Service Manual

Service Manual
Pedestrian Stackers
PS • PSH
PS PSH SERVICE MANUAL

The content of this manual is protected by copyright law and may not be copied,
fully or in part, without written permission.
The material has undergone careful examination with regard to correctness. We
reserve the right to make changes.
© Copyright UniCarriers Europe AB, 2015
PS/PSH
Table of contents
2016w38
01 General information and technical data 1

2016w38
1.1 Introduction........................................................................................................................ 1
1.2 Safety ................................................................................................................................ 1
1.3 Environmental considerations ........................................................................................... 5
1.4 Preparations ...................................................................................................................... 5
1.5 Data ................................................................................................................................... 6
1.6 Component specification ................................................................................................. 10
1.7 Recommended consumable materials ............................................................................ 10
1.8 Standards and abbreviations............................................................................................11
02 Special tools 17
2016w38
2.1 List of tools ...................................................................................................................... 17
03 Service 18
2016w38
3.1 Routine periodic maintenance ......................................................................................... 18
3.2 Specific instructions......................................................................................................... 28
04 Chassis 31
2016w38
4.1 Design and function......................................................................................................... 31
4.2 Repair and maintenance instructions .............................................................................. 32
05 Drive unit 36
2016w38
5.2 Maintenance and repair instructions................................................................................ 37
5.3 Diagnostics and trouble shooting .................................................................................... 42
06 Mast system 44
2016w38
07 Steering 63
2016w38
7.2 Maintenance and repair instructions................................................................................ 63
PS/PSH
Table of contents
08 Hydraulic system 70
2016w38
09 Lift cylinders 94
2016w38
10 Electrical system 107

2016w38
10.1 Design and function....................................................................................................... 107
10.2 Repair and maintenance instructions ............................................................................ 108
10.3 Diagnostics and trouble shooting .................................................................................. 145
10.4 Appendix 1, Overview of the menu trees....................................................................... 182
11 Speed control and brake systems 230

2016w38
11.1 Design and function....................................................................................................... 230
11.2 Maintenance and repair instructions.............................................................................. 230
PS/PSH
01 General information and technical data
01 GENERAL INFORMATION AND TECHNICAL DATA

1.1 Introduction
1.1.1 General
You may find contradictions in this Manual compared to the models supplied due to special
design features, upgrades, and other detail differences.
The content of this Manual is protected by copyright law and may not be copied, fully or in
part, without written permission. The material has undergone careful examination with regard
to correctness. Subject to alteration.
In the event of inconsistent information in the Swedish and translated editions, it is the
Swedish edition that applies.
Modifications and updates will be distributed via Service Manual Change. For further
information concerning Service Instructions, operation of the truck and the ATC truck
computer, refer to the truck Instruction Handbook supplied.
1.1.2 The trucks

The manual covers the PS and PSH stackers which are included in the P series of stackers
and low lifters .
1.1.3 Structure of the Manual

This Manual is arranged in accordance with a system consisting of 12 Chapters, where
Chapters 4-12 contain information limited to specific parts of the truck. For example the Mast
(Chapter 6) and Hydraulic System (Chapter 8). Chapters 1 - 3 in this Manual contain more
general information regarding technical data, general service instructions and tools.
The software is described in Chapter 10.
The main principle for extra accessories is to place them in their respective Chapters.
Otherwise they are located in Chapter 12 "Others". For this reason Chapter 12 is not always
included in the Service Manual.
For specific problems or information about procedures, look in the main index for the correct
section in the manual.
1.1.4 Symbol key

WARNING!
Used for risk of personal injury.
CAUTION!
Used with the risk of damage to the machine.
NOTE!
Used for general observation.
1.2 Safety
1.2.1 General
Extreme importance must be placed on precautionary measures to avoid accidents during all
work on the vehicle.
A general rule is to always implement preventive measures that are adapted to the type of
vehicle to be worked on. The general rules below must always be observed:
PS/PSH 1
• Local fire directives should always be followed.

• Smoking or naked flames are strictly forbidden as there is a risk of explosion in the
vicinity of batteries and while working on gas equipped vehicles.
• The battery should always be protected during grinding work.
• The drive wheel must always be lifted up free from the floor during service work to
prevent the vehicle from moving.
• Before working on the electrical system, the battery plug must be pulled out The battery
plug may only be connected while troubleshooting, while taking great care (with the
truck raised).
• It is essential that all cables (especially the battery cables) are connected correctly as
the electronics used in the truck are sensitive to incorrectly polarised supply voltage.
• When working on or close by the electrical system, all metal objects such as watches
and rings should be taken off. A short-circuit from such objects can result in serious burn
injuries.
• To ensure correct operation, all dust and magnetic particles should be regularly cleaned
off solenoid switches and magnets.
• Always pull out the battery plug to prevent pinching injury when working on and around
the truck. The battery plug may only be connected while trouble shooting, while taking
great care (with the truck raised).
WARNING!
Having the power connected to the truck while working on and around the
mast can lead to fatal injury!
• When working on and around lifting devices and the hydraulic unit, they must be locked
by using the mast lock, wooden blocks or some other appropriate means.
• No other persons should be in the vicinity of the truck when it is test run in conjunction
with repair work, in view of the risk of accidents or near-accidents from the truck making
an unexpected manoeuvre.
• Ensure that straps, wires or chains have a sufficient lifting capacity before lifting the
truck.
• When the truck is lifted, for example using a jack, make sure you secure it with blocks.
The truck must not rest on the jack while work is carried out.
2 PS/PSH
• The system should not be pressurised, e.g. the pump motor shut off and the forks down,
when dismantling parts of the hydraulic system.
Figure 1. Emergency release valve in the hydraulic unit.

• If the forks need to be released in an emergency, due to a short-circuit or similar
occurrence. Press the emergency release valve in the hydraulic unit.
• Always use genuine spare parts. This ensures correct and safe operation of the truck
and is a condition for any guarantee claim to succeed. Anyone using non-approved
spare parts must accept, without exception, full responsibility for any resulting damage.
Hydraulic hoses should be kept so that they do not age too quickly.
• Servicing and maintenance may only be carried out by authorised service personnel.
We cannot accept responsibility for servicing or maintenance that is carried out by
non-authorised service personnel.
1.2.2 Truck modification

NOTE!
Unauthorized truck modification is not permitted.
No modifications or alterations to a powered industrial fork lift truck, which may affect, for
example, the capacity, stability or safety requirements of the truck, shall be made without the
prior written approval of the truck manufacturer, its authorized representative, or a successor
thereof. Contact an authorized dealer before making any modification or alteration to your
industrial truck that may affect, for example braking, steering, visibility and the addition of
removable attachments. After obtaining approval from the truck manufacturer, its authorized
representative, or a successor thereof, the capacity plate, decals, labels and operation and
maintenance handbooks shall also be changed appropriately.
Only in the event that the truck manufacturer is no longer in business and there is no
successor in the interest to the business, the user may arrange for a modification or
alteration to a powered industrial truck, provided, however, that the user shall:
• Arrange for the modification or alteration to be designed, tested and implemented by an
engineer(s) expert in industrial trucks and their safety;
• Maintain a permanent record of the design, test(s) and implementation of the
modification or alteration;
PS/PSH 3
• Approve measures and in an equivalent manner make appropriate changes to the

capacity plate(s), decals, labels and Instruction Handbooks.
• Affix a permanent and readily visible label to the truck stating the manner in which the
truck has been modified or altered together with the date of the modification or
alteration, and the name and address of the organization that accomplished the tasks.
1.2.3 Lifting the truck

Inspection and preparation
• When the truck is lifted using a jack, make sure you secure it with blocks. The truck
must not rest on the jack while work is carried out.
• Ensure that straps, wires or chains have a sufficient lifting capacity before lifting the
truck.
• Ensure that the drive wheel runs free of the floor before trouble shooting.
Lifting points
Figure 2. Permitted lifting points

• Permitted fork lift truck lifting points. The lifting points are marked with a decal
representing a lifting hook.
WARNING!
The machine must never be lifted in any other points than the ones shown.
1.2.4 Welding on the truck

• During welding work the battery plug must always be disconnected and all connections
to the control units and controllers (applies to all electronic units) disconnected. On
completion of welding work the connectors must first be connected to the electronic
units, after which the battery plug is then connected to the battery.
• The welding ground connection must always be connected as close to the welding area
as possible to eliminate damage to surrounding components.
4 PS/PSH
1.2.5 Gas spring

WARNING!
During service and preventive maintenance it is important to check that the
steering arm is raised up automatically when the driver releases it. If this does not
happen it should be reported to the truck supervisor, with the recommendation that
the truck be taken out of service until the requisite measures have been
implemented.
WARNING!
Care must be taken when dismantling the gas springs.
1. Make sure that no other persons are in the vicinity, or in the lengthwise
direction of the gas springs.
2. Stand to the side of the gas spring when removing.
3. Never point the gas spring toward any person or part of the body.
1.3 Environmental considerations

1.3.1 We respect the environment
The majority of our products consist of steel, and can be completely recycled.
Environmental impact
All products have an impact on the environment throughout their entire life cycle.
The consumption of energy when in use is one of the most important factors that influences
the environment.
Through correct care, maintenance and use the consumption of energy can be reduced,
thereby reducing the environmental impact.
Waste
Waste material in conjunction with repairs, maintenance, cleaning, or scrapping, must be
collected and disposed of in an environment-friendly way and in accordance with the
directives of respective countries.
Such work should only be carried out in areas intended for this purpose.
Recyclable material should be taken care of by specialised authorities.
Environmentally hazardous waste, such as oil filters, hydraulic oil, batteries and electronic
equipment, can, if handled incorrectly, have a negative effect on the environment and human
health.
1.4 Preparations
1.4.1 Service
• Go through all the safety instructions.
• Make sure that you have all the essential tools close at hand before starting work.
• Before wiring or other electrical components are disconnected, check the colour codes
and check for any damage to the wiring or connections.
• When complex components are repaired and dismantled, make sure that you keep track
of the different component parts to avoid the risk of confusion.
• When repairing or maintaining sensitive components, make sure that you use clean
tools and work on a clean work surface.
• Dismantle, inspect and adjust components according to the prescribed routines. Refer to
the respective Chapters for detailed information.
PS/PSH 5
1.4.2 Trouble shooting

When you suspect that a component is defective, do not replace it immediately. First check
the surrounding equipment and carry out complete trouble shooting routines. Make sure you
know the reason for the fault before replacing a component.
1.5 Data
1.5.1 Designations
1.5.1.1 Truck designation
Truck Type Load capacity
PS 125 Pedestrian stacker 1250 kg
PSH 160 Pedestrian stacker 1600 kg
PSH 200 Pedestrian stacker 2000 kg
Explanation of Model designation

Table 1. Truck designations
Example: PS 125 TV 299
Truck Type PS
Load capacity *10 [kg] 125
Mast type TV
Mast lifting height [cm] 299 = lifting height [cm]
6 PS/PSH
1.5.1.2 Type designation
Figure 3. Example of type plate (–2006w36)

1. Model designation. 3. Year of manufacture, week, and warranty
2. Type Series no./Version (S=Special ver.). period in months (on the assumption that the
service instructions in the warranty
regulations are followed).
4. Where appropriate, load limitations
depending on the position of the load on the
forks (D) and/or lifting height (Q).
PS/PSH 7
Figure 4. Example of type plate (2006w37-)

1. Model designation. 3. Year of manufacture, week, and warranty
2. Type Series no./Version (S=Special ver.). period in months (on the assumption that the
service instructions in the warranty
regulations are followed).
4. Where appropriate, load limitations
depending on the position of the load on the
forks (D) and/or lifting height (Q).
NOTE!
If the machine plate is lost or becomes illegible, it must be replaced as soon as
possible. In order to identify the serial number of the machine there is a label
placed on each principal component, such as the traction motor, gearbox,
hydraulic unit, TMC, etc. On some machines there is also a label glued inside the
battery space or the serial number is punched on the side of the mast.
8 PS/PSH
Figure 5. Example of a serial number label.
1.5.2 Dimensions and weights

1.5.2.1 Dimension designations
Figure 6. Positions for dimension designations PS XXX PSH
PS/PSH 9
1.6 Component specification

Table 2. Component specifications, PS and PSH
Component Specification
Traction motor Drive voltage 24 V
Output standard 1.1 kW
60 min.
Insulation resistance 25 MΩ
Gearbox ZF Gear ratio (standard) 28,0:1
Oil volume 1.5 litre
Hydraulic system Max pressure 150-160 bar
PS 125 Oil volume max 6.0 litre
PSH 160/200 Oil volume max 12.0 litre
Hydraulic unit (motor PS 125 Output 2.2 kW
and pump)
PSH 160/200 Output 3.0 kW
Control system for traction motor Type FZ2009 AC0 CAN
Voltage 24 V
Max. current 150A (RMS) for 2 min
Fuses Control fuse 7.5 A (1 pcs)
PS 125 Pump motor fuse 125 A (1 pcs)
PSH 160/200 Pump motor fuse 160 A (1 pcs)
Drive motor fuse 100 A (1 pcs)
1.7 Recommended consumable materials

1.7.1 Oil and grease types
The table below shows the lubricants which are used in production and are recommended
for servicing. They have been carefully selected and are suitable for, among other things:
• extending the life of the products
• reducing electrical consumption
• having the greatest respect for the environment
If the recommended lubricants cannot be obtained, alternative lubricants must comply with
the stated classifications. Bear in mind that it is important to use the stipulated
environmentally friendly oils for the guarantee to be valid.
Biodegradable-classified oils have a poor conductive ability and therefore require that both
the oil and the filter are well grounded to the chassis.
If secure grounding is not present, this can cause problems, such as static discharge through
the oil. All truck models are earthed. It is important that different products and brands are not
mixed – particularly synthetic and mineral oils.
CAUTION!
Never mix different lubricants, and definitely not synthetic oil with mineral oil!
Product Part no. Class

Hydraulic oil
Standard 008935 ISO VG 32, viscosity index 150 or greater.
10 PS/PSH
Product Part no. Class

Cold store 008936 ISO VG 26, viscosity index 300 or greater, (Liquid
temperature, -40°C or better).
Biodegradable oil 014160 SS 15 54 34.
CAUTION!
The guarantee only applies if the truck is
delivered with this oil from the factory, as
this oil cannot be mixed with other types
of oil.
Oil for the food industry 014161 NSF H1.

CAUTION!
The guarantee only applies if the truck is
delivered with this oil from the factory, as
this oil cannot be mixed with other types
of oil.
Gearbox oil
Drive unit, all models
Standard 116444 Class GL5, 85W-90.
Cold store 116447 Class GL5, 75W-90.
Biodegradable oil
Grease
Standard/Cold stores 014163 Fully synthetic, lithium complex, NLGI grade 1.5.
180 kg viscosity 220. -40 °C to +180 °C.
Standard 001197 -20 °C to +110 °C.
0.4 kg tube
Cold store 014164 -40 °C to 150 °C.
0.4 kg tube
Grease, ball bearings 001207 Grease for bearings.
Protective grease for electrical 124525 Tool for tube, part no. 110782. Electrical grease
contacts. For cold store 30 g tube specification. -50°C to +270°C.
version truck only.
Miscellaneous
Rust protection 014162 No specification.
Chain spray 001196 No specification.
Electronics spray 001198 No specification.
Degreasing compound 112268 No specification.
1.8 Standards and abbreviations

1.8.1 Screws
1.8.1.1 Tightening torques for screws and nuts
Table 3. Tensile grade
DIM 4,6 Nm 8,8 Nm 10,9 Nm 12,9 Nm
M4 1,1 2,9 4,0 4,9
M5 2,2 5,7 8,1 9,7
M6 3,7 9,8 14 17
M8 8,9 24 33 40
PS/PSH 11
DIM 4,6 Nm 8,8 Nm 10,9 Nm 12,9 Nm

M10 17 47 65 79
M12 30 81 114 136
M14 48 128 181 217
M16 74 197 277 333
M18 103 275 386 463
M20 144 385 541 649
The tightening torques in the table are standard values. In some cases a specific tightening
torque is specified in the respective Chapter. If no tightening torque is specified in the service
instructions, the values shown in the table apply.
CAUTION!
The above-mentioned tightening torques do not apply to screws tightened in
plastic. Only tighten hand-tight so as not to damage the truck.
1.8.1.2 Tightening torques for hydraulic couplings

Table 4. Pipe thread/metric threads
DIM Whitworth pipe thread MA (Nm) with pipe MA (Nm) with elastic
olive
M10 x 1 G 1/8" 25 10
M12 x 1.5 30 20
M14 x 1.5 G 1/4" 50 30
M16 x 1.5 G 3/8" 80 35
M18 x 1.5 90 40
M20 x 1.5 G 1/2" 130 50
M22 x 1.5 150 60
M26 x 1.5 250 70
M27 x 1.5 G 3/4" 250 80
M27 x 2 250 90
G 1" 350 140
M33 x 2 400 140
M42 x 2 G 11/4" 600 240
M48 x 2 G 11/2" 800 300
NOTE!
Other bolts and screws are to be tightened to the torques stated in this Chapter.
1.8.1.3 Conversion table for tightening torques

Newton metres (Nm) Kilopond metre (kpm) Pound force inch (lbg Pound force foot (lbf x
x in) ft)
1 0,10 8,85 0,74
9,81 1 86,80 7,23
0,11 0,01 1 0,08
1,36 0,14 12,00 1
12 PS/PSH
1.8.1.4 Conversion table, pressure units

Pa (N/m2) Bar (1mb=1hPa) at (kp/cm2) torr (mm Hg, 0 C) atm
1 10-5 1,020*10-5 7,501*10-3 9,869*10-6
9,807*104 0,9807 1 735,6 0,9678
133,3 1,333*10-3 1,360*10-3 1 1,316*10-3
1,013*105 1,013 1,033 760 1
1.8.1.5 Conversion table, speed

m/s km/h
1 3,6
0,278 1
1.8.2 Standard abbreviations and units

Magnitude Unit Designations
Current Ampere A
Voltage Volt V
Resistance Ohm Ω
Output Watt W
Torque Newton metre Nm
Pressure Pascal Pa
- Kilo (=1000) k
- Mega (=1 000 000) M
1.8.3 Screw types and tensile grades

Screw type Designation Tensile grade
M6S Hexagon screw 8,8
10,9
MC6S Hexagon hole screw 8,8

10,9
12,9
MLC6S Hexagon socket screw, low 8,8
head
MF6S Hexagon hole screw, 10,9
countersunk
MCS Slotted screw 4,6
PS/PSH 13
Screw type Designation Tensile grade

MVBF Oval head countersunk screw 4,6
K6SF Oval head socket screw 10,9
Markings with the manufacturer’s trademark, including the tensile grade, is compulsory for
screws with a thread diameter from 5 mm and in tensile grades according to the table above.
Marking only takes place when the shape of the product permits this.
NOTE!
Other screw heads and types exist, but they have no general tightening torques
based on the tensile grade.
1.8.4 Machine colour codes

Machine colour Part Number
Yellow, spray 001816
Yellow, 1 litre 001815
Dark grey, spray 001550
Dark grey, 1 litre 001553
Silver, spray 001389
Light grey, spray 150788
1.8.5 Colour coding according to NCS

Machine colour Designations
Yellow NCS 0070-Y20R
Medium grey NCS 7000
Dark grey NCS 8000
Light grey NCS 5000
1.8.6 Colour codes for wiring diagrams

Code Cable colour
BL Blue
BN Brown
14 PS/PSH
Code Cable colour

GN Green
GR Grey
OR Orange
P Pink
R Red
SB Black
VO Violet
W White
Y Yellow
NOTE!
Two-colour cables are shown with both colour codes separated by a slash.
Example: Blue/yellow cable is defined by colour code BL/Y.
1.8.7 Designations for electrical components

Electrical components normally have a designation of two letters:
Table 5. First letter

Code Designation Designation (Eng)
A Component or function without Component or function without
its own letter in the list its own letter below
C Capacitor Capacitor
D/V Diode Diode
E Electrical component Electrical component
F Fuse Fuse
I Indicator Indicator
K Contactor/relay Contactor/relay
L Coil/inductive element Coil/inductive element
M Motor Motor
P/X Connection Connection
R Resistor Resistor
S Switch/Change-over switch Switch/Change-over switch
T Terminal Terminal
Y Valve/brake Valve/brake
H Audible warning unit/lamps/lights Audible warning unit/lamps/lights
G Battery Battery
Table 6. Second letter

B Brake Brake
C Control system Control system
E Emergency function Emergency function
F Forward Forward
H Hour Hour
PS/PSH 15

K Key Key
L Lower Lower
M Manoeuvre Manoeuvre
P Pump Pump
R Reverse Reverse
S Speed Speed
16 PS/PSH
02 Special tools
02 SPECIAL TOOLS
2.1 List of tools
Table 7. List of tools
Tools Part number P/N Application
Communications cable, truck 108005 Data transfer cable between
computer (ATC) truck and PC
ESD wristband 158066
Lifting eye 104737 Lifting eye for drive unit
Insulation test instrument 111111
Crimping tool (Molex) 006454 Cable connections
Pin extractor (Molex minifit) 006456 Cable connectors
Cleaning fluid 112268 Cleaning of electric motors from
gearbox oil and other dirt
Chain spray 001196 Lubrication of chains
For detailed information on the above products, please contact the truck manufacturer's
spare parts department.
All special tools can be ordered from the truck manufacturer's spare parts department.
PS/PSH 17
03 Service
03 SERVICE
3.1 Routine periodic maintenance
3.1.1 Introduction
Preventive maintenance should be carried out regularly when the truck is used in normal
conditions. The planned service includes operations such as test driving, function tests, and
the changing of filters and oils etc. Service is planned at different intervals depending on the
running time of the truck. If the truck is working in extreme conditions or in demanding
environments, servicing must be planned at tighter intervals.
3.1.2 Safety
NOTE!
Check under each separate section which safety instructions are applicable for
work on the truck.
Inspection of the external functions in the power steering system should be carried out after
every service and after work carried out in the electrical system. All functional tests of the
safety system must be carried out with the truck speed controller in its neutral position, see
Section 10, page 107.
3.1.3 Recommendation
Information on what the truck owner should take into consideration.
Regular inspection should be carried out by specially appointed and trained personnel with a
good working knowledge of the function and maintenance of the truck. To obtain the best
results from your truck investment, we advise you to contact your local truck representative
and to sign up for a service contract for regular inspection.
3.1.4 Daily inspection

For instructions, refer to the Operator´s Manual
3.1.5 Weekly inspection (30 hours of operation)

For instructions, refer to the Operator´s Manual
3.1.6 First service (200 hours)

The first service must be carried out after 200 hours. This service has the purpose of
ensuring the function of the truck and its component parts.
• Change the oil in the gearbox.
• Change the hydraulic oil filter.
• Test the function of the entire machine in accordance with Section 3.1.7, page 18
3.1.7 Main service

EN-1726 and ISO 3691 specify that regular preventive maintenance should be carried out on
the truck. To guarantee high quality, operational reliability and personal safety, this
maintenance should be carried out by specially trained personnel. To comply with this
requirement, we have prepared the following main service points (A service), which must be
checked every 500 hours of operation, on condition that the truck is being used in normal
conditions.
• Check for external damage on chassis.
• Check of weld joints at vital points.
• Check of lifting devices.
18 PS/PSH
03 Service
• Check of component attachments.

• Functional test, lever, lever bolts, 195 Nm.
• Check of the horn.
• Test drive backwards and forwards, and turning.
• Check of the drive unit.
• Check of all the wheels.
• Test of the brake function.
• Change the oils and filter in accordance with instructions.
• Check for oil leakage.
• Check of the hydraulic unit, pipes and hoses.
• Check of the cylinders.
• Function test, lifting and lowering
• Lubrication in accordance with lubrication chart.
• Measurement and check of the battery and charging function.
3.1.8 Extra service inspections

What has been mentioned above is applicable on the assumption that the machine is
working in normal conditions on single shifts. In dirty or dusty environments, poor floor
conditions, or where there are large variations in temperatures, the service intervals must be
arranged more frequently.
None of the inspections mentioned above can be charged to the truck manufacturer.
3.1.9 Check list, service inspection

For further information about procedures for inspections, repairs and replacements refer to
respective sections. Planned service inspections are implemented in accordance with the
following points:
Table 8. Chassis
Chassis
Inspection points Symptom Inspection A Service Service code
Signs/Decals None, illegible Visual X 1024, 1101
Panels Attachment, Visual, tools X 1102, 1032
damage
Load wheel, Castor Damage, wear Visual X 1108, 1109
wheel
Noise Listen, tool X
Attachment Visual, tools X
Rubber mats, Damage Visual X 1105, 1058
Rubber protectors
Chassis, general Appearance Visual X 1001, 1033, 1112
Damage Visual X
Loose screws Tools X
Table 9. Mast
Mast
Push rods Locking. Tools X 2105
Damage Visual X
PS/PSH 19
03 Service
Mast
Forks Cracks, damage Visual X 2026
Wear Visual X
Angle, deformation Visual, tools X
Fork carriage* Cracks, damage Visual X 2007, 2004
Play, damage, Visual, operating X
wear on rollers test
Angle, deformation Visual X
Attachment rollers Visual, tools X
Mast profiles* Cracks, damage Visual X 2101
Wear, cracks Visual X
Table 10. Drive unit

Drive unit
Gearbox Oil level Visual, filling X 3006, 3101, 3107
Oil leakage Visual, tools X
Traction motor Function, noise Listen, tool X 7028, 7113, 7039,
7027, 7112
Cable connections Visual, tools X
Drive wheel Noise Listen, tool X 3002, 3005
Damage, wear Visual X
Attachment, play Visual, tools X
Sliding bearing Noise Listen, lubricate X 3103
Drive shaft Noise Listen, tool X 3104
Gear Noise Listen, tool X 3102, 3106
Table 11. Steering

Steering
Steering Bearing Noise Listen, lubricate X 4101
Tiller arm Play Visual X 4103
attachment
Attachments Tools X
Table 12. Brake Assembly

Brake Assembly
Braking force Malfunction Function test, tools X 5012
Parking brake Malfunction Function test, tools X 5014
Brake cable Abrasion Visual X 5002
Brake disc Wear Visual, tools X 5104
20 PS/PSH
03 Service
Table 13. Hydraulic system

Hydraulic system
Hydraulic fluid tank Oil level Visual, filling X 6012, 6102
Damage, leakage, Visual, cleaning X
contamination
Filter blocked Visual, replace X
Cylinders Functionality Function test, stop X 6001, 6017
watch
Damage Visual, replace X
Leakage Visual, tools, X
replace
Weld damage Visual, tools, X
replace
Damage, chain Visual, tools X
attachments
Hoses Leakage, damage Visual, tools X 6007, 6008
Nipples Leakage Visual, tools X 6019
Pump motor Function, noise Visual, tools X 7030, 7029
Cable connections Visual, tools X
Hydraulic pump Leakage Visual, tools X 6109
Damage Visual, tools X
Noise Listen X
Overflow valve Malfunction Test X 6105
Leakage Visual, tools X
Solenoid valve Malfunction Test X 6018
Prop. valve Malfunction Test X 6018
For more information regarding the hydraulic system, see also Section 08, page 70 and
Section 09, page 94.
Table 14. Electrical system

Electrical system
Contactors Malfunction Visual, tools, X 7107
replace
Cable break Visual, tools X
Contactor tip Visual, tools X
Battery Charging Tools X 7032
Low acid level Tools X
Low acid weight Tools X
Damage Visual X
PS/PSH 21
03 Service
Electrical system
Transistor system Cable break Visual, tools X 7025
AC.
Cabling Damage, break Visual, tools X 7007, 7009 7010,
7039 7104, 7112
Horn Malfunction Function test X 7014
Speed Controller Attachments Visual, tools X 7011, 7106
Malfunction Function test X
Calibration X
Fuses Blown Visual, replace X 7103
Battery plug Malfunction Function test, tools X 7008
Hour meter Malfunction X 7012
Battery indicator Malfunction X 7013
Safety circuit Emergency stop Malfunction X 7020
breaker.
Microswitch Functionality Function test X 7017
ATC T4 Function, cable Visual X 7004
connections
3.1.10 Code explanation

Table 15. Chassis
Chassis
Code Description Check Reference
1001 Machine housing Cracks in weld joints, collision damage, Section 01, page 1
tightening of screws/attachments.
1024 Machine plate Attachment: text must correspond with Section 01, page 1
machine type, and symbols and warning
decals must be present.
1032 Panels Attached with screws and clips, as well as Section 04, page 31
bonded parts.
1033 Colour Paint scrapes and attachment/missing decals. Section 01, page 1
1042 Load Guard Cracks in welded joints, collision damage, Section 01, page 1
tightening of screws/attachments.
1058 Rubber strips Attached with glue or screws/weld bolts. -
1101 Decals Damage. -
1102 Chassis, covers Damage, battery cover Section 04, page 31
1108 Load wheel bearing The operation is frictionless, remove any Section 04, page 31
string, plastic bands etc. that have stuck.
1109 Castor wheel Section 06, page 44
Vulkollan wheel wear. Dirt.
bearing
1112 Accessories User Manual, areometer and battery water -
bottle.
22 PS/PSH
03 Service
Table 16. Mast

Mast
2004 Frame section Mast attachment to machine housing. Section 01, page 1
2007 Rollers in fork Washers. Lubrication of roller surfaces. Section 01, page 1
carriage
Section 06, page 44
2026 Forks Cracks, damage, parallelism , height above Section 06, page 44
floor level.
2101 Mast play Check maximum play, Cams. Lubricate slide Section 06, page 44
surfaces.
2102 Lift chains Check wear. Section 04, page 31
2105 Push rods / Pull Locking, damage. Section 06, page 44
rods
Table 17. Drive unit

Drive unit
3002 Drive wheel Damage, wear. Clean. Section 05, page 36
3005 Drive wheel bolt Attachment. Section 05, page 36
3006 Oil leakage Leakage from shafts, joints, plugs or material. Section 05, page 36
3101 Oil level Oil level. Oil change. Section 01, page 1
Section 05, page 36
3102 Noise Gears. Section 05, page 36
3103 Sliding bearing Noise, lubrication needed. Section 05, page 36
3104 Drive shaft Tightening,play. Section 05, page 36
3106 Gears Gear ratio Section 05, page 36
3107 Gear housing Check wear. Section 05, page 36
Table 18. Steering

Steering
4103 Tiller arm Play, bushings, attachment Section 07, page 63
attachment
4104 Steering Bearing Play, lubrication Section 01, page 1
Section 07, page 63
Table 19. Brake unit

Brake unit
5002 Brake cable Attachment, damage. Section 11, page 230
5012 Braking force Braking distance Section 11, page 230
5014 Parking brake Function, cable connections. Section 11, page 230
5104 Brake discs Friction surface greater than minimum level all Section 11, page 230
round.
PS/PSH 23
03 Service
Table 20. Hydraulic system

Hydraulic system
6001 Lift cylinders Leakage at attachments, welded joints, wiper Section 09, page 94
seals, piston rod.
6007 Couplings Leakage. -
6008 Hoses Cracks, wear, damage. Section 01, page 1
6012 Oil level in tank Oil level between min. and max. Section 01, page 1
Section 08, page 70
6017 Lowering Check lowering speed. Section 08, page 70
6018 Solenoid Leakage at the slide. Connections. Tightening. -
6019 Nipples Leakage. Tightening. -
6102 Filter Replacement necessary. Section 08, page 70
6105 Pressure relief Function, setting to maximum lift capacity. Section 08, page 70
valve Locking.
6109 Hydraulic pump Leakage between pump and motor. -
Table 21. Electrical system

Electrical system
7004 Truck computer Error log. Section 10, page 107
7007 Battery cables Attachment, damage. -
7008 Battery connections That cable connections are not overheating.
Remove oxide.
7009 Main power cable Attachment, damage. -
7010 Control cable Attachment, damage. -
7011 Speed Controller Function. -
7014 Horn Operation. Oxide deposits.
7017 Microswitch Operation. Attachment.
7020 Emergency switch Function. -
7025 Transistor system Dirt, moisture. Cable connections. Oxidation.
7029 Pump motor carbon Wear. Section 08, page 70
brushes
7030 Pump motor Attachment. Cleaning. Section 05, page 36
7032 Battery Acid level, charging. Note: read-off from
hydrometer, clean if necessary.
7035 Speed switch Switches in gates and platform that control Section 10, page 107
creep speed. Attachment.
7103 Fuses That they are not brittle, oxidised. Section 01, page 1
7104 Cabling Cable connections, attachment, run free from
sharp edges. Insulation.
7106 Speed Controller Attachment and function. Section 11, page 230
7107 Contactors Contact surfaces, cable connections, dust -
guard.
7112 Traction motor Attachment, damage. Insulation. Oxidation.
7039 cables Cleaning.
24 PS/PSH
03 Service
Electrical system
7113 Storage of traction Noise, grease, play. Section 05, page 36
motor
7004 Truck computer Error log. Section 10, page 107
3.1.11 Lubrication chart

3.1.11.1 General
NOTE!
For recommended oil and grease types, see Section 1.7, page 10.
PS/PSH 25
03 Service
3.1.11.2 PS
Figure 7. Lubrication chart.
26 PS/PSH
03 Service
3.1.11.3 PSH
1. 500 hour service 2. Annual service

Servicing consists partly of servicing that is required due to how heavily the truck is loaded
an how often it is used (see Section 3.1.9, page 19), and partly of annual routine servicing.
3.1.11.4 Components requiring lubrication

Location Explanation Location Explanation
A1 Mast profile roller surfaces and G Castor wheel - sliding bearing,
slide surfaces grease nipple
A2 Thrust rollers H Speed and brake controls - slide
surfaces and springs
B Lift chains I Steering arm - gas spring
C Straddle legs J Steering arm housing
PS/PSH 27
03 Service
Location Explanation Location Explanation

D Fork carriage K Hydralic tank
E Bogie wheel L Guide ring
F Battery rollers M Gearbox
3.1.11.5 Symbol key, lubrication chart

Table 22. Symbols in the lubrication chart
Symbol Explanation Symbol Explanation
Hydraulic oil Hydraulic oil, oil filter and air
filter, change
Gearbox oil Gearbox oil, change
Grease Chain spray
Chain spray/oil Only cold store version
Applicable in general for the symbols:

• Unfilled symbol: Check/lubricate
• Filled symbol: Replacement
3.2 Specific instructions

3.2.1 Storage of machines and motors
Machines in storage that will not to be used within one month, must be given special
attention so that problems do not occur when they are to be used again. Dust, dirt,
condensation and moisture caused by large changes in temperature and problems with rust
and oxidisation must be prevented. Motors should therefore be protected with waxed paper
or the like, and a moisture absorbing material.
3.2.2 Traction motor

Preventive maintenance
Preventive maintenance is implemented at the recommended intervals in accordance with
the service chart.
In some cases, however, exceptions must be made and the intervals shortened in relation to
the conditions at the customer, e.g. a severe environment with dust, high humidity levels, or
salt, etc.
• Listen for abnormal noise from the bearings while the motor is running. Check that it
does not vibrate abnormally.
• The motor is blown clean with dry compressed air, or cleaned with a vacuum cleaner. If
oil has leaked from the gearbox into the motor, a special cleaning fluid must be used to
drive out oil and dirt, see Section 02, page 17. Finally, blow dry with compressed air.
• Check the insulation resistance of the motor, see Section 1.6, page 10 for the correct
value.
3.2.3 Gearbox
First service
After about 25 hours of operation:
28 PS/PSH
03 Service
• Tighten the wheel nuts.

• Inspect for possible damage, leaks and the oil levels.
• Tighten the securing bolts between the motor and gearbox.
After about 200 hours of operation:
• The first oil change must be made after 200 hours.
• Top up with the recommended type of oil, see Section 1.7, page 10.
After approx. 1500 hours of operation, or at least once a year (whichever comes first):
• Oil change
• Inspect for possible damage, leaks and the oil levels.
Preventive maintenance
• The oil level is checked during each service.
• The guide bearing must be greased at least once a year. New greasing is essential if
steam cleaning or high-pressure washing has been carried out.
• In the case of operation in a dusty or damp environment, (such as a cold store), the
steering bearings must be re-greased twice per month.
NOTE!
Remember to fill up the gearbox after changing the oil or changing the gearbox.
Se Section 05, page 36 for the procedure.
NOTE!
Spent oil should be taken care of and recycled according to the applicable
legislation in respective countries.
3.2.4 Lift chains and forks

Check
For safety reasons the forks and all lifting chains should be checked during each service.
Section 3.1.9, page 19.
If a lifting chain fails to be approved in any respect, the complete chain must be replaced and
it is not permitted to replace single parts of a lifting chain.
NOTE!
If the lifting chain is not up to standard at any point, the complete chain must be
replaced. See Section 6.2.3, page 54 for instructions concerning the checking of
chains and forks.
Regular maintenance
The chain should be kept clean.
Lubricant (see Section 3.1.9, page 19) must be regularly applied on the chain so that all
the working surfaces are constantly lubricated.
The chains must be kept in motion when lubricating to ensure that the lubricant penetrates
the working surfaces between the link plates and pins. All excess lubricant must be wiped
off, but solvent must not be used.
If the chain runs dry it should be lubricated more often, and this also applies if the truck is
working in special environments such as cold stores, etc.
PS/PSH 29
03 Service
3.2.5 Hydraulic oil

NOTE!
Intervals
After 500 hours of operation: The hydraulic oil tank air filter must be changed after no
more than 500 hours of operation. Clean the suction filter.
After every 1000 hours of operation: Change the hydraulic oil after 1,000 hours of
operation, or once every year (whichever comes first).
If the hydraulic oil has been heated over 60 degrees Celsius the oil and the filter should be
immediately changed since its lubricating properties will have been altered.
If the hydraulic oil has been contaminated with water (e.g. from cold store) this can be
detected in that the oil becomes milky, or smells bad.
Hydraulic oil must be filtered when filling.
3.2.6 Recommended replacement

Hydraulic hoses should be replaced after 5 years, since the rubber in the hose is perishable.
30 PS/PSH
04 Chassis
04 CHASSIS
4.1 Design and function
4.1.1 Scope
A chassis normally includes the supporting parts of a construction and in the case of a truck
the chassis consists of the machine housing, panels and caster wheel.
The straddle lift and load wheel could be considered to be part of the chassis, but since they
are part of the mast the instructions for these are to be found in Section 06, page 44.
4.1.2 Machine housing

The chassis consists of a machine housing. This is where all the truck components, such as
the mast, drive unit, and hydraulic system are mounted.
Figure 8. PS chassis
4.1.3 Covers and panels

The function of the panels is to protect the driver from moving parts, electrical components,
oils and fluids, and to protect the components inside from external damage and dirtying.
4.1.4 Caster wheel

The castor wheel functions as a support wheel, since the drive wheel is mounted
asymmetrically on one side of the truck.
The caster wheel is a completely separate and free-turning wheel placed under the machine
housing. It consists of a wheel mounted in a wheel fork. The caster wheel is sprung to
maintain good contact with the floor surface and to reduce noise.
Shims are mounted between the castor wheel attachment plate and the machine housing to
compensate for differences in the diameter of the drive wheel and castor wheel.
PS/PSH 31
04 Chassis
4.2 Repair and maintenance instructions

4.2.1 Covers and panels
4.2.1.1 General
The recyclable panels are manufactured of sheet metal and durable plastic.
4.2.1.2 Dismantling of panels

• Remove the panels with an Allen key, size 5.
• Clean the panels using a soapy water solution.
• White impact marks may appear with minor damage. These can be removed by
carefully heating with a hot air gun.
32 PS/PSH
04 Chassis
4.2.2 Caster wheel

4.2.2.1 Removing the caster wheel/bearing
Figure 9. Caster wheel

1) Remove the plastic cover from the machine housing.
2) Lift up the machine housing approx. 30 cm, and secure with blocks underneath.
3) Remove the bolts, item 1, Figure 9, page 33.
4) Take out the caster wheel assembly and support the fork in a vice.
5) Remove the bolt, (item 2), and drive out the wheel axle, (item 3), so that the wheel can
be removed from the fork.
NOTE!
Re-use the spacers and shims.
6) Support the wheel in the vice.

7) Pull out the bearings with a bearing extractor.
4.2.2.2 Fitting the caster wheel/bearing

1) Lubricate the wheel bearing seats with grease, and press in the bearings with a suitable
drift.
2) Lay the wheel fork with the side facing down.
3) Hold the wheel and spacers together, and insert the wheel in the fork.
4) Fit the wheel axle (item 3).
5) Fit the bolts (item 2).
PS/PSH 33
04 Chassis
6) Lift up the complete castor wheel under the machine housing. Fit the screws (item 1).
NOTE!
Check the positioning to make sure the grease cup comes in the right
direction.
7) Tighten to the correct torque.

8) Refit the covers and lower down the machine to the floor.
4.2.3 Battery
4.2.3.1 Battery replacement
PS
Work in an area where the old battery can be removed without risk to the environment from
battery acid. Wear acidproof gloves and clothes, plus acidproof glasses, to provide
protection from burn injuries.
WARNING!
Take care not to splash waste acid or oxide from the battery.
1) Separate the battery plug.
2) Open the battery cover.

3) Attach the lifting device in the lifting eyes.
4) Lift the battery and set it to one side.
4.2.3.2 Battery replacement

PSH
NOTE!
A battery carriage must be used when changing battery.
WARNING!
Take care not to splash waste acid or oxide from the battery.
1) Remove the battery plug

2) Open the battery cover.
34 PS/PSH
04 Chassis
3) Open the battery door using the battery key.

4) Roll out the battery on the battery carriage.
4.2.3.3 Replacing the battery rollers

1) Remove the battery.
WARNING!
Take care not to splash waste acid or oxide from the battery
2) The battery rollers are loose in their attachments.
PS/PSH 35
05 Drive unit
05 DRIVE UNIT
5.1.1 Introduction
The drive unit is mounted in an assembly containing the brakes, drive motor, gearbox and
drive wheel. The steering servo motor is mounted on the same motor bed. For technical data
regarding the component parts, see Section 01, page 1.
1. Wheel nuts 6. Traction motor

2. Wheel axle 7. Upper oil plug
3. Gearbox housing 8. Lower oil plug
4. Drive wheel 9. Grease nipple for centre bearing
5. Centre bearing

The dive motor is a three phase asynchronous motor. A pulse transducer is enclosed in the
bearing on the non-driving end of the motor and this provides speed feedback to the traction
controller, see Section 10, page 107.
The motor is mounted directly on the gearbox and the transmission of power takes place via
individually adjusted gear wheels.
5.1.3 Gearbox
The gearbox is designed to produce the best gear ratio over the speed range of the traction
motor.
36 PS/PSH
05 Drive unit
5.2 Maintenance and repair instructions

5.2.1 Introduction
NOTE!
Only relevant for Sauer-Danfoss/ZF
traction units.
For field service it is important to know that the

turning bearing (item C) and the gearbox (item D)
will fall down when all motor screws (item X) are
removed from the motor housing (item A).
The cover (B) stays with the axle body, or rather
with the machine housing since it is separately
attached.
When servicing the traction unit the gearbox must
be secured to make sure that it cannot fall down
and cause personal injury.
5.2.2 Preparatory work

1) Switch off all electrical power.
2) Remove the panels on the machine housing, see Section 4.2.1.2, page 32.

5.2.3.1 General
The traction motor is mounted on the top of the inner ring in the guide bearing, with a total of
eight screws.
During all maintenance work on the bearing block it is important to observe care during
assembly and dismantling to avoid damaging the bearing and shaft seal. Special attention
should also be paid to the gear wheel, since damage to this can result in abnormal noise.
5.2.3.2 Motor screws

Since the motor screws (item X) are secured with Loctite the recommended tool to loosen
the screws is an Allen key with guide point in accordance with DIN 6911.
Torque
The motor bolts (item X) must be tightened to a torque of 10.9 Nm.
PS/PSH 37
05 Drive unit
Figure 10. Motor screws (M8x35mm/DIN 6912).
5.2.3.3 Assembly of the transducer bearing

When fitting the transducer bearing (item 1) in the upper housing on the motor it is very
important that it is pressed into place. The transducer bearing must not be exposed to any
form of shock loads. It is also important that the pressure is applied directly on the outer
bearing ring. No pressure must be applied on the inner bearing ring.
Figure 11. Transducer bearing in the traction motor.
CAUTION!
The transducer bearing must not be exposed to any form of shock loads.
Once the transducer bearing is in position in the upper housing it is secured with its lock ring
and the extra protective ring, and with the screws and underlying lock rings.
After fitting the transducer bearing the rotor shaft is pressed into the inner bearing ring. It is
important not to expose the outer bearing ring to pressure, and this is achieved in that the
inner bearing ring receives counter pressure during the pressing.
38 PS/PSH
05 Drive unit
The assembly of the rotor shaft is complete when the unit is fixed by the circlip in its groove.
5.2.3.4 Assembly of ball bearing and shaft seal in the guide bearing inner ring/gear
box upper housing
The ball bearing (item 2) is pressed into place in the inner ring on the guide bearing. The
pressure must be applied on the outer bearing ring to avoid damaging the balls and ball
races. The bearing is secured by fitting a circlip (item 3) in its groove. The shaft seal can now
be fitted.
Figure 12. Ball bearing and circlip

When assembling the complete motor on the gearbox the inner ring on the guide bearing
and the inner surface shaft seal should be protected with grease to avoid damage, especially
on the sealing surface.
5.2.3.5 Storage of traction motor

Machines in storage that will not to be used within one month must be given special attention
so that problems do not occur when they are to be used again. Dust, dirt, condensation and
moisture caused by large changes in temperature and problems with rust and oxidisation
must be prevented. Motors should therefore be protected by waxed paper or the like,
together with a moisture absorbing material.
5.2.3.6 External Speed Sensor Assembly

The external sensor is mounted on the outside of the traction motor which makes it easy to
maintain and repair.
PS/PSH 39
05 Drive unit
Figure 13. External speed sensor

The traction motor control unit uses the feedback information about the actual speed and
direction of motor rotation.
The sensor is a two-channel Hall effect tacho sensor with two phases 90 degrees apart.
The sensor detects the movement of ferromagnetic structures, such as gears, by sensing
changes in the magnetic flux.
Wheel teeth and gaps which move past the sensor affect the magnetic field in different ways.
The output signal from the sensor is a square wave which reflects the changes in magnetic
flux.
5.2.4 Gearbox
5.2.4.1 General
Service work on the gearbox is limited to changing the wheel studs on the wheel and
changing the lower shaft seal.
5.2.4.2 Changing the wheel studs

Torque
After removing the wheel stud that is to be changed the threads on the new wheel
stud and the threads in the hole should be cleaned from oil and grease. The
threads should be treated with Loctite 270 or the equivalent before the new wheel
stud is screwed in. The stud must be tightened to a torque of 25 Nm.
40 PS/PSH
05 Drive unit
5.2.4.3 Service and fitting of the lower shaft seal on the gearbox
The shaft seal can be removed after removing the protective disc.
The seal seat in the casing and the surface to which the seal is to seal should be cleaned
before fitting a new seal. The seal should also be greased before it is fitted. The protective
disc is replaced after fitting the shaft seal.
5.2.4.4 Applying more grease to the centre bearing in the gearbox upper housing
1) Locate the two grease nipples (item 9) on the side of the gearbox upper housing.
2) Use a hand grease gun to apply grease while rotating the gear.
3) Turn the gear several times to spread the grease evenly.
4) Remove any surplus grease from the centre bearing.
5.2.4.5 Checking the oil level and filling up with oil

Oil is poured in through the upper filler screw hole (item 7). The correct level is at the lower
edge of the hole.
The oil level should be regularly checked to avoid damaging the gearbox.
Torque
Tighten the oil plug to a tightening torque of 22 Nm.
5.2.4.6 Oil change

The oil is drained out through the lower oil plug hole (item 8). The oil can be drained more
easily if it is warm.
Spent oil should be taken care of and recycled according to the applicable legislation in
respective countries.
Torque
Before screwing in the oil plug again it should be cleaned. Tighten the plug to a
tightening torque of 22 Nm.
5.2.5 Drive wheel

5.2.5.1 Replacing the drive wheel
1) Lift up the truck so that the drive wheel can rotate freely.
2) Release the battery plug.
3) Turn the drive wheel 45°.
PS/PSH 41
05 Drive unit
4) Loosen the wheel nuts.

5) Replace the drive wheel.
6) Tighten the wheel nuts.
Torque
Use a tightening torque of 80 Nm.
7) Start the truck and test drive in both directions. The wheel must not catch or jam.
5.3 Diagnostics and trouble shooting

5.3.1 Troubleshooting chart
Symptom Cause Procedure
The wheel has a flapping sound The tyre has separated due to an 1. Change the wheel.
when driving. impact. 2. Examine the floor for any
irregularities.
The wheel squeaks continuously Bearing is damaged. 1. Replace bearing.
when driving. 2. Inform the driver that string
and plastic etc. should be
removed daily, and the floor
kept clean.
The wheel is flat after long The wheel mass has become Try a different type of wheel.
breaks, but becomes round after warm while driving and deforms
driving for a while. when parked.
The wheel has a deformity that A “blow out” has taken place due Change the wheel.
does not disappear when driving. to overheating and changed the
molecular structure of the wheel
mass.
The truck seems to jerk when Hard foreign object has fastened 1. Remove the object or
driving. in the drive wheel. change the wheel.
2. See also items above.
The truck jumps at regular The wheel is oval. 1. Change the wheel.
intervals, proportional to the 2. Check/adjust the brake.
speed, when driving.
3. See also items above.
The wheel has transverse The wheel has been heated. 1. Adjust to reduce the
cracks, and small bits have fallen Small cracks appear with hard acceleration and reversing
out of the tyre. acceleration and reversing. rate.
2. Change the wheel if
necessary.
The wheel has one or more Locking of the brakes so that the 1. Remove objects on the
small deformations. wheel slides, or loose objects on floor.
the floor that prevent the wheel 2. Tell the driver to brake more
from rotating. smoothly.
Oil on the floor. Leaking seal around the drive • Replace seal
axle.
or:
• If there are cracks in the
casting the gearbox must
be replaced.
Grating noise when accelerating Defective gear wheel in the drive Check the teeth by removing the
or using the reversing brake. unit. cover.
Too little oil in the gearbox. If there are cracks in the casting
the gearbox must be replaced.
42 PS/PSH
05 Drive unit
Symptom Cause Procedure

Grating noise when the truck is Faulty bearing in the traction Dismantle and renovate the
lifted up and the drive wheel can motor. traction motor.
rotate freely and the motor
rotates.
The truck rolls "sluggishly". The brakes are applied. • Replace brake disc.
If this does not help:
• replace the complete brake
unit.
The drive unit has seized. If there are cracks in the casting
the gearbox must be replaced.
Clicking sound when driving. Faulty wheel bearing. Change the wheel.
Clicking sound when driving. Loose wheel. • Tighten the wheel.
If this does not help:
• Change the wheel.
PS/PSH 43
06 Mast system
06 MAST SYSTEM
6.1.1 Mast system
6.1.1.1 General
There are four mast types as standard, depending on the application or roof height etc.
Table 23. Mast types

Designation Description PS PSH
T Telescopic mast – 160
TV Telescopic Free-view 125 160
mast
TFV Telescopic Free-lift 125 160, 200
Free-view mast
DTFV Double Telescopic – 160, 200
Free-lift Free-view mast
A telescopic mast consists of an outer and inner mast, fork carriage and lift cylinder. The fork
carriage is lifted up and down in the inner mast, which in turn moves up and down in the
outer mast. The lift cylinder first lifts the fork carriage approx. 15 cm, and then the mast
system follows the lifting movement.
A mast of the double telescopic type also has, in addition to an inner and outer mast, an
intermediate mast. The lifting movement is the same as for a telescopic mast, and all the
masts begin to move up (or down) simultaneously.
A mast type with free-lift function works in a similar way, but with the difference that the fork
carriage moves to its top position in the inner mast before the next mast section starts to lift.
Free-lift frames can be used to advantage in rooms with low ceilings or low door openings.
A mast of the free-view type implies that the distance between the mast profiles is longer,
which gives better visibility.
PSH 160 is available with adjustable straddle legs.
6.1.2 Fork carriage

Different fork arrangements are mounted on the back of the fork carriage.
Fixed forks
Forks with a fixed width and length.
Figure 14. Fork carriage with fixed forks

Laterally adjustable forks
The forks can be adjusted to different widths.
44 PS/PSH
06 Mast system
Figure 15. Fork carriage with laterally adjustable forks
6.1.3 Straddle lift

Straddle lift means that the straddle legs can be raised sufficiently high to lift a pallet from the
floor. On masts with straddle lifting, pallets can be transported by the fork carriage. And if the
fork carriage is raised high enough, it is possible to transport a pallet directly on the straddle
legs. This enables two pallets to be transported at the same time
Figure 16. Straddle lift
PS/PSH 45
06 Mast system

6.2.1 Replacing the mast/straddle legs
6.2.1.1 Dismantle the mast/straddle legs from the chassis
1) Remove the battery.
2) Block up the chassis.
Figure 17. Blocking up the chassis

3) Support the mast to relieve the attachment
Figure 18. Supporting the mast

If the mast has straddle lift:
Figure 19. Straddle lift
46 PS/PSH
06 Mast system
4) Screw a screw into one of the screw holes on the spacer between the guide and chassis
in order to hold up the spacer when dismantling.
Figure 20. Screw, spacer/guides

5) Remove the screws attaching the mast to the chassis.
Figure 21. Upper screw attachment, mast

6) Detach the hydraulic connections.
CAUTION!
Contain surplus hydraulic oil in a suitable way
PS/PSH 47
06 Mast system
Figure 22. Hydraulic connection
6.2.1.2 Mount the mast/straddle legs on the chassis

1) Make sure that the mast is suitably supported so that it cannot move
Figure 23. Example of supported mast

2) If the mast has straddle lift:
Make sure to screw tight the spacer between the mast and chassis in the guide in one of
the screw holes that are not used.
Figure 24. Screw, spacer/guides
48 PS/PSH
06 Mast system
3) Insert a suitable number of shims. Normally 3.
Figure 25. Shims

4) Lower the mast so that the link arms slide in under the chassis when the mast and
chassis are brought together.
5) Connect the hydraulic couplings together.
6) Bring the mast and chassis together and tighten the screws.
7) Torque
The tightening torque between the mast and the machine housing when
reassembling must be 277 Nm.
If the mast has straddle lift:

8) Remove the screw holding the spacer to the guides.
Figure 26. Remove screw, spacer/guides

9) Check that there is sufficient clearance between the floor and forks, see Section 6.2.6.1,
page 60.
6.2.2 Replacing mast

6.2.2.1 Dismantling and assembling the masts
The following is generally applicable for all types of masts when dismantling:
• Stand in an area with adequate ceiling height and with approved lifting devices.
The following is generally applicable for all types of masts when assembling:
• The mast is assembled in the reverse order to dismantling.
Inspecting or repairing the mast system:
PS/PSH 49
06 Mast system
• Check that the thrust rollers bear against the roller surfaces on the mast. Also check that
they roll easily.
• A function test must be made after each measure/action on the mast system. The mast
must not jam or run slowly (the mast sections move in the wrong order) when lifting and
lowering.
6.2.2.2 Adjustment of the side lean in the top position

1) Lower the mast and slacken the chains.
2) Adjust the attachment of the outer cylinders with the top nut (item 1). Adjust both
cylinders equally so that the mast does not pull skew.
3) If there is sufficient movement in the cylinder attachment, the rollers will be in contact
with the running surfaces of the mast at all lifting heights.
4) Test the operation of the lifting movement. Lift up to top position and check that the mast
does not swing to the side when the end position is reached.
5) Lock the top nut with the locking screw (item 2).
6) Tighten the chain and check that the rollers still make contact with the running surface.
7) The cylinder attachment should be flexible.
8) Adjusting the mast, see Section 6.2.2.3, page 50.
Figure 27. Attachment of outer cylinder
6.2.2.3 Adjusting the play in the mast

The lateral play is adjusted with 0.5 or 1 millimetre shims behind the thrust rollers. If there is
excessive play between thrust roller and roller surface on the mast profile, the thrust roller
must be replaced with a new roller with a larger diameter.
Thrust rollers are available in three different diameters (the diameter is specified on each
roller):
160 mast:
• 78.2 mm, 78.6 mm 79.0 and 79.4 mm.
50 PS/PSH
06 Mast system
200 mast and TF-mast:

• 107.0 mm, 107.5 mm 108.0 mm, and 108.5 mm.
Mast type Permitted play between thrust rollers and roller surfaces between mast
sections and fork carriage and mast
160 0,5 mm
200 0,6 mm
6.2.2.4 Replacing T mast

1) Lower the fork carriage onto a European pallet, or equivalent, so that the intermediate
cylinder lift chain slackens.
2) Release the lift chain from the intermediate cylinder by releasing the chain bolt, and
removing the pin between the bolt and chain.
3) Lift until the fork carriage comes free from the inner mast.
4) Lower the mast to its bottom position.
5) Secure the lift cylinder so that it cannot move sideways.
6) Remove and plug the oil pipes.
7) Release the upper retaining bolts on the lift cylinder from the inner mast.
8) Remove the lower retaining screw.
9) Carefully lift up the inner mast until it can be lifted out from the cylinder.
10) Lift the inner mast straight up until the inner mast's lower support roller and the outer
mast's upper support roller meet. Then pull the inner mast forward to release it from the
outer mast. If the ceiling is too low dismantle the mast, see Section 6.2.1.1, page 46,
and set it down.
Figure 28. Position for dismantling intermediate masts

11) Torque
6.2.2.5 Replacing TV mast

1) Lower the fork carriage onto a European pool pallet, or equivalent, so that the lifting
chains slacken.
2) Release the lift chains from the outer mast by removing the upper pins.
PS/PSH 51
06 Mast system
3) Lift until the fork carriage comes free from the inner mast.
5) Remove the upper retaining screws for the side cylinders.
outer mast.

7) Torque
6.2.2.6 Replacing TFV mast

3) Lift the mast until the fork carriage comes free from the inner mast.
5) Release the hose from the outer mast and plug it. Remember to remove the cable ties.
6) Remove the upper securing screws for the side cylinders.
outer mast.
52 PS/PSH
06 Mast system

8) Torque
6.2.2.7 Replacing DTFV mast

3) Lift the mast until the fork carriage comes free from the inner mast.
4) Place a wooden block on the straddle legs between the outer profiles so that it comes
under the intermediate cylinder. Lower the inner and intermediate mast so that the inner
mast rests on the wooden block and the outer chains slacken.
5) Remove the two outer chains by removing the pins in the upper chain attachment.
6) Release the hoses that run in the mast from the block in the outer mast, and plug them.
7) Remove the pulley wheel for the hoses from the intermediate mast.
8) Remove the pulley wheel for the chains from the intermediate mast.
9) Unscrew the screw for the lifting stop.
PS/PSH 53
06 Mast system
Figure 31. Screw, lifting stop

10) Lift the inner mast straight up until the inner mast's lower support roller and the
intermediate mast's upper support roller meet. Then pull the inner mast forward to
release it from the intermediate mast. If the ceiling is too low dismantle the mast, see
Section 6.2.1.1, page 46, and set it down.

11) Remove the upper retaining screws for the side cylinders.
12) Lift out the intermediate mast in the same way as the inner mast.
13) Torque
6.2.3 Lift chains

6.2.3.1 Replacement
1) Remove any stop screw in the inner mast.
54 PS/PSH
06 Mast system
2) Lower the fork carriage onto a European pool pallet, or equivalent, so that the lifting
chains slacken.
3) Remove the lift chain.
6.2.3.2 Re-fitting the chains

When chains are re-fitted it is important to align them correctly, and that there is no
deterioration of the clearance.
6.2.3.3 Checking the lift chains

For safety reasons, all the lift chains should be checked at maximum intervals of
1000 hours of operation.
If the lifting chain is not up to standard at any point, the complete chain must be replaced. It
is not permitted to change any part of a lift chain.
• Check that the chain is clean. Measure when the forks are unloaded.
• Measure the chain elongation. Measure along the 25 links that go over the pulley wheel,
since elongation is normally greatest here. Compare with the measurements below, If
the chain has stretched by more than 2% it must be replaced.
Figure 33. Chain dimensions

1. Nominal pitch dimension 2. Height of the chain's link plate
Chain Nominal pitch Actual pitch Measured over 25 Maximum stretch

dimensions dimension (mm) dimension (mm) links New chain over 25 links is
(inches) (mm) 2% (mm)
Measurement 1 in Measurement 1 in
figure above figure above
1/2”-2*2 12.70 12.59 314.75 321.05
5/8”-4*4 15.88 15.875 396.88 404.81
3/4”-3*4 19.05 19.05 476.25 485.78
3/4”-4*4 19.05 18.91 472.75 482.21
1”-4*4 25.40 25.32 633.00 645.66
1 1/4”-4*4 31.75 31.54 788.50 804.27
1 1/2”-4*4 38.10 38.06 951.50 970.53
• Measure the height of the chain's link plates, measurement 2 in Figure 33, page 55.
Max. wear is 5%. Measure the original height where the chain is not worn as a
comparison.
Example: A chain has an original plate height of 23.2 mm. Therefore the plate height must
be at least 23.2 - 5% = 23.2 x 0.95 = 22 mm.
PS/PSH 55
06 Mast system
• Make sure than none of the pins in the plates have twisted.
Figure 34. Chain pin

A. Correct pin B. Twisted pin
• Make sure that there are no cracks in the plates.
• Look for traces of mechanical damage or rust.
• Check that the chain runs easily over the pulley wheel and does not jam.
• Lubricate the chain after cleaning and inspection. For the recommended types of oil and
grease, see Section 1.7, page 10.
6.2.4 Forks
6.2.4.1 Adjusting the lowest height on forged forks
1) The inner and outer masts should be lowered.
2) Adjust the two outer lifting chains so that the mast just hangs a little from them.
3) Adjust the middle chain so that the fork head is 5 ± 2 mm from the ground.
6.2.4.2 Adjusting the lowest height on welded forks

1) The inner and outer masts should be lowered.
2) Adjust the two outer lifting chains so that the mast just hangs a little from them.
3) Adjust the lifting chains so that the fork height is as shown in the table.
Fork height in lowered position:
Table 24. Height of forks over floor in rest position

Mast type Min Max (mm)
PS 85 95
PSH 160 controlled by ground clearance 89
PSH 200 controlled by ground clearance 91
6.2.4.3 Inspection of forged forks

6.2.4.3.1 General
CAUTION!
Inspection of the forks must be carefully performed by trained personnel.
56 PS/PSH
06 Mast system
The purpose of the inspection is to detect damage, faults, deformation, etc. Forks showing
this type of damage may not be used before they have been repaired and tested in
accordance with ISO 2330.
Several test points are included in the fork inspection. A fork inspection in accordance with
ISO/ 5057 must be carried out on at least one (1) occasion per year on forks that are in use;
if deformation, damage or other permanent changes are discovered at any other time, an
inspection must be carried out immediately. If the forks are often used for heavy lifting, the
fork inspection interval may be shorter. If the forks fail to meet any of the inspection points,
the machine must be taken out of service. If the customer is not prepared to do this, it should
be written in the report that: "The forks do not comply with the requirements in ISO/ 5057".
When the customer subsequently signs the service order, they bear the responsibility for the
defective forks.
In case of doubt, comply with the requirements set by the applicable ISO standard or by the
fork manufacturer. See table.
The fork blade is bent ISO/5057
Crack formation ISO/5057
Wear ISO/5057
Fork tip Fork manufacturer
Fork angle Fork manufacturer
Difference in height between the tips of the forks ISO/5057
Locking device ISO/5057
Worn fork hook ISO/5057
Fork labelling ISO/5057
6.2.4.3.2 The fork blade is bent
A. Ruler B. Deformation location

The fork blade must not be bent downwards by more than a certain proportion of the length
of the fork.
l= fork blade length in mm.
k= measurement in mm between the fork blade tips and a ruler.
Measurement when a blade must be changed: greater than k=l/33. Example: k=1150/33= 34
mm.
PS/PSH 57
06 Mast system
6.2.4.3.3 Crack formation
A. Attachment hooks B. Heel

Use a non-destructive method to check if there are cracks in the forks. Take extra care when
checking around the insides of the holes and the securing hooks. If cracks are detected, the
forks must not be used.
6.2.4.3.4 Wear
Figure 35. Wear/markings

A. Fork labelling. C. Wear in the fork heel.
B. Location for measuring the shank thickness.
Check the forks for wear, especially around the heel. If 10% of the original thickness of the
fork has been worn away, the fork must not be used.
Example: original thickness (n) = 40 mm -> limit after which the fork must not to used =
36 mm. (n)-10% = fork must be replaced.
Worn forks must not be welded or repaired in any other way.
The original thickness is found by:
• read the markings. The markings must show the lifting capacity in kg for one fork and
the centre of gravity distance in mm. The markings often also show the original
thickness.
• measure the blade thickness at the centre of the shank (position B).
6.2.4.3.5 Fork tip
As soon as a fork tip is worn, it must be shortened or the complete fork changed.
58 PS/PSH
06 Mast system
6.2.4.3.6 Fork angle
Measure 500 mm along the fork blade and 500 mm along the back of the fork and mark
these positions. Measure the diagonal distance between these two points and use the table.
The distance must be within the acceptable values in accordance with Table 25, page 59,
otherwise the forks must not be used.
Table 25. Fork angle

The results Measurement result
Optimal 707 mm
Acceptable 695-713 mm
6.2.4.3.7 Difference in height between the tips of the forks
A. Difference in height between the forks

The difference in height between the fork tips must not exceed 3% of the fork blade length.
Example: fork length 1150 mm - max. height difference 34 mm.
If the difference in height between the fork blades is greater than 3%, the forks must not be
used.
6.2.4.3.8 Locking device
Figure 36. Locking device

The function of the locking device is to prevent the fork from moving sideways by itself.
Check that the originally fitted locking device works as intended. If this is not the case, the
forks must not be used until the fault in the locking device has been rectified.
PS/PSH 59
06 Mast system
6.2.4.3.9 Worn fork hook
Sideways forces and long periods of use can result in bent fork hooks. If this has occurred,
the forks must not be used.
6.2.4.3.1 Fork labelling

0
The fork markings must be clearly legible and include the lifting capacity in kg for one fork,
and the centre of gravity distance in mm. If the markings are illegible, the forks must not be
used. See Figure 35, page 58.
Older forks do not have these markings, but may be used anyway. The prohibition applies to
forks which have markings but are damaged.
6.2.5 Fork carriage

6.2.5.1 Adjusting the fork carriage
1) The thrust rollers have a specific clearance to the roller surfaces.
2) The lateral play is adjusted by adjusting the number of shims behind the load rollers,
and by replacing the rollers.
For the amount of permitted play, see Section 6.2.2.3, page 50.
6.2.5.2 Dismantling the fork carriage

1) Lower down the fork carriage on to a Euro pallet, or equivalent.
2) Remove the lift chain.
3) Lift up the inner mast with truck’s standard hydraulic system until the fork carriage is
released.
CAUTION!
Observe great caution!
4) Reverse the truck away.
6.2.6 Straddle lift

6.2.6.1 Adjusting the straddle lift
1) Place the truck on a level floor and lower the forks and the adjustable straddle lift.
2) Check that the distance between the floor and top of the forks corresponds to Table 26,
page 61. Measure at four points:
• at each fork tip
• at the back of the fork on each side
3) Check that the distance is the same between mast and guides. If necessary, adjust to
the same distance with the adjusting screws, both at the top and bottom.
4) The side play of the mast must not exceed 0-0.5 mm. Because of the tolerance in the
linearity of the mast section a maximum amount of play of 1.5 mm is permitted at the
60 PS/PSH
06 Mast system
“worst point”, raised or lowered. This means that if for example the play is 0.5 mm with
the straddle lift raised, the play with the straddle lift in its lower position should be max
1.5 mm, and the reverse.
5) Check the play between the roller surfaces on the mast and guides. For permitted play
see Section 6.2.2.3, page 50, 160 mast.
6) Check that the forks are horizontal.
7) If the fork tips point upwards, the shims over the pressure plate should be removed (on
the assumption that the forks are straight).
8) If the fork tips point downwards, shims should be added over the pressure plate (on the
assumption that the forks are straight).
Figure 37. Positioning of shims

9) When the forks are parallel, check the height. The cylinders can be extended if it is too
small.
10) Test lift, and check that the straddle lift does not lift skew. If so, adjust the length of the
cylinders until the best lifting movement is obtained.
11) Check measure, and if necessary make further adjustments.
Table 26. Truck with straddle lift

Truck with straddle lift
Distance to top of fork Max 95 mm
Distance to top of straddle leg Max 90 mm
Min 85 mm
6.2.6.2 Dismantling and assembling of straddle lift

1) Lift up the straddle lift with the truck. Place a block under the tips of the straddle lift and
lower down the straddle lift. The load wheel thereby lifts up from the floor.
2) Tap out the retaining pin through the shaft and drive out the shaft holding the wheel fork.
3) Tap out the retaining pin at the pressure link arm and pull out the load wheel, pull rods
and pressure link arm complete.
4) Tap out the shafts from the ends of the pull rods.
5) Check for wear and replace damaged parts if necessary.
6) Install in the reverse order.
7) Check the lifting movement. If the straddle lift pulls at an angle it must be adjusted. See
Section 6.2.6.1, page 60.
PS/PSH 61
06 Mast system

6.3.1 Troubleshooting chart
Table 27. Symptom/Corrective action table
Symptom Possible cause Corrective action
Play in mast. Mast rollers are not shimmed Adjust shimming.
enough.
The mast lowers unevenly, and Mast rollers are too severely Adjust shimming.
jerks. shimmed.
No lubrication on the mast roller Grease the roller surfaces.
surfaces.
The mast squeaks. No lubrication on the mast roller Grease the roller surfaces.
surfaces.
62 PS/PSH
07 Steering
07 STEERING
7.1.1 General
The steering movement is transferred mechanically from the tiller arm directly to the traction
unit.
7.1.2 Steering
The truck is steered by turning the complete tiller arm, which directly affects the angle of the
drive wheel. There is a switch in the arm, which by means of switching off the current and
actuating the brake causes the truck to stop when the arm is in its upper and lower end
positions. It is therefore only possible to drive the truck when the arm is between these end
positions. There is also a belly switch, which stops the truck when pushed in. The purpose of
the belly switch it to prevent the operator being crushed between the truck and other objects.

7.2.1 Cleaning
The tiller arm and tiller arm head are cleaned with compressed air, or by vacuum cleaning.
The covers can be cleaned with lukewarm water and a mild soap solution.
CAUTION!
High-pressure washing must not be used.
7.2.2 Tiller arm head (-2007w27)

7.2.2.1 Replacement
1) Remove the three screws (item 20), that secure the upper cover.
2) Press in the belly safety switch (item 7), and release the cover by carefully pushing it
upwards and outwards.
PS/PSH 63
07 Steering
3) Remove the two screws (item 15).

4) Loosen the requisite connectors to replace the head.
5) Refit in the reverse order.
CAUTION!
Lubricate all moving parts, except for axel through the circuit board. For the
recommended types of oil and grease. refer to Section 1.7, page 10.
7.2.2.2 Gas spring
CAUTION!
implemented.
64 PS/PSH
07 Steering
WARNING!
1. Make sure that no other persons are in the vicinity, or in the lengthwise
direction of the gas springs.
2. Stand to the side of the gas spring when removing.
3. Never point the gas spring toward any person or part of the body.
7.2.3 Tiller arm head (2007w28-)

7.2.3.1 Removal and installation of the tiller arm head
1) Remove the three screws that hold the upper and lower covers together.
2) Release the snap fastener (item A) furthest forward on the tiller head.
3) Carefully lift up the front part of the upper cover (item B). Then move the upper cover
backwards (item C).
4) Lift the upper cover over to the right. The cover can now hang on the main cabling.
CAUTION!
Ensure that the programming cable is not strained.
CAUTION!
Ensure that no cables are trapped when the head is assembled.
PS/PSH 65
07 Steering
7.2.3.2 Removal and installation of the lift/lower buttons

1) Open the tiller arm head in accordance with Section 7.2.3.1, page 65
2) Remove the buttons by releasing the snap fasteners from inside in accordance with the
illustration.
Figure 38. Dismantling of the lift/lower buttons

3) Remove the inner part by pushing it in the direction of the shaft. Then lift the part out
from above.
NOTE!
After dismantling a new button must be fitted, since the snap fastener may have
been damaged.
7.2.3.3 Removal and installation of the speed controls
1. Screw 3. Mechanical spring

2. Wing 4. Bearing
1. Remove the screws (item 1) from speed controller wing (item 2).
2. Remove the wing.
3. Remove the mechanical spring (item 3).
4. Remove the bearing (item 4).
5. Refit in the reverse order.
NOTE!
Grease the springs during assembly.
66 PS/PSH
07 Steering
NOTE!
Apply thread locking fluid, such as Loctite 243, to the accelerator screws during
assembly.
NOTE!
Ensure that accelerator springs are working properly after assembly. To achieve
this, the wing must be installed at the correct angle relative to the bearing.
7.2.3.4 Fitting the main cabling

Securing the tiller arm main cabling
The cabling is secured by cable clips to the tiller arm head. The cabling is secured inside the
truck by cable ties to the motor.
CAUTION!
The cabling must have enough slack so that the arm can be lowered to its lowest
position without straining the cable. It must also be possible to open the upper part
of the tiller head with being restricted by the cabling.
CAUTION!
The cabling must not be so long that the programming cable takes the load when
the upper part is hanging on the cabling.
Cable routing, standard version
Figure 39. Cable routing, standard version
PS/PSH 67
07 Steering
Cable routing, options
Figure 40. Cable routing, options
Table 28. Cable routing, options

Position Descriptions
1 Smart card
2 Heat resistance
3 Tiller Up Drive
68 PS/PSH
07 Steering
7.2.4 Tiller arm (2007w28-)

7.2.4.1 Removing the gas spring
Figure 41. Tiller arm
WARNING!
implemented.
WARNING!
1) Remove the rubber damper (item 10).

2) Move the arm forwards.
3) Release the gas spring by first opening the clip on the bearing holder with a screwdriver.
Then pull the gas spring away from the ball roller screw.
NOTE!
Apply grease to the bearing holder.
PS/PSH 69
08 Hydraulic system
08 HYDRAULIC SYSTEM
8.1.1 General
8.1.1.1 Lift
In the hydraulic system there is a pressure limiting valve which limits the maximum hydraulic
oil pressure. The pressure of the hydraulic oil is built up when the cylinder goes towards its
end position. The relief valve opens if the maximum system pressure is reached and leads
the oil from the pump back to the tank. The opening pressure of the relief valve is set at the
factory, so that the machine will be able to handle the load it is designed for.
WARNING!
The relief valve must only be adjusted by authorised and trained personnel, since
it is a safety part. All work with the hydraulic system must be carried out in a
pressureless state, and in a clean environment.
8.1.1.2 Lower
Between the hydraulic pump and the cylinder there is a restrictor, on certain trucks in the
form of a lowering brake valve, which regulates the lowering speed by restricting the return
flow of hydraulic oil.
8.1.2 Hose rupture valve

Hose rupture valves, the purpose of which is to prevent the forks from dropping down out of
control if, for example, a hydraulic hose ruptures, are fitted in most of the lift cylinders. They
are placed in front of the nipples that are connected for the supply of hydraulic oil.
8.1.3 Electric solenoid valve

8.1.3.1 General
The electric solenoid valve controls the lifting and lowering movements on the truck. The
solenoid valve is actuated electrically by the driver by means of a switch.
8.1.3.2 Lifting function

The pump produces a pressure and flow to the lift cylinder. If the lift cylinder is obstructed, or
has an excessive load, the oil goes back to the tank through the relief valve.
8.1.3.3 Lowering function

opens to release the oil from the lift cylinder. When the fork carriage presses down the lift
cylinder the oil flow goes through the lowering valve, which regulates the lowering speed.
8.1.4 Hydraulic diagram

Table 29. List of hydraulic schematic diagrams
Descriptions Reference
Hydraulic schematic diagram, hydraulic unit PS (–2007w23) Figure 47, page 74
Hydraulic schematic diagram, hydraulic unit PS (2007w24-) Figure 48, page 75
Hydraulic schematic diagram, hydraulic unit PSH (–2008w37) Figure 49, page 76
Hydraulic schematic diagram, hydraulic unit PSH (2008w38–2009w51) Figure 50, page 77
Hydraulic schematic diagram, hydraulic unit PSH (2009w52–) Figure 51, page 78
Hydraulic schematic diagram, hydraulic unit PSH straddle lift (–2008w37) Figure 53, page 80
70 PS/PSH
08 Hydraulic system
Descriptions Reference
Hydraulic schematic diagram, hydraulic unit PSH straddle lift Figure 54, page 81
(2008w38–2009w51)
Hydraulic schematic diagram, hydraulic unit PSH straddle lift (2009w52–) Figure 55, page 82
Table 30. Symbol explanations

Symbol Explanation Symbol Explanation
A1 Hydraulic lift cylinder, e Flow control valve
forks
A2 Hydraulic lift cylinder, Y2 Lowering control valve
straddle lift
M Hydraulic motor Y3 Proportional valve
a Pressure relief valve Y4 Directional valves, A2
b Check valve Y5 Directional valves, A1
d Auxiliary port
Hydraulic unit PS (–2007w23)
Figure 42. Hydraulic unit PS (–2007w23)

Hydraulic unit PS (2007w24–)
Figure 43. Hydraulic unit PS (2007w24–)
PS/PSH 71
08 Hydraulic system
Hydraulic unit PSH (–2008w37)
Figure 44. Hydraulic unit PSH (–2008w37)

Hydraulic unit, PSH (2008w37-)
Figure 45. Hydraulic unit, PSH (2008w37-)
72 PS/PSH
08 Hydraulic system
Hydraulic unit, PSH straddle lift (2008w38–)
Figure 46. Hydraulic unit, PSH straddle lift (2008w38–)
PS/PSH 73
08 Hydraulic system
Hydraulic schematic diagram, hydraulic unit PS (–2007w23)
Figure 47. Hydraulic schematic diagram, hydraulic unit PS (–2007w23)
74 PS/PSH
08 Hydraulic system
Hydraulic schematic diagram, hydraulic unit PS (2007w24-)
Figure 48. Hydraulic schematic diagram, hydraulic unit PS (2007w24-)
PS/PSH 75
08 Hydraulic system
Hydraulic schematic diagram, hydraulic unit PSH (–2008w37)
Figure 49. Hydraulic schematic diagram, hydraulic unit PSH (–2008w37)
76 PS/PSH
08 Hydraulic system
Hydraulic schematic diagram, hydraulic unit PSH (2008w38–2009w51)
Figure 50. Hydraulic schematic diagram, hydraulic unit PSH (2008w38–2009w51)
PS/PSH 77
08 Hydraulic system
Hydraulic schematic diagram, hydraulic unit PSH (2009w52–)
78 PS/PSH
08 Hydraulic system
Hydraulic schematic diagram, hydraulic unit PSH (2010w38–2012w13)
PS/PSH 79
08 Hydraulic system
Hydraulic schematic diagram, hydraulic unit PSH straddle lift (–2008w37)
Figure 53. Hydraulic schematic diagram, hydraulic unit PSH straddle lift (–2008w37)
80 PS/PSH
08 Hydraulic system
Hydraulic schematic diagram, hydraulic unit PSH straddle lift (2008w38–2009w51)
Figure 54. Hydraulic schematic diagram, hydraulic unit PSH straddle lift (2008w38–2009w51)
PS/PSH 81
08 Hydraulic system
Hydraulic schematic diagram, hydraulic unit PSH straddle lift (2009w52–)
Figure 55. Hydraulic schematic diagram, hydraulic unit PSH straddle lift (2009w52–)
82 PS/PSH
08 Hydraulic system
Hydraulic schematic diagram, hydraulic unit PSH-H straddle lift (2012w14–
Figure 56. Hydraulic schematic diagram, hydraulic unit PSH-H straddle lift (2012w14–
PS/PSH 83
08 Hydraulic system
Hydraulic schematic diagram, hydraulic unit PSH (2012w14–)
Figure 57. Hydraulic schematic diagram, hydraulic unit PSH (2012w14–)
84 PS/PSH
08 Hydraulic system

8.2.1 Hydraulic system
General rules
NOTE!
Cleanliness during all work with hydraulic components is of the greatest
importance for the operating safety and service-life of the system. The following
should be taken into consideration:
• Dirt particles must not get into components.
• Do not use cloths that release fibres or particles.
• Only use clean tools.
• Carefully clean tanks, pipes and hoses before installation.
• Welded or hot-bent pipes must be pickled (cleaned in an acid bath) and
washed before they are built in.
• The oil tank must be closed and provided with an efficient air filter to prevent
dirt contaminating the hydraulic oil.
• Sealing compounds such as flax, cement or thread tape are not permitted.
• Take into consideration the specified operating data.
• Do not exceed the permitted pressures and volume flows.
• Do not exceed or go below the specified temperature range.
• Pay attention to specified electrical voltages and power consumption.
NOTE!
All work with the hydraulic system should be carried in a pressureless state and in
a clean environment.
Installation
To prevent dirt and corrosion in the hydraulic system all hydraulic components must be
provided with plastic plugs blocking the connections before they are delivered. Only remove
these plugs just before the component is to be installed in the machine. Retaining screws
and connections must correspond with those on the drawing. Retaining screws should not be
tightened with a higher torque than what is specified on the drawing. If such information is
missing, the torque should not exceed that specified in Section 1.8.1.1, page 11.
Connections
Couplings must be fitted in accordance with the tightening torques specified in the table at
Section 1.8.1.2, page 12. We recommend couplings with elastic seals.
Connect pipes and hoses in accordance with the hydraulic diagram. Pay attention to the
connection designations. Do not use force, and avoid building-in tensions in pipes, etc,
Start up
Check that everything is connected in accordance with the hydraulic diagram. Set the relief
valves down to a very low pressure if they are not sealed. Start-up with low pressure and
volume flows.
Test the function and tightness of the system. Check the oil level. Slowly increase the
pressures and volume flows to their appropriate values. If measuring equipment is fitted,
check this continuously. Pay attention to the noise level since abnormal noise implies
defects. Test during variable loads that components are correctly fitted, and that the system
is tight.
PS/PSH 85
08 Hydraulic system
In the event of returning equipment to the manufacturer, protect polished surfaces from
damage and dirt by covering them with foil and protective paper. Fit plastic plugs in all
connections. Send the complete components, not loose parts.
8.2.2 Hydraulic oil

8.2.2.1 Properties of the hydraulic oil
The hydraulic oils that are recommended in this manual have properties that promote a long
service life and good functionality, and these are the oils that must be used in the truck.
These contribute to:
• Smooth action.
• Long service-life.
• High viscosity index with wide range of temperature applications.
• Good low-temperature properties.
• High filterability.
• Good air and water separating capacity.
• Good wear protection.
• Good oxidation stability.
• Minimum foaming.
• Provide protection from rust and corrosion.
• Good adhesive capacity.
NOTE!
Never mix oils of different types or brands! Environmentally adapted oils must not
be used without the approval of the truck manufacturer if the warranty is to be
valid.
NOTE!
8.2.2.2 Checking the hydraulic oil level

1) Carefully raise the fork carriage to its topmost position.
2) Check that the hydraulic pump is not drawing in air. This can be recognised by the
function in operation moving jerkily, or by an abnormal screeching noise.
3) If the hydraulic pump is drawing in air, move all the hydraulic functions to their lowest
positions, open the machine housing cover, and check the oil level in the hydraulic tank.
4) Fill with hydraulic oil of the grade recommended in Section 8.2.2.1, page 86 so that
the level rises a few cm. Then perform the “test lift” and check as above.
5) Repeat this procedure until a normal function is obtained.
8.2.3 Hydraulic unit motor

8.2.3.1 General
If the performance of the electric motor changes it should be inspected internally. One of the
most common sources of faults is wear on the carbon brushes in the motor.
The brushes can wear out, or stick in the brush holders. In both cases inadequate contact
between the brushes and the commutator can lead to serious damage on the commutator
surface.
86 PS/PSH
08 Hydraulic system
8.2.3.2 When should the brushes be replaced?

• If a carbon brush cannot move freely in the brush holder. To check this the brush holder
must be released from the brush rigging. The force from the brush spring should then
press out the brush from the brush holder as far as is permitted by the cable.
• If a carbon brush is approaching the end of its usable length. The length of the brushes
must never be less than 10 mm (a new brush has a length of 17 mm). Since this is
difficult to measure there is an alternative method. Measure the difference between the
cable and the groove in the brush holder. The difference must be at least 1 mm. Even if
the difference is only slightly more, it is recommended that the brushes are changed
anyway, since their remaining service life may be shorter than the interval to the next
inspection.
8.2.3.3 Replacing the brushes

The brushes themselves cannot be changed, as they are part of a set consisting of the
brush, brush holder and spring. Installation is in accordance with the following instructions.
Figure 58. Replacing the brushes

1) Release the cables from the terminals on the motor (item 1, Figure 58, page 87).
2) Remove the through bolts from the rear end of the motor (item 2, Figure 58, page 87).
3) Lift out the electric motor from the truck.
4) Place the electric motor on the drive end.
5) Remove the nuts from the terminals, (item 3, Figure 58, page 87). If the motor has an
earth return, the earth connection on the rear end of the motor should also be detached
(pos 4, Figure 58, page 87).
6) Remove the rear end (item 5, Figure 58, page 87). Make sure that the terminals
remain in their positions.
PS/PSH 87
08 Hydraulic system
Figure 59. Replacing the brushes

7) Disconnect all four carbon brushes by releasing the screws (pos 6, Figure 59,
page 88).
• A. Then press each brush set towards the commutator.
• B Remove the brush set from the brush rigging.
• C. The old brush set is replaced with a new set by the reverse procedure.
It is recommended to replace each brush separately to avoid confusion. Make sure that
each brush set is replaced with the correct part, i.e. one that has the cable on the
correct side. (The service kits consist of two matching pairs of brush sets!)
8) Torque
Tighten the screw (item 6, Figure 59, page 88), to approx. 1.3-1.8 Nm.
9) Replace the terminals in the grooves in the rear end, and replace it back on the motor.
Check that there is a washer between the rotor and the end (pos 12, Figure 59,
page 88) and that the attachment is held in place by a lug and a slot on the casing
and the end.
10) Torque
Insert the through bolts and replace the electric motor in the truck. Tighten the
bolts to approx. 4.8-6.8 Nm.
11) Torque
Tighten the terminal nuts to 10-14 Nm (item 3, Figure 58, page 87).
12) Replace the cables to the motor terminals.
8.2.3.4 Tips for prolonging the service-life of the motor

• The rapid wearing of carbon brushes and the commutator is often caused by oil. Oil or
grease is burned by the sparks produced at the brushes, and leaves a residue of
abrasive ash. If oil or grease is detected in the motor the reason for this must be
eliminated immediately.
• Never overload the motor. Brushes that have been severely overheated expand
permanently and can fasten in the brush holders.
88 PS/PSH
08 Hydraulic system
• The service-life of the brushes does not only depend on the loading, but also on how
worn the commutator is. The commutator should have smooth, level and greyish black
surface. A worn commutator must be machine milled (never use abrasive paper,
grindstone or a file!) to a surface finish of Ra = 0.8-1.8µm and a maximum runout of
0.03 mm (with the rotor resting in the bearing seats). The service-life of the commutator
is prolonged if it is machined a little and often, rather than seldom and a lot. The
minimum permitted diameter of the commutator is 40.8 mm.
• The motor must not be exposed to full load immediately after changing the brushes.
• Look for signs of overheating on the windings, dark patches, brittle or burned insulation,
and damage to the soldering on the commutator. The electric motor should be replaced
if such damage is found.
• If possible, remove dust and dirt from inside the motor with compressed air.
• A dirty commutator should always be cleaned with a cloth moistend with petrol (do not
used cotton rags since these shred fibres), and carefully blown dry with compressed air.
• If the bearing cup looks as if it has run out of oil (i.e. if there is a lot of oil on the rotor
washer or brush holder) lubricate it with a little bearing grease.
8.2.4 Hose rupture valve

8.2.4.1 Dismantling and assembling
1) Lower the forks and relieve the pressure.
2) Place protective paper under the cylinder to be repaired.
3) Loosen the pipe or hose that goes to the cylinder, and plug it.
4) Remove the nipple placed in the cylinder.
5) Unscrew the hose rupture valve (item 1, see Figure 60, page 89) that is screwed into
the cylinder.
Figure 60. Hose rupture valve

6) If a fault is suspected, check the length of the spring in relation to the table or data
sheet. Adjust, or fit a new valve.
7) Fit the nipple, connect the pipes, and wipe clean.
8) Test run.
PS/PSH 89
08 Hydraulic system
Figure 61. Hose rupture valve
8.2.5 Solenoid
8.2.5.1 General instructions when working with solenoid valve
1. Cleanliness
• Dirt particles must not be allowed to get into components.
• Cloths must not shed fibres and particles.
• Tools must be clean.
• Tanks, pipes and hoses must be carefully cleaned before installation.
• Welded or hot-bent pipes must be pickled and cleaned before they are built-in
• The oil tank must be closed and provided with an efficient breather filter that
prevents the penetration of dirt.
2. Sealing compound
• Hemp, cement or sealing tape is not permitted.
3. Operating data
• Do not exceed the permitted pressures and volume flows.
• Do not go beyond the specified temperature range.
• Pay attention to specified electrical voltages and maximum power consumption.
8.2.5.2 Solenoid valve, dismantling and assembling

1) Lower down the forks and relieve the pressure in the hydraulic system.
2) Place protective paper under the valve and release the electric cables to the valve.
3) Loosen all the oil pipes connected to the valve and plug them.
4) Loosen the valve from the truck, and lift it out.
5) When fitting, tighten the valve and then the oil pipes.
6) Adjust the relief valve to the rated weight in accordance with the machine plate.
7) Seal the setting.
8.2.6 Installation instruction for pipe couplings

To achieve a safe and tight connection when installing pipe couplings in the hydraulic
system, the following points should be taken into consideration:
CAUTION!
Do not cut the pipe, as this could mean that metal chips would get into and
damage the hydraulic system.
1) Small pipe dimensions can be fitted directly in the coupling connected to the machine
part. Screw the nut by hand until it lies flush with pipe olive, press the pipe towards the
shoulder in the coupling cone, and tighten the nut a ¾ turn.
90 PS/PSH
08 Hydraulic system
NOTE!
The pipe must not follow round.
2) The pipe olive will now have gripped the pipe, which no longer needs to be pressed
against the shoulder. Complete the fitting with an additional ¾ turn of the nut. Marking
the nut simplifies complying with the prescribed torque (see Figure 62, page 91).
Figure 62. A mark on the nut simplifies the specified torque

3) Larger pipe dimensions and couplings in free pipes are preferably fitted by placing the
coupling body in a vice. The U-ring spanner length should be 15 times the nut width (the
spanner can be extended with a piece of pipe). Otherwise fit according to point 3.
If several couplings of the same type are to be fitted, make sure that each pipe end goes
in the same coupling cone it was previously fitted in. Final fitting is facilitated if the nut is
loosened a little and oil is applied between the friction surfaces.
4) After fitting, release the cap nut and check that the pipe olive has pressed up a visible
swelling in the area in front of it (see Figure 63, page 91). If not, give it another short
turn. It is of no importance whether the pipe olive can still be turned.
Figure 63. A visible swelling should have formed after tightening

After a visible swelling has formed the nut should be fitted without extension of the
U-ring spanner, and without excessive force.
NOTE!
Refitting: After a visible swelling has formed the nut should be fitted without
extension of the U-ring spanner, and without excessive force.
PS/PSH 91
08 Hydraulic system
5) If the pipe is to be bent after a coupling, the straight pipe end should have a length of at
least 2 nut heads, H.
Long and heavily loaded pipes should be provided with pipe clips.
Figure 64. Straight pipe length between bend and coupling

6) The final assembly must be done with at least 1 turn of the nut from the point where it
can no longer be turned by hand.

8.3.1 Symptom and Action
A number of fault symptoms have been listed in the table below, with a number of possible
faults and repair procedures. It is therefore possible for other faults to have occurred in
addition to the ones listed.
Symptom Possible fault Procedure
The lift motor runs, but the fork The lowering valve has jammed 1. Close the valve.
carriage does not lift. and is open. 2. Adjust, or remove any dirt
from the valve.
The lift motor runs, but the fork The machine is overloaded. Lighten the load.
carriage lifts very slowly.
The overflow valve is defective. Adjust the valve to the rated
weight.
A foreign object has partially Take apart and clean.
blocked a hose, hydraulic pipe or
valve.
Hydraulic hose has been Rearrange the hose and clamp
clenched. secure.
The lift motor emits a screeching The oil level is too low in the 1. Fill with hydraulic oil. When
noise just before the fork hydraulic tank. the tank is almost full, try
carriage reaches the top. with 0.1 litre at a time to
avoid overfilling.
2. Find out the reason for the
low level, and rectify the
fault.
The fork carriage will not lower. Valve does not open on return Dismantle the valve and clean it.
because of foreign object in the
system.
The hose rupture valve is closed Limit the lowering speed.
because the lowering speed is
too high.
The hose rupture valve is closed Replace the hose rupture valve.
because the spring in the valve
is defective.
92 PS/PSH
08 Hydraulic system
Symptom Possible fault Procedure

The fork carriage lowers too Lowering valve or lowering brake 1. Run the lift motor for a
slowly. valve is dirty or defective. maximum of 1 minute to
see if the dirt releases.
2. If not, dismantle the valve
and clean, or replace
defective parts.
The oil filter is blocked and dirty. Change filter.
The fork carriage lowers too The lowering brake valve is Replace the lower brake valve.
quickly. defective.
The lowering brake valve is Adjust the lowering brake valve.
incorrectly adjusted.
Hydraulic oil flows out via the air Oil level too high. Reduce the oil level to correct
filter. level.
The oil foams. Change the oil with oil that has
the correct properties.
Condensation water in oil tank. Empty the tank of oil and fill with
new hydraulic oil to correct level.
The fork carriage rocks when Air in the hydraulic system. Bleed the system via the air
lifting. cylinders.
The hydraulic oil has a bad The oil separators in the 1. Change the oil and filter.
smell, sulphur. hydraulic oil are ruined. 2. Flush the complete system
Motor oil has been used and with new hydraulic oil.
caused the hydraulic oil to
emulsify with water and become
contaminated.
PS/PSH 93
09 Lift cylinders
09 LIFT CYLINDERS
9.1.1 General
The lift cylinders consist of single-acting hydraulic cylinders, where hydraulic oil is pumped
into the cylinder, pressing out the piston rod.
When the driver activates the lowering function the cylinders are pressed together through a
control valve releasing oil out from the cylinders. They are then pushed together by the
weight of the forks, at the same time as the oil returns to the hydraulic tank.

9.2.1 General
9.2.1.1 Bleeding of the hydraulic cylinders with the air bleed screw
WARNING!
When bleeding, the air screw must be opened no more than approx. a half turn. If
the air screw is opened completely the oil will spurt out and the forks crash
uncontrollably to their bottom position. The hose rupture valves do not function in
this phase.
Figure 65. Example, air screw.

1) Open the air bleed screw about half a turn.
2) Check that there is sufficient oil in the hydraulic tank and that the pump does not suck
air.
3) When oil without air bubbles comes out, the cylinders have been bled.
4) Tighten the air bleed screw.
5) Adjust the oil level in the hydraulic tank.
6) Repeatedly lift from bottom to top position.
7) Check that the forks do not bounce. If they do, bleed the air one or more times.
9.2.1.2 Bleeding of the hydraulic cylinders without a bleed air screw

Cylinders without bleed air screws are bled by running the cylinder repeatedly between its
end positions.
94 PS/PSH
09 Lift cylinders
NOTE!
Check the oil level regularly.
9.2.2 Lift cylinder TV/ TFV (PS)

1) Lift the forks until the inner mast is raised approx. 20 cm. Place wooden blocks under
the inner mast, and lower it down onto the blocks.
2) Loosen the securing screw (item 1).
3) Lower the cylinder to its compressed position.
4) Disconnect, and plug the oil pipe.
5) Lift out the cylinder.
PS/PSH 95
09 Lift cylinders
96 PS/PSH
09 Lift cylinders
9.2.2.2 Dismantling
1) Make a nore of how far the adjusting screw (1) is screwed into the piston rod end (this
will be needed when reassembling).
2) Unscrew the adjusting screw (1).
3) Support the lower end of the cylinder in a vice.
CAUTION!
Risk of deformation: use moderate force.
4) Place a container for oil spillage under the cylinder.

5) Unscrew and remove the top nut (item 2). Pull out the piston rod (item 3).
6) Remove the sealing rings and guides rings (item 4) from the top nut.
7) Remove the guide rings (item 5) from the piston rod.
8) Clean all parts and check for damage. Replace if necessary.
NOTE!
Always use original spare parts for maximum safety and service life.
9) Install in the reverse order. Lubricate all parts with hydraulic oil before fitting.
PS/PSH 97
09 Lift cylinders
9.2.3 Lift cylinder T (PSH)

1) Lower the forks, e.g. on a pallet, so that the chains slacken. Remove the split pin bolt
(item 1) that sits in the top end of the cylinder.
2) Remove the chain and place it over the back of the fork carriage.
3) Release the fork carriage from the mast by lifting up the inner mast with the hydraulic
pump. Reverse the truck away.
4) Place a wooden block, 10-15 cm thick, under the inner mast, and carefully lower the
inner mast until it rests on the block.
98 PS/PSH
09 Lift cylinders
5) Secure the cylinder so that it cannot drop out of the mast! Remove the circlip (item 2)
and remove the lower securing screw (3).
6) Lower carefully so that the piston rod comes out of the yoke (item 4). When the piston
rod is fully pushed in, remove the oil pipe and return pipe. Tilt the cylinder forward and
lift it out.

1) Place the cylinder on a bench with the chain attachment facing down.
2) Slacken and remove the top nut (1) with a hook spanner.
3) Pull out the piston rod (item 2) and place it carefully on the bench to avoid damaging it.
4) Remove the parts (items 3, 5, 6, 7 and 8).
NOTE!
PS/PSH 99
09 Lift cylinders
9.2.4 Lift cylinder TV/TFV/DTFV (PSH)

1) Lift the forks until the inner mast is raised approx. 20 mm. Place wooden blocks under
the inner mast, and lower it down onto the blocks.
2) Remove the upper securing screws (item 1).
3) Lower the cylinder to its compressed position.
4) Loosen, disconnect, and plug the oil pipe.
5) Remove the retaining screw (item 2).
100 PS/PSH
09 Lift cylinders

1) Make a nore of how far the adjusting screw (1) is screwed into the piston rod end (this
will be needed when reassembling).
2) Unscrew the adjusting screw (item 1).
CAUTION!

5) Unscrew and remove the top nut (item 2). Pull out the piston rod (item 3).
6) Remove the sealing rings and guides (item 4) from the top nut.
7) Remove the guide rings (item 5) from the piston rod.
NOTE!
PS/PSH 101
09 Lift cylinders
9.2.5 Free lift cylinder, TFV/DTFV (PSH)

1) Remove the retaining screw that holds the lower end of the cylinder.
2) Lower the forks, e.g. on a pallet, so that the chains slacken. Remove the chain pin that
goes through the chain bolt on the cylinder, and place the chain over the back of the fork
carriage.
3) Release the fork carriage from the mast by lifting up the inner mast with the hydraulic
pump. Reverse the truck away.
102 PS/PSH
09 Lift cylinders
4) Lower so that all the cylinders are pushed together completely.

5) Loosen the bolts that hold the clamp at the top end of the cylinder, without removing it.
6) Disconnect the oil pipe.
7) Remove the clamp, and lift out the cylinder.
8) Plug the oil pipe.
9.2.5.2 Dismantling
CAUTION!
2) Remove the circlip (1) and remove the yoke (2).

PS/PSH 103
09 Lift cylinders
4) Remove the top nut (3) with a suitable tool and take it off the piston rod.
5) Pull out the piston rod.
6) Remove the seals (4) and guide rings (5) on the piston. Use a thin tool that will not
scratch.
7) Remove the seal (6) and scraper (7) from the top nut and O-ring (8).
NOTE!
9.2.6 Lift cylinder, vertically adjustable support arm (PSH 160)

1) Lower the forks so that all the cylinders are pushed together completely.
2) Remove the screws that hold the cylinder lower and upper holders, see Figure 66,
page 105.
3) Disconnect the oil pipe.
5) Plug the oil pipe.
104 PS/PSH
09 Lift cylinders
Figure 66. Lift cylinder, vertically adjustable support arm
9.2.6.2 Dismantling
CAUTION!
2) Remove the swivel head (item 9) and nut (item 8), see Figure 67, page 106.
4) Remove the circlip (item 17), and press in the guide (item 16) so that the securing ring
(item 15) is released. Take out the securing ring (item 15) and the guide (item 16).
5) Pull out the piston rod (item 2).
6) Remove the seal (item 11) and guide ring (item 12).
7) Remove the seal (item 6), guide ring (item 3) and O-ring (item 4).
NOTE!
PS/PSH 105
09 Lift cylinders
Figure 67. Lift cylinder, vertically adjustable support arm
106 PS/PSH
10 Electrical system
10 ELECTRICAL SYSTEM
10.1.1 General
10.1.1.1 Component descriptions, PS (–2011w15), PSH (–2012w22)
1. Traction motor, TM 4. Hydraulic valve controller, HVC.

2. Pump motor, PM 5. Truck computer, ATC.
3. Traction motor controller, TMC.
PS/PSH 107
10.1.1.2 Component descriptions, PS (2011w16–), PSH (2012w23–)
1. Traction motor, TM 3. Combination controller, CMC.

2. Pump motor, PM 4. Truck computer, ATC.
10.1.1.3 Description of components and interface
The ATC system consists of a keyboard (pos. 1), display (pos. 2) and an ATC card (pos. 3).

10.2.1 General
10.2.1.1 Safety procedures
Extreme importance must be placed on precautionary measures to avoid accidents during all
work on the vehicle.
• The drive wheel should always be lifted up free from the floor during service work to
prevent the vehicle from moving.
• The battery plug should be pulled out before working on the electrical system. The
battery plug may only be connected while trouble shooting, while taking great care (with
the truck raised).
108 PS/PSH
• No other persons should be in the vicinity of the truck when it is test run in conjunction
with repair work, in view of the risk of accidents or near-accidents occurring due to the
truck making an unexpected manoeuvre.
• All metal objects such as watches, chains, spectacles and rings should be removed
when working on the electrical system, or in its immediate vicinity. A short circuit through
such an object can result in very serious burn injuries.
• Working with electrical vehicles can result in personal injury. All testing, trouble shooting
and adjusting must be carried out by authorised personnel. The drive wheel should run
free of the floor and be able to rotate freely during work.
WARNING!
Working with electrical vehicles can result in personal injury.
Electronic controllers
• All the electronic controllers in the truck have multiple safety systems.
• When replacing or repairing the electronic controllers, or removing wiring, the battery
must always be disconnected.
NOTE!
Incorrectly connected battery cables can destroy the electronic controllers.
WARNING!
During all work on the truck the drive wheel must be lifted up from the floor to
prevent accidents occurring.
After the power has been disconnected to the controller and work or trouble shooting is to be
conducted, there can be residual voltage in the capacitors for a few minutes. For this reason
observe care when working with current-carrying tools during this period.
10.2.1.2 Acronyms and abbreviations

Abbreviatio Full name Explanation
n
AC Alternating Current Alternating current
B+ Battery positive Battery positive terminal
B- Battery negative Battery negative terminal
CAN Controller Area Network The truck computer's communication interface with
external units.
CMC Combi Motor Controller Combination controller
DC Direct Current Direct current
ELCB Electronically Load Compensated Brake with electronic load compensation
Brake
EPS Electric Power Steering Control regulator for electrical servo steering
ESD Electrostatic Discharge Electrostatic discharge
GND Ground Ground
HVC Hydraulic Valve Controller Hydraulic valve controller
PMC Pump Motor Controller Regulator that controls the pump motor
S3 Support systems Assistance system for stability and safety
TMC Traction Motor Controller Traction motor controller
TV Telescopic View Telescopic sight
WG Wire Guidance Wire guidance
PS/PSH 109
10.2.2 Battery
10.2.2.1 Battery capacity
Figure 68. Battery capacity

The battery capacity is shown to the left on the bottom row on the display. Measurements
are fully controlled by software, and no further electronics are required. The capacity is
measured by measuring the battery voltage.
When the battery capacity gets too low the battery capacity value starts flashing and a
buzzer is actuated.
A lift stop is connected to the battery capacity measurement and is activated when only 20%
capacity remains.
Table 31. Battery capacity

Battery capacity % Unloaded pole voltage Acid density g/cm3
0 22,92 1.070
10 23,20 1.093
20 23,47 1.116
30 23,75 1.139
40 24,03 1.162
50 24,30 1.185
60 24,58 1.208
70 24,85 1.231
80 25,13 1.254
90 25,41 1.277
100 25,68 1.300
Calibration of the battery indicator

CAUTION!
Calibration is performed when the truck is manufactured, and must not be done
afterwards.
Incorrect calibration can damage the battery. Only use the factory values.
110 PS/PSH
1. Switch on the voltage to the truck.

2. Go into “Lowering high“ (Service menu » Settings » Battery » Lowering high). This
parameter ((0-9) determines how quickly BDI reduces the indicated level when the
battery has just been charged.
• If the indication does not show 100% after a complete charging cycle, or falls too
quickly in the range 100%-60%, this parameter must be reduced.
• If the indication falls too slowly in the range 100%-60%, this parameter must be
increased.
3. Go into “Lowering low“ (Service menu » Settings » Battery » Lowering low). This
parameter ((0-9) determines how quickly BDI reduces the indicated level when the
battery is almost discharged.
• If the indication falls too quickly in the range 60%-20%, this parameter must be
reduced.
• If the indication falls too slowly in the range 60%-20%, shows too high a battery
status, or if the truck stops due to a low voltage level alarm, this parameter must be
increased.
10.2.3 General handling

10.2.3.1 Keyboard operation
The keyboard is used for driver identification, settings, and for diagnostics. The keyboard
consists of 12 keys, which have different functions depending on which position the system
is in.
Table 32. 10.2

Function in
Key: Input mode: Service mode:
Operation mode:
Enter a zero. - -
Enter an eight. - -
Enter a two. Switch between creep Step one step down in the
speed and full speed. menu tree.
Enter a three. - -
Enter a four. - Step one step to the left in

the menu tree.
Enter a five. - -
Enter a six. - Step one step to the right in

the menu tree.
Enter a seven. - -
Enter an eight. Set the truck to full speed. Step one step up in the
menu tree.
Enter a nine. - -
- Set the truck to standby Steps to the upper menu

mode, or else log off. level loop if pressed during
input in the upper level.
See Section 10.2.3.2,
page 112.
Used to accept the shown - Used to select the shown
value. menu alternative.
PS/PSH 111
Function key combinations

A “monitor menu” can be obtained if the keys are pressed down at the same time in
the Operational mode.
WARNING!
As the monitor menu is active, the truck reacts physically by activating the
controls.
10.2.3.2 Menu tree – start-up and top level
Figure 69. Menu tree

On the Operational mode:
If the [i] key is pressed and held down for one second the truck will go to the “stand-by”
mode. The changeover is confirmed by a beep sound.
In Stand-by mode
If the [i] key is pressed for less than one second the truck will go to the “Operational mode”
without asking for a PIN code. If the [i] key is pressed and held down for one second, the
truck will return to the upper level and ask for an operator ID.
There is no reason for the operator to release the [i] key if the intention is to log out directly
from the "Operational mode".
112 PS/PSH
10.2.4 Contactors in cold storage rooms

10.2.4.1 Greasing electrical connectors in cold storage rooms
Kryotox grease must be applied to all electrical connectors in the truck that are not
self-sealing.* A hand pump must be used for this. The grease should be applied to the
contact surfaces when the connectors are disconnected, after which the connectors are
reconnected and the grease is pressed from behind into the connector housings so that each
are filled. All blocks that have more than one cable are considered to be contact blocks. Flat
pins, ring terminals and other simple equipment does not need to be greased.
* In spaces in the truck which are considered to be particularly exposed, sealed connectors
have been chosen, to protect against damp and dirt. These connectors do not need to be
greased in the cold store version. To identify whether a connector is of the sealed type, look
at the back piece of the connector. If there is a seal around the wiring in the connector
housing, the connector is sealed.
10.2.5 Positioning of ferrites

NOTE!
The ferrites present on the truck must be put back in the same locations after any
part of the truck has been replaced.
Ferrite ring P/N

A 118212
B 118213
PS/PSH 113
Figure 70. (-2005w42), 2006w22-
114 PS/PSH
Figure 71. 2005w43-2006w21
Ferrite ring, PS (2011w16–) P/N

A 014516
PS/PSH 115
Figure 72. PS 2011w16-; PSH 2012w23-
10.2.6 Drive and valve controller, PS (–2011w15), PSH (–2012w22)

10.2.6.1 Connector traction motor controller, specification
The traction motor controller has two connectors
with inputs and outputs for valves, sensors,
switches, programming tools, etc. Each connector
pin is specified below with, where appropriate, the
voltage level in the connected condition.
Connector X6 (figure shows connector from the

cabling side).
Table 33. 10.3 Connector X6 traction motor controller AC0

Pin Description Comment
X6.1 Controlling of Drive contactor. Controlled to B-.
X6.2 Supply to Drive contactor. +24 V
X6.3 Controlling of electric brake. Controlled to B-.
X6.4 Controlling of pump contactor. Controlled to B-.
X6.5 Supply to pump contactor/horn. +24V
X6.6 Controlling of horn. Controlled to B-.
116 PS/PSH

X6.7 CAN communication. CAN Low.
X6.8 Temp SW In. -
X6.9 Pos. supply to drive motor encoder. +12 V
X6.10 Neg. supply to drive motor encoder. B-
X6.11 Controlling of lowering valve. +24 V
X6.12 Neg. supply to lowering valve. B-
X6.13 Signal input temp. sensor.
X6.14 - -
X6.15 - -
X6.16 +12 V supply to the HVC. +12 V
X6.17 CAN communication. CAN High.
X6.18 - -
X6.19 Input A from drive motor encoder. Synchronises the motor movement with
pulses from the encoder.
X6.20 Input B from drive motor encoder. Synchronises the motor movement with
pulses from the encoder.
Connector X5 (figure shows connector from the

cabling side).
Table 34. 10.4 Connector X5 traction motor controller AC0

X5.1 Supply from F3 fuse. +24 V
X5.2 Joint supply to all digital inputs. +24 V
X5.3 Input from brake switch. Closes in the upper and lower arm position.
X5.4 - -
X5.5 - -
X5.6 - -
X5.7 Digital input. Accessories: Input from lift stop switch,
closed, breaks during lift stop.
X5.8 Digital input. Brake open. The switch must be closed to be
able to drive the truck.
X5.9 - -
X5.10 - -
X5.11 - -
X5.12 - -
10.2.6.2 Hydraulic valve controller HVC, connector
PS/PSH 117

X23.1 Proportional valve Activated during fork lifting and
lowering
X23.2 - -
X23.3 Electrically operated valve, forks Closes during fork lifting and
lowering
X23.4 Electrically operated valve, Closes when the "straddle"
support arms option is selected and the
support arms are raised or
lowered.
X23.5 Positive supply to proportional +24 V
valve
X23.6 Common positive supply to +24 V
electrically operated valves
X23.7 - -
X23.8 - -

X22.1 Supply from TMC +12V
X22.2 Supply to outputs +24V
X22.3 CAN communication CAN low
X22.4 Negative supply B
X22.5 - -
X22.6 CAN communication CAN high
Connector X24 is not used on PS/PSH.
10.2.6.3 Wiring diagram, PS (-2011w15), PSH (–2012w22)

All the electrical wiring diagrams can be found in a separate "Wiring diagram handbook".
Contact the truck manufacturer for further information.
Descriptions Machine Reference Document code
Wiring diagram PS/PSH 118281
116384 (2007w28–)
Circuit diagram PS/PSH 118280
10.2.7 Combination controller, PS (2011w16–), PSH (2012w23–)

10.2.7.1 Description of combination controller
To improve the handling ability when lifting and lowering, PS and PSH have been equipped
with a speed regulated pump motor controlled by a single CMC (Combi Motor Controller).
The CMC replaces the TMC (Traction Motor Controller), HVC (Hydraulic Valve Controller)
and pump contactor used in earlier models.
This solution gives a smoother and more precise control, has a low sound level and is in
combination with an equally smooth and precise proportional valve for the lowering function.
It also reduces the number of major components in the truck.
The lift motor is protected against overheating by a temperature sensor inside which will
open at 120 °C to turn off the lift function if the motor becomes overheated.
The CMC consists of an AC Traction Motor Controller, a DC Pump Motor Controller and
drivers for hydraulic valves in one unit.
118 PS/PSH
There are two sizes of CMC with different part numbers depending on the truck model.
PS (TMC 220A/PMC 270A)
PSH (TMC 220A/PMC 400A)
The traction function of the CMC is the same as the earlier TMC using the same traction
motor.
Pump motor speed, and therefore lift speed, is regulated by the CMC pump motor controller.
The lowering speed is controlled by the CMC opening proportional valve Y3, which
corresponds to a command signal from the ATC.
10.2.7.2 Combination controller connector

The combination controller has a connector with inputs and outputs for valves, sensors,
switches, programming tools, etc. Each connector pin is specified below with, where
appropriate, the voltage level in the connected condition.
Table 35. Connector X5 for Combination controller AC0

X5.1 Input from brake switch. Closes in the upper and lower
arm position.
X5.2 Controlling of electric brake. Controlled to B+.
X5.3 Supply to valves and horn. +24 V.
X5.5 Negative supply to Traction Controlled to B-.
motor encoder and temp SW In.
X5.6 -
X5.7 -
X5.8 -
X5.9 Controlling of lowering valve. Controlled to B-.
X5.10 Supply from F3 fuse. +24 V.
X5.11 -
X5.12 Control of main contactor. Controlled to B-.
X5.13 Input B from drive motor Synchronises the motor
encoder. movement with pulses from the
encoder.
X5.14 Input A from drive motor Synchronises the motor
encoder. movement with pulses from the
encoder.
X5.15 -
PS/PSH 119

X5.16 -
X5.17 -
X5.18 -
X5.19 Digital input. Brake open. The switch must be
closed to be able to drive the
truck.
X5.20 -
X5.21 -
X5.22 Temp SW Out.
X5.23 -
X5.24 Proportional valve. Activated to lift the forks.
X5.25 Positive supply to Traction motor +12 V.
encoder and temp SW In.
X5.27 CAN communication. CAN Low.
X5.28 CAN communication. CAN High.
X5.29 -
X5.30 -
X5.31 -
X5.32 -
X5.33 Electrically operated valve, forks. Closes during fork lifting and
lowering
support arms. option is selected and the
support arms are raised or
lowered.
X5.35 -
10.2.7.3 Wiring diagram, PS (2011w16-), PSH (2012w23-)

All the electrical wiring diagrams can be found in a separate "Wiring diagram handbook".
Contact the truck manufacturer for further information.
The relevant wiring diagrams are specified in the table below.
Descriptions Machine Reference Document code
Wiring diagram PS, PSH 118951
Circuit diagram PS, PSH 118952
10.2.8 Insulation resistance

10.2.8.1 Insulation test
To protect the truck's three controllers, computer and display, the connectors (plugs) must be
disconnected before the truck is insulation tested. This is because damage can occur, which
will shorten the life of component parts. In the event of large insulation errors it is appropriate
to use a universal instrument until the error has been found and then make a final insulation
test.
This applies to all electronic units on the truck.
120 PS/PSH
WARNING!
The instrument has a dangerous voltage across the measuring terminals. Do not
touch the terminals during testing.
Routines for insulation testing of all truck models.

1) Set the test voltage to 100 V on the insulation test instrument.
2) Pull out the battery plug. Electrical components and electronic systems can be damaged
by the test voltage. For this reason always disconnect connections and connectors to
these before doing the test.
3) Connect the instrument’s earth lead to the truck chassis at a point with good electrical
contact. The other lead is connected to the minus pole on the electrical panel plug.
4) Press the start button and wait until the display has stabilised. Then release the button
and read off the value on the display. The approved value on 24 V machines must be at
least 24000 Ω (24 kΩ).
5) Let the earth lead remain attached to the chassis and connect the other lead to the
plus pole on the electrical panel plug. After this repeat point 4.
10.2.9 Main controller unit ATC, operation

10.2.9.1 Menus
When starting the ATC system there are four different basic menus the user can select. The
user navigates between these different menus by means of the [i] key as shown in the
illustration. Certain menus are password-protected.
1. Operator ID:
?
2.
3. Local code:
????
4.
5. Authorised service code:
????
6.
7. Settings
Navigation in the menus takes place by means of the keys on the keyboard. The keys four
and six are used to step up and down, and keys two and eight to step from side to side. The
arrows on the display show the possible directions.
The enter key is used to go into the submenus. To leave a selected menu, use the Exit
selection together with the Enter key. One refinement is that the horn key can be used as an
escape key. It can also be used to step back in the menus to the Exit position. This function
can also be used to cancel an initiated parameter change.
The menus are divided into three levels, as follows:
Operation mode
This menu is used to log on to the Operational mode. Logon takes place by selecting driver
ID, entering a password, and finally using the safety switch as an enter key. In the
Operational mode it is possible to use the truck and all its functions.
PS/PSH 121
Local Service
In the Local Service menu it is possible to change passwords for local service, add and
remove drivers, and set the time/date, LCD contrast, and key sound. Certain statistical
functions are also available here. A password is needed to access the Local Service menu.
Authorised service
The Auth. Service menu includes all the functions that may be used by authorised service
personnel. A password is needed to access the Auth. Service menu. The Auth. Service
menu is built up as shown in fig.
1. Authorised service menu:
< Exit >
< Options >
< Settings >
< Tests >
< Calibrate >
< Logs/counters >
< SET ACCESS >
< Reset menu >
• Exit – selected to exit the Auth. Service menu.

• Options – possibility to set those options that are available for the truck.
• Settings – possibility to set driver parameters, hydraulic parameters and battery
parameters.
Table 36. Hydraulic lifting settings:

Settings Range [%] With HVC With Combi controller
Raise min 0–100 The amount of voltage used to open The pump motor speed on receiving
the proportional valve on receiving the command for minimal lifting
the command for minimal lifting
Raise max 0–100 The amount of voltage used to open The pump motor speed on receiving
the proportional valve on receiving the command for maximum lifting
the command for maximum lifting
Lower min 0–100 The amount of voltage used to open The amount of voltage used to open
the proportional valve on receiving the proportional valve on receiving
the command for minimal lowering the command for minimal lowering
Lower max 0–100 The amount of voltage used to open The amount of voltage used to open
the proportional valve on receiving the proportional valve on receiving
the command for maximum the command for maximum
lowering lowering
122 PS/PSH
Settings Range [%] With HVC With Combi controller

Break point 0–100 Adjusts the curve for both the lifting Adjusts the curve for both the lifting
and lowering functions and lowering functions
Dead zone 8–100 Dead zone for both the lifting and Dead zone for both the lifting and
lowering functions lowering functions
Table 37. Pump settings

Settings
Speed ctrl Can be set for the motor or valve. Depends on whether the truck is equipped with a
Combi controller unit or if the throttle is controlled by a proportional valve.
Cont delay Delay before the pump contactor is activated. This function is used to allow the
valves to open before the pump motor starts. Not used on machines with a Combi
controller.
Delay1 Delay1 is used to set the delay from pressing the button to initiate lifting until lowering
is again possible. The proportional valve must remain completely open until the delay
has elapsed. Delay1 is set in steps of 100 ms. The range is 0–255 seconds.
Delay2 Delay2 is used to delay the closing of valves Y2 and Y5 when the buttons change
from lifting/lowering to the neutral position. Delay2 is set in steps of 100 ms. The
range is 0–255 seconds.
Lower acc Defines how quickly the lowering movement can accelerate.
Lower ret Defines how quickly the lowering movement can be retarded.
During lowering, the signal from the button changes linearly. The value from the button for
lowering is between 0 and -32 767. Lower acc and lower ret define how much the value can
change for each program cycle. This filters the signal so that small changes are applied
immediately, while large changes are divided into several smaller changes which take a
longer time to reach the full value.
• Test menu - tests the inputs and outputs.

• Calibrate – possibility to calibrate inputs.
• Logs – possibility to read and clear temperature log, error log and hour counter.
• Set access – possibility to add drivers and set passwords for Auth. Service and Local
service.
• Reset menu - possibility to reset all parameters, accessories, users, calibrations and log
on to the factory settings.
Table 38. Hydraulic lifting settings:

Parameter PS (sw -2.28) PS (sw 2.29-) PSH PSH with T mast
Raise ctrl Speed Speed Speed Speed
Raise min 42% 10% 55% 55%
Raise max 12% 100% 12% 12%
Lower min 20% 24% 20% 20%
PS/PSH 123

Lower max 50% 40% 80% 70%
Break point 35% 35% 35% 35%
Dead zone 10% 10% 10% 10%
Table 39. Pump settings

Speed Ctrl Valve Motor Valve Valve
Cont delay 0 0 0 0
Delay 1 5 0 6 6
Delay 2 8 6 6 6
Lower acc 10 6 3 3
Lower ret 9 11 9 9
Pump acc 100% 100% 100% 100%
Pump dec 100% 100% 100% 100%
Temp guard No Yes No No
10.2.9.2 Settings
Under the Settings menu it is possible to select the language to be shown in the display.
Swedish, English, German, French, and a “custom” language can be selected (preselected
as Spanish). It is possible by using a PC and a special program to add on a “custom”
language.
10.2.9.3 Total reset

In the Total Reset menu it is possible to reset all parameters, accessories, users, calibrations
and log on to the original values.
• All drivers: Removes all users and goes back to the original setting. Also the Service
code and Local code will be reset to the original settings.
• Options: Resets all the accessories to their original values.
• Settings: Resets all the settings to their original values.
NOTE!
If executing a "Total reset" on Settings the truck type must be selected.
• Calibration: Removes all calibrated values. A new calibration procedure must be carried
out for the truck to be capable of operation again.
• Logs: Clear all logs. The hour counters are not reset to zero.
In order to exit from the Total Reset menu the system must be restarted by switching off the
power.
10.2.9.4 State the type of truck

After all the settings have been removed, or a new ATC has been installed, the type of truck
must be stated. When the truck is restarted after the intervention, the ATC will automatically
open a menu where it is possible to select which type of truck the ATC is to be used in.
PS <-
Mark the appropriate type of truck and press Enter. If the wrong type of truck is selected, use
the Rest menu to reset all the settings and try again.
124 PS/PSH
10.2.9.5 Monitor menu

By pressing the Enter and 7 key at the same time it is possible to access the Monitor menu
from the Operational mode.
WARNING!
As the monitor menu is active, the truck reacts physically by activating the
controls.
The Monitor menu shows the rotation speed, power consumption, motor temperature and
TMC temperature.
1. Monitor menu
Traction
2. Monitor menu
Pump
3. Monitor menu
Steering
4. Monitor menu
Wire guide
5. Monitor menu
In/Out
Driving
Under the Traction menu it is possible to control the motor speed in real time and the power
consumption or motor and TMC temperatures.
C: 025 degC
M: 027 degC
1800 RPM
56 A
Pump: Not applicable for PS.

Steering: Not relevant for PS.
Wire guidance Not applicable for PS.
In/Out
Under In/Out it is possible to check all inputs to ATC, TMC and HVC in real time. It is also
possible to check the ATC internal interlock functions. The function to check the inputs is
built up as shown in fig:
1. ATC inputs:
2. TMC inputs:
3. HVC inputs:
4. EPS inputs:
5. ATC in/out:
PS/PSH 125
Note that the truck is in Operational mode when the Monitor menu is shown. In other words
the truck can be driven, and therefore it is appropriate to block it up in accordance with the
safety instructions.
10.2.9.6 Switch off HVC

It is possible to switch off HVC. This is done in Auth. service => settings => hydraulics =>
hvc setup.
HVC 1: off
v^
10.2.9.7 Selection of options

There are several different selections under options. hey are used to tell the ATC which
accessories the truck is equipped with. More information regarding the options and their
functions are found under Section 10.2.9.29, page 138.
In the first row of the display, the option's name and the status of the option (off or on) are
indicated . Setting an option is done as follows:
1) Step to the option that is to be set and press Enter.
Lift stop: no
0: 1:yes
2) Press the 0 key to turn off the option or 1 to turn it on.
Lift stop: yes

New value saved!
10.2.9.8 Calibrate the proportional buttons

1) Open the Auth. service menu => Calibrate => Lift. The following display appears:
Release lift and press ENT
2) Make sure that no buttons are pushed and press ENT.
Order full raise and press ENT
3) Push the lift button completly and push ENT.

4) Repeat the steps for the lowering button.
5) The following display appears:
Signal check: x.xx V Out: xxx%
In this menu it is now possible to check that the calibration is correct. In the case of full
lifting the signal check must show the following:
• PS signal check: 5,2 V and 0%, (18% for ATC units older than version 2.18)
• PSH signal check: 5.2 V and 0%.
In the case of full lowering the voltage is not affected, but Out must show 100%. To
proceed further press ENT. If this is not met, repeat the procedure until it corresponds.
6) Press ENT to leave the menu.
7) Disconnect the battery and then restart the truck.
8) Perform a functional test for the lifting/lowering functions.
126 PS/PSH
Dual proportional buttons

If the truck is equipped with dual proportional buttons, it is neccessary to activate Dual lift in
the Auth. service menu => Options => Dual Lift => Yes.
1. Enter the Auth. service menu => Calibrate => Channel 2. The following is displayed:
Release k. 2 and press ENT
2. Make sure that no buttons are pushed and press ENT.
Order full + direction and press ENT
3. Push the lift button completly and push ENT.
4. Repeat the steps for the lowering button.
5. Signal check as for the standard proportional buttons.
10.2.9.9 Calibrating the speed controller

Under Calibrate it is possible to calibrate the speed controller. This is done as follows:
1) Navigate to Service menu » Calibrate » Accelerator. Then press Enter. The following
display appears:
Release throttle
press ENT
2) Leave the speed controller in neutral, and press enter. The following display appears:
Go to end points
press ENT
3) Give maximum speed in both directions, without pressing hard to the end position, and
then press enter.
The display shows whether the calibration was successful or not. (only software 2.23–)
OK
Press ENT
Not successful
Press ENT
Press Enter
4) The calibration is now finished. A window is shown where it is possible to test the
response of the speed controller. Press enter to end.
Signal check:
2.3V Out: 064%
NOTE!
The speed controller must be calibrated at each service.
10.2.9.10 Calibration of lifting and lowering controller (ATC T4mk2, 2007w28–)

NOTE!
The lifting and lowering controller must be calibrated for both ON/OFF and
proportional regulation.
1) Navigate to Service menu » Calibrate » Lift. The following display appears:
PS/PSH 127
Lift settings to 0
press ENT
2) Check that no controllers are activated. Then press ENT. The following display appears:
Order full raise

press ENT
3) Press lift completely down on the right lifting and lowering control. Then press ENT.
4) The following display then appears:
Order full lower

press ENT
5) Press lower completely down on the right lifting and lowering control. Then press ENT.
6) The display shows whether the calibration was successful or not. (only software 2.23–)
OK
Press ENT
Not successful
Press ENT
7) The following display appears:
Signal check:
x.xV Out: xxx%
In this menu it is now possible to check that the calibration is correct. The signal check
must show the following values:
• With lifting activated: 4.7 V (± 0.1 V)
• Neutral (control not activated): 2.7 V (± 0.1 V)
• With lowering activated: 0.6 V (± 0.1 V)
Press ENT.
8) Repeat the same calibration procedure for the left lifting and lowering control by
selecting Channel 2, and performing steps 1-6. Finish after this with ENT.
9) Exit the Auth. service menu by going to Exit and pressing ENT.
10) Disconnect the battery and then restart the truck.
11) Perform a functional test of the lifting/lowering functions.
10.2.9.11 Adding a new driver

New drivers can be added via the Set Access menu. Select Operator to add a new driver.
1) Select new/update, and press enter.
OPERATOR:
New/update v^
2) Enter the driver ID to be altered or changed.
Operator ID:
?
128 PS/PSH
3) Select the driver category the driver is to belong to.
Op category 3
?
4) Select the code applicable for the driver. If the code or category is to be changed for an
existing driver, the code associated with this driver ID must be specified first.
New code:
????
5) To verify the code it must be entered one more time.
Verify new code:

***?
6) Press enter to end.
OK
Press ENT
10.2.9.12 Changing the format of the driver ID and access code

In the submenu Set Access there is a function to set the number of digits in the driver ID and
access code. Both these can be set from between one to seven digits. Note that drivers with
longer codes will not be able to logon if the number of digits is reduced! On the other hand if
the number of digits is increased the requisite number of zeros will be added to existing,
shorter codes.
1) The format of the code/ID is changed in Set access » Driver » Format.
OPERATOR:
Format v^
2) A warning in two parts is shown. Press 2 to see the second part of the warning.
Continue by pressing 1.
CAUTION! Reduced
length may lead-
-to lost entries

0:end 1:continue
3) Changing the length of the ID or Code.
ID length: 5
v
Code length: 4
^
4) Step out by pressing a four, or the horn key.
10.2.9.13 Changing the access code for the Local or Authorised service menu
The codes for both Local and Authorised service can be changed in Set Access. This is
done in the same way for both, as follows:
1) Select Set access » Local and press enter.
PS/PSH 129
SET ACCESS:
Local v^
2) Specify the valid code.
Old code:
****???
3) Write in the new code.
New code:
???????
4) Verify the new code.
Verify new code:

****???
5) Press enter to end.
OK
Press ENT
10.2.9.14 Log functions and hour counter

There are two different log functions in ATC, error log and temperature log. Both can be read
and cleared in the Authorised Service .
There are also a number of hour counters, and these can divided into two categories, total
time and trip time. Both can be read in the Authorised Service , but only the trip category can
be cleared. The times measured are:
• Active time – the time the truck is used actively, or in other words the total of travel time
and pump time.
• Log time – the time the system has been logged on.
• Travel time – the time the traction motor has been used.
• Pump time – the time the pump motor has been used.
The hour counters can also be read in external units, e.g. a TMC or HVC.
The hour counter for total time can be set in the Auth. service menu => Logs/Counters =>
Hour meters. Note that the hour counter for total time can only be set to a value greater than
the existing value. If a lower value is entered, there will be no error message, but the new
value will not be saved.
10.2.9.15 Read hour counter

1) Navigate to Service menu » Logs/counters » Hour meters
LOGS/COUNTERS:
Hour meters v^
Press Enter.
2) Select Trip, Total or Read external.
Hour meters:
Total v^
130 PS/PSH
Hour meters:
Trip v^
Hour meters:
Read external v^
Press Enter.
3) Navigate between the four different hour counters.
TOTAL pump:
00001.246h
4) Step back with the 4 key or with the horn key.
10.2.9.16 Temperature log

The temperature log registers temperature measurements from the TMC at five different
temperature intervals. The log saves the number of hours the different temperatures have
been measured.
A distinction is made between TMC and drive motor temperatures in different intervals,
where TMC belongs to the lower intervals and the drive motor to the higher.
Table 40. Temperature log

Temperature levels: Hours (the information is an example)
-40°C 436.53 h
41-50°C 271.28 h
51-60°C 42.74 h
61-70°C 3.61 h
>71°C 0.00 h
Table 41. High intervalls (Drive motor)

Temperature levels: Hours (the information is an example)
-60°C 137.63 h
61-80°C 41.77 h
81-100°C 24.88 h
101-120°C 2.6 h
>121°C 0.32 h
10.2.9.17 Error log

ATC has an error log system that logs external and internal errors. External errors are errors
that external units detect and report to ATC. Internal errors are errors that ATC detects itself.
The error code, description of the error, date and time, are saved in the error log.
The error log function is based on four error classes:
• A – Shown in the display and saved in the log. Only cleared after it has been read in the
error log.
• B – Shown in the display and saved in the log. Cleared when the error has ceased.
• C – Saved in the log. Not shown in the display.
• Warning – Gives a text warning. Certain warnings are logged.
PS/PSH 131
In addition to being shown in the display, also indicates an error through an audible signal.
The signal is repeated every other minute as long as the error/warning is shown in the
display. The warning is shown in the full top bar on the display, while the error is shown in the
second bar position 5-8.
The error log is divided into primary and secondary faults. A secondary error is an error that
occurs 2 seconds after the first error occurred. If the last primary error is repeated without
any other error occurring, this error will not be logged separately in the log. It will be added to
a counter in the log of the last error instead.
Figure 73. ATC T4 fault log (example)
NOTE!
If the log is reset, the fault code E027 is logged.
Figure 74. Fault log (primary log and secondary log)
132 PS/PSH
10.2.9.18 Read error log

• The error log is opened with Logs » Error log
SERVICE MENU:
< Logs >
• The primary faults in the error log are navigated with the 8 and 2 keys. Information is
read from the error log as follows:
• The [i] key is used to access the secondary log. The secondary errors can then be
navigated with the 2 and 8 keys.
NOTE!
The error log must not normally be cleared, since it contains the history of the
machine, which may be critical during trouble shooting.
10.2.9.19 Performance parameters

The performance parameters in ATC are divided into two levels, machine parameters and
driver parameters. The machine parameters represent the basic setting of the machine.
They are preset at the factory and can only be changed by using a special PC program. The
driver parameters are percentages of the machine parameters.
10.2.9.20 Pump settings (2008w37–)

Settings for the pump are located in the Auth. service menu –› Settings –› Pump.
Delay1 and Delay2
Delay1 is used to set the required delay from pressing the button to initiate fork lifting until
lowering is again permitted. The proportional valve is completely open until the delay has
elapsed. Delay1 is set in steps of 100 ms. The time can be set between 0 and 255 seconds.
(For the basic settings refer to the information that was delivered together with the truck)
Delay2 is used to delay the closing of valves Y2 and Y5 when the buttons change from
lifting/lowering to the neutral position. This gives a smoother braking movement for the forks.
Delay2 is set in steps of 100 ms. The value can be set to between 0 and 255. (For the basic
settings refer to the information that was delivered together with the truck.)
PS/PSH 133
Delay1: xxx% ENT -> Delay1: xxx

New value: ?
^ Delay1: x
New value saved!
^ <- Not successful!

Press ENT
Delay2: xxx% ENT -> Delay2: xxx

New value: ?
^ Delay2: x
New value saved!

Press ENT
Cont Delay
Cont Delay determines the time delay before the pump motor starts after the button for fork
lifting is pressed. A higher value provides a longer delay. The value can be set to between 0
and 255. (For the basic settings refer to the information that was delivered together with the
truck.)
Cont Delay: xr ENT -> Cont Delay: xr

New value: ?
^ Cont Delay: xr
New value saved!

Press ENT
Lower acc and Lower ret

A higher value for Lower acc provides a lower acceleration of the lowering movement of the
forks. A higher value for Lower ret provides a lower speed reduction of the lowering
movement of the forks. (For the basic settings refer to the information that was delivered
together with the truck)
Lower acc: xxx% ENT -> Lower acc: xxx

New value: ?
^ Lower acc: xxx

New value saved!

Press ENT
Lower ret: xxx% ENT -> Lower ret: xxx

New value: ?
^ Lower ret: xxx

New value saved!

Press ENT
134 PS/PSH
10.2.9.21 Driver categories

The software in ATC supports four different driver categories. These are used to give
different drivers difference performances. One example is the possibility to have a category
for experienced drivers and one for beginners. All driver IDs must be associated with a driver
category.
Parameter Description Limits
Fwd speed Maximum speed forward 20-100%
Rev speed Maximum speed in reverse 20-100%
Tract accel Acceleration 20-100%
Cutback 1 Creep speed 0-90%
Cutback 2 Tiller up drive speed 0-90%
Tract curr Current limit 20-100%
Rdc brake Braking torque for reducer brake 0-100%
Neut brake Braking torque for neutral position brake 0-100%
Rev brake Braking torque for reversing brake 50-100%
10.2.9.22 Set driver parameters

NOTE!
The driver parameters must normally not be adjusted.
1) Select Settings » Performance. Select in which category the driver parameters are to be
changed.
PERFORMANCE:
Driver category:1 v^
2) Navigate amoung the different driver paraemeters with the 2 and 8 keys. Press Enter to
select parameter.
Cutback 2 20%
v^
3) Write in a new value and press enter.
Cutback 2 25%
New value saved!
10.2.9.23 Pin code

ATC uses a pin code instead of a key switch. Each driver is defined with a unique ID number.
A pin code is linked to each driver ID, which can be 1-7 digits in length. Up to 100 driver IDs
can be saved. The driver ID and code are used together to access the truck, thereby
replacing the key switch.
10.2.9.24 Safety checks

When logging into the truck there is a safety check of the brake switch, lift system, safety
switch and speed controller. The lifting and speed controllers must be inactivated while
logging on and the brake switch must previously have been in its neutral position before
logging on. If any of these safety tests fail a warning is shown in the display, with a request to
reset the activated control to neutral position. Depending on which control is activated, an
interlock function will be actuated to prevent the use of certain of the truck functions.
PS/PSH 135
Table 42. 10.8

Warning text in display Cause Interlock function actuated
Release throttle The speed controller is actuated Speed interlock

during logon. This warning can
also be shown if the steering arm
is moved to operational mode
with excessive throttle
application.
Release tiller The brake switch was not in Safety interlock
neutral position during start-up.
Release controls One of the keys for Lift interlock
lifting/lowering was actuated
during logon. Also shown if more
than one lifting/lowering control
is actuated simultaneously.
Release controls The safety switch has returned to Safety interlock
neutral position after logon.
Table 43. 10.9

Interlock function System in the truck obstructed
Speed interlock Drive system
Safety interlock Drive system
Lift interlock Lift system
10.2.9.25 Speed limits

In ATC there are two ways of achieving a reduction in speed during the operation of the
truck, creep speed and tiller-up drive.
Creep speed is selected by switching with the 2 key between creep speed and full speed
(key 8 to go straight to full speed). The actual position is shown in the display with a symbol
representing a tortoise or a hare.
Tiller-up drive is a function that enables the truck to be operated with the tiller arm in raised
position. This function is intended to facilitate manoeuvring in confined spaces. The speed of
the truck is severely limited when this function is actuated. There is no indication on the
display to confirm that tiller-up drive is actuated.
10.2.9.26 General functional description

For the truck to be in neutral position the following is necessary:
• The tiller arm must be raised.
• The drive wheel must point straight forwards.
• Forks in bottom position.
• Battery plug disconnected.
This means that all the sensors in the truck are affected, in accordance with the way they are
described in the circuit diagram for the truck.
10.2.9.27 Truck position

The truck can be in four different positions:
136 PS/PSH
• OFF: Voltage disconnected.

• Logged on/Operational mode: To be compared with the battery plug connected and the
key in the lock, key in "on" position.
• Logged off: To be compared with the battery plug connected but the key removed.
• Standby: To be compared with the battery plug connected and the key in the lock, but in
off position.
In Operational mode all the truck functions such as lifting/lowering and travel can be used.
Logon with ID and pin code is required to access the Operational mode. In the Operational
mode the driver can utilise a lot of information via the display, such as date, time, battery
status, error codes and warning messages, etc.
• Date - shows ATC date.

• Time - shows ATC time.
• Field for error codes – an error code is shown when an error occurs. When a warning is
shown it is shown in the full upper bar instead.
• Symbol for creep speed/full speed - shows if the truck is in full speed or creep speed
mode.
• Hour counter – shows active or logged on time, depending on which selection was
made in the options menu.
• Battery indicator – shows battery status. When 20% battery status is reached the lift
system ceases to be available.
PS/PSH 137
10.2.9.28 Temperatures
Controller temperature
Situation Procedure Indication
Warning level Actual limiting starts. TMC sends warning "Check heat".
75-80°C
Stop level The actual limiting reaches the Warnings as above remain.
~100°C zero level.
Motor temperature
Situation Procedure Indication
Warning level Actual limitation to 70% of control TMC sends warning "Motor hot".
Adjustable temp. maximum.
level.
Stop level Actual limitation to 0% of control Warnings as above remain.
Adjustable temp. maximum.
level.
10.2.9.29 Options
Options Descriptions
Lifting stop Lift stop for fork lift. Shuts off pump as lift stop switch affected. Lift stop is
connected to a digital input on the TMC.
Restart Restart of fork lifting, activated by pressing 2 on the keyboard.
Safety system Safety system S3 (only full servo). When the safety system is switched in, the
speed is reduced while turning. The safety system is included in Fleet
management.
Efficiency Efficiency log. Included in Fleet management.
Collision detection Collision sensor. Included in Fleet management. The collision sensor is based
completely on software. The speed is monitored and sudden and rapid
reductions in speed are interpreted as various grades of collision.
*Log level -Setting for logging collisions.
*Warning levels-Settings for collision warnings on the display.
*Signal level-Setting for a collision that will sound the horn.
*Stop level-Setting for a collision that will stop the truck.
*Foreman level-Setting for a collision that will require the truck to be
unlocked using a code.
Damage log Damage log. 10 seconds after logging on, the truck goes down to creep
speed and the driver is asked a number of questions concerning possible
damage. If the driver answers in the negative, the truck goes to Operational,
i.e. it can be driven in the normal manner. Otherwise, questions are asked
about damage to various parts of the truck. Included in Fleet management.
Log off time Time for automatic logging off.
*Time segment a -Time to go to Standby.
*Time segment b -Time to log off.
*Dis tiller res (Disable tiller reset)-If this parameter is set to “Yes”, log on
from Standby to Operational by pressing the “I” button twice. If the parameter
is set to “No”, log on by activating the tiller arm brake switch.
Smart card The Smart card is a unit which is mounted on the machine housing (PP
Servo) or the tiller arm.With the Smart card, logging on is with a card instead
of a PIN code.
*Damage log-Smart card damage log.
138 PS/PSH
Options Descriptions
Display the log If the option is activated, the logged time is shown on the display. Otherwise,
total active time is displayed.
Summer time Automatically sets the clock to summer time.
key switch If this option is activated, the key switch is to be used instead of the PIN code
for logging on.
Speed red Speed reduction, which is connected to a digital input on the TMC.
Service alarm Automatic service reminder.
*Range-Time for service intervals.
Fixed platf Activated when a fixed platform is used (only PLP).
TillerUpD By pressing and holding in a button on the tiller arm, the truck can be driven
at creep speed, without the tiller arm brake switch being activated (only
PLL/PSD/PS).
Foot switch Activates the foot switch for the driver lifting platform (only PP).
Reversing warning Reversing warning that is switched in by the HVC (only PP).
Asociated controls Associated controls (only PP).
Stop on Ramp If the “Stop on Ramp” parameter is set to “ON” the truck will not roll back, if
parked on a gradient of 8% or less, due to the truck being electrically held.
This command will also override the “Autoparkbrake” parameter (applies to
software versions from 2.24) (not PP).
Dual lift Dual proportional buttons (only PS/PSH)
Vert. adj. straddle Vertically adjustable straddle legs (only PSH). Cannot be combined with Dual
legs lift.
Belly start If this parameter is set to “Yes”, the belly switch must be activated in order to
be able to log on (used as an “Enter” button). If the parameter is set to “No”,
log on immediately after entering the code.
Battery creep If this parameter is set to “Yes”, the truck driving speed is reduced by 30% if
the battery capacity has been 20% or less for 3 minutes of active time.
*Only shown if the option is activated.
WARNING!
Those options where it is stated that they are only used on a specific type of truck
must under no circumstances be activated on any type of truck other than those
stated. This is because the software uses the same digital inputs for different
functions on the different types of truck.
10.2.10 ATC Logic

10.2.10.1 General
The truck control logic is nowadays mainly generated in the ATC software, and not as
previously with cabling and the series and parallel connection of switches. For this reason, it
is no longer possible to measure all the logical conditions by means of a multimeter. This can
now be done with the help of the Monitor menu function for input control. There is no circuit
diagram for the software. Instead, a graphic description of the software conditions required
for ATC to request procedures has been generated.
The condition does not rule if it is true. Can be
compared to an NC contact.
The condition rules if it is true. Can be compared

to an NO contact.
PS/PSH 139
Two conditions after each other generate an “and”condition, i.e. both conditions must rule
for the objective to be achieved. Two parallel conditions generate an"or" condition, which
means that it is sufficient for one of the conditions to rule for the objective to be achieved.
Below is an example of how the horn works:
It is thus sufficient for one of the horn buttons to be activated for the horn to sound.
10.2.10.2 Direction selector PS
An explanation of the different interlock conditions is available under Section 10.2.9.24,

page 135. For more information about options, see Section 10.2.9.29, page 138.
140 PS/PSH
10.2.10.3 Brake system PS

page 135. Note that the brake will be automatically engaged after 500 ms on a stationary
truck with the speed controller in neutral position.
10.2.10.4 PS Lift system

page 135.
10.2.10.5 Printing of statistics

A function is available under customer service to print out all statistic functions, either
individually or all at once. For this Any serial printer or a PC can be used for this purpose.
10.2.10.6 ATC connector

ATC, connector and pin numbering. Connections seen from above.
PS/PSH 141
Figure 75. Cortex card
10.2.10.7 Digital I/Os

Digital inputs ATC
There are 12 digital inputs on the ATC card, of which seven are used for the pushbuttons on
the tiller arm. The pushbuttons control the functions lift/lower, the horn, Tiller-up drive, and
the raising/lowering of the straddle lift. The signal voltage is 5 V.
The other five digital inputs are not used in these truck models.
The fact that the inputs are read by the ATC can easily be confirmed in the Auth, service
menu by selecting Test => Inputs, and then activating the different functions.
The signal supply of approx. 5 V is on pin no. 1 in the following connectors:
Connector Functionality Comment
XJ1.3 Lift PS
XJ2.3 Lower PS
XJ3.3 Lift (alternative)
XJ4.3 Lower (alternative)
XJ5.3 Creep drive (Tiller-up drive)
XJ14.4 Horn 1 Supply 5 V pin no. 2
XJ14.3 Horn 2
Digital inputs TMC, PS (–2011w15), PSH

There are ten digital inputs in TMC, of which three are used for these truck models.
Signal supply of 24 V is taken from pin no. X5.2.
142 PS/PSH

X5.3 Brake switch Closed in the upper and lower
arm positions.
X5.7 Top position switch Breaks at end position
X5.8 Open brake Prevents driving when the brake
is mechanically disconnected.
The switch is closed during
normal operation.
Digital inputs CMC, PS (2011w16–)

There are eleven digital inputs in the CMC, of which two are used for these particular truck
models.
X5.1 Brake switch Closed in the upper and lower
arm positions.
X5.19 Open brake Prevents driving when the brake
is mechanically disconnected.
The switch is closed during
normal operation.
Digital 24V outputs ATC

All the outputs in ATC are of the “low side” type, which means that they close to B-.
Only one output is used in these trucks. Signal supply of 24 V is on XJ11.3.
XJ11.4 Creep drive relay Energises the creep drive relay
K4 when the creep drive button
is activated. The function of the
relay is to release the brake
when the arm is in its upper
position and the Tiller-up drive
function is used.
Digital 24V outputs TMC, PS (–2011w15), PSH

There are five digital outputs in TMC. Four of these are of the “low side” type, which means
that they close to B-. The fifth output is of the “high side” type, which means that it closes to
B+. It is this fifth output that closes the lowering valve Y2.
X6.1 Energises main contactor K1 24 V supply from X6.2
X6.3 Energises the electric brake Y1 24V supply via brake switch
X6.4 Energises the lift contactor K2 24 V supply via X6.5
X6.6 Energises the horn H1 24 V supply via X6.5
X6.11 Energises the lowering valve Y2 0 V supply via X6.12.
CAUTION!
This output is not
short-circuit-proof
Digital 24V outputs CMC, PS (2011w16–)

There are seven digital outputs in the CMC. All of these are of the “low side” type, which
means that they close to B-.
PS/PSH 143

X5.2 Controlling of electric brake. Controlled to B+.
X5.9 Controlling of lowering valve. +24V.
X5.12 Control of main contactor. Controlled to B-.
X5.33 Electrically operated valve, forks. Closes during fork lifting and
lowering.
straddle legs. option is selected and the
straddle legs are raised or
lowered.
Digital 24V outputs HVC, PS (–2011w15), PSH

The HVC module consists of five outputs, of which one can also be used as a proportional
output. All the outputs are of the “low side” type and close to B-. 24 V supply to the valves is
taken from X23.7.
X23.4 Energises valve Y4 Activated together with the pump
during lifting of the forks, and
together with valve Y2 during
lowering of the forks.
10.2.10.8 Cold resistance values, PS (-2011w15), PSH

Component Resistance (Ω)
Contactor K1 approx. 30
Contactor K2 approx. 30
Valve coil Y2 approx. 26
Brake Y1 approx. 23
Temperature sensor drive motor approx. 940 Ω at room temperature. The sensor
has a positive temperature coefficient
10.2.10.9 Cold resistance values, PS (2011w16–)

Component Resistance (Ω)
Contactor K1 48
Valve coil Y2 40
Valve coil Y3 30
Valve coil Y4 -
Valve coil Y5 -
Brake Y1 21
Temperature sensor 940
144 PS/PSH
10.2.11 Fuses, PS (–2011w15), PSH

Fuses
F1 100 A Traction motor
F2 125 A Pump motor (PS)
160 A Pump motor (PSH)
F3 7.5 A Manoeuvring
10.2.12 Fuse, PS (2011w16–)

Fuses
F1 160 A Traction motor/Pump motor
F3 7.5 A Manoeuvring
F4 7.5 A Valves/Horn

10.3.1 ATC fault code indications
The error codes 1-33 are all memory errors that can occur in conjunction with program errors
during unsuccessful reprograming or during electrostatic discharge.
Fault code indications Class Explanation Control/Procedure
E1 ATC invalid NVM access Warning B Attempt to write to invalid Settings lost. No action
E2PROM address required.
E2
E3
E4
E6 ATC NVM (timer) access Warning B Time out under Settings lost. No action
lost READ/WRITE access to required.
E2PROM in timer module
E7 ATC NVM (statistics) Warning B Time out under Settings lost. No action
access lost READ/WRITE access to required.
E2PROM in statistics
module
E8 Not used
E9 Not used
E10 Not used
E11 ATC NVM parameters C One or more parameters New settings may be
partially reset during start-up (parameters/accessories/sett necessary.
ings) out of range. This can
also happen when the
system starts up for the first
time.
E12 ATC NVM local code C Local access code out of New settings may be
reset during start-up range (0-9999999). This can necessary.
also happen when the
system starts up for the first
time.
E13 ATC NVM Auth. service C Auth. service access code New settings may be
code reset during start-up out of range (0-9999999). necessary.
This can also happen when
the system starts up for the
first time.
PS/PSH 145

E14 ATC NVM user entry C User ID/code or profile New settings may be
cleared during start-up outside area necessary.
E15 ATC NVM error log C Error log corrupt No action required.
cleared during start-up
E16 ATC NVM timer (timers) C Timer outside area No action required.
cleared during start-up
E17 Not used
E18 Not used
E19 Not used
E20 Not used
E21 ATC NVM all users C All users forced to reset in New settings may be
forced to reset the reset menu necessary.
E22 ATC NVM all users C Accessory parameters New settings may be
forced to reset forced to reset in the reset necessary.
menu
E23 ATC NVM setting of C Setting parameters forced to New settings may be
parameters forced to reset reset in the reset menu necessary.
E24 ATC NVM calibration C Calibration parameters New settings may be
parameters forced to reset forced to reset in the reset necessary.
menu
E25 ATC NVM all logs forced C All logs forced to reset in the No action required.
to reset reset menu
E26 C Not used
E27 ATC NVM error log C Error logs forced to be No action required.
forced to reset manually reset in the Auth.
service menu
E28 ATC NVM temperature C Temperature log forced to be No action required.
log forced to reset reset manually in the Auth.
service menu
E29 ATC NVM trip meter C Trip meter time/utilisation No action required.
time/utilisation forced to forced to be reset manually
reset in the Auth. service menu
E30 ATC NVM driver log C driver log forced to resest in No action required.
forced to reset in the Local the LOCAL menu
menu
E31 ATC NVM effective time C Effective time forced to No action required.
forced to reset in the Local resest in the LOCAL menu
menu
E32 ATC NVM damage log C Damage log forced to resest No action required.
forced to reset in the Local in the LOCAL menu
menu
E33 ATC NVM collision log C Collision log forced to resest No action required.
forced to reset in the Local in the LOCAL menu
menu
E34 Not used No action required.
E35 ATC analogue speed B Analogue speed input not Approved range approx. 0.3
input not within approved within approved voltage – 4.8V
voltage range range
1. Recalibrate
2. Change the ATC
146 PS/PSH

E36 ATC analogue brake B Analogue speed input not Not used on these truck
input not within approved within approved voltage models. If the error code still
voltage range range comes up, check that the
ATC is correctly connected,
or else change it.
E37 ATC analogue lift input B Analogue lift input not within Not used on these truck
not within approved voltage approved voltage range models. If the error code still
range comes up, check that the
or else change it.
E38 ATC analogue lower B Analogue lower input not Not used on these truck
input not within approved within approved voltage models. If the error code still
voltage range range comes up, check that the
or else change it.
E39 ATC Analogue XJ3.3 B Analogue XJ.3 (A-IN1) input Not used on these truck
(A-IN1) input not within not within approved voltage models. If the error code still
approved voltage range range comes up, check that the
or else change it.
E40 ATC Analogue XJ4.3 B Analogue XJ4.3 (A-IN1) Not used on these truck
(A-IN1) input not within input not within approved models. If the error code still
approved voltage range voltage range comes up, check that the
or else change it.
E41 ATC Analogue B Analogue potentiometer Not used on these truck
potentiometer input, low input, low value not within models. If the error code still
value not within approved approved range comes up, check that the
range ATC is correctly connected,
or else change it.
E42 ATC Safety switch A Check of safety switch If error recurs, change ATC.
monitoring lost redundancy lost
E43 ATC speed controller B Analogue speed 1. Recalibrate
monitoring lost controller/check of speed 2. Change the ATC
controller signal in neutral
position, lost
E44 Not used
E45 Not used
E46 ATC Error detected on A Error detected on servo input Not used on these truck
servo input models.
E47 A
E48
E49
E50 ATC/TMC low battery C Current battery status Charge the battery. In the
received from TMC is less case of repeated E50 logs,
than 20% check the BDI settings (See
Section 10.2.2.1, page 110)
E51 Error low common pot B Error low common supply 1. Replace the lift/lower
range switch.
2. If the error still occurs
replace the ATC.
E52 Not used
PS/PSH 147

E53 Error high hydraulic pot B Error in supply range, high 1. Replace the lift/lower
feed to hydraulic controller switch.
2. If the error still occurs
replace the ATC.
E54 Not used
E55 Not used
E56 Lift range fault B Lift/lower signal outside • Tiller with on/off
permitted range buttons: Reset
calibration of lift lower
and aux 1.
• Tiller with rocker switch:
Check the inductive
sensors and the
connections.
E57 Not used
E58 Not used
E59 Not used
10.3.2 Fault code indications, TMC (trucks with CMC)

E100 CAN error B CAN communication fault 1. Check that TMC
in the TMC during start up receives voltage
supply
2. Check the CAN
communication link
between the ATC and
the TMC to make
sure there is no fault
or short-circuit in the
cables. Refer to the
wiring diagram.
3. There may be a
short-circuit on the
ATC, TMC or HVC
communication port.
Disconnect HVC and
see if the error
recurs, otherwise
change TMC first and
ATC as the other
unit.
E101 TMC Watchdog B TMC monitoring has Try restarting the truck. If
triggered this does not help, change
CMC.
148 PS/PSH

E102 TMC logic error 1 B Positive supply voltage to 1. Try restarting
the logic is outside the 2. Charge the battery if
range it is getting flat.
3. Check that the thick
cables between the
motor and CMC are
properly tightened
and that they have a
low ohm factor.
Check also the
supply cables to
CMC, and the cable
and voltage supply to
contact X5.10.
4. Change the CMC
5. Change traction
motor
E103 TMC logic error 2 B Error in the part of the 1. Try restarting.
logic that handles the 2. Charge the battery if
return supply of the phase it is getting flat.
voltage
3. Check that the thick
cables between the
motor and CMC are
properly tightened
and that they have a
low ohm factor. Akso
check the supply
cables to the CMC,
and the cable and
voltage supply to
contact X5.10.
4. Change the CMC
5. Change traction
motor
E104 TMC logic error 3 B Error in the part of the 1. Try restarting. If the
logic that handles the error recurs, change
overlead protection CMC.
2. Change the motor
E105 TMC emergency B Communication response 1. Restart
monitoring has tripped from TMC has not been 2. Check the CAN bus
received in time cabling carefully, if
the error occurs
repeatedly, to make
sure there is no play
in the contacts and
that the terminal
resistance maintains
120 Ω +/- 5% 3.
Check that the CAN
bus is separated from
the heavy duty
cables. Interferance
can give rise to the
error.
PS/PSH 149

E106 TMC supply low B This test is done on 1. Motor cable fault,
start-up and when connection fault,
E107 TMC supply high
stationary. (No drive insulation fault in the
manoeuvre is given) motor or to chassis.
2. Change the CMC
E108 TMC contactor A The main contactor Check main contactor K1
closed contact tips are closed to make sure the contact
before voltage has tips are not welded, or that
reached the coil it is not short-circuited
over the terminals via the
cables.
E109 TMC contactor open A The logic has low voltage 1. Break in cables to the
to main contactor K1 but coil.
the contactor tips do not 2. Break in coil.
close
3. The contactor tips do
not close, or fail to
connect with CMC.
E110 TMC current B Check that the current is Change the CMC
measurement in the zero when truck is
standby mode is not equal stationary
to zero
E111 TMC capacitor B The capacitor in TMC 1. Check that there is
charging does not charge up as it battery voltage to
should during start-up TMC, between B-
and contact X5.10. If
not, check battery
voltage, supply
cables and their
connections.
2. Change the CMC
E112 TMC output A The output to the main 1. Check that there is
short-circuited contactor coil is no short-circuit in
short-circuited main contactor K1,
the coil, or that the
freewheel diode is
not reversed or
short-circuited. Cut
the diode and check
that there is no
short-circuit in the
cables to the coil.
2. Change the CMC
E113 TMC contactor B The output for the main Change the CMC
output contactor does not
function
150 PS/PSH

E114 TMC coil A One of the outputs X5.10, 1. There is a
short-circuited X5.12, X5.4/X5.2 or X5.26 short-circuit in either
is short circuited the main contactor
coil K1, the brake coil
Y1, the lift contactor
coil K2, or in the
horn.
2. There is a
cabling that connects
to the components or
in the freewheel
diodes, or in the
capacitor that
suppresses the horn.
3. Internal short-circuit
in one of these
outputs, change
CMC
E115 TMC generic fault B TMC self-test failed Try restarting a few times.
If this does not rectify the
problem, change TMC.
NOTE!
The fault is
probably
logged
together with
E123, but
should
normally never
occur. If E115
or E123 still
log, this should
be reported to
the service
function at the
truck
manufacturer.
E116 TMC CAN bus A Communication command 1. If other CAN errors

from ATC not received in are logged, rectify
time these first
2. There may be an
error on ATC,
interference on the
CAN bus, or play in
the CAN bus
connector ring
E117 TMC wrong battery B Incorrect battery voltage The TMC may be
incorrectly configured.
Change the CMC
E118 TMC pulse B Error on the signal from Check and measure the
transducer error the transducer bearing in transducer in accordance
the traction motor with the trouble shooting
chart for "Traction motor",
see Section 10.3.6.5,
page 167.
PS/PSH 151

E119 TMC Brake output A Brake output X5.4/5.2 is 1. If there are other
defective error codes logged,
rectify these errors
first
2. Change the CMC
E120 TMC EEPROM error C EEPROM set to default. The battery settings have
Error in the range that probably been lost. See
includes adjustable Section 10.2.2.1,
values. page 110
E121 TMC controller Warning C The internal temperature 1. See Trouble
temperature monitor has exceeded the shooting: Section
75° C warning level. The 10.3.6.8, page 170
current is limited in 2. Change the CMC
relation to the
temperature. TMC stops
completely at 100°C.
E122 TMC motor Warning C The drive motor See Trouble shooting:
temperature temperature has Section 10.3.6.7,
exceeded the warning page 169
level.
E123 TMC generic Warning C Generic warning Try restarting a few times.
If the error does not
disappear, change TMC.
NOTE!
The fault is
probably
logged
together with
E115, but
should
normally never
occur. If E115
or E123 still
log, this should
be reported to
the service
function at the
truck
manufacturer.
E124 TMC PEV output B The output to lowering First confirm that the valve
valve Y2 connection X5.9 coil is not short-circuited,
is defective that the freewheel diode
short-circuits or is
reversed, or that there is a
short-circuit in the cabling.
NOTE!
This output
connects to B+
and is not
short-circuit-
proof. For this
reason make
sure to check
that no external
short-circuit
exists before
changing CMC.
152 PS/PSH

E125 TMC temperature Warning C The internal temperature Change the CMC
sensor sensor is defective
E126 TMC Temperature Warning C The drive motor First check trouble
sensor traction motor temperature sensor is shooting for: Section
defective 10.3.6.7, page 169
E127 TMC Current sensor B Current calibration in Try restarting a few times.
error progress If this does not help,
change the CMC.
10.3.3 Fault code indications, TMC (trucks before CMC)

E100 CAN error B CAN communication 1. Check that the
fault in the TMC during TMC is receiving a
start up voltage supply.
2. Check the CAN
communication link
between the ATC
and the TMC to
make sure there is
no fault or
cables. Refer to the
wiring diagram.
3. The may be a
short-circuit on the
ATC, TMC or HVC
communikation
port. Disconnect
HVC and see if the
error recurs,
otherwise change
TMC first and ATC
as the other unit.
E101 TMC Watchdog B TMC monitoring has Try restarting the truck.
triggered If this does not help,
change TMC.
E102 TMC logic error 1 B Positive supply voltage 1. Try restarting.
to the logic is outside 2. Charge the battery
the range if it is getting flat.
3. Check that the
thick cables
between the motor
and TMC are
properly tightened
and that they have
a low ohm factor.
Also check the
supply cables to
the CMC, and the
cable and voltage
supply to contact
X5.1.
4. Change TMC.
5. Change the
traction motor
PS/PSH 153

E103 TMC logic error 2 B Error in the part of the 1. Try restarting.
logic that handles the 2. Charge the battery
return supply of the if it is getting flat.
phase voltage
3. Check that the
thick cables
between the motor
and TMC are
properly tightened
and that they have
a low ohm factor.
Also check the
supply cables to
the TMC, and the
cable and voltage
supply to connector
contact X5.1.
4. Change TMC.
5. Change the
traction motor
E104 TMC logic error 3 B Error in the part of the 1. Try restarting. If the
logic that handles the error recurs,
overlead protection change TMC.
2. Change the motor.
E105 TMC emergency B Communication 1. Restart.
monitoring has tripped response from TMC has 2. Check the CAN
not been received in bus cabling
time carefully if the error
occurs repeatedly,
to make sure that
there is no play in
the contacts and
that the terminal
resistance
maintains
120 Ω +/- 5%.
3. Check that the
CAN bus is
separated from the
thick cables.
Interferance can
give rise to the
error.
E106 TMC supply low B This test is done on 1. Motor cable fault,
start-up and when connection fault,
E107 TMC supply high
stationary. (No drive insulation fault in
manoeuvre is given) the motor or to
chassis.
2. Change TMC.
E108 TMC contactor A The main contactor Check main contactor
closed contact tips are closed K1 to make sure the
before voltage has contact tips are not
reached the coil welded, or that it is not
short-circuited over the
terminals via the cables.
154 PS/PSH

E109 TMC contactor A The logic has low 1. Break in cables to
open voltage to main the coil.
contactor K1 but the 2. Break in coil.
contactor tips do not
3. The contactor tips
close
do not close, or fail
to connect with
TMC.
E110 TMC current B Check that the current is Change the TMC
measurement in the zero when truck is
standby mode is not stationary
equal to zero
E111 TMC capacitor B The capacitor in TMC 1. Check that there is
charging does not charge up as it battery voltage to
should during start-up TMC, between B-
and contact X5.1. If
not, check battery
voltage, supply
cables and their
connections.
2. Change TMC.
E112 TMC output A The output to the main 1. Check that there is
short-circuited contactor coil is no short-circuit in
short-circuited main contactor K1,
the coil, or that the
freewheel diode is
not reversed or
short-circuited. Cut
the diode and
check that there is
no short-circuit in
the cables to the
coil.
2. Change TMC.
E113 TMC contactor B The output for the main Change the TMC
output contactor does not
function
PS/PSH 155

E114 TMC coil A One of the outputs X6.1, 1. There is a
short-circuited X6.3, X6.4 or X6.6 is short-circuit in
short circuited either the main
contactor coil K1,
the brake coil Y1,
the lift contactor
coil K2, or in the
horn.
2. There is a
cabling that
connects to the
components or in
the freewheel
diodes, or in the
capacitor that
suppresses the
horn.
3. Internal
short-circuit in one
of these outputs,
change the TMC.
E115 TMC generic fault B TMC self-test failed Try restarting a few
times. If this does not
rectify the problem,
change the TMC.
NOTE!
The fault is
probably
logged
together with
E123, but
should
normally
never occur.
If E115 or
E123 still log,
this should
be reported
to the service
function at
the truck
manufacturer
.
E116 TMC CAN bus A Communication 1. If other CAN errors

command from ATC not are logged, rectify
received in time these first.
2. There may be an
ATC error,
interference on the
CAN bus, or play in
the CAN bus
connector ring.
E117 TMC wrong B Incorrect battery voltage The TMC may be
battery incorrectly configured.
Change TMC.
156 PS/PSH

E118 TMC pulse B Error on the signal from Check and measure the
transducer error the transducer bearing transducer in
in the traction motor accordance with the
trouble shooting chart:
Section 10.3.6.5,
page 167.
E119 TMC Brake output A Brake output X6.3 is 1. If there are other
defective error codes logged,
rectify those errors
first
2. Change TMC.
E120 TMC EEPROM C EEPROM set to default. The battery settings
error Error in the range that have probably been lost.
includes adjustable See Section 10.2.2.1,
values. page 110.
E121 TMC controller Warning C The internal 1. See Trouble
temperature temperature monitor has shooting: Section
exceeded the 75° C 10.3.7.7,
warning level. The page 178.
current is limited in 2. Change TMC.
relation to the
temperature. TMC stops
completely at 100°C.
E122 TMC motor Warning C The traction motor 1. See Trouble shooting:
temperature temperature has Section 10.3.6.8,
exceeded the warning page 170
level.
E123 TMC generic Warning C Generic warning Try restarting a few
times. If the error does
not disappear, change
TMC.
NOTE!
The fault is
probably
logged
together with
E115, but
should
normally
never occur.
If E115 or
E123 still log,
this should
be reported
to the service
function at
the truck
manufacturer
.
PS/PSH 157

E124 TMC PEV output B The output to lowering First confirm that the
valve Y2 connection valve coil is not
X6.11 is defective short-circuited, that the
freewheel diode
short-circuits or is
reversed, or that there is
a short-circuit in the
cabling.
NOTE!
This output
connects to
B+ and is not
short-circuit-
proof. For
this reason
make sure to
check that no
external
short-circuit
exists before
changing
TMC.
E125 TMC temperature Warning C The internal Change TMC.

sensor temperature sensor is
defective
E126 TMC Temperature Warning C The traction motor First check trouble
sensor traction motor temperature sensor is shooting for: Section
defective 10.3.6.7, page 169.
E127 TMC Current C Current calibration in Try restarting a few
sensor error progress times. If this does not
help, change TMC.
158 PS/PSH
10.3.4 Fault code indications, HVC (trucks with CMC)

E130 HVC emergency B Communication 1. Restart.
monitoring fault response from HVC has 2. Check the CAN
not been received in bus cabling
time carefully if the error
occurs repeatedly,
to make sure that
there is no play in
the contacts and
that the terminal
resistance is still
120 Ω +/- 5%.
3. Check that the
CAN bus is
separated from the
thick cables.
Interference can
give rise to the fault
E133 HVC proportional B The proportional output This function is not used
output is short-circuited is defective for these truck models.
If the error still occurs,
check that CMC has not
been connected
incorrectly. If not,
change the CMC.
E134 HVC On/Off B One or more On/Off 1. Check that there is
outputs short-circuited outputs short-circuited no short-circuit in
the cabling or
freewheel diodes to
valve coils Y3 and
Y4. The resistance
when cold must be
approx. 23 Ω.
2. Change CMC.
E135 HVC generic fault B HVC self-test failed Try restarting a few
times. If this does not
rectify the problem,
change the CMC.
NOTE!
Should
normally
never occur.
If E135 still
logs anyway,
this should
be reported
to the service
function at
the truck
manufacturer
.
PS/PSH 159

E136 HVC CAN bus B Communication 1. If other CAN errors
command from ATC has are logged, rectify
not been received in these first.
time 2. There may be an
error on ATC,
interference on the
CAN bus, or play in
the CAN bus
connector ring.
E139 HVC EEPROM C EEPROM set to default Log off and on, and note
error that the error codes
disappear from the log
book.
E140 HVC On/Off C On/Off outputs not OK 1. If there are other
outputs not OK error logs in
conjunction with
this error, trouble
shoot these first.
2. Do same trouble
shooting as for
error codes E134
and E138.
E141 HVC proportional C The proportional output This function is not used
output not OK is not OK for these truck models.
If the error still occurs,
check that HVC has not
been connected
incorrectly. If not,
change the HVC.
E142 HVC ff coils C The proportional output This output is not used
is not OK for these truck models.
E144 HVC The B The proportional valve is Check that the cabling
proportional valve is not not connected between to Y3 is correctly
connected X23.1 and X23.5 and connected and that the
the parameter EVP TYP wiring is not damaged.
in the SET menu is
analogue or digital.
E149 TMC Brake B The brakes are not 1. Check that the
working. brakes are
correctly connected
between
connectors X5.2
och X5.4.
2. Change the CMC.
E150 TMC Traction B The traction motor is not Change the CMC.
motor working.
E151 TMC Key off B The Key off signal is low 1. Check the
signal is low at Key on. connection of the
power cable from
the battery
terminals, positive
and negative, to
the contactor and
CMC.
2. Change the CMC.
160 PS/PSH

E152 TMC motor B One of the motor 1. Check that the
phases are open phases is open motor wiring is
circuited circuited. correctly connected
to the motor and
regulator.
2. Change the CMC.
E153 TMC Low voltage B X5.3 is not connected to 1. Check that there is
X5.3 the battery or has a 24V at connector
different voltage. X5.3.
2. Change the CMC.
E154 TMC Slip profile B Incorrect parameters for Check the hardware and
the “slip” profile setting. the values in the
settings menu for these
parameters.
E155 TMC Program B The program or the Change the CMC.
corrupted flash memory in the
CMC is corrupted.
E160 PMC CAN fault B CAN communication See E100.
fault in the PMC during
start up.
E161 PMC Emergency B See E105. See E105.
monitoring has tripped
E162 C Pump chopper. The Change the CMC.
current sensor feedback
is outside the permitted
standby range.
E163 PMC VMN low C 1. Motor cable fault,
connection fault,
insulation fault
beweeen the motor
and chassis.
2. Change the CMC.
E164 PMC VMN high C 1. Motor cable fault,
connection fault,
insulation fault
beweeen the motor
and chassis.
2. Change the CMC.
E165 PMC CAN bus B See E116. See E116.
E166 PMC Pump motor C Pump motor First check trouble
temperature sensor temperature sensor shooting for: Section
faulty. 10.3.6.4, page 167.
PS/PSH 161
10.3.5 Fault code indications, HVC (trucks before CMC)

E130 HVC emergency B Communication response 1. Restart.
monitoring fault from HVC has not been 2. Check the CAN bus
received in time cabling carefully if the
error occurs repeatedly,
to make sure that there
is no play on the
contacts and that the
terminal resistance
maintains 120 Ω +/- 5%.
3. Check that the CAN bus
is separated from the
thick cables.
Interferance can give
rise to the error.
E131 HVC Watchdog B HVC monitoring has Try restarting the truck. If this
triggered does not help, change HVC.
E132 HVC “hi side drivers” B 24V supply to X22.2 1. Check that the battery
voltage is not low, also
that it does not fall to
less than 16 V when
under load. Charge the
battery and check that
there is a good
low-resistance
connection between
X16 and X19.1 and
from X19.1 to X22.2.
Check also the minus
cable K2.4- to X19.4
and from X19.4 to
X22.4.
2. Change HVC.
E133 HVC proportional B The proportional output is This function is not used for
output is short-circuited defective these truck models. If the
error still occurs, check that
HVC has not been
connected incorrectly. If not,
change the HVC.
E134 HVC On/Off outputs B One or more On/Off outputs 1. Check that there is no
short-circuited short-circuited short-circuit in the
cabling or freewheel
diodes to valve coils Y3
and Y4. The resistance
when cold must be
approx. 23 Ω.
2. Change HVC.
162 PS/PSH

E135 HVC generic fault B HVC self-test failed Try restarting a few times. If
this does not rectify the
problem, change the TMC.
NOTE!
Should normally
never occur. If
E135 still logs
anyway, this
should be
reported to the
service function
at the truck
manufacturer.
E136 HVC CAN bus B Communication command 1. If other CAN errors are
from ATC has not been logged, rectify these
received in time first.
2. There may be an error
in the ATC, interference
on the CAN bus, or play
in the CAN bus
contacts.
E137 HVC positive feed low Warning C Positive logic supply is low Check that the HVC receives
approx. 12 V measured
between X22.1 and X22.4. If
not, check that TMC sends
12 V from X6.16 whether
loaded or unloaded. If the
voltage rises unloaded it
may be HVC consuming too
much current, or alternatively
TMC that cannot drive the
output specified for 100mA.
If there is a voltage drop
between TMC and HVC,
check the low-resistance
connection X6.16 to X19.1
and from X19.1 to X22.1,
and also the minus side
K2.4- to X19.4, and from
X19.4 to X22.4.
E138 HVC short-circuit in Warning C Short-circuit in one or more 1. Check that there is no
coil On/Off control units short-circuit in the
cabling or freewheel
diodes to valve coils Y3
and Y4, or that one of
the coils is speed
short-circuited. The
resistance when cold
must be approx. 23 Ω.
2. Change HVC.
E139 HVC EEPROM error C EEPROM set to default Log off and on, and note that
the error codes disappear
from the log book.
PS/PSH 163

E140 HVC On/Off outputs Warning C On/Off outputs not OK 1. If there are other error
not OK logs in conjunction with
this error, trouble shoot
these first.
2. Do same trouble
shooting as for error
codes E134 and E138.
E141 HVC proportional Warning C The proportional output is This function is not used for
output not OK not OK these truck models. If the
error still occurs, check that
HVC has not been
connected incorrectly. If not,
change the HVC.
E142 HVC ff coils Warning C The proportional output is This output is not used for
not OK these truck models.
E143 HVC CAN Warning C No response from HVC on 1. If TMC also reports
communication error start-up error E100, trouble
shoot for this error first.
2. Check the CAN
communication
connection between
TMC and HVC.
3. Check that HVC is
actually supplied
correctly from TMC.
There must be 12 V
measured between
contacts X22.1 and
X22.4 4. If the HVC is
not supplied correctly
by the TMC, the TMC
must be changed.
Otherwise the HVC
must be changed.
10.3.6 Other trouble shooting (trucks with CMC)

10.3.6.1 Main contactor does not close
There may be other reasons why the main contactor does not close. For this reason, start
trouble shooting by rectifying the last logged primary error code.
1. Have any related error codes been logged?

Yes: Step 2 No: Step 3
2. See trouble shooting for respective fault codes.

Fault trace completed
3. Is there 0 V out from TMC connection X5.12?

4. Change CMC.
164 PS/PSH
5. Is there 24 V as far as the main contactor plus connection K1.A1?

6. Check connection X5.10 - K1.A1

7. Measure directly over the main contactor coil. Is there 24 V?

8. Check if cable connection K1.2 - X5.12 is OK and has low resistance by measuring
the resistance to the front edge of X5, when the connector is pulled from TMC, to the
front edge of the flat pin. If there is no connection, change or repair the cabling.
Otherwise, change CMC
9. Replace contactor.
*The normal cold contactor resistance is approx. 48 Ω.
10.3.6.2 The truck and ATC have total function loss – the display does not go on
NOTE!
If the truck is equipped with a charger there may be a fault on this. If the truck
functions when X21 is toggled, the charge should be changed.
All minus cables = blue

All plus cables in machine housing = red/white
All plus cables in steering arm = red
NOTE!
There may be an error in the display or display cable
1. Is there voltage between F1.1 and E2.B-?

2. Check the battery, battery plug, electrical panel plug and their connections.
3. Is there voltage between X1.1 och E2.B-?

4. Check that there is 24 V at the following locations: X21.1, X21.2 and X8.2
5. Is there 24 V between X1.1 and X1.5?

PS/PSH 165
6. Indicates break or poor connection in the blue minus cable between E2.B and X1.5.
7. Open the steering arm head. Is there 24 V between XJ10.1 and XJ10.5?
8. Change the steering arm cabling, or repair.

9. Change ATC.
10.3.6.3 Säkring
The fuse for the drive motor (F1) is defective.
The most likely reason is that the mean current exceeds the rated current of the fuse. In
conjunction with the change, carefully check the motor cables and the plus and minus cables
to the CMC to make sure they are correctly connected.
Increased friction, increased load, high speed and rapid starting/stopping increase the
average current for the controller. The truck may have been driven over its maximum
performance.
If the truck has been run with a heavy load and at a high speed and with many stops and
starts, or in some other way has exceeded its limitations, try to reduce the speed, load,
acceleration and retardation.
1. Change the fuse (with correct fuse value) and restart.

Continue with:Step 2
2. Does the fuse blow just after the main contactor has closed?
3. Change CMC. If CMC is defective the most likely error is an exciter error with error
4. Start the truck again.

5. Does the fuse blow again after the truck has been running for some time?
Yes: Step 6 No: Fault trace completed
6. Check that the mechanical torque in the gearbox is not excessive.

166 PS/PSH
10.3.6.4 High pump motor temperature, E166

If other error codes are logged, rectify those first. The pump motor may have become
overheated because it has been run above its performance level for a long period. Check the
motor.
1. Is the warning also given when the motor is cold?

Yes: Fault trace completed No: Step 2
2. The truck may have been driven over its maximum performance. There may be a
fault in the motor. Temporarily reduce the lift performance.
3. Ensure that the temperature switch S36 is closed when the motor is cold. If it is not,
this means that the switch is defective and must be changed. Ensure that there is 24
V DC at the connections X36.2 and X5.20.
Did this solve the problem?
4. Change the ATC

10.3.6.5 Traction motor

The traction motor only runs at low speed and with a ticking sound, or alternatively the motor
does not start or runs irregularly with a low torque. TMC encoder error E118 is probably
logged.
1. Pull out contact X9 that connects to the drive motor.

Is there 12 V between pin X5.5 and X5.25 in the CMC?
2. Pull out the connector X5 and check that the connections X5.5 - X9.4 and X5.25 - X9
are intact and there is no short circuit in the wiring when measuring the resistance
between X5.25 och X9.1. If the connections are OK, change the CMC.
3. Is there 12 V between pins 1 and 4 in connector X9?

4. Repair or change the cabling.

5. Replace the contacts and measure the voltage between X5.5 and X5.14 at the same
time as the motor is run. An average value of 4-6 V must be read off when measuring
the DC.
OK?
PS/PSH 167
6. Carefully check that the cabling connection between X5.14 and X9.3 is OK and has a
low resistance. If not, repair or change the cabling, otherwise change the drive motor.
7. Measure the voltage between X5.5 and X5.13 at the same time as the motor is run.
An average value of 4-6 V must be read off when measuring the DC.
OK?
9. An oscilloscope is required for further trouble shooting to determine whether the

pulses from the motor sensor bearing are OK and 90 degrees out of phase. The error
can either be in the motor or in TMC. Try the motor if it has low insulation resistance
to the chassis. Otherwise start with CMC.
10.3.6.6 Drive function

The drive function does not work in one or two directions.
NOTE!
The brake switch input is tested for a coonection to X5.3 at every start. If there is
no connection, a message is given to release up the arm before driving is
permitted.
1. NOTE!
If the brakes are applied and correctly adjusted they will hold the truck in
spite of full modulation. For this reason, always check if the controller is
working. It can be heard as a slight humming sound.
Can a noise be heard?

2. Reset the truck.

Check that the safety switch has not temporarily jammed. If the error remains it will
not be possible to restart the truck, and the question about the safety switch will still
be in the display. Check also that the modulation from the ATC works from approx.
2.5 V in neutral position to close to 5 V when driving in the direction of the forks, and
close to 0 V when driving in the opposite direction to the forks. Recalibrate if
necessary. There may be an error on the brake switch. Check that the brake switch
has not jammed by checking the input for this via the test menu. The switch is
normally open when the arm is between its upper and lower position. If there is 24 V
on the TMC contact X5.1 the controller will not modulate and the brake will not be
electrically actuated. Check also that the brake open switch functions as it should do.
The switch should normally be closed when the brake is not disconnected, and there
should be 24 V to the CMC contact X5.19. If not, check the cables and switch.
168 PS/PSH
3. Reset the truck.

Is there 24V to brake contact X7 when the truck is manoeuvred?
4. Check that there is 24 V on the brake switch contact X4.3 when the arm is in drive
position. Also check that there is a connection between X4.3 och X7.1. If not, repair
or change the cabling, or alternatively change the brake switch S9 if this does not
work.
5. There is either a mechanical or an electrical fault in the brake. The resistance must
be approx. 23 Ω. Test if the brake functions if it is released from the motor. If not,
change the brake.
10.3.6.7 High temperature in drive motor E122

If other error codes are logged, rectify those first. The drive motor may have become
overheated because it has been run over its performance level for a long period. Check
motor and gearbox.
For information on temperature log, see Section 10.2.9.16, page 131.

fault on the motor or gearbox. Temporarily reduce the drive performance.
3. Check that the cabling connection between X5.5 and X9.5 is OK and has
low-resistance, and do the same for X5.22 and X9.6. If not, repair or change the
cabling. If the cabling is OK there is a fault on the temperature sensor, and error code
E126 has probably been logged. The temperature sensor resistance at room
temperature must be approx. 940 Ω, with increased resistance at rising temperature.
This means that a cable break or a break in the sensor causes a max temperature
alarm. The temperature sensing can be temporarily removed by connecting an
external resistance of 1 kΩ ½ W. To repair the temperature sensing the motor must
be cooled.
4. Change the CMC

PS/PSH 169
10.3.6.8 The traction motor loses power and the speed slowly reduces
High temperature in drive controller, error code E121 may be logged. A warning text is
normally shown in the display.
The CMC begins to linearly reduce the motor current at 75°C and stops it completely at
100°C. If the fault occurs with a cold controller there is probably an fault in the CMC internal
temperature monitoring. If other error codes are logged, start the trouble shooting by
rectifying these first. Otherwise, change the controller.
1. Run the truck for an extended period in raised position and without load.
Does the temperature in the controller still go over 75°C?
2. The truck may have been driven over its maximum performance. Try to reduce the
speed, load, acceleration and retardation.
3. Try to confirm if there is something that is increasing the torque, such as worn or
jamming gearbox, and if the motor is working normally.
OK?
4. Rectify the gearbox or change the motor.

5. Change the CMC

10.3.6.9 Lowering of the forks does not work

NOTE!
If other pushbuttons for the hydraulic function are actuated at the same time as the
lowering button, the lowering is stopped. “Release controls” comes up in the
display.
1. See Section 10.2.9.28, page 138.

Does ATC read the input(s) in the menu “test inputs”?
2. Check that the pushbutton closes at approx. 5V to the ATC. Check also that 5 V is
available, otherwise change the ATC.
3. Is there 24 V across the valve coil during lowering?

170 PS/PSH
4. Test the cable connections between X5.9 and Y2.2 and between X5.3 and Y2.1. If
OK, change the CMC.
5. Check that there is no break in the valve coil. A normal resistance value is approx.
30-39 Ω. If not, change coil.
10.3.6.10 The top position switch for lifting does not work
If the truck is equipped with top position switch for lifting this must normally be closed to
enable lifting. The switch function can be checked in Section 10.2.9.5, page 125.
1. Pull apart contact X15 and measure the resistance of the switch between pin 1 and 2
when the forks are completely lowered. OK?
2. Check that the switch is not in mechanically actuated position. If OK, change switch.
3. Check that there is 24 V to the switch and that the TMC receives 24 V at contact
X5.7. OK?
4. Check the cabling and that the TMC supplies 24 V from contact X5.2. If not, change
the TMC.
5. Remove the option for top position switch in the options menu, or alternatively
change the TMC.
10.3.6.11 Tiller-up drive does not work

1. See Section 10.2.9.28, page 138
Is the input read by ATC?
2. Check that the pushbutton switches, otherwise change pushbutton. Check that the
ATC supplies approx. 5 V to the pushbutton. If not, change the ATC.
3. Measure if there is 24 V to relay K4 across the coil between K4.86 and K4.85.
OK?
PS/PSH 171
4. Check the arm cabling, and up to the relay. If defective, change cabling. Check that
the ATC supplies 24 V between pins 3 and 4 in connector XJ11. If not, change the
ATC.
5. Does relay K4 disconnect 24 V from connector pin K4.87?

6. Change relay.
7. Does relay K4 disconnect 24 V from the brake switch contact connection X4.3 when
the arm is in its upper position?
8. Check the connection K4.87 - X4.3 Probably an open circuit or poor contact.
9. Check that 24 V goes to the brake connector pin X7.1. If not, check the wiring.
10.3.6.12 No hydraulic operations work

The pump runs for lifting operations but no hydraulic operations function. The truck can be
driven.
1. Check that the HVC is set to “ON”. See Section 10.2.9.3, page 124.
Is it?
2. Set HVC to “ON”.

3. Is the CMC supplying 24 V to the valve coils Y4 and Y5 from contacts X5.33 and
X5.34?
4. Change CMC.
5. Check that the cabling is not damaged and that there is no break between X5.33 and
Y5.1 or between X5.34 and Y4.2.
OK?
6. Change or repair the cabling.

172 PS/PSH
7. Change CMC.
10.3.7 Other trouble shooting (trucks before CMC)

10.3.7.1 Main contactor does not close
There may be many reasons why the main contactor does not close. For this reason, start
trouble shooting by rectifying the last logged primary error code.
*The normal cold contactor resistance is approx. 47 Ω.
1. Have any related error codes been logged?

2. See trouble shooting for respective error codes.

3. Is there 24V from TMC connection X6.2?

4. Change TMC.
5. Is there 24 V as far as the main contactor plus connection K1.1?

6. Check connection X6.2 - K1.1

7. Measure directly over the main contactor coil. Is there 24 V?

8. Check if cable connection K1.2 - X6.2 is OK and has low resistance by measuring
the resistance to the front edge of X6, when the connector is pulled from TMC, to the
front edge of the flat pin. If there is no connection, change or repair the cabling.
Otherwise, change TMC
9. Replace contactor
10.3.7.2 The truck and ATC have total function loss – the display does not go on
NOTE!
If the truck is equipped with a charger there may be a fault on this. If the truck
functions when X21 is toggled, the charge should be changed.
All minus cables = blue
PS/PSH 173
All plus cables in machine housing = red/white

All plus cables in steering arm = red
NOTE!
There may be an error in the display or display cable
1. Is there 24 V between F1 (between the large fuses) and the large pump contactor
connection K2.4?
2. Check the battery, battery plug, electrical panel plug and their connections.
3. Is there 24 V between insulation bolt X16 and the large pump contactor connection
K2.4?
4. Check 7.5A fuse F3, and that there is 24 V to one side of the fuse holder. Only
measured with the fuse pulled out of the holder.
5. Is there 24 V between X1.1 (the contact that connects to the steering arm) and the
large pump contactor connection K2.4?
6. Check that there is 24 V on all the red/white cable connections in connector X21.
Either there is a break or poor contact between X16 and X21.1, in toggle X21.1 -
X21.2, or in the connection X21.2 - X1.1
7. Is there 24 V between X1.1 and X1.5?

8. Indicates break or poor connection in the blue minus cable between K2.4 and X1.5.
9. Open the steering arm head.

Is there 24 V between XJ10.1 and XJ10.5?
10. Change the steering arm cabling, or repair.

11. Change ATC.

174 PS/PSH
10.3.7.3 Säkring
The fuse for the drive motor (F1) is defective.
The most likely reason is that the mean current exceeds the rated current of the fuse. In
conjunction with the change, carefully check the motor cables and the plus and minus cables
to the TMC to make sure they are correctly connected.
Increased friction, increased load, high speed and rapid starting/stopping increase the
average current for the controller. The truck may have been driven over its maximum
performance.
If the truck has been run with a heavy load and at a high speed and with many stops and
starts, or in some other way has exceeded its limitations, try to reduce the speed, load,
acceleration and retardation.
1. Change the fuse (with correct fuse value) and restart.

Continue with:Step 2
2. Does the fuse blow just after the main contactor has closed?
3. Change TMC. If TMC is defective the most likely error is an exciter error with error
4. Start the truck again.

5. Does the fuse blow again after the truck has been running for some time?
Yes: Step 6 No: Fault trace completed
6. Check that the mechanical torque in the gearbox is not excessive.

10.3.7.4 Traction motor

The traction motor only runs at low speed and with a ticking sound, or alternatively the motor
does not start or runs irregularly with a low torque. TMC encoder error E118 is probably
logged.
1. Pull out contact X9 that connects to the drive motor. Is there 12 V between pin X6.9
and X6.10 in the TMC?
2. Pull out the connector X6 and check that the connections X6.9 - X9.1 and X6.10 -
X9.4 are intact and there is no short circuit in the wiring when measuring the
resistance between X9.1 och X9.4. If the connections are OK, change the TMC.
3. Is there 12 V between pins 1 and 4 in connector X9?

PS/PSH 175
4. Repair or change the cabling.

5. Replace the contacts and measure the voltage between X6.10 and X6.19 at the
same time as the motor is run. An average value of 4-6 V must be read off when
measuring the DC. OK?
7. Measure the voltage between X6.10 and X6.20 at the same time as the motor is run.
An average value of 4-6 volt should be read off when measuring the DC. OK?
9. An oscilloscope is required for further trouble shooting to determine whether the

pulses from the motor sensor bearing are OK and 90 degrees out of phase. The error
can either be in the motor or in TMC. Try the motor if it has low insulation resistance
to the chassis. Otherwise start with TMC.
10.3.7.5 Drive function

The drive function does not work in one or two directions.
NOTE!
The brake switch input is tested for a coonection to X5.3 at every start. If there is
no connection, a message is given to release up the arm before driving is
permitted.
1. NOTE!
If the brakes are applied and correctly adjusted they will hold the truck in
spite of full modulation. For this reason, always check if the controller is
working. It can be heard as a slight humming sound.
Can a noise be heard?

2. Reset the truck.

Check that the safety switch has not temporarily jammed. If the error remains it will
not be possible to restart the truck, and the question about the safety switch will still
be in the display. Check also that the modulation from the ATC works from approx.
2.5 V in neutral position to close to 5 V when driving in the direction of the forks, and
close to 0 V when driving in the opposite direction to the forks. Recalibrate if
176 PS/PSH
necessary. There may be an error on the brake switch. Check that the brake switch
has not jammed by checking the input for this via the test menu. The switch is
normally open when the arm is between its upper and lower position. If there is 24 V
on the TMC contact X5.1 the controller will not modulate and the brake will not be
electrically actuated. Check also that the brake open switch functions as it should do.
The switch should normally be closed when the brake is not disconnected, and there
should be 24 V to the CMC contact X5.19. If not, check the cables and switch.
3. Reset the truck.

Is there 24 V to brake contact X7 when the truck is manoeuvred?
4. Check that there is 24 V on the brake switch contact X4.3 when the arm is in drive
position. Also check that there is a connection between X4.3 och X7.1. If not, repair
or change the cabling, or alternatively change the brake switch S9 if this does not
work.
5. There is either a mechanical or an electrical fault in the brake. The resistance must
be approx. 23 Ω. Test if the brake functions if it is released from the motor. If not,
change the brake.
10.3.7.6 High temperature in drive motor E122

If other error codes are logged, rectify those first. The drive motor may have become
overheated because it has been run over its performance level for a long period. Check
motor and gearbox.

fault on the motor or gearbox. Temporarily reduce the drive performance.
3. Check that the cabling connection between X5.5 and X9.5 is OK and has
low-resistance, and do the same for X5.22 and X9.6. If not, repair or change the
cabling. If the cabling is OK there is a fault on the temperature sensor, and error code
E126 has probably been logged. The temperature sensor resistance at room
temperature must be approx. 940 Ω, with increased resistance at rising temperature.
This means that a cable break or a break in the sensor causes a max temperature
alarm. The temperature sensing can be temporarily removed by connecting an
external resistance of 1 kΩ ½ W. To repair the temperature sensing the motor must
be cooled.
PS/PSH 177
4. Change the CMC

10.3.7.7 The traction motor loses power and the speed slowly reduces
High temperature in drive controller, error code E121 may be logged. A warning text is
normally shown in the display.
The CMC begins to linearly reduce the motor current at 75°C and stops it completely at
100°C. If the fault occurs with a cold controller there is probably an fault in the CMC internal
temperature monitoring. If other error codes are logged, start the trouble shooting by
rectifying these first. Otherwise, change the controller.
1. Run the truck for an extended period in raised position and without load.
Does the temperature in the controller still go over 75°C?
2. The truck may have been driven over its maximum performance. Try to reduce the
speed, load, acceleration and retardation.
3. Try to confirm if there is something that is increasing the torque, such as worn or
jamming gearbox, and if the motor is working normally.
OK?
4. Rectify the gearbox or change the motor.

5. Change the CMC

10.3.7.8 Lowering of the forks does not work

NOTE!
If other pushbuttons for the hydraulic function are actuated at the same time as the
lowering button, the lowering is stopped. “Release controls” comes up in the
display.

Does ATC read the input(s) in the menu “test inputs”?
178 PS/PSH
2. Check that the pushbutton closes at approx. 5V to the ATC. Check also that 5 V is
available, otherwise change the ATC.
3. Is there 24 V across the valve coil during lowering?

4. Test the cable connections between X6.11 and X2.1 and between X6.12 and Y2.2. If
OK, change the TMC.
5. Check that there is no break in the valve coil. A normal resistance value is approx. 39
Ω. If not, change coil.
10.3.7.9 Lifting of the forks does not work

NOTE!
Certain trucks are equipped with end position stop. Before trouble shooting,
temporarily set this option to “no”. If this solves the problem the top position switch
should be checked in accordance with the trouble shooting chart for this.
If the pump runs and the forks still do not lift there may be a fault in the hydraulics, a pump
fault, or incorrectly connected hydraulic hoses.
NOTE!
• Remember to reset the option for end position switch lift.
• If the battery is below 20% the lift stop will be actuated. Charge the battery.
• If other pushbuttons for the hydraulic function are actuated at the same time
as the lifting button, the lifting is stopped. “Release controls” comes up in the
display.
• The normal pump motor current value is approx. 38 A off-load, 105 A with
2500 kg and 125 A at the end stop. The end stop value can be checked via
the option "lift limit" being temporarily set to "NO". See “Options menu” in
Section 10.4.3, page 189.
1. Does the lift contactor actuate without the pump running?

2. Check that the inputs for lift are read by ATC in the “inputs” menu in the test menu. If
not, check that the pushbuttons work and close when actuated. Check that the
pushbuttons receive approx. 5 V from the ATC. If not, change the ATC. Check that
there is not a break to pump contactor K2 by checking the cabling, and that there is
not a break in the connector coil. If there is +24 V as far as the contactor with B- as a
reference and the contactor still does not pull, change the TMC.
3. Is the fuse F2 intact?

PS/PSH 179
4. Change the fuse.

5. Check that 24 V goes to the motor terminal. OK?

6. The contact tips do not seem to conduct.

7. Check the brushes to the hydraulic unit, and that they are rest against the
commutator. OK?
8. Change the brushes, or adjust.

9. Change the unit.

10.3.7.10 The top position switch for lifting does not function
If the truck is equipped with top position switch for lifting this must normally be closed to
enable lifting. The switch function can be checked in Section 10.2.9.5, page 125.
1. Pull apart contact X15 and measure the resistance of the switch between pin 1 and 2
when the forks are completely lowered. OK?
2. Check that the switch is not in mechanically actuated position. If OK, change switch.
3. Check that there is 24 V to the switch and that the TMC receives 24 V at contact
X5.7. OK?
4. Check the cabling and that the TMC supplies 24 V from contact X5.2. If not, change
the TMC.
5. Remove the option for top position switch in the options menu, or alternatively
change the TMC.
180 PS/PSH
10.3.7.11 Tiller-up drive does not work

Is the input read by ATC?
2. Check that the pushbutton switches, otherwise change pushbutton. Check that the
ATC supplies approx. 5 V to the pushbutton. If not, change the ATC.
3. Measure if there is 24 V to relay K4 across the coil between K4.86 and K4.85.
OK?
4. Check the arm cabling, and up to the relay. If defective, change cabling. Check that
the ATC supplies 24 V between pins 3 and 4 in connector XJ11. If not, change the
ATC.
5. Does relay K4 disconnect 24 V from connector pin K4.87?

6. Change relay.
7. Does relay K4 disconnect 24 V from the brake switch contact connection X4.3 when
the arm is in its upper position?
8. Check the connection K4.87 - X4.3 Probably an open circuit or poor contact.
9. Check that 24 V goes to the brake connector pin X7.1. If not, check the wiring.
10.3.7.12 No hydraulic operations work

The pump runs for lifting operations, but no hydraulic operations work. The truck can be
driven.
1. Check that the HVC is set to “ON”. See Section 10.2.9.3, page 124.
Is it?
2. Set HVC to “ON”.

PS/PSH 181
3. Is HVC supplied with voltage? It should be possible to measure 24 V between X22.2

and X22.4, and there should be 12 V between X22.1 and X22.4. Are these voltages
present?
4. If 24 V is missing, check the cabling. If 12 V is missing, check the cabling and that
the TMC is actually supplying the HVC with 12 V. If not, change the TMC.
5. Is the HVC supplying 24 V to the valve coils Y3 and Y4 from contact X23.7?
6. Change HVC.
7. Check that the cabling is not damaged and that there is no break between X23.8 and
Y3.2, nor between X23.4 and Y4.2.
OK?
8. Change or repair the cabling.

9. Change HVC.
10.4 Appendix 1, Overview of the menu trees

10.4.1 General
In the following section, Appendix 1, there are menu trees (version 2.28) for the following
listed menus:
• Menu tree, Local menu
• Menu tree, Service menu
• Menu tree, Monitor menu
• Menu tree, Reset
• Menu tree, Select language
• Menu tree, TRAC
182 PS/PSH
10.4.2 Local menu tree

Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Remarks:
LOCAL
MENU:
< Exit >
LOCAL SET OPERATOR Operator The level 3

MENU: ACCESS: : ID: displays are
always
< Set Operator New/Chan ?
followed in
access > ^ v ge ^ v
sequence.
The no of
question
marks
corresponds
to the chosen
id length
(Authorised
menu).
Operator
categ:x
?
Old This screens

code: will only be
displayed if
????
the user ID
exists and
New user code
code: length > 0
????
The no of
question
marks
corresponds
to the chosen
code length
(Authorised
menu).
Verify OK This screens
new will only be
Press
code: displayed if
ENT
the user ID
????
exists and
user code
length > 0
The no of
question
marks
corresponds
to the chosen
code length
(Authorised
menu).
PS/PSH 183
Not Invalid old

successf code / verified
ul! code wrong /
category out
Press
of range (1..4)
ENT
/ all 100 user
IDs used / no
access to
E2PROM
OPERATOR CAUTION!
: Reduced
Format length
may
lead.
v^
.to lost
entries
0:escape
1:go on
v1
ID ID ID
length: length: length
x x : x
v New New
value: ? value
saved!
Input
reject
ed!
Press
ENT
Code Code Code

x x : x
^ New New
value: ? value
saved!
Input
reject
ed!
Press
ENT
SET Operator The level 3

ACCESS: ID: displays are
always
Delete ?
followed in
oper ^ v
sequence.
184 PS/PSH
Delete OK
op x? Press
0:No ENT
1:Yes
(No)
Not invalid ID /
successf 0:(No)
ul! pressed or
input aborted/
Press
no access to
ENT
E2PROM
SET Old The level 3
ACCESS: code: displays are
always
Local ^ ???????
followed in
v
sequence.
New
code:
???????
Verify OK
new Press
code: ENT
???????
Not invalid old

successf code /
ul! verifyed code
wrong / no
Press
access to
ENT
E2PROM
LOCAL FLEET This menu

MENU: MANAGER: entry resets
the Impact
<Fleet Unlock ^
Sensor
manager v
actions. To be
>
used by
warehouse
management
to
acknowledge
impact.
FLEET READ <o>: List of the 30
MANAGER: LOGS: [date] most recent
operator
Read Operator [time] -
sessions.
logs ^ v log ^ v [time]
PS/PSH 185
READ EFFICIEN <o>: List sorted

LOGS: CY: xx(mn)% from worst to
best operator
Efficien Worst ^ Curr:iii
(Act). xx =
cy ^ v v (mn)A
active time /
logged on
EFFICIEN <o>: time * 100; iii
CY: xx(mn)% = mean main
Best ^ v Curr:iii active current
(mn)A draw; mn =
correspondin
g mean value
for all
operators;
Operator <o>: Any
ID: xx(mn)% operator's
efficiency.
? T:xx(mn)
<o> =
P:xx(mn)
operator id (1
- 100) T =
traction; P =
pump; mn =
correspondin
g mean value
for all
operators;
ID not
found!
Press
'<' key
READ DAMAGE <o>: <o> =

LOGS: LOG: xxx(mn) operator who
used the truck
Damage Worst ^ <o>:
immediately
log ^ v v xxx(mn)
before
damage was
DAMAGE <o>: reported. xxx
LOG: xxx(mn) = number of
Best ^ v <o>: reported
xxx(mn) damages. List
sorted from
greatest to
smallest no of
reported
damages.
DAMAGE 30:[date List sorted in
LOG: ] [time] chronological
order. <o> =
Chronolo <o>:
operator who
gical ^ <dc>
used the truck
v
immediately
v
before
v damage was
reported.
v <dc> =
damage code
(max. two
characters
long).
186 PS/PSH
01:[date
] [time]
<o>:
<dc>
not
implemented
yet !
READ IMPACT <o>: Top = peak
LOGS: LOG: ^xx(mn) impact value;
mn = mean
Impact Worst ^ IOM:xxx
impact value
log ^ v v Mn:xxx%
for all
operators;
IMPACT <o>: IOM =
LOG: ^xx(mn) number of
Best ^ v IOM:xxx impacts over
Mn:xxx% mean (mn);
Mn =
operator's
mean value.
IMPACT 30:[date List sorted in
LOG: ] [time] chronological
order. <o> =
Chronolo <o>:
operator who
gical ^ <il>
used the truck
v
immediately
v
before
v damage was
reported. <il>
v = impact level
(max. two
characters
long).
01:[date
] [time]
<o>:
<il>
Send fleet
manager data
to serial port.
FLEET RESET Reset Successf
MANAGER: LOG: optr ul reset
Reset ^ Operator log? Press
v log ^ v 0:No ENT
1:Yes
(No)
Reset
aborted
Press
ENT
PS/PSH 187
RESET Reset Successf

LOG: this ul reset
Effic/Dm log? Press
g/Imp 0:No ENT
1:Yes
(No)
Reset
aborted
Press
ENT
RESET Time Successf number of

LOG: stamp ul reset days since
last reset
Time xxx days Press
stamp ^ ENT
v
Reset
aborted
Press
ENT
LOCAL SETTINGS TIME & 11:39 hh:mm

MENU: : DATE: New OK!
< < Time & Set time time: Press
Settings Date ^ v ^ v hh:mm ENT
>
Input
rejected
!
Press
ENT
TIME & dd.mm.yy 2001-09-

DATE: yy 18
Set date New: OK!
^ v yy-mm-dd Press
ENT
Input
rejected
!
Press
ENT
TIME & Select

DATE: format:
Date 2001-09-
format ^ 18 ^ v
v 18-Sep-
01 ^ v
18.09.20
01 ^ v
09.18.20
01 ^ v
188 PS/PSH
SETTINGS LCD LCD LCD x = 0..9

: contrast contrast contrast
LCD : : x : y
contrast New New
^ v value: ? value
saved!
Input
rejected
!
Press
ENT
SETTINGS Key Key Key

: sound: sound: sound:
Key xxx xxxx yyy
sound ^ 0:no New
v 1:yes value
saved!
Input
rejected
!
Press
ENT
LOCAL CARD smartcar smartcar smartcar

MENU: READER: d:xxx d:xxx d:yyy
< Card Enable/d ^ v 0:no New
reader > isable 1:yes value
saved!
Input
rejected
!
Press
ENT
10.4.3 SERVICE menu tree

SERVICE
MENU:
< Exit >
SERVICE Lift Lift Lift xxx =

MENU: limit: limit: limit: currently
xxx xxx yyy used value.
<
Options ^ v 0:no New New value
> 1:yes value 'yyy' replaces
saved! the old 'xxx'.
Input Screen stays

rejected on for 1 s.
! Displayed if
Press value is out of
ENT range.
PS/PSH 189
Restart: Restart: Restart:

xxx xxx yyy
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
Safety Safety Safety

syst:xxx syst:xxx syst:yyy
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
Effici Effici Effici

log:xxx log:xxx log:yyy
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
Impact Impact Imp

sens:xxx sens:xxx sensor:y
^ v 0:no yy
1:yes New
value
saved!
Input
rejected
!
Press
ENT
190 PS/PSH
Log Log Log Appears only

level: level: level: if Impact
xxx xxx yyy sensor is
“yes” above!
^ v New New
value: ? value
saved!
Input
rejected
!
Press
ENT
Warning Warning Warning

level: level: level
xxx xxx :yyy
^ v New New
value: ? value
saved!
Input Appears only

rejected if Impact
! sensor is
“yes” above!
Press
ENT!
Horn Horn Horn Appears only

level level level if Impact
:xxx :xxx :yyy sensor is
“yes” above!
^ v New New
value: ? value
saved!
Input
rejected
!
Press
ENT
Stop Stop Stop Appears only

level:xx level:xx level:yy if Impact
x x y sensor is
“yes” above!
^ v New New
value: ? value
saved!
Input
rejected
!
Press
ENT
PS/PSH 191
Supervis Supervis Supervis Appears only

lev: xxx lev: xxx lev: yyy if Impact
sensor is
^ v New New
“yes” above!
value: ? value
saved!
Input
rejected
!
Press
ENT
Damage Damage Damage

rep:xxx rep:xxx rep:yyy
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
Time Time Time

logoff:x logoff:x logoff:y
xx xx yy
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
Del time Del time Delay Appears only

a: xxx a:xxs time if Time logoff
a:yys is “yes”
^ v New
above!
value: ? New
value
saved!
Input
rejected
!
Press
ENT
192 PS/PSH
Del time Del time Delay Appears only

b: xxx b:xxmin time if Time logoff
b:yymin is “yes”
^ v New
above!
value: ? New
value
saved!
Input
rejected
!
Press
ENT
Dis Dis Dis Appears only

tiller tiller tiller if Time logoff
res:xxx res:xxx res:yyy is “yes”
above!
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
Smartcar smartcar smartcar

d:xxx d:xxx d:yyy
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
Damage Damage Damage Appears only

rep:xxx rep:xxx rep:yyy if Time logoff
is “yes”
^ v 0:no New
above!
1:yes value
saved!
Input
rejected
!
Press
ENT
PS/PSH 193
Disp log Disp log Disp log

on:xxx on:xxx on:yyy
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
Summer Summer Summer

time:xxx time:xxx time:yyy
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
Keyswitc Keysw Keysw

h :xxx pwr pwr
^ v off:xxx off:yyy
0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
Speed Speed Speed

red:xxx red:xxx red:yyy
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
194 PS/PSH
Cutback3 Cutback3 Cutback3 Appears only

: xxxx% : xxxx% : yyyy% if Speed red
is 'yes' above!
^ v New New
value: ? value
saved!
Input
rejected
!
Press
ENT
Service Service Service

alrm:xxx alrm:xxx alrm:yyy
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
Interval Interval Interval Appears only

: xxxxh : xxxxh : yyyyh if Service
alarm is 'yes'
^ v New New
above!
value: ? value
saved!
Input
rejected
!
Press
ENT
Fixed Fixed Fixed

platf: platf:xx Platf:yy
xxx x y
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
PS/PSH 195
TillerUp TillerUp TillerUp

D: xxx D: xxx D: yyy
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
Reverse Reverse Reverse

ind: xxx ind: xxx ind: yyy
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
HVC1 HVC1 HVC1 Appears only

:xxx :xxx :xxx if Revers ind
is 'yes' above!
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
Raise Raise Raise

steer: steer: steer:
xxx xxx yyy
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
196 PS/PSH
Stop on Stop on Stop on

ramp: Ramp: ramp:
xxx xxx yyy
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
Straddle Straddle Straddle

: xxx : xxx : yyy
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
Belly Belly Belly

start: start: start:
xxx xxx yyy
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
Battery Battery Battery

creep: creep: creep:
xxx xxx yyy
^ v 0:no New
1:yes value
saved!
Input
rejected
!
Press
ENT
PS/PSH 197
Charger: Charger: Charger:

xxx xxx yyy
^ v 0:no New
1:yes value
saved!
Input
rejected
Press
ENT
OH OH OH
Guard: Guard: Guard:
xxx xxx yyy
^ v 0:no New
1:yes value
saved!
Input
rejected
Press
ENT
SERVICE SETTINGS PERFORMA Fwd Fwd Fwd xxx =

MENU: : NCE: speed: speed: speed: currently
xxx% xxx% yyy% used value.
< Performa Op
Settings nce ^ v category ^ v New New New value
> 1 ^ v value: ? value 'yyy' replaces
Input Screen stays

reject on for 1 s.
ed! Displayed if
ENT range.
Rev Rev Rev

speed: speed: speed:
xxx% xxx% yyy%
^ v New New
value: ? value
saved!
Input
reject
ed!
Press
ENT
Tract acc to above!

accel:xx
x%
^ v
198 PS/PSH
Tract acc to above!

cutb1:xx
x%
^ v
Tract acc to above!

cutb2:xx
x%
^ v
Tract acc to above!

curr:
xxx%
^ v
Rdc acc to above!

brake:
xxx%
^ v
Neut acc to above!

brake:
xxx%
^ v
Rev acc to above!

brake:
xxx%
^ v
Brake acc to above!

pedal:xx
x%
^ v
PERFORMA According to
NCE: the above!
Op
category
2 ^ v
NCE: the above!
Op
category
3 ^ v
NCE: the above!
Op
category
4 ^ v
PS/PSH 199
SETTINGS TRACTION Breakp Breakp Breakp Defines the

: : lo: xxx% lo: xxx% lo: output signal
yyy% level at 30%
Traction Throttle ^ v New
of the input
^ v map ^ v value: ? New
signal
value
'xxx' = 'on' or
saved!
'off' (currently
used)
New value
'yyy' replaces
the old 'xxx'.
Input Screen stays
reject on for 1 s.
ed! Displayed if
ENT range.
Breakp Breakp Breakp Defines the

hi: xxx% hi: xxx% hi: output signal
yyy% level at 70%
^ v New
of the input
value: ? New
signal
value
'xxx' = 'on' or
saved!
'off' (currently
used)
New value
'yyy' replaces
the old 'xxx'.
Input Screen stays
reject on for 1 s.
ed! Displayed if
ENT range.
Dead Dead Dead 'xxx' = 'on' or

zone: zone: zone: 'off' (currently
xxx% xxx% xxx% used)
^ v New New New value
value: ? value 'yyy' replaces
Input Screen stays

reject on for 1 s.
ed! Displayed if
ENT range.
TRACTION Breakp Breakp Breakp Defines the

: lo: xxx% lo: xxx% lo: output signal
xxx% level at 30%
Brake ^ v New
of the input
map ^ v value: ? New
signal
value
'xxx' = 'on' or
saved!
'off' (currently
used)
New value
'yyy' replaces
the old 'xxx'.
200 PS/PSH
Input Screen stays

reject on for 1 s.
ed! Displayed if
ENT range.
Breakp Breakp Breakp Defines the

hi: xxx% hi: xxx% hi: output signal
xxx% level at 70%
^ v New
of the input
value: ? New
signal
value
'xxx' = 'on' or
saved!
'off' (currently
used)
New value
'yyy' replaces
the old 'xxx'.
Input Screen stays
reject on for 1 s.
ed! Displayed if
ENT range.
Dead Dead Dead 'xxx' = 'on' or

zone: zone: zone: 'off' (currently
xxx% xxx% xxx% used)
^ v New New New value
value: ? value 'yyy' replaces
Input Screen stays

reject on for 1 s.
ed! Displayed if
ENT range.
TRACTION Motor: Motor: Motor:

: NN NN NN
Motor 0:Kordel New
type ^ v 1:Sauer value
saved!
Input
reject
ed!
Press
ENT
SETTINGS
:
Brake ^
v
PS/PSH 201
SETTINGS Speed Speed Speed

: ctrl: xx ctrl: ctrl:
Pump ^ v ^ v xxxxx xxxxx
0: valve New
1: motor value
saved!
Input
rejected
!
Press
ENT
Cont Cont Cont

Delay: Delay: Delay:
xr xr xr
^ v New New
value: value
?r saved!
Input
rejected
!
Press
ENT
Delay1: Delay1: Delay 1:

xxx xxx x
^ v New New
value: value
?r saved!
Input
rejected
!
Press
ENT
Delay2: Delay2: Delay 2:

xxx xxx x
^ v New New
value: value
?r saved!
Input
rejected
!
Press
ENT
202 PS/PSH
Lower Lower Lower

acc: xxx acc: xxx acc: xxx
^ v New New
value: value
?r saved!
Input
rejected
!
Press
ENT
Lower Lower Lower

ret: xxx ret: xxx ret: xxx
^ v New New
value: value
?r saved!
Input
rejected
!
Press
ENT
Pump Pump Pump

acc: xxx acc: xxx acc: xxx
^ v New New
value: ? value
saved!
Input
rejected
!
Press
ENT
Pump Pump Pump

dec: xxx dec: xxx dec: xxx
^ v New New
value: ? value
saved!
Input
rejected
!
Press
ENT
PS/PSH 203
Temp Temp Temp

guard: guard guard
xxx 0:no New
^ v 1:yes value
saved!
Input
rejected
!
Press
ENT
SETTINGS HYDRAULI HVC 1: HVC 1: HVC 1: 'xxx' = 'on' or

: CS: xxx xxx yyy 'off' (currently
used)
Hydrauli HVC ^ v 0:off New
cs ^ v Setup ^ 1:on value New value
v saved! 'yyy' replaces
the old 'xxx'.
Input Screen stays
reject on for 1 s.
ed! Displayed if
ENT range.
HVC 1 HVC 1 HVC 1 'xxx' = 'on' or

PWM:xxxx PWM:xxxH PWM:yy 'off' (currently
Hz z yHz used)
^ v 0:off New New value
1:on value 'yyy' replaces
Input Screen stays

reject on for 1 s.
ed! Displayed if
ENT range.
HVC 2: acc to
xxx above!
^ v
HVC 2 acc to
PWM:xxxx above!
Hz
^ v
HVC 3: acc to
xxx above!
^ v
HVC 3 acc to
PWM:xxxx above!
Hz
^ v
204 PS/PSH
HVC4 acc to
:xxx above!
^ v
HVC 4 acc to
PWM:xxxx above!
Hz
^ v
HYDRAULI Raise Raise Raise 'xxx' = 'on' or

CS: ctrl:xxx ctrl:xxx ctrl:y 'off' (currently
xx xx yyyy used)
Lift ^ v
^ v 0:OnOff New New value
1:Speed value 'yyy' replaces
Input Screen stays

reject on for 1 s.
ed! Displayed if
ENT range.
Raise Raise Raise Appears only

min: min: xxx min: if speed
xxx% yyy control is
New
selected
^ v value: ? New
above!
value
saved! Refers to [
valve PWM ]
Input or [ pump
reject motor speed ]
ed! depending on
Press choice above.
ENT Note that the
min/max
parameters
only are used
if speed
control are
selected.
Raise acc to Appears only
max: above! if speed
xxx% control is
selected
^ v
above!
Lower acc to Appears only
min: above! if speed
xxx% control is
selected
^ v
above!
Lower acc to Appears only
max: above! if speed
xxx% control is
selected
^ v
above!
PS/PSH 205
Breakp: acc to Defines the

xxx% above! output signal
level at 50%
^ v
of the input
signal
Appears only
if speed
control is
selected
above!
Dead acc to Appears only
zone: above! if speed
xxx% control is
selected
^ v
above!
Open acc to Open delay of
delay: above! the
xxx proportional
valve.
^ v
Parameter
range
between
0-255. Unit
s/20.
Appears only
if speed
control is
selected
above!
Close acc to Close delay
delay: above! of the
xxx proportional
valve.
^ v
Parameter
range
between
0-255. Unit
s/20.
Appears only
if speed
control is
selected
above!
Dither acc to Dither
freq: x above! frequency.
Parameter
^ v
range
between 0-9.
Appears only
if speed
control is
selected
above!
206 PS/PSH
HYDRAULI Ch2 Ch2 Ch2 ''xxxxx' =

CS: ctrl: ctrl: ctrl: currently
xxxxx xxxxx yyyyy used value
Channel
2 ^ v ^ v 0:OnOff New New value
1:Speed value 'yyyyy'
saved! replaces the
old 'xxxxx'.
Input Screen stays
reject on for 1 s.
ed! Displayed if
ENT range.
Speed Speed Speed Appears only

ctrl:xxx ctrl:xxx ctrl:y if speed
xx xx yyyy control is
selected
^ v 0:Valve New
above!
1:Motor value
saved!
Input
reject
ed!
Press
ENT
Ch2 pos Pos min: Pos Refers to [

min:xxx% xxx min: valve PWM ]
yyy or [ pump
^ v New
motor speed ]
value: ? New
depending on
value
choice above.
saved!
Appears only
Input if speed
reject control is
ed! selected
Press above!
ENT
Ch2 pos acc to Appears only

max:xxx% above! if speed
control is
^ v
selected
above!
Ch2 neg acc to Appears only
min:xxx% above! if speed
control is
^ v
selected
above!
Ch2 neg acc to Appears only
max:xxx% above! if speed
control is
^ v
selected
above!
PS/PSH 207
Breakp: acc to Defines the

xxx% above! output signal
level at 50%
^ v
of the input
signal
Appears only
if speed
control is
selected
above!
Dead acc to Appears only
zone: above! if speed
xxx% control is
selected
^ v
above!
HYDRAULI Hydra Hydra
CS: lock: xx lock: xx
Hydraul 0:off New
lock ^ v 1:on value
saved!
Input
rejected
!
Press
ENT
SETTINGS FB Adj FB Plese Restar This menu

: adjust mode wait, t appears
storing system when FB
Steering ^ v 0:off
data. and adjust mode
^ v 1:on
adjust is 'On'
FB
FB This menu
adj. appears
Comple when FB
te adjust mode
is 'Off'
Restar
t
system
EPS :xxx EPS :xxx EPS: yyy

^ v 0:off New
1:on value
saved!
Input
rejected
!
Press
ENT
208 PS/PSH
Numbness Numbness Numbness

x x x
^ v New New
value: ? value
saved!
Input
rejected
!
Press
ENT
Steer Steer Speed

ctrl:xxx ctrl:xxx ctrl:yyy
xx xx yy
^ v 1:Speed New
2:Posit value
saved!
Input
rejected
!
Press
ENT
Lim. Lim. Lim.

rough rough rough: x
CW: CW: x New
^ v New value
value: ? saved!
Input
rejected
!
Press
ENT
Lim. Lim. Lim.

rough rough rough
CCW: CCW: x CCW: x
^ v New New
value: ? value
saved!
Input
rejected
!
Press
ENT
PS/PSH 209
Limit Limit Limit

fine CW: fine CW: fine CW:
xx x x
^ v New New
value: ? value
saved!
Input
rejected
!
Press
ENT
Limit Limit Limit

fine fine fine
CCW: CCW: x CCW: x
^ v New New
value: ? value
saved!
Input
rejected
!
Press
ENT
Steer hi Steer hi Steer hi

spd: spd: xx spd: xx
^ v New New
value: ? value
saved!
Input
rejected
!
Press
ENT
SETTINGS BATTERY: Battery Battery

: Battery type: x type: x
Battery type: Wet:0 New
^ v ^ v Gel:1 x value
saved!
Input
rejected
!
Press
ENT
210 PS/PSH
BATTERY: Wet Stepdown Stepdo

Wet battery: hi: x wn hi:
battery Stepdown New y
^ v hi ^ v value: ? New
value
saved!
Input
reject
ed!
Press
ENT
Wet Stepdown Stepdo

battery: lo: x wn lo:
Stepdown New y
lo ^ v value: ? New
value
saved!
Input
reject
ed!
Press
ENT
BATTERY: Gel Stepdown Stepdo

Gel battery: hi: x wn hi:
battery Stepdown New y
^ v hi ^ v value: ? New
value
saved!
Input
reject
ed!
Press
ENT
Gel Stepdown Stepdo

battery: lo: x wn lo:
Stepdown New y
lo ^ v value: ? New
value
saved!
Input
reject
ed!
Press
ENT
SETTINGS TRUCK XX =
: TYPE trucktype
Truck XX
type ^
PS/PSH 211
SERVICE TESTS: TEST 11122233 Strings of the

MENU: INPUTS: 3444555A same digit
Inputs ^
are bar
< Tests v Overview 66677BCD
graphs for
> ^ v EFGHIJK
analogue/ste
ering enc
inputs. The
digit identifies
the input, the
number of
digits
represents
the input
signal level.
E.g "1"
means:
10%<spd
cmd<50%,
"11" means:
50%<spd
cmd<90%,
"111" means:
spd
cmd>90%.
Single letters
means digital
input
activated.
TEST Signal s' = sign
INPUTS: check:
Accelera x.x V
tor ^ v Out:syyy
%

INPUTS: check:
Brake ^ x.x V
v Out:syyy
%

INPUTS: check:
Lift ^ v x.x V
Out:syyy
%

INPUTS: check:
Aux AI 1 x.x V
^ v Out:syyy
%

INPUTS: check:
Aux AI 2 x.x V
^ v Out:syyy
%
212 PS/PSH

INPUTS: check:
Aux AI 3 x.x V
^ v Out:syyy
%
TEST Steering s' = sign

INPUTS: rpm:
Steering syyy
^ v
TEST SP pot:
INPUTS: x.xxV
EPS FB pot:
sensors x.xxV
TESTS: TEST If "ENT" is

OUTPUT: pressed, the
Outputs
currently
^ v LED 1 ^
displayed
v
output will be
engaged as
long as the
key is kept
pressed
TEST
OUTPUT:
LED 2 ^
v
TEST
OUTPUT:
LED 4 ^
v
TEST
OUTPUT:
HEATER ^
v
TEST
OUTPUT:
ANALOG
OUT
TESTS: READ HW:

Versions VERSION: SW:
^ v Traction
^ v
READ HW:
VERSION: SW:
HVC ^ v
PS/PSH 213
READ HW:
VERSION: SW:
Power
steering
^ v
READ OS date:
VERSION: yy-mm-dd
ATC ^ v OS ver:
MM.mm ^v
HW:
MM.mm
VCL SW:
MM.mm ^v
TESTS: Disable? enc

TM 0:no disabled
encoder 1:yes: Press
^ v ENT
Not
successf
ul!
Press
ENT
TESTS: Disable? Footsw.

PP 0:no disabled
footswit 1:yes: Press
ch ^ ENT
Not
Successf
ul!
Press
ENT
TESTS: MeasureD
Battery : xx.xV
^ v
SERVICE CALIBRAT
MENU: E:
< All ^ v
Calibrat
e >
CALIBRAT Release Covers both

E: throttle butterfly and
and pedal type
Accelera
press throttle
tor ^ v
ENT The level 3
displays are
always
followed in
sequence.
214 PS/PSH
Go to OK!: Signal
end Press check:
points ENT x.x V
and Out:syyy
press %
ENT
Not Signal s = sign (+

successf check: raise, - lower)
ul! x.x V
Press Out:syyy
ENT %
CALIBRAT Release The level 3

E: brake displays are
and always
Brake ^
press followed in
v
ENT sequence.
Order OK!: Signal

full Press check:
brake ENT x.x V
and Out:syyy
press %
ENT
CALIBRAT Release Not Signal Covers both

E: lift and successf check: combined
press ul! and separate
Lift ^ v x.x V
ENT raise/lower
Press Out:syyy
controls.
ENT %
The level 3
displays are
always
followed in
sequence.
Order
full
raise
and
press
ENT
Order OK!: Signal

full Press check:
lower ENT x.x V
and Out:syyy
press %
ENT
Not Signal
successf check:
ul! x.x V
Press Out:syyy
ENT %
PS/PSH 215
CALIBRAT Release
E: ch2 and
Channel press
2 ^ v ENT
Order
full
+dir and
press
ENT
Order OK!: Signal

full Press check:
-dir and ENT x.x V
press Out:syyy
ENT %
Not Signal
successf check:
ul! x.x V
Press Out:syyy
ENT %
CALIBRAT According to
E: “Channel 2”
Channel
3 ^ v
CALIBRAT According to
E: “Channel 2”
Channel
4 ^ v
CALIBRAT Center Calibrat

E: steering ion done
Steering and press
^ v press ENT
ENT
Calibrat
ion
failed
press
ENT
CALIBRAT Update
E: angle
Update
angle ^
v
216 PS/PSH
SERVICE LOGS/COU 30: Exxx +01: Latest error is

MENU: NTERS: Exxx shown first.
[date]
<Logs/co Error [time] Offset: The [i] key
unters > log ^ v zzz ms can be used
v^ to jump
[error directly to the
[error next error
text
text (primary and
line 1]
line 1] secondary
[error
[error
text error log)
text
line 2] xxx is the
line 2]
error code
v^
v^ yyy is the
+02: number of
#yyy errors
Exxx
occurred occurred
: Offset:
zzz ms "+" indicates
[date]
[time] that there is a
v^ secondary
v^ error
next primary [error
error… text
line 1]
[error
text
line 2]
v^
+03:
Exxx
Offset:
zzz ms
v^
[error
text
line 1]
[error
text
line 2]
v^
+04:
Exxx
Offset:
zzz ms
v^
PS/PSH 217
[error
text
line 1]
[error
text
line 2]
v^
VCL (or Appears only
OS) if the error is
ERROR a VCL or OS
ERROR
Module
instead of the
id: mmm
two screens
^ v above! No
secondary log
is possible.
Error Appears only
id: eee if the error is
a VCL or OS
Line:
ERROR
LLL
instead of the
two screens
above! No
secondary log
is possible.
LOGS/COU TEMP LOG Log Temperatures
NTERS: 1temp for traction
Traction
motor,
Temp log ctrl -40C:
traction
^ v xxxx.x h
controller,
pump motor,
Log pump
1temp controller,
41-50C: hydr oil,
xxxx.x h power
steering
Log motor, power
1temp steering
controller, all
51-60C:
in five
xxxx.x h
intervals.
Intervals
Log differs
1temp depending on
61-70C: the objects
xxxx.x h working
temperature
Log range.
1temp
>71C:
xxxx.x h
TEMP LOG acc to

Traction above!
motor
218 PS/PSH
TEMP LOG acc to

ATC above!
TEMP LOG acc to

Log 4 above!
TEMP LOG acc to

Log 5 above!
TEMP LOG acc to

Log 6 above!
TEMP LOG acc to

Log 7 above!
LOGS/COU HOUR TOTAL xxxxx ->

NTERS: METER: Active: hours
Hour Total ^ xxxxx.yy yyy -> 1/1000
meters ^ v yh hours
v
TOTAL
Logged
on:
xxxxx.yy
yh
TOTAL
Traction
:
xxxxx.yy
yh
TOTAL
Pump:
xxxxx.yy
yh
PS/PSH 219
HOUR TRIP xxxxx ->

METER: Active: hours
Trip ^ v xxxxx.yy yyy -> 1/1000
yh hours
TRIP
Logged
on:
xxxxx.yy
yh
TRIP
Traction
:
xxxxx.yy
yh
TRIP
Pump:
xxxxx.yy
yh
HOUR READ
METER: Traction
Read :
external xxxxx h
^ v
READ
Pump:
xxxxx h
READ Pwr
Steer:
xxxxx h
LOGS/COU Tract: "iii" is the

NTERS: iii A calculated
xx% "mean main
Utilisat
active
ion ^ v Pump:
current", "xx"
iii A
is calculated
xx%
as: [active
time] /
[calendar
time since
last reset].
LOGS/COU RESET: Reset Successf
NTERS: Error error ul reset
Reset ^ log ^ log? Press
v 0:no ENT
1:yes
Reset
aborted!
Press
ENT
220 PS/PSH
RESET: Reset
Temp log aborted!
^ Press
ENT
RESET: Reset Successf

Trip trip/uti ul reset
meters/U l log? Press
til^ 0:no ENT
1:yes
Reset
aborted!
Press
ENT
RESET: Reset Successf

Service service? ul reset
alarm ^ 0:no Press
v 1:yes ENT
Reset
aborted!
Press
ENT
LOGS/COU SET Logged Logged Logged Hour meters

NTERS: HOURS: on xxxh on: xxx on: can only be
yyy set to a
Set hour Logged ^ v New
higher value
mtrs ^v on ^ v value: ? New
than before.
value
saved!
Input
reject
ed!
Press
ENT
SET Active: Active: Active

HOURS: xxxh xxx : yyy
Active ^ ^ v New New
v value: ? value
saved!
Input
reject
ed!
Press
ENT
PS/PSH 221
SET Traction Traction Tracti

HOURS: : xxxh : xxx on:
Traction ^ v New yyy
^ v value: ? New
value
saved!
Input
reject
ed!
Press
ENT
SET Pump: Pump: Pump:

HOURS: xxxh xxx yyy
Pump ^ v ^ v New New
value: ? value
saved!
Input
reject
ed!
Press
ENT
LOGS/COU Send all above logs to serial port truck serial no, versions and settings
NTERS: (not fleet manager statistics)
Download
^ v
SERVICE SET OPERATOR Operator The level 3

MENU: ACCESS: : ID: displays are
always
< Set Operator New/Chan ?
followed in
access > ^ v ge ^ v
sequence.
Operator
categ:x The no of
? question
marks
corresponds
to the chosen
id length
(Authorised
menu).
Old this screens
code: will only be
displayed if
????
the user ID
exists and
user code
length > 0
The no of
question
marks
corresponds
to the chosen
id length
(Authorised
menu).
222 PS/PSH
New this screens

code: will only be
displayed if
????
the user code
length > 0
The no of
question
marks
corresponds
to the chosen
code length
(Authorised
menu).
Verify OK this screens
new will only be
Press
code: displayed if
ENT
the user code
????
length > 0
Not
successf The no of
ul! question
Press marks
ENT corresponds
to the chosen
code length
(Authorised
menu).
OPERATOR CAUTION!
: Reduced
Format ^ length
v may
lead.
to lost
entries.
0:escape
1:go on
ID ID ID
x x : x
^ New New
value: ? value
saved!
Input
reject
ed!
Press
ENT
Code Code Code

x x : x
New New New
value value: ? value
saved! saved!
PS/PSH 223
Input
reject
ed!
Press
ENT
SET Old
ACCESS: code:
Local ^ ???????
v
New
code:
???????
Verify OK
new Press
code: ENT
???????
Not invalid old

successf code /
ul! verifyed code
wrong / no
Press
access to
ENT
E2PROM
SET acc to
ACCESS: above!
Service
^ v
SERVICE Go to Reset
MENU: menu
< Total
reset >
224 PS/PSH
Table 44. Hydraulic Control Channels

Lift channel Selection is done Selection is decided in
'semiautomatically' during SETTINGS between:
CALIBRATION between: 1. On/Off control.
1. Combined raise/lower 2. Speed control.
control (e.g. joystick) a) Valve PWM
2. Individual raise and control.
lower controls (e g b) Pump motor
pushbuttons in the tiller Every unique VCL sw speed control.
head) variant includes rules for:
Channel 2 Selection is done 1. which inputs are Selection is decided in
'semiautomatically' during allowed to be used to SETTINGS between:
CALIBRATION between: each channel. The final 1. On/Off control.
1. Combined raise/lower decision to determine
2. Speed control.
control (e.g. joystick) which of these allowed
a) Valve PWM
inputs will be used is
made by the
'auto-sense' feature
pushbuttons in the tiller speed control.
during calibration.
head)
2. which outputs will be
Channel 3 Selection is done used: Selection is decided in
'semiautomatically' during • if on/off control is SETTINGS between:
CALIBRATION between: selected 1. On/Off control.
control (e.g. joystick) • if valve PWM is
selected a) Valve PWM
lower controls (e g • if motor speed
control is selected. b) Pump motor
head) 3. which interlocks should
Channel 4 Selection is done exist between the Selection is decided in
'semiautomatically' during different channels. SETTINGS between:
CALIBRATION between: 1. On/Off control.
control (e.g. joystick) a) Valve PWM
head)
Example 1 - tiller application

Lift channel is analogue, with valve PWM output. Inputs are decided in Authorised
menu/Calibrate/Lift menu. When the display requests "full raise" the proportional pushbutton
connected to J9 (lift) is activated by the engineer followed by ENT. Cortex then recognises
this input as the raise input. The display requests "full lower" and the operator pushes the
button connected to J8 (lower). Cortex has now detected which inputs are used for raise and
lower, and has also stored at which input levels full output should be given. Output type is
selected in Authorised menu/Settings/Hydraulics/Lift. First of all, speed control is selected.
Now, further settings are needed. In this case, a proportional valve will be controlled by HVC
1. The engineer selects valve speed control. Fixed outputs for contactor prop valve and dir
valve are hardcoded. Output relations to dead zone passing and to calibrated maximum
input are entered.
Channel 2 is 'digital', with onoff valve control. No input calibrations need to be done, since
output is defined as 'onoff'. Hardcoded definitions for input and output associations take
effect.
Example 2 - rider stacker
Lift channel is analogue, with joystick and pump motor speed control. Input calibration is
carried out as in example 1. Cortex recognizes the a 'combined' raise/lower control from the
PS/PSH 225
voltage levels read during calibration. Output setting s are set to 'speed control' and 'motor'.
Raise command is sent to hardcoded address in PMC, lower command is sent to HVC 1.
10.4.4 Monitor menu

Level 1 Level 2 Level 3 Remarks
MONITOR
MENU:
< Exit >
MONITOR TRACTION: xxxxrpm "xxxx" = motor

MENU: speed in rpm;
Drive +/-iii A
< Traction > Monitor ^ v "iii" = motor current
TRACTION: C: +/-ttt "ttt" = controller

degC temperature; "TTT"
Temp Monitor
= motor
^ v M: +/-TTT
temperature
degC
MONITOR PUMP: yyyy V "yyyy" = pump

MENU: motor voltage
Pump monitor +/-iii A
< Pump > ^ v "iii" = motor current
MONITOR Adjust FB Steer 90deg

MENU: v^ left and
< Steering > press ENT
Steer 90deg
right and
press ENT
Adjustment Jumps to 'Exit'

done when pressing
ENT
Press ENT
Read sensors SP pot: "n.nn"= Read value

n.nnV in Volts
v^
FB pot:
n.nnV
FB pot:
n.nnV
FB pot:
n.nnV
EPS 0 Set steer Save value 0 -> "EPS 0

position 0-pos position" menu
0:no 1:yes
v^ <7 nnnnmV 9> 1 -> "Exit" menu
"nnnn"= 0-position in mV, ENT and key 4 works as escape

button.
Angle: xx
Record angle
MONITOR Not implemented

MENU: yet
< Wire guide
>
226 PS/PSH
MONITOR IN/OUT: Accelerator

MENU: ATC inputs: xxx
< In/Out > ^ v Raise1 xxx
Raise2 xxx
Lower1 xxx
Lower2 xxx
Belly x
BellyInv x
TillerUpD x
Horn x
Dig_In1 x
Dig_In2 x
Dig_In3 x
Dig_In4 x
Dig_In5 x
IN/OUT: Dig_In1 x
TMC inputs: Dig_In2 x
^ v Dig_In3 x
Dig_In4 x
Dig_In5 x
Dig_In6 x
Dig_In7 x
IN/OUT: Dig_In1 x
HVC inputs: Dig_In2 x
^ v Dig_In3 x
A_in 1 xxx
IN/OUT: Not yet

implemented.
EPS inputs:
^ v
IN/OUT: Lift int x

ATC int/out: Speed int x
^ v Safety int x
Max spd xxx
Forward x
Reverse x
Brake x
Liftstop x
10.4.5 Reset menu

Level 1 Level 2 Level 3 Level 4 Level 5 Remarks:
RESET: Reset all Successful

All users users? reset
^ v 0:no 1:yes Press ENT
Reset
aborted!
Press ENT
PS/PSH 227
RESET: Reset Successful

Options ^ options? reset
v 0:no 1:yes Press ENT
Reset
aborted!
Press ENT

Settings ^ settings? reset
v 0:no 1:yes Press ENT
Reset
aborted!
Press ENT

Calibratio calib? reset
n ^ v 0:no 1:yes Press ENT
Reset
aborted!
Press ENT

Logs ^ v logs? reset
0:no 1:yes Press ENT
Reset
aborted!
Press ENT
10.4.6 Language tree

Level 1 Level 2 Level 3 Level 4 Level 5 Remarks
:
SELECT LANGUAGE:
English ^ v
SELECT LANGUAGE
Svenska ^ v
SELECT LANGUAGE
Deutsch
SELECT LANGUAGE
Francais
SELECT LANGUAGE
Custom
228 PS/PSH
10.4.7 TRAC
TRAC MENU:
< Exit >
TRAC MENU: Answer call

< Answer call >
PS/PSH 229
11 Speed control and brake systems
11 SPEED CONTROL AND BRAKE SYSTEMS

11.1.1 Electric brake
The truck is equipped with an electric brake. The electric brake is a safety brake with two
friction surfaces. The braking torque is created by spring pressure. The brake is activated
when the voltage over the coil is lost, i.e. the truck is braked when it is without voltage.
When the brake is activated the springs press on the plate, which is pressed axially to the
rotor. When the brake is to be released the coil is supplied with battery voltage. The
magnetic field created between the plate and the magnetic part allows the rotor to rotate
freely.
The brake is activated in different ways (see also the wiring diagram).
1. Via the drive motor controller when the controller indicates a serious fault.
2. Via the steering servo controller, which breaks the brake coil supply to the plus pole on
the battery if a serious fault is indicated.

11.2.1 Electric brake
11.2.1.1 Introduction
The brake requires a minimum of maintenance. It does not need to be adjusted, and
compensates automatically for wear. The A dimension is 0.3 mm. The rotor must be
replaced when the A gap is a maximum of 0.6 mm.
NOTE!
The rotor should be replaced when the A gap is a maximum of 0.6 mm.
230 PS/PSH
11.2.1.2 Manual release of the brake

NOTE!
Only applies to PS.
WARNING!
The brake may only be released when the truck is standing still on clean, level and
solid ground.
The brake can be released manually. This is to enable a truck without power to be moved.
Release the brake by turning the handle at the top of the brake clockwise (A). The truck
cannot be driven in this position. To return to normal operation, turn the handle anticlockwise
back to normal position (B).
PS/PSH 231
232 PS/PSH

Service Manual - PS-PSH - EnG - 159221 - 2016w38

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Service Manual - PS-PSH - EnG - 159221 - 2016w38

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© Copyright UniCarriers Europe AB, 2015

01 General information and technical data 1

10 Electrical system 107

11 Speed control and brake systems 230

01 GENERAL INFORMATION AND TECHNICAL DATA

1.1.2 The trucks

1.1.3 Structure of the Manual

1.1.4 Symbol key

• Local fire directives should always be followed.

Figure 1. Emergency release valve in the hydraulic unit.

1.2.2 Truck modification

• Approve measures and in an equivalent manner make appropriate changes to the

1.2.3 Lifting the truck

Figure 2. Permitted lifting points

1.2.4 Welding on the truck

1.2.5 Gas spring

1.3 Environmental considerations

1.4.2 Trouble shooting

Explanation of Model designation

1.5.1.2 Type designation

Figure 3. Example of type plate (–2006w36)

Figure 4. Example of type plate (2006w37-)

Figure 5. Example of a serial number label.

1.5.2 Dimensions and weights

Figure 6. Positions for dimension designations PS XXX PSH

1.6 Component specification

1.7 Recommended consumable materials

Product Part no. Class

Product Part no. Class

Oil for the food industry 014161 NSF H1.

1.8 Standards and abbreviations

DIM 4,6 Nm 8,8 Nm 10,9 Nm 12,9 Nm

1.8.1.2 Tightening torques for hydraulic couplings

1.8.1.3 Conversion table for tightening torques

1.8.1.4 Conversion table, pressure units

1.8.1.5 Conversion table, speed

1.8.2 Standard abbreviations and units

1.8.3 Screw types and tensile grades

MC6S Hexagon hole screw 8,8

MCS Slotted screw 4,6

Screw type Designation Tensile grade

K6SF Oval head socket screw 10,9

1.8.4 Machine colour codes

1.8.5 Colour coding according to NCS

1.8.6 Colour codes for wiring diagrams

Code Cable colour

1.8.7 Designations for electrical components

Table 5. First letter

Table 6. Second letter

Code Designation Designation (Eng)

3.1.4 Daily inspection

3.1.5 Weekly inspection (30 hours of operation)

3.1.6 First service (200 hours)

3.1.7 Main service

• Check of component attachments.

3.1.8 Extra service inspections

3.1.9 Check list, service inspection

Table 10. Drive unit

Table 11. Steering

Table 12. Brake Assembly

Table 13. Hydraulic system

Table 14. Electrical system

3.1.10 Code explanation