
current. wiring harness at the
motor control and the
Truck behaviour motor and measure the
The drive is stopped immedi- ohms of the wiring har-
ately with the parking brake ness between the
phases and verify that
there is no contact.
3) Replace T1
trol”.
3:587 Battery voltage exceeds 33 V • Voltage loss on supply to 1) Check battery voltage
T1 Check the voltage using
• Battery defective the built-in test proced-
Truck behaviour ure and comparing with
Everything is stopped at once, value from external volt
the parking brake is activated, meter
and the main contactor opens Check connectors, joints
or corrosion.
3:589 Battery voltage is below 12 V • The battery is dis- 1) Charge the battery.
Allt stoppas direkt, parkerings- charged 2) Check the voltages in T1
broms aktiveras och huvudkon- • Voltage loss on power Check fuses F50 and F1
taktor öppnas. supply to T1 Check the voltage using
• The battery is defective a volt meter (Measuring
• Battery parameter # 107 pare with the TruckCom
has an erroneous value value “Battery
ues?) (TBD)
pare with the TruckCom
value “Battery
ues?) If the contactor is
open, there is several
volts of difference -- nor-
mal. If the contactor is
closed, voltage should
match the point across
±XX
joints and splices
Check that any extra

7 Troubleshooting

3:589 Battery voltage is below 12 V equipment is connected
Allt stoppas direkt, parkerings- in accordance with our
broms aktiveras och huvudkon- recommendation.
taktor öppnas. 3) Check the battery.
4) Check parameters
tion.
7
3:590 Change in rpms • Broken wiring 1) Check wiring after the
Drivning stoppas direkt med • Defective component break.
parkeringsbroms. Disconnect the battery
• Change in surface fric- Using instruments, check
The change exceeds 1000 rpm tion combined with slip- that there is no break in
in 20 ms page any wire.
tions activated
speed sensor
Disconnect the B11.
sensor points.
erly mounted.
3) Drive carefully if there is
a risk of slipping
3:591 Improbable motor rpm • Defective component 1) Check the rotational
Rpms over 15.000 rpm speed sensor
Disconnect the B11.
Truck behaviour Check that there are no
The drive is stopped immedi- metal fragments on B11
ately with the parking brake sensor points.
erly mounted.
3:592 Internal electrical fault. • Defective motor control 1) Replace T1
Sensor offset is too high See section “14.7.2 Re-
Truck behaviour trol”.
The drive is stopped immedi-
ately with the parking brake
3:593 Signal error B11. • Broken wiring 1) Check wiring after the
Loss of channel A in the rota- • Defective component break.
tional speed sensor detected Disconnect the battery
Truck behaviour that there is no break in
The drive is stopped immedi- any wire.
ately with the parking brake

7 Troubleshooting

3:593 Signal error B11. Measure and check the
Loss of channel A in the rota- voltage with the func-
tional speed sensor detected tions activated
Truck behaviour 2) Check the rotational

The drive is stopped immedi- speed sensor
ately with the parking brake Disconnect the B11.
sensor points.
erly mounted.
3:594 Signal error B11. • Broken wiring 1) Check wiring after the
Loss of channel B in the rota- • Defective component break.
tional speed sensor detected Disconnect the battery
Truck behaviour that there is no break in
The drive is stopped immedi- any wire.
ately with the parking brake Measure and check the
tions activated
speed sensor
Disconnect the B11.
sensor points.
erly mounted.
3:596 High temperature • Intensive use of the truck 1) Intensive use of the
The motor control unit temperat- • Cooling is reduced or the truck. Let the truck cool
ure exceeds +110°C. temperature sensor is down.
Truck behaviour defective. 2) Check the cooling

The drive is stopped immedi- Check the cooling
ately with the parking brake flanges of the transistor
regulator, motor and
the battery charger and
to work properly.
T1 and motor fan)
connected

7 Troubleshooting

3:596 High temperature for T1 and T13 and from
The motor control unit temperat- B1 using the built-in test
ure exceeds +110°C. or TruckCom. Determine
Truck behaviour nals are plausible relat-
The drive is stopped immedi- ive to the real temperat-
ately with the parking brake ures of the components.
kit. 7
The motor temperature exceeds • Cooling is reduced or the truck. Let the truck cool
+180°C. temperature sensor is down.

The drive is stopped immedi- Check the cooling
ately with the parking brake flanges of the transistor
to work properly.
T1 and motor fan)
connected
kit.
3:598 Internal voltage is outside of • Defective motor control 1) Replace T1
permitted range See section “14.7.2 Re-
Internal 5V outside of valid placing the motor con-
range: 4.12V - 5.88V or internal trol”.
15V voltage outside valid range:
10.56V - 19V
Truck behaviour

7 Troubleshooting

3:599 Voltage regulator for analogue • High power consumption 1) Check for overcurrent or
sensors or short circuit short circuit:
Outside of valid range: 4V - 6V Check the ohms and the
Creep speed, blocked lifting/ setpoint values if they
lowering movement outside the accepted
range.
short-circuit.
jammed.
plying component.
4:001 Lifting/lowering control is not in • Control manipulated 1) Let go of the control, and
neutral position at start-up. wait for four seconds
Blockerad lyft/sänk rörelse.
Lifting is prevented until the lift-
ing/lowering controller is back in
the neutral position.
4:003 Armature current on pump mo- • Low power consumption 1) Check wiring and com-
tor too low. Check F2 or break ponent after the break
Visually inspect the wir-
Truck behaviour ing harness
Blocked lifting movement Using instruments, check
any wire
range.
functions.
4:101 Signal error • Defective component, 1) Check the sensilift
Blockerad lyft/sänk rörelse. short circuit or wire cut Check that the sensor
off has a supply voltage of
The signal from the sensilift is approx. 5V
out of valid range: 0.23V - 4.71V Compare the measured
output from the sensilift
with the corresponding
value in TruckCom or
built-in test. If the values
are the same and are out
of the valid range, it in-
dicates an error in the
sensilift potentiometer or

7 Troubleshooting

4:101 Signal error the wiring harness. Re-
Blockerad lyft/sänk rörelse. pair or replace the com-
ponent.
The signal from the sensilift is If the values are not the
out of valid range: 0.23V - 4.71V same, it points to an er-
ror in A5. - Replace A5.
4:102 Signal error • Incorrect value for para- 1) Check parameters
Blockerad lyft/sänk rörelse. meter 1102 Check that factory para- 7
• Error in hydraulic con- meters are set according
Signal from the sensilift poten- to the truck configura-
tiometer detected even though trols
tion.
parameter 1102 does not have Check that other para-
the value 4. meters are set correctly.
2) Replacement of the hy-
draulic control.
See section "13.1 Steer-
ing arm C4110".
4:103 Internal error in T1 • Defective motor control 1) Replace T1
Blocked lifting movement
4:105 Voltage from B127 is outside of • Defective component, 1) Check the analogue
permitted range: 0.3 V - 4.7 V short circuit or wire cut sensors
off Check that the sensor
• Tilt sensor in the wrong has a 5V or 24V power
Truck behaviour supply (depending on
Creep speed, blocked lifting position
the component)
movement • Tilt sensor incorrectly Compare the measured
calibrated output from the sensor
sensor or the wiring har-
ness. Repair or replace
the component.
If the values are not the
same, it points to an er-
ror in T1. Replace T1
trol”.
2) Check the tilt sensor
Check that B127 has
been fitted correctly and
securely.
Make sure the truck is
parked on a level sur-
face.
B127 via Service Inform-
ation mode 8 or Truck-

7 Troubleshooting

4:105 Voltage from B127 is outside of Com. Type value 2.5 V =
permitted range: 0.3 V - 4.7 V 0°. Adjust B127 mechan-
ically if necessary.
Calibrate B127 via calib-
Truck behaviour ration 4
Creep speed, blocked lifting
movement 3) See point 2
4:107 Valve does not close • B123 incorrectly adjus- 1) Check decompression
Expected position of valve Q71 ted locking
does not match read position of
B123. Decompression lock
valve Q71 is stuck in the open
position
Truck behaviour
movement
4:108 B140 indicates a low oil level in • 1) Check decompression
spring decompression locking locking
Truck behaviour
movement
4:110 Template • B123 incorrectly adjus- 1) Check decompression
Expected position of valve Q71 ted locking
does not match read position of
B123. Decompression lock
valve Q71 is stuck in the closed
position
Truck behaviour
movement
4:120 Sensor offset is too high • Defective motor control 1) Replace T1
4:121 High current • Pump motor or its wiring 1) Check the pump motor
Software in T1 detects too high harness defective Disconnect the motor
a current in the pump power cables. Insulation test.
stage The current is 150% of Check that the coils are
maximum current. not electrically connec-
ted to the chassis. If mo-
Truck behaviour tor is not insulated, re-
Blocked lifting movement place the motor (M3)
4:123 Field winding output overloaded • Intensive use of the truck 1) Intensive use of the
• Pump motor or its wiring truck. Let the truck cool
harness defective down.
Truck behaviour
Blocked lifting movement 2) Check the pump motor
Disconnect the motor
cables
Insulation test. Check
that the coils are not
electrically connected to

7 Troubleshooting

4:123 Field winding output overloaded the chassis. If motor is
not insulated, replace the
motor (M3)
Truck behaviour
4:180 Pressure sensor signal • Defective component, 1) Check the analogue
B4 is outside the valid range: short circuit or wire cut sensors
0.3 V - 4.86 V off Check that the sensor
has a 5V or 24V power
Truck behaviour supply (depending on 7
Creep speed, blocked lifting the component)
movement Compare the measured
output from the sensor
the component.
ror in T1.
Replace T1 see section
“14.7.2 Replacing the
motor control”.
4:181 Signal outside of valid range • Defective component, 1) Check the analogue
The signal from the pressure short circuit or wire cut sensors
sensor B5 is out of valid range: off Check that the sensor
0.3 V - 4.86 V has a 5V or 24V power
supply (depending on
Truck behaviour the component)
Creep speed, blocked lifting Compare the measured
movement output from the sensor
the component.
trol”.

7 Troubleshooting

4:182 Signal outside of valid range • Defective component, 1) Check the analogue
The signal from the reach short circuit or wire cut sensors
sensor B14 is out of the valid off Check that the sensor
range: 0.3 V - 4.86 V has a 5V or 24V power
Creep speed, blocked lifting Compare the measured
movement output from the sensor
the component.
trol”.
4:200 Low pressure in Powertrak cir- • Defective component, 1) Check the analogue
cuit short circuit or wire cut sensors
during transport (lifting height < off Check if Q58/Q59 and
1.8 m). Signal from B5 too low • PowerTrak B4/B5 are correctly con-
in relation to B4. Min. value 300 nected or have been
mV mistaken for one an-
other.
Truck behaviour Check that the sensor
Creep speed, blocked lifting has a 5V or 24V power
movement supply (depending on
the component)
Compare the measured
the component.
trol”.
2) Check PowerTrak

7 Troubleshooting

4:201 High pressure in Powertrak cir- • Defective component, 1) Check the analogue
cuit short circuit or wire cut sensors
in stacking mode (lifting height > off Check if Q58/Q59 and
1.8 m). Signal from B5 too high. • PowerTrak B4/B5 are correctly con-
Max. value 1500 mV nected or have been
mistaken for one an-
Truck behaviour other.
Creep speed, blocked lifting Check that the sensor
movement has a 5V or 24V power
supply (depending on 7
the component)
Compare the measured
the component.
trol”.
2) Check PowerTrak
4:231 Current through output to • Defective transistor on 1) Replace T1
Powertrak valve the output. See section “14.7.2 Re-
(Q58) is more than 200 mA placing the motor con-
even though the output is not trol”.
active.
Truck behaviour
Exceeds 200mA to the pump the output. See section “14.7.2 Re-
contactor (Q25) when it is not placing the motor con-
active. trol”.
Truck behaviour
4:233 Current through output to Q70 • Defective transistor on 1) Replace T1
Exceeds 200mA even though the output. See section “14.7.2 Re-
the output is not active placing the motor con-
trol”.
Truck behaviour

7 Troubleshooting

4:234 Current through output to Q4/ • Defective transistor on 1) Replace T1
Q40 the output. See section “14.7.2 Re-
Current through the Q4/Q40 placing the motor con-
output is more than 200 mA trol”.
even though the output is inact-
ive.
Truck behaviour
4:235 Current through output to Q41/ • Defective transistor on 1) Replace T1
Exceeds 200 mA even though placing the motor con-
the output is not active trol”.
Truck behaviour
4:236 Too high current in output to • Defective transistor on 1) Replace T1
Current more than 200mA when placing the motor con-
not activated trol”.
Truck behaviour
Plug braking to stop, then the
parking brake is activated and
the main contactor opens
4:238 Too high current in output to • Defective transistor on 1) Replace T1
shunt the output. See section “14.7.2 Re-
Current more than 200mA when placing the motor con-
not activated trol”.
Truck behaviour
4:242 Pump motor (M3) output is short • Pump motor or its wiring 1) Check the pump motor
circuited or too high a current harness defective Disconnect the motor
through the output cables
Insulation test. Check
that the coils are not
Truck behaviour electrically connected to
Plug braking to stop, then the the chassis. If motor is
parking brake is activated and not insulated, replace the
the main contactor opens motor (M3)
4:243 Lowering valve (Q4/Q40) • High power consumption 1) Check for overcurrent or
Output is short circuited or cur- or short circuit. short circuit:
rent too high through the output Check the ohms and the
to lowering valve. Valid limit val- amperes of the compon-
ues - maximum value = 2.5 A, ent, compare them to the
continuous value = 1.5 A setpoint values if they
Truck behaviour range.
Blocked lifting/lowering move- Check the connections
ment and wiring harness for

7 Troubleshooting

4:243 Lowering valve (Q4/Q40) short-circuit.
Output is short circuited or cur- Check that the compon-
rent too high through the output ent does not seize or is
to lowering valve. Valid limit val- jammed.
ues - maximum value = 2.5 A, If points 1-3 are OK, it in-
continuous value = 1.5 A dicates that the output
Truck behaviour Replace the power-sup-
Blocked lifting/lowering move- plying component
ment
7
4:244 Solenoid (Q41/Q23) • High power consumption 1) Check for overcurrent or
to lowering valve. Valid limit val- amperes of the compon-
Blocked lifting/lowering move- Check the connections
ment and wiring harness for
short-circuit.
jammed.
plying component
4:245 Drain valve Powertrak (Q58) • High power consumption 1) Check for overcurrent or
to the drain valve. Valid limit val- amperes of the compon-
Creep speed, blocked lifting Check the connections
movement and wiring harness for
short-circuit.
jammed.
plying component

7 Troubleshooting

4:246 Hardware protection in T1 • High power consumption 1) Check for overcurrent or
Detected a short circuit in output or short circuit short circuit:
Q25 (pump contactor). The cur- Check the ohms and the
rent through the contactor (Q25) amperes of the compon-
is above the valid limit value. ent, compare them to the
Maximum value = 2.5 A, con- setpoint values if they
tinuous value = 1.5 A outside the accepted
range.
Blocked lifting/lowering move- and wiring harness for
ment short-circuit.
jammed.
plying component
4:247 Hardware protection in T1 • High power consumption 1) Check for overcurrent or
Q70 (decompression locking Check the ohms and the
valve) or current through the amperes of the compon-
valve output exceeds the limit ent, compare them to the
values. Maximum value = 2.5 A, setpoint values if they
continuous value = 1.5 A outside the accepted
range.
Creep speed, blocked lifting and wiring harness for
movement short-circuit.
jammed.
plying component
4:248 Filling valve (Powertrak Q59) • High power consumption 1) Check for overcurrent or
Q59 or current through the Check the ohms and the
valve output exceeds the limit amperes of the compon-
values. Maximum value = 2.5 A, ent, compare them to the
Creep speed, blocked lifting Check the connections
movement and wiring harness for
short-circuit.
jammed.
plying component

7 Troubleshooting

4:250 Short circuit • High power consumption 1) Check for overcurrent or
Short circuit detected or short circuit short circuit:
Truck behaviour amperes of the compon-
Creep speed, blocked lifting ent, compare them to the
movement setpoint values if they
range.
and wiring harness for 7
short-circuit.
jammed.
plying component
4:280 High temperature • Cooling is reduced or the 1) Check the cooling
The temperature sensor for the temperature sensor is Check the cooling
pump power stage in T1 is out- defective. flanges of the transistor
side of the limit values. The regulator, motor and
temperature shown exceeds steering motor as well as
130°C the battery charger and
Truck behaviour mulations of dirt and
Blocked lifting movement dust. Too much dust and
to work properly.
T1 and motor fan)
connected
kit.
The temperature in T1's pump temperature sensor is Check the cooling
power stage exceeds 85°C. defective. flanges of the transistor
Truck behaviour steering motor as well as
Blocked lifting movement the battery charger and

7 Troubleshooting

4:281 High temperature mulations of dirt and
The temperature in T1's pump dust. Too much dust and
power stage exceeds 85°C. dirt cause the cooling not
to work properly.
Truck behaviour Check that the fans work
Blocked lifting movement when the speed control
T1 and motor fan)
connected
kit.
4:561 Current on Powertrak valve • Low power consumption 1) Check wiring and com-
(Q58) output is too low or break ponent after the break
Current below limit of 100mA Disconnect the battery
Creep speed, blocked lifting Using instruments, check
movement that there is no break in
any wire
range.
functions.
4:562 Pump contactor output current • Low power consumption 1) Check wiring and com-
too low (Q22, Q25, Q52) or break ponent after the break
Limit value 100mA Disconnect the battery
Blocked lifting/lowering move- Using instruments, check
ment that there is no break in
any wire

7 Troubleshooting

4:562 Pump contactor output current range.
too low (Q22, Q25, Q52) Reconnect the battery.
Limit value 100mA Measure and check the
Truck behaviour functions.
Blocked lifting/lowering move-
ment
4:563 Current on decompression lock- • Low power consumption 1) Check wiring and com-
ing valve (Q70) output is too low or break ponent after the break
Limit value 100mA Disconnect the battery 7
any wire
range.
functions.
Too low a current on lowering or break ponent after the break
valve output (Q4 - Q40) - limit Disconnect the battery
value 100 mA Visually inspect the wir-
ing harness
Truck behaviour Using instruments, check
Blocked lifting/lowering move- that there is no break in
ment any wire
range.
functions.
4:565 Too low a current on valve out- • Low power consumption 1) Check wiring and com-
put (Q23 - Q41) or break ponent after the break
Limit value 100mA Disconnect the battery
Blocked lifting/lowering move- Using instruments, check
ment that there is no break in
any wire

7 Troubleshooting

4:565 Too low a current on valve out- outside the accepted
put (Q23 - Q41) range.
Limit value 100mA Reconnect the battery.
Truck behaviour voltage for the activated
Blocked lifting/lowering move- functions.
ment
4:566 Current on filler valve (Power- • Low power consumption 1) Check wiring and com-
trak) output is too low or break ponent after the break
any wire
range.
functions.
4:568 Short circuit detected in the field • High power consumption 1) Check for overcurrent or
circuit or short circuit short circuit:
Creep speed, blocked lifting setpoint values if they
movement outside the accepted
range.
short-circuit.
jammed.
plying component
4:600 Reach sensor error • Defective component, 1) Check the analogue
The reach movement is activ- short circuit or wire cut sensors
ated for no apparent reason. off Check that the sensor
has a 5V or 24V power
Truck behaviour supply (depending on
Plug braking to stop, then the the component)
parking brake is activated and Compare the measured
the main contactor opens output from the sensor

7 Troubleshooting

4:600 Reach sensor error dicates an error in the
The reach movement is activ- sensor or the wiring har-
ated for no apparent reason. ness. Repair or replace
the component.
Truck behaviour
4:601 Reach sensor error • Defective component, 1) Check the analogue
The reach sensor was triggered, short circuit or wire cut sensors 7
but not reach movement oc- off Check that the sensor
curred has a 5V or 24V power
Plug braking to stop, then the Compare the measured
parking brake is activated and output from the sensor
the main contactor opens with the corresponding
the component.
The temperature in the steering • Cooling is reduced or the truck. Let the truck cool
motor power stage exceeds temperature sensor is down.
68°C. defective. 2) Check the cooling
Truck behaviour Check the cooling
Not influenced flanges of the transistor
to work properly.
T1 and motor fan)
connected

7 Troubleshooting

5:035 High temperature If not, replace T1,T13 or
The temperature in the steering replace B1 with a repair
motor power stage exceeds kit.
68°C.
Truck behaviour
Not influenced
5:080 Reference sensor error • Broken wiring 1) Check wiring after the
Current below limit of 500µA • Defective component break.
Truck behaviour Using instruments, check
Not influenced that there is no break in
any wire.
functions
2) Check the reference
sensor
Steer slightly to the right
so that the gear ring is
correctly positioned in re-
lation to the reference
sensor.
Cut off power to the
truck.
Check the clearance
between the sensor and
the gear ring elevation
using a feeler gauge.
Nominal measurement:
1.5 mm Note: Risk of
personal injury if power
is restored to the truck
while work is performed
on the gear ring.
Restore power to the
truck.
Check if there is any
power supply to B17, 9.8
- 13.5V between wires
95 and 97.
If there is a power sup-
ply, replace B17.
Check if there is a short
circuit between wires 95
and 97, but also between
wire 95 and the rest of
the electrical system.
If there is no power sup-
ply or short circuit, re-
place the T13
5:081 Power supply to reference • Defective component 1) Check the reference
sensor outside of valid range. sensor
It should be 9.8 - 13.5V Steer slightly to the right
between the wires 95-97. so that the gear ring is
Truck behaviour lation to the reference
Not influenced sensor.

7 Troubleshooting

5:081 Power supply to reference Cut off power to the
sensor outside of valid range. truck.
It should be 9.8 - 13.5V Check the clearance
between the wires 95-97. between the sensor and
Truck behaviour using a feeler gauge.
Not influenced Nominal measurement:
is restored to the truck 7
on the gear ring.
truck.
95 and 97.
ply, replace B17.
and 97, but also between
place the T13
5:135 Steering motor overloaded • Intensive steering with 1) Avoid steering the truck
Overloaded steering motor to stationary truck when stationary
80% of maximum capacity. • Turning of drive wheel 2) Checking the steerability
Truck behaviour was prevented. of the drive unit.
Creep speed Check why the drive
wheel cannot be turned
with the help of the
steering motor in the fol-
lowing places.
Steering motor
Gears of the steering
motor
Gears
Steering bearings
Crown wheel/ steering
motor gear
Drive wheel/surface
5:136 Error in power supply to brake • High power consumption 1) Check for overcurrent or
coil in (A83). or short circuit short circuit:
Current differs from requested • Low power consumption Check the ohms and the
current by 100 mA and current or break amperes of the compon-
exceeds 2 A. ent, compare them to the
Truck behaviour outside the accepted
Creep speed range.
short-circuit.

7 Troubleshooting

5:136 Error in power supply to brake jammed.
coil in (A83). If points 1-3 are OK, it in-
Current differs from requested dicates that the output
current by 100 mA and current stage is short circuited -
exceeds 2 A. Replace the power-sup-
plying component.
Truck behaviour
Creep speed 2) Check wiring and com-
ponent after the break
ing harness
any wire
range.
functions.
3)
5:180 Steering angle signal is outside • Defective component, 1) Check the analogue
the valid range short circuit or wire cut sensor
(applies only to mechanical off Check that the sensor
steering, not power steering) has a 5V or 24V power
Valid range: 0.18V - 4.86V supply (depending on
the component)
Truck behaviour Compare the measured
Creep speed output from the sensor
sensor or the wiring. Re-
pair or replace the com-
ponent.
ror in T1. Replace the
T1. See section “14.7.2
Replacing the motor con-
trol”.
5:182 When B17 indicates 0 degrees, • The clearance between 1) Check the reference
A83 must lie in the interval +/- 7 reference sensor and sensor
degrees crown wheel is wrong Steer slightly to the right
• Defective component so that the gear ring is
Truck behaviour • Erroneous steering angle lation to the reference
Creep speed signal sensor.
Cut off power to the

7 Troubleshooting

5:182 When B17 indicates 0 degrees, truck.
A83 must lie in the interval +/- 7 Check the clearance
degrees between the sensor and
Truck behaviour Nominal measurement:
Creep speed 1.5 mm Note: Risk of
while work is performed 7
on the gear ring.
truck.
95 and 97.
ply, replace B17. Check
if there is a short circuit
between wires 95 and
97, but also between
place the T13
2) See above
3) Check the steering angle
sensor
Check the wiring
between T13 and A83
for short circuit or disrup-
tion - repair or replace
the wiring.
Digital PWM signal from
A83 cannot be meas-
ured, use an A83 that
works as a reference.
Compare the steering
angle with the steering
angle that is indicated by
the system via Service
Information Mode 13 or
TruckCom - If it does not
seem to be the same,
check the mechanical
fastening of the steering
arm and make a new
steering angle calibra-
tion.

7 Troubleshooting

5:301 Steering motor control power • Voltage loss on supply to 1) Check the voltages in
stage defective T13 T13
• No software compatibility Check that there is bat-
tery voltage between
Truck behaviour • Defective electronic unit conductors 23/[A5:8] +
Everything is stopped at once, [A5:16] and 40/[A5:7] +
the parking brake is activated, [A5:15].
and the main contactor opens Check fuse F53
ware
Update the truck entire
3) Replace the T13, see
section “10.2.2 Repla-
cing the steering motor”.
5:303 Start of T13 failed • Voltage loss on supply to 1) Check the voltages in
T13 T13
• Error on CAN bus wiring Check the voltage using
Truck behaviour a volt meter (Measuring
Everything is stopped at once, or connections
points wires 40 and 23 at
the parking brake is activated, • No software compatibility T13), and compare with
and the main contactor opens the value from Truck-
Com “DC Bus Voltage”
Compare with battery
voltage.
joints and splices.
Check fuse F53
2) Check the CAN bus
Check that CAN is intact
in terms of wiring har-
ness, resistance and
the battery. Check that
(X41:3) and (X41:4) is 54
- 66 ohms.
ing harness is not
ance between the
kOhm
ware
Update the truck entire
5:320 Voltage below valid level: 12V • Voltage loss on supply to 1) Check the voltages in
T13 T13
• The battery is defective Check the voltage using
Truck behaviour a volt meter (Measuring
Everything is stopped at once, • Battery parameter # 107 points wires 40 and 23 at
the parking brake is activated, has an erroneous value T13), and compare with

7 Troubleshooting

5:320 Voltage below valid level: 12V the value from Truck-
Truck behaviour voltage.
Everything is stopped at once, Check the connectors,
the parking brake is activated, joints and splices.
and the main contactor opens Check fuse F53
3) Check parameters
7
tion.
5:325 Overloaded steering motor • Turning of drive wheel 1) Checking the steerability
was prevented. of the drive unit.
• Intensive steering with Check why the drive
Truck behaviour wheel cannot be turned
Everything is stopped at once, stationary truck
the parking brake is activated, steering motor in the fol-
and the main contactor opens lowing places.
Steering motor
motor
Gears
Steering bearings
motor gear
Drive wheel/surface
2) Avoid steering the truck
when stationary
The temperature in the steering • Cooling is reduced or the truck. Let the truck cool
motor power stage exceeds temperature sensor is down.
85°C. defective. 2) Check the cooling
Truck behaviour Check the cooling
Everything is stopped at once, flanges of the transistor
the parking brake is activated, regulator, motor and
and the main contactor opens steering motor as well as
to work properly.
T1 and motor fan)
connected

7 Troubleshooting

5:326 High temperature the temperature sensors
The temperature in the steering for T1 and T13 and from
motor power stage exceeds B1 using the built-in test
85°C. or TruckCom. Determine
Truck behaviour nals are plausible relat-
Everything is stopped at once, ive to the real temperat-
the parking brake is activated, ures of the components.
and the main contactor opens If not, replace T1,T13 or
kit.
5:335 The internal parameters in the • No software compatibility 1) Update the truck soft-
steering motor are erroneous • Wrong electronic unit in ware
the motor servo in con- Update the truck soft-
nection with change ware to the latest ver-
Truck behaviour sion.
Everything is stopped at once, • Defective electronic unit
the parking brake is activated, 2) Check the P/N of the
and the main contactor opens electronic unit.
5:336 The internal parameters in the • No software compatibility 1) Update the truck soft-
steering motor are erroneous • Wrong electronic unit in ware
the motor servo in con- Update the truck soft-
nection with change ware to the latest ver-
Everything is stopped at once, • Defective electronic unit
the parking brake is activated, 2) Check the P/N of the
and the main contactor opens electronic unit.
5:337 T13 reports an error during ref- • Defective component 1) Check the reference
erence run • Turning of drive wheel sensor
was prevented. Steer slightly to the right
Truck behaviour correctly positioned in re-
Everything is stopped at once, lation to the reference
the parking brake is activated, sensor.
and the main contactor opens Cut off power to the
truck.
Check the clearance
on the gear ring.
truck.
95 and 97.

7 Troubleshooting

5:337 T13 reports an error during ref- If there is a power sup-
erence run ply, replace B17.
Truck behaviour and 97, but also between
Everything is stopped at once, wire 95 and the rest of
the parking brake is activated, the electrical system.
and the main contactor opens If there is no power sup-
place the T13. See sec- 7
tion “10.2.2 Replacing
the steering motor”.
2) Checking the steerability
of the drive unit.
Check why the drive
lowing places.
Steering motor
motor
Gears
Steering bearings
motor gear
Drive wheel/surface
Temperature in steering motor • Cooling is reduced or the truck. Let the truck cool
exceeds high temperature temperature sensor is down.

Everything is stopped at once, Check the cooling
the parking brake is activated, flanges of the transistor
and the main contactor opens regulator, motor and
to work properly.
T1 and motor fan)
connected

7 Troubleshooting

5:380 High temperature ures of the components.
Temperature in steering motor If not, replace T1,T13 or
exceeds high temperature replace B1 with a repair
kit.
Truck behaviour
Between A5 and T13. T13 does or connections Check that CAN is intact
not get any commands from A5 in terms of wiring har-
- 66 ohms.
ing harness is not
ance between the
kOhm
Between A5 and T13. A5 gets or connections Check that CAN is intact
no responses from T13 or an- in terms of wiring har-
swers are corrupted ness, resistance and
Truck behaviour the battery. Check that
Everything is stopped at once, the resistance between
the parking brake is activated, (X41:3) and (X41:4) is 54
and the main contactor opens - 66 ohms.
ing harness is not
ance between the
kOhm
Between A5 and T13. A5 gets or connections Check that CAN is intact
no response from T13. in terms of wiring har-
- 66 ohms.
ing harness is not
ance between the
kOhm

7 Troubleshooting

Between A5 and T13 or connections Check that CAN is intact
Truck behaviour ness, resistance and
Everything is stopped at once, connectors. Disconnect
the parking brake is activated, the battery. Check that
and the main contactor opens the resistance between
(X41:3) and (X41:4) is 54
- 66 ohms.
ing harness is not
ance between the
kOhm
5:421 Voltage above limit of 39V • Voltage loss on supply to 1) Check battery voltage
T1 Check the voltage using
• Voltage measurement the built-in test proced-
Truck behaviour ure and comparing with
Everything is stopped at once, error in T13
the parking brake is activated, • The battery is defective meter
and the main contactor opens Check connectors, joints
or corrosion.
2) Check the voltages in
T13
points wires 40 and 23 at
T13), and compare with
the value from Truck-
voltage.
joints and splices.
Check fuse F53
5:422 Current exceeds limit value 95 • Short circuit in steering 1) Replace M6
A. motor See RM for instructions
Short circuit in steering motor • Short circuit in power (TBD)
power stage. stage 2) Replace T13
Truck behaviour See section “10.2.2 Re-
Everything is stopped at once, placing the steering mo-
the parking brake is activated, tor”.
5:435 Internal program error • Software failure 1) Update the truck soft-
sion.
Truck behaviour

7 Troubleshooting

5:436 Interruptions in one or more • Interruption in servo mo- 1) Replace M6
phases in T13/M6 tor See RM for instructions
• Interruption in power (TBD)
Truck behaviour stage 2) Replace T13

Everything is stopped at once, See RM for instructions
the parking brake is activated, (TBD)
5:437 T13 detects an erroneous signal • Defective components 1) Replace M6
from Hall sensor internally in M6 See RM for instructions
• Faulty input signal (TBD)
Truck behaviour 2) Replace T13

Everything is stopped at once, See RM for instructions
the parking brake is activated, (TBD)
5:438 T13 detects a problem with • Internal error in electron- 1) Replace the T13 or the
voltage measurement ics complete unit (TBD)
Truck behaviour
5:500 Unknown steering motor error • No software compatibility 1) Update the truck soft-
ware
Truck behaviour ware to the latest ver-
Everything is stopped at once, sion.
Send a report to the
manufacturer.
Truck behaviour
5:502 A5 detects T13 • Incorrect value for para- 1) Check parameters
Parameter 1107 is set to mech- meter 1107 Check that factory para-
anical steering meters are set according
Truck behaviour tion.
Everything is stopped at once, Check that other para-
the parking brake is activated, meters are set correctly.
5:520 Power supply to A83 • Defective component, 1) Check the power supply
Outside of valid range: short circuit or internal to the steering angle
4.5V-5.5V error in T13 sensor
Check the wiring
Truck behaviour between T13 and A83
Everything is stopped at once, for short circuit or disrup-
the parking brake is activated, tion - repair or replace
and the main contactor opens the wiring.
Measure the voltage
between wires 91 and
94. Set point: 4.5V - 5.5V

7 Troubleshooting

5:520 Power supply to A83 If the voltage is too high -
Outside of valid range: replace T13
4.5V-5.5V If the voltage is too low -
open splice A83 and
Truck behaviour measure output 4 on
Everything is stopped at once, T13. If the voltage is too
the parking brake is activated, low - replace T13, other-
and the main contactor opens wise replace A83
5:540 T13 detects a short circuit • Defective component, 1) Check the steering angle
between steering angle sensor short circuit or internal sensor 7
signals 1 and 2 error in T13 Check the wiring
between T13 and A83
Truck behaviour tion - repair or replace
Everything is stopped at once, the wiring.
the parking brake is activated, Digital PWM signal from
and the main contactor opens A83 cannot be meas-
arm and make a new
tion.
5:580 Reference run not terminated • Defective component 1) Check the reference
within 15 seconds • Turning of drive wheel sensor
was prevented Steer slightly to the right
Truck behaviour correctly positioned in re-
Everything is stopped at once, lation to the reference
the parking brake is activated, sensor.
and the main contactor opens Cut off power to the
truck.
Check the clearance
on the gear ring.
truck.
95 and 97. If there is a
power supply, replace
B17. Check if there is a

7 Troubleshooting

5:580 Reference run not terminated short circuit between
within 15 seconds wires 95 and 97, but also
between wire 95 and the
rest of the electrical sys-
Truck behaviour tem.
Everything is stopped at once, If there is no power sup-
the parking brake is activated, ply or short circuit, re-
and the main contactor opens place the T13
2) Checking the steerability
of the drive unit.
Check why the drive
lowing places.
Steering motor
motor
Gears
Steering bearings
motor gear
Drive wheel/surface
5:582 Steering angle signal 1 and 2 • Defective component, 1) Check the steering angle
out of valid range short circuit or internal sensor
error in T13 Check the wiring
between T13 and A83
Truck behaviour for short circuit or disrup-
Everything is stopped at once, tion - repair or replace
the parking brake is activated, the wiring.
and the main contactor opens Digital PWM signal from
A83 cannot be meas-
arm and make a new
tion.
5:583 Steering angle signal 1 out of • Defective component, 1) Check the steering angle
valid range short circuit or internal sensor
error in T13 Check steering angle
signal 1 between pin 3
Truck behaviour (contact A83) and pin 5
Everything is stopped at once, (contact T13)
the parking brake is activated, Check the wiring
and the main contactor opens between T13 and A83
the wiring.

7 Troubleshooting

5:583 Steering angle signal 1 out of A83 cannot be meas-
valid range ured, use an A83 that
Truck behaviour angle with the steering
Everything is stopped at once, angle that is indicated by
the parking brake is activated, the system via Service
and the main contactor opens Information Mode 13 or
seem to be the same, 7
arm and make a new
tion.
5:584 Steering angle signal 2 out of • Defective component, 1) Check the steering angle
valid range short circuit or internal sensor
error in T13 Check steering angle
signal 2 between pin 4
Truck behaviour (contact A83) and pin 13
Everything is stopped at once, (contact T13)
the parking brake is activated, Check the wiring
and the main contactor opens between T13 and A83
the wiring.
A83 cannot be meas-
arm and make a new
tion.
5:585 Incorrect configuration of steer- • No software compatibility 1) Update the truck soft-
ing motor ware
5:586 Sums of steering angle signals • Defective component, 1) Check the steering angle
1 and 2 out of valid range short circuit or internal sensor
error in T13 Check the wiring
between T13 and A83
Truck behaviour for short circuit or disrup-
Everything is stopped at once, tion - repair or replace
the parking brake is activated, the wiring.
and the main contactor opens Digital PWM signal from

7 Troubleshooting

5:586 Sums of steering angle signals A83 cannot be meas-
1 and 2 out of valid range ured, use an A83 that
Truck behaviour angle with the steering
Everything is stopped at once, angle that is indicated by
the parking brake is activated, the system via Service
and the main contactor opens Information Mode 13 or
arm and make a new
tion.
8:001 The impact sensor has re- • Collision 1) Resetting truck after col-
gistered a collision. • Parameters 105 and 106 lision
Kryphastighet set too low. 2) Check parameters
Impact sensor has registered Check that factory para-
impact levels above the set limit meters are set according
values as defined by paramet- to the truck configura-
ers 105 and 106. tion.
8:002 The truck was intentionally • 1)
taken out of service via I_site
Kryphastighet
8:003 Argument error in option. • Option argument error, 1) Check parameters

Inte påverkad. Tillvalet som lar- parameters 1003 - 1042 Check that factory para-
mar fungerar inte. meters are set according
Invalid configuration in one or tion.
more options. Check that other para-
8:004 Option buttons activated • Option button pressed 1) Check your option but-
Samtliga tillvalsknappar ur funk- during start-up tons
tion tills den påverkade tillval- Check the function of the
sknappen blir opåverkad. option buttons via the
built-in test mode, Ser-
One or more option buttons on vice Information mode 9
A5 is activated at start-up. or TruckCom.
If there is still a signal
from a seemingly uninflu-
enced button, the button
must be checked for
jamming or unwanted
connection.
With the built-in charger T14 at ness, resistance and
start-up connectors. Disconnect

7 Troubleshooting

8:010 CAN communication problem (X41:3) and (X41:4) is 54
Inte påverkad. - 66 ohms.
With the built-in charger T14 at ing harness is not
start-up pinched. Measure resist-
ance between the
kOhm
8:011 CAN communication problem • Error on CAN bus wiring 1) Check the CAN bus 7
With the built-in charger T14. ness, resistance and
(X41:3) and (X41:4) is 54
- 66 ohms.
ing harness is not
ance between the
kOhm
8:020 Low voltage • Battery not connected to 1) Check the battery char-
Inte påverkad. charger ger cables.
T14 detects no battery, voltage by disconnecting the
below valid level: 6V connector and power
cable from the charger.
Measure the ohms on
red and black cable from
T14 to X1. Replace the
cables in case of break-
age.
8:021 Low voltage • The battery is defective 1) Check the battery.
Inte påverkad.
T14 detects excessively low
battery voltage when charging.
Voltage below valid level: 19.8V
8:022 High voltage • The battery is defective 1) Check the battery.
Inte påverkad.
T14 detects excessively high
battery voltage when charging.
Voltage above valid level: 34.8V
8:023 Low temperature • Truck used in cold envir- 1) Inform the client that the
Inte påverkad. onments. truck should be stored in
normal ambient temper-
T14 detects excessively low atures to avoid unneces-
temperature when charging. sary wear and tear of the
battery and other com-
ponents.

7 Troubleshooting

Inte påverkad. temperature sensor is Check the cooling
defective. flanges of the transistor
T14 has reduced the charging regulator, motor and
current to 0A because of high steering motor as well as
temperature. the battery charger and
to work properly.
T1 and motor fan)
connected
kit.
8:027 Internal error in T14 • No software compatibility 1) Update the truck soft-
Inte påverkad. • Defective component ware
sion.
2) Replace the T14
See section “18.6 Built-in
battery charger C5170”.
8:028 Charging time • Battery parameters 109 1) Check parameters
Inte påverkad. and 110 incorrectly set. Check that factory para-
• The battery is defective meters are set according
The main charging time is ex- to the truck configura-
ceeded by 5-11 hours depend- tion.
ing of battery capacity. Check that other para-
8:029 Charged capacity exceeds bat- • Battery parameters 109 1) Check parameters
tery capacity. and 110 incorrectly set. Check that factory para-
Inte påverkad. • The battery is defective meters are set according
tion.

7 Troubleshooting

8:030 Parameter 1101 not activated • Incorrect value for para- 1) Check parameters
Inte påverkad. meter 1101 Check that factory para-
Communication with charger to the truck configura-
T14 exists, but factory para- tion.
meter 1101 is not activated. Check that other para-
8:031 Saving parameter in T14 failed. • No software compatibility 1) Update the truck soft-
Inte påverkad. ware
Update the truck soft- 7
sion.
8:032 Wrong battery type selected via • Battery parameters 109 1) Check parameters
parameters 109 and 110. and 110 incorrectly set. Check that factory para-
Inte påverkad. meters are set according
tion.
Kryphastighet, blockerad lyft/ or connections Check that CAN is intact
sänk rörelse. in terms of wiring har-
between A5 and A36/A37 connectors. Disconnect
(X41:3) and (X41:4) is 54
- 66 ohms.
ing harness is not
ance between the
kOhm
Kryphastighet, blockerad lyft/ or connections Check that CAN is intact
sänk rörelse. in terms of wiring har-
between A5 and A36/A37 connectors. Disconnect
(X41:3) and (X41:4) is 54
- 66 ohms.
ing harness is not
ance between the
kOhm
between A5 and B90 ness, resistance and

7 Troubleshooting

8:112 CAN communication problem the battery. Check that
Inte påverkad. the resistance between
(X41:3) and (X41:4) is 54
between A5 and B90 - 66 ohms.
ing harness is not
ance between the
kOhm
8:123 Argument error in option. • Argument error option 1) Check parameters
Kryphastighet, blockerad lyft/ Check that factory para-
sänk rörelse. meters are set according
Invalid configuration in one or tion.
more options. Check that other para-
8:130 CAN communication error • Error on CAN bus wiring 1) Check the CAN bus
CAN communications error with or connections Check that CAN is intact
li-ion battery in terms of wiring har-
Creep speed, blocked lifting the battery. Check that
movement If CAN key connec- the resistance between
ted - creep speed (X41:3) and (X41:4) is 54
- 66 ohms.
ing harness is not
ance between the
kOhm
2)
3)
8:131 Temperature in the li-ion battery • 1) Let the battery cool down
is too high
Truck behaviour
movement
8:132 Current in the li-ion battery is • Regenerative braking 1) No action.
too high with fully-charged bat- 2) Check battery voltage
tery. Check the voltage using
Truck behaviour • the built-in test proced-
Creep speed, blocked lifting ure and comparing with
movement value from external volt
meter
or corrosion.

7 Troubleshooting

8:133 Li-ion battery temperature below • 1) Move the truck to a
permitted level warmer area
Truck behaviour
movement
8:134 Defective hardware in the li-ion • Defective sensor in the 1) Contact the battery man-
battery module. ufacturer.
7
Truck behaviour
movement
8:135 Internal CAN problem • Communication problem 1) Contact the battery man-
in the li-ion battery between modules in the ufacturer.
battery. 2)
Truck behaviour
Creep speed, blocked lifting 3)
movement
8:136 Overvoltage in the li-ion battery • A module in the battery 1) Restart the battery.
has been switched off
because its voltage is
Truck behaviour too high.
movement
8:137 Battery cells deactivated by in- • Some battery functions 1) Overvoltage, under-
ternal monitoring are not working. voltage, temperature too
high, temperature too
low. Let the battery rest
Truck behaviour and then restart the bat-
Creep speed, blocked lifting tery.
movement
8:138 Low battery voltage • Battery discharged 1) Charge the battery
in the li-ion battery • Voltage drop. 2) Check battery voltage
Truck behaviour Check the voltage using
Creep speed, blocked lifting the built-in test proced-
movement ure and comparing with
meter
or corrosion.
8:139 Wrong type of battery • Battery parameter 1045 1) Check parameters
selected via parameter 1045 has incorrect setting. Check that factory para-
Truck behaviour to the truck configura-
Creep speed, blocked lifting tion.
movement Check that other para-

7 Troubleshooting

8:140 Start-up problem • Internal program error 1) Update the truck soft-
between truck and li-ion battery ware
during start-up. Create a truck report.
Send a report to the
Truck behaviour manufacturer.
Creep speed, blocked lifting Update the truck soft-
movement ware to the latest ver-
sion.
Cold Low temperature 1) Inform the client that the
Motorstyrning minskar linjärt truck should be stored in
den maximala accelererande normal ambient temper-
strömmen atures to avoid unneces-
sary wear and tear of the
The power stage of the motor battery and other com-
control is very cold. The motor ponents.
control temperature is below
-20°C. The motor temperature 2) Check the cooling
sensor detects a low temperat- Check the cooling
ure. The motor temperature is flanges of the transistor
below -35°C regulator, motor and
Truck used in cold environ- the battery charger and
ments fans and filters for accu-
Cooling is reduced or the tem- mulations of dirt and
perature sensor is defective. dust. Too much dust and
to work properly.
T1 and motor fan)
connected
kit.
ESO Emergency stop circuit open • Emergency stop activ- 1) Return the emergency
low voltage on T1:114 ated stop switch to the normal
• Open electrical circuit position and restart the
Truck behaviour truck
the parking brake is activated, 2) Check the circuit of the
and the main contactor opens emergency stop
Check that the emer-
gency stop is in the nor-
mal position

7 Troubleshooting

ESO Emergency stop circuit open Check fuse F51
low voltage on T1:114 Check wiring and S21
after the break
Truck behaviour
Fold UP The tiller arm comes down too • The tiller arm comes 1) Raise the arm.
quickly after start. down before the motor
control unit is running. 7
Truck behaviour
Driving stopped
Foot Foot indicated outside of truck • A foot is breaking the 1) Keep the feet inside the
profile light barrier truck profile.
sensor B124/B125 • Signal error 2) Check the foot protection
Truck behaviour sensor
Driving stopped Check whether the light
source is misdirected
Check the wiring har-
ness for a break
Check whether dirt or
another object is block-
ing the light
gATE Gate position • The gate is not lowered 1) Lower the platform or
The position of the gate in com- when the platform is lower the gate.
bination with the platform posi- raised. 2) Move the gate to a
tion and height sensor (SPE, • Gate in an undefined po- defined position
SWE) is not permitted sition 3) Lower the gate for stack-
Truck behaviour • Gate raised when stacking above 1.8 meters in
Driving or lifting stopped ing above height limit 1.8 order to have three es-
m cape routes
4) Check the sensor signal
Check that the distance
the opposite part is cor-
rect
the sensor
Inspect cabling.
Measure the signals
ing TruckCom or the
nal is correct.
High The forks are higher than 1.8 m
The forks are lifted higher than

1.8 m at the same time as the
tiller arm or the hydraulic sys-
tem is activated.

7 Troubleshooting

Hot High temperature • Intensive use of the truck 1) Intensive use of the
The power stage in T1 shows a • Cooling is reduced or the truck. Let the truck cool
high temperature. The temper- temperature sensor is down.
ature is above 85°C. The motor defective. 2) Check the cooling
temperature sensor detects a Check the cooling
high temperature. The motor flanges of the transistor
temperature exceeds +150°C regulator, motor and
Truck behaviour steering motor as well as
The motor control reduces the the battery charger and
maximum accelerating voltage fans and filters for accu-
linearly mulations of dirt and
to work properly.
T1 and motor fan)
connected
kit.
LoAd The load on the forks exceed 1) Reduce the load on the
the maximum permitted. forks, never lift more
Sänk om du kan than the rated maximum
load.
The load on the forks exceeds

the maximum permitted by more
than 10%.
Plug Built-in charger • The plug of the charger Place the plug in the sensor
The plug of the charger is not is not placed in the bracket.
placed in the sensor bracket sensor bracket when
when charging is finished. charging is finished
Truck behaviour
Truck will not start.
Only available in certain mar-
kets.
S-0h Time for service • Time for service 1) After service is complete,
enter a new or the same
value in parameter 101
Truck behaviour
Not influenced

7 Troubleshooting

SLO Reduced travel speed • Travel speed reduced 1)
because of activated
Click-2-Creep, turtle or
Truck behaviour emergency drive mode.
Reduced speed and accelera-
tion
StOP The platform is lowered but not • Platform in undefined po- 1) Move the platform to a
loaded sition defined position
2) Check the sensor signal
and/or adjust the plat- 7
Truck behaviour
Driving stopped form
Check that the distance
the opposite part is cor-
rect
the sensor
Inspect cabling.
Measure the signals
ing TruckCom or the
nal is correct.
tilt Tilt angle • The truck is tilting side- Lower the forks below 1.8
The truck is tilting too much ways more than ±1.5° meter.
sideways when the forks reach the same time the forks
the 1.8 meter sensor. reach the 1.8 meter
sensor.
Truck behaviour
Lifting stopped

7 Troubleshooting

Chassis C0000 8
8.1 Overview ............................................................................................................................................................ 8 - 1
8.2 Frame, chassis C0300 ....................................................................................................................................... 8 - 1
8.2.1 Inspection of the rear chassis .............................................................................................................. 8 - 1
8.2.2 Inspection covers C0340 ..................................................................................................................... 8 - 2
8.2.2.1 Motor compartment covers................................................................................................... 8 - 2
8.2.3 Support arms, stabilizers C0350 ......................................................................................................... 8 - 7
8.2.3.1 Replacing the roller on the torsion tube................................................................................ 8 - 7
8.2.3.2 Replacing the wheel fork bushing ........................................................................................ 8 - 9
8.2.4 Fork structure (low-lifter) C0380 ........................................................................................................ 8 - 10
8.2.4.1 Overview ............................................................................................................................ 8 - 10
8.2.4.2 Replacing the fork carriage ................................................................................................ 8 - 11
8.2.4.3 Checking the fork carriage ................................................................................................. 8 - 17
8.2.4.4 Replacing the torsion tube-linkage-wheel fork ................................................................... 8 - 18
8.2.4.5 Checking the torsion tube-linkage-wheel fork .................................................................... 8 - 22
8.2.4.6 Push rod weld..................................................................................................................... 8 - 22
8.2.4.7 Checking the wheel fork flexibility ...................................................................................... 8 - 26
8.2.4.8 Checking the linkage .......................................................................................................... 8 - 26
8.2.4.9 Checking the fork carriage ................................................................................................. 8 - 26
8.2.4.10 Lubricating the beams ........................................................................................................ 8 - 27
8.2.4.11 Checking the fork lift height limitation................................................................................. 8 - 27
8.2.4.12 Checking the fork carriage play.......................................................................................... 8 - 27
8.2.5 Battery compartment parts C0390..................................................................................................... 8 - 28
8.2.5.1 Overview ............................................................................................................................ 8 - 28
8.2.5.2 Overview ............................................................................................................................ 8 - 29
8.2.5.3 Description ......................................................................................................................... 8 - 29
8.2.5.4 Checking the battery lock ................................................................................................... 8 - 30
8.2.5.5 Checking the battery lock ................................................................................................... 8 - 30
8.2.5.6 Adjusting the battery lock ................................................................................................... 8 - 30
8.3 Frame/chassis components C0400 ................................................................................................................. 8 - 31
8.3.1 Motor mount/brackets C0450 ............................................................................................................ 8 - 31
8.3.1.1 Checking the motor mounts ............................................................................................... 8 - 31
8.3.1.2 Drive unit mountings........................................................................................................... 8 - 31

8 Chassis C0000
8.3.1.3 PowerTrak .......................................................................................................................... 8 - 47
8.4 Operator compartment, cab C0500 ................................................................................................................. 8 - 62
8.4.1 Platform including fixing points C0560 .............................................................................................. 8 - 62
8.4.1.1 Overview ............................................................................................................................ 8 - 62
8.4.1.2 Overview ............................................................................................................................ 8 - 63
8.4.1.3 Overview ............................................................................................................................ 8 - 64
8.4.1.4 Checking the function of the platform switches .................................................................. 8 - 65
8.4.1.5 Adjusting the position sensor [B120] .................................................................................. 8 - 65
8.4.1.6 Checking the platform ........................................................................................................ 8 - 66
8.4.1.7 Gas strut............................................................................................................................. 8 - 66
8.4.1.8 Platform suspension........................................................................................................... 8 - 69
8.4.1.9 Safety switch, platform [B119]............................................................................................ 8 - 71
8.4.1.10 Safety switch, platform [B119]/[B120] ................................................................................ 8 - 73
8.4.1.11 Replacing the platform ....................................................................................................... 8 - 74
8.5 Safety equipment C0800 ................................................................................................................................. 8 - 81
8.5.1 Operator protection C0840 ................................................................................................................ 8 - 81
8.5.1.1 Fixed side guard................................................................................................................. 8 - 81
8.5.1.2 Gate.................................................................................................................................... 8 - 86
8.5.1.3 Back rest ............................................................................................................................ 8 - 97
8.5.2 Signs, warnings, labels C0850 .......................................................................................................... 8 - 99
8.5.2.1 Checking signs and labels.................................................................................................. 8 - 99
8.5.2.2 Placement of signs ............................................................................................................. 8 - 99

8 Chassis C0000
Overview
8 Chassis C0000
8
Chassis C0000
8.1 Overview
8.1
Overview
a 8
b
f c
Pos. Designation
a Battery compartment
b Fork body
c Drive unit mountings
d Platform
e Gate
f Hoods, covers
8.2 Frame, chassis C0300

8.2
Frame, chassis C0300
8.2.1 Inspection of the rear chassis

8.2.1
Inspection of the rear chassis
1. Check for cracks and other damage on the rear chassis. Con-
tact the truck manufacturer if you find any cracks or other dam-
age.

8 Chassis C0000
8.2.2 Inspection covers C0340

8.2.2
Inspection covers C0340
8.2.2.1 Motor compartment covers

8.2.2.1
Motor compartment covers
8.2.2.1.1 Overview
8.2.2.1.1
Overview
d
e
c
b
Pos. Designation
a Service cover
b Side cover
c Emblem cover
d Upper cover
e Gate cover

8 Chassis C0000
8.2.2.1.2 Replacing a service cover

8.2.2.1.2
Replacing a service cover
8.2.2.1.2.1 Removing a service cover

8.2.2.1.2.1
Removing a service cover
1. Undo the screws.
2. Turn out the upper edge of the cover.
3. Carefully remove it from the rubber seal.
8.2.2.1.2.2 Installing a service cover

8.2.2.1.2.2
Installing a service cover
1. Fit the lower edge of the cover.
2. Turn in the cover.
3. Fit the screws
8.2.2.1.3 Replacing a side cover

8.2.2.1.3
Replacing a side cover
8.2.2.1.3.1 Removing a side cover

8.2.2.1.3.1
Removing a side cover
Removing a service cover, page 8 - 3

8 Chassis C0000
1. Undo the screws.
2. Remove the cover.
8.2.2.1.3.2 Installing a side cover

8.2.2.1.3.2
Installing a side cover
1. Hook the side cover into the upper cover and install. Make sure
the washers are seated in the rubber grommets.
2. Fit the screws.
Resetting
Installing a service cover, page 8 - 3
8.2.2.1.4 Replacing an emblem cover

8.2.2.1.4
Replacing an emblem cover
8.2.2.1.4.1 Removing an emblem cover

8.2.2.1.4.1
Removing an emblem cover
Removing a side cover, page 8 - 3

8 Chassis C0000
1. Pry loose the cover and move the cover downwards.
8.2.2.1.4.2 Installing an emblem cover

8.2.2.1.4.2
Installing an emblem cover
1. Insert the pins in the holes and press the snap lock so that it
engages. Fitting is easier if you take one side at a time.
Installing a side cover, page 8 - 4
8.2.2.1.5 Replacing an upper cover

8.2.2.1.5
Replacing an upper cover
8.2.2.1.5.1 Removing an upper cover

8.2.2.1.5.1
Removing an upper cover
Removing an emblem cover, page 8 - 4

8 Chassis C0000
1. Undo the screws and remove the cover.
8.2.2.1.5.2 Installing an upper cover

8.2.2.1.5.2
Installing an upper cover
1. Position the cover and screw it in place.
2. Fit the cover to the CAN connector.
Installing an emblem cover, page 8 - 5
8.2.2.1.6 Replacing a cover

8.2.2.1.6
Replacing a cover
8.2.2.1.6.1 Removing a cover

8.2.2.1.6.1
Removing a cover
Part number: 7530299
1. Remove the screws and remove the cover.

8 Chassis C0000
8.2.2.1.6.2 Installing a cover

8.2.2.1.6.2
Installing a cover
1. Refit the cover.
8.2.3 Support arms, stabilizers C0350

8.2.3
Support arms, stabilizers C0350
8.2.3.1 Replacing the roller on the torsion tube

8.2.3.1
Replacing the roller on the torsion tube
8.2.3.1.1 Removing the roller on the torsion tube

8.2.3.1.1
Removing the roller on the torsion tube
Preparations
1. Tap out the spring pin and shaft.

8 Chassis C0000
2. Remove the roller.
8.2.3.1.2 Fit the roller on the torsion tube

8.2.3.1.2
Fit the roller on the torsion tube
1. Fit the roller.

8 Chassis C0000
2. Tap the shaft and spring pin into place.
Resetting
8.2.3.2 Replacing the wheel fork bushing

8.2.3.2
Replacing the wheel fork bushing
8.2.3.2.1 Removing the bushing

8.2.3.2.1
Removing the bushing
Serial number: 6401033-

Preparations
Removing single wheels, page 11 - 30
Removing single wheels, page 11 - 31
Removing bogie wheels, page 11 - 34
1. The bushings can be knocked out using a suitable drift.

8 Chassis C0000
8.2.3.2.2 Installing the bushing

8.2.3.2.2
Installing the bushing
1. Press the bushes into the wheel fork.
Resetting
Single wheel installation, page 11 - 32
Single wheel installation, page 11 - 33
Fitting the bogie wheel, page 11 - 35
8.2.4 Fork structure (low-lifter) C0380

8.2.4
Fork structure (low-lifter) C0380
8.2.4.1 Overview
8.2.4.1
Overview
a d
z b e
aa c
f
h g
u vxy
i j
k
l
t
s
r m
q p n
o
Pos. Designation Pos. Designation
a Shaft b Bushing
c Spring pin d Wheel fork
e Bushing f Spring pin
g Shaft h Push rod
i Screw j Shaft

8 Chassis C0000

k Bushing l Torsion tube
m Spring pin n Shaft
o Shaft p Bushing
q Spring pin r Roller
s Locking plate t Washer
u Roller v Circlip
w x Washer
y Control units z Battery cover lock
aa Stop lug (The stop lug is de-
signed to protect the linkage 8
and is designed to break).
8.2.4.2 Replacing the fork carriage

8.2.4.2
Replacing the fork carriage
8.2.4.2.1 Removing the fork carriage

8.2.4.2.1
Removing the fork carriage
Preparations
Removing an upper cover, page 8 - 5
1. Lift the truck and support it on trestles so that the chassis does
not tip over when the fork carriage is removed.
2. Remove the screws of the emergency stop bracket and move it

aside so the fork carriage can be lifted out.
3. Remove the hydraulic hose bracket.

8 Chassis C0000
4. Remove the fork carriage stop.
5. Lift the fork carriage halfway up. Only use a lifting device that is
suitable for this work.
6. Remove the lug (lifting height limiter).
7. Remove the battery connector bracket.

8 Chassis C0000
8. Remove the bracket of the battery wiring harness in the battery

tray.
9. Remove the bracket of the battery wiring harness inside the

chassis.
10. Pull the battery wiring harness out of the battery tray.
11. Lift the fork carriage until the fork wheels hang freely. Only use
a lifting device that is suitable for this work.
Check that the torsion tubes have free clearance under the
truck. If not, move the fork wheels backwards so that the tor-
sion tubes have free clearance during the lift.

8 Chassis C0000
12. Lift away the fork carriage. Only use a lifting device that is suit-
able for this work.
8.2.4.2.2 Installing the fork carriage

8.2.4.2.2
Installing the fork carriage
1. Lift the fork carriage. Only use a lifting device that is suitable
for this work.
2. Lower the fork carriage halfway.

8 Chassis C0000
3. Insert the battery wiring harness into the battery tray.
4. Fit the lug (lifting height limiter).
5. Lower the fork carriage, taking care to ensure the guide pins on
the lift cylinders enter the guide holes.
Check that the battery wiring harness and the guides in the fork
carriage are not pinched or badly positioned when fitting the
chassis.

8 Chassis C0000
6. Remove the blocks and lower the truck.
7. Fit the battery connector bracket.
8. Fit the bracket of the battery wiring harness in the battery tray.

8 Chassis C0000
9. Fit the bracket of the battery wiring harness inside the chassis.
8
10. Fit the fork carriage stop.
11. Fit the emergency switch off bracket.
12. Fit the hydraulic hose bracket.
Resetting
8.2.4.3 Checking the fork carriage

8.2.4.3
Checking the fork carriage
1. Check that the fork carriage runs freely up and down in the chassis and that the lifting height limiter is correctly
fitted.

8 Chassis C0000
8.2.4.4 Replacing the torsion tube-linkage-wheel fork

8.2.4.4
Replacing the torsion tube-linkage-wheel fork
8.2.4.4.1 Removing the torsion tube-linkage-wheel fork

8.2.4.4.1
Removing the torsion tube-linkage-wheel fork

• Support block 651154
1. Lift the forks all the way and support on trestles. Support block
651154, page 21 - 6
2. Switch off the truck.
3. Undo the fork carriage stop.

8 Chassis C0000
4. Tap out the spring pin of the linkage attachment.
5. Tap out the linkage shaft.
6. Remove the plate stop.
7. Remove the screws

8 Chassis C0000
8. Pull out the shaft using a puller hammer.
9. Tap out the spring pin of the torsion tube and the wheel fork.
8.2.4.4.2 Fitting the torsion tube-linkage-wheel fork

8.2.4.4.2
Fitting the torsion tube-linkage-wheel fork
1. Fit the wheel fork and push rod.
2. Tap the shaft in place.
3. Tap in the spring pin.

8 Chassis C0000
4. Fit the torsion tube and push rod.
7. Position the linkage.
9. Position the stop plate and fix in place with screws.

The pin must be flush with the bottom edge.

8 Chassis C0000
12. Fit the wheel fork.
13. Lift up the fork frame.
14. Remove the blocks.
15. Lower the forks.
8.2.4.5 Checking the torsion tube-linkage-wheel fork

8.2.4.5
Checking the torsion tube-linkage-wheel fork
1. Check that the fork carriage runs freely up and down in the chassis.
8.2.4.6 Push rod weld

8.2.4.6
Push rod weld
Preparations
Removing the fork carriage, page 8 - 11
Removing the torsion tube-linkage-wheel fork, page 8 - 18

8 Chassis C0000
1. Fit the wheel fork and front push rod.
2. Fit the fork.
3. Tap in the shaft and lock it in place with the spring pin..
4. Fit the torsion tube in the fork carriage.
5. Cut the push rod to the correct length. L (push rod) = X-287 as
measured in the fork's home position.
287
X

8 Chassis C0000
287
X
L ±1,5
19
6. Position the push rod in the fork carriage.
7. Fit the push rod in the torsion tube, tap in the shaft and lock it
in place with the spring pin.
8. Check that all parts are properly positioned.

2 Contact between wheel fork and fork tip
2 Q see table
(Q)
2x

8 Chassis C0000
303 +1,5
-0
9. Machine Battery Fork length U measure- Q (mm)

type compart- (mm) ment (mm)
4 c( x2) ment
LPE250 342 2350 750 19.5
LPE250 342 2150 750 19.5
LPE250 245 2100 330 19.5
LPE250 342 1150 330 19.5
LPE250 245 1150 330 19.5
LPE250 197 1150 330 19.5
LPE250 342 800 330 19.5
LPE200 245 2350 750 19.5
LPE220
LPE200 342 2150 750 19.5
LPE220
LPE200 342 1150 330 9.5
LPE220
LPE200 197 1150 330 9.5
LPE220
LPE200LP 245 1000 330 9.5
E220
LPE200LP 197 1000 330 9.5
E220
Secure with a tack weld – one on each side of the V-joint.
10. Weld the front push rod and the push rod together.
Welding must be carried out in accordance with ISO 5817.
Weld class C

8 Chassis C0000
11. Turn the fork carriage and weld the top. Weld through the hole
on the top of the fork.
a3 c (x2) Welding must be carried out in accordance with ISO 5817.
Weld class C
Resetting
Installing the fork carriage, page 8 - 14
8.2.4.7 Checking the wheel fork flexibility

8.2.4.7
Checking the wheel fork flexibility
1. Check that the wheel fork can move back and forth.
If the torsion tube is bent or damaged it must be replaced, seeReplacing the torsion tube-linkage-wheel fork, page
8 - 18
Make sure the torsion tube is not damaged and has not seized. Replace if necessary. Replacing the torsion tube-
linkage-wheel fork, page 8 - 18
8.2.4.8 Checking the linkage

8.2.4.8
Checking the linkage
1. Check for cracks and other damage on the linkage. Replacing

the torsion tube-linkage-wheel fork, page 8 - 18
8.2.4.9 Checking the fork carriage

8.2.4.9
Checking the fork carriage
1. Check for cracks and other damage on the fork carriage.

In case of cracks or any other damage. Replacing the fork car-
riage, page 8 - 11

8 Chassis C0000
8.2.4.10 Lubricating the beams

8.2.4.10
Lubricating the beams
1. Lubricate the beams, lubricant type F, see Lubricants specifica-

tion, page 6 - 4.
8.2.4.11 Checking the fork lift height limitation

8.2.4.11
Checking the fork lift height limitation
1. Lift the fork carriage as far up as possible, and check that the fork carriage lift height limitation is working prop-
erly.
Adjust the sensor if the lift height limitation does not switch off.
8.2.4.12 Checking the fork carriage play

8.2.4.12
Checking the fork carriage play
1. Check the fork carriage for lateral play at the rollers. Add shims to the rollers, or replace them if needed.

8 Chassis C0000
8.2.5 Battery compartment parts C0390

8.2.5
Battery compartment parts C0390
8.2.5.1 Overview
8.2.5.1
Overview
d
c
b
a
Pos. Designation
a Screw (T=45±11Nm)
b Washer
c Plate
d Plate
e Nut

8 Chassis C0000
8.2.5.2 Overview
8.2.5.2
Overview
c
k
b d
j
e
f
g

a Spring b Nut
c Magnet d Damper
e Washer f Screw
g Frame h Shim
i Stopper j Rivet
k Handle
8.2.5.3 Description
8.2.5.3
Description
8.2.5.3.1 Battery lock, quick

8.2.5.3.1
Battery lock, quick
The quick battery lock is screwed into place in the chassis and holds the battery in place. The recommended force re-
quired to close the battery lock is 250-350 N. The lock is released by pulling the handle towards you and then pulling it
up.
8.2.5.3.2 Battery lock, fixed

8.2.5.3.2
Battery lock, fixed
The fixed battery lock is screwed into the chassis and locks the battery into place. It is used when the battery is charged
in the truck instead of being replaced.

8 Chassis C0000
8.2.5.4 Checking the battery lock

8.2.5.4
Checking the battery lock
1. Check that the battery lock keeps the battery in place. The re-
commended force required to close the battery lock is 250-350
N. If it is too easy/difficult to close the battery lock, shim the
rubber lug to get the recommended value, see: Adjusting the
battery lock, page 8 - 30
8.2.5.5 Checking the battery lock

8.2.5.5
Checking the battery lock
1. Check that the battery lock keeps the battery in place.
8.2.5.6 Adjusting the battery lock

8.2.5.6
Adjusting the battery lock
1. Remove the rubber lugs, add or remove shims to get the cor-
rect force. The recommended force required to close the bat-
tery lock is 250-350 N.

8 Chassis C0000
Frame/chassis components C0400
8.3 Frame/chassis components C0400

8.3
8.3.1 Motor mount/brackets C0450

8.3.1
Motor mount/brackets C0450
8.3.1.1 Checking the motor mounts

8.3.1.1
Checking the motor mounts
1. Check for cracks and other damage on the motor mounts/

PowerTrak. In case of cracks and other damages, replace
them, see Drive unit mountings, page 8 - 31.
8.3.1.2 Drive unit mountings

8.3.1.2
Drive unit mountings
8.3.1.2.1 Drive unit mountings 6/8 km/h.

8.3.1.2.1
Drive unit mountings 6/8 km/h.
8.3.1.2.1.1 Overview 6/8 km/h.

8.3.1.2.1.1
Overview 6/8 km/h.
a
b
f c
g
h d
Pos. Designation
a Rod
b Upper lug
c Initial spring
d Lower lug
e Upper bracket
f PowerTrak spring
g Drive gear bracket
h Lower bracket

8 Chassis C0000
8.3.1.2.1.2 Replacing the drive unit mountings 6/8 km/h.

8.3.1.2.1.2
Replacing the drive unit mountings 6/8 km/h.
8.3.1.2.1.2.1 Removing the drive unit mountings 6/8 km/h.

8.3.1.2.1.2.1
Removing the drive unit mountings 6/8 km/h.
Preparations
Removing a battery using a lifting device, page 13 - 4
, page 8 - 92
Removing the platform, page 8 - 74
Removing the platform [Fixed side guards], page 8 - 77
Removing the steering damper [A83], page 12 - 84
Removing the steering motor [M6], page 9 - 8
Removing the drive gear, page 10 - 4
1. Undo the wiring harness clips in the water trough.
2. Disconnect the connector [X65], page 19 - 4
3. Disconnect the connector, [A83], page 19 - 2 for power

steering or [B13], page 19 - 2 for mechanical steering.

8 Chassis C0000
4. Remove the steering shaft and pull the entire tiller arm straight
up.
5. Detach the hydraulic hose of the drive unit suspension.

Make sure the hydraulic system has been depressurised be-
fore removing the hose.
Do not forget to seal the hydraulics to prevent foreign objects
from entering the system.
Dismantling the hydraulic coupling. Removing a quick change
connector (male), page 14 - 5
6. Screw out the screws through the battery wall. The fork car-
riage must be raised and lowered to gain access to all drive
unit suspension screws.
Use an overhead crane or another suitable lifting device to lift
the fork carriage when removing the screws.

8 Chassis C0000
X2
X4
X4
7. Lift out the drive unit mounting assembly
8. Place it on a suitable work space.

away the drive unit suspension.

8 Chassis C0000
8.3.1.2.1.2.2 Installing the drive unit mountings 6/8 km/h

8.3.1.2.1.2.2
Installing the drive unit mountings 6/8 km/h
1. Lift out the entire drive unit mounting assembly.

the drive unit suspension into place.
2. Use a stud/guide pin M8x65 in the lower holes to facilitate fit-

ting.
0 0
3. Guide in the lower lugs and guide pins on the rear of the sus-
pension in the battery wall.

8 Chassis C0000
4. Screw in the lower screws.
5. Screw in the screws through the battery wall. The fork carriage
must be raised and lowered to gain access to all drive unit sus-
pension screws.
1
the fork carriage when fitting the screws. 28 ⁄-1 N·m
6. Fit the hydraulic hose to the drive unit mounting.

8 Chassis C0000
7. Fit the steering shaft and tiller arm80 N·m
8. Connect the connector [X65], page 19 - 4
9. Connect the connector, [A83], page 19 - 2 for power steering

or [B13], page 19 - 2 for mechanical steering.

8 Chassis C0000
10. Tie the cable clamp between the markings on the wire. Then
twist the wire forward so that the wire is flat against the water
trough. Then tighten the cable clamp.
11. Place the cable clamp on the tape mark of the wiring harness.
Mount the cable clamp to the bracket so that it leans back as
much as possible to enable the wiring harness to lie snugly in
the water trough.
Make sure the clamp is fitted to the tape. The wiring harness
will be damaged if it is fitted to the wrapping.
12. Turn to the right and left and raise and lower 3 times to check
that the wiring harness does not bend or stretches.
Resetting
Installing the drive gear, page 10 - 6
Installing the steering motor [M6], page 9 - 9
Installing the steering damper [A83], page 12 - 85
, page 8 - 93
Installing the platform, page 8 - 77
Fitting the platform [Fixed side guards], page 8 - 79
Installing a battery using a lifting device, page 13 - 5
Installing a battery using a battery changing table, page 13 - 7

8 Chassis C0000
8.3.1.2.2 Drive unit mountings 10/12.5 km/h.

8.3.1.2.2
Drive unit mountings 10/12.5 km/h.
8.3.1.2.2.1 Overview 10/12.5 km/h.

8.3.1.2.2.1
Overview 10/12.5 km/h.
a
f b
zy y z
x x
c
d
8
h
e
Pos. Designation
a Rod
b Upper lug
c Initial spring
d PowerTrak spring
e Lower lug
f Upper bracket
g Drive gear bracket
h Lower bracket
8.3.1.2.2.2 Replacing the drive unit mountings 10/12.5 km/h.

8.3.1.2.2.2
Replacing the drive unit mountings 10/12.5 km/h.
8.3.1.2.2.2.1 Removing the drive unit mountings 10/12.5 km/h.

8.3.1.2.2.2.1
Removing the drive unit mountings 10/12.5 km/h.
Preparations
Removing a battery using a lifting device, page 13 - 4
Removing a battery using a battery changing table, page 13 - 7
, page 8 - 92

8 Chassis C0000
3. Disconnect the connector, [A83], page 19 - 2 for power

steering or [B13], page 19 - 2 for mechanical steering.
4. Undo the screws of the electric panel and move it aside.

8 Chassis C0000
5. Remove the steering shaft and pull the entire tiller arm straight
up.
6. Detach the hydraulic hose of the drive unit suspension.

Make sure the hydraulic system has been depressurised be-
fore removing the hose.
Do not forget to seal the hydraulics to prevent foreign objects
from entering the system.
7. Screw out the screws through the battery wall. The fork car-
riage must be raised and lowered to gain access to all drive
unit suspension screws.
the fork carriage when removing the screws.

8 Chassis C0000
8. Lift out the drive unit mounting assembly.

away the drive unit suspension.
9. Place it on a suitable work space.

8 Chassis C0000
8.3.1.2.2.2.2 Installing the drive unit mountings 10/12.5 km/h

8.3.1.2.2.2.2
Installing the drive unit mountings 10/12.5 km/h
1. Lift the entire drive unit suspension into the truck.

the drive unit suspension into place.
2. Use a stud/guide pin M8x65 in the lower holes to facilitate fit-

ting.
0 0
3. Guide in the lower lugs and guide pins on the rear of the sus-
pension in the battery wall.

8 Chassis C0000
4. Screw in the lower screws.
5. Screw in the screws through the battery wall. The fork carriage
must be raised and lowered to gain access to all drive unit sus-
1
pension screws. 28 ⁄-1 N·m
the fork carriage when fitting the screws.
6. Attach the hydraulic hose of the drive unit suspension.

8 Chassis C0000
7. Fit the steering shaft and tiller arm80 N·m
9. Connect the connector, [A83], page 19 - 2 for power steering

or [B13], page 19 - 2 for mechanical steering.

8 Chassis C0000
10. Reposition the electric panel and screw it in place.
the water trough.

8 Chassis C0000
Resetting
, page 8 - 93
Installing a battery using a battery changing table, page 13 - 7
Installing a battery using a lifting device, page 13 - 5
8.3.1.3 PowerTrak
8.3.1.3
PowerTrak
8.3.1.3.1 Description
8.3.1.3.1
Description
8.3.1.3.1.1 Design
8.3.1.3.1.1
Design

8 Chassis C0000
Lower drive wheel pressure without load.
Higher drive wheel pressure with load

The PowerTrak system is a well-proven design used to keep the drive wheel pressure towards the floor at an optimal
level regardless of load. The PowerTrak system is mounted linearly on bearings and contains fewer moving parts com-
pared to its predecessor. In addition, tiller arm mounting has been integrated in the upper bracket. With mechanical
steering, the vertical movements of the drive unit are absorbed by the bearings between the driver and the steering rod
so that the truck operator does not feel these in the tiller arm.
The principle of this system is that hydraulic pressure applied on the fork cylinders is proportional to the fork load when
the forks are raised.
When the pressure from the fork lift cylinder increases, the pressure in the PowerTrak cylinder also increases. This in-
creases the downward force on the drive wheel.

8 Chassis C0000
8.3.1.3.2 Increasing the spring tension

8.3.1.3.2
Increasing the spring tension

• Fitting tool V08-18302
1. Fit the springs, rings (only for Ø30 rods) and the upper bracket
to the drive unit mount.
Do not use pressing tools or similar if the upper bracket sticks.
There is a "risk of damage to the seals and the bushings". Use
a plastic mallet to carefully tap the bracket straight down over
the bars.
2. Fit the tool.Fitting tool V08-18302, page 21 - 6

8 Chassis C0000
3. Compress the drive unit suspension so much that it is possible

to fit the pins to the shafts.
WARNING It is only permitted to use hand tools

Do not use a power tool or similar when compressing with the
tool, only hand tools are permitted
4. Fit the pins.
5. Release the springs with the tool so that the pins are in ten-
sion.


8 Chassis C0000
6. Remove the tool.
Resetting
Drive unit mountings, page 8 - 31
8.3.1.3.3 Increasing the spring tension

8.3.1.3.3
Increasing the spring tension
Serial number: -6486639

1. Fit the springs, rings (only for Ø30 rods) and the upper bracket
to the drive unit mount
Do not use pressing tools or similar if the upper bracket sticks.
There is a "risk of damage to the seals and the bushings". Use
a plastic mallet to carefully tap the bracket straight down over
the bars.

8 Chassis C0000
3. Compress the drive unit suspension so much that it is possible

to fit the semi-circular spacers to the shafts.

4. Fit the semi-circular spacers on the shafts.

8 Chassis C0000
5. Fit washers and screws to the top of the shafts.
6. Release the spring tension with the tool so that the semi-circu-
lar spacers are clamped in place.

7. Remove the tool.
Resetting

8 Chassis C0000
8.3.1.3.4 Releasing the spring tension

8.3.1.3.4
Releasing the spring tension
Do not forget to fit the pins on the shafts before starting work.
Fix the suspension over the edge of a table or similar using a clamp; make sure that it is firmly in place and can-
not fall down.
Preparations

Use the same screws that secure the suspension in the
chassis.
2. Using the tool, compress the drive unit suspension just enough
to release the pins.


8 Chassis C0000
3. Remove the pins.
4. Release spring tension using the tool.

Use a plastic mallet to carefully tap on the upper bracket if it

sticks when removing.
Make sure that all spring compression is gone before removing
the tool.
8.3.1.3.5 Releasing the spring tension

8.3.1.3.5
Releasing the spring tension
Serial number: -6486639
Do not forget to fit the pins on the shafts before starting work.
Fix the suspension over the edge of a table or similar using a clamp; make sure that it is firmly in place and can-
not fall down.
Preparations

8 Chassis C0000

Use the same screws that secure the suspension in the
chassis.
2. Using the tool, compress the drive unit suspension just enough
to free the semi-circular spacers.

3. Remove the spacer by turning the screw through the semi-cir-

cular spacer towards the shaft.

8 Chassis C0000
4. Undo the screws and washers at the top of the shafts.
5. Release spring tension using the tool.

Use a plastic mallet to carefully tap on the upper bracket if it

sticks when removing.
Make sure that all spring compression is gone before removing
the tool.
8.3.1.3.6 Adjusting tool V08-18302

8.3.1.3.6
Adjusting tool V08-18302
It is possible to adjust the tool stiffness to prevent the tool springing back when compressing the drive unit sus-
pension.
1. Loosen the nut.

8 Chassis C0000
2. Adjust the screw in/out to make the screw suitably stiff to pre-
vent the tool springing back.
3. Tighten the nut.
8.3.1.3.7 Replacing the initial pressure spring

8.3.1.3.7
Replacing the initial pressure spring
8.3.1.3.7.1 Removing the initial pressure spring

8.3.1.3.7.1
Removing the initial pressure spring
Preparations
Releasing the spring tension, page 8 - 54
1. Lift the top cover to the drive unit mounting.

8 Chassis C0000
2. Remove the initial pressure spring.
8.3.1.3.7.2 Fitting the initial pressure spring

8.3.1.3.7.2
Fitting the initial pressure spring
1. Fit the initial pressure springs.
2. Fit the rings (only for Ø30 rods) and the upper bracket to the
drive unit mount.
Resetting
Increasing the spring tension, page 8 - 49

8 Chassis C0000
8.3.1.3.8 Replacing the PowerTrak spring

8.3.1.3.8
Replacing the PowerTrak spring
8.3.1.3.8.1 Removing the PowerTrak spring

8.3.1.3.8.1
Removing the PowerTrak spring
Secure the suspension across the edge of a workbench or such, using a clamp.
Preparations
2. Lift out the PowerTrak spring.

8 Chassis C0000
8.3.1.3.8.2 Installing the PowerTrak spring

8.3.1.3.8.2
Installing the PowerTrak spring
1. Fit the PowerTrak spring.
2. Fit the rings (only for Ø30 rods) and the upper bracket to the
drive unit mount.
Resetting

8 Chassis C0000
Operator compartment, cab C0500
8.4 Operator compartment, cab C0500

8.4
8.4.1 Platform including fixing points C0560

8.4.1
Platform including fixing points C0560
8.4.1.1 Overview
8.4.1.1
Overview
a
b c
h
m
k i
l

a Inductive sensor b Bracket
c Spring d Bracket
e Shim f Bracket
g Tube h Spring
i Washer j Screw
k Bushing l Damper
m Ball screw

8 Chassis C0000
8.4.1.2 Overview
8.4.1.2
Overview
Part number: 7523935-031 7552772
Pos. Designation
a Screw
b Carpet
c Platform
d Stop screw

8 Chassis C0000
8.4.1.3 Overview
8.4.1.3
Overview
Part number: 7533840 7553032 7553032 7564282
c
b
g
h
i
e
Pos. Designation
a Screw
b Carpet
c Floor (cold store)
d Plate
e Frame
f Nut
g Shaft
h Plate
i Screw

8 Chassis C0000
8.4.1.4 Checking the function of the platform switches

8.4.1.4
Checking the function of the platform switches
1. Check the platform switch [B119], page 19 - 2

In case the platform switch does not react when the platform is
loaded
Checking the position sensor [B119], page 8 - 72
Replacing sensor [B119], page 8 - 73
8.4.1.5 Adjusting the position sensor [B120]

8.4.1.5
Adjusting the position sensor [B120]
1. Loosen the locking nut.
5
2. Adjust the play with the stop screw=4 ⁄3mm
Resetting
Checking the function of the platform switches, page 8 - 65

8 Chassis C0000
8.4.1.6 Checking the platform

8.4.1.6
Checking the platform
1. Inspect the platform for crack formation and other damage. If

the platform has cracks or any other damage it must be re-
placed, see Replacing the platform, page 8 - 74.
8.4.1.7 Gas strut

8.4.1.7
Gas strut
8.4.1.7.1 Checking the gas strut

8.4.1.7.1
Checking the gas strut
Installing a gas strut, page 8 - 68
1. Check that the platform springs back.

In case the platform does not spring back: Replacing a gas
strut, page 8 - 66
8.4.1.7.2 Replacing a gas strut

8.4.1.7.2
Replacing a gas strut
8.4.1.7.2.1 Removing a gas strut

8.4.1.7.2.1
Removing a gas strut
1. Disconnect the platform sensor connector[B119], page

19 - 2.

8 Chassis C0000
2. Undo the screws securing the platform.
3. Place a block or similar with height =50 mm between the 8

standing plate and the cast iron section. This will make dis-
mantling/assembly easier.
M
4. Remove the platform from the truck.
5. Remove the support.
6. Detach the bracket to relieve the pressure in the gas strut.

8 Chassis C0000
7. Use a screwdriver or similar tool to undo the spring lock at

each end of the gas strut.
8.4.1.7.2.2 Installing a gas strut

8.4.1.7.2.2
Installing a gas strut
1. Fit the new gas strut, making sure it is fitted in the right direc-
tion.
2. Tighten the gas strut bracket.
3. Open the platform with a crowbar or similar tool (using one of

the fitting screw holes). Position the block between the stand-
ing plate and the cast iron section
4. Guide in the platform.
5. Screw the platform into place.

8 Chassis C0000
6. Refit the connector[B119], page 19 - 2 to the platform

sensor.

8
8.4.1.8 Platform suspension
8.4.1.8
Platform suspension
8.4.1.8.1 Adjusting platform suspension

8.4.1.8.1
Adjusting platform suspension
Preparations
Replacing the platform suspension, page 8 - 70
1. Adjust the suspension so that the play between the sleeve and
+0.5
the screw is =7 ⁄-0.2mm.
Resetting
Adjusting the position sensor play [B119], page 8 - 71
8.4.1.8.2 Adjusting the platform suspension [Fixed side guards]

8.4.1.8.2
Adjusting the platform suspension [Fixed side guards]
Preparations
Fitting the platform suspension, page 8 - 70
1. mm 1: Adjust the suspension so that the play between the

0.2
sleeve and the screw is=6 ⁄-0mm
mm 2: Adjust the suspension so that the play between the
0
sleeve and the screw is =7.5 ⁄-0.3mm
mm 1 mm 2

8 Chassis C0000
Resetting
Adjusting the position sensor play [B119], page 8 - 71
8.4.1.8.3 Replacing the platform suspension

8.4.1.8.3
Replacing the platform suspension
8.4.1.8.3.1 Removing the platform suspension

8.4.1.8.3.1
Removing the platform suspension
Removing a gas strut, page 8 - 66
1. Remove the nut on the top of the platform bracket.
2. Remove the spring and bolt from the platform bracket.
3. Remove the spring.
8.4.1.8.3.2 Fitting the platform suspension

8.4.1.8.3.2
Fitting the platform suspension
1. Lubricate the bolt. Lubricant type E Lubricants specification,

page 22 - 2
2. Fit the spring on the bolt.

8 Chassis C0000
3. Fit the spring and bolt in the platform bracket.
4. Position the nut and tighten it.
Installing a gas strut, page 8 - 68
8.4.1.9 Safety switch, platform [B119]

8.4.1.9
Safety switch, platform [B119]
8.4.1.9.1 Adjusting the position sensor play [B119]

8.4.1.9.1
Adjusting the position sensor play [B119]
Adjusting platform suspension, page 8 - 69, Adjusting the platform suspension [Fixed side guards], page 8 - 69.
1. Remove the sensor bracket.[B119], page 19 - 2

8 Chassis C0000
2. Add or remove shims to achieve minimal play
3. Fit the sensor bracket. [B119], page 19 - 2
8.4.1.9.2 Checking the position sensor [B119]

8.4.1.9.2
Checking the position sensor [B119]
Preparations
Adjusting the position sensor [B120], page 8 - 65
1. Place a 30 kg weight at the very end of the platform.
2. Make sure that the position sensor is not activated. The light is
not lit.
In case the sensor activates: Adjusting the position sensor
[B120], page 8 - 65
3. Remove the weight
5. Make sure that the position sensor is activated. The light is lit.
In case the sensor does not activate: Adjusting the position
sensor [B120], page 8 - 65

8 Chassis C0000
8.4.1.10 Safety switch, platform [B119]/[B120]

8.4.1.10
Safety switch, platform [B119]/[B120]
8.4.1.10.1 Measuring the detection distance [B120]

8.4.1.10.1
Measuring the detection distance [B120]
Installing the platform, page 8 - 77, Fitting the platform [Fixed side guards], page 8 - 79
1. Measure the space between the sensor[B120], page 19 - 2

5
and the platform arm=4 ⁄3mm
If the space is outside the permitted range: Adjusting the posi-
tion sensor [B120], page 8 - 65
M 8
8.4.1.10.2 Replacing sensor [B119]

8.4.1.10.2
Replacing sensor [B119]
8.4.1.10.2.1 Removing the platform position sensor [B119]

8.4.1.10.2.1
Removing the platform position sensor [B119]
Removing the platform, page 8 - 74, Removing the platform [Fixed side guards], page 8 - 77
1. Remove the spring of the detection plate.
2. Move the plate rearwards.
3. Remove the sensor.[B119], page 19 - 2
8.4.1.10.2.2 Fitting the platform position sensor [B119]

8.4.1.10.2.2
Fitting the platform position sensor [B119]
1. Fit the sensor.[B119], page 19 - 2
2. Move the detection plate back into position.
3. Fit the spring.

8 Chassis C0000
Resetting
Checking the function of the platform switches, page 8 - 65
8.4.1.10.3 Replacing sensor [B120]

8.4.1.10.3
Replacing sensor [B120]
8.4.1.10.3.1 Removing the platform position sensor [B120]

8.4.1.10.3.1
Removing the platform position sensor [B120]
1. Disconnect the connector [B119], page 19 - 2
2. Detach the cable bracket.
3. Remove the sensor.
8.4.1.10.3.2 Fitting the platform position sensor [B120]

8.4.1.10.3.2
Fitting the platform position sensor [B120]
1. Fit the sensor.[B120], page 19 - 2
2. Fit the cable bracket to the chassis.
3. Connect the sensor.
Installing the platform, page 8 - 77, Fitting the platform [Fixed side guards], page 8 - 79
8.4.1.11 Replacing the platform

8.4.1.11
Replacing the platform
8.4.1.11.1 Removing the platform

8.4.1.11.1
Removing the platform
Part number: 7523935-031 7552772

Preparations

8 Chassis C0000
1. Disconnect the platform sensor connector[B119], page

19 - 2.
2. Undo the screws securing the platform.

8
3. Place a block or similar with height =50 mm between the

standing plate and the cast iron section in order to make dis-
mantling/assembly easier.
M
4. Remove the platform from the truck.
5. Detach the bracket to relieve the pressure in the gas strut.

8 Chassis C0000

7. Loosen the screw holding the shaft lock plate in position.
8. Remove the lock.
9. Tap out the shaft.
10. Remove the platform.

8 Chassis C0000
8.4.1.11.2 Removing the platform [Fixed side guards]

8.4.1.11.2
Removing the platform [Fixed side guards]
Part number: 7533840 7553032 7539279 7564282

Preparations
1. Disconnect the connector [B119], page 19 - 2.
2. Undo and remove the bolts securing the platform.
3. Lift out the platform.
8.4.1.11.3 Installing the platform

8.4.1.11.3
Installing the platform
Part number: 7523935-031 7552772
1. Fit the platform to the frame.

Make sure the spacer rings remain in place when refitting.

8 Chassis C0000
2. Fit the shaft.
3. Fit the locking plate.
4. Fit the gas strut.
5. Fit the gas strut bracket.

8 Chassis C0000
6. Open the platform with a crowbar or similar tool (using one of

the fitting screw holes). Position the block between the stand-
ing plate and the cast iron section
7. Guide in the platform.
8. Install the platform.
9. Connect the platform sensor connector[B119], page 19 - 2.
Resetting
8.4.1.11.4 Fitting the platform [Fixed side guards]

8.4.1.11.4
Fitting the platform [Fixed side guards]
Part number: 7533840 7553032 7539279 7564282
1. Lift the platform in place.
2. Install the platform

8 Chassis C0000
3. Connect the connector.[B119], page 19 - 2
Resetting

8 Chassis C0000
Safety equipment C0800
8.5 Safety equipment C0800

8.5
8.5.1 Operator protection C0840

8.5.1
Operator protection C0840
8.5.1.1 Fixed side guard

8.5.1.1
Fixed side guard
8.5.1.1.1 Overview [Fixed side guards]

8.5.1.1.1
Overview [Fixed side guards]
8
b
d
c
e
f
g
h
l i
j

a Cushion b Cushion
c Plate d Plate
e Cover f Storage compartment cover
g Storage compartment cover h Cover
i Cover plate j Cover plate
k Cover plate l Plate

8 Chassis C0000
8.5.1.1.2 Replacing the fixed side guard

8.5.1.1.2
Replacing the fixed side guard
8.5.1.1.2.1 Removing the fixed side guard

8.5.1.1.2.1
Removing the fixed side guard
1. Undo and remove the storage compartment cover screws.
2. Loosen and remove the nuts and bolts through the chassis.
3. Disconnect connector [B125], page 19 - 2 left and [B124],

page 19 - 2 right.
4. Detach and remove the side cover.

8 Chassis C0000
5. Loosen and remove the side guard screws.
6. Loosen the lock nut and screw in the bolt to release the side
guard.
8.5.1.1.2.2 Fitting fixed side guards

8.5.1.1.2.2
Fitting fixed side guards
1. Attach the side guards to the chassis.
2. Connect connector [B125], page 19 - 2 left and [B124], page

19 - 2 right.

8 Chassis C0000
3. Fit the side screws.
4. Fit the side cover.
5. Fit the storage compartment cover.

8 Chassis C0000
6. Adjust the side guard so it does not rattle, tighten the lock nut.
8.5.1.1.3 Checking the position sensor [B119] [Fixed side guards]

8.5.1.1.3
Checking the position sensor [B119] [Fixed side guards]
not lit.
[B120], page 8 - 65

8 Chassis C0000
8.5.1.2 Gate
8.5.1.2
Gate
8.5.1.2.1
8.5.1.2.1
f e
Pos. Designation
a Bearing block
b Damper

8 Chassis C0000
Pos. Designation
c Gate bar
d Pad
e Upper position sensor [B121], page 19 - 2
f Lower position sensor [B122], page 19 - 2
8.5.1.2.2 Checking the gate bar

8.5.1.2.2
Checking the gate bar
Installing the gate bar, page 8 - 96, , page 8 - 96
1. Move up the gate to release the mechanical lock, let the bar fall 8
to the lower position by its own weight.
In case the gate does not fall to its lower position: Replacing a
gas strut, page 8 - 87
Check that the bar does not stick on the way down.
8.5.1.2.3 Checking the function of the gate switches

8.5.1.2.3
Checking the function of the gate switches
1. Check the function of the gate switches. The truck’s behaviour

should change depending on whether the gate is up or down.
Replace the switches in the event of a fault; see [B121], page
19 - 2 or [B122], page 19 - 2.
8.5.1.2.4 Replacing a gas strut

8.5.1.2.4
Replacing a gas strut
8.5.1.2.4.1 Removing the gate damper

8.5.1.2.4.1
Removing the gate damper

8 Chassis C0000

2. Remove the damper.
8.5.1.2.4.2 Removing the gate damper

8.5.1.2.4.2
Removing the gate damper

2. Remove the damper.
8.5.1.2.4.3 Fitting the gate damper

8.5.1.2.4.3
Fitting the gate damper
1. Fit the gas strut with the piston rod up.
Checking the gate bar, page 8 - 87

8 Chassis C0000
8.5.1.2.4.4 Fitting the gate damper

8.5.1.2.4.4
Fitting the gate damper
1. Fit the gas strut with the piston rod up.
8.5.1.2.5 Replacing the pad

8.5.1.2.5
Replacing the pad
8.5.1.2.5.1 Removing the pad

8.5.1.2.5.1
Removing the pad
Serial number: 6348361-6395170
1. Remove the pad using a screwdriver or a similar tool.
2. Drill away the blind rivet securing the pad holder in the gate
bar.

8 Chassis C0000
3. Pull off the pad bracket.
8.5.1.2.5.2
8.5.1.2.5.2
1. Remove the pad.
2. Remove the pad holder.

8 Chassis C0000
8.5.1.2.5.3 Fitting pads

8.5.1.2.5.3
Fitting pads
1. Thread the pad holder onto the gate bar.
2. Fasten the pad holder using a blind rivet.
3. Press the pads in place.

8 Chassis C0000
8.5.1.2.5.4
8.5.1.2.5.4
1. Fit the pad holder to the gate bar.
2. Fit the pad.
8.5.1.2.6 Replacing the gate

8.5.1.2.6
Replacing the gate
8.5.1.2.6.1
8.5.1.2.6.1
1. Disconnect the sensor connectors,[B121], page 19 - 2 and

[B122], page 19 - 2.

8 Chassis C0000
2. Remove the water trough from the gate bracket.
3. Undo the screws securing the gate to the chassis.
4. Disassemble the gate and the bracket.
8.5.1.2.6.2
8.5.1.2.6.2
3 1. Fit the gate and bracket on the chassis.
4 2. Carefully note the order: 1 > 2 > 3 > 4

1
Fit the screws 23 N·m press the gate forwards, tightening at
the same time.
2

8 Chassis C0000
3. Connect the sensor connectors,[B121], page 19 - 2 and

[B122], page 19 - 2.
4. Fit the trough to the gate bracket. 2.8 N·m
5. Lubricate the locking lug with lubricant type A. Lubricants spe-

cification, page 22 - 2

8 Chassis C0000
8.5.1.2.7 Replacing the gate bar

8.5.1.2.7
Replacing the gate bar
8.5.1.2.7.1 Removing the gate bar

8.5.1.2.7.1
Removing the gate bar

Preparations
Removing the gate damper, page 8 - 87
1. Remove the bearing blocks.
2. Remove the gate bar. 8
8.5.1.2.7.2
8.5.1.2.7.2

Preparations
1. Remove the bearing blocks.
2. Remove the gate bar.

8 Chassis C0000
8.5.1.2.7.3 Installing the gate bar

8.5.1.2.7.3
Installing the gate bar
1. Lubricate the bearing races with lubricant type A Lubricants

specification, page 22 - 2
2. Fit the gate bar.
3. Install the bearing blocks.
Resetting
Fitting the gate damper, page 8 - 88
8.5.1.2.7.4
8.5.1.2.7.4
1. Lubricate the bearing races with lubricant type A Lubricants

specification, page 22 - 2
2. Fit the gate bar.
3. Install the bearing blocks
Resetting

8 Chassis C0000
8.5.1.3 Back rest

8.5.1.3
Back rest
8.5.1.3.1 Overview [Back protection]

8.5.1.3.1
Overview [Back protection]
b
c
d
e
f
Pos. Designation
a Back rest
b Storage compartment
c Platform
d Sensor [B119], page 19 - 2
e Platform suspension
f Mounting screw
g Mounting screw
8.5.1.3.2 Checking the position sensor [B119 back protection]

8.5.1.3.2
Checking the position sensor [B119 back protection]

8 Chassis C0000
not lit.
[B120], page 8 - 65
8.5.1.3.3 Replacing the back guard

8.5.1.3.3
Replacing the back guard
8.5.1.3.3.1 Removing the back guard

8.5.1.3.3.1
Removing the back guard

8 Chassis C0000
a 1. Remove the back guard by removing the screws (a and b) and

disconnecting the presence sensor (c) [B119], page 19 - 2
8
b
8.5.1.3.3.2 Installing the back guard

8.5.1.3.3.2
Installing the back guard
a 1.
139
Fit the back guard using screws a and b =109 ⁄82Nmand then
connect the presence sensor (c) [B119], page 19 - 2.
8.5.2 Signs, warnings, labels C0850

8.5.2
Signs, warnings, labels C0850
8.5.2.1 Checking signs and labels

8.5.2.1
Checking signs and labels
1. Inspect all signs and adhesive labels to ensure they are intact
Replace any sign or label that is damaged or cannot be read. Placement of signs, page 8 - 99
8.5.2.2 Placement of signs

8.5.2.2
Placement of signs
WARNING Illegible warning and information signs

The warning and information signs on the truck contain important information about the truck and for personal safety. If
a warning and information sign is missing there is a risk of danger. The signs must always be legible.
► Replace broken or missing warning and information signs

8 Chassis C0000
a
b
c
d
e
f
g
h
i
j
k
g h
The figure shows the position and significance of the signs on the truck.
a) Modification plate (only for trucks adapted to customers or applications)
b) Maximum capacity
c) Identification plate
d) Radio transmitter (option)
e) The truck is equipped with a lithium-ion battery (option)
f) Adapted for cold storage environments (option)
g) Hydraulic oil filler neck cold store (option)
h) Hydraulic oil filler neck
i) Risk of crushing

Motors C1000 9
9.1 Lubrication / cooling system C1300 ................................................................................................................... 9 - 1
9.1.1 Mechanical cooling fan C1380 ............................................................................................................ 9 - 1
9.1.1.1 Checking the cooling system................................................................................................ 9 - 1
9.2 Electric motors C1700........................................................................................................................................ 9 - 1
9.2.1 Electric pump motor C1710 ................................................................................................................. 9 - 1
9.2.1.1 Overview .............................................................................................................................. 9 - 1
9.2.1.2 Description ........................................................................................................................... 9 - 2
9.2.1.3 Replacing the carbon brushes.............................................................................................. 9 - 2
9.2.1.4 Replacing the pump motor ................................................................................................... 9 - 4
9.2.2 Electric steering motor C1730 ............................................................................................................. 9 - 7
9.2.2.1 Overview .............................................................................................................................. 9 - 7
9.2.2.2 Description ........................................................................................................................... 9 - 7
9.2.2.3 Cleaning the ring gear .......................................................................................................... 9 - 7
9.2.2.4 Checking the electrical connections ..................................................................................... 9 - 8
9.2.2.5 Checking the steering motor gears ...................................................................................... 9 - 8
9.2.2.6 Checking the steering motor ................................................................................................ 9 - 8
9.2.2.7 Lubricating the ring gear....................................................................................................... 9 - 8
9.2.2.8 Check the drive gear's attachment ....................................................................................... 9 - 8
9.2.2.9 Replacing the steering motor ............................................................................................... 9 - 8
9.2.2.10 Replacing the control unit................................................................................................... 9 - 10
9.2.3 Electric fan motor/fan C1740 ............................................................................................................. 9 - 12
9.2.3.1 Overview ............................................................................................................................ 9 - 12
9.2.3.2 Replacing the motor control fan ......................................................................................... 9 - 12
9.2.4 Electric drive motor C1760 ................................................................................................................ 9 - 15
9.2.4.1 Overview 1.8, 2.5 kW ......................................................................................................... 9 - 15
9.2.4.2 Overview ............................................................................................................................ 9 - 16
9.2.4.3 Checking the electrical connections ................................................................................... 9 - 17
9.2.4.4 Checking the drive motor ................................................................................................... 9 - 17
9.2.4.5 Listen for any abnormal noise in the drive motor bearings................................................. 9 - 17
9.2.4.6 Check the drive motor fitting (1.8 and 2.5 kW) ................................................................... 9 - 18
9.2.4.7 Check the drive motor fitting (2.8 kW) ................................................................................ 9 - 18
9.2.4.8 Checking the rotational speed sensor ................................................................................ 9 - 18

9 Motors C1000
9.2.4.9 Check the rotational speed sensor fitting ........................................................................... 9 - 19
9.2.4.10 Replacing the drive motor .................................................................................................. 9 - 19
9.2.4.11 Replacing the temperature sensor ..................................................................................... 9 - 31
9.2.4.12 Replacing the rotational speed sensor ............................................................................... 9 - 32
9.2.4.13 Replacing the toothed wheel .............................................................................................. 9 - 35

9 Motors C1000
Lubrication / cooling system C1300
9 Motors C1000
9
Motors C1000
9.1 Lubrication / cooling system C1300

9.1
Lubrication / cooling system C1300
9.1.1 Mechanical cooling fan C1380

9.1.1
Mechanical cooling fan C1380
9.1.1.1 Checking the cooling system

9.1.1.1
Checking the cooling system
1. Check the cooling flanges of the transistor regulator, motor and steering motor as well as the battery charger and
fans and filters for accumulations of dirt and dust. Too much dust and dirt cause the cooling not to work properly.
2. Check that the fans work when the speed control is activated (fans behind T1 and motor fan).
3. Check that the fan on charger T14 works when the charging starts, i.e. when the mains cable is connected. 9
4. Check the signal from the temperature sensors for T1 and T13 and from B1 using the integrated test or Truck-
Com. Determine if the temperature signals are plausible relative to the real temperatures of the components. If
not, replace T1,T13 or replace B1 with a repair kit.
9.2 Electric motors C1700

9.2
Electric motors C1700
9.2.1 Electric pump motor C1710

9.2.1
Electric pump motor C1710
9.2.1.1 Overview
9.2.1.1
Overview
Pos. Designation
a Motor
b Brush bridge
c Carbon brush

9 Motors C1000
9.2.1.2 Description
9.2.1.2
Description
9.2.1.2.1 Construction
9.2.1.2.1
Construction
The pump motor is a compound motor, with a stator coil in series with the rotor coil and with an additional stator coil con-
nected in parallel to these.
9.2.1.3 Replacing the carbon brushes

9.2.1.3
Replacing the carbon brushes
9.2.1.3.1 Removing the carbon brushes

9.2.1.3.1
Removing the carbon brushes
Removing the pump motor [M3], page 9 - 4
1. Undo the nuts of the electrical connections.
2. Carefully lift the top cover straight up.

9 Motors C1000
3. Carefully tap out the rotor.
4. Detach and remove the brushes.
9.2.1.3.2 Fitting carbon brushes

9.2.1.3.2
Fitting carbon brushes
1. Fit and connect the brushes.

9 Motors C1000
2. Fit the rotor. Hold out the brushes out of the way to facilitate fit-
ting.
3. Turn the cover upside down and insert the motor.

Fit the spring washer in the cover before fitting the motor.
4. Torque tighten the screws to the electric connectors to 8,5

+0,5
⁄-0,5 N·m.
Installing the pump motor [M3], page 9 - 5
9.2.1.4 Replacing the pump motor

9.2.1.4
Replacing the pump motor
9.2.1.4.1 Removing the pump motor [M3]

9.2.1.4.1
Removing the pump motor [M3]
Preparations
Removing the hydraulic unit, page 14 - 24

9 Motors C1000
1. Loosen and remove the screws holding the motor in the valve
block.
2. Lift the motor straight up.
9.2.1.4.2 Installing the pump motor [M3]

9.2.1.4.2
Installing the pump motor [M3]
1. Turn the connection assembly so the parts align.

9 Motors C1000
2. Fit the motor.

Check that the O-ring is in place and is undamaged.
3. Fit the motor to the valve unit.
Resetting
Installing the hydraulic unit, page 14 - 25

9 Motors C1000
9.2.2 Electric steering motor C1730

9.2.2
Electric steering motor C1730
9.2.2.1 Overview
9.2.2.1
Overview
Pos. Designation
a Motor
b Steering unit
9.2.2.2 Description
9.2.2.2
Description
9.2.2.2.1 Technical data

9.2.2.2.1
Technical data
Specifications LPE200 LPE220 LPE250

Type Brushless, permanently magnetised, three-phase synchronous motor
Result kW 240
Torque constant Nm/A 0.06
Max. current A 45
Continuous current A 13
Rotational speed rpm 3250
Minimum carbon brush mm N/A
length
Minimum commutator dia- mm N/A
meter
Resistance, armature Ohm N/A
9.2.2.3 Cleaning the ring gear

9.2.2.3
Cleaning the ring gear
1. Carefully clean the ring gear (servo, option).

9 Motors C1000
9.2.2.4 Checking the electrical connections

9.2.2.4
Checking the electrical connections
1. Inspect the electrical connections of the steering motor.
9.2.2.5 Checking the steering motor gears

9.2.2.5
Checking the steering motor gears
1. Inspect the steering motor pinion, if it is damaged, the steering

motor must be replaced, see Replacing the steering motor,
page 9 - 8.
9.2.2.6 Checking the steering motor

9.2.2.6
Checking the steering motor
1. Check that the steering motor is not damaged.

In case of damage. Replacing the steering motor, page 9 - 8
9.2.2.7 Lubricating the ring gear

9.2.2.7
Lubricating the ring gear
1. Lubricate the ring gear (Servo, option) Lubricant type E, see Lubricants specification, page 6 - 4.
9.2.2.8 Check the drive gear's attachment

9.2.2.8
Check the drive gear's attachment
+3
1. Check the drive gear's attachment, tightening torque 26 ⁄-3 N·m.
9.2.2.9 Replacing the steering motor

9.2.2.9
Replacing the steering motor
9.2.2.9.1 Removing the steering motor [M6]

9.2.2.9.1
Removing the steering motor [M6]
1. Disconnect the connector.

9 Motors C1000
2. Detach and remove the screw.
9
3. Pull the steering motor straight up.
y z
9.2.2.9.2 Installing the steering motor [M6]

9.2.2.9.2
Installing the steering motor [M6]
1. Fit the steering motor to the motor plate.
y z

9 Motors C1000
+3
2. Tighten the screws to 26 ⁄-3 N·m.
3. Connect the connector.
Resetting
9.2.2.10 Replacing the control unit

9.2.2.10
Replacing the control unit
9.2.2.10.1 Removing the control unit

9.2.2.10.1
Removing the control unit
Preparations
1. Remove the control unit from the motor.

9 Motors C1000
2. Disconnect the wiring.

Make a note of the wire colour codes so that the reassembly is
made correctly.
4
1 2 3 Put aside the defective control unit.
Proceed to the installing procedure Installing the control unit,
page 9 - 11
9.2.2.10.2 Installing the control unit

9.2.2.10.2
Installing the control unit
Remove the new control unit from the ESD bag, holding it only by the heatsink
1. Hold the heatsink with one hand. Touch the motor with your
other hand (discharging any residual static charge). Connect
the wiring from the power steering motor to the control unit.
4 Cable Colour
1 2 3
1 Red
2 Black
3 Yellow
4 5-pin signal wire

9 Motors C1000
2. Install the control unit. 0.8 N·m

Pay attention when installing the control unit as to not crush the
wiring harness and that the rubber seal is correctly placed.
Resetting
9.2.3 Electric fan motor/fan C1740

9.2.3
Electric fan motor/fan C1740
9.2.3.1 Overview
9.2.3.1
Overview
a b
Pos. Designation
a Motor control (ACT/ACC)
b Fan [M12, M13]
9.2.3.2 Replacing the motor control fan

9.2.3.2
Replacing the motor control fan
9.2.3.2.1 Removing a motor control fan

9.2.3.2.1
Removing a motor control fan
Removing the motor control panel, page 13 - 32

9 Motors C1000
2. Detach the brackets from the panel plate.
3. Remove the screws securing the fan.

9 Motors C1000
9.2.3.2.2 Installing a motor control fan

9.2.3.2.2
Installing a motor control fan
1. Install the fan.
2. Attach the brackets to the panel plate.
Resetting
Installing the motor control panel, page 13 - 33
Installing the motor control panel, page 13 - 34

9 Motors C1000
9.2.4 Electric drive motor C1760

9.2.4
Electric drive motor C1760
9.2.4.1 Overview 1.8, 2.5 kW

9.2.4.1
Overview 1.8, 2.5 kW
Part number: 7560160 7560159

b c d
e
f
g
a h 9
i

a Speed sensor b N-shield
c Rotor d Toothed wheel
e Power cable (U) f Power cable (V)
g Power cable (W) h B1
i B11 j Mounting screw
k Motor screw

9 Motors C1000
9.2.4.2 Overview
9.2.4.2
Overview

c
d
b
e
Pos. Designation
a Rotor
b B11
c Toothed wheel
d N-shield
e B1
f Mounting screw
g Power cable (W)
h Power cable (V)
i Power cable (U)

9 Motors C1000
9.2.4.3 Checking the electrical connections

9.2.4.3
Checking the electrical connections
1. Inspect the cable connections of the drive motor. Tighten if

needed.
+1
Install the motor cables U, V and W, tightening torque 6 ⁄-1
N·m.
9
9.2.4.4 Checking the drive motor
9.2.4.4
Checking the drive motor
1. Check that the drive motor is not damaged.

Replace the motor if it is damaged. Replacing the drive motor,
page 9 - 19
9.2.4.5 Listen for any abnormal noise in the drive motor bearings
9.2.4.5
Listen for any abnormal noise in the drive motor bearings
1. Listen for any abnormal noise in the drive motor bearings

In case of noise:
Check the drive motor's attachment.Check the drive motor fit-
ting (1.8 and 2.5 kW), page 9 - 18, Check the drive motor fit-
ting (2.8 kW), page 9 - 18
Replace the motor bearings.
Replace the motor. Replacing the drive motor, page 9 - 19.

9 Motors C1000
9.2.4.6 Check the drive motor fitting (1.8 and 2.5 kW)
9.2.4.6
Check the drive motor fitting (1.8 and 2.5 kW)
Part number: 7560160 7560159
1. Check the screws to the drive motor, torque the screws in two
+1
stages crosswise, tightening torque 7 ⁄-1 N·m
9.2.4.7 Check the drive motor fitting (2.8 kW)

9.2.4.7
Check the drive motor fitting (2.8 kW)
1. Check the screws to the drive motor, torque the screws in two stages crosswise, tightening torque 9.5 N·m.
9.2.4.8 Checking the rotational speed sensor

9.2.4.8
Checking the rotational speed sensor
1. Disconnect [B11], page 19 - 2.
z x
2. Check that there are no metal fragments on [B11], page

19 - 2 sensor points.

9 Motors C1000
9.2.4.9 Check the rotational speed sensor fitting

9.2.4.9
Check the rotational speed sensor fitting
1. Check the rotational speed sensor [B11], page 19 - 2 fitting

Replace the sensor in case of malfunction. Replacing the rota-
tional speed sensor, page 9 - 32
9
9.2.4.10 Replacing the drive motor
9.2.4.10
Replacing the drive motor
9.2.4.10.1 Removing the drive motor [M1]

9.2.4.10.1
Removing the drive motor [M1]

Preparations
Removing the parking brake, page 11 - 11
1. Detach the motor cables U, V and W.
U
V
W
3X

9 Motors C1000
2. Disconnect the connectors[B1], page 19 - 2 and [B11], page

19 - 2.
3. Detach the cable bracket at the rotational speed sensor, or cut

the cable tie.
4. Remove the screws securing the motor.
5. Undo the screws securing the motor so they are loose, but not
removed.

9 Motors C1000

9.2.4.10.2

Preparations
U
V
W
3X

9 Motors C1000

19 - 2.
3. Detach the cable bracket at the rotational speed sensor, or cut

the cable tie.
5. Undo the screws securing the motor so they are loose, but not
removed.

9 Motors C1000

9.2.4.10.3

Preparations
U
V

9 Motors C1000

19 - 2.
3. Remove both wire brackets from the plate with the connection
socket and the mounting screw, or cut the straps.

9 Motors C1000
9.2.4.10.4 Installing the drive motor [M1]

9.2.4.10.4
Installing the drive motor [M1]
1. Lower the motor in the drive gear, taking care so as not to

damage the splines on the drive shaft.
2. Install the screws that secure the motor before installing.
3. Install the motor and torque tighten the screws, torque tighten
+1
to 7 ⁄-1 N·m.

9 Motors C1000
4. Connect the connectors[B1], page 19 - 2 and [B11], page

19 - 2.
+1
5. Install the motor cables U, V and W, torque tighten to 6 ⁄-1
N·m.
U
U
V
W
3X

9 Motors C1000
6. Install the rotational speed sensor bracket or fit new straps.
Resetting
Fitting the parking brake, page 11 - 13

9.2.4.10.5

damage the splines on the drive shaft. Make sure the screws
securing the motor are tightened loosely.
+1
2. Install the motor and torque tighten the screws to 7 ⁄-1 N·m.

9 Motors C1000

19 - 2.
+1
4. Install the motor cables U, V and W, torque tighten to 6 ⁄-1
N·m.
U
U
V
W
3X

9 Motors C1000
5. Install the rotational speed sensor bracket or fit new straps.
Resetting

9.2.4.10.6

damage the splines on the drive shaft.
2. Install the motor, torque tighten 9.5 N·m and replace the cable
bracket on the mounting screw.

9 Motors C1000

19 - 2.
4. Install the motor cables U, V and W, tightening torque 15 N·m.
U
V
W

9 Motors C1000
5. Fit the cable bracket to the connection plinth.
9
Resetting
9.2.4.11 Replacing the temperature sensor

9.2.4.11
Replacing the temperature sensor
9.2.4.11.1 Installing the temperature sensor

9.2.4.11.1
Installing the temperature sensor
Preparations
1. Clean the surface where the new temperature sensor will be

mounted.

9 Motors C1000
2. Place the temperature sensor as shown in the picture.
3. Apply plastic steel over the sensor. The entire sensor must be
covered.
4. Affix the steel plastic and the sensor with masking tape and al-
low to set.
5. Remove the masking tape. The temperature sensor should

now be firmly positioned and entirely covered by the plastic
steel.
6. Connect the harness
9.2.4.12 Replacing the rotational speed sensor

9.2.4.12
Replacing the rotational speed sensor
9.2.4.12.1 Removing a rotational speed sensor

9.2.4.12.1
Removing a rotational speed sensor
1. Remove the screw.

9 Motors C1000
2. Pull out the sensor.
9
z x
3. Disconnect the connector [B11], page 19 - 2.
z x
4. Detach the sensor's cable connection from the motor.
z x

9 Motors C1000
9.2.4.12.2 Installing a rotational speed sensor

9.2.4.12.2
Installing a rotational speed sensor
1. Check the O-ring of the new sensor.
2. Fit the sensor.
z x
3. Screw the sensor in place.
4. Connect the sensor's cable connection to the motor.
z x

9 Motors C1000
5. Connect the connector [B11], page 19 - 2.
z x
9
y
9.2.4.13 Replacing the toothed wheel

9.2.4.13
Replacing the toothed wheel
9.2.4.13.1 Removing a toothed wheel

9.2.4.13.1
Removing a toothed wheel
Removing the drive motor [M1], page 9 - 19, Removing the drive motor [M1], page 9 - 21, Removing the drive mo-
tor [M1], page 9 - 23
Removing a rotational speed sensor, page 9 - 32
Disassembling the brake hub, page 11 - 7
1. Remove the circlip at the toothed wheel.
2. Remove the toothed wheel. If needed, use a puller and save

the key.

9 Motors C1000
9.2.4.13.2 Installing a toothed wheel

9.2.4.13.2
Installing a toothed wheel
1. Fit the toothed wheel.
2. Install the circlip, make sure it ends up pressing on the toothed

wheel.
Installing a brake hub, page 11 - 8

Installing a rotational speed sensor, page 9 - 34
Installing the drive motor [M1], page 9 - 25, Installing the drive motor [M1], page 9 - 27, Installing the drive motor
[M1], page 9 - 29

Transmission/Drive gear C2000 10
10.1 Drive unit, final gear C2500 ............................................................................................................................. 10 - 1
10.1.1 Drive unit/gear C2550 ....................................................................................................................... 10 - 1
10.1.1.1 Overview ............................................................................................................................ 10 - 1
10.1.1.2 Overview ............................................................................................................................ 10 - 2
10.1.1.3 Description ........................................................................................................................ 10 - 2
10.1.1.4 Check the drive gear's attachment .................................................................................... 10 - 3
10.1.1.5 Checking for leaks in the drive gear ................................................................................... 10 - 3
10.1.1.6 Checking for noise in the drive gear................................................................................... 10 - 4
10.1.1.7 Replacing the drive gear ................................................................................................... 10 - 4
10.1.1.8 Replacing the wheel hub seal ........................................................................................... 10 - 7
10.1.1.9 Drive gear oil change ......................................................................................................... 10 - 9
10.1.1.10 Replacing the drive gear steering bearing ....................................................................... 10 - 13
10.1.1.11 Stud replacement ............................................................................................................. 10 - 16

10 Transmission/Drive gear C2000

Drive unit, final gear C2500

10
Transmission/Drive gear C2000
10.1 Drive unit, final gear C2500

10.1
10.1.1 Drive unit/gear C2550

10.1.1
Drive unit/gear C2550
10.1.1.1 Overview
10.1.1.1
Overview
Part number: 7540136 7525837 7530286

b
10
a e
Pos. Designation
a Transmission housing
b Motor bearing and packing box
c Steering bearings
d Seal and cover ring
e Stud M12X1.5

10.1.1.2 Overview
10.1.1.2
Overview
Part number: 7525839 7540133

c
b e
Pos. Designation
a Seal and cover ring
b Transmission housing
c Motor bearing and packing box
d Steering bearings
e Stud M14X1.5
10.1.1.3 Description
10.1.1.3
Description
10.1.1.3.1 Design
10.1.1.3.1
Design
The drive gear is a two-stage angle gear that is integrated with the motor and brake assembly in a complete drive unit.
The drive gear is bolted to the chassis. At the top edge of the gear, the steering bearing and a gear ring for the steering
motor (option) are fitted.
A complete reconditioning of the drive gear must be performed in the workshop by trained technicians.

10.1.1.3.2
Technical data
Part number: 7525839 7540133
Description Value
Type Two-stage angle gear
Gear ratio 16.96
Oil quality 1.05 litres
Drive wheel Ø 250

Description Value
Oil type See Lubricants specification, page
22 - 2

10.1.1.3.3
Technical data
Part number: 7540136 7525837 7530286
Description Value
Type Two-stage angle gear
Gear ratio 18.39
Oil quality 0.9 litres
Drive wheel Ø 230
Oil type See Lubricants specification, page 10
22 - 2
10.1.1.4 Check the drive gear's attachment

10.1.1.4
Check the drive gear's attachment
1. Check the drive gear's attachment. Tighten the screws if ne-

cessary. 23 N·m
10.1.1.5 Checking for leaks in the drive gear

10.1.1.5
Checking for leaks in the drive gear
1. Check the drive gear for leaks. If there are any leaks, change
the oil seal, see Replacing the wheel hub seal , page 10 - 7.

10.1.1.6 Checking for noise in the drive gear

10.1.1.6
Checking for noise in the drive gear
1. Listen for any abnormal noise in the drive gear bearings

In case of noise:
Check if the oil level is up to the bottom edge of the filler hole,
see Lubricants specification, page 22 - 2.
Replace the steering bearing. Replacing the drive gear steering
bearing , page 10 - 13
10.1.1.7 Replacing the drive gear

10.1.1.7
Replacing the drive gear
10.1.1.7.1 Removing the drive gear

10.1.1.7.1
Removing the drive gear
Preparations
1. Turn the drive wheel as much as possible in one direction.
2. Switch off the truck and disconnect the battery connector.
WARNING Risk of personal injury and material and prop-

erty damage
For trucks with power steering, the truck battery must be dis-
connected when working on the drive gear/drive wheel.
► The drive wheel will automatically return to the original
position when the truck is started.
Removing the drive motor [M1], page 9 - 19, Removing the drive
motor [M1], page 9 - 21, Removing the drive motor [M1], page
9 - 23

3. Undo and remove the screws to the drive gear.
10
4. Lift the truck 100 mm and support it on trestles.
WARNING Risk of crushing under the truck

Risk of crushing since a poorly supported truck could fall
down.
► Secure the truck in a safe manner.
5. Remove the gear from the truck.
6. Mark the position of the steering bearing.

10.1.1.7.2 Installing the drive gear

10.1.1.7.2
Installing the drive gear
1. Lift the drive gear in place.

Turn the wheel towards you (rearwards) to facilitate the lift.
2. Rotate the steering bearing to the right position; see marking.
3. Lower the truck and position the gear in place.
4. Fit the drive gear.

Remember to tighten the screws crosswise

Resetting
Installing the drive motor [M1], page 9 - 25
10.1.1.8 Replacing the wheel hub seal

10.1.1.8
Replacing the wheel hub seal
10.1.1.8.1 Removing the wheel hub seal

10.1.1.8.1
Removing the wheel hub seal
Disassembling the drive wheel, page 11 - 17
1. Remove the cover ring using a screwdriver or similar to remove

the seal.
10

2. Remove the seal using a screwdriver or similar to remove the

seal.
10.1.1.8.2 Installing the wheel hub seal

10.1.1.8.2
Installing the wheel hub seal
1. Fit the seal. Tap lightly to get it into the right position.

2. Fit the cover ring. Tap it lightly into place.
Installing a drive wheel, page 11 - 18
10
10.1.1.9 Drive gear oil change
10.1.1.9
Drive gear oil change
1. Empty the oil from the drive gear. Empty the drive gear oil, page
10 - 10, Empty the drive gear oil, page 10 - 11
2. Fill oil into the drive gear. Filling oil in the drive gear, page
10 - 12, Filling oil in the drive gear, page 10 - 13

10.1.1.9.1 Empty the drive gear oil

10.1.1.9.1
Empty the drive gear oil
1. Undo and remove the oil plug on the lower part of the gear
housing.
2. Drain all old oil into a suitable receptacle.
3. Clean away dirt and metal shavings from the oil plug.
4. Install the oil plug, tighten to 20 N·m.

10.1.1.9.2 Empty the drive gear oil

10.1.1.9.2
Empty the drive gear oil
1. Undo and remove the oil plug on the lower part of the gear
housing.
10
2. Drain all old oil into a suitable receptacle.
3. Clean the oil plug of any dirt and shavings. Refit the oil plug,
tighten to 20 N·m.

10.1.1.9.3 Filling oil in the drive gear

10.1.1.9.3
Filling oil in the drive gear
1. Remove the oil filler plug on the upper part of the gear housing.
2. Top up with oil up to the lower edge of the hole to reach the
correct level, Lubricants specification, page 22 - 2.
3. Screw in the plug.

10.1.1.9.4 Filling oil in the drive gear

10.1.1.9.4
Filling oil in the drive gear
1. Remove the oil filler plug on the upper part of the gear housing.
10
2. Top up with oil up to the lower edge of the hole to reach the
correct level, Lubricants specification, page 22 - 2.
3. Screw in the plug.
10.1.1.10 Replacing the drive gear steering bearing

10.1.1.10
Replacing the drive gear steering bearing
10.1.1.10.1 Removing the drive gear steering bearing

10.1.1.10.1
Removing the drive gear steering bearing
Part number: 7525839 7540133

1. Undo and remove the screws to the steering bearing.
2. Lift away the steering bearing.
10.1.1.10.2 Removing the drive gear steering bearing

10.1.1.10.2
Removing the drive gear steering bearing
Part number: 7540136 7525837
1. Undo and remove the screws to the steering bearing.

2. Lift away the steering bearing.
10
10.1.1.10.3 Installing the drive gear steering bearing

10.1.1.10.3
Installing the drive gear steering bearing
Part number: 7525839 7540133
1. Install the steering bearing.

Check that the bearing rotates before fitting it in the truck.

10.1.1.10.4 Installing the drive gear steering bearing

10.1.1.10.4
Installing the drive gear steering bearing
Part number: 7540136 7525837
1. Install the steering bearing.

Check that the bearing rotates before fitting it in the truck.
10.1.1.11 Stud replacement

10.1.1.11
Stud replacement
10.1.1.11.1 Removing a stud

10.1.1.11.1
Removing a stud
Disassembling the drive wheel, page 11 - 17

1. Remove the damaged studs.
• Studs with damaged threads can be removed using the

stud extractor.
• For broken studs, there are two methods:
Method 1: Drill a hole in the centre of the stud and remove it
using a bolt extractor.
Method 2: If the stud will not come loose with a bolt extractor, it
will have to be drilled out
• Drive a centre punch as close to the centre of the stud

as possible.
• Drill a pilot hole in the stud using a 5 mm bit.
• Drill out the screw with a drill.
10
• Try to remove the stud remains using pliers, etc. If that
does not work, remove the remains by clearing the
threads with a tap.
10.1.1.11.2 Installing a stud

10.1.1.11.2
Installing a stud
1. Apply Loctite 270 to the stud threads.

Loctite XXX
2. Use the stud tool to fit the new stud and tighten to 35 N·m.
Installing a drive wheel, page 11 - 18


Brake/wheel/track system C3000 11
11.1 Travel brake system C3100 ............................................................................................................................. 11 - 1
11.1.1 Description......................................................................................................................................... 11 - 1
11.1.1.1 Brake types ........................................................................................................................ 11 - 1
11.2 Parking brake details C3300............................................................................................................................ 11 - 2
11.2.1 Electrical parking brake, magnet brake C3370.................................................................................. 11 - 2
11.2.1.1 Overview ............................................................................................................................ 11 - 2
11.2.1.2 Description ......................................................................................................................... 11 - 3
11.2.1.3 Cleaning the parking brake ................................................................................................ 11 - 3
11.2.1.4 Adjusting the parking brake gap......................................................................................... 11 - 4
11.2.1.7 Tighten the parking brake mounting bolts .......................................................................... 11 - 6
11.2.1.8 Emergency release of the parking brake............................................................................ 11 - 6
11.2.1.9 Checking the parking brake................................................................................................ 11 - 7
11.2.1.10 Replacing the brake hub .................................................................................................... 11 - 7
11.2.1.11 Replacing the friction disc .................................................................................................. 11 - 8
11.2.1.12 Replacing the parking brake............................................................................................. 11 - 11
11.3 Wheels C3500 ............................................................................................................................................... 11 - 15
11.3.1 Drive wheel C3530 .......................................................................................................................... 11 - 15
11.3.1.1 Overview .......................................................................................................................... 11 - 15
11.3.1.2 Measuring the drive wheel tread ...................................................................................... 11 - 15
11.3.1.3 Measuring the drive wheel tread ...................................................................................... 11 - 16
11.3.1.4 Check the drive wheel mountings .................................................................................... 11 - 16
11.3.1.5 Check the drive wheel mountings .................................................................................... 11 - 17
11.3.1.6 Replacing the drive wheel ................................................................................................ 11 - 17
11.3.2 Support arm wheels/castor wheels C3540 ...................................................................................... 11 - 19
11.3.2.1 Overview .......................................................................................................................... 11 - 19
11.3.2.2 Cleaning castor wheels .................................................................................................... 11 - 20
11.3.2.3 Measuring the castor wheel tread .................................................................................... 11 - 20

11 Brake/wheel/track system C3000
11.3.2.7 Checking the castor wheels ............................................................................................. 11 - 21
11.3.2.8 Replacing the castor wheel .............................................................................................. 11 - 21
11.3.2.9 Replacing the castor wheel assembly .............................................................................. 11 - 25
11.3.3 Fork wheels/support arm wheels C3550 ......................................................................................... 11 - 27
11.3.3.1 Overview .......................................................................................................................... 11 - 27
11.3.3.2 Description ....................................................................................................................... 11 - 28
11.3.3.3 Cleaning the fork wheels .................................................................................................. 11 - 28
11.3.3.4 Measuring the fork wheel tread ........................................................................................ 11 - 29
11.3.3.5 Checking the fork wheel mounting ................................................................................... 11 - 29
11.3.3.6 Checking the fork wheel bushings.................................................................................... 11 - 29
11.3.3.7 Replacing a single wheel.................................................................................................. 11 - 30
11.3.3.8 Replacing bogie wheels ................................................................................................... 11 - 34
11.3.3.9 Replacing a bogie link ...................................................................................................... 11 - 36

Travel brake system C3100

11
Brake/wheel/track system C3000
11.1 Travel brake system C3100

11.1
Travel brake system C3100
11.1.1 Description
11.1.1
Description
11.1.1.1 Brake types

11.1.1.1
Brake types
The truck has three different types of brake:

- travel brake,
- parking brake,
- emergency brake.
11.1.1.1.1 Travel brake

11.1.1.1.1
Travel brake
The travel brake is designed as a system: 11

- Regenerative motor braking using the drive motor.
11.1.1.1.2 Emergency brake

11.1.1.1.2
Emergency brake
Emergency braking of the truck takes place in the event of a fault with the steering system or a serious fault in the elec-
trical system.
The parking brake on the drive motor is the main emergency brake.
Motor braking can operate during emergency braking provided there is a supply voltage.
11.1.1.1.3 Parking brake

11.1.1.1.3
Parking brake
The brake [Q1] is a single stage electromechanical spring-loaded brake that is released when the magnetic coil is ener-
gised. This brake serves as a parking brake and emergency brake.
The parking brake is activated/is active as follows:
• The parking brake is applied automatically when the truck stops during operation. The brake is released when the
truck moves off.
• The parking brake remains active after the main power has been switched on.

Parking brake details C3300
11.2 Parking brake details C3300

11.2
11.2.1 Electrical parking brake, magnet brake C3370

11.2.1
Electrical parking brake, magnet brake C3370
11.2.1.1 Overview
11.2.1.1
Overview
a i
b
c
Pos. Designation
a Screw
b Wiring harness
c Magnet housing
d Guard
e Locking screw
f Hub
g Friction disc
h Pressure disc
i Sleeved screw M5x35

11.2.1.2
Description

11.2.1.2.1
Technical data
Description Standard Unit

Brakes Non-CCV
Type Single stage electromechanical
spring-loaded brake
Nominal brake torque 21 Nm
Nominal air gap 0.2 +0.15/-0.05 mm
Maximum gap before replacement 0.65 mm
Coil resistance 7.68 Ohms at 20° C Ohms
Result 18.75 W
Nominal clearance in applied posi- 0.2 mm 11
tion
Minimum brake disc thickness Breaks when the friction mater- mm
ial is completely worn
Thickness of new brake disc 7.5 mm

11.2.1.2.2
Technical data
Part number: 7552246 7549853
Description Standard Unit

Brakes Non-CCV/CCV
Type Single stage electromechanical
spring-loaded brake
Nominal brake torque 30 Nm
Nominal air gap 0.2 ± 0.05 mm
Maximum gap before replacement 0.5 mm
Coil resistance 6.261 Ohms at 20° C Ohms
Result 23 W
Nominal clearance in applied posi- 0.2 mm
tion
Minimum brake disc thickness Breaks when the friction mater- mm
ial is completely worn
Thickness of new brake disc 7.5 mm
11.2.1.3 Cleaning the parking brake

11.2.1.3
Cleaning the parking brake
Preparations

1. Clean the inside of the brake. Use compressed air to carefully

blow away the brake dust inside the brake.
If using compressed air does not help, the brake must be re-
moved and cleaned. Replacing the parking brake, page 11 - 11
2. Place the parking brake on a workbench with the magnet hous-

ing facing downwards.
3. Remove the immovable pressure disk.
4. Lift out the friction disc.
5. Clean the brake using compressed air. Clean from the inside
outwards.
6. If there are particles that cannot be cleared away with com-

pressed air, these may be carefully scraped away.
7. Place the friction disc on the revolving pressure disk.
8. Place the immovable pressure disk on top of the friction disc,

making sure the screw holes are correctly positioned
9. Check that the friction disc is centred in relation to the magnet

housing.
10. Reinstall the parking brake. Fitting the parking brake, page
11 - 13
It is extremely important that an air gap of min. 0.15mm is
maintained all around the brake. If the prescribed measure-
ment cannot be maintained after cleaning or adjustment, the
brake must be replaced
11. Repeat the cleaning as necessary until a 0.15 mm feeler gauge

can be inserted. Measure the air gap between the magnet
housing of the brake unit and the movable pressure disc.
Measuring must be done around the entire pressure disc, both
on the inside and the outside.
11.2.1.4 Adjusting the parking brake gap

11.2.1.4
Adjusting the parking brake gap
Part number: 7552246 7549853

Preparations
1. Check that the parking brake is applied.

2. Use a feeler gauge to check that the gap between the brake
unit's magnet housing and the movable pressure disc is =0.3
+0.2
⁄-0.15mm. If the gap is not within the permitted values, the
brake must be cleaned or the friction disc replaced, see Clean-
ing the parking brake, page 11 - 3 or Replacing the friction disc,
page 11 - 8.
Resetting

11
11.2.1.5
Part number: 7552244 7588119
If the brake has an air gap that cannot be adjusted, the rotating friction disc must be replaced with a new one be-
fore the maximum air gap is exceeded.
Preparations
1. Check that the parking brake is applied.
2. Use a feeler gauge to check that the gap between the brake
unit's magnet housing and the movable pressure disc is =0.4
+0.25
⁄-0.25 mm. If the gap is not within the permitted values, the
brake must be cleaned or the friction disc replaced, see Clean-
ing the parking brake, page 11 - 3 or Replacing the friction disc,
page 11 - 8.
Resetting

11.2.1.6
Preparations
Adjusting the parking brake gap, page 11 - 4
1. Undo the screws.

2. Carefully turn the lock screw using a combination spanner.

– counter-clockwise to increase the gap.
– clockwise to decrease the gap.
1/6 of a turn changes the gap about 0.15 mm.
+1.2
3. Tighten the bolts to 11.3 ⁄-1.2 N·m.
Resetting
11.2.1.7 Tighten the parking brake mounting bolts

11.2.1.7
Tighten the parking brake mounting bolts
1. Tighten the parking brake mounting bolts to a torque of 11.3

+1.2
⁄-1.2 N·m.
11.2.1.8 Emergency release of the parking brake

11.2.1.8
Emergency release of the parking brake
An emergency release of the brakes should only be performed when the truck needs to be moved in connection
with work for service and repairs.
Preparations

1. Screw in two screws M5×35 evenly and gradually.
2. Connect the battery.
3. Move the truck with great caution.
4. Disconnect the battery.
WARNING Emergency release of the parking brake

Risk of personal injury and material and property damage.
► Make sure the sleeved screws have the correct length.
► The sleeved screws must be removed in order to en-
gage the parking brake.
5. Unscrew the two sleeved screws gradually.

11
11.2.1.9 Checking the parking brake

11.2.1.9
Checking the parking brake
1. Drive the truck at crawl speed and press the emergency stop
switch.
The truck must brake to a safe stop using the parking brake.
2. Drive the truck carefully and move the tiller arm up and down to
test the activation of the plug braking and the parking brake.
3. Check if the sleeved screws have been removed if the brake is

not activated. Emergency release of the parking brake, page
11 - 6.
Measure the spacing of the brake: Adjusting the parking brake
gap, page 11 - 4, Adjusting the parking brake gap, page 11 - 5.
Replace the brake pressure plate: Replacing the friction disc,
page 11 - 8.
11.2.1.10 Replacing the brake hub

11.2.1.10
Replacing the brake hub
11.2.1.10.1 Disassembling the brake hub

11.2.1.10.1
Disassembling the brake hub

1. Remove the circlip.
2. Remove the hub.

If the hub is stuck, you will need to use a puller to remove it.
11.2.1.10.2 Installing a brake hub

11.2.1.10.2
Installing a brake hub
1. Fit the hub carefully.

Carefully knock the hub onto the shaft.
2. Fit the circlip.
11.2.1.11 Replacing the friction disc

11.2.1.11
Replacing the friction disc
11.2.1.11.1 Removing the friction disc

11.2.1.11.1
Removing the friction disc

1. Place the brake assembly on a clean, dry work bench with the
magnet housing facing downwards.
2. Remove the rubber protection.
11
3. Remove the immovable pressure disk.
4. Lift out the friction disc.
11.2.1.11.2 Fitting the friction disc

11.2.1.11.2
Fitting the friction disc


making sure the locking screw holes are correctly positioned.
3. Fit the rubber protection.
11.2.1.11.3 Fitting the friction disc

11.2.1.11.3
Fitting the friction disc


making sure the locking screw holes are correctly positioned.
3. Fit the rubber protection.
11
11.2.1.12 Replacing the parking brake

11.2.1.12
Replacing the parking brake
11.2.1.12.1 Removing the parking brake

11.2.1.12.1
Removing the parking brake
WARNING Removing the parking brake

► When the load is relieved from the parking brake friction disc or if the brake is released mechanically and
removed from the truck, the truck may move unintentionally.
Before starting work with the parking brake unit, the truck must be secured in such a way that it cannot
start to move.
Preparations

1. Disconnect the connector (Q1) to the brake.
2. Remove the dust guard.
3. Fit the sleeved screws.

4. Remove the brake.
11
11.2.1.12.2 Fitting the parking brake
11.2.1.12.2
Fitting the parking brake
1. Fit the brake to the hub, be careful so that the splines are not
+1.2
damaged in the process. 11.3 ⁄-1.2 N·m
2. Remove the sleeved screws.

3. Fit the dust guard.
4. Connect the connector (Q1).
WARNING Test drive after working on the parking brake

Be careful when test driving after performing work on the
truck parking brake.
► The sleeved screws must be removed in order to en-
gage the parking brake.
Resetting

Wheels C3500
11.3 Wheels C3500

11.3
Wheels C3500
11.3.1 Drive wheel C3530

11.3.1
Drive wheel C3530
11.3.1.1 Overview
11.3.1.1
Overview
11
b c
a
Pos. Designation
a Wheels
b Washer
c Nut
11.3.1.2 Measuring the drive wheel tread

11.3.1.2
Measuring the drive wheel tread
Part number: 7528903 7528908 7528910 7528911 7535433 7535852
1. Measure the drive wheel tread. The tread must be ≥12.5 mm. If the tread is less than the minimum size, the drive
wheel must be replaced, see Replacing the drive wheel, page 11 - 17.

Wheels C3500
11.3.1.3 Measuring the drive wheel tread

11.3.1.3
Measuring the drive wheel tread
Part number: 7535733 7535734 7535735 7535737 7556522
1. Measure the drive wheel tread. The tread must be ≥15 mm. If
the tread is less than the minimum size, the drive wheel must
M be replaced, see Replacing the drive wheel, page 11 - 17.
11.3.1.4 Check the drive wheel mountings

11.3.1.4
Check the drive wheel mountings
Part number: 7535733 7535734 7535735 7535737 7556522
1. Check the wheel bolts, tightening torque 78 N·m.
2. Tighten the bolts crosswise as per the picture, tighten number

1 twice.
4
1
2
3
5

Wheels C3500
11.3.1.5 Check the drive wheel mountings

11.3.1.5
Check the drive wheel mountings
Part number: 7528903 7528908 7528910 7528911 7535433 7535852
1. Check the wheel bolts, tightening torque 130 N·m.
2. Tighten the bolts crosswise as per the picture, tighten number

11
1 twice.
4
1
2
3
5
11.3.1.6 Replacing the drive wheel

11.3.1.6
Replacing the drive wheel
11.3.1.6.1 Disassembling the drive wheel

11.3.1.6.1
Disassembling the drive wheel
1. Set the drive wheel as per the illustration.

Wheels C3500
2. Switch off the truck and disconnect the battery connector.
WARNING Replacing the drive wheel

► For trucks with power steering, the truck battery must
be disconnected when working on the drive gear/drive
wheel. The drive wheel will automatically return to the
original position when the truck is started.
3. Support the truck:
WARNING Risk of crushing under the truck

Risk of crushing since a poorly supported truck could fall
down.
► Secure the truck in a safe manner.
4. Remove the drive wheel.
11.3.1.6.2 Installing a drive wheel

11.3.1.6.2
Installing a drive wheel
1. Fit the drive wheel.

78 N·mM12
130 N·mM14

Wheels C3500
2. Lower the truck.
WARNING Replacing the drive wheel

► For trucks with power steering, the truck battery must
be disconnected when working on the drive gear/drive
wheel. The drive wheel will automatically return to the
original position when the truck is started.
WARNING The drive gear/drive wheel must turn freely

► Please be careful to check that everything is correctly
fitted and also that the gears / drive wheel can turn
freely before the truck is powered up.
Install the platform, see Installing the platform, page 8 - 77, Fitting the platform [Fixed side guards], page 8 - 79.
11
11.3.2 Support arm wheels/castor wheels C3540

11.3.2
Support arm wheels/castor wheels C3540
11.3.2.1 Overview
11.3.2.1
Overview
a d
b e
c f
Pos. Designation
a Single wheel assembly
b Shaft set
c Single wheel
d Twin wheel assembly
e Shaft set
f Twin wheels

Wheels C3500
11.3.2.2 Cleaning castor wheels

11.3.2.2
Cleaning castor wheels
Preparations
1. Clean the castor wheel from strings and other dirt.
Resetting
11.3.2.3 Measuring the castor wheel tread

11.3.2.3
Measuring the castor wheel tread
1. Measure the castor wheel tread. The tread must be ≥10mm. If

the tread is less than the minimum size, the castor wheel must
be replaced, see Replacing the castor wheel, page 11 - 21.

11.3.2.4


Wheels C3500

11.3.2.5
1. Measure the castor wheel tread. The tread must be ≥7.5mm. If

11
11.3.2.6

11.3.2.7 Checking the castor wheels

11.3.2.7
Checking the castor wheels
1. Check that the castor wheel is properly attached and that it ro-
tates and pivots freely. In case of faults, replace the castor
wheel, see Replacing the castor wheel assembly, page 11 - 25.
11.3.2.8 Replacing the castor wheel

11.3.2.8
Replacing the castor wheel
11.3.2.8.1 Removing the castor

11.3.2.8.1
Removing the castor
Part number: 7523193 7523406
Removing the castor wheel assembly, page 11 - 25

Wheels C3500
1. Remove the wheel shaft nut.
2. Pull out the shaft.
3. Remove the wheel
11.3.2.8.2 Removing the castor

11.3.2.8.2
Removing the castor
Part number: 7523192 7535851
Removing the castor wheel assembly, page 11 - 25

Wheels C3500
1. Remove the wheel shaft nut.
11
2. Pull out the shaft.
3. Remove the wheel

Wheels C3500
11.3.2.8.3 Installing a castor wheel

11.3.2.8.3
Installing a castor wheel
Part number: 7523193 7523406
1. Fit the wheel.

Do not forget to refit the washers.
2. Fit the wheel shaft.
3. Fit the nut on the wheel shaft, tightening torque 160 N·m.
Installing the castor wheel assembly, page 11 - 26.

Wheels C3500
11.3.2.8.4 Installing a castor wheel

11.3.2.8.4
Installing a castor wheel
Part number: 7523192 7535851
1. Fit the wheel.
11
3. Fit the nut on the wheel shaft, tightening torque 160 N·m.
Installing the castor wheel assembly, page 11 - 26
11.3.2.9 Replacing the castor wheel assembly

11.3.2.9
Replacing the castor wheel assembly
11.3.2.9.1 Removing the castor wheel assembly

11.3.2.9.1
Removing the castor wheel assembly

Wheels C3500
1. Support the truck, =80mm.
2. Remove the castor wheel.
11.3.2.9.2 Installing the castor wheel assembly

11.3.2.9.2
Installing the castor wheel assembly
1. Fit the castor wheel.

Wheels C3500
2. Lower the truck to the ground.
Installing the platform, page 8 - 77, Fitting the platform [Fixed side guards], page 8 - 79 11
11.3.3 Fork wheels/support arm wheels C3550

11.3.3
Fork wheels/support arm wheels C3550
11.3.3.1 Overview
11.3.3.1
Overview
d
h
b
i
g
d
Pos. Designation
a Boogie wheels

Wheels C3500
Pos. Designation
b Link
c Screw
d Single wheel
e Shaft
f Circlip
g Nut
h Screw
i Bracket
11.3.3.2
Description
11.3.3.2.1 Wheel wear

11.3.3.2.1
Wheel wear
Type mm Normal dimensions, Minimum dimensions,

mm (H) mm
Support arm wheel D = 85 10 5
11.3.3.3 Cleaning the fork wheels

11.3.3.3
Cleaning the fork wheels
1. Clean the fork wheels from strings and other dirt.

Wheels C3500
11.3.3.4 Measuring the fork wheel tread

11.3.3.4
Measuring the fork wheel tread
1. Measure the fork wheel tread. The tread must be ≥5 mm.

If the fork wheel tread is less than the minimum size Replacing
a single wheel, page 11 - 30orReplacing bogie wheels, page
11 - 34
11.3.3.5 Checking the fork wheel mounting

11.3.3.5
Checking the fork wheel mounting
11
1. Check the fork wheel mounting, if the mounting is damaged,
replace the wheel, see Replacing a single wheel, page 11 - 30
or Replacing bogie wheels, page 11 - 34.
11.3.3.6 Checking the fork wheel bushings

11.3.3.6
Checking the fork wheel bushings
1. Check that the bushings in the wheel fork are not worn.
Replace the parts if they are worn Replacing the wheel fork
bushing, page 8 - 9
Replace the wheel shaft if it is worn.

Wheels C3500
11.3.3.7 Replacing a single wheel

11.3.3.7
Replacing a single wheel
11.3.3.7.1 Removing single wheels

11.3.3.7.1
Removing single wheels
1. Remove the wheel shaft lock.
170mm
3. Tap out the wheel shaft.
4. Remove the wheel.
1
2

Wheels C3500
11.3.3.7.2 Removing single wheels

11.3.3.7.2
Removing single wheels
1. Remove the wheel shaft lock.
11
170mm
3. Tap out the wheel shaft.
1
2

Wheels C3500
11.3.3.7.3 Single wheel installation

11.3.3.7.3
Single wheel installation
1. Fit the wheel.
2
1
3. Fit the wheel shaft lock and turn the shaft to the correct posi-
tion and tighten the screw.
4. Lower the truck.
1
2
2 170mm

Wheels C3500
11.3.3.7.4 Single wheel installation

11.3.3.7.4
Single wheel installation
1. Fit the wheel.
2 11
1
3. Lower the truck.
1
2
2 170mm
4. Fit the wheel shaft lock.

Wheels C3500
11.3.3.8 Replacing bogie wheels

11.3.3.8
Replacing bogie wheels
11.3.3.8.1 Removing bogie wheels

11.3.3.8.1
Removing bogie wheels
170mm
2. Remove the wheel screw.

Wheels C3500
11
11.3.3.8.2 Fitting the bogie wheel
11.3.3.8.2
Fitting the bogie wheel
1. Fit the wheel.
2. Centre the wheel with shims.

The wheels must be centred with a maximum play of 0.5 mm.
Max. 0,5mm

Wheels C3500
3. Fit the wheel screw.
4. Lower the truck.
1
2
2 170mm
11.3.3.9 Replacing a bogie link

11.3.3.9
Replacing a bogie link
11.3.3.9.1 Removing a bogie link

11.3.3.9.1
Removing a bogie link
Removing bogie wheels, page 11 - 34

Wheels C3500
1. Remove the bogie link
11
11.3.3.9.2 Installing a bogie link
11.3.3.9.2
Installing a bogie link
1. Install the bogie link
Fitting the bogie wheel, page 11 - 35

Wheels C3500

Steering system C4000 12
12.1 Description ....................................................................................................................................................... 12 - 1
12.1.1 Power steering................................................................................................................................... 12 - 1
12.2 Mechanical steering system C4100 ................................................................................................................. 12 - 1
12.2.1 Steering arm/wheel/lever C4110 ....................................................................................................... 12 - 1
12.2.1.1 Overview tiller arm.............................................................................................................. 12 - 1
12.2.1.2 Operating panel.................................................................................................................. 12 - 3
12.2.1.3 Tiller arm handle............................................................................................................... 12 - 19
12.2.1.4 Tiller arm .......................................................................................................................... 12 - 21
12.2.1.5 Steering yoke ................................................................................................................... 12 - 32
12.2.1.6 Steering adapter............................................................................................................... 12 - 42
12.2.1.7 Tiller arm wiring harness .................................................................................................. 12 - 59
12.2.1.8 Replacing the steering bearing......................................................................................... 12 - 68
12.2.1.9 Replacing the rubber seals............................................................................................... 12 - 75
12.3 Electric steering system C4300 ..................................................................................................................... 12 - 77
12.3.1 Overview.......................................................................................................................................... 12 - 77
12.3.2 Overview.......................................................................................................................................... 12 - 78
12.3.3 Steering angle sensor C4350 .......................................................................................................... 12 - 78
12.3.3.1 Description ....................................................................................................................... 12 - 78
12.3.3.2 Replacing the steering angle sensor servo unit. .............................................................. 12 - 79
12.3.3.3 Checking the reference sensor ........................................................................................ 12 - 81
12.3.3.4 Replacing the steering angle sensor mech. .................................................................... 12 - 82
12.3.3.5 Replacing the steering damper ........................................................................................ 12 - 84

12 Steering system C4000

Description

12
Steering system C4000
12.1 Description
12.1
Description
12.1.1 Power steering

12.1.1
Power steering
The steering system is electric and uses a "Steer-By-Wire" design. There is no mechanical contact between the handle
and the steered drive wheel.
Steering is progressive, which means that when the truck is operated at low speed the steering wheel gearing ratio is
higher than at high speeds. This allows the truck to be operated in a safe and efficient manner.
If the drive wheel is not in the home position “straight ahead” 0° when the truck is started, it will return to the home posi-
tion automatically. This is important to remember when performing service and repairs when cover are removed and
when working in the motor compartment.
12.2 Mechanical steering system C4100

12.2
Mechanical steering system C4100
12.2.1 Steering arm/wheel/lever C4110

12.2.1
Steering arm/wheel/lever C4110
12
12.2.1.1 Overview tiller arm
12.2.1.1
Overview tiller arm
Pos. Designation
a Tiller arm handle Tiller arm handle, page
12 - 19

Pos. Designation
b Operating panel Operating panel, page
12 - 3
c Tiller arm cover
d Steering yoke
e Steering adapter cover
f Steering adapter
g Steering shaft

12.2.1.2 Operating panel

12.2.1.2
Operating panel
12.2.1.2.1 Overview operating panel

12.2.1.2.1
Overview operating panel
f i
j
a a
12
b
e k
c d

a Cover b Plug
c Wiring harness d Cover
e Butterfly switch f Horn button
g Button "lifting/lowering" h Display
i Horn button j Switch "horn"


k Display l Electronic card "A5"
m Stomach button n Speed control
12.2.1.2.2 Controls
12.2.1.2.2
Controls
12.2.1.2.2.1 Checking the hydraulic functions

12.2.1.2.2.1
Checking the hydraulic functions
1. Run through all the hydraulic functions of the truck by activat-

ing the respective switch/toggle switch.
Check that the hoses and the wiring harness are not worn/
squeezed and that there is no noise, jerky movement or vibra-
tion when running all the hydraulic functions.
Check the corresponding valve on the hydraulic unit if a func-
tion does not work properly. Component list, page 20 - 3
Check fuses.
12.2.1.2.2.2 Checking the stomach button

12.2.1.2.2.2
Checking the stomach button
1. Check the function of the safety reversing.

If the safety reversing does not operate:
Check the Hall elements Speed control, page 7 - 6
Check the stomach button Safety reversing, page 7 - 6
Replace the A5 card Replacing the logic card, page 12 - 16
12.2.1.2.2.3 Replacing the signal button/switch

12.2.1.2.2.3
Replacing the signal button/switch
12.2.1.2.2.3.1 Removing the signal button/switch

12.2.1.2.2.3.1
Removing the signal button/switch
Removing the logic card, page 12 - 16
1. Remove the button using a screwdriver.
2. Disconnect the connector to the switch on the logic card.
3. Press out the switch from its bracket.

12.2.1.2.2.3.2 Fitting the signal button/switch

12.2.1.2.2.3.2
Fitting the signal button/switch
1. Fit the new switch and connect the wire to the logic card.
2. Align the button with the catch and secure it by hand.
Installing a logic card, page 12 - 17
12
12.2.1.2.2.4 Replacing the lift/lower button
12.2.1.2.2.4
Replacing the lift/lower button
12.2.1.2.2.4.1 Removing the lift/lower button

12.2.1.2.2.4.1
Removing the lift/lower button
Preparations
1. Remove the speed control
2. Use a screwdriver and carefully press down the button fitting

3. Pull the button straight out, compress the spring when remov-
ing it
12.2.1.2.2.4.2 Fitting the lift/lower button

12.2.1.2.2.4.2
Fitting the lift/lower button
1. Fit the button straight down, compress the spring when in-
stalling it.
2. Make sure the button is properly installed

3. Lubricate the spring with Molycote PG 75
12
4. Put the speed control hardware in place, hook the ends of the
spring around the two lugs in the cover
Make sure there is no play when operating the rocker, adjust
the spring legs if necessary.

Resetting
12.2.1.2.2.5 Replacing a switch button

12.2.1.2.2.5
Replacing a switch button
12.2.1.2.2.5.1 Removing a switch button

12.2.1.2.2.5.1
Removing a switch button
1. Press out the button laterally with the fingers.
2. Insert a screwdriver in the slot as shown in the picture and

carefully pry loose the pushbutton.
3. Unscrew the button-holder and arm.
12.2.1.2.2.5.2 Fitting a switch button

12.2.1.2.2.5.2
Fitting a switch button
1. Screw the button-holder and arm in place.
2. Place a screwdriver as illustrated and carefully push the button

in place.
3. Press out the button laterally with the fingers.

12.2.1.2.2.6 Changing the position of the controls - support arm lift/fork lift
12.2.1.2.2.6
Changing the position of the controls - support arm lift/fork lift
1. Pry off the lift control buttons using a thin screwdriver and
switch the positions with the rear buttons.
2. Make sure that the lugs hook on when the new buttons are fit-
ted in place.
3. See parameter 1102, page 4 - 23 for more information
4. Start the truck and make sure the change is correct.
12
12.2.1.2.2.7 Replacing the safety reversing switch
12.2.1.2.2.7
Replacing the safety reversing switch
12.2.1.2.2.7.1 Removing the safety reversing switch

12.2.1.2.2.7.1
Removing the safety reversing switch
1. Remove the keypad by undoing the screw and disconnecting

the connector.
2. Loosen the screws securing the upper part of the tiller arm.
3. Loosen the screws until the switch brackets come loose.

4. Remove the button by unhooking the catches on both sides.
12.2.1.2.2.7.2 Fitting the safety reversing switch

12.2.1.2.2.7.2
Fitting the safety reversing switch
1. Position the button by hooking the catches on both sides.
2. Fit the screws that hold the switch bracket.

3. Fit the screws to upper part of the control unit.
4. Connect the connector and replace the key pad.
12
12.2.1.2.2.8 Replacing the keypad

12.2.1.2.2.8
Replacing the keypad
12.2.1.2.2.8.1 Removing the keypad

12.2.1.2.2.8.1
Removing the keypad
1. Remove the keypad and disconnect it from the logic card.
12.2.1.2.2.8.2 Installing a keypad

12.2.1.2.2.8.2
Installing a keypad
1. Connect the keypad and screw it in position.

12.2.1.2.3 Replacing the operating panel

12.2.1.2.3
Replacing the operating panel
12.2.1.2.3.1 Removing the operating panel

12.2.1.2.3.1
Removing the operating panel
Preparations
Removing the tiller arm cover, page 12 - 29
Removing the keypad, page 12 - 11
1. Remove the screws holding the upper cover and keep hold of
the upper cover to prevent damage to the logic card cable
2. Disconnect the CAN connection to the logic card.
12.2.1.2.3.2 Installing an operating panel

12.2.1.2.3.2
Installing an operating panel
1. Connect the CAN bus connection to the logic card.

2. Press together the upper and the lower sections, and tighten
the screws five complete turns. Start at the left side, continue
with the right side.
x5
3. Turn the screws a further four full turns, total of nine, which cor-
responds to around 1 N·m in a cross-shaped pattern as shown
in the illustration.
12
2 3
x4
4 1
4. Check that there is no space between the handle and the

steering head.
5. Make sure that the control can be moved back and forth
without difficulty, and that the control returns to the neutral pos-
ition. Adjust the screws as explained in step 3 if the control is
difficult to move.
Resetting
Installing a keypad, page 12 - 11
Installing the tiller arm cover, page 12 - 30
12.2.1.2.3.3 Checking the speed control

12.2.1.2.3.3
Checking the speed control
Preparations
Installing an operating panel, page 12 - 12

1. Drive the truck and move the speed control back and forth.
Make sure there is no play when operating the rocker, adjust
the spring legs if necessary. Fitting the lift/lower button, page
12 - 6
In case the control does not spring back: Replacing the operat-
ing panel, page 12 - 12
If the truck does not react despite the display being lit.Speed
control, page 7 - 6
If the truck does not react despite being activated, check the
wiring harness to the tiller arm. Replacing the tiller arm wiring
harness, page 12 - 59
12.2.1.2.4 Replacing the operating panel "Built-in"

12.2.1.2.4
Replacing the operating panel "Built-in"
12.2.1.2.4.1 Removing the operating panel "Built-in"

12.2.1.2.4.1
Removing the operating panel "Built-in"
Preparations
Removing the tiller arm cover, page 12 - 29
Removing the keypad, page 12 - 11
1. Remove the screws holding the upper cover and hold of the
upper cover to prevent damage to the cable to the logic board.
2. Disconnect the CAN connection to the logic card.

12.2.1.2.4.2 Installing the operating panel "Built-in"

12.2.1.2.4.2
Installing the operating panel "Built-in"
1. Connect the CAN bus connection to the logic card
2. Press together the upper and the lower sections, and tighten
the screws five complete turns. Start at the left side, continue
with the right side. 12
x5
3. Turn the screws a further four full turns, total of nine, which cor-
responds to around 1 N·m in a cross-shaped pattern as shown
in the illustration.
2 3
x4
4 1
4. Check that there is no space between the handle and the

steering head.
5. Make sure that the control can be moved back and forth
without difficulty, and that the control returns to the neutral pos-
ition. Adjust the screws as explained in step 3 if the control is
difficult to move.
Resetting
Installing a keypad, page 12 - 11
Installing the tiller arm cover "Built-in", page 12 - 31

12.2.1.2.5 Replacing the logic card

12.2.1.2.5
Replacing the logic card
12.2.1.2.5.1 Removing the logic card

12.2.1.2.5.1
Removing the logic card
WARNING Static electricity

Risk of static discharge that can damage the electronics.
► Make sure you take the necessary steps to prevent static electricity, ESD protection, before starting work
on the steering module.
Preparations
1. Remove the screws holding the cover over the logic card and
carefully lift away the cover.
Keep a finger between the cover and the shaft for the speed
control buttons to prevent the speed control assembly from fall-
ing down.
2. Lift away the speed control assembly.

3. Pull out the logic card, and pull off the connectors.
12
12.2.1.2.5.2 Installing a logic card

12.2.1.2.5.2
Installing a logic card
1. Fit the new logic card in place and connect it.
2. Check the cable connection to the logic card and that the con-
nectors are correctly connected.
3. Fit the speed control assembly in position. Hook the ends of

the spring around two the lugs in the cover.

4. Fit the cover in place and screw it down. Make sure the conduit
entry is intact and correctly positioned.
Resetting
12.2.1.2.5.3 Logic card [A5]

12.2.1.2.5.3
Logic card [A5]
Electronic
Ferdinand card A5
1 Electronic Card
X200 1 dig in (horn)

22 hall sensors
X201 1 dig in (horn)
6 dig in (option buttons)

X203 1 dig in (second CAN ID)
Display control X300
X205 2 ana in
Power Supply Keyboard/

BDM
CAN Smart Access
X100 X202 X204
Connector Type Pin Function

X100 Tyco MQS 2X4 pin Supply from truck and CAN
X200, X201 AMP MTE 1x2 pin Horn
X202 Tyco-AMP alt. MPE-GARRY 2x3 pin BDM
X203 AMP 2x8 pin Option buttons
X204 BERG 1x10 pin Keypad
X205 AMP MTE 1x4 pin
X300 AMP 1x6 pin Display

12.2.1.3 Tiller arm handle

12.2.1.3
Tiller arm handle
12.2.1.3.1 Replacing the handle to the tiller arm

12.2.1.3.1
Replacing the handle to the tiller arm
12.2.1.3.1.1 Removing the tiller arm handle

12.2.1.3.1.1
Removing the tiller arm handle
Preparations
Removing the operating panel, page 12 - 12
1. Remove the cable bracket/handle in the tiller arm
12
12.2.1.3.1.2 Fitting the handle to the tiller arm

12.2.1.3.1.2
Fitting the handle to the tiller arm
1. Fit the handle/cable bracket. 12 N·m

Install the harness bracket so that the wiring harness does not
get pinched.

Resetting
12.2.1.3.2 Replacing the tiller arm handle "Built-in"

12.2.1.3.2
Replacing the tiller arm handle "Built-in"
12.2.1.3.2.1 Removing the tiller arm handle "Built-in"

12.2.1.3.2.1
Removing the tiller arm handle "Built-in"
Preparations
Removing the operating panel "Built-in", page 12 - 14
1. Remove the handle in the tiller arm

12.2.1.3.2.2 Installing the tiller arm handle "Built-in"

12.2.1.3.2.2
Installing the tiller arm handle "Built-in"
1. Install the handle. 9.8 N·m Apply Loctite 243 on the screws.
Resetting
12
Installing the operating panel "Built-in", page 12 - 15
12.2.1.4 Tiller arm

12.2.1.4
Tiller arm
12.2.1.4.1 Replacing the tiller arm

12.2.1.4.1
Replacing the tiller arm
12.2.1.4.1.1 Removing the tiller arm

12.2.1.4.1.1
Removing the tiller arm
Preparations
Removing the tiller arm handle, page 12 - 19
1. Remove the dampers.

2. Remove the screw that securing the shaft in place.
3. Remove the shaft lock.
4. Knock out the shaft and lay the arm down.

Secure the arm so the wiring harness does not get stretched.

5. Remove the spring stop.
12.2.1.4.1.2 Fitting tiller arm

12.2.1.4.1.2
Fitting tiller arm
12
1. Fit the spring stop.
2. Fit the tiller arm.

Move the arm obliquely forward so that is suspended from the
spring ends.
3. Press the arm in place.

4. Tap in the shaft, leaving the adjuster wheel outside.
5. Fold down the arm, adjust the shaft so the hole points straight
up and tap in the shaft.
6. Fit the shaft lock.

7. Fit the screw and lock the shaft.
8. Install the dampers.

12
Resetting
Fitting the handle to the tiller arm, page 12 - 19
12.2.1.4.2 Replacing the tiller arm "Built-in"

12.2.1.4.2
Replacing the tiller arm "Built-in"
12.2.1.4.2.1 Removing the tiller arm "Built-in"

12.2.1.4.2.1
Removing the tiller arm "Built-in"
Preparations
Removing the tiller arm handle "Built-in", page 12 - 20
1. Remove the spring, unhooking it from the bracket. Make sure

that the spring does not fly off.

2. Remove the shafts.
3. Disassembling the tiller arm.

12.2.1.4.2.2 Installing the tiller arm "Built-in"

12.2.1.4.2.2
Installing the tiller arm "Built-in"
1. Fit the tiller arm bracket.
2. Fit the spring.

12

3. Fit the shaft on the right side in the fork direction.
4. Fit the shaft on the left side in the fork direction.

Press the tiller arm bracket downwards to fit the shaft. Do not
use any tools. Use hand force only when fitting so as not to
damage the bushings.
Resetting
Installing the tiller arm handle "Built-in", page 12 - 21
12.2.1.4.3 Checking the brake microswitches

12.2.1.4.3
Checking the brake microswitches
1. Check the operation of the brake microswitch in the upper and

lower brake positions. The lower position means that you have
to press down to activate the switch. If the function is not satis-
factory, the switches must be replaced, see Replacing the
safety switch, page 12 - 37.

12.2.1.4.4 Checking the play and the return travel

12.2.1.4.4
Checking the play and the return travel
1. Move the tiller arm fully in both directions, the tiller arm must
move in both directions without sticking.
If the steering has seized, check if dirt and such has not caught
in the wheels or the ring gear.
Check the bearing play in the tiller arm, replace if needed. Re-
placing the steering bearing, page 12 - 68
12.2.1.4.5 Replacing the tiller arm cover

12.2.1.4.5
Replacing the tiller arm cover
12.2.1.4.5.1 Removing the tiller arm cover

12.2.1.4.5.1
Removing the tiller arm cover
12
1. Remove the cover on the front of the tiller arm. It is held with
catches on each side.

12.2.1.4.5.2 Installing the tiller arm cover

12.2.1.4.5.2
Installing the tiller arm cover
1. Refit the cover.
12.2.1.4.6 Replacing the tiller arm cover "Built-in"

12.2.1.4.6
Replacing the tiller arm cover "Built-in"
12.2.1.4.6.1 Removing the tiller arm cover "Built-in"

12.2.1.4.6.1
Removing the tiller arm cover "Built-in"
1. Remove the cover
2. Remove the cover.

12.2.1.4.6.2 Installing the tiller arm cover "Built-in"

12.2.1.4.6.2
Installing the tiller arm cover "Built-in"
1. Refit the cover.
2. Refit the cover. Insert the guide pins when fitting the covers.
12

12.2.1.5 Steering yoke

12.2.1.5
Steering yoke
12.2.1.5.1 Overview
12.2.1.5.1
Overview
d f
e
c
a g
h
i
k
l
p
o

a Cover b Bracket
c Roller d Spring
e Bushing f Shaft
g Bracket h Plate
i Screw j Sensor
k Damper l Plate
m Cover n Screw


o Bar p Cover
12.2.1.5.2 Overview steering servo

12.2.1.5.2
Overview steering servo
4
6
3 5
2
12
1 7
8
9
10
11
12
17
14 13
16
15

a Cover b Bracket
c Roller d Spring
e Shaft f Bushing
g Bracket h Plate


i Screw j Sensor
k Damper l Plate
m Cover n Screw
o Bar p Cover
q Push button
12.2.1.5.3 Overview Ergo

12.2.1.5.3
Overview Ergo
q
b
v d
c f
e
j
g h i
u t
s
n
k
l
m
r
q
p o

a Cover b Cover


c Pin d Spring
e Damper f Push button
g Screw h Sensor
i Bracket j Clamp
k Shaft l Screw
m Screw n Spring
o Screw p Cover
q Bracket r Cover
s Bushing t Screw
u Cover v Cover
12.2.1.5.4 Replacing the steering yoke

12.2.1.5.4
Replacing the steering yoke
12.2.1.5.4.1 Removing the steering yoke

12.2.1.5.4.1
Removing the steering yoke
12
Preparations
Removing a gas strut - height adjuster, page 12 - 53
Removing the steering adapter cover, page 12 - 52
Removing the safety switch [B60], page 12 - 37
1. Remove the screws.
2. Lift the yoker straight up.

Remove the bolt and nut of the height adjustment to ease the
removing of the rear screws. (Power steering)

12.2.1.5.4.2 Installing a steering yoke

12.2.1.5.4.2
Installing a steering yoke
1. Fit the yoke in the steering adapter. 30 N·m

Be careful with the wiring harness so that it does not get
pinched between the yoke and the steering adapter.
2. Install the height adjustment. 5 N·m
Installing the safety switch [B60], page 12 - 39

Installing the safety switch [B60], page 12 - 39
Installing a gas strut - height adjuster, page 12 - 54
Installing the steering adapter cover, page 12 - 53
12.2.1.5.5 Changing the tiller arm spring

12.2.1.5.5
Changing the tiller arm spring
12.2.1.5.5.1 Removing the tiller arm spring

12.2.1.5.5.1
Removing the tiller arm spring
Preparations
Removing the tiller arm, page 12 - 21

1. Lift out the spring stop.

Make a note of which is the left side and which is the right side
of the plastic roller, marked H and V respectively
12.2.1.5.5.2 Installing the tiller arm spring

12.2.1.5.5.2
Installing the tiller arm spring
12
1. Fit the spring package into the yoke.
Make sure that the spring holder is turned the correct way, the
markings H (right) and V (left) in the fork direction. Fit into the
groove of the spring holder so that it is led onto the bushings,
turn a quarter turn upwards
Resetting
Fitting tiller arm, page 12 - 23
12.2.1.5.6 Replacing the safety switch

12.2.1.5.6
Replacing the safety switch
12.2.1.5.6.1 Removing the safety switch [B60]

12.2.1.5.6.1
Removing the safety switch [B60]
Removing the tiller arm spring, page 12 - 36

1. Unscrew and remove the sensor bracket.
2. Remove the sensor from the snap lock.

12.2.1.5.6.2 Installing the safety switch [B60]

12.2.1.5.6.2
Installing the safety switch [B60]
1. Fit the sensor in the snap lock.
12
3. Fit the sensor bracket into the yoke.
Installing the tiller arm spring, page 12 - 37
12.2.1.5.7 Replacing the safety switch "Built-in"

12.2.1.5.7
Replacing the safety switch "Built-in"
12.2.1.5.7.1 Removing the safety switch "Built-in"

12.2.1.5.7.1
Removing the safety switch "Built-in"
Preparations
Removing the tiller arm handle "Built-in", page 12 - 20

1. Remove the switch.
12.2.1.5.7.2 Installing the safety switch "Built-in"

12.2.1.5.7.2
Installing the safety switch "Built-in"
1. Install the switch.

Resetting
Installing the tiller arm handle "Built-in", page 12 - 21
12

12.2.1.6 Steering adapter

12.2.1.6
Steering adapter
12.2.1.6.1 Overview steering servo

12.2.1.6.1
Overview steering servo
c
e
d
b
f
h
g
k
j

a Steering pin b Nut
c Steering adapter d Screw
e Push button f Lever
g Bushing h Screw
i Spring j Shaft


k Bushing l Shaft
m Stopper n Pin
12.2.1.6.2 Overview Mechanical steering

12.2.1.6.2
Overview Mechanical steering
12
d
e
f
g
Pos. Designation
a Steering adapter
b Screw
c Shaft
d Pin
e Stopper

Pos. Designation
f Washer
g Nut
12.2.1.6.3 Overview Mechanical steering

12.2.1.6.3
Overview Mechanical steering
d
Pos. Designation
a Steering adapter
b Spring pin
c Shaft
d Pin

Pos. Designation
e Stopper
f Stop screw
12.2.1.6.4 Replacing the steering adapter

12.2.1.6.4
Replacing the steering adapter
12.2.1.6.4.1 Removing the steering adapter

12.2.1.6.4.1
Removing the steering adapter
Removing the steering yoke, page 12 - 35
12

3. Undo the screws and pull the adapter straight up.

12.2.1.6.4.2
Removing a gas strut - height adjuster, page 12 - 53


3. Remove the lock to the height adjustment.
4. Detach and remove the guide pin.
5. Pull the steering adapter straight up.

12

12.2.1.6.4.3

3. Remove the steering adapter.
12.2.1.6.4.4 Installing a steering adapter

12.2.1.6.4.4
Installing a steering adapter
1. Install the steering adapter using the screws.

the water trough.
12
4. Turn to the right and left 3 times to check that the wiring har-
ness does not bend or stretch.
Installing a steering yoke, page 12 - 36


12.2.1.6.4.5
1. Fit the steering adapter and tighten the guide pins.=45Nm Use
Loctite 243
2. Install the lock to the height adjustment.=5Nm
the water trough.

6. Connect the connector [X65], page 19 - 4.

Installing a gas strut - height adjuster, page 12 - 54
12

12.2.1.6.4.6
1. Fit the steering adapter, screw tight and tap in the pin.

the water trough.
4. Turn to the right and left 3 times to check that the wiring har-
ness does not bend or stretch.
12.2.1.6.5 Replacing the steering adapter cover

12.2.1.6.5
Replacing the steering adapter cover
12.2.1.6.5.1 Removing the steering adapter cover

12.2.1.6.5.1
Removing the steering adapter cover
Preparations

1. Loosen the screw.
2. Turn the cover to the left and pull it down.
3. Open the cover by moving the rear part downwards.
12.2.1.6.5.2 Installing the steering adapter cover

12.2.1.6.5.2
Installing the steering adapter cover
12
1. Fit the cover around the steering adapter. The rear part is ap-
prox. 1 cm lower.
2. Assemble the parts, guide the cover into the groove and turn it
to the right.
3. Screw the cover into place.
Resetting
Installing an upper cover, page 8 - 6
12.2.1.6.6 Replacing a gas strut - height adjuster

12.2.1.6.6
Replacing a gas strut - height adjuster
12.2.1.6.6.1 Removing a gas strut - height adjuster

12.2.1.6.6.1
Removing a gas strut - height adjuster
Preparations
1. Lift the tiller arm to the uppermost position.
2. Compress the gas strut, press down with your hand until it is
possible to turn out the gas strut.
The gas strut is only inserted into the steering adapter.
Do not let go of the gas strut, let it carefully extend upwards.
3. Use a screwdriver or similar tool to undo the spring lock at the

bottom of the gas strut.

12.2.1.6.6.2 Installing a gas strut - height adjuster

12.2.1.6.6.2
Installing a gas strut - height adjuster
1. Fit the gas strut onto the ball screw.
2. Compress the gas strut by hand and turn it under the steering
adapter and let it carefully expand upwards.
Resetting
12.2.1.6.6.3 Checking the height adjuster

12.2.1.6.6.3
Checking the height adjuster
1. Check that the height adjuster runs freely and the gas strut is
able to bear the weight of the tiller arm.
In case of malfunction, replace the gas strut, see Replacing a
gas strut, page 8 - 66 or replace the steering adapter, see Re-
placing the steering adapter, page 12 - 45.
12.2.1.6.7 Replacing the height adjustment lock

12.2.1.6.7
Replacing the height adjustment lock
12.2.1.6.7.1 Removing the height adjustment lock

12.2.1.6.7.1
Removing the height adjustment lock

1. Undo and remove the bolt and nut that hold the arm.
2. Pull out the guide pin from the brass sleeve.
3. Lower the complete arm.
12.2.1.6.7.2 Installing the height adjustment lock

12.2.1.6.7.2
Installing the height adjustment lock
12
1. Push the arm up into the steering adapter and fit the guide pin
in the brass sleeve.
2. Install the arm.
Resetting
12.2.1.6.7.3 Checking the height adjustment lock

12.2.1.6.7.3
Checking the height adjustment lock
1. Check that the tiller arm can be lifted and lowered and that the
lock does not seize in the steering adapter.

12.2.1.6.8 Replacing the mechanical stop of the steering shaft

12.2.1.6.8
Replacing the mechanical stop of the steering shaft
12.2.1.6.8.1 Removing the mechanical stop of the steering shaft (power steering)
12.2.1.6.8.1
Removing the mechanical stop of the steering shaft (power steering)
Preparations
Removing the steering adapter, page 12 - 45
1. Unscrew the nut that locks the steering shaft
2. Knock the shaft straight up. Use a rubber mallet or other suit-
able tool.
3. Remove the ball screw.

4. Remove the spring pin.
5. Remove the mechanical stop.

12
12.2.1.6.8.2 Fitting the mechanical stop of the steering shaft (power steering)
12.2.1.6.8.2
Fitting the mechanical stop of the steering shaft (power steering)
1. Fit the mechanical stop, ensuring it ends up facing the right

way.

2. Fit the spring pin.
3. Fit the ball screw.
4. Fit the steering shaft

5. Fit the nut that locks the steering shaft.
Resetting
Installing the steering damper [A83], page 12 - 85 12
Installing a steering adapter, page 12 - 48
12.2.1.7 Tiller arm wiring harness

12.2.1.7
Tiller arm wiring harness
12.2.1.7.1 Replacing the tiller arm wiring harness

12.2.1.7.1
Replacing the tiller arm wiring harness
12.2.1.7.1.1 Removing the tiller arm wiring harness

12.2.1.7.1.1
Removing the tiller arm wiring harness
Preparations
Removing the operating panel, page 12 - 12
1. Remove the cable bracket in the tiller arm

2. Remove the dampers.
3. Remove the screw that securing the shaft in place.
4. Remove the shaft lock.

5. Knock out the shaft and lay the arm down.
6. Remove the spring stop.

12
7. Lift out the spring stop.

Make a note of which is the left side and which is the right side
of the plastic roller, marked H and V respectively

8. Unscrew and remove the sensor bracket.
9. Disconnect the connector. [B60], page 19 - 2

11. Disconnect the connector [X65], page 19 - 4 and pull out the
wiring harness
12.2.1.7.1.2 Fitting the tiller arm wiring harness

12.2.1.7.1.2
Fitting the tiller arm wiring harness
12
the water trough.

4. Connect the connector [X65], page 19 - 4.
5. Route the cable through the yoke and connect [B60], page
19 - 2

6. Fit the sensor into the yoke.
7. Fit the rear cable bracket on the adapter.

12
8. Fit the spring package into the yoke.

Make sure that the spring holder is turned the correct way, the
markings H (right) and V (left) in the fork direction. Fit into the
groove of the spring holder so that it is led onto the bushings,
turn a quarter turn upwards

9. Fit the spring stop.
10. Fit the tiller arm.

Move the arm obliquely forward so that is suspended from the
spring ends.
11. Press the arm in place.
12. Tap in the shaft, leaving the adjuster wheel outside.

13. Fold down the arm, adjust the shaft so the hole points straight
up and tap in the shaft.
14. Fit the axle shaft lock.

12
15. Fit the screw and lock the shaft.

16. Install the dampers.
17. Fit the cable and cable bracket in the tiller arm. 12 N·m
Resetting
12.2.1.8 Replacing the steering bearing

12.2.1.8
Replacing the steering bearing
12.2.1.8.1 Removing the steering bearing

12.2.1.8.1
Removing the steering bearing
Removing the steering adapter, page 12 - 45, Removing the steering adapter, page 12 - 46, Removing the steering
adapter, page 12 - 47
Removing the steering angle sensor mech., page 12 - 82

1. Undo the nut that locks the steering shaft.
2. Knock the shaft straight up. Use a rubber mallet or other suit-
able tool.
12
3. Turn the driver to the side.

4. The upper steering bearing is removed upwards.
5. Lower bearing, remove the circlip and knock out the bearing.
12.2.1.8.2 Removing the steering bearing

12.2.1.8.2
Removing the steering bearing
Removing the steering adapter, page 12 - 45, Removing the steering adapter, page 12 - 46, Removing the steering
adapter, page 12 - 47
Removing the steering damper [A83], page 12 - 84, Removing the steering damper [A83], page 12 - 85
1. Undo the nut that locks the steering shaft.

2. Tap the shaft straight up. Use a rubber mallet or other suitable
tool.
3. The upper steering bearing is removed downwards.

12
4. Lower bearing, remove the circlip and knock out the bearing.

12.2.1.8.3 Fitting the steering bearing

12.2.1.8.3
Fitting the steering bearing
1. Fit the lower steering bearing and the circlip.
2. Fit the upper steering bearing.
3. Turn back the driver.

4. Fit the steering shaft.
5. Screw on the nut that locks the steering shaft, 50 N·m.

12
Installing the steering angle sensor mech., page 12 - 83

Installing a steering adapter, page 12 - 48, Installing a steering adapter, page 12 - 50, Installing a steering adapter,
page 12 - 51
12.2.1.8.4 Fitting the steering bearing

12.2.1.8.4
Fitting the steering bearing
1. Fit the lower steering bearing and the circlip.

2. Fit the upper steering bearing.
3. Fit the steering shaft
4. Fit the nut that locks the steering shaft, 50 N·m.
Installing the steering damper [A83], page 12 - 85, Installing the steering damper [A83], page 12 - 87
Installing a steering adapter, page 12 - 48, Installing a steering adapter, page 12 - 50, Installing a steering adapter,
page 12 - 51

12.2.1.9 Replacing the rubber seals

12.2.1.9
Replacing the rubber seals
12.2.1.9.1 Removing rubber seals

12.2.1.9.1
Removing rubber seals
1. Use your fingers or carefully use a screwdriver to remove the

seals around the gate bar and steering adapter.
12.2.1.9.2 Installing rubber seals

12.2.1.9.2
Installing rubber seals
1. Fit the seals at the gates. Make sure that the seal is properly
positioned with the notches for the lugs in the covers.
12
2. Press the seal into place at the front and rear edge, with the
line facing the right direction.
Line should always face the operator. On trucks without gate,
there is a line on each side of the seal.
3. Then press the sides into place using your fingers or a plastic
drift.
4. Use a plastic tool to ensure the cover is situated in the groove.

that the seal is in place.
Make sure that the rubber ring does not fold together.

Electric steering system C4300
12.3 Electric steering system C4300

12.3
12.3.1 Overview
12.3.1
Overview
12
Pos. Designation
a Steering angle sensor
b Driver
c Steering valve

12.3.2 Overview
12.3.2
Overview
Pos. Designation
a Steering damper
b Servo motor
c Steering angle sensor
d Gear ring
12.3.3 Steering angle sensor C4350

12.3.3
Steering angle sensor C4350
12.3.3.1
Description
12.3.3.1.1 Design
12.3.3.1.1
Design
The steering angle reference sensor [B17] is used as a reference for 0° for the 360° steering. It is located on the drive
unit house.

12
The sensor signal changes status when the drive wheel is positioned so that the truck moves straight forward/back = 0°.
Steering is calibrated through a reference search when the truck is started.
Each time the signal from the reference sensor changes status, there is a check that steering angle is 0°.
The reference sensor is also monitored in that the drive wheel may not be turned by more than 180°, plus a certain toler-
ance, between each sensor status change.
12.3.3.2 Replacing the steering angle sensor servo unit.

12.3.3.2
Replacing the steering angle sensor servo unit.
12.3.3.2.1 Removing the steering angle sensor

12.3.3.2.1
Removing the steering angle sensor

2. Remove the screw securing the sensor.
3. Pull the sensor straight up.
12.3.3.2.2 Installing steering angle sensor

12.3.3.2.2
Installing steering angle sensor
1. Fit the sensor.

2. Fit the screw. 10 N·m
12
12.3.3.3 Checking the reference sensor

12.3.3.3
Checking the reference sensor
1. Steer slightly to the right so that the gear ring is correctly positioned in relation to the reference sensor.
2. Cut off power to the truck.
3. Check the clearance between the sensor and the elevated part of the gear ring using a feeler gauge. Nominal
gap =1.5mm.
4.
WARNING Powering up the truck
There is a risk of personal injury if power is restored to the truck while work is performed on the gear ring.
5. Check if there is any power supply to [B17], 9.8 - 13.5V V between wires 95 and 97.
6. If there is power, replace [B17].
7. Check if there is a short circuit between wires 95 and 97, but also between wire 95 and the rest of the electrical
system.
8. If there is no power supply or short circuit, replace the T13.

12.3.3.4 Replacing the steering angle sensor mech.

12.3.3.4
Replacing the steering angle sensor mech.
12.3.3.4.1 Removing the steering angle sensor mech.

12.3.3.4.1
Removing the steering angle sensor mech.
1. Turn the tiller arm =90°.
2. Disconnect the connector [B13].
3. Remove the shaft stop screw.

4. Unscrew the bracket.
x2
5. Unscrew the sensor and remove the wire clip at the back.
12
12.3.3.4.2 Installing the steering angle sensor mech.

12.3.3.4.2
Installing the steering angle sensor mech.
1. Fit and turn the sensor so that the screw is centred in the
screw holes.

2. Fit the sensor bracket and the cable clamp to the angled plate.
3. Fit the sensor to the steering shaft.
4. Screw down the angled bracket securely
5. Connect [B13].
12.3.3.5 Replacing the steering damper

12.3.3.5
Replacing the steering damper
12.3.3.5.1 Removing the steering damper [A83]

12.3.3.5.1
Removing the steering damper [A83]
Preparations

2. Remove the steering damper.
12.3.3.5.2 Removing the steering damper [A83]

12.3.3.5.2
Removing the steering damper [A83]
Preparations
2. Remove the steering damper.
12
12.3.3.5.3 Installing the steering damper [A83]

12.3.3.5.3
Installing the steering damper [A83]
1. Lubricate the hole at the bottom of the shaft with Klüberplex®

BEM 34-132

2. Lubricate the entire journal on the steering damper with lubric-

ant type H
3. Fit the rubber bushing on the journal.
4. Install the steering damper

When refitting, check that the steering shaft fits properly before
installing the steering damper.
5. Connect the connector

Resetting
12.3.3.5.4 Installing the steering damper [A83]

12.3.3.5.4
Installing the steering damper [A83]
1. Lubricate the hole at the bottom of the shaft with Klüberplex®

BEM 34-132.
2. Lubricate the entire journal on the steering damper with lubric-

ant type H. 12
3. Fit the rubber bushing on the journal.

4. Install the steering damper

When refitting, check that the steering shaft fits properly before
installing the steering damper.
Resetting

13.1 Description ....................................................................................................................................................... 13 - 1
13.1.1 General .............................................................................................................................................. 13 - 1
13.2 Using the anti-static carpet .............................................................................................................................. 13 - 1
13.3 Programming tools........................................................................................................................................... 13 - 1
13.3.1 TruckCom .......................................................................................................................................... 13 - 1
13.3.1.1 Connect the CAN interface to the truck.............................................................................. 13 - 1
13.3.2 Software............................................................................................................................................. 13 - 2
13.3.2.1 Software update ................................................................................................................. 13 - 2
13.4 General electric equipment C5100 .................................................................................................................. 13 - 2
13.4.1 Battery C5110.................................................................................................................................... 13 - 2
13.4.1.1 Cleaning the battery ........................................................................................................... 13 - 2
13.4.1.2 Checking the connections .................................................................................................. 13 - 3
13.4.1.3 Checking the battery cables ............................................................................................... 13 - 3
13.4.1.4 Checking the battery .......................................................................................................... 13 - 3
13.4.1.5 Checking cell and terminal protectors ................................................................................ 13 - 4
13.4.1.6 Checking the level of the electrolyte................................................................................... 13 - 4
13.4.1.7 Checking the electrolyte density......................................................................................... 13 - 4
13.4.1.8 Battery replacement ........................................................................................................... 13 - 4
13.4.2 Battery Li-ion C5110 .......................................................................................................................... 13 - 9
13.4.2.1 Battery module ................................................................................................................... 13 - 9
13.4.3 General alarm signals (audible/visual) C5160 ................................................................................. 13 - 10
13.4.3.1 Horn.................................................................................................................................. 13 - 10
13.4.4 Battery charger (built-in) C5170 ...................................................................................................... 13 - 11
13.4.4.1 Checking the battery charger cables................................................................................ 13 - 11
13.4.4.2 Checking the battery charger parameters ........................................................................ 13 - 11
13.4.5 Battery cut out switch, main contactor C5190 ................................................................................. 13 - 11
13.4.5.1 Main contactor.................................................................................................................. 13 - 11
13.5 Instrument panel, display C5200 ................................................................................................................... 13 - 18
13.5.1 Menu................................................................................................................................................ 13 - 18
13.5.1.1 Menus............................................................................................................................... 13 - 18
13.5.1.2 Menu navigation ............................................................................................................... 13 - 19
13.5.1.3 Menu overview ................................................................................................................. 13 - 20

13 Electrical system C5000
13.5.1.4 Menu list ........................................................................................................................... 13 - 20
13.5.1.5 Menu information.............................................................................................................. 13 - 21
13.5.1.6 Show hour meter values................................................................................................... 13 - 21
13.5.1.7 Show error codes ............................................................................................................. 13 - 22
13.5.1.8 Show part numbers for software/hardware ...................................................................... 13 - 22
13.5.1.9 Built-in test ICH ................................................................................................................ 13 - 22
13.5.1.10 Show collisions................................................................................................................. 13 - 22
13.5.1.11 Show/change parameters ................................................................................................ 13 - 23
13.5.1.12 Emergency driving mode.................................................................................................. 13 - 23
13.5.1.13 Calibration ........................................................................................................................ 13 - 23
13.5.1.14 Show/change PIN code.................................................................................................... 13 - 23
13.5.1.15 PIN codes......................................................................................................................... 13 - 23
13.5.2 Hour counter, tachograph C5290 .................................................................................................... 13 - 26
13.5.2.1 Checking error log and operating hours ........................................................................... 13 - 26
13.6 Control system travel function C5300 ............................................................................................................ 13 - 27
13.6.1 Direction selector/speed regulator ................................................................................................... 13 - 27
13.6.2 Safety reversing............................................................................................................................... 13 - 27
13.6.3 Battery indicator............................................................................................................................... 13 - 27
13.6.4 Hour meter....................................................................................................................................... 13 - 27
13.6.5 Lifting and lowering control .............................................................................................................. 13 - 27
13.6.6 Signal buttons .................................................................................................................................. 13 - 27
13.6.7 Option buttons ................................................................................................................................. 13 - 27
13.6.8 Display ............................................................................................................................................. 13 - 27
13.6.9 Symbols on keypad and display ...................................................................................................... 13 - 27
13.6.10 Weighing system ............................................................................................................................. 13 - 28
13.6.11 Pressure equalization ...................................................................................................................... 13 - 28
13.7 Power system travel function C5400 ............................................................................................................. 13 - 29
13.7.1 Transistor panel C5460 ................................................................................................................... 13 - 29
13.7.1.1 Overview ACT .................................................................................................................. 13 - 29
13.7.1.2 Overview ACC.................................................................................................................. 13 - 30
13.7.1.3 Description ....................................................................................................................... 13 - 30
13.7.1.4 Checking the contactors................................................................................................... 13 - 31

13.7.1.5 Checking the cable connections....................................................................................... 13 - 31
13.7.1.6 Checking the electric panel mounting .............................................................................. 13 - 31
13.7.1.7 Cleaning the electric panel heatsink................................................................................. 13 - 32
13.7.1.8 Replacing the motor control panel.................................................................................... 13 - 32
13.8 Control system, working function C5500 ....................................................................................................... 13 - 35
13.8.1 Work function harnesses/fuse C5590.............................................................................................. 13 - 35
13.8.1.1 Checking the wiring harnesses ........................................................................................ 13 - 35
13.9 Power system working function C5600.......................................................................................................... 13 - 35
13.9.1 Pump contactor C5610 .................................................................................................................... 13 - 35
13.9.1.1 Replacing the pump contactor.......................................................................................... 13 - 35
13.10 Control/protection electronics C5700............................................................................................................. 13 - 39
13.10.1 Protective electronics wiring harness and fuse C5790 .................................................................... 13 - 39
13.10.1.1 Check the CAN bus.......................................................................................................... 13 - 39
13.10.1.2 Check the CAN node........................................................................................................ 13 - 39
13.11 Protective sensors, position sensors C5800.................................................................................................. 13 - 39
13.11.1 Description....................................................................................................................................... 13 - 39
13.11.1.1 Pressure sensor ............................................................................................................... 13 - 39
13.11.2 Safety probes/sensors C5830 ......................................................................................................... 13 - 40
13.11.2.1 Emergency switch off ....................................................................................................... 13 - 40
13.11.2.2 Gate switches [B121]/[B122] ............................................................................................ 13 - 40
13.11.2.3 Photocell........................................................................................................................... 13 - 46
13.12 Calibrations .................................................................................................................................................... 13 - 47
13.12.1 Steering angle calibration ................................................................................................................ 13 - 47
13.12.2 Weight measuring calibration .......................................................................................................... 13 - 48
13.12.4 Steering angle manual steering ....................................................................................................... 13 - 49


Description

13
Electrical system C5000
13.1 Description
13.1
Description
13.1.1 General
13.1.1
General
The electrical system in the AC powered trucks consists of a number of electronic modules, [A5-T1], which communicate
with each other via two separate CANs (Controller Area Network). Communication is active as long as the truck is
switched on.
The following electronic units are found in the tiller arm: ICH, integrated control panel [A5]
The following electronic units are found in the chassis: ACT/ACC, motor control unit [T1]
The input signals for the various truck functions received by the electronic modules are both digital (switches and
sensors) and analogue (potentiometers and sensors).
Likewise, the output signals for the various truck functions received by the electronic modules are both digital (valves,
drive wheel brakes, etc.) and analogue (proportional valves).
13.2 Using the anti-static carpet

13.2
Using the anti-static carpet
13
Preparations
Electrostatic risks, page 2 - 2
• Anti-static carpet 148115
1. Disconnect the power source.
2. Attach the clamp to the area that is to be protected, and the

other end to the wrist. Anti-static carpet 148115, page 21 - 7.
13.3 Programming tools

13.3
Programming tools
13.3.1 TruckCom
13.3.1
TruckCom
13.3.1.1 Connect the CAN interface to the truck

13.3.1.1
Connect the CAN interface to the truck
See the separate TruckCom manual to see the various connection alternatives available.

• PC to CAN cable 163793
• CASTOR USB 7521083

General electric equipment C5100
1. Ensure that the truck is switched off before making the connec-
tion
2. Connect the PC to CAN cable 163793, page - 7 and CASTOR

USB 7521083, page - 7 cables.
3. Connect the CAN connector to the truck
4. Connect the USB to the TruckCom equipment.
13.3.2 Software
13.3.2
Software
13.3.2.1 Software update

13.3.2.1
Software update
See the TruckCom manual.
Preparations
Connect the CAN interface to the truck, page 13 - 1
CAN key 7516707, page - 000
CAN key 7513225, page - 000
• CAN key 7516707
1. Connect the CAN connector to X41
2. Create a truck report before updating. This can be used if the parameter values are corrupted during updating
3. Download the new software package.
4. Compare the old parameter values in the truck report with the new ones, and adjust if needed.
5. Copy the truck configuration to a secondary unit (from ICH to ACT/ACC). If this is not done, the truck will gener-
ate the error code 2.004 at startup.
13.4 General electric equipment C5100

13.4
13.4.1 Battery C5110

13.4.1
Battery C5110
13.4.1.1 Cleaning the battery

13.4.1.1
Cleaning the battery
1. Clean the battery. Use a cloth and a mild detergent.

13.4.1.2 Checking the connections

13.4.1.2
Checking the connections
1. Inspect all connections to the battery, truck and charger

Replace the wiring harness if it is deemed to be too damaged
13.4.1.3 Checking the battery cables

13.4.1.3
Checking the battery cables
Preparations
Removing a service cover, page 8 - 3 13
1. Check the battery cables/cable protectors between the fork
carriage and the chassis, replace if too damaged.
Resetting
13.4.1.4 Checking the battery

13.4.1.4
Checking the battery
1. Check that the battery data complies with the truck specifica-
tion, see the serial number plate.Signs, warnings and adhesive
labels, page 6 - 3

13.4.1.5 Checking cell and terminal protectors

13.4.1.5
Checking cell and terminal protectors
1. Verify that the cell and terminal protectors are not damaged.
Replace the battery if needed: Replace the battery
13.4.1.6 Checking the level of the electrolyte

13.4.1.6
Checking the level of the electrolyte
1. Check the electrolyte level. Top up with deionized water as ne-

cessary.
13.4.1.7 Checking the electrolyte density

13.4.1.7
Checking the electrolyte density
1. Check electrolyte density and temperature.

In case of a faulty battery. Replace the battery
13.4.1.8 Battery replacement

13.4.1.8
Battery replacement
13.4.1.8.1 Replacing a battery using a lifting device

13.4.1.8.1
Replacing a battery using a lifting device
13.4.1.8.1.1 Removing a battery using a lifting device

13.4.1.8.1.1
Removing a battery using a lifting device
WARNING Falling battery

The battery may fall if it is not securely supported to the correct height when you release the lifting hook.
► Check the height of the supporting material before releasing the lifting hook.

Preparations
1. Pull out the battery connector and release the catch.
2. Lift the battery into place using an approved lifting device and a suitable battery lifting yoke or lifting loops.
3. Only lift the battery so much that it goes free.
4. Move the battery sideways and place it down.
13.4.1.8.1.2 Installing a battery using a lifting device

13.4.1.8.1.2
Installing a battery using a lifting device

Only change to a battery that meets the data given on the product identification plate. The weight of the battery
affects the stability and braking capacity of the truck. Information on the minimum permitted battery weight is on
the product identification plate.
NOTICE Check parameter 107

Parameter 107 must always be checked and adapted to the battery installed in the truck. The parameter setting
13
depends on battery type, truck type, battery size and the truck application.
1. Open the cover to the battery compartment,
2. Move the truck next to the battery.

If the battery is not installed, do as follows:
Connect a temporary cable between the truck and battery.
Move the truck to the battery.
Disconnect the temporary cable.
3. Lift the battery into place using an approved lifting device and a
suitable battery lifting yoke or lifting loops.

4. Lock the battery.
5. Connect the battery cables/battery connector.


7. If the truck is not to be used straight away, you must check to

ensure that logout has taken place.
13.4.1.8.2 Replacing a battery using a battery changing table

13.4.1.8.2
Replacing a battery using a battery changing table
13.4.1.8.2.1 Removing a battery using a battery changing table

13.4.1.8.2.1
Removing a battery using a battery changing table
13
► The polarity must be correct. Compare the markings on the cables with those on the battery terminals.
Preparations
1. Move the truck close to the battery changing table.

-Connect a temporary cable between the truck and the battery.
-Move the truck to the battery changing table.
-Disconnect the temporary cable.
2. Release the catch and roll the battery over to the battery changing table.
13.4.1.8.2.2 Installing a battery using a battery changing table

13.4.1.8.2.2
Installing a battery using a battery changing table

Only change to a battery that meets the data given on the product identification plate. The weight of the battery
affects the stability and braking capacity of the truck. Information on the minimum permitted battery weight is on
the product identification plate.
NOTICE Check parameter 107

Parameter 107 must always be checked and adapted to the battery installed in the truck. The parameter setting
depends on battery type, truck type, battery size and the truck application.
1. Open the cover to the battery compartment,
2. Move the truck close to the battery changing table.

Connect a temporary cable between the truck and battery.
Move the truck to the battery changing table.
Disconnect the temporary cable.

3. Push the battery into position.
4. Lock the battery.
5. NOTICE Risk of short-circuiting

Connect the battery connector.

7. If the truck is not to be used straight away, you must check to

ensure that logout has taken place.
13
13.4.2 Battery Li-ion C5110

13.4.2
Battery Li-ion C5110
13.4.2.1 Battery module

13.4.2.1
Battery module
13.4.2.1.1 Disconnection/connection
13.4.2.1.1
Disconnection/connection
13.4.2.1.1.1 Resetting/restarting the battery

13.4.2.1.1.1
Resetting/restarting the battery
If error codes are generated or the battery lamp does not light with a steady green glow, the battery can be re-
started.
1. Disconnect the battery yoke.

The yoke must be removed from the battery.

2. Disconnect the CAN connector [X111].
3. Wait until the light goes out.
4. Connect the CAN connector.
5. Wait until the lamp on the battery is lit steady green.
6. Reconnect the battery yoke.
13.4.3 General alarm signals (audible/visual) C5160

13.4.3
General alarm signals (audible/visual) C5160
13.4.3.1 Horn
13.4.3.1
Horn
13.4.3.1.1 Overview
13.4.3.1.1
Overview
Pos. Designation
a Horn

13.4.3.1.2 Checking the horn function

13.4.3.1.2
Checking the horn function
1. Press the horn button

Check connectors and fuses if there is no signal.
Replace the horn:
13.4.4 Battery charger (built-in) C5170

13.4.4
Battery charger (built-in) C5170
13.4.4.1 Checking the battery charger cables

13.4.4.1
Checking the battery charger cables
1. Cut the power to the truck (disconnect the connector and power cable from the charger).
13
2. Measure the ohms on red and black cables from [T14], page 19 - 4 to X1, page 19 - 4. Replace the cables in
case of breakage.
13.4.4.2 Checking the battery charger parameters

13.4.4.2
Checking the battery charger parameters
1. Check that the factory parameters are set according to the truck configuration.
2. Check that other parameters are set correctly.
13.4.5 Battery cut out switch, main contactor C5190

13.4.5
Battery cut out switch, main contactor C5190
13.4.5.1 Main contactor

13.4.5.1
Main contactor
13.4.5.1.1 Replacing the main contactor

13.4.5.1.1
Replacing the main contactor
13.4.5.1.1.1 Removing the main contactor

13.4.5.1.1.1
Removing the main contactor
1. Disconnect and move aside the wiring harness.

2. Undo the nuts of the electrical connections.
3. Loosen and remove the plate.
4. Remove the fuses and cable.

5. Disconnect the connector and unscrew the electric panel.
6. Move aside the electric panel.
13
7. Undo the screws securing the main contactor.

8. Guide out the main contactor.
13.4.5.1.1.2 Removing the main contactor

13.4.5.1.1.2
Removing the main contactor
1. Undo the nuts and remove the connectors.
2. Remove the fuse.

4. Undo the four screws and remove the main contactor.
13.4.5.1.1.3 Fitting the main contactor

13.4.5.1.1.3
Fitting the main contactor
1. Guide in the main contactor.
13
0.25
2. Screw the main contactor into place. 2.5 ⁄0.25 N·m

3. Move the electric panel back into position.
4. Connect the connector and screw the electric panel into place.
5. Fit the fuses and cable.

1
6. Fit the plate. 8 ⁄1 N·m
0.5
13
7. Tighten the nuts of the connections. 8.5 ⁄0.5 N·m
8. Connect the wiring harness.

Instrument panel, display C5200
13.4.5.1.1.4 Fitting the main contactor

13.4.5.1.1.4
Fitting the main contactor

0.25
1. Fit the main contactor using four screws, 2.5 ⁄0.25 N·m.
3. Fit the fuse.
0.5
4. Connect the connectors with the nuts. 8.5 ⁄0.5 N·m
13.5 Instrument panel, display C5200

13.5
13.5.1 Menu
13.5.1
Menu
13.5.1.1 Menus
13.5.1.1
Menus
The speed control is used for menu navigation.

To select a menu item, press and release the horn button.

Menu item "ESC" always returns you to the previous menu.

If logged in without CAN key or TruckCom, only a limited number of menus are available.
13.5.1.2 Menu navigation

13.5.1.2
Menu navigation
Proceed as follows if you only want to view the different truck settings:
1. Ensure that the truck is switched off. Connect or enter the PIN code. Note: Do not press the ON button.
3. Move between menus by turning the speed control several times.
4. Press and release the horn button to select which menu to view.
5. Turn the speed control several times to move between the different positions in the selected menu.
6. If logged in without CAN key or TruckCom, only a limited number of menus are available and unavailable menus are
not shown.
The following are not shown:
- Calibration (CAL)
- PIN code menu (Pin) 13
- Collision sensor log (c)
- Service mode (Ser)
7. Switch off the truck by pressing the OFF button or return to the previous menu by selecting "ESC".

13.5.1.3 Menu overview

13.5.1.3
Menu overview
Log on using horn
Parameter set/ PIN code menu Escape

Info menu Emergency drive Calibrate
view “CAL” “Pin” “ESC”
“InFo” “Ed” “Cal”
“PAr” Truck resets
Starts truck in
First parameter emergency drive 1st calibrate Enter PIN code
“1” mode. All LEDs function edit function
are flashing “1”
Last parameter Last calibrate

“XXXX” function
“X”
Escape Escape
“ESC” “ESC”
Back to prev menu Back to prev menu
Part number Build in test ICH Escape

Hour meter display Error log display Shock lockout log
display “tESt” “ESC”
“H” “E” “c”
“Pn” Back to prev menu
A time “A” Software part no Display test Latest shock PIN

Latest error “1”
Total key on time “SPn” Walking 8 “1”
B time “b” Oldest error “XX” Hardware part no Oldest shock PIN
Throttle
Active time (XX max 50) “HPn” “10”
Accessible to
the operator
C time “c” Escape Escape
Machine no Emergency
Drive avtive time “ESC” “ESC”
“no” Reverese
Back to prev menu Back to prev menu
D time “d” Only accessible

Hydraulic active Hardware serial no Lift/Lower with the CAN key,
time “HSn” operator
S time “S” Escape

“ESC” Sensilift
Time to service
Back to prev menu
Escape
“ESC” Keyboard
Back to prev menu
Escape by
pressing horn
13.5.1.4 Menu list

13.5.1.4
Menu list
Software: 7579262; 7528678

Classification missing
Sym. Description Symbol Description

Software/hardware order numbers Built-in test ICH
Pn tESt


Calibration Error code log list
Cal E
Collision log list Emergency driving mode
c If there is a collision sensor installed Ed
on the CAN bus, it registers when the
truck bumps into something. Informa-
tion about the collision is stored in the
truck's internal memory. The last ten
registered collisions can be read dir-
ectly from the display together with op-
erator identity via the PIN code. Addi-
tional information is available via
TruckCom, where collision levels and
time indications can also be read.
Collision log list Checking error log and
operating hours, page 13 - 26 13
PIN Hour meter values
Pin H
Show/change parameters
13.5.1.5 Menu information

13.5.1.5
Menu information
An explanation/description of the various menus is found below.

For access and navigation among the menus. Menu navigation, page 13 - 19.
13.5.1.6 Show hour meter values

13.5.1.6
Show hour meter values
“H” is shown on the display.
1. Press the horn button to select. The hour counter symbol is lit.
2. You can obtain the following information by pressing the speed control repeatedly:
- Total time (A)
- Total operating time (b)
- Total operating time drive motor (c)
- Total operating time hydraulic motor (c)
- Time until service (S)
3. To show an hour meter value, release the speed control when the required hour meter symbol is shown on the
display. The hour meter value in question is shown on the display.

13.5.1.7 Show error codes

13.5.1.7
Show error codes
“E” is shown on the display.

A maximum of 50 error codes are stored.
1. Press the horn button to select.
- Latest error code (1)
Next error code, etc. (2)
Last error code (XX, max 50)
3. To show an error code, release the speed control when the required error code is shown on the display.
13.5.1.8 Show part numbers for software/hardware

13.5.1.8
Show part numbers for software/hardware
“Pn” is shown on the display.
SPn - Software package
HPn - Logic card
no - Machine number
HSn . Logic card serial number
3. To show a part number, release the speed control when the required part number is shown on the display.
13.5.1.9 Built-in test ICH

13.5.1.9
Built-in test ICH
“tESt" is shown on the display.
1. See section Built-in test function for the tiller arm, page 7 - 5
13.5.1.10 Show collisions

13.5.1.10
Show collisions
If there is a collision sensor installed on the CAN bus, it registers when the truck bumps into something. Informa-
tion about the collision is stored in the truck's internal memory. The last ten registered collisions can be read dir-
ectly from the display together with operator identity via the PIN code. Additional information is available via
TruckCom, where collision levels and time indications can also be read.
“c” is shown on the display.
2. By pressing the speed control repeatedly, you can see the last 10 collisions.
3. If a 5-digit PIN code is shown, the first digit is shown and then the other 4 digits are shown.

13.5.1.11 Show/change parameters

13.5.1.11
Show/change parameters
“Par” is shown on the display.
2. By pressing the speed control repeatedly, you can move through the parameter list. Parameter list, page 4 - 2
3. To show a parameter, release the speed control when the required parameter is shown on the display. Press the
horn button to change the parameter.
13.5.1.12 Emergency driving mode

13.5.1.12
“Ed" is shown on the display. 13

Emergency driving mode, page 7 - 4
13.5.1.13 Calibration
13.5.1.13
Calibration
“Cal" is shown on the display.

Calibrations, page 13 - 47
13.5.1.14 Show/change PIN code

13.5.1.14
Show/change PIN code
“Par” is shown on the display.
2. By pressing the speed control repeatedly, you can move through the parameter list. Parameter list, page 4 - 2
3. To show a parameter, release the speed control when the required parameter is shown on the display. Press the
horn button to change the parameter.
13.5.1.15 PIN codes

13.5.1.15
PIN codes
13.5.1.15.1 General
13.5.1.15.1
General
1. The PIN codes can be used e.g. to link different operator experience levels to specific truck characteristics – Op-
erator profiles.
Operator parameters can be adjusted individually for up to ten different operator profiles.
The PIN codes are organised in blocks and profiles. Each block can hold ten operator profiles, each with its own
PIN code.
In order to use the PIN codes in a block, the block must first be activated.
By default, block zero (0) is always active, which means that the truck has three ready-to-use operator profiles
from the beginning. PIN code defaults, page 13 - 26
PIN codes can be activated or changed according to the preferences of the operator. An operator profile is activ-
ated upon normal log-in by all PIN codes whose block number is activated.

13.5.1.15.2 PIN code for resetting the truck

13.5.1.15.2
PIN code for resetting the truck
1. If the truck has stopped as a result of a collision, it needs to be reset by entering a special PIN code. This PIN
code must be programmed by a service technician during installation, see section Programming PIN codes, page
13 - 24
The PIN code to be activated can be found in operator profile 1 and special block 10. The default value of the
PIN code is 0000. This must be changed to the PIN code selected by the service technician.
The PIN code cannot contain the same combination of digits as any of the other programmed PIN codes.
With parameter Resetting procedure after collision it is possible to change how reset after collision is carried out.
13.5.1.15.3 Programming PIN codes

13.5.1.15.3
Programming PIN codes
If the truck is configured to handle PIN codes, 100 different PIN codes can be programmed.
There are two possible methods for programming PIN codes. The first and the simplest is to use TruckCom,
which provides clear instructions. The other alternative is to use the truck keypad.
The first time a block is activated, all PIN codes in the block are set to “0000”. If a block with PIN codes not set to
“0000”, is deactivated and later reactivated, the PIN codes with other values than “0000” will again be valid.
Use of PIN code “0000” is permitted, but it means that the position is deactivated. It is never possible to log in
with PIN code “0”.
The truck firmware stores the standard PIN-code set according to the table, see PIN code defaults, page 13 - 26.
The truck program will not accept attempts to program PIN codes that have already been set. The previous code
will be restored.
When a PIN code is programmed, there is a check to ensure that it is not used elsewhere in the table, regardless
of whether the block is active or inactive.
The PIN code setting menu is used for managing PIN codes; the menu can only be accessed when a service key
is connected.
1. Ensure that the truck is switched off.
2. Connect CAN key 7516707, page 21 - 7 to connector [X41]. Enter the PIN code.
4. Turn the speed control several times until “Pin” is shown on the display.

6. Select programming commands according to the following table:
Function Programming Comments

Restore factory settings Press 1 + ON button Blocks 1-9 are deactivated. The ori-
ginal PIN codes are reset according
to the Default assignment of PIN
codes table.
Activate a new PIN code block Press 2 + b + ON button b = Block 0-9
Upon activation of a PIN code block,
the codes already saved become
available again.
Deactivate a PIN code block Press 3 + b + ON button b = Block 0-9
No codes will be deleted. They will
be available again when the PIN
code's block is reactivated.
Programming a new PIN code Press 4 + b + P + NNNN + ON but- b = Block 0-9
ton
P = Operator profile 1-10
Note: The block in question must 13
NNNN = PIN code
first be activated.
Note: It is only possible to assign
If the PIN code is correct, the code is
one digit to an operator profile. As a
shown for 3 seconds, followed by
result, operator profile 10 should be
the text "donE" for 2 seconds. It is
assigned as 0 (zero).
possible to enter a new PIN code
within these 5 seconds by pressing a
key on the keyboard. If the PIN code
is wrong, the display shows “Err”. If
you press the red button, the new
PIN code is not saved.
PIN code programming for truck re- Press 6 + NNNN + ON button NNNN = PIN code
set after collision
7. Switch off the truck by pressing the OFF button. Programming of PIN codes is now complete. Verify that pro-
gramming has been done correctly by logging in using one of the new PIN codes.
For PIN code management via TruckCom, refer to the TruckCom manual.
It is important to ensure the correct operator profile is activated when a specific PIN code is entered. This is es-
pecially important when an operator profile has been set to apply for a specific truck application.

13.5.1.15.4 PIN code defaults

13.5.1.15.4
PIN code defaults
1. When replacing an electronic unit (main computer), all PIN codes will be set as 0 (zero). This means that the PIN
codes must be configured in the truck using TruckCom.
Log-in with PIN codes will not be affected if you are only updating the truck software.
Service personnel are urged to keep notes on activated blocks, changed PIN codes and special operator profile
settings.
The PIN codes are factory set so that only block 0/operator profiles 1–9 are activated.
PIN code defaults

Operator profile 1 2 3 4 5 6 7 8 9 10
no.
Block 0 0001 0002 0003 0004 0005 0006 0007 0008 0009 0000
Block 1 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 2 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 3 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 4 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 5 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 6 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 7 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 8 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 9 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 10 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
2. The factory-set operator profiles are classified as follows:
Profile Characteristic Remarks

1 Standard profile -
2 Beginner profile -
3 Advanced profile Operator parameters set to max. values
13.5.2 Hour counter, tachograph C5290

13.5.2
Hour counter, tachograph C5290
13.5.2.1 Checking error log and operating hours

13.5.2.1
Checking error log and operating hours
1. Inspect the error log and operating hours. Menus, page 13 - 18

Control system travel function C5300
13.6 Control system travel function C5300

13.6
13.6.1 Direction selector/speed regulator

13.6.1
Direction selector/speed regulator
Travel direction and speed are selected by rotating the speed contract in the required direction with an angle equivalent
to the required speed. The speed control signal is processed to emulate a potentiometer, even though there are discrete
sensor steps.
When navigating in menus, the speed control is used to move between different positions.
13.6.2 Safety reversing

13.6.2
Safety reversing
When ERB is pressed, at least one specific Hall element is activated. Since the Hall elements are also used control mo-
tor speed, they are continually monitored.
13.6.3 Battery indicator

13.6.3
Battery indicator
The battery capacity is shown in %, counting down from 100.

When the truck battery is 80% discharged, truck capacity is limited and the lifting capacity is disengaged.
13
13.6.4 Hour meter
13.6.4
Hour meter
Total operating time (b) is normally shown in the display. The following information is shown if you enter the menu sys-
tem. See.
- Total time (A)
- Total operating time (b)
- Total operating time drive motor (c)
- Total operating time hydraulic motor (c)
- Time until service (S)
13.6.5 Lifting and lowering control

13.6.5
Lifting and lowering control
Lifting and lowering is controlled by two controls that are integrated in the handle. Factory parameter #1102 determines
which hydraulic function the two controls have.
13.6.6 Signal buttons

13.6.6
Signal buttons
Fixed buttons on each side of the handle. Activation of either of these buttons will in normal mode activate the horn. If the
CAN key is connected during login, the horn button is used to move to the desired position in the service information.
13.6.7 Option buttons

13.6.7
Option buttons
There are six option buttons in the handle, all of which can be used for different options.
13.6.8 Display
13.6.8
Display
The display is a four-digit, seven segment, numeric information display with coloured LED symbols, together with a
menu-based information system as the primary communication tool between the operator/technician and the truck.
In logged-in mode, the display is always lit and shows battery capacity in the numeric field while the battery indicator is
lit.
13.6.9 Symbols on keypad and display

13.6.9
Symbols on keypad and display
A keypad and a numeric information display with coloured LED symbols are used together with a menu-based informa-
tion system as the primary communication tool between the operator/technician and the truck.

In logged-in mode, the display is always lit and shows battery capacity in the numeric field while the battery indicator is
lit.
Symbol Description
ON button. This button is used to start the truck and
confirm entered settings during PIN code management
OFF button
Error code
Battery charge as a percentage
Parameter
Hour meter
13.6.10 Weighing system

13.6.10
Weighing system
Calibration sequence 13 must be run before you use “Weight indication on fork lift value 2” for the first time.
By setting parameter 311 to 1 = support arm lift or 2 = fork lift, you can get an estimated load weight based on hydraulic
pressure. The display automatically shows the load weight in increments of 100 kg on the support arm lift and 50 kg on
the fork lift if the forks are lowered shorter than 300 ms. The load weight is shown on the display for four seconds.
13.6.11 Pressure equalization

13.6.11
Pressure equalization
Activates and controls a pressure equalization pulse after a lift. This is to equalize the pressure, and to get a better
measurement of the load weight. Set to 0 via parameter 312 to switch off the function (standard). If it is set to a higher
value than 0, the duration of the lowering pulse will be a multiple of the parameter value 20 ms. The truck must have a
pressure sensor to enable the function.

Power system travel function C5400
13.7 Power system travel function C5400

13.7
13.7.1 Transistor panel C5460

13.7.1
Transistor panel C5460
13.7.1.1 Overview ACT

13.7.1.1
Overview ACT
13
Pos. Designation
a Transistor panel C5460, page 13 - 29
b Battery cut out switch, main contactor C5190,
page 13 - 11
c Pump contactor C5610, page 13 - 35

13.7.1.2 Overview ACC

13.7.1.2
Overview ACC
Pos. Designation
a Transistor panel Transistor panel C5460, page
13 - 29
b Main contactor Battery cut out switch, main
contactor C5190, page 13 - 11
13.7.1.3
Description
13.7.1.3.1 General
13.7.1.3.1
General
Drive/pump motor output control is done via transistor regulators, ACT or ACC.
The regulators contain software for drive motor and pump motor output control. They are configured for their function
during programming with TruckCom via the truck's CAN service socket.
The transistor regulators have dedicated internal monitoring of CAN communication, DC voltage levels, their own tem-
perature and motor temperature.
Any errors are recorded via internal monitoring and are sent via the CAN to ICH, where the error code is registered and
subsequently displayed on the display [A6].
The regulators have a green LED to indicate status:

• Start-up – LED flashes twice

• Normal operation – LED remains lit
• Error – LED flashes or is unlit.
Power is fed via two copper bars B+ and B-. B+ is secured with a fuse.
13.7.1.4 Checking the contactors

13.7.1.4
Checking the contactors
1. Check the contactor electrical connections. Gently pull on all

the cable connections and copper plate. Tighten if needed. Re-
placing the motor control panel, page 13 - 32
13
13.7.1.5 Checking the cable connections

13.7.1.5
Checking the cable connections
1. Inspect the cable connections on the electric panel. Gently pull

on all the cable connections and copper plate. Tighten if
needed. Replacing the motor control panel, page 13 - 32
13.7.1.6 Checking the electric panel mounting

13.7.1.6
Checking the electric panel mounting
Preparations
1. Check the electric panel's attachment.

If the electric panel is not properly fastened, tighten the screws
or renew the threads.

13.7.1.7 Cleaning the electric panel heatsink

13.7.1.7
Cleaning the electric panel heatsink
1. Clean the heatsink of the electric panel by blowing carefully

with compressed air
13.7.1.8 Replacing the motor control panel

13.7.1.8
Replacing the motor control panel
13.7.1.8.1 Removing the motor control panel

13.7.1.8.1
Removing the motor control panel
Preparations
1. This action requires access to TruckCom.

Detach the cable connections, the plate and the connector on
the panel.
2. Loosen and remove the panel screws.
3. Remove the panel from the truck.

13.7.1.8.2 Installing the motor control panel

13.7.1.8.2
Installing the motor control panel
1. Position the panel and screw it in place.
13
2. Attach the cable connections, the plate and the connector on
the panel. Tightening torque T1: 7.5 N·m, T2: 9 N·m.
T1
T2
Resetting

13.7.1.8.3 Installing the motor control panel

13.7.1.8.3
Installing the motor control panel
1. Position the panel and screw it in place.
2. Attach the cable connections, the plate and the connector on

1 0.5
the panel. Tightening torque T1: 8 ⁄1 N·m, T2: 7.5 ⁄0.5 N·m
T1 T1
T1 T1
T1
T1
T2 T2 T2
Resetting

Control system, working function C5500
13.8 Control system, working function C5500

13.8
Control system, working function C5500
13.8.1 Work function harnesses/fuse C5590

13.8.1
Work function harnesses/fuse C5590
13.8.1.1 Checking the wiring harnesses

13.8.1.1
Checking the wiring harnesses
1. Check all wiring harnesses (including their attachment devices and contacts) for wear, damage and proper at-
tachment.
Replace any wiring harness that is damaged.
13.9 Power system working function C5600

13.9
Power system working function C5600
13.9.1 Pump contactor C5610

13.9.1
Pump contactor C5610
13.9.1.1 Replacing the pump contactor

13.9.1.1
Replacing the pump contactor
13.9.1.1.1 Removing the pump contactor

13.9.1.1.1
Removing the pump contactor

13
1. Undo and remove the connection nuts.
2. Remove the wire and plate.

3. Remove the fuse holder.
4. Loosen and remove the nuts of the connections to the pump

contactor.
5. Push out the pump contactor.

13.9.1.1.2 Fitting the pump contactor

13.9.1.1.2
Fitting the pump contactor
Serial number: 6277977-6520197 13

2. Push in the pump contactor.

0.25
3. Torque tighten the screws to the pump contactor.2.5 ⁄0.25 N·m
0.7
4. Fit the fuse holder. 2.8 ⁄0.7 N·m
5. Fit the cable and plate.

Control/protection electronics C5700
2
6. Tighten the nuts of the connections. 9 ⁄1 N·m
13
13.10 Control/protection electronics C5700
13.10
Control/protection electronics C5700
13.10.1 Protective electronics wiring harness and fuse C5790

13.10.1
Protective electronics wiring harness and fuse C5790
13.10.1.1 Check the CAN bus

13.10.1.1
Check the CAN bus
1. Check that CAN bus is intact in terms of wiring harness, resistance and connectors. Disconnect the battery.
+6
Check that the resistance between (X41:3) and (X41:4) is =60 ⁄-6ohm.
2. Check that the CAN wiring harness is not pinched. Measure resistance between the chassis and CAN connector.
Limit value >24kOhm.
13.10.1.2 Check the CAN node

13.10.1.2
Check the CAN node
1. Deactivate and disconnect the option unit connected to the CAN wiring (e.g. K110,B90,T14 and A36/A37).
2. Activate and then connect them one by one to identify which unit produces the communication error.
13.11 Protective sensors, position sensors C5800

13.11
Protective sensors, position sensors C5800
13.11.1 Description
13.11.1
Description
13.11.1.1 Pressure sensor

13.11.1.1
Pressure sensor
The output voltage range is 0.5 V - 4.5 V in the pressure range 0 - 25 MPa (250 bar).

13.11.2 Safety probes/sensors C5830

13.11.2
Safety probes/sensors C5830
13.11.2.1 Emergency switch off

13.11.2.1
Emergency switch off
13.11.2.1.1
Description
13.11.2.1.1.1 Task and function

13.11.2.1.1.1
Task and function
When the emergency switch [S21], page 19 - 3 is pressed, the main contactor [Q10], page 19 - 3 is opened, and this
is indicated on the truck Central Information Display.
The user must log out before the truck can be activated again. If the truck is started while the emergency switch off de-
pressed, the emergency switch off must be pulled up before the truck can be started.
13.11.2.1.2 Checking the emergency switch function

13.11.2.1.2
Checking the emergency switch function
1. Press the emergency switch

If it is still possible to drive the truck: Troubleshoot the wiring
harness, replace the emergency switch.
13.11.2.2 Gate switches [B121]/[B122]

13.11.2.2
Gate switches [B121]/[B122]
13.11.2.2.1 Replacing the gate switch [B120]

13.11.2.2.1
Replacing the gate switch [B120]
13.11.2.2.1.1 Removing the position sensor [B121]

13.11.2.2.1.1
Removing the position sensor [B121]
Removing the gate bar, page 8 - 95, , page 8 - 95

1. Remove the bearing block.
2. Disconnect the sensor connector [B121], page 19 - 2.
3. Remove the sensor [B121], page 19 - 2.
13
13.11.2.2.1.2
13.11.2.2.1.2
1. Disconnect the sensor connector [B121], page 19 - 2.

2. Remove the sensor [B121], page 19 - 2.
13.11.2.2.1.3 Installing the position sensor [B121]

13.11.2.2.1.3
Installing the position sensor [B121]
1. Fit and connect the sensor. [B121], page 19 - 2
2. Install the bearing block

13.11.2.2.1.4
13.11.2.2.1.4
1. Fit the sensor. [B121], page 19 - 2
13
13.11.2.2.2 Replacing the gate switch [B122]

13.11.2.2.2
Replacing the gate switch [B122]
13.11.2.2.2.1 Removing the position sensor [B122]

13.11.2.2.2.1
Removing the position sensor [B122]
Removing the gate bar, page 8 - 95, , page 8 - 95
1. Disconnect the sensor connector. [B122], page 19 - 2

2

2. Disconnect the sensor. [B122], page 19 - 2
13.11.2.2.2.2
13.11.2.2.2.2
1. Disconnect the sensor connector. [B122], page 19 - 2
2. Disconnect the sensor. [B122], page 19 - 2

13.11.2.2.2.3 Installing the position sensor [B122]

13.11.2.2.2.3
Installing the position sensor [B122]
2. Connect the sensor. [B122], page 19 - 2 13
13.11.2.2.2.4
13.11.2.2.2.4

2. Connect the connector. [B122], page 19 - 2
13.11.2.3 Photocell
13.11.2.3
Photocell
13.11.2.3.1 Overview [Photocells for fixed side guards]

13.11.2.3.1
Overview [Photocells for fixed side guards]
a
B120
B124
B125
b
Pos. Designation
a Photocell receiver [B124], page 19 - 2
b Photo cell transmitter [B125], page 19 - 2
13.11.2.3.2
Description
13.11.2.3.2.1 Function
13.11.2.3.2.1
Function
Transmitter/receiver photocell = a transmitter sends a light beam to a separate receiver which is activated when the light
beam is interrupted.

Calibrations
13.11.2.3.3 Checking the photocell

13.11.2.3.3
Checking the photocell
1. Check the photocell (Built-in) to ensure it cuts out if a foot is outside the platform.
If the photocell does not cut out: The photocell does not disconnect if the foot is outside the platform for longer
than 500 ms when driving slower than 6 km/h.
Adjust the sender and the receiver so that they are pointing directly at each other.
13.12 Calibrations
13.12
Calibrations
13.12.1 Steering angle calibration

13.12.1
Steering angle calibration
The calibration function is used for calibration of the steering angle (steering angle potentiometer). Calibration
sets the centre position of steering (straight ahead). The CAN key 7516707, page 21 - 7 must be connected in
order to perform calibration.
The following situations may require this calibration to be done.
When the steering angle potentiometer has been disconnected or replaced.
The truck does not steer straight ahead when the steering unit points straight ahead. May also require adjust- 13
ment of parameter 1253.
Display of error code 5.582 or 5.586.
Before carrying out this calibration, check that the reference sensor (B17) works and is correctly set.

• CAN key 7516707
1. Place the steering unit in the straight-ahead position and maintain this position.
2. Make sure that the truck is switched off.
3. Connect the CAN key.
5. Turn the speed control several times until “CAL” is shown on the display. The parameter symbol is lit.
7. Press the horn button to select Calibration of the steering angle "1".
8. In calibration mode, “push” will be shown on the display until you press one of the two horn buttons.
9. “Done" is shown on the display. The setting has now been stored.
10. Switch off the truck by pressing the OFF switch.

If the steering position needs to be fine-tuned, see parameter1253, page 4 - 36
The calibration process affects the following parameters:
- Analogue offset 1251, page 4 - 36
- Checksum 1252, page 4 - 36
These parameters must not be adjusted manually after calibration.

Calibrations
13.12.2 Weight measuring calibration

13.12.2
Weight measuring calibration

• CAN key 7516707
2. Connect CAN key 7516707, page 21 - 7.
4. Turn the speed control several times until “CAL” is shown on the display. The parameter symbol lights.
6. Turn the speed control to move between the calibration modes.

If there is no menu "3", this is because there is no tilt pressure sensor on this truck model, and calibration is not
needed.
7. Press the horn button to select Weight calibration "3".
8. Make sure there is not load on the forks, press the horn button and keep it pressed until the first lifting/lowering
sequence is over.
9. Use the speed control to select the weight for the load for which you are calibrating. Press the horn button to se-
lect. Insert the forks under the load. Minimum 1000 kg and maximum 2500 kg.
10. Press the horn button again, and keep it pressed until the sequence is done, and that "donE" is displayed.
11. Calibration is now complete.

13.12.3
This calibration is only carried out when the battery is not mounted in the truck.

• CAN key 7516707

needed.
7. Press the horn button to select Weight measuring calibration "6".
8. Set the value/weight of the battery. Use the speed control to select the weight of the battery. Press the horn but-
ton to select.

Calibrations
sequence is over.
13.12.4 Steering angle manual steering

13.12.4
Steering angle manual steering
The calibration function is used for calibration of the steering angle (steering angle potentiometer). Calibration
sets the centre position of steering (straight ahead). The CAN service key must be connected in order to perform
calibration.
The following situations may require this calibration to be done.
• When the steering angle potentiometer has been disconnected or replaced. 13

Before carrying out this calibration, check that the reference sensor (B13) works and is correctly set.

• CAN key 7516707

If there is no menu "10", this is because there is no steering angle potentiometer on this truck model, and calibra-
tion is not needed.
7. Press the horn button to select calibration of the steering angle "10".
8. In calibration mode, keep pressing one of the two horn buttons. Move the tiller arm to the right and to the left end
positions.
9. Release the horn button. "Done" is shown on the display. The setting has now been stored.
10. Switch off the truck by pressing the OFF button.

13.12.5
Used in production when calibrating the weight indication is made with a production battery.

• CAN key 7516707

Calibrations

needed.
7. Press the horn button to select Weight measuring calibration "11".
8. Set the value/weight of the battery. Use the speed control to select the weight of the battery. Press the horn but-
ton to select.
sequence is over.

Hydraulics/Pneumatics C6000 14
14.1 Overview .......................................................................................................................................................... 14 - 1
14.2 Description ....................................................................................................................................................... 14 - 1
14.2.1 Hydraulic hygiene .............................................................................................................................. 14 - 1
14.2.1.1 Definitions – hydraulic parts ............................................................................................... 14 - 1
14.2.1.2 Inside cleaning ................................................................................................................... 14 - 2
14.2.1.3 Packaging........................................................................................................................... 14 - 2
14.2.1.4 Handling ............................................................................................................................. 14 - 2
14.2.1.5 Storage............................................................................................................................... 14 - 2
14.2.1.6 Work procedures ................................................................................................................ 14 - 2
14.2.2 Construction....................................................................................................................................... 14 - 3
14.3 Quick change connectors ................................................................................................................................ 14 - 3
14.3.1 Overview quick change connectors ................................................................................................... 14 - 3
14.3.2 Removing female quick change connectors ...................................................................................... 14 - 3
14.3.3 Installing female quick change connectors ........................................................................................ 14 - 4
14.3.4 Removing a quick change connector (male) ..................................................................................... 14 - 5
14.3.5 Installing a quick change connector (male) ....................................................................................... 14 - 6
14.3.6 Installing a quick change connector (male) ....................................................................................... 14 - 6
14.4 Hydraulic unit C6100........................................................................................................................................ 14 - 8
14.4.1 Overview............................................................................................................................................ 14 - 8
14.4.2 Hydraulic oil tank C6110.................................................................................................................... 14 - 9
14.4.2.1 Overview ............................................................................................................................ 14 - 9
14.4.2.2 Cleaning the tank ............................................................................................................... 14 - 9
14.4.2.3 Checking the tank............................................................................................................... 14 - 9
14.4.2.4 Oil change ........................................................................................................................ 14 - 10
14.4.2.5 Replacing the tank............................................................................................................ 14 - 11
14.4.3 Filter, filter housing C6130............................................................................................................... 14 - 12
14.4.3.1 Air filter ............................................................................................................................. 14 - 12
14.4.3.2 ......................................................................................................................................... 14 - 13
14.4.3.3 Oil filter replacement ........................................................................................................ 14 - 13
14.4.3.4 Replacing the return filter ................................................................................................. 14 - 14
14.4.4 Hydraulic pump C6140 .................................................................................................................... 14 - 16
14.4.4.1 Overview .......................................................................................................................... 14 - 16

14 Hydraulics/Pneumatics C6000
14.4.4.2 Description ....................................................................................................................... 14 - 16
14.4.4.3 Replacing the hydraulic pump .......................................................................................... 14 - 16
14.4.5 ......................................................................................................................................................... 14 - 20
14.4.5.1 Checking the pressure limiting valve................................................................................ 14 - 20
14.4.5.2 Replacing the flow control valve....................................................................................... 14 - 21
14.4.5.3 Replacing the pressure limiting valve............................................................................... 14 - 22
14.4.5.4 Adjusting the lifting capacity ............................................................................................. 14 - 23
14.4.6 Replacing the hydraulic unit ............................................................................................................ 14 - 24
14.4.6.1 Removing the hydraulic unit ............................................................................................. 14 - 24
14.4.6.2 Installing the hydraulic unit ............................................................................................... 14 - 25
14.4.7 Replacing the valve coil ................................................................................................................... 14 - 26
14.4.7.1 Removing the valve coil ................................................................................................... 14 - 26
14.4.7.2 Removing the valve coil ................................................................................................... 14 - 27
14.4.7.3 Fitting a solenoid valve..................................................................................................... 14 - 28
14.4.7.4 Fitting a solenoid valve..................................................................................................... 14 - 29
14.4.8 Replacing the pressure sensor ........................................................................................................ 14 - 29
14.4.8.1 Removing the pressure sensor [B4] ................................................................................. 14 - 29
14.4.8.2 Fitting the pressure sensor [B4] ....................................................................................... 14 - 30
14.5 Hydraulic system, fitted to chassis C6200 ..................................................................................................... 14 - 31
14.5.1 Main valve lift/reach/tilt C6210......................................................................................................... 14 - 31
14.5.1.1 Overview .......................................................................................................................... 14 - 31
14.6 Hydraulic system, fitted on the mast C6300 .................................................................................................. 14 - 31
14.6.1 Mast hydraulic conduits C6320 ....................................................................................................... 14 - 31
14.6.1.1 Checks for leaks from hydraulic conduits and connections, hydraulic unit ...................... 14 - 31
14.7 Hydraulic cylinder C6600 ............................................................................................................................... 14 - 32
14.7.1 Main lift cylinders C6610 ................................................................................................................. 14 - 32
14.7.1.1 Description ....................................................................................................................... 14 - 32
14.7.1.2 Checking the attachment of the lift cylinders.................................................................... 14 - 32
14.7.1.3 Checking for leaks in the lift cylinder ................................................................................ 14 - 32
14.7.1.4 Replacing the main lift cylinders....................................................................................... 14 - 32
14.7.2 PowerTrak cylinder C6680 .............................................................................................................. 14 - 37
14.7.2.1 Replacing the PowerTrak cylinder.................................................................................... 14 - 37

Overview
14
Hydraulics/Pneumatics C6000
14.1 Overview
14.1
Overview
14
Pos. Designation
a Main lift cylinders C6610, page 14 - 32
b Hydraulic hose to left lift cylinder
c PowerTrak cylinder C6680, page 14 - 37
d Hydraulic hose to PowerTrak
e Hydraulic unit C6100, page 14 - 8
f Hydraulic hose to right lift cylinder
g Hydraulic oil tank C6110, page 14 - 9
14.2 Description
14.2
Description
14.2.1 Hydraulic hygiene

14.2.1
Hydraulic hygiene
14.2.1.1 Definitions – hydraulic parts

14.2.1.1
Definitions – hydraulic parts
• "Clean oil" is defined by the purity code 19/16/13 according to ISO4406:1999 or better.
• Hydraulic components (valves, lines, etc.) must be replaced with genuine spare parts specified by the manufac-
turer in order to guarantee the safety and functionality of the machine.

Description
14.2.1.2 Inside cleaning

14.2.1.2
Inside cleaning
If new, genuine components specified by the manufacturer are used, they do not normally require cleaning. These are
cleaned to a sufficiently high level for the hydraulic system. New, individual components such as hydraulic couplings
must be blown clean with dry, filtered air since they have been stored in a service vehicle. All genuine hoses specified by
the manufacturer are washed internally to the right level of cleanliness.
If the technician intends to reuse the machine's hydraulic parts in the same machine they came from after removal and
servicing, these may requiring cleaning; see Work procedures, page 14 - 2.
14.2.1.3 Packaging
14.2.1.3
Packaging
All genuine spare parts specified by the manufacturer are packaged in a manner that ensures cleanliness, e.g. with a
protective bag or a plug to prevent contamination.
As a minimum, loose hydraulic parts must be stored in a clean box with a closed lid.
The packaging (protective plugs, masking, plastic bag, etc.) must not be removed until immediately before the compon-
ent is to be fitted in a workplace suitable for handling hydraulic parts. All protective materials must be discarded after use.
14.2.1.4 Handling
14.2.1.4
Handling
Hydraulic parts must be handled and transported with the greatest care. The transport packaging must be used through-
out the entire handling chain and only opened when it is time for installation in the machine.
Make sure that no contamination, like dust and dirt, is found on the packaging before it is opened.
14.2.1.5 Storage
14.2.1.5
Storage
Hydraulic components must be handled and stored so that:
• no rusting can occur

• they are protected against dust and dirt particles, e.g. through storage in clean boxes with lids
• no mechanical deformation can occur
14.2.1.6 Work procedures

14.2.1.6
Work procedures
When working on the hydraulic system, a clean environment must be created so that no impurities can enter the system.
No work that generates particles may be carried out in the same workplace or close to where work is being carried out on
the hydraulic system.
The service technician must ensure that the hydraulic parts used are undamaged and that the cleanliness for genuine
spare parts specified by the manufacturer is maintained.
Couplings for pipe ends or other openings must never be removed until the part is to be fitted to the receiving compon-
ent.
Before you start the job:

• Remove all dirt in the area in which the work will be performed. Clean around the various hydraulic parts if you in-
tend to remove them.
• All hydraulic parts, like pipe couplings and unions, must be blown clean with dry, filtered air prior to fitting.
• If the hydraulic tank is removed, protect it with e.g. a large bag to prevent dust from entering the tank. If the inside
of the hydraulic tank must be cleaned, agitate with new hydraulic oil and then drain the oil. Do not use cloths or
the like inside the tank. Fill new oil via the tank's oil filter.
• Sealing material like flax, caulking compounds or Teflon are not permitted.
When the job is done:

• Check components and connections for leaks.
• Listen for abnormal noise when starting the hydraulic system.

Quick change connectors
• Tighten all screwed joints, plugs and screws in the system after releasing the pressure.
• Check the oil level with the cylinders retracted after purging the system, top up if needed.
14.2.2 Construction
14.2.2
Construction
The hydraulic system consists of a hydraulic unit with contactor-controlled DC motor for lifting and an On/Off-controlled
solenoid valve for lowering. The lowering flow and thereby the lowering speed is regulated hydraulically by a flow control
valve. The PowerTrak cylinder has a constant connection to the lift cylinders and will thereby always have the same
pressure as these. Its speed during filling and emptying is limited by a restrictor.
14.3 Quick change connectors

14.3
14.3.1 Overview quick change connectors

14.3.1
Overview quick change connectors
a b c
14
Pos. Designation
a WEO insert (female)
b Disassembly ring
c Assembly stop
14.3.2 Removing female quick change connectors

14.3.2
Removing female quick change connectors
1. Place the removal tool up against the WEO insert

19mm WEO insert removal

2. Remove the WEO insert
3. Fit protective plugs to the insert and the male connector in or-
der to avoid oil spills. Plug 19 mm / 1/4" (male)
Plug 23 mm / 3/8" (male)
Plug 26 mm / 1/2" (male)
Plug 19 mm / 1/4" (female)
14.3.3 Installing female quick change connectors

14.3.3
Installing female quick change connectors
1. Clean the threads.

2. Screw the WEO insert into the threads.
3. Place the fitting tool against the WEO insert.

Installing 19mm WEO insert
Installing 23 mm WEO insert
Installing 26 mm WEO insert
4. Fit the WEO insert. (See table for the correct torque)
Size Tightening torque

+5
1/4" (19mm) 30 ⁄-5 N·m
+5
3/8" (23mm) 35 ⁄-5 N·m
+5
1/2" (26mm) 45 ⁄-5 N·m
Resetting
Installing a quick change connector (male), page 14 - 6
Installing a quick change connector (male), page 14 - 6
14
14.3.4 Removing a quick change connector (male)
14.3.4
Removing a quick change connector (male)
Preparations
• Plug 10 mm / 1/4" (male) 254526
• Plug 13 mm / 3/8" (male) 254527
• Plug 16 mm / 1/2" (male) 254528
• Plug 10 mm / 1/4" (female) 254529
• Plug 13 mm / 3/8" (female) 254530
• Plug 16 mm / 1/2" (female) 254531
1. Use a screwdriver or similar tool to remove the assembly stop.
2. Push the male fitting all the way into the fitting.
3. Pull the male fitting out of the insert.

4. Refit the assembly stop in the male fitting.
5. Fit protective plugs to the insert and the male connector in or-
der to avoid oil spills.
Plug 10 mm / 1/4" (male) 254526, page - 8
Plug 13 mm / 3/8" (male) 254527, page - 8
Plug 16 mm / 1/2" (male) 254528, page - 8
Plug 10 mm / 1/4" (female) 254529, page - 9
14.3.5 Installing a quick change connector (male)

14.3.5
Installing a quick change connector (male)
It is important that the instructions for fitting quick change connectors are followed. Otherwise, both the hose and
the WEO insert must be replaced.
1. Fit the assembly stop to the hose coupling’s male fitting. Check
that the disassembly ring runs freely in the groove.
2. Push the male fitting into the female fitting until the assembly
stop makes contact with the female fitting.
3. The coupling is now made and locked.

Check that the male connector is correctly assembled by
pulling on the connector.
14.3.6 Installing a quick change connector (male)

14.3.6
Installing a quick change connector (male)
It is important that the instructions for fitting quick change connectors are followed. Otherwise, both the hose and
the WEO insert must be replaced.

1. Make sure that the assembly stop is correctly in place. Check

that the disassembly ring runs freely in the groove.
2. Push the male fitting into the female fitting until the assembly
stop makes contact with the female fitting.
3. The coupling is now made and locked.

14
Check that the male connector is correctly assembled by
pulling on the connector.

Hydraulic unit C6100
14.4 Hydraulic unit C6100

14.4
14.4.1 Overview
14.4.1
Overview
a
g
b h
c
d i
j
e k

a Connector kit b Pressure limiting valve
c Flow control valve d Lowering valve
e Lowering valve coil f Motor
g Valve unit h PowerTrak restrictor
i Non-return valve j WEO insert
k Pump l Return filter
m Suction strainer

14.4.2 Hydraulic oil tank C6110

14.4.2
Hydraulic oil tank C6110
14.4.2.1 Overview
14.4.2.1
Overview
14
Pos. Designation
a Air filter with splash guard
b Tank, oil volume 1.8 L ±0.1
14.4.2.2 Cleaning the tank

14.4.2.2
Cleaning the tank
1. Blow off any visible particles from the hydraulic system.

Rinse the tank with clean hydraulic fluid.
14.4.2.3 Checking the tank

14.4.2.3
Checking the tank
1. Check the tank for cracks or other damage. In case of cracks

or other damage, replace the tank, see Replacing the tank,
page 14 - 11.

14.4.2.4 Oil change

14.4.2.4
Oil change
1. Change the hydraulic oil, Lubricant B, see Lubricants specifica-

tion, page 6 - 4.
Draining oil, page 14 - 10
Topping up with oil, page 14 - 10
14.4.2.4.1 Draining oil

14.4.2.4.1
Draining oil
Removing the tank, page 14 - 11
1. Suction or pour out the oil into a suitable receptacle.
2. Clean and wipe out the tank and check it for defects.
Fitting the tank, page 14 - 12
14.4.2.4.2 Topping up with oil

14.4.2.4.2
Topping up with oil
1. Remove the filler pipe cap.
2. Fill with new oil.

Only use new oil approved for the application.

3. Refit the filler pipe cap.
14.4.2.5 Replacing the tank

14.4.2.5
Replacing the tank
14
14.4.2.5.1 Removing the tank
14.4.2.5.1
Removing the tank
1. Undo and remove the screws holding the tank to the valve unit.
2. Pull the tank straight down.

14.4.2.5.2 Fitting the tank

14.4.2.5.2
Fitting the tank
1. Fit the tank.
2. Make sure that the O-ring is in the correct position.
3. Fit the tank.
14.4.3 Filter, filter housing C6130

14.4.3
Filter, filter housing C6130
14.4.3.1 Air filter

14.4.3.1
Air filter
14.4.3.1.1 Cleaning the air filter

14.4.3.1.1
Cleaning the air filter
1. Use compressed air to clean the suction filter, replace the filter
if needed, see Replacing the suction filter, page 14 - 13

14.4.3.2
14.4.3.2
14.4.3.2.1 Replacing the suction filter

14.4.3.2.1
Replacing the suction filter
14.4.3.2.1.1 Removing suction filter

14.4.3.2.1.1
Removing suction filter
Preparations
1. Loosen and unscrew the pipe/strainer.

If you are only replacing the filter, just pull it straight down.
14
14.4.3.2.1.2 Installing the suction filter

14.4.3.2.1.2
Installing the suction filter
1. Press the filter on to the pipe, or screw the pipe/filter in lace30

5
⁄0 N·m
Resetting
14.4.3.3 Oil filter replacement

14.4.3.3
Oil filter replacement
14.4.3.3.1 Oil filter replacement

14.4.3.3.1
Oil filter replacement
Preparations
Draining oil, page 14 - 10
1. Change the oil filter at the same time you change the oil

Resetting
14.4.3.4 Replacing the return filter

14.4.3.4
Replacing the return filter
14.4.3.4.1 Removing the return filter

14.4.3.4.1
Removing the return filter
1. Loosen and unscrew the suction strainer.
2. Remove the return filter by pulling it straight down.

14.4.3.4.2 Fitting the return filter

14.4.3.4.2
Fitting the return filter
1. Press the return filter straight up on the pipe.
2. Screw the suction strainer in place, tightening by hand until you

reach the stop.
14

14.4.4 Hydraulic pump C6140

14.4.4
Hydraulic pump C6140
14.4.4.1 Overview
14.4.4.1
Overview
Pos. Designation
a Text missing
14.4.4.2
Description
14.4.4.2.1
Construction
The hydraulic pump is an outer gear pump driven directly by the pump motor.
14.4.4.3 Replacing the hydraulic pump

14.4.4.3
Replacing the hydraulic pump
14.4.4.3.1 Removing the hydraulic pump

14.4.4.3.1
Removing the hydraulic pump
Removing the return filter, page 14 - 14

1. Loosen and remove the screws holding the pump in the block.
2. Lift the pump straight up.
14
14.4.4.3.2 Removing the hydraulic pump

14.4.4.3.2
Removing the hydraulic pump
1. Loosen and remove the screws holding the pump in the block.

2. Lift the pump straight up.
14.4.4.3.3 Installing the hydraulic pump

14.4.4.3.3
Installing the hydraulic pump
1. Fit the pump, making sure the O-ring is in the correct position.
+5
2. Torque tighten the screws of the pump to 20 ⁄-0 N·m.
Fitting the return filter, page 14 - 15

14.4.4.3.4 Installing the hydraulic pump

14.4.4.3.4
Installing the hydraulic pump
1. Fit the pump, making sure the O-ring is in the correct position.
+5
2. Torque tighten the screws of the pump to 25 ⁄-0 N·m.
14

14.4.5
14.4.5
14.4.5.1 Checking the pressure limiting valve

14.4.5.1
Checking the pressure limiting valve
The truck should be able to lift the rated load to the top at normal lift speed.
The pressure limiting valve may need adjusting if:
• The valve is replaced

• The complete hydraulic unit is replaced
In either of the above cases, proceed as follows:
• Verify that the truck is able to lift the rated load

• If the truck is able to lift the rated load, add another 15% (of weight) on the forks and check that the truck
is not able to lift the load.
The pressure limiting valve may also need adjustment if the truck lift speed is abnormally low and no other fault
can be found in the hydraulic system.
Loosen the lock nut by turning it anti-clockwise.
1. Place a rated load on the forks and check that the truck can lift
this weight to the top position. If the truck cannot lift the rated
load, the pressure limiting valve must be adjusted, see Adjust-
ing the lifting capacity, page 14 - 23.

2. Place the rated load +15% on the forks and check that the
truck is not able to lift it. If the truck can lift the rated load +
15%, the pressure limiting valve must be adjusted, see Adjust-
ing the lifting capacity, page 14 - 23.
+5
3. Torque tighten the lock nut clockwise to 10 ⁄-0 N·m. Maintain
the adjusting screw with an Allen key while tightening the lock-
ing nut.
14
14.4.5.2 Replacing the flow control valve

14.4.5.2
Replacing the flow control valve
14.4.5.2.1 Removing the flow control valve

14.4.5.2.1
Removing the flow control valve
Removing the return filter, page 14 - 14
1. Unscrew the return filter pipe.

2. Unscrew the valve.
14.4.5.2.2 Fitting the flow control valve

14.4.5.2.2
Fitting the flow control valve
+3
1. Torque tighten the screws of the valve to 5 ⁄-0 N·m.
+10
2. Torque tighten the pipe to the return filter to 5 ⁄-0 N·m.
Screw on by hand.
Fitting the return filter, page 14 - 15
14.4.5.3 Replacing the pressure limiting valve

14.4.5.3
Replacing the pressure limiting valve
14.4.5.3.1 Removing the pressure limiting valve

14.4.5.3.1
Removing the pressure limiting valve

1. Loosen and unscrew the valve.
14.4.5.3.2 Fitting the pressure limiting valve

14.4.5.3.2
Fitting the pressure limiting valve
+5
1. Torque tighten the screws of the valve to 65 ⁄-0 N·m.
14
Checking the pressure limiting valve, page 14 - 20
14.4.5.4 Adjusting the lifting capacity

14.4.5.4
Adjusting the lifting capacity
14.4.5.4.1 Adjusting the lifting capacity, reducing

14.4.5.4.1
Adjusting the lifting capacity, reducing
1. If the truck cannot lift the rated load or can lift the rated load +
15%, adjust the pressure limiting valve using the adjuster
screw.
- To reduce the lifting capacity, turn the adjusting screw anti-
clockwise.

14.4.5.4.2 Adjusting the lifting capacity, increasing

14.4.5.4.2
Adjusting the lifting capacity, increasing
1. If the truck cannot lift the rated load or can lift the rated load +
15%, adjust the pressure limiting valve using the adjuster
screw.
- To increase the lifting capacity, turn the adjusting screw
clockwise.
14.4.6 Replacing the hydraulic unit

14.4.6
Replacing the hydraulic unit
14.4.6.1 Removing the hydraulic unit

14.4.6.1
Removing the hydraulic unit
Removing a side cover, page 8 - 3
1. Detach and disconnect all connections.
2. Loosen and remove the screw securing the clamp across the
hydraulic unit.
z x

3. Move the clamp to one side.
4. Remove the unit.
14.4.6.2 Installing the hydraulic unit

14.4.6.2
Installing the hydraulic unit
1. Lifting the unit into place.
2. Fit the clamp.

14
3. Screw it in place.
z x
4. Connect and mount all connections.

Installing a side cover, page 8 - 4

Checking the pressure limiting valve, page 14 - 20
14.4.7 Replacing the valve coil

14.4.7
Replacing the valve coil
14.4.7.1 Removing the valve coil

14.4.7.1
Removing the valve coil
2. Undo the solenoid valve nut.

3. Pull the solenoid valve straight out.
14.4.7.2 Removing the valve coil

14.4.7.2
Removing the valve coil
14
2. Undo the solenoid valve nut.
3. Pull the solenoid valve straight out.

14.4.7.3 Fitting a solenoid valve

14.4.7.3
Fitting a solenoid valve
1. Fit the solenoid valve.
+1
2. Torque tighten the nut of the valve to 4 ⁄-0 N·m.

14.4.7.4 Fitting a solenoid valve

14.4.7.4
Fitting a solenoid valve
1. Fit the solenoid valve.
+1
2. Torque tighten the nut of the valve to 4 ⁄-0 N·m.
14
14.4.8 Replacing the pressure sensor

14.4.8
Replacing the pressure sensor
14.4.8.1 Removing the pressure sensor [B4]

14.4.8.1
Removing the pressure sensor [B4]

1. Unscrew the sensor.
14.4.8.2 Fitting the pressure sensor [B4]

14.4.8.2
Fitting the pressure sensor [B4]
+7
1. Torque tighten the sensor to 35 ⁄-5 N·m.

Hydraulic system, fitted to chassis C6200
14.5 Hydraulic system, fitted to chassis C6200

14.5
Hydraulic system, fitted to chassis C6200
14.5.1 Main valve lift/reach/tilt C6210

14.5.1
Main valve lift/reach/tilt C6210
14.5.1.1 Overview
14.5.1.1
Overview
14
Pos. Designation
a Pressure limiting valve
b Lowering valve
c Pressure sensor/plug
d PowerTrak hose connection
e Non-return valve
f Air cylinder connection
g Air cylinder connection
14.6 Hydraulic system, fitted on the mast C6300

14.6
Hydraulic system, fitted on the mast C6300
14.6.1 Mast hydraulic conduits C6320

14.6.1
Mast hydraulic conduits C6320
14.6.1.1 Checks for leaks from hydraulic conduits and connections, hydraulic unit
14.6.1.1
Checks for leaks from hydraulic conduits and connections, hydraulic unit
1. Check that there are no leaks from hydraulic hoses and hose
couplings.
Check that the hoses and couplings are correctly fitted in case
you discover any leakage.

Hydraulic cylinder C6600
14.7 Hydraulic cylinder C6600

14.7
14.7.1 Main lift cylinders C6610

14.7.1
Main lift cylinders C6610
14.7.1.1
Description
14.7.1.1.1
Construction
Two plunger cylinders are used for fork carriage lifting.
14.7.1.2 Checking the attachment of the lift cylinders

14.7.1.2
Checking the attachment of the lift cylinders
1. Check the attachments of the lift cylinders, replace if any fault is detected, see Replacing the main lift cylinders,
page 14 - 32.
14.7.1.3 Checking for leaks in the lift cylinder

14.7.1.3
Checking for leaks in the lift cylinder
1. Inspect the lift cylinders for leaks, replace if any leak is detected, see Replacing the main lift cylinders, page
14 - 32.
14.7.1.4 Replacing the main lift cylinders

14.7.1.4
Replacing the main lift cylinders
14.7.1.4.1 Removing the lift cylinder, right side

14.7.1.4.1
Removing the lift cylinder, right side

1. Lift the fork carriage so that the lift cylinder is freed and place
trestles under the forks for support. Keep pressing the lowering
switch another 5-10 seconds to relieve the pressure in the sys-
tem.
2. Remove the clamp holding the cylinder.
3. Lift the cylinder straight up and move it out.
14
4. Disconnect the hydraulic hose.
14.7.1.4.2 Removing the lift cylinder, left side

14.7.1.4.2
Removing the lift cylinder, left side
Removing the motor control panel, page 13 - 32

1. Lift the fork carriage so that the lift cylinder is freed and place
trestles under the forks for support. Keep pressing the lowering
switch another 5-10 seconds to relieve the pressure in the sys-
tem.
2. Remove the clamp holding the cylinder.
3. Lift the cylinder straight up and move it out.
4. Disconnect the hydraulic hose.

14.7.1.4.3 Fitting the lift cylinder, right side

14.7.1.4.3
Fitting the lift cylinder, right side
1. Connect the hydraulic hose.
2. Fit the cylinder in the chassis.

If a new cylinder is fitted, fit the spring pin before fitting the cyl- 14
inder in the chassis.
3. Fit the clamp and attach the cylinder.
4. Lower the fork carriage, making sure the pin goes into the fork
carriage.

14.7.1.4.4 Fitting the lift cylinder, left side

14.7.1.4.4
Fitting the lift cylinder, left side
1. Connect the hydraulic hose.
2. Fit the cylinder in the chassis.

If a new cylinder is fitted, fit the spring pin before fitting it in the
chassis.
3. Fit the clamp and attach the cylinder.
4. Lower the fork carriage, making sure the pin goes into the fork
carriage.
Installing the motor control panel, page 13 - 33, Installing the motor control panel, page 13 - 34

14.7.2 PowerTrak cylinder C6680

14.7.2
PowerTrak cylinder C6680
14.7.2.1 Replacing the PowerTrak cylinder

14.7.2.1
Replacing the PowerTrak cylinder
14.7.2.1.1 Removing the PowerTrak cylinder

14.7.2.1.1
Removing the PowerTrak cylinder
Preparations
14
2. Remove the circlip.

3. Lower the cylinder.
14.7.2.1.2 Installing the PowerTrak cylinder

14.7.2.1.2
Installing the PowerTrak cylinder
1. Move up the cylinder into the top bracket.
2. Fit the circlip.

3. Put back the top cover to the drive unit mounting.
Resetting
14


Work function - lifting masts C7000 15

15 Work function - lifting masts C7000


15
Work function - lifting masts C7000
15


Auxiliary equipment, installation
16
equipment C8000

Auxiliary equipment, installation
16
equipment C8000

16 Auxiliary equipment, installation equipment C8000

16
Auxiliary equipment, installation equipment C8000
16


Optional equipment/Extra equipment
17
C9000
17.1 Overview .......................................................................................................................................................... 17 - 1
17.2 Extra electrical equipment C9400 .................................................................................................................... 17 - 2
17.2.1 Extra power socket ............................................................................................................................ 17 - 2
17.2.1.1 Overview ............................................................................................................................ 17 - 2
17.2.1.2 Description ......................................................................................................................... 17 - 2
17.2.2 Truck log equipment, code lock C9420 ............................................................................................. 17 - 3
17.2.2.1 Overview ............................................................................................................................ 17 - 3
17.2.2.2 I_Site .................................................................................................................................. 17 - 3
17.2.2.3 Impact Manager ................................................................................................................. 17 - 4
17.3 Other extra equipment C9500.......................................................................................................................... 17 - 4
17.3.1 Ground strap...................................................................................................................................... 17 - 4
17.3.1.1 Replacing the ground strap ................................................................................................ 17 - 4
17.3.2 Fire extinguisher ................................................................................................................................ 17 - 6
17.3.2.1 Description ......................................................................................................................... 17 - 6
17.3.2.2 Inspection of fire extinguisher............................................................................................. 17 - 7
17.3.3 Horizontal E-bar................................................................................................................................. 17 - 8
17.3.3.1 Overview ............................................................................................................................ 17 - 8
17.3.3.2 E-bar................................................................................................................................... 17 - 8
17.3.3.3 Description ......................................................................................................................... 17 - 9
17.3.3.4 Checking the E-bar lock ................................................................................................... 17 - 10
17.3.4 Spider expansion unit ...................................................................................................................... 17 - 10
17.3.4.1 Description ....................................................................................................................... 17 - 10

Optional equipment/Extra equipment
17
C9000

17 Optional equipment/Extra equipment C9000
Overview

17
Optional equipment/Extra equipment C9000
17.1 Overview
17.1
Overview
c b a
17
g
e
f
Pos. Designation
a DC/DC-converter 24-12V
b I_Site antenna
c Power cable BCU
d SEU
e Built-in charger (BCU)
f Collision sensor
g I_Site main unit

Extra electrical equipment C9400
17.2 Extra electrical equipment C9400

17.2
17.2.1 Extra power socket

17.2.1
Extra power socket
17.2.1.1 Overview
17.2.1.1
Overview
Pos. Designation
a DC/DC converter
17.2.1.2
Description
17.2.1.2.1 DC/DC converter

17.2.1.2.1
DC/DC converter
The truck can be equipped with a DC/DC converter to supply power to equipment such as a PC, scanner, etc. The con-
verter on the input side is protected against polarity reversal, short circuit and thermal overload. The chassis is not live,
and the in/outputs are galvanically separated. The output sits on the E-bar profile.

17.2.2 Truck log equipment, code lock C9420

17.2.2
Truck log equipment, code lock C9420
17.2.2.1 Overview
17.2.2.1
Overview
c
b
Pos. Designation
a Keypad
17
b ID unit
c ID tag
17.2.2.2 I_Site
17.2.2.2
I_Site
17.2.2.2.1
Description
17.2.2.2.1.1 I_Site
17.2.2.2.1.1
I_Site
I_Site is a system that collects data from the trucks.

I_Site is available in two different versions:
I_Site including a DHU/DHU2 and an antenna.
I_Site including a DHU/DHU2, an antenna and a collision sensor.
The data handling unit (DHU) receives data from the truck and transfers it to a central server at a set interval. The data is
then accessible to users with an authorised code via a website. No hardware installation is required at the customer site.
Communication is via the GSM 900/1800 network for the DHU. DHU2 is also approved for UMTS FDDI/ VIII 900/ 1900/
2100 MHz.
Reports can be viewed showing information such as the following:
- Truck usage
- Operator usage
- Battery use and charging patterns
- Hour counter indications
If the system includes a collision sensor, the following collision data can be viewed:
- Operator that was involved in any collision
- Severity of any collision
- Error codes generated by a collision
- Time when the collision occurred and how long the truck was in use before the collision
Collision sensitivity and the post-collision resetting procedure can be programmed separately for each individual truck.
For instructions on installation, configuration, setup and troubleshooting, see the separate manual for I_Site.

Other extra equipment C9500
17.2.2.3 Impact Manager

17.2.2.3
Impact Manager
17.2.2.3.1 Impact sensor

17.2.2.3.1
Impact sensor
Pos. Designation
a Impact sensor
17.2.2.3.2
Description
17.2.2.3.2.1 Impact sensor

17.2.2.3.2.1
Impact sensor
If an impact sensor is installed on the CAN bus, this registers when the truck bumps against something. If an impact ex-
ceeds a certain level, specified by parameters Collision sensor sensitivity in X och Collision sensor sensitivity in Y, this is
logged as a collision.
17.2.2.3.3 Checking the impact sensor parameters

17.2.2.3.3
Checking the impact sensor parameters
1. Check that factory parameters are set according to the truck configuration.
2. Check that other parameters are set correctly.
17.2.2.3.4 Checking DHU/I-site [K110]

17.2.2.3.4
Checking DHU/I-site [K110]
1. Check that the DHU's green LED is lit. If the LED is not lit: Check that the DHU's feed voltage = battery voltage.
2. Make sure it is possible to connect TruckCom to the DHU. If it is possible to connect them, check the DHU's con-
figuration. If there is a power supply, but no communication, check the CAN bus.
3. If it is still not possible to establish communication with the DHU, replace the unit.
17.3 Other extra equipment C9500

17.3
17.3.1 Ground strap

17.3.1
Ground strap
17.3.1.1 Replacing the ground strap

17.3.1.1
Replacing the ground strap
17.3.1.1.1 Removing the ground strap

17.3.1.1.1
Removing the ground strap
Preparations

1. Remove the screws.
2. Remove the ground strap.
17
17.3.1.1.2 Installing a ground strap

17.3.1.1.2
Installing a ground strap
1. Fit a ground strap bracket

2. Screw it in place.
Resetting
17.3.2 Fire extinguisher

17.3.2
Fire extinguisher
17.3.2.1
Description
17.3.2.1.1 Fire extinguisher

17.3.2.1.1
Fire extinguisher
The truck can be fitted with a fire extinguisher. Useful in areas where flammable materials are handled, always at hand in
case of fire.
Two versions of fire extinguisher are available:
Type Size Standard Market

Standard ABC 2 kg EN3 Countries following EU
regulations
USA ABC 2 kg ANSI/UL711 & ANSI/ Countries following
UL299 American regulations
A = Combustible material such as paper, wood, cardboard and plastic.
B = Ignitable or combustible fluids such as petrol, kerosene, grease and oil.
C = Electrical equipment such as devices, cables and power sockets.
In the event of fire, the powder extinguisher should be employed as follows:
1. Remove the safety catch.
2. Aim the nozzle at the base of the flames
3. Press the handle down

Regular checks of the fire extinguisher – truck operator

- Check regularly that the pressure gauge indicator is in the green field. If the indicator is in the red field, the fire extin-
guisher is not fit for use and must be recharged.
- Recharge the extinguisher immediately after use. Contact an authorised service company.
- Make sure that the extinguisher is checked once a year by a qualified service engineer (from an authorised service
company for fire protection) and that a workshop review is carried out every 10 years.
Note: Only material/parts approved by the manufacturer may be used.
Inspection of fire extinguisher during service inspection of the truck
The fire extinguisher must be checked once a year in connection with servicing of the truck.
- Check regularly that the pressure gauge indicator is in the green field. If the indicator is in the red field, the fire extin-
guisher is not fit for use and must be recharged.
- Check that the fire extinguisher is intact and in working order and is in the correct location in the truck.
- If the fire extinguisher does not appear to function satisfactorily, make sure that an authorised service company is con-
tacted.
17.3.2.2 Inspection of fire extinguisher

17.3.2.2
Inspection of fire extinguisher
1. Check that the fire extinguisher is intact, has no damage, and

is properly mounted in the machine.
If the fire extinguisher does not seem to be operational, replace
it. 17
2. Check that the pressure gauge indicator is in the green field.

If the indicator is in the red field, the fire extinguisher is not fit
for use and must be recharged.

17.3.3 Horizontal E-bar

17.3.3
Horizontal E-bar
17.3.3.1 Overview
17.3.3.1
Overview
b
c
Pos. Designation
a Load protection
b E-bar mounted
c Pivoting E-bar
17.3.3.2 E-bar
17.3.3.2
E-bar
a b
Pos. Designation
a E-bar mounted
b Pivoting E-bar

17.3.3.3
Description
17.3.3.3.1 E-bar
17.3.3.3.1
E-bar
Use the E-bar profile for quick and easy installation of optional accessories, such as a computer equipment, scanner,
writing tablet, etc. The accessories are then easily accessible from the operator's position.
Accessories can be fixed with standard brackets. The brackets can be used on all trucks with E-bar profile, making it
easy to move equipment between the trucks.
17
Loctite 243

Use the screws on the brackets of each accessory to adjust the accessories for the most comfortable operating position.
WARNING Installing accessories

► To prevent accessories from becoming loose and eliminate the risk of accidents, only use mounting brackets
specially approved by the manyfacturer for mounting accessories on the E-bar.
► Never install accessories so that the view out or the truck’s safety functions are impaired, e.g. emergency switch
off, steering, brakes, controls.
► To prevent accidents, make sure all fastening screws are securely tightened.
17.3.3.4 Checking the E-bar lock

17.3.3.4
Checking the E-bar lock
1. Check the E-bar lock.
17.3.4 Spider expansion unit

17.3.4
Spider expansion unit
17.3.4.1
Description
17.3.4.1.1 Spider expansion unit

17.3.4.1.1
Spider expansion unit
The spider expansion unit, called SEU, allows the main logic card to handle a greater number of inputs and outputs. The
SEU does not have its own truck controller logic, which means that a defective SEU can be replaced without the replace-
ment affecting any truck functions.
The SEU is used for modification of the truck to meet special customer requirements.
Electronic
card
Truck Log
System
Spider
Extra/Customised
Expansion
function(s)
Unit
CAN bus
Pump
controller
CAN service
connector
Motor
Controller
The picture shows how the SEU is used to allow a greater number of functions to be controlled via the CAN bus. SEU
has a 42-pin, multi-pin contact that manages all inputs, outputs, CAN and power supply signals.

Instructions for disposal 18
18.1 General ............................................................................................................................................................ 18 - 1
18.2 Marking of plastics ........................................................................................................................................... 18 - 1
18.2.1 General marking of products and packaging ..................................................................................... 18 - 1
18.2.2 Marking according to the manufacturer’s standards.......................................................................... 18 - 1
18.2.2.1 Abbreviations...................................................................................................................... 18 - 1
18.2.2.2 Marking examples .............................................................................................................. 18 - 2
18.3 Pressure vessels.............................................................................................................................................. 18 - 2
18.3.1 Gas struts .......................................................................................................................................... 18 - 2
18.4 Sorting categories ............................................................................................................................................ 18 - 3

18 Instructions for disposal

General

18
Instructions for disposal
18.1 General
18.1
General
The disposal instructions were developed to support our company's objective of protecting the environment. By recycling
materials, resources can be utilised more efficiently, while reducing emissions.
The instructions below indicate the proper sorting category for the materials used in the various truck components. To
achieve optimum sorting, all components should be disassembled to a level corresponding to the sorting categories.
18.2 Marking of plastics

18.2
Marking of plastics
18.2.1 General marking of products and packaging

18.2.1
General marking of products and packaging
Markings on plastics consist of three arrows, a number and usually also a designation of the plastic material used. This
example shows the marking for polypropylene.
18
• 01: PET – Polyethylene terephthalate

• 02: PE-HD – Polyethylene with high density
• 03: PVC – Polyvinyl chloride
• 04: PE-LD – Polyethylene with low density
• 05: PP - Polypropylene
• 06: PS – Polystyrene
• 07: O – Other
18.2.2 Marking according to the manufacturer’s standards

18.2.2
Marking according to the manufacturer’s standards
Standards: 58-02-001, 58-02-003 and 58-02-004.

A few examples of markings are given here. For more information, please refer to the standards above.
The product material and trade name of each item are indicated between arrows. Example: >PP<.
18.2.2.1 Abbreviations
18.2.2.1
Abbreviations
ABS
Acrylonitrile/butadiene/styrene
HDPE
High Density Polyethylene
LDPE
Low Density Polyethylene

Pressure vessels
PA
Polyamide
PA6
Amide resin 6
PA66
Amide resin 66
PBT
Polybutylene terephtalate
PC
Polycarbonate
PET
Polyethylene terephtalate
PMMA
Plexiglas
POM
Polyoxymethylene, Polyformaldehyde
PP
Polypropylene
PUR
Polyurethane
18.2.2.2 Marking examples

18.2.2.2
Marking examples
Products made from a single substance

ABS (acrylonitrile/butadiene/polystyrene):
>ABS<
Polyurethane:
>PUR<
Plastic compounds
A compound based on acrylonitrile/butadiene/polystyrene and carbonate plastic:
>ABS+PC<
Filled or reinforced materials
Polypropylene with 30% mineral powder:
>PP-MD30<
18.3 Pressure vessels

18.3
Pressure vessels
Pressure vessels sent for recycling/destruction must have been depressurised beforehand and, if possible, opened.
Examples of existing pressure vessels are gas struts and accumulators used in hydraulic systems.
18.3.1 Gas struts

18.3.1
Gas struts
WARNING High interior pressure

Gas struts have extremely high internal pressure.
► Always follow the manufacturer's recommendations.
► Always use protective goggles when dismantling struts.

Sorting categories
To allow the gas to escape, only open and disassemble gas struts as recommended by the manufacturer. An example of
how to perform this is given for "Stabilus Lift-O-Mat/Inter-stop":
2 1
m1
m1 = approx. 20 mm
1. Drill or cut a hole in the cylinders, approximately 20 mm from the bottom.
2. Drill or cut a hole in the recess at the piston rod end.
18.4 Sorting categories

18.4
Sorting categories
• Plastic and rubber material

• Iron/steel (including bolts, washers and nuts)
18
• Oils
• Oil filters
• Oil-polluted material
• Electronic parts (including switches and sensors)
• Wires
• Hazardous waste
• Complex materials - large amounts in several categories but non-combustible and not hazardous
• Combustible material, including small plastic and rubber parts
• Please return batteries to the manufacturer.
Component Category Comments

Chassis Iron/steel
Inspection covers, sheet metal Iron/steel
Handle: >ABS<
Inspection covers, plastic Plastic Sort according to the material marking
Forks and frames Iron/steel
Operator's platforms Iron/steel, including any gas struts Be sure to depressurise struts
Mats, cushions: combustible
Roofs and overhead guards Iron/steel
Gates and operator protective devices Iron/steel
Plastic handles: >PA<
Crush protectors: >PMMA<
Hydraulic unit Oil Ensure that the system has been de-
Hydraulic hoses: Oil-polluted material pressurised. Carefully drain all oil. Any
Oil tank: >PP< accumulators should be emptied of gas
Motor, valves: Electronic components and if possible opened.
Pump: Iron/steel
Accumulator: Iron/steel

Sorting categories
Component Category Comments

Travel motors Motor: Electronic components
Wires
Parking brake: Hazardous waste
Drive gears Iron/steel Carefully drain all oil
Oil Hazardous waste
Wheels Tread: Plastic according to marking If the tread and hub cannot be separ-
Hub: Iron/steel ated, then sort the wheel as complex
material
Tiller arms Electronic parts, wires, iron/steel, also Be sure to depressurise struts
gas struts
Electrical system PCBs, transistor regulators, Expansion Hazardous waste
unit SEU, contactors: Electronic com-
ponents
Wires
Small batteries Hazardous waste
Fluorescent tubes Hazardous waste.
Because of the chemical content in
fluorescent tubes, do not break them.
Obsolete fluorescent tubes must be
packaged and transported according to
local regulations.
Mast Mast beams, rollers, cylinders, hy- Oil-polluted components should be
draulic pipes: handled as hazardous waste
Iron/steel
Hydraulic hoses: Oil-polluted ()
Wires
Sensors/switches: Electronic compon-
ents
Plastic components: According to
marking or as combustible waste
Chargers and connectors Electronic components
Wires

Wiring diagram 19
19.1 Colour code table............................................................................................................................................. 19 - 1
19.2 List of fuses...................................................................................................................................................... 19 - 1
19.3 Diagram ........................................................................................................................................................... 19 - 2
19.3.1 Component list................................................................................................................................... 19 - 2
19.3.2 Component placement ...................................................................................................................... 19 - 5
19.3.3 Detailed diagrams............................................................................................................................ 19 - 19

19 Wiring diagram

19 Wiring diagram
Colour code table
19 Wiring diagram
19
Wiring diagram
19.1 Colour code table

19.1
Colour code table
Abbreviation Colour
RD Red
BK Black
BU Blue
BN Brown
YE Yellow
GY Grey
GN Green
OG Orange
PK Pink
VT Violet
WH White
TQ Turquoise
SCR Shielded
19.2 List of fuses

19.2
List of fuses
The fuses are of the type "FKS" flat pin fuses. The rated current is printed on the top of the fuses and is also indicated by
the colour coding of the fuse body.
a
19
3.6
19 5
(13.2)
19.7
6.5
5.2 0.62
(4.1) 3.5
14.5 3.8
17
The fuses' measurements, in mm, without given tolerances a = rated current.

Rated current (A) Colour Remarks
1 Black -
3 Violet -
5 Light brown -
7.5 Brown -
10 Red -
15 Blue -
20 Yellow -
25 White Brown print
30 Light green -

19 Wiring diagram
Diagram
19.3 Diagram
19.3
Diagram
19.3.1 Component list

19.3.1
Component list
Des. Function Component type Other Image Sheet

A5 Electronics card Electronic circuit , p. 19 - 14 , p. 19 - 27
(ICH) board , p. 19 - 28
, p. 19 - 29
A83 TFD (Torque feed- Steering damper , p. 19 - 16 , p. 19 - 23
back device)
B1 Drive motor temper- Temperature sensor , p. 19 - 5 , p. 19 - 20
ature sensor
B4 Lifting pressure Pressure sensor , p. 19 - 20
B11 Motor speed sensor Speed sensor , p. 19 - 5 , p. 19 - 20
B13 Steering angle Potentiometer , p. 19 - 22
sensor
B17 Drive wheel centring Inductive switch , p. 19 - 5 , p. 19 - 23
reference
B60 Drive position Inductive switch , p. 19 - 21
sensor
B61 Fork lift limiter Inductive switch , p. 19 - 8 , p. 19 - 21
B90 Collision registration Collision sensor , p. 19 - 9 , p. 19 - 31
B119 Platform down mon- Inductive switch , p. 19 - 6 , p. 19 - 24
itoring , p. 19 - 25
, p. 19 - 26
B120 Monitoring that plat- Inductive switch , p. 19 - 6 , p. 19 - 24
form is not folded up , p. 19 - 26
B121 Gates up monitoring Inductive switch , p. 19 - 7 , p. 19 - 24
B122 Gates down monit- Inductive switch , p. 19 - 7 , p. 19 - 24
oring
B124 Monitoring, fixed Photo cell receiver , p. 19 - 26
side guards
B125 Monitoring, fixed Photo cell transmit- , p. 19 - 26
side guards ter
B130 Monitoring, UK head Sensor , p. 19 - 30
connector BCU
F1 Main fuse 175A Fuse Picture 13, p. 19 - 17 , p. 19 - 19
F50 Fuse 7.5 A Fuse Picture 13, p. 19 - 17 , p. 19 - 19
F51 Fuse 7.5 A Fuse Picture 13, p. 19 - 17 , p. 19 - 19
F52 Fuse 7.5 A Fuse
F53 Fuse 20 A Fuse Picture 13, p. 19 - 17 , p. 19 - 19
F54 Fuse 7.5 A Fuse , p. 19 - 31
G1 Truck battery. Battery 24 V , p. 19 - 8 , p. 19 - 19
G10 Li-ion battery Battery , p. 19 - 33

19 Wiring diagram
Diagram

K110 Data Handling Unit Electronic circuit , p. 19 - 10 , p. 19 - 32
(DHU) board
M1 Truck traction Motor , p. 19 - 5
M3 Pump motor Motor , p. 19 - 19
M6 Steering motor Motor , p. 19 - 5 , p. 19 - 23
M12 Motor control cool- Fan Picture 14, p. 19 - 17 , p. 19 - 21
ing
M13 Motor control cool- Fan Picture 14, p. 19 - 17 , p. 19 - 21
ing
P4 Horn Horn , p. 19 - 11 , p. 19 - 21
P6 Display of truck Display , p. 19 - 13 , p. 19 - 28
functions
Q1 Mechanical brake Electromagnetic , p. 19 - 5 , p. 19 - 21
brake
Q4 Fork lowering – hy- Proportional valve , p. 19 - 21
draulic control
Q10 Main contactor Contactor Picture 14, p. 19 - 17 , p. 19 - 19
S18:1 Horn button (left) Switch , p. 19 - 13
S18:2 Horn button (right) Switch , p. 19 - 13
S21 Emergency stop Switch , p. 19 - 12 , p. 19 - 21 19
switch
S206 Creep function Switch , p. 19 - 28
S223 Log in with PIN Key pad - Smart Picture 11, p. 19 - 15 , p. 19 - 29
code - Smart card card
T1 Motor control (ACT/ Electronic module , p. 19 - 19
ACC) , p. 19 - 20
, p. 19 - 21
, p. 19 - 22
, p. 19 - 24
, p. 19 - 25
, p. 19 - 26
, p. 19 - 30
T1 Motor control (ACT/ Electronic module , p. 19 - 19
ACC) , p. 19 - 20
, p. 19 - 21
, p. 19 - 22
, p. 19 - 24
, p. 19 - 25
, p. 19 - 26
, p. 19 - 30
T7 DC/DC converter, Circuit board , p. 19 - 11
24V/12V
T8 DC/DC converter, Circuit board , p. 19 - 11 , p. 19 - 31
24V/24V

19 Wiring diagram
Diagram

T13 Steering motor Electronic circuit , p. 19 - 5 , p. 19 - 23
board
T14 Built-in charger BCU Charger , p. 19 - 9 , p. 19 - 30
T20 Antenna, T.W.I.S Antenna , p. 19 - 12 , p. 19 - 32
X1 Battery connector Port , p. 19 - 8
X23 Socket, DC/DC con- Port , p. 19 - 11 , p. 19 - 30
verter , p. 19 - 31
X40 Optional socket Port , p. 19 - 30
, p. 19 - 31
, p. 19 - 32
X41 External CAN com- Port , p. 19 - 8 , p. 19 - 27
munication
X65 Tiller arm Port , p. 19 - 16 , p. 19 - 21
, p. 19 - 27
, p. 19 - 30

19 Wiring diagram
Diagram
19.3.2 Component placement

19.3.2
Component placement
[Q1]
[T13]
M6
[M6]
[B1]
[B11]
19
[M1]
[B17]
Picture 1

19 Wiring diagram
Diagram
[B119]
[B120]
Picture 2

19 Wiring diagram
Diagram
[B121]
[B122]
19
Picture 3

19 Wiring diagram
Diagram
[G1]
[X1]
[B61]
[X41]
Picture 4

19 Wiring diagram
Diagram
[T14]
[B90]
19
Picture 5

19 Wiring diagram
Diagram
[K110]
Picture 6

19 Wiring diagram
Diagram
[X23]
[T8]
[P4]
19
[T7]
Picture 7

19 Wiring diagram
Diagram
[T20]
[S21]
Picture 8

19 Wiring diagram
Diagram
[P6] [S18:2]
[S18:1]
19
Picture 9

19 Wiring diagram
Diagram
[X100]
[A5]
Picture 10

19 Wiring diagram
Diagram
19
[S223]
Picture 11

19 Wiring diagram
Diagram
[X65] [A83]
Picture 12

19 Wiring diagram
Diagram
[F50]
[F51]
[F1]
[F53]
Picture 13
19
[M12]
T[1]
[M13]
[Q10]
Picture 14

19 Wiring diagram
Diagram

19.3.3 Detailed diagrams
19.3.3
Detailed diagrams
B-
OUT. U-OUT. V 02-9
16-1
119 OUT.FAN-112 OUT. SIGNAL HORN 03-9
OPTION 93 OUT. 5V-113 OUT GND 04-9
94 INP.MAN ON PLATFORM-97 INP. PLATFORM
NOT FOLDED UP 06-9

94 INP. MAN ON PLATFORM-97 INP.PLATFORM NOT FOLDED UP 07-9
94 INP. MAN ON PLATFORM-97 INP. PLATFORM NOT FOLDED UP 08-9

Li-Ion B+ 94 INP. MAN ON PLATFORM-97 PHOTCELL,FOOT PROTECT 08-9
16-1 90 INP. MAINS CONNECTOR PARKED- 12-11
[Q10]
30 A1 A2 32
03-1 118 OUT. MAIN CONTACTOR
01-5 33
06-1 116 OUT. NEG. SENSORS
07-1
08-1 7
OUT P-
08-1 300A
03-1 PUMP MOTOR [Q10] [F1] [G1]
1 [M3] 2 1 2 X1 + - X1 40
INP. B-
01-5 24V
20A
[F53]
23 1 2
05-11
7,5A
[F51]
21 1 2
03-1
19 - 19
7,5A
[F50]
20 1 2
09-1
05-1
12-1
14-1 1
15-1 12-1
13-1
8
INP. B+
20
INP. ENABLE / PRE-CHARGE
05-11
09-1
12-1 40
13-1
14-1
15-1
03-1 [T1]
MOTOR CONTROLLER
7609115-B-1
Diagram
19 Wiring diagram

19
01-9
U 2
Diagram
OUT. U
V 3
[M1] OUT. V
W 4
OUT. W
DRIVE MOTOR

1
19 Wiring diagram
[B11] 60
85 OUT. +5V SPEED SENSOR
[B11] 2
RD BU [B11] 61
104 INP. CH A, SPEED SENSOR
3
BK WH [B11] 62
103 INP. CH B, SPEED SENSOR
2
[B1] RD 2 [B1] 63
92 INP. THERMAL SENSOR
TEMP. DRIVE MOTOR 1
GN 1 [B1]
4
[B11] 64 64
105 OUT. NEG.SPEED
19 - 20
PRESSURE SENSOR /THERMAL.SENS.
[B4]
41 1 P 2 50
04-1 91 INP. PRESSURE LIFT
3
27
04-1
[T1]
MOTOR CONTROLLER
7609115-B-2
01-9
EMERGENCY SWITCH OFF

[S21]
21 1 2 24 24
01-1 114 INP. +24V "HIGH SIDE DRIVER"
FAN 1 T1
1 [M12] 2 35
119 OUT.FAN
FAN 2 T1
1 [M13] 2
[P4]
1 3 39
06-1 2 112 OUT. SIGNAL HORN
07-1
[B60]
08-1 [X65]
24 [X65] 1 2 57
08-1 87 INP. TILLER ARM IN DRIVE POS
3
40 [X65]
01-2
[B61]
1 2 49
95 INP LIFT LIMIT
33 3
01-1
30 30
19 - 21
01-1 115 OUT.+24 V "HIGH SIDE DRIVER"
[Q1]
1 2 31
117 OUT. BRAKE RELEASE
09-1 [Q4]
05-11 1 2 38
09-1 12-1 108 OUT.LOWER VALVE
05-11 14-1 119/RD
106 CAN TERMINATION R120
12-1 15-1
119/RD 119/RD
14-1 16-1 100 INP. CAN LOW
15-1 120/WH 120/WH
16-1 99 INP. CAN HIGH
[T1]
MOTOR CONTROLLER
7609115-B-3
Diagram
19 Wiring diagram

19
Diagram
ONLY TRUCKS WITHOUT

SERVO

19 Wiring diagram
01-9
27 27
02-1 93 OUT. 5V
41 41
02-1 113 OUT GND
[B13]
27 1
2 70
101 INP. STEER SENSOR
19 - 22
41 3
[T1]
MOTOR CONTROLLER
7609115-B-4
ONLY TRUCKS WITH SERVO
RD 91 40
INP +5VDC SENSOR. 1 4 OUT. + 5VDC POWER 0VDC 7 01-2
GN 93
OUT: SENSOR 1. 3 5 INP.SENSOR 1 POWER 0VDC 15
OG 92 23
OUT SENSOR 2. 4 13 INP.SENSOR 2 POWER + 24VDC 8 01-1
BK 94
INP.0V SENSOR. 2 14 OUT. 0VDC POWER +2 4VDC 16
WH 98 119/RD
INP. COIL -. 6 9 OUT. COIL - CAN HIGH 2 03-3
BU 99 120/WH
INP.COIL + . 5 1 OUT: COIL + CAN LOW 10 03-2
[A83]
TFD
95
3 OUT. SUPPLY +12 VDC
[B17]
1 2 96
11 INP. REFERENCE SWITCH
[M6]
3
19 - 23
97
12 OUT.SUPPLY 0VDC
20
01-1 6 INP.ENABLE
[T13]
EPS
7609115-B-5
Diagram
19 Wiring diagram

19
Diagram
01-9
[B119]
24 1 2 65
03-1 94 INP.MAN ON PLATFORM
3

19 Wiring diagram
[B120]
1 2 56
97 INP. PLATFORM
3 NOT FOLDED UP
[B121]
1 2 58
88 INP. GTAES UP
3
[B122]
1 2 59
96 INP. GATES DOWN
19 - 24
3
33
01-1
[T1]
MOTOR CONTROLLER
7609115-B-6
BACK PROTECTION,WITH FIXED PLATFORM
SIDE PROTECTION,WITH FIXED PLATFORM
01-9
[B119]
24 1 2 65:1
03-1 94 INP. MAN ON PLATFORM
3
33 97 INP.PLATFORM NOT FOLDED UP

01-1
88 INP.GATES UP
96 INP.GATES DOWN
19 - 25
[T1]
MOTOR CONTROLLER
7609115-B-7
Diagram
19 Wiring diagram

19
PLATFORM WITHOUT GATES
01-9
[B119]
Diagram
24 1 2 65:2
3
33
01-1
[B120]
1 2 56:1
97 INP. PLATFORM NOT FOLDED UP

19 Wiring diagram
88 INP. GATES UP
INP. GATES DOWN

BUILD IN PLATFORM T1
MOTOR CONTROLLER
01-9
[B119]
24 1 2 65:3
3
19 - 26
33
01-1
TR
[B125]
[B120] + - [B120]
REC
[B124]
[B120] + A [B120] 56:2
97 PHOTCELL,FOOT PROTECT
-
[T1]
MOTOR CONTROLLER
7609115-B-8
X300:1 +5VDC-X300:2 SI 10-11
11-11
120/WH [X65] 120/WH

03-2 X100:3 CAN LOW
119/RD [X65] 119/RD

03-3 X100:7 CAN HIGH
40 [X65] 40
01-2 X100:2 INP. 0VDC
20 [X65] 20
01-1 X100:6 INP. +24V DC
A5:S300-S308 A5:S310-S318
3
SPEED REF. VALUE
[X41]
19 - 27
CAN SERVICE CONNECTOR A5:S322
FORK LOWER
A5:S323
FORK LIFT
[A5]
ELECTRONIC CARD TILLER ARM
7609115-B-9
Diagram
19 Wiring diagram

19
09-11
X1 1 X300:1 +5VDC
Diagram
DISPLAY
P6 X1 2 X300:2 SI
8 8 8 8 X1 3 X300:3 SCK

19 Wiring diagram
X1 4 X300:4 ENABLE
X1 5 X300:5 LCLK
X1 6 X300:& 0VDC
[P6]
DISPLAY
[S18:1]
X200 1 INP. HORN 1
19 - 28
X200 2 OUT.0VDC HORN 2
[S18:2]
X201: INP. HORN 2
X201 1 OUT. 0VDC HORN 2

[S206]
X203:10 TURTLE
OPTION
X203 TURTLE
[A5]
ELECTRONIC CARD TILLER ARM
7609115-B-10
09-11
X204 1 1 4 7 -
X204 2 2 5 8 0
1 2 3
X204 3 3 6 9
4 5 6
7 8 9 X204 4 1 2 3
0 I
X204 5 4 5 6
X204 6 7 8 9
SMART CARD X204 7 - 0
X204 8 LED_GREEN
X204 9 LED_RED
19 - 29
X204 10 0VDC
[S223] [A5]
KEY BOARD / SMART CARD ELECTRONIC CARD TILLER ARM
7609115-B-11
Diagram
19 Wiring diagram

19
OPTION
ONBOARD CHARGER
Diagram
01-9
1 [B130]
20 [X65] 1 2 [X65] 71
01-1 90 INP. MAINS CONNECTOR PARKED
3
[T1]
[X65] MOTOR CONTROLLER

19 Wiring diagram
1 1
01-2 + OUT.POSITIVE CHARGER VOLTAGE
40 40
01-2 - OUT. NEGATIVE CHARGER VOLTAGE
120/WH [X40] 120/WH

03-2 4 INP. CAN LOW
119/RD [X40] 119/RD

03-3 3 INP CAN HIGH
19 - 30
[X23]
MAINS VAC
MAINS VAC
MAINS VAC
[T14]
BCU
7609115-B-12
OPTION
DC/DC CONVERTER
(T7=24/12V, T8=24/24V)
7.5A
[F54]
1 1 2 25
01-2 INP. +24 VDC
40 40
01-2 INP. 0VDC
26
1 OUT. 12VDC/24VDC
2
41:1
OUT.0VDC
[X23]
[T7]/[T8]
DC/DC CONVERTER
7609115-B-13
OPTION
SHOCK SENSOR
19 - 31
[X40] 20
01-1 1 INP. +24VDC
[X40] 40
01-2 2 INP. 0VDC
[X40] 119/RD
03-3 3 CAN HIGH
[X40] 120/WH
03-2 4 CAN LOW
[B90]
SOCK SENSOR
7609115-B-14
Diagram
19 Wiring diagram

19
OPTION
DATA HANDLING UNIT(DHU)
Diagram
[X40] 20
01-1 1 INP. +24VDC
[X40] 119/RD
03-3 2 CAN HIGH

[X40] 120/WH
19 Wiring diagram
03-2 3 CAN LOW
[X40] 40
01-2 8 INP. 0VDC
[T20]
[K110]
DHU
7609115-B-15
19 - 32
OPTION Li-ION
CHARGER CONNECTOR JUMPER CONNECTOR

+ B+
B+ O UT
1 1
BATTERY
2 2 MODULES
3 3
4 4
- B-
119/RD
03-3 X111:3 INP.CAN HIGH
120/WH
19 - 33
03-2 X111:4 INP. CAN LOW
J1
X111:7 INP:ENABLE
J1
X111:8 INP.ENABLE
B+
01-1 + OUT.B+ (POLE BOLT)
B-
01-1 - OUT.B-(POLE BOLT)
[G10]
Li-Ion BATTERY
7609115-B-16
Diagram
19 Wiring diagram

19
19 Wiring diagram
Diagram

Hydraulics schematics 20
20.1 List of symbols ................................................................................................................................................. 20 - 1
20.2 Component list ................................................................................................................................................. 20 - 3
20.3 Component location ......................................................................................................................................... 20 - 4
20.3.1 Picture 1............................................................................................................................................. 20 - 4
20.3.2 Picture 2............................................................................................................................................. 20 - 5
20.3.3 Picture 3............................................................................................................................................. 20 - 6
20.4 Diagram ........................................................................................................................................................... 20 - 7

20 Hydraulics schematics

List of symbols
20
Hydraulics schematics
20.1 List of symbols

20.1
List of symbols
The list explains the various symbols that are used in the hydraulic flow diagram.
Symbols

Accumulator: Operational conduit
Operational conduit, connection Operational conduit, cross-operation
Needle valve (manual lowering valve) Non-return valve
20
Non-return valve, spring-loaded (hose Double-acting hydraulic cylinder with

rupture valve) damper (reducer)
Electric motor and pump Single-acting hydraulic cylinder

With fixed displacement
Bi-directional flow
Single-acting hydraulic cylinder with Filter

purging

List of symbols

Flow control valve Hydraulic lock
Hydraulic motor Framing of two or more functions con-

centrated in one single unit
With fixed displacement
Bi-directional flow
Counter-balance valve Counter balance valve (above centre

valve)
Air drier Back-pressure valve, with integrated

non-return valve
Pilot pipe PowerTrak
Proportional valve, controlled by Proportional valve, controlled by

solenoid solenoid
Proportional valve, controlled by Proportional valve, controlled by

solenoid solenoid
Proportional valve, auto-controlling of Directional valve 2/2

proportional type
Two ports
Two distinct positions
Controlled by solenoid

Component list

Directional valve 2/2 Directional valve 4/2
Two ports Two distinct positions
Draining Spring-back
Two distinct positions Controlled by solenoid
Directional valve 4/3 Directional valve 6/2
Four ports
Three distinct positions
Directional valve 6/3 Shuttle valve
Throttling Tank
20
Pressure limiting valve Pressure compensating valve, closing

action
Pressure sensor, analogue
20.2 Component list

20.2
Component list
Pos. Component type Function Picture Diagram

1 PowerTrak cylinder Increases the pulling capa- 1 1
city with a loaded machine
2 Lift cylinder Fork carriage lift 1 1
3 Valve Pressure limiting valve, 2 1
max. 250 Bar
4 Solenoid valve Lowering valve 2 1
5 Pressure sensor Pressure sensor/cavity plug 2 1

Component location
Pos. Component type Function Picture Diagram

6 Flow control valve Hydraulic oil flow restriction 2 1
10 l/min (std)
8 l/min (option)
5 l/min (option)
7 Motor Electric motor and pump 2 1
8 Connection PowerTrak 2 1
9 Valve Non-return valve 2 1
10 Connection F1 Lifting cylinder fork carriage 2 1
lift
11 Connection F2 Lifting cylinder fork carriage 2 1
lift
12 Pump Hydraulic pressure 2
13 Filter Return filter 2 1
14 Suction strainer Coarse filtering of oil, pump 2 1
suction side.
15 Air filter Tank ventilation 3 1
16 Tank Hydraulic oil tank 3 1
20.3 Component location

20.3
Component location
20.3.1 Picture 1
20.3.1
Picture 1
2 2

Component location
20.3.2 Picture 2
20.3.2
Picture 2
8
3
4 9
10
11
5 12
6
20
14

Component location
20.3.3 Picture 3
20.3.3
Picture 3
15
16

Diagram
20.4 Diagram
20.4
Diagram
2 2 1 5
10 11 8
F1 F2 PT M
(WEO 1/4”) (WEO 1/4”) (WEO 1/4”) (G 1/4”)
Q4
Dia 1.1
4
9
3 Max 250 Bar
6
20
7
16
13
15 14

Diagram

Tools 21
21.1 Tools for electric connectors ............................................................................................................................ 21 - 1
21.1.1 AMP connectors ................................................................................................................................ 21 - 1
21.1.2 MQS connectors ................................................................................................................................ 21 - 1
21.1.3 CPC connectors................................................................................................................................. 21 - 2
21.1.4 AMP Seal connectors ........................................................................................................................ 21 - 3
21.1.5 Super Seal connectors ...................................................................................................................... 21 - 3
21.1.6 Molex connectors .............................................................................................................................. 21 - 4
21.2 Lubricating tool................................................................................................................................................. 21 - 5
21.3 Special tools..................................................................................................................................................... 21 - 6

21 Tools

21 Tools
Tools for electric connectors
21 Tools
21
Tools
21.1 Tools for electric connectors

21.1
21.1.1 AMP connectors

21.1.1
AMP connectors
PT = Power Timer (4.8; 5.8; 6.3 mm).

JPT = Junior Power Timer (2.8 mm)
MPT = Micro Power Timer (1.5 mm).
Tools Number Use

213296 Removal of pins/sleeves (JPT, PT)
213298 Removal of pins/sleeves (MPT)

21
1=163787 (JPT) Crimping sleeves

2=163788 (JPT)
1 1=213336 (MPT)
2 2=213337 (MPT)
1=213336 (JPT) Crimping 0.5-2.5mm² pins

2=213549 (JPT)
1
2
21.1.2 MQS connectors

21.1.2
MQS connectors

21 Tools
Tools Number Use

25781 MQS Basic toolbox.
The box contains:
1 pair crimping pliers
1 pair stripping pliers
25x splicing sleeves 0.5–1.5 mm2
2x complete 2, 3, 4, 6, 8 and 12-pin
connectors (male and female) with
prewired cables and splicing sleeves.
Please use to replace damaged con-
nectors on the truck.
25782 MQS refill box.

Use to refill the “MQS 257843 Com-
plete toolbox”.
The refill box contains:
200x splicing sleeves 0.2–0.5 mm2
200x splicing sleeves SWS 0.2-0.5
mm2
400x splicing sleeves SWS 0.5-0.75
mm2
100x splicing sleeves "Clean body"
0.5-0.75 mm2
200x pins SWS 0.2–0.5 mm2 400x pins
SWS 0.5–0.75 mm2 1200x seals
200x plugs and connectors
25783 MQS Complete toolbox.
The tool box contains four pliers:
MQS SWS 0.25–0.5 mm2
MQS SWS 0.5-0.75 mm2
MQS Std&”Clean body” 0.25–0.5 mm2,
MQS Std&”Clean body” 0.5–0.75 mm2,
Puller for 2, 3, 4, 6, 8 and 12-pin male
and female connectors.
21.1.3 CPC connectors

21.1.3
CPC connectors

21 Tools
Tools Number Use

1=163787 Application of sleeve (CPC)
2=163788
1
2
18593 Removal of pins/sleeves (CPC)
21.1.4 AMP Seal connectors

21.1.4
AMP Seal connectors
Tools Number Use

1=261599 Application of sleeve
2=261600
1 21
2
21.1.5 Super Seal connectors

21.1.5
Super Seal connectors
Tools Number Usage

159232 Crimping tool for fitting sleeves/pins

21 Tools
Tools Number Usage

159228 Removal tool for pins/sleeves
159229 Tool for removing lock
159230 Tool for fitting secondary locking, 1-2

pins
159231 Tool for fitting secondary locking, 3-6

pins
21.1.6 Molex connectors

21.1.6
Molex connectors
Tools Number Usage

156936 Crimping tool for fitting sleeves/pins
156937 Removal tool for pins/sleeves

21 Tools
Lubricating tool
21.2 Lubricating tool

21.2
Lubricating tool
Tools Number Usage

24981 Tool with a pointed nozzle used to ap-
ply grease. Length 170 mm.
202154PM Pointed nozzle for grease guns used to

apply grease in recessed nipples. Fits
grease guns with hose and discharge
pipe. Length 125 mm.
755132 Single-hand grease gun with straight

discharge pipe and nozzle.
755142 Two-handed grease gun with angled

discharge pipe and nozzle.
21
755152 Two-handed grease gun with hose and

nozzle.
755145 Lubricating hose 450 mm.

755140 Nozzle for necked nipples. Fits grease

guns with hose and discharge pipe.

21 Tools
Special tools
21.3 Special tools

21.3
Special tools
Tools No. Use Classification /

Inspection interval
Eye bolt Max 1200 kg /

7541426
M20 -
M20
Hydraulic pressure -/
219730
gauge (Manometer) -
Support block
-/
651154 Block for supporting the -
truck
Fitting tool
-/
V08-18302 Used to compress the -
PowerTrack springs.

21 Tools
Special tools

Inspection interval
Anti-static carpet
Anti-static carpet with -/
148115
armband and spiral -
cable.
PC to CAN cable
PC to CAN cable for -/
163793
programming in Truck- -
Com.
21
CASTOR USB
Service instrument for -/
7521083
programming in Truck- -
Com.
CAN key
-/
7516707 Used for for setting -
parameters

21 Tools
Special tools

Inspection interval
Plug 10 mm /
1/4" (male)
Plug for quick change -/
254526
connectors type WEO -
(male).
Size: 19 mm / 1/4”.
Plug 13 mm /
3/8" (male)
254527
(male).
Size: 23 mm / 3/8".
Plug 16 mm /
1/2" (male)
Plug for quick change
-/
254528 connectors type WEO
-
(male). With 1/2” con-
nector.
Size: 26 mm / 1/2”.

21 Tools
Special tools

Inspection interval
Plug 10 mm / 1/4" (fe-

male)
254529
(female).
Size: 19 mm / 1/4”.
Plug 13 mm / 3/8" (fe-

male)
254530
(female).
Size: 23 mm / 3/8".
21
Plug 16 mm / 1/2" (fe-

male)
Plug for quick change
-/
254531 connectors type WEO
-
(female). With 1/2” con-
nector.
Size: 26 mm / 1/2”.

21 Tools
Special tools

Service data and grease specifica-
22
tions
22.1 General tightening torques............................................................................................................................... 22 - 1
22.1.1 Galvanised, non-oiled screws............................................................................................................ 22 - 1
22.1.2 Untreated, oiled screws ..................................................................................................................... 22 - 1
22.2 Lubricants specification.................................................................................................................................... 22 - 2

Service data and grease specifica-
22
tions

22 Service data and grease specifications
General tightening torques

22
Service data and grease specifications
22.1 General tightening torques

22.1
General tightening torques
Millimetre threads M3 to M24. The following applies in the case of good conditions, e.g. steel against steel.
NOTICE General tightening torques

Experience has shown that if the torque wrench is adjusted to the values for untreated screws, the correct torque value
for galvanised screws will also be obtained.
► Do not tighten more than the values indicated in the table, otherwise the screws can be destroyed.
22.1.1 Galvanised, non-oiled screws

22.1.1
Galvanised, non-oiled screws
Dimension Strength class

8.8 10.9 12.9
M3 1.1 1.6 2.0
M4 2.8 3.8 4.7
M5 5.5 7.7 9.3
M6 9.5 13 16
M8 23 32 38
M10 45 62 76
M12 78 109 130
M14 123 174 208
M16 189 266 320
M20 370 519 623
M24 638 898 1075
Tightening torque ‘T’ (Nm) 22
22.1.2 Untreated, oiled screws

22.1.2
Untreated, oiled screws
Dimension Strength class

8.8 10.9 12.9
M3 1, 2 1.7 2.1
M4 2.9 4.0 4.9
M5 5.7 8.1 9.7
M6 9.8 14 17
M8 24 33 40
M10 47 65 79
M12 81 114 136
M14 128 181 217
M16 197 277 333
M20 385 541 649
M24 665 935 1120
Tightening torque ‘T’ (Nm)

22.2 Lubricants specification

22.2
Pos. Lubricant type Specification Usage

A Grease S213366, Q8 Rubens WB Bearings and
bushes
B Hydraulic oil See table below Hydraulic system
C Transmission oil Synthetic base hypoid oil Gears
SAE 75W-90, Class API-GL5
C Transmission oil Cassida Fluid GL 150 Gears
Synthetic Approved for the
NSF H1 food processing in-
dustry
NSF ISO 21469
D Grease See table below Chains
E Grease Grafloscon, A-G1 (Klüber) Gear ring
F Grease Gletmo 805 Beams, rib
F Grease Rembrandt EP2 Beams, flanges
G Grease Staburags, NBU 8EP Steering bearings
H Grease Klüberplex BEM 34-132 Steer axle/steering
damper
I Cold store hydraulic oil Viscosity class VG27,5 Decompression
Viscosity index index VI min 350 (according to ASTM D locking
2270)
Pos. Ambient temperature Viscosity class Usage

B 0°C – 40°C ISO VG 32 Hydraulic system
ISO 6743-4 category HM
DIN 51524 part 2 = HLP
B -35°C - 40° C ISO VG 27.5 Hydraulic system
ISO 6743-4 category HV
DIN 51524 part 3 = HVLP
B 0°C – 40°C Cassida Fluid HF 32 / ISO VG 32 Hydraulic system
ISO 6743-4 category HM Approved for the food processing
DIN 51524 part 2 = HLP industry
NSF H1
NSF ISO 21469
Pos. Ambient temperature Viscosity class Recommended products*

D > -40°C VG 15 Klüberoil 4UH 1-15, Klüber Lubrication
< -30°C
D >-30°C VG 68 Klüberoil 4UH 1-68N, Klüber Lubrication
< +5°C Anticorit LBO 160 TT, Fuchs DEA
D > +5°C VG 150 Klüberoil 4UH 1-150N, Klüber Lubrication
< +45°C Anticorit LBO 160, Fuchs DEA
Rexoil, Rexnord Kette
D > +45°C VG 220 Klüberoil 4UH 1-220N, Klüber Lubrication
< +80°C

Technical data 23
23.1 Truck Dimensions ............................................................................................................................................ 23 - 1
23.2 Truck data ........................................................................................................................................................ 23 - 1

23 Technical data

23 Technical data
Truck Dimensions
23 Technical data
23
Technical data
23.1 Truck Dimensions

23.1
Truck Dimensions
The figures show the outer dimensions of a standard-version truck.

h 14
h14
h3
h 23
h7
h13
y m2 s
l2 l2 l
l1 l1
e
23
b 11
b10
b5
b1
wa
23.2 Truck data

23.2
Truck data

Brand name Toyota Toyota Toyota
1.2 Model LPE200 LPE220 LPE250
1.3 Drive unit Electric Electric Electric
Identification
1.4 Driving mode Standing/walking Standing/walking Standing/walking

1.5 Lifting capacity Q kg 2000 2200 2500
1.6 Load centre distance c mm 600 600 600
1.8 Distance, centre of support arm wheel to fork back, x mm 913/957 913/957 913/957
raised/lowered forks
1.9 Wheel base, raised/lowered forks y mm 1362:1406 1410:1454 1410:1545

23 Technical data
Truck data

2.1 Weight of truck with battery kg 718 826 826
Weight
2.2 Axle load, with load, drive/caster/fork wheels kg 466/585/1667 679/834/1513 641/911/1774
2.3 Axle load, without load, drive/caster/fork wheels kg 184/294/140 389/311/126 389/311/126
3.1 Drive/caster/fork wheels Vulkollan®/ Vulkollan®/ Vulkollan®/
Vulkollan®/ Vulkollan®/ Vulkollan®/
Vulkollan® Vulkollan® Vulkollan®
Wheels, chassis
3.2 Wheel size, front mm Ø 230x70 Ø 250x75 Ø 250x75

3.3 Wheel size, rear mm Ø 85x95 Ø 85x95 Ø 85x95
3.4 Other wheels mm Ø 125x50 Ø 125x50 Ø 150x54
3.5 Wheels, number front/rear (x=drive wheels) 1x+2/2 eller 4 1x+2/2 eller 4 1x+2/2 eller 4
3.6 Track width, front b10 mm 500 500 500
3.7 Track width, rear b11 mm 370 370 370
4.4 Lift h3 mm 120 120 120
Lift height h23 mm 205 205 205
4.8 Platform height h7 mm 190 190 190
Manual control h14 mm 1100/1413 1100/1413 1100/1413
Power steering, upper position h14 mm 1201/1413 1201/1413 1201/1413
Power steering, lower position h14 mm 1101/1313 1101/1313 1101/1313
4.15 Height, lowered forks h13 mm 85 85 85
Dimensions
4.19 Total length l1 mm 1816 1864 1864

4.20 Length to fork back l2 mm 666 714 714
4.21 Overall width b1 mm 730 730 730
4.22 Fork dimensions s/e/l mm 78/180/1150 78/180/1150 78/180/1150
4.25 Width over fork b5 mm 550 550 550
4.32 Ground clearance, wheelbase centre m2 mm 30 30 30
4.33 Path requirements for pallet size 1000x1200, hand- Ast mm 2430 2477 2477
ling by the long side
4.34 Path requirements for pallet size 800x1200, handling Ast mm 2277 2324 2324
by the narrow side
4.35 Turning radius, raised forks Wa mm 1585 1632 1632
5.1 Speed with/without load
Manual control km/h 8.0:8.0 7.5:10.0 7.0:12.5
Power steering km/h 8.0:8.0 9.0:10.0 11.0:12.5
5.1 Speed with/without load (ANSI only)
Performance
Manual control km/h 8.0:8.0 6.0:9.5 7.0:11.5

Power steering km/h 8.0:8.0 6.0:9.5 8.5:11.5
5.1 Travel speed, Click-2-Creep km/h 1.7 1.7 1.7
5.2 Lift speed with/without load m/s 0.06:0.08 0.06:0.08 0.06:0.08
5.3 Lowering speed with/without load m/s 0.08:0.07 0.08:0.07 0.08:0.07
5.8 Max. gradient capability, with/without load % 8:18 8:18 8.5:18
5.9 Acceleration time, with/without load (0-10m) s 5.5 5.0 4.5
5.10 Travel brake Electromagnetic Electromagnetic Electromagnetic
6.1 Drive motor S2 @ 60 min kW 2.5 2.5 2.8
Electric mo-
6.2 Lifting motor S3 10% kW 2.2 2.2 2.2

tor
6.4 Battery voltage/nominal capacity K5 V/Ah 24:300 24:400 24:400

6.5 Battery weight kg 241 305 305
8.1 Type of control unit Variable AC Variable AC Variable AC
10.7 Sound pressure level, average value over time ac- dB(A) 60 60 59
Other
cording to EN 12053, margin of error 4 dB

Full body vibration value according to EN 13059 and m/s2 0.6 0.6 0.6
EN 12096, margin of error 30 %

24 Index
24 Index
24
Index
24

24 Index

TOYOTA Material Handling Group

LPE200 LPE220 LPE250 (Levio AC) RM7572514-040 From 63045331 (Updated 2018)

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Repair manual 7572514 en

Publication No.: 7572514-040

Model T-Code Valid from serial number

Date Change Change description

General safety rules 2

Transmission/Drive gear C2000 10

Brake/wheel/track system C3000 11

Steering system C4000 12

Electrical system C5000 13

Work function - lifting masts C7000 15

Auxiliary equipment, installation equipment C8000 16

Optional equipment/Extra equipment C9000 17

Instructions for disposal 18

Service data and grease specifications 22

Repair manual 7572514 en

Repair manual 7572514 en

1.1 Pictograms ......................................................................................................................................................... 1 - 1

1.2 Abbreviations ..................................................................................................................................................... 1 - 1

Repair manual 7572514-040

Repair manual 7572514-040

Symbol Procedure Symbol Procedure

Check that screws, nuts, etc. are tightened to

Listening for noise. Lubrication, application.

Check of functions. Calibration

An example of another type of pictogram is “Cut cable ties”:

Abbrevi- Meaning Explanation

1-1 Repair manual 7572514 en

Abbrevi- Meaning Explanation

Repair manual 7572514 en 1-2

2.1 Authorised personnel ......................................................................................................................................... 2 - 1

2.2 Work safety ........................................................................................................................................................ 2 - 1

2.3 Electrical system ................................................................................................................................................ 2 - 2

2.3.1 Electrostatic risks................................................................................................................................. 2 - 2

2.3.2 Battery handling................................................................................................................................... 2 - 2

2.4 Safe lifting .......................................................................................................................................................... 2 - 3

2.5 Product modification .......................................................................................................................................... 2 - 4

2.7 Hydraulic system................................................................................................................................................ 2 - 4

Repair manual 7572514-040

Repair manual 7572514-040

2 General safety rules

2.1 Authorised personnel

2.2 Work safety

For safe work, always remember:

▷ always disconnect the battery when performing welding work.

▷ Keep all tools well maintained.

▷ The drive unit oil may be hot.

▷ Store and transport changed oil according to applicable local directions.

2-1 Repair manual 7572514 en

2.3 Electrical system

When working on the electric system, keep the following in mind:

WARNING Short-circuiting/Burn injuries

▷ Always use insulated tools when working on the electrical system.

▷ Never remove the warranty seals on the electronic cards.

2.3.1 Electrostatic risks

▷ Use electrostatically protected footwear!

▷ Use an antistatic surface: Anti-static carpet 148115, page 21 - 7.

2.3.2 Battery handling