242330-040 pp13

Service Manual
en
SP10, SP10S, PP13

Valid from serial number: 904526- (SP10, SP10S) 914369- (PP13)
Order number: 242330-040

Issued: 2008-07-11 ITS
©TOYOTA Industrial Equipment Europe SARL Ancenis, France

Document revisions:
Issue date Order Changes

number
2006-09-29 242330-040 Completely new issue. Manual replaces part number: 235568
and 208588 (now combined to one manual).
2008-07-11 242330-040 Updated chapters:Tools, 2000, 6000, 7000.
This manual covers following truck models:
T-code Model Serial number

795 SP10 904526-
795 SP10S 904526-
675 PP13 914369-
© TIEE SARL Service Manual SP10, SP10S, PP13

Table of Contents
Order number Date Valid from serial number T-code
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
1- Table of Contents
2- Technical data ..................................................................................... 2-1
2.1 General tightening torques............................................................. 2-4
3- Maintenance ........................................................................................ 3-1

3.1 Safety regulations with maintenance work ..................................... 3-2
3.2 Cleaning and washing.................................................................... 3-4
3.2.1 External cleaning ............................................................. 3-4
3.2.2 Cleaning the motor compartment .................................... 3-4
3.2.3 Electrical components ..................................................... 3-4
3.3 Safe lifting ...................................................................................... 3-5
3.4 Lifting the truck SP10, SP10S ........................................................ 3-6
3.5 Lifting the truck PP13 ..................................................................... 3-8
3.5.1 Using a lifting device ........................................................ 3-8
3.5.2 Lifting points, using another fork lift truck ........................ 3-8
3.6 Placing the truck on its side SP10, SP10S..................................... 3-9
3.7 Maintenance Schedule ................................................................ 3-10
3.8 Oil and lubricants ......................................................................... 3-14
4- Tools ..................................................................................................... 4-1

4.1 Super Seal connectors................................................................... 4-1
4.2 AMP connectors............................................................................. 4-2
4.2.1 AMP Connectors, 040 series ........................................... 4-3
4.3 Molex connectors........................................................................... 4-3
4.4 Grease guns .................................................................................. 4-4
4.5 Other tools ..................................................................................... 4-5
5- Chassis - 0000 ..................................................................................... 5-1

5.1 Support arms SP10........................................................................ 5-1
5.1.1 Placement of supportarms ............................................... 5-2
5.2 Support arms SP10S ..................................................................... 5-3
5.2.1 General ............................................................................ 5-3
5.2.2 Main Components ........................................................... 5-3
5.2.3 Maintenance .................................................................... 5-4
5.2.4 Adjusting the support arm width ...................................... 5-4
5.2.5 Replacing support arms ................................................... 5-4
6- Drive unit/drive gear – 2000 ................................................................ 6-1

6.1 Component parts ........................................................................... 6-1
6.2 Service and repairs ........................................................................ 6-2
6.2.1 Dismantling the motor from the truck ............................... 6-2
6.2.2 Inspection/replacement of the carbon brushes ................ 6-2
6.2.3 Replacing the drive wheel ............................................... 6-3
6.2.4 Cleaning .......................................................................... 6-4
6.2.5 Maintenance of brakes .................................................... 6-4
6.2.6 Replacing the brake disc ................................................. 6-4
© TIEE SARL Service Manual SP10, SP10S, PP13 1- 1

Table of Contents
T-code Valid from serial number Date Order number
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
7- Wheel system - 3000 ........................................................................... 7-1

7.1 Castor wheel suspension SP10, SP10S ........................................ 7-1
7.1.1 Components .................................................................... 7-1
7.1.2 Lubricating the nipples ..................................................... 7-2
7.1.3 Adjusting the castor wheel pressure ................................ 7-2
7.2 Castor wheel PP13 ........................................................................ 7-3
7.2.1 Lubricating the nipples ..................................................... 7-4
8- Steering system – 4000 ....................................................................... 8-1

8.1 Components .................................................................................. 8-1
9- Electrical system – 5000 ..................................................................... 9-1

9.1 General .......................................................................................... 9-1
9.1.1 Firmware (truck control software) .................................... 9-1
9.2 Names of parts............................................................................... 9-1
9.3 Electric equipment list summary .................................................... 9-2
9.3.1 Electric component overview ........................................... 9-4
9.4 Access to the main electric panel................................................... 9-7
9.5 Electric circuit overview.................................................................. 9-8
9.6 Symbol list...................................................................................... 9-9
9.7 Electric wiring diagram ................................................................. 9-10
9.8 Automatic height adjustment........................................................ 9-16
9.9 Functional description .................................................................. 9-22
9.9.1 Operating principle ........................................................ 9-22
9.9.2 Transistor regulator ....................................................... 9-26
General .......................................................................... 9-26
Safety ............................................................................ 9-26
9.9.3 Battery charging on-board the truck
(machine number 947624-) 9-28
Charging ........................................................................ 9-28
Technical data ............................................................... 9-29
Alarm indications on charger ......................................... 9-30
9.9.4 Battery charge level status ............................................ 9-31
Battery display (option) .................................................. 9-31
9.9.5 Built-in charger for charging on a lorry - PP13 .............. 9-32
General .......................................................................... 9-32
Installation recommendations for the
“connection point” on a lorry .......................................... 9-32
Installation on the truck .................................................. 9-33
Charging ........................................................................ 9-35
Troubleshooting ............................................................. 9-35
Technical data ............................................................... 9-35
9.9.6 Limiting the travel speed ................................................ 9-36
9.9.7 Hour meter modes ......................................................... 9-36
9.9.8 Hand-held terminal ........................................................ 9-37
General .......................................................................... 9-37
Connecting the hand-held terminal ................................ 9-37
Hand-held terminal overview ......................................... 9-37
Hand-held terminal menus ............................................ 9-39
1- 2 Service Manual SP10, SP10S, PP13 © TIEE SARL

Table of Contents
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9.10 Troubleshooting ........................................................................... 9-40

9.10.1 General .......................................................................... 9-40
9.10.2 Displaying error codes ................................................... 9-40
Direct error code display ................................................ 9-40
Displaying error code on the hand-held terminal ........... 9-40
Error history ................................................................... 9-41
9.10.3 Error code list ................................................................ 9-42
9.10.4 TESTER function ........................................................... 9-45
9.11 Parameters and settings .............................................................. 9-47
9.11.1 General .......................................................................... 9-47
9.11.2 Setting the parameters .................................................. 9-47
9.11.3 Parameter list ................................................................ 9-48
9.11.4 Parameter description ................................................... 9-49
Acceleration ramp time (ACC.DELAY) .......................... 9-49
Deceleration ramp time (ACC.DELAY) .......................... 9-49
Release breaking intensity (RELEASE BRAKING) ....... 9-49
Inversion braking intensity (INVERSION BRAKING) ..... 9-49
Maximum speed (CUTBACK SPEED 3) ....................... 9-49
Reset service counter (CHECK UP DONE) .................. 9-49
Select service warning type (CHECK UP TYPE) .......... 9-49
”Time to next service” (CHECK UP HOURS) ................ 9-50
9.11.5 Transferring parameter settings .................................... 9-50
General .......................................................................... 9-50
From the truck to the hand-held terminal ....................... 9-51
From the hand-held terminal to the truck ....................... 9-52
9.11.6 Speed potentiometer calibration .................................... 9-52
General .......................................................................... 9-52
Procedure ...................................................................... 9-53
9.12 Technical data.............................................................................. 9-54
9.12.1 SEM-X transistor regulator ............................................ 9-54
10- Hydraulic system – 6000 ................................................................. 10-1

10.1 SP10, SP10S ............................................................................... 10-1
10.2 Hydraulics diagram and main components SP10, SP10S ........... 10-2
10.3 Hydraulics diagram and components PP13 ................................. 10-4
10.4 Description SP10, SP10S, PP13 ................................................. 10-6
Lift .................................................................................. 10-6
Lower ............................................................................. 10-6
Operating pressure and pressure limitation ................... 10-6
10.5 Adjustments ................................................................................. 10-7
10.5.1 Adjustment of the pressure limit valve SP10, SP10S .... 10-7
10.5.2 Adjustment of the pressure limit valve PP13 ................. 10-8
10.6 Tools SP10, SP10S ..................................................................... 10-9

Table of Contents
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
11- Lift mast SP10, SP10S – 7000 ......................................................... 11-1

11.1 Main mast .................................................................................... 11-1
11.1.1 Components .................................................................. 11-1
11.1.2 Maintenance .................................................................. 11-2
Mounting ........................................................................ 11-2
Lubrication ..................................................................... 11-2
11.1.3 Cylinder ......................................................................... 11-3
Disassembly .................................................................. 11-3
Assembly ....................................................................... 11-3
11.2 Fork carriage................................................................................ 11-4
11.2.1 Maintenance .................................................................. 11-4
11.3 Main lift chain system................................................................... 11-5
11.3.1 General .......................................................................... 11-5
11.3.2 Checking the chain setting ............................................ 11-5
11.3.3 Chain inspection ............................................................ 11-5
Noise ............................................................................. 11-5
Surface rust ................................................................... 11-5
Rusty links ..................................................................... 11-5
Stiff links ........................................................................ 11-6
Bolt rotation ................................................................... 11-6
Loose bolts .................................................................... 11-6
Outline wear .................................................................. 11-7
Stretching ...................................................................... 11-8
Damage ......................................................................... 11-9
Damaged discs .............................................................. 11-9
Damaged bolts .............................................................. 11-9
Dirty chain ...................................................................... 11-9
11.3.4 Cleaning ........................................................................ 11-9
11.3.5 Lubrication ................................................................... 11-10
12- Accessories – 9000 ......................................................................... 12-1

12.1 Automatic height adjustment SP10, SP10S ................................. 12-1
12.1.1 General .......................................................................... 12-1
12.1.2 Electrical wiring diagram ................................................ 12-3

Table of Contents
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
13- Destruction instructions ................................................................. 13-1

13.1 General ........................................................................................ 13-1
13.2 Procedure .................................................................................... 13-1
13.3 Abbreviations ............................................................................... 13-2
13.4 Sorting ......................................................................................... 13-2
13.5 Chassis (0300)............................................................................. 13-3
Disassembly .................................................................. 13-3
Material handling ........................................................... 13-3
13.6 Hoods, hatches (0340)................................................................. 13-3
Disassembly .................................................................. 13-3
13.7 Electric Pump Motor (1710)......................................................... 13-3
Disassembly .................................................................. 13-3
13.8 Drive assembly/drive motor (1760/2550) ..................................... 13-4
Disassembly .................................................................. 13-4
13.9 Wheels (3500).............................................................................. 13-5
Disassembly .................................................................. 13-5
13.10 Tiller arm (4110)........................................................................... 13-6
Disassembly .................................................................. 13-6
13.11 General electrical equipment (5100) ............................................ 13-7
Disassembly .................................................................. 13-7
13.12 Hydraulic unit (6100) .................................................................... 13-8
Disassembly .................................................................. 13-8
13.13 Hydraulic cables/cylinders (6230/6610) ....................................... 13-9
Disassembly .................................................................. 13-9
13.14 Main mast and fork carriage (7100) ........................................... 13-10
Disassembly ................................................................ 13-10
Material handling ......................................................... 13-10

Table of Contents
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This page is intentionally left blank

Technical data
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2- Technical data
Model SP10 SP10S PP13

Drive motor
Type TSL115-16 TSL115-16 TSL115-16
Output 0.5 kW 0.5 kW 0.5 kW
Duty cycle S2, 60 min S2, 60 min S2, 60 min
Minimum carbon brush length 14.5 mm 14.5 mm 14.5 mm
Nominal commutator diameter 43 mm 43 mm 43 mm
Minimum commutator diameter 40 mm 40 mm 40 mm
Resistance, shunt field winding, at 1.3 Ω 1.3 Ω 1.3 Ω
25 C°
Resistance, armature winding, at 0.0156 Ω 0.0156 Ω 0.0156 Ω
24 C°
Insulation resistance between wind- >=1 Mohm >=1 Mohm >=1 Mohm
ings and motor casing
Weight 25 kg 25 kg 25 kg
Brakes
Type 891.270.0 891.270.0 891.270.0
Brake power 10 Nm 10 Nm 10 Nm
Output 28 W 28 W 28 W
Resistance, coil 20,8 Ω 20,8 Ω 20,8 Ω
Minimum thickness brake disc 6.75 mm 6.75 mm 6.75 mm
Thickness of new brake disc 6.90 mm 6.90 mm 6.90 mm
Transmission/drive gear
Type 2-stage wheel 2-stage wheel 2-stage wheel
gear gear gear
Gear ratio 24,8:1 24,8:1 24,8:1

Technical data
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040

Wheels
Drive wheel Ø250x60 mm Ø250x60 mm Ø250x60 mm
Axle pressure without load 210 kg 440 kg 175 kg
Axle pressure at rated load 360 kg 580 kg 570 kg
Tightening torque for wheel bolts 20 Nm 20 Nm 20 Nm
Fork wheels Ø85 mm Ø85 mm Ø85 mm
Axle pressure without load 2x60 kg 2x80 kg 2x18 kg
Axle pressure at rated load 2x500 kg 2x515 kg 2x496 kg
Support arm wheels Ø100x40 mm - Ø100x40 mm
Axle pressure without load 2x70 kg - 2x30 kg
Axle pressure at rated load 2x70 kg - 2x24 kg
Hydraulic system
Output 1.4 kW 1.4 kW 1.2 kW
Duty cycle 3.5 % 3.5 % 10 %
Minimum carbon brush length 10 mm 10 mm 7.5 mm
Minimum commutator thickness/diam- 28,6 mm 28,6 mm 4.75 mm
eter
Pressure at rated load 190 bar 190 bar 110 bar
Overflow pressure 210 bar 210 bar 130 bar
Pump flow 4.5 l/min 4.15 l/min 4.7 l/min
Tank volume 2l 2l 1l
Batteries
Capacity 63 Ah 63 Ah 63 Ah
Weight 2x23 kg 2x23 kg 2x23 kg
Driving speeds
Without load 5.4 km/h (1.5 m/s) 5.4 km/h (1.5 m/s) 5.4 km/h (1.5 m/s)
With rated load 4.3 km/h (1.2 m/s) 4.3 km/h (1.2 m/s) 4.0 km/h (1.1 m/s)
Lift/lowering speed
Lifting without load 0.22 m/s 0.19 m/s 1.7 s
Lift with rated load 0.12 m/s 0.10 m/s 3.0 s
Lowering without load 0.14 m/s 0.14 m/s 3.0 s
Lowering with rated load 0.15 m/s 0.15 m/s 3.0 s

Technical data
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675

Power consumption (truck at room temperature)
Driving without load 20 A 20 A 13 A
Driving with rated load 26 A 26 A -
Lifting without load 39 A 39 A -
Lifting with rated load 132 A 132 A -
Hill-climbing ability
With rated load 5% 5% 5%
Without load 10 % 10 % 10 %
Measurement
Measurments L2 530 mm 530 mm 420 mm
Turning radius WA 1340 mm 1365 mm 1410 mm
Lift height 1580 mm / 1540 mm / 205 mm
2000 mm 1960 mm
Weight
Truck without battery 420 kg / 430 kg 560 kg / 580 kg 200 kg

Technical data
General tightening torques
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
2.1 General tightening torques

Millimetre thread M3 to M24.
The following applies under ideal conditions, e.g. steel against steel.
Table 1: General tightening torques [Nm]

M3 M4 M5 M6 M8 M10
B C B C B C B C B C B C
A 8,8 1,15 1,2 2,8 2,9 5,5 5,7 9,5 9,8 23 24 45 47
12,9 2,0 2,1 4,7 4,9 9,3 9,7 16,3 17,0 38,5 40,0 75,8 79,0
M12 M14 M16 M20 M24
B C B C B C B C B C
A 8,8 77,7 81 123 128 189 197 369,6 385 638,5 665
12,9 130,5 136 208 217 319,7 333 623 649 1075 1120
A = Strength class
B = Galvanised, non-oiled bolts
C = Untreated, oiled bolts
NOTE:
Experience has shown that if you adjust the torque wrench to the val-
ues for untreated bolts, you will achieve the correct torque value for
galvanised bolts. Do not tighten more than the values set out in the ta-
ble, as the bolts may otherwise be destroyed.

Maintenance
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
3- Maintenance
All points in the service program should be carried out to attain the high-
est safety and the least possible downtime. The service intervals are
only a guide and do not need to be followed to the letter. The operator
may adapt them to local conditions, but it is important that the intervals
comply with TOYOTA’s minimum requirements.
The service intervals are based on the running times and can be adapt-
ed to most normal 8 hour shifts. The service interval may be shortened
if the truck is used more frequently or in more demanding situations, e.g
cold store, dusty or corrosive situations. The following running times
have been used when calculating the intervals:
- Day time: 08.00-17.00 (20 hr/week)
- 2-shifts: 06.00-14.00, 14.00-22.00 (40 hr/week)
- 3-shifts: 06.00-14.00, 14.00-22.00, 22.00-06.00 (60 hr/week)
Ensure the truck is given a regular maintenance service after every 500
driving hours. The truck’s safety, efficiency and service life is depend-
ent on the service and maintenance it is given.
Only use TOYOTA approved spare parts when service and repair work
are carried out.

Maintenance
Safety regulations with maintenance work
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
3.1 Safety regulations with

maintenance work
Only personnel that have been trained in the service and repair of this
type of truck are authorised to carry out service and repair work.
• Do not carry out any maintenance work on the truck unless you have
the correct training and knowledge to do so.
• Keep the area where you carry out the service clean. Oil or water
makes the floor slippery.
• Never wear loose objects or jewellery when working on the truck.
WARNING!
Short-circuiting/Burns.
When working with the truck’s electrical system, short-circuiting/
burns can occur if a metal object comes into contact with live electri-
cal connections.
Remove watches, rings or other types of metal jewellery.
• Always disconnect the battery by pulling out the battery isolator
when carrying out maintenance work on the truck unless otherwise
stated in this Service Manual.
• Always switch off the truck’s power supply before opening the cov-
ers on the drive unit or electrical system.
• Relieve the system pressure slowly before starting work on the
truck’s hydraulic system.
• Use paper or a rigid sheet of cardboard when checking for oil leak-
age. Never use your hand.
• Bear in mind that the oil in the transmission or the hydraulic system
can be hot.
WARNING!
Risk of burns.
Hot transmission and hydraulic oil.
Let the truck cool before changing the oil.
• Only fill the hydraulic system with new and clean oil.
WARNING!
The hydraulic system can be damaged.
If the oil is contaminated hydraulic components can be damaged.
Always use new and clean oil in the hydraulic system.
• Store and dispose of changed oil in accordance with local directives.
• Do not release solvents and the like, which are used for cleaning/
washing, into drains that are not intended for this purpose. Follow
the local directives that apply for disposal.
• Disconnect the battery when welding on the truck.
NOTE!
The battery can be damaged. When welding using an electric power
source the welding current can enter the battery. The battery should
therefore be disconnected.

Maintenance
Safety regulations with maintenance work
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
• Remove at least 100 mm of paint around the welding/grinding area

through sand-blasting or the use of a paint stripper when welding or
grinding on painted surfaces.
CAUTION!
Harmful gases.
Paint that is heated gives off harmful gases.
Remove 100 mm of paint from the work area.

Maintenance
Cleaning and washing
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
3.2 Cleaning and washing

Cleaning and washing of the truck is important to ensure the truck’s reli-
ability.
• Carry out general cleaning and washing weekly.
NOTE!
Risk of short-circuiting.
The electrical system can be damaged
Disconnect the battery before washing by pulling out the battery con-
nector.
3.2.1 External cleaning

• Remove rubbish, etc. from the wheels daily.
• Use a well-known degreasing agent, diluted to a suitable concentra-
tion.
• Rinse off loose grime using tepid water.
NOTE!
Jamming, corrosion.
Mechanical components can be damaged.
After washing, the truck should be lubricated as set out in the chapter
Maintenance and lubrication chart.
3.2.2 Cleaning the motor compartment

• Cover the electric motors, connections and valves before washing.
NOTE!
The electrical system can be damaged.
Electrical components must not be cleaned with a high pressure
washing unit.
• Clean the motor compartment using a well-known degreasing agent,
diluted to a suitable concentration.
• Rinse off loose grime using tepid water.
3.2.3 Electrical components

• Blow electric motors down using compressed air.
• Clean the electrical panels, electronic boards, contactors, connec-
tions, solenoid valves, etc. using a damp cloth and a cleaning agent.
NOTE!
Electrical components can be damaged.
Do not break the guarantee seal on the electronic board.

Maintenance
Safe lifting
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
3.3 Safe lifting

All lifting must be carried out on a flat, non-slip and firm surface. Avoid
new laid asphalt or asphalt on a hot summer’s day.
• Activate the parking brake to prevent the truck from moving during
the lift. If the lift applies to the brake wheel, chock the other wheels
so that the truck stands still.
• Select a lifting point so that the lift is as easy as possible (one corner
at a time). If the truck has marked lifting points on the under side of
the chassis these can be used to obtain a well balanced lift.
• Ensure that the surface under the jack is clean and free from oil and
grease.
• Ensure that your hands and the jack’s lever are free from oil and
grease.
• Use the lever that belongs to the jack. A lever that is too short re-
quires more force than is necessary. If the lever is too long there is a
risk of the jack being overloaded.
• Support the truck:
- as close as possible to the part of the chassis that is to be lifted.
This reduces the risk of the truck tipping over.
- so that the truck cannot roll.
• Never lift up the jack in order to lift higher.
• Never work under a lifted truck unless it is well supported.
WARNING!
Risk of crushing.
A badly supported truck can fall.
Never work under a truck that is not supported on trestle-blocks and
secured by a lifting device.

Maintenance
Lifting the truck SP10, SP10S
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
3.4 Lifting the truck SP10, SP10S

• Lift the truck from the marked lifting points when using a lifting de-
vice.
WARNING!
Risk of overturning.
The truck can overturn if it is lifted from the wrong lifting points.
Always lift the truck from the marked lifting points.

Maintenance
Lifting the truck SP10, SP10S
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
• Lift from the truck’s centre of gravity when using another fork lift
truck.
550 100 mm
700 100 mm
• Secure the truck to the lifting truck’s forks.

• Lift with the greatest of care.
WARNING!
The truck can overturn if it is lifted incorrectly.
Always lift the truck secured to, and with the centre of gravity be-
tween, the lifting truck’s forks.

Maintenance
Lifting the truck PP13
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
3.5 Lifting the truck PP13
3.5.1 Using a lifting device

Lift the truck at the marked out lifting points with the lifting equipment.
WARNING!
The truck can overturn if it is lifted from the wrong lifting points.
Always lift the truck from the marked lifting points.
3.5.2 Lifting points, using another fork lift

truck
WARNING!
The truck can overturn if it is lifted incorrectly.
Always lift the truck secured to, and with the centre of gravity be-
tween, the lifting truck’s forks.

Maintenance
Placing the truck on its side SP10, SP10S
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
3.6 Placing the truck on its side SP10,

SP10S
In order to perform certain service checks, the truck must be placed on
its side.
Table 2: Placing the truck on its side

Description Pictures
1 Plug both air filters, for exam-
ple by placing a piece of soft
plastic between the air filter and
the filling pipe.
2 Loosen the battery cables and

remove both batteries. Also
place a suitable mat beside the
truck. The lift up one side of the
truck, using, for example, a
jack.
3 Use the mast and lower the

truck onto its side. The under-
side of the truck will then be
completely accessible for serv-
ice checks for the drive axle
and the wheels, for example.

Maintenance
Maintenance Schedule
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
3.7 Maintenance Schedule

A = PP13
B = SP10, SP10S
Pos. Work to carry out Opera- Service techni-
tor cian
Interval in days/weeks/months - can vary 1 d 1 w 12 m 36 m
depending on application
0000 Chassis
0000.1 Inspect links and locking pins A A
0000.2 Inspect for cracking and other damage AB AB
0000.3 Visually inspect the bolt joints between the chassis B B
and support arms.
0000.4 Press grease into the lubricant nipples B B
0000.5 Inspect cover locking AB AB AB AB
0000.6 Inspect signs and stickers AB AB AB AB
0380.1 Inspect for cracking and other damage A A
0380.2 Inspect the bushings for play A A
0380.3 Press grease into the lubricant nipples A A
1000 Motors
1700.1 Inspect the connections AB AB
1700.2 Inspect the drive motor carbon-brushes AB AB
1700.3 Clean the drive motor AB AB
1700.4 Retighten the drive motor mounting bolts (45 Nm) AB AB
2000 Drive gear
2550.1 Inspect the guide bearing for play AB AB
2550.2 Replace grease AB
2550.3 Retighten the mounting bolts AB AB
2550.4 Inspect for abnormal noise AB AB AB AB
3100 Brake
3100.1 Inspect brake disc wear AB AB
3100.2 Clean AB AB

Maintenance
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
A = PP13
B = SP10, SP10S
tor cian
3500 Wheels
3500.1 Inspect drive wheel wear (A: Ø >235 mm, AB AB
B: Ø >245 mm) and bolts (20 Nm)
3500.2 Inspect castor wheel wear AB AB
3500.3 Inspect fork/support arm wheel wear AB AB
3500.4 Press grease into the greasable bushings of the cas- AB AB
tor wheel
3500.5 Check whether the castor wheel swings freely AB AB
3500.6 Inspect the drive wheel pressure using the castor B B
wheel setting in relation to the drive wheel
3500.7 Remove strings and other rubbish AB AB AB AB
4000 Control system
4100.1 Inspect tiller arm mounting AB AB
4100.2 Inspect the strength of the gas strut and the locking AB AB AB AB
performance
5000 Electrical system
5000.1 Inspect connectors and cabling AB AB
5000.2 Clean electronic components and check for secure AB AB
mounting
5000.3 Retighten cable connections AB AB
5000.4 Inspect the contactors AB AB
5000.5 Inspect the battery indicator and the hour meter AB AB
(option)
5000.6 Inspect the fork lift height switch A A A A
5000.7 Inspect brake switch operation AB AB AB AB
5000.8 Inspect emergency stop switch operation AB AB AB AB
5000.9 Check the function of the horn AB AB AB AB
5000.10 Inspect collision safety switch operation AB AB AB AB
5000.11 Inspect charging plug/start prevention device AB AB AB AB
5110.1 Inspect battery locking AB AB
5110.2 Inspect connections to battery, truck and charger AB AB AB
5110.3 Inspect the battery tray, cell and pole protectors for AB AB AB
damage

Maintenance
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
A = PP13
B = SP10, SP10S
tor cian
6000 Hydraulics
6000.1 Inspect hoses and pipes for wear AB AB
6000.2 Replace the oil and clean the oil tank AB1 AB1
6000.3 Replace or clean the oil filter AB1 AB1
6000.4 Inspect the oil level AB AB AB
6000.5 Inspect for leakage AB AB AB AB
6600.1 Inspect cylinder mounting AB AB
7000 Lifting mast
7100.1 Inspect for cracks and other damage B B
7100.2 Inspect the lifting chains and chain rollers for wear B B
7100.3 Lubricate the mast rails at the guide rollers B B
7100.4 Retighten the mast mounts. B B
7100.5 Adjust the lifting chain if necessary B B
7100.6 Inspect the chain bolt pins and the split cotter pins B B
7100.7 Lubricate the lifting chain To prevent corrosion dam- B B
age, make sure the lifting chain has been properly
greased.
7100.8 Inspect the mast top covers B B
7420.1 Inspect for cracking and other damage B B
7420.2 Inspect the guides for wear B B
7420.3 Inspect the play between the mast girder and the fork B B
carriage rollers
1 = Replace the oil and clean the filter the first time after 12 months and
then every 24 months.

Maintenance
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
4100
6600
6000
5110
0000
5000
7000
0380
1700
2550 3100
7420
3500

Maintenance
Oil and lubricants
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
3.8 Oil and lubricants
Table 3: Lubrication chart

Service point 12 months 24 months 36 months
1 Hydraulic system Oa O
2 Driving gear (0,35 kg grease) K F
3 Pilot bearing S
4 Bearings and bushings S
5 Mast: Inside surfaces of beam flanges S
6 Mast: Inside surfaces of beam ribs S
7 Lifting chain S
S = Lubricate, K = Check, O = Oil replacement, F = Grease replacement
a.Replace the oil and clean the filter the first time after 12 months and then every 24 months.
TRUCK WITH MAST

5, 6, 7
2
3
4
2
3 TRUCK WITHOUT MAST

Maintenance
Oil and lubricants
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
Table 4: Oil and Grease Specification

Lubri- Specification Product name Part number
cant
1 Hydraulic ISO-VG32 Toyota Industrial 4x5 litres:
oil >-15°C Quality level: Hydraulic Oil 32 W5020-F0011-99
ISO 6743-4 category HM 208 litres:
DIN 51524 del 2 category HLP W5020-F0010-99
Bulk:
W5020-F0015-99
Hydraulic ISO-VG27,5 Statoil 131 1 litre: 233916-001
oil <-15°C Quality level: 5 litres: 233916-002
ISO 6743-4 category HV 20 litres: 233916-003
DIN 51524 del 3 category 208 litres: 233916-
HVLP 004
Bulk: 233916-005
2 Grease Esso, Unirex N2
3 Grease Staburags NBU 8EP,
Klüber Lubrication
4 Grease -30°C – +130°C Q8, Rembrandt EP2 Cartridge: 223690-
5 Quality level: 001
ISO 6743 18 kg: 223690-002
DIN 51502 180 kg: 223690-003
6 Grease -20°C – +110°C Gleitmo 805 29586
<-15°C Gleitmo 805K
7 Chain oil VG150 Rexoil, Rexnord Kette 236794
-10°C – +150°C
VG15 Klüberoil 4UH 1-15,
-40°C – -30°C Klüber Lubrication
VG68 Klüberoil 4UH 1-68N,
-30°C – +5°C Klüber Lubrication
Anticorit LBO 160 TT,
Fuchs DEA
+5°C – +45°C Klüber Lubrication
Anticorit LBO 160,
Fuchs DEA
+45°C – +80°C Klüber Lubrication

Maintenance
Oil and lubricants
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040

Tools
Super Seal connectors
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
4- Tools
4.1 Super Seal connectors
3
3
Figure Number Application

159232 Tools for fitting pins/sleeves
159229 Tools for loosening locks (1)
159230 Tool for fitting secondary locks

1-2 poles (2)
159231 Tool for fitting secondary locks

3-6 poles (2)
159228 Tools for removing pins/sleeves (3)

Tools
AMP connectors
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
4.2 AMP connectors

PT = Power Timer (4,8. 5,8. 6,3 mm)
JPT = Junior Power Timer (2,8 mm)
MPT = Micro Power Timer (1,5 mm)

151080 (PT) Tools for removing pins/sleeves
213296 (JPT) Tools for removing pins/sleeves
213298 (MPT) Tools for removing pins/sleeves
1=163787 Tools for fitting sleeves

2=163788
1=213336 (MPT)
2=213337 (MPT)
1
2
1=213336 (JPT) Tools for fitting pins
2=213549 (JPT) For 0,5-2,5 mm2
1
2

Tools
Molex connectors
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
4.2.1 AMP Connectors, 040 series

213130 Pin removal tool
213129 Tools for fitting pins
4.3 Molex connectors

16
9
8
1
156937 Tools for fitting pins/sleeves
156936 Tools for fitting sleeves/pins

Tools
Grease guns
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
4.4 Grease guns
Figur Nummer Användning

24981 A tool with a pointed nozzle used to apply
grease. Length 170 mm.
755132 Single-hand grease gun with straight discharge

pipe and nozzle.
755142 Two-hand grease gun with angled discharge

fif
pipe and nozzle.
755152 Two-hand grease gun with hose and nozzle.
755146 Grease hose 450 mm.

Grease hose 750 mm.
Grease hose 1500 mm.
202154PM Pointed nozzle for grease guns used to apply

grease in recessed nipples.
Fits grease guns with hose and discharge pipe.
Length 125 mm.
755140 Nozzle for neck nipples. Fits grease guns with
hose and discharge pipe.

Tools
Other tools
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
4.5 Other tools

08-13022 Driving gear puller
207881 Hand terminal for communica-

tion with the transistor regulator.
Needed for the following uses:
• Changing parameters.
• Uploading and downloading
parameter settings.
• Display of error messages.
• Calibration.

Tools
Other tools
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040

Chassis - 0000
Support arms SP10
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
5- Chassis - 0000
5.1 Support arms SP10
2
3 1
4
If the bolt joint between the chassis and the support arms are to be
adjusted or if the support arms are to be replaced, the bolts must be
replaced with new ones. Two guides (4) should be at both position 1
and 2. Tightening is done first to 20 Nm of torque at 1 and 2 in order.
Then full tightening is done in the same order to 200 Nm of torque.
Finally position 3 is tightened to 200 Nm of torque.

Chassis - 0000
Support arms SP10
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
5.1.1 Placement of supportarms
1
1
2 2
A B 3
Pos. Name
1 Inner hole
2 Outer hole
3 Marking
Same supportarm can be used for different width. Check for correct
measure between supportarms. To do that, check the marking for each
supportarm according to the table below:
Marking Hole Width of forks

1 550 ,mm
2 685 mm
1 536

Chassis - 0000
Support arms SP10S
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
5.2 Support arms SP10S
5.2.1 General
The truck is composed of a unit assembled so that the support arm
chassis and the separate assembly points for the mast and the support
arms are screwed onto the drive section.
The support arms on the support arm chassis are adjustable for differ-
ent interior support arm widths from 900 mm to 1300 mm to accommo-
date different pallet sizes. Normally, the support arm width is only
adjusted prior to delivery to a customer.
5.2.2 Main Components
Pos. Name
1 Support arms
2 Clamps (mounting)
3 Screws and nuts, MC6S16x100
4 Locking screw and nut, M6S 12x60H

Chassis - 0000
Support arms SP10S
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
5.2.3 Maintenance
If the bolt joint between the chassis and the support arms are to be
adjusted or if the support arms are to be replaced, the bolts must be
replaced withnew ones. Tightening of the clamp bolts (3) is done using
a torque wrench set at 220 Nm.
5.2.4 Adjusting the support arm width

To adjust the distance between the support arms, proceed as follows:
• Lift up one side of the truck.
WARNING !
The truck can tip over.
Do not lift up both support arms at the same time.
Lift one side at a time and support it while you work.
• Loosen the locking nut and the locking screw (4) on the front of the
cross bar.
• Loosen the screws and nuts of the clamp (3).
• Adjust the support arm, ensuring that the setting is the same on both
sides.
• Tighten the lock.
• Insert new screws and nuts and tighten them loosely (crosswise) us-
ing a spanner.
• Loosen the lock slightly and then tighten the nuts to 220+/-12 Nm.
5.2.5 Replacing support arms
2b 2a
7
1b 1a
3
6
5 4
Replacing a support arm is a more extensive task than adjusting the

width
• Lift out the battery.

Chassis - 0000
Support arms SP10S
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
• Lift up the side of the truck where the support arm is to be replaced.
• Loosen the locking bolt on the front of the cross bar (4).
• Loosen the bolts of the clamp (3).
• Pull out the support arm.
• Install the new support arm and adjust the width as per the chapter
“Adjusting the support arm width”.
• Lower the truck to the floor.
• Lift in the battery.

Chassis - 0000
Support arms SP10S
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040

Drive unit/drive gear – 2000
Component parts
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
27
31
6- Drive unit/drive gear – 2000
26
30
24 29 6.1 Component parts
23 28
22 25 Table 5: Components drive gear
21 Pos Name Pos Name
25
20 1 Screw, 7 pcs 21 Rotor
2 Washer 22 Carbon brush, 4 pcs
19
3 Cap 23 Locking ring
18 4 Locking ring 24 Ball bearing

5 Ball bearing 25 Driver
17
6 Key 26 Screw
16
7 Axle 27 Connector
8 Venting nipple 28 Guide pin
15 9 Gear housing 29 Locking ring

10 Screw, 8 pcs 30 Stropping
14 11 Sealing ring 31 Brake complete
12 Gear ring 32 Gear wheel
13 13 O-ring 33 Locking ring
14 Ball bearing 34 Gear wheel
12
15 Locking ring 35 Sealing ring
11 16 Drive track 36 Locking ring

17 Screw, 8 pcs (20 Nm) 37 Washer
39
10 18 Locking ring 38 Ball bearing
9 38
19 Magnetic coil 39 Sealing ring
37 20 Key
8
36
7
4
6 35
5 34
4 33
3 5
2 32
1 4

Service and repairs
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
6.2 Service and repairs
6.2.1 Dismantling the motor from the truck

• Shutdown the truck, pull out the plug from the start block.
• Remove the hoods from the battery compartment.
• Loosen the battery connections.
• Lift out the batteries.
• Loosen the two screws holding the instrument panel.
• Place the instrument panel in the truck.
• Seal the oil-filling plug.
• Loosen the connections on the tiller arm.
• Dismantle the cover plate and the two nuts on the tiller arm.
• Lift off the tiller arm.
• Place the truck on its side.
• Loosen the four bolts on the motor’s chassis mounting.
• Carefully lift out the motor and place on a clean surface.
Essential service and repair work can now be carried out on the motor.
• Assembly takes place in the reverse order.
6.2.2 Inspection/replacement of the carbon

brushes
• Shut down the truck, pull out the plug from the start block.
• Refit the instrument panel.
• Dismantle the covers from the carbon brushes.
• Loosen the cable connections are push back the carbon brush
springs.
• Pull out the carbon brushes and inspect/measure the wear. (See ta-
ble)

Service and repairs
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6.2.3 Replacing the drive wheel

• Shut down the truck, pull out the plug from the start block.
• Refit the instrument panel.
• Loosen the cable connections on the motor.
• Release the brake.
• Loosen the 8 bolts holding the drive wheel.
• To disassemble the wheel, screw two screws into the threaded holes
(a).
• Carefully lift off the wheel, avoid damaging the seals.
• NOTE! The securing bolts should always be replaced when replac-
a ing the drive wheel.

Service and repairs
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
6.2.4 Cleaning
An extremely critical factor to ensure correct functioning of the motor is
that it is kept as clean as possible. The motor and the motor compart-
ment must be regularly checked for dust, oil, and other impurities.
A vacuum cleaner with an appropriate nozzle can be used to clean the
motor if the motor windings and inner compartment are dry Com-
pressed air can be used in combination with a vacuum cleaner. In which
case the compressed air must be clean and dry.
A cloth of non-fluffing material should be used if the windings have a
coating. The cloth can also be moistened with a grease-dissolving,
organic and volatile detergent that does not damage the windings. Use
detergent sparingly to avoid it penetrating into the parts of the motor.
Residual detergent should be removed with an appropriate solvent, if it
leaves a greasy surface.
If the parts of the motor are heavily fouled it may be necessary to use a
solvent that is sprayed onto the parts. It is important that the detergent
is applied in a way to prevent dirt from penetrating into the parts of the
motor, especially for the rotor.
One method of cleaning the rotor is to dip it in solvent. If this is done
then the rotor must always be dried with the application of heat. There
must be adequate ventilation during the drying process, and the drying
should continue until a number of measurements of the insulation
resistance provide equivalent and approved results.
6.2.5 Maintenance of brakes

In general the brakes require no maintenance when used in a normal
working environment. However, according to the chart for preventive
maintenance it is recommended that the brake discs are regularly
inspected with regard to wear.
6.2.6 Replacing the brake disc

The brake disc should be replaced when its overall thickness has
decreased to 6.75 mm.
• Disconnect the electrical cables routed to the brake.
• Loosen and remove the two securing bolts.
• Loosen the brake disc from the hub and check the wear. Replace the
brake disc if the surface shows signs of uneven wear.
• Assemble the brake again.
• Connect the electrical cables.

Wheel system - 3000
Castor wheel suspension SP10, SP10S
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
7- Wheel system - 3000
7.1 Castor wheel suspension SP10,

SP10S
7.1.1 Components
3
4
5
6
Table 6: Components, castor wheel

suspension
Pos. Name Pos. Name
1 Castor wheel, complete 4 Nut
2 Stop screw 5 Holder
3 Washer 6 Grease nipple

Wheel system - 3000
Castor wheel suspension SP10, SP10S
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
7.1.2 Lubricating the nipples

The nipples should be greased regularly according to the maintenance
schedule. The nipples are located above the castor wheels and are
most easily accessed when the truck is placed on its side.
7.1.3 Adjusting the castor wheel pressure
Table 7: Adjusting the castor wheel

pressure
Description Pictures
1 The castor wheel pressure
should be 40+/-10 kg. To check
this, place a 3 mm high flat iron
bar under the drive wheel and
check that the castor wheel
meets with some degree of
resistance when rotated.
3 mm
2 If the pressure is incorrect, pro-

ceed as follows: Place the truck
on its side (see separate chapter
on maintenance). Unscrew the
nut and the stop screw.
3 Screw the entire holder clock-

wise for lower drive wheel pres-
sure and counter clockwise for
higher drive wheel pressure.
Ensure that the holder’s notch
lines up with the stop screw.

Wheel system - 3000
Castor wheel PP13
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
7.2 Castor wheel PP13

5
1 4
Table 8: Components, castor wheel

Pos. Name Pos. Name
1 Castor wheel 4 Ball bearing
2 Castor wheel fork 5 Greasing nipple
3 Bush

Wheel system - 3000
Castor wheel PP13
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
7.2.1 Lubricating the nipples

The nipples are to be greased regularly according to the maintenance
schedule. The nipples are located above the castor wheels and are
most easily accessed via holes (A) in the chassis. See the following pic-
ture.
A A

Steering system – 4000
Components
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
8- Steering system – 4000
8.1 Components
1
5
4
12
8
9
10
11
Table 9: Steering system components

Handle
Pos. Designation
1 Screw 3 Handle
2 Washer 4 Screw
Tiller arm bracket
5 Tiller arm bracket 9 Switch
6 Gas spring 10 Cylindrical roller bearing
7 Bundling tie holder 11 Axle
8 Bracket 12 Nut

Steering system – 4000
Components
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040

Electrical system – 5000
General
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
9- Electrical system – 5000
9.1 General
The truck's electrical system is based on the SEM-X system.
• The main power source consists of two 12 V DC traction batteries.
• The drive motor is a Separate Excitation Motor (SEM). The drive mo-
tor is controlled by an independent transistor regulator using Pulse
Width Modulation (PWM).
• The lift unit motor is a standard DC motor without any external field
winding connections. The electric motor in hydraulic unit is activated
using a contactor.
• A set of parameters used to adjust truck performance and brake
characteristics is stored in the transistor regulator. The regulator
also monitors any error conditions that may appear.
9.1.1 Firmware (truck control software)

The current firmware version used in the transistor regulator is V1.10.
The firmware in the transistor regulator cannot be updated or modified.
9.2 Names of parts

Information in square brackets [ ] refers to the component names used
in the electric wiring diagrams. See “9.3.1 Electric component over-
view” on page 4.
{high} is a voltage level that is approximately of the same magnitude as
the supply voltage level.
{low} is a voltage level of approximately 0 volt.
s/c = short-circuit.
o/c = open circuit.

Electric equipment list summary
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
9.3 Electric equipment list summary

A2:S300-311 A2:S312-318 A2
A2:S317 A2:S321 A2:S320
S227
S226
S18 S62
A2:S321
A2:S320
OPTION
AUT. HEIGHT L1 A2:S317 L1
ADJUST.
S31
Fig. 1

242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
F51 F50 S170 H81

F52 H80 S17 S21
H1
A30
A40
PTC
S171
F1
A1
K30
CONS
K10
X30
S10
M3
A6
A15
Y41
G1 G2
Y1
M1
Fig. 2

795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
9.3.1 Electric component overview

The table below is a summary of the most important electric compo-
nents on the truck.
Table 10: Component name overview

Symbol Function Component type Diagram Pic- Inf.
ref. ture
ref.
Power and shut-off of main power supply
G1, G2 Main electric power source Traction battery 12 V Fig. 4 Fig. 2
S170 Start interlock Interlocking device Fig. 5 Fig. 2
K10 Main contactor Contactor Fig. 4 Fig. 2
S171 Secondary interlock Auxiliary contactor Fig. 4 Fig. 2 2
switch
R2 Temporary supply PTC resistor Fig. 4 Fig. 2
Truck part protection
F1 Drive and pump motor protec- Fuse 125 A Fig. 4 Fig. 2
tion
F50 A1 operation circuit protection Fuse 5 A Fig. 4 Fig. 2
F51 A30 battery charger protection Fuse 10 A Fig. 4 Fig. 2
F52 A15 battery charger protection Fuse 20 A Fig. 7 Fig. 2 4
Control and signal handling
A1 Drive and brake power control Transistor regulator Fig. 4, Fig. 5 Fig. 2
A2 Truck control Electronic board Fig. 1 Fig. 1
A6 Detailed battery status Display Fig. 8 Fig. 2 4
S17 Key switch Switch Fig. 5 Fig. 2
H80 Battery status indicator LED Fig. 7 Fig. 2 4
H81 Battery status indicator (BDI) LED Fig. 5 Fig. 2
Safety and brakes
S21 Emergency switch Switch Fig. 5 Fig. 2
S10 Tiller arm in drive position Switch Fig. 5 Fig. 2
A2:S317 Emergency reverse Hall sensor - Fig. 1
Y1 Mechanical brake Electromagnetic brake Fig. 4 Fig. 2
H1 Warning signal Horn Fig. 1 Fig. 2
S18 Horn actuation Switch Fig. 1 Fig. 1
S62 Horn actuation Switch Fig. 1 Fig. 1

242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
Table 10: Component name overview

Symbol Function Component type Diagram Pic- Inf.
ref. ture
ref.
Driving
L1 Speed control and travel direc- Lever - Fig. 1 1
tion selector (toggle switch)
A2:S300-318 Speed control Hall sensor - Fig. 1
M1 Driving Motor Fig. 4 Fig. 2
Lifting/lowering of forks
S31 Lift height limiter Switch Fig. 1 Fig. 1 5
A2:S320 Fork lifting control Hall sensor - Fig. 1
A2:S321 For lowering control Hall sensor - Fig. 1
Y41 Fork lowering – hydraulic con- Magnetic valve Fig. 4 Fig. 2
trol
K30 Fork lifting (pump motor activa- Contactor Fig. 4 Fig. 2
tion)
M3 Pump motor Motor Fig. 4 Fig. 2
Automatic height adjustment
A40 Automatic height adjustment Electronic board Fig. 12 Fig. 2 4
control
H97 Automatic height adjustment Lamp Fig. 12 Fig. 1 4
indication
S22 Emergency switch Switch Fig. 12 Fig. 1 4
S32 Stopping lowering of forks Magnetic switch Fig. 12 Fig. 1 4
when forks < 15 cm
S33 Stopping lifting of forks when Magnetic switch Fig. 12 Fig. 1 4
forks are in top position
S225 Detection of correct load height Photocell Fig. 12 Fig. 1 4
S226 Fork lifting control Switch Fig. 12 Fig. 1 4
S227 Fork lowering control Switch Fig. 12 Fig. 1 4
Miscellaneous
A15 Battery charging on lorry Battery charger Fig. 7 Fig. 2 4
A30 Onboard truck battery charging Battery charger Fig. 6 Fig. 2
CONS Hand-held terminal connector Adapter - Fig. 2 3
X30 Flexible lead connector Fig. 2
Footnotes to the table above:

795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
1 – L1 refers only to the physical control device (toggle switch). There is

no explicit reference to this device in the system's electric wiring dia-
grams.
2 – This switch is installed directly on the main contactor. It is activated
with the contactor opens or closes.
3 – For more information on the hand-held terminal, see “9.9.8 Hand-
held terminal” on page 37.
4 – Option.
5 – Only PP13.

Access to the main electric panel
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
9.4 Access to the main electric panel

Access to the main electric panel - Fig. 3 B is required in case one of the
following procedures needs to be performed:
• Checking the alarm status using the LEDs.
• Connecting the hand-held terminal to the transistor regulator.
• Checking/replacing fuses.
• Checking/replacing components mounted on the panel.
• Inspecting the drive motor or hydraulic unit.
A NOTE:
Before removing the electric panel, make sure the key switch [S17]
has been switched off and the mains plug of the charger has been dis-
connected from the start interlocking device [S170] and the wall out-
B let. To ensure maximum safety, disconnect the minus terminal from
the battery [G2].
• Remove the screws securing the main cover (Fig. 3 A) and remove
the cover from the truck.
• Remove the two mounting screws securing the main electric panel
Fig. 3 Access to the elec- (Fig. 3 B).
tric panel
• Lift the panel straight up approx. 1 cm.
• The upper edge of the panel can now be lifted away from the truck,
allowing the panel to ”swing out”. Swing out the panel to allow it to
”rest” in this position.
• Check to make sure no cables in the wiring harness are subject to
unnecessary strain.
Fig. 1 Electric panel ”swung out”

Electric circuit overview
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
9.5 Electric circuit overview

1
A30 K10 F1
ONBOARD OPTION PTC (R2)
CHARGER F50 AUTO H. ADJ.
A/C IN.40 20 21
9 F51
S21 S22 S170
1
G1
23
G2
H81 S10
BK 22
INP.KEY SWITCH OUT.BATT.IND 59 S17
BK
F52
RD K10
POWER INP. OUT.NEG.MAIN CONTACTOR 42
RD INP.SUPPLY MAIN CONTACTOR 23
A15 + BATT
3
BK LORRY M1
CHARGER A1
M
A2
H80 4 E1 S E2
OUT.FIELD 1
BU
RD A1
OUT.FIELD 2 5
BK 6
ARMATURE
OPTION S171(K10) M3
8 A1
M
A2
K30
43
OUT.NEG K30/Y41
S18 H1
57 34
INP.LOWER TRUCK
WITHOUT
S62 Y41 MAST
33
INP.LIFT
OPTION S31
22 +24 VDC 51 INP.SPEED CONTROL.
53 INP.DRIVE STEERED WHEEL DIR. 6
54 A6
40 0 VDC
INP.DRIVE FORK DIR. - BATT 40 DISPLAY
55
INP.BELLY BUTTON Y1
31 41
A2 INP.TILLER SWITCH OUT.NEG.MAG.BRAKE
31
34
35
AUT. HEIGHT ADJUSTMENT 134 34

OPTION ON TRUCK LOWER LOWER
135 35
WITH MAST LIFT PUMP
22 24 VDC
201 200 PHOTO CELL
202 24 VDC
204 203
S225 AUTO UP REQ.
S226
205
A40
FORKS <150 MM
S32
207
H97 S227 INP.TILLER ARM 31
208 LIFT LIMIT AUTO
S33 40 0 VDC
201
AUTO ENABLED
Based on 232993 rev. E

Symbol list
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
9.6 Symbol list
Table 11: Symbol list

Symbol Description Symbol Description
Truck battery Horn
Fuse Emergency stop switch, NC
PTC resistora Switch, key operated, NO
DC motorb (SEM type)c Micro-switch, NO

A1 A2
M
E1 S E2
DC motor Micro-switch (pushbutton), NO
Contactor Switch (with coil), NC
Brake coil (usually active) Hydraulic-magnetic valve coil
Terminal LED
Switch with photocell, NC Magneto switch, NO
Lamp NO = Normally Open

NC = Normally Closed
a. PTC = Positive Temperature Coefficient (resistance increases as temperature increases)

b. DC = Direct Current
c. SEM = Separate Excitation Motor

9- 10
T-code
795, 675
Fig. 4
ELECTRONIC CARD
A1
5A
G1 G2
F50
20 1 40
Electric wiring diagram
Sh.2 - BATT INP. POWER SUPPLY 0VDC
10A
+ - + -
F51 R2
9
Sh.4
PTC
125A
F1
RD 3
Sh.5 + BATT INP. POWER SUPPLY 24VDC
2 1
PUMP MOTOR
M3 M1
Valid from serial number
BK 8 A1 A2 A1 A2 6
Sh.5 M M VMN ARMATURE WINDING
2 1
Service Manual
FIELD
40 4
Sh.3 F1 FIELD WINDING
F2 F1
13
S171 5
LOWER VALVE F2 FIELD WINDING
904526- (SP10, SP10S) 914369- (PP13)
Y41 14
34 43 Y1
Sh.2 2 1 X31 X31 41
A11 OUT, NEGATIVE, MAGNETIC BRAKE
1 2
SP10, SP10S, PP13

31 31
Sh.2 A4 INP, TILLER SWITCH
K10
42
A14 OUT, NEGATIVE, MAIN CONTACTOR
A1 A2
Date
9.7 Electric wiring diagram
23 23
Sh.2 A15 IN, SUPPLY, MAIN CONTACTOR
2008-07-11
K30
43 43
A2 OUT, NEG, PUMP CONTACTOR/LOWER VALVE
A1 A2
33 33
Sh.3 A10 INP, LIFT
1/6 PROD A
242330-040
232993
Order number
© TIEE SARL
Fig. 5
© TIEE SARL
242330-040
ELECTRONIC CARD
A1
Order number
EMERGENCY SWITCH OFF KEY

S21 START INTERLOCK S17 A16 INP, 24VDC KEY SWITCH
20 21 (*) 23 22
Sh.1 1 2 2 1
S170
H81
59
A12 OUT, BATTERY INDICATOR
PLUG:A (*)
Date
Sh.4
PLUG:B NOTE:
Sh.4 WHEN ONBOARD LORRY OPTION;
2008-07-11
23:A CONNECT RECEPTACLE 23:A TO

Sh.5 START INTERLOCK AND TAB 23:B
23:B TO CABLE 23.
Sh.5
23
Sh.1
Service Manual
TILLER SWITCH
S10
31 X30 X30
Sh.1 COM NO
22
Sh.3
51 51
Sh.3 A1 INP, WIPER, DRIVE POT.
SP10, SP10S, PP13

53 53
Sh.3 A6 INP, DRIVE, STEERED WHEEL DIRECTION.
54 54
Sh.3 A7 INP, DRIVE, FORK DIRECTION.
904526- (SP10, SP10S) 914369- (PP13)
55 55
Sh.3 A5 INP, BELLY BUTTON.
34 34
Sh.1 3 A13 INP, LOWER
T-code
795, 675
2/6 PROD A
232993
9- 11
9- 12
T-code
795, 675
Fig. 1
ELECTRONIC CARD TILLER ARM

A2
22 X30 22
Sh.2 A2:5 INP. +24V
S18
NO COM
H1
S62
Service Manual
BK RD X30 57 NO COM
40 X30 40
Sh.1 4 A2:6 INP. 0V DC
904526- (SP10, SP10S) 914369- (PP13)
55 X30 55
Sh.2 A2:1 OUT. BELLY BUTTON
LIFT LIMIT, PP13
S31
33 X30 35
Sh.1 A2:2 OUT. LIFT
SP10, SP10S, PP13

COM NC
JUMPER, SP10/SP10S
34 X30 34
Sh.2 A2:3 OUT. LOWER
Date
51 X30 51
Sh.2 A2:4 OUT. SPEED REF. VALUE
2008-07-11
54 X30 54
Sh.2 A2:7 OUT. DRIVE FORK DIRECTION
53 X30 53
Sh.2 A2:8 OUT. DRIVE WHEEL DIRECTION
242330-040
3/6 PROD A
232993
Order number
© TIEE SARL
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
Fig. 6
4/6 PROD A
232993
OUT, NEGATIVE CHARGER VOLTAGE
OUT, POSITIVE CHARGER VOLTAGE
INP, MAINS VAC
INP, MAINS VAC

ONBOARD CHARGER
INP, GROUND
A30
40
9
PLUG:A
PLUG:B
40
9
Sh.2
Sh.2
Sh.1
Sh.3

9- 14
T-code
795, 675
Fig. 7
OPTION
CHARGER/BOOSTER ONBOARD LORRIES
A15
Service Manual
20A
F52
RD RD
Sh.1 OUT, POSITIVE CHARGER VOLTAGE
BK BK
Sh.1 OUT, NEGATIVE CHARGER VOLTAGE
904526- (SP10, SP10S) 914369- (PP13)
POWER INP. CONNECTOR

1+ RD
INP, HOSTING VEHICLE POSITIVE
2+
1- BK
INP, HOSTING VEHICLE NEHATIVE
SP10, SP10S, PP13

2-
23:A BK
INP, TRUCK DISABLE RELAY CONTACT
Date
Sh.2
23:B BK
Sh.2 OUT, TRUCK DISABLE RELAY CONTACT
2008-07-11
H80
- RD
OUT, +24VDC, LED INDICATOR
+
BU
OUT, GND, LED INDICATOR
242330-040
5/6 PROD A
232993
Order number
© TIEE SARL
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
Fig. 8
6/6 PROD A
232993
+12VDC SUPPLY VOLTAGE
ELECTRONIC CARD
NCLRXD
PCLRXD
NCLTXD
PCLTXD
GND
B1
B5
B6
B4
B3
B2
A1
101
102
103
104
105
106
OPTION
101
102
103
104
105
106
1
6
PCLRXD
GND
NCLRXD
NCLTXD
PCLTXD
12VDC SUPPLY VOLTAGE
DISPLAY; MDI
A6

9- 16
T-code
795, 675
Fig. 9
ELECTRONIC CARD
A1
5A
S21 G1 G2
F50
21 20 1 40
Sh.4 - BATT INP. POWER SUPPLY 0VDC
1 2
10A
+ - + -
F51 R2
9
Sh.5
PTC
125A
F1
3
+ BATT INP. POWER SUPPLY 24VDC

2 1
PUMP MOTOR
M3 M1
8 A1 A2 A1 A2 6
Service Manual
M M VMN ARMATURE WINDING
2 1
FIELD
40 4
Sh.3 F1 FIELD WINDING
F2 F1
13
5
904526- (SP10, SP10S) 914369- (PP13)
LOWER VALVE S171 F2 FIELD WINDING

Y41 14
34 43 Y1
Sh.2 2 1 X31 X31 41
1 2
SP10, SP10S, PP13

31 31
Sh.2 A4 INP, TILLER SWITCH
K10
42
Date
A1 A2
23 23
Sh.2 A15 IN, SUPPLY, MAIN CONTACTOR
2008-07-11
K30
43 43
A2 OUT, NEG, PUMP CONTACTOR/LOWER VALVE
A1 A2
9.8 Automatic height adjustment
35 35
Sh.4 A10 INP, LIFT
242330-040
1/6 PROD A
233150
Order number
© TIEE SARL
Fig. 10
© TIEE SARL
ELECTRONIC CARD
242330-040
A1
KEY
Order number
START INTERLOCK S17 A16 INP, 24VDC KEY SWITCH

221 23 22
Sh.4 2 1
S170
H81
59
PLUG:A
Sh.5
Date
PLUG:B
Sh.5
2008-07-11
23
Sh.1
Service Manual
TILLER SWITCH
S10
31 X30 X30
Sh.1 4 COM NO
22
Sh.3
51 51
Sh.3 A1 INP, WIPER, DRIVE POT.
SP10, SP10S, PP13

53 53
Sh.3 A6 INP, DRIVE, STEERED WHEEL DIRECTION.
54 54
Sh.3 A7 INP, DRIVE, FORK DIRECTION.
904526- (SP10, SP10S) 914369- (PP13)
55 55
Sh.3 A5 INP, BELLY BUTTON.
34 34
Sh.1 4 A13 INP, LOWER
T-code
795, 675
2/6 PROD A
233150
9- 17
9- 18
T-code
795, 675
Fig. 11
ELECTRONIC CARD TILLER ARM

A2
X30
22 22
Sh.2 4 A2:5 INP. +24V
S18
NO COM
H1
Service Manual
S62
BK RD X30 57 NO COM
40 X30 40
Sh.1 4 A2:6 INP. 0V DC
904526- (SP10, SP10S) 914369- (PP13)
55 X30 55
Sh.2 A2:1 OUT. BELLY BUTTON
135 X61 135
SP10, SP10S, PP13

Sh.4 A2:2 OUT. LIFT
134 X61 134

Sh.4 A2:3 OUT. LOWER
Date
51 X30 51
Sh.2 A2:4 OUT. SPEED REF. VALUE
2008-07-11
54 X30 54
Sh.2 A2:7 OUT. DRIVE FORK DIRECTION
53 X30 53
Sh.2 A2:8 OUT. DRIVE WHEEL DIRECTION
3/6 PROD A
242330-040
233150
Order number
© TIEE SARL
ELECTRONIC CARD
A40
Fig. 12
22 X30 X61 22
© TIEE SARL
242330-040
Sh.3 11 INP. 24VDC

Order number
31 X61 31
Sh.2 3 INP. TILLER ARM SWITCH
34 X30 X61 34
Sh.2 15 OUT. LOWER VALVE
Date
35 X30 X61 35
Sh.1 1 OUT. PUMP CONTACTOR
2008-07-11
40 X30 X61 40
Sh.3 5 14 INP. 0VDC
134 134
Sh.3 10 INP. LOWER FORKS
135 135
Service Manual
Sh.3 2 INP. LIFT FORKS
S225
21 X60 RD/YE BN 201 1 4 BK X60 200
Sh.1 13 INP. PHOTO CELL
3
H97
221 X60 GN/WH X2 X1 BU 40 X60
Sh.2
X61 202
12 OUT. 24VDC TO SWITCHES
S226
SP10, SP10S, PP13

COM NO X61 203
17 INP. AUTO UP REQ.
NC
S32
X61 X62 204 1 2 X62 205
18 INP. FORKS <150MM
S227
X61
904526- (SP10, SP10S) 914369- (PP13)
COM NO 206
8 INP. AUTO LOWER REQ.
NC
S33
X61 X62 207 1 2 X62 208
16 INP. LIFT LIMIT AUTO MODE
201
9 OUT. AUTO ENABLED
T-code
795, 675
4/6 PROD A
233150
9- 19
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
Fig. 13
5/6 PROD A
233150
INP, MAINS VAC
INP, MAINS VAC

ONBOARD CHARGER
INP, GROUND
A30
40
9
PLUG:A
PLUG:B
40
9
Sh.2
Sh.2
Sh.1
Sh.4

242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
Fig. 14
6/6 PROD A
233150
+12VDC SUPPLY VOLTAGE
ELECTRONIC CARD
NCLRXD
PCLRXD
NCLTXD
PCLTXD
GND
B1
B5
B6
B4
B3
B2
A1
101
102
103
104
105
106
OPTION
101
102
103
104
105
106
1
6
PCLRXD
GND
NCLRXD
NCLTXD
PCLTXD
12VDC SUPPLY VOLTAGE
DISPLAY; MDI
A6

Functional description
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
9.9 Functional description
9.9.1 Operating principle

This section uses tables to describe the basic principles of main truck
functions. The table briefly describes what happens when one of the
main truck functions operates.
• Event – The main operating steps for the main truck functions are re-
ferred to as ”events”. Each separate event is numbered.
• Prior event – Indicates the event number that must have taken place
immediately prior to the current event in order for this to operate cor-
rectly.
• Measure(s) – One or more necessary interventions by the operator
required to execute the event.
• Influencing elements – Conditions that must be fulfilled in order for
an event to occur. The result of the event may also be influenced by
specific parameter settings.
• Resulting conditions – These describe important occurrences that
can be checked to verify that a function operates as it is supposed
to.
• Logic – Indicates the logic relationship between input data and out-
put data for a specific event.
Please note that ”resulting conditions” indicate what is expected when
an error state is not present.

242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
Table 12: Operating principle

Event: 1. Connection of battery
Prior event -
Measure(s) Connect the mains plug from the charger [A30] to the start interlocking unit
[S170].
Influencing ele- Operation circuit fuse OK [F50].
ments Emergency stop switch not depressed [S21].
Resulting condi- Truck is ready for switch-on.

tions Quick test: Depress the horn button [S18]/[S62]! The horn should sound.
Event: 2. Switch-on
Prior event 1
Measure(s) Turn the key switch [S17].
Influencing ele- [A1:INP 24VDC KEY SWITCH] input {high}.
ments Tiller arm switch not activated [S10], [A1:INP TILLER SWITCH] input {low}.
Lift/lowering switches not active, [A1:INP.LIFT] and [A1:INP.LOWER] inputs
{low}.
[L1] in neutral position.
Resulting condi- Battery status indicator [H81] lights up for 2 seconds and then goes out.
tions This indicates that the battery charge level > 60%.
Main contactor [K10] remains in open position, [A1:OUT.NEG.MAIN CON-
TACTOR] {high}
The mechanical brake is applied, [Y1, A1:OUT.NEGATIVE MAGNETIC
BRAKE] {high}
Truck is ready for operation.
Event: 3. Tiller arm lowered for driving
Prior event 2
Measure(s) Lower the tiller arm handle.
Influencing ele- Tiller arm switch [S10].
ments Main contactor [K10]
Secondary interlocking device [S171].
Resulting condi- Tiller arm switch [S10] active.
tions [A1:INP TILLER SWITCH] input {high}.
[A1:OUT.NEG MAIN CONTACTOR] output goes {low}.
Main contactor [K10] closes and auxiliary switch [S171] closes.

795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040

Event: 4. Driving in the fork direction
Prior event 3
Measure(s) Set the toggle switch [L1] to the fork direction travel position.
Influencing ele- Fuse [F1].
ments Toggle switch [L1].
Battery charge level (can limit the maximum travel speed).
Lifting/lowering of forks (limits the maximum travel speed if used during
truck travel).
Resulting condi- [A1:DRIVE FORK DIRECTION] input goes {high}.
tions [A2] feeds DC voltage to [A1:SPEED CONTROL] input (1-10 V).
[A1:OUT. NEG. MAGNETIC BRAKE] goes {low}.
Brake coil [Y1] is activated, and the mechanical brake is released.
Current fed to traction motor field winding (F1 +ve and F2 -ve).
Pulsating current feed to the drive motor armature in proportion to the incli-
nation of the toggle switch [L1].
Event: 5. Driving in the drive wheel direction
Prior event 3
Measure(s) Set the toggle switch [L1] to the drive wheel direction travel position.
ments Toggle switch [L1].
Battery charge level (can limit the maximum travel speed).
Use of fork lifting (limits the maximum travel speed if used during truck
travel).
Resulting condi- [A1:DRIVE STEERED WHEEL DIRECTION] input goes {high}.
tions [A2] feeds DC voltage to [A1:SPEED CONTROL] input (1-10 V).
[A1:OUT. NEG. MAGNETIC BRAKE] goes {low}.
Brake coil [Y1] is activated, and the mechanical brake is released.
Current fed to traction motor field winding (F1 -ve and F2 +ve).
Pulsating current feed to the drive motor armature in proportion to the incli-
nation of the toggle switch [L1].
Event: 6. Neutral braking
Prior event 4 or 5
Measure(s) Let the toggle switch [L1] return to the neutral position while the truck is
moving.
Influencing ele- Parameter settings [RELEASE BRAKING].
ments
Resulting condi- The traction motor [M1] acts as a generator, which converts the truck's
tions kinetic energy into electrical energy via the transistor regulator [A1], thus
reducing the travel speed. The brake force depends on a parameter set-
ting.
The mechanical brake [Y1] is activated when the truck comes to a stand-
still. [A1:OUT. NEG. MAGNETIC BRAKE] goes {high}.

242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675

Event: 7. Inversion brake
Prior event 4 or 5
Measure(s) Set the toggle switch [L1] to the opposite travel direction.
Influencing ele- Parameter settings [INVERSION BRAKING].
ments
Resulting condi- The traction motor [M1] acts as a generator, which converts the truck's
tions kinetic energy into electrical energy via the transistor regulator [A1], thus
reducing the travel speed. The brake force is proportional to the inclination
of the toggle switch. The mechanical brake [Y1] is activated when the truck
comes to a standstill. [A1:OUT. NEG. MAGNETIC BRAKE] goes {high}.
Event: 8. Using the mechanical brake
Prior event 4 or 5
Measure(s) Set the tiller arm to the top or lower position.
Influencing ele- Tiller arm switch [S10].
ments
Resulting condi- [A1:INP TILLER SWITCH] input goes {low}.
tions Brake coil [Y1] is deactivated, and the mechanical brake is applied.
Event: 9. Fork lifting

Prior event 2
Measure(s) Depress the fork lift button.
ments Main contactor [K10]
Fork lift button.
Battery charge level status.
Resulting condi- [A1: INP.LIFT] goes {high}.
tions The pump contactor [K30] is activated.
The pump motor [M3] starts.
Event: 10. Lowering forks
Prior event 9
Measure(s) Depress the fork lowering button.
Influencing ele- Main contactor [K10]
ments Fork lowering button.
Resulting condi- [A1:INP.LOWER] goes {high}.
tions The magnetic valve - fork lowering [Y41] is activated.

795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
9.9.2 Transistor regulator
1
B
1 2 3 4 5 6 7 8 B
F1
1
A
1 2 3 4 5 6 7 8 A
9 10 11 12 13 14 15 16 F2
ALARM
AL B+ B-
Fig. 15 SEM-X transistor regulator VMN
General
The ZAPI SEM-X transistor regulator controls the drive motor. Using
pulse width modulation (PWM, it adjusts the revolutions by varying the
armature voltage. At the same time, the activation time of the MOS
transistors used to adjust the armature current is varied.
The travel direction of the truck changes by switching the polarity in the
field winding (F1-F2). The regulator is fitted with a four-quadrant tran-
sistor bridge and a single-quadrant transistor bridge for the armature
winding.
A status LED (Fig. 15 AL) is used to indicate possible error conditions
that may have occurred.
Fig. 15 B shows the connector for the hand-held terminal.
NOTE:
To check the alarm status LED or gain access to the connector for the
hand-held terminal, the main electric panel must be swung open. See
“9.4 Access to the main electric panel” on page 7.
Safety
The regulator is a heavy-current component. When working on a bat-
tery operated vehicle, necessary precautions should be taken. This
includes, but is not limited to, correct training, use of eye protectors,
avoiding use of lose-fitting clothes, removing watches and jewellery,
and only using insulated tools. Other measures may also become nec-
essary.
WARNING!
Remove all watches, jewellery and always use insulated tools only.

242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
Table 13: Transistor regulator connections

Pin Ref. Description
A Signal check connector
A1 CPOT Input signal from cable 51 from [A2]
A2 NLIFT Connector for internal noise suppression/protective components
A3 PPOT Not used
A4 TILLER Input signal from tiller arm switch [S10], active when high (B+)
A5 BELLY Input signal from cable from [A2], which is used for instant reversal of travel
direction, active when high (B+). 3K3 to B+ when not operated.
A6 FW Input signal from cable 53 from [A2] for driving in the drive wheel direction,
active when high (B+)
A7 REV Input signal from cable 54 from [A2] for driving in the fork direction, active
when high (B+)
A8 H&S Reserved for future use
A9 NPOT Not used
A10 PLIFT Input signal from cable 33 from [A2] for fork lifting
A11 NEB Output for electromagnetic brake coil [Y1], 1.5 A continuous, protected
against short-circuits
A12 NLED Output for powering the battery status LED [H81], max. 100 mA.
A13 PEVD Input signal from cable 34 from [A2] for fork lowering
A14 NMC Output for main contactor coil [K10], 1.0 A continuous, protected against
short-circuits
A15 PMC Connector for noise suppression of main contactor [K10]
A16 KEY Transistor regulator control voltage, input signal from key switch [S17]
B Hand terminal connector
B1 --
B2 NCLRXD -”-
B3 PCLTXD -”-
B4 NCLTXD -”-
B5 GND -”-
B6 +12 -”-
B7 -- -”-
B8 --
Voltage connections
+B Positive feed from battery
-B Negative feed from battery
VMN Negative feed (via controller) to motor
F1, F2 Connectors for drive motor field winding

795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
9.9.3 Battery charging on-board the truck

(machine number 947624-)
The trucks are fitted with:
• Valve-regulated traction gel batteries with increased battery capacity
• Charger with improved charger status display
NOTE:
If only the charger is replaced (and not the cabling), the mains con-
nection must be modified. See the instructions supplied with the
charger.
The new batteries have the same characteristics as the previous bat-
teries and as such can be used with previously delivered SP10, SP10S
and PP13 trucks.
c
Charging
The batteries should be charged when the LED [H81] (C) starts blink-
ing. If charging is not performed and truck operation continues, the LED
will eventually light continuously, and the truck's travel speed will be
reduced in two steps. Please note that in the second step, the truck will
hardly move. In this case, perform charging until the green LED on the
charger lights.
Charging for a minimum of 30 minutes is more gentle to the batteries
and will not shorten the battery service life. However, it is necessary to
charge the truck batteries over night at least once a week or until the
green LED on the charger lights.
NOTE:
If the old charger is used to charge the new batteries, charging could
last one or two hours longer depending on the degree of battery dis-
charge.
Always be sure to switch off the truck prior to battery charging by turn-
ing the start key to the 0 position and removing the key.
A 1. Disconnect the charging plug (A) from the truck’s start prevention
B device.
2. Pull out the flexible cable and connect it to a wall outlet. Charging
of the truck batteries starts automatically.
- When main charging is in progress, only a yellow LED lights on
the charger. The LEDs on the charger can be seen through the
mains lead hole in the truck’s electric panel.
- When main charging is complete, the yellow LED continues to
light while a green LED on the charger also lights up. This indi-
cates equalising charging.
- When equalising charging is complete, the yellow LED goes out
and only the green LED remains lit. This indicates the truck is
ready for use.
3. Return the flexible cable and reconnect the charging plug to the
truck's start prevention device.

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Technical data
Batteries and Value

chargers
Battery capacity 63 Ah
Battery charger 8A
Voltage 2x12 V
Battery weight 2x23 kg

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Alarm indications on charger

See the table below regarding the various alarm indications that may
appear during battery charging.
Red Yellow Green Reason

Mains lead not connected
Time limit exceeded. Incomplete charging.
High battery voltage. Charging interrupted.
High battery voltage. Charging interrupted (option).
High battery voltage. Charging interrupted (option).
High charger temperature. Reduced charging current.
Battery not connected.
Low battery voltage. Low phase of current.
Low charger temperature or sensor error.
Maximum Ah limit exceeded.
High battery temperature (option).
Low battery temperature or low temperature sensor error

(option).
Defective charger
Very low battery voltage. Pulse charging.
Explanation of symbols:
= Off = On = Blinking

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9.9.4 Battery charge level status

The battery status LED [H81] indicates the remaining battery charge
level in the batteries.
Table 14: Battery charge level status

LED [H81] condition Energya Battery capacityb
Off > 45% energy remains > 60% charging remains
Blinks < 45% energy remains < 60% charging remains
Lit < 15% energy remains < 40% charging remains
a.Energy that can be consumed from the battery.
b.Battery capacity according to the hand-held terminal. If the battery capacity becomes less than 30%, the battery
service life will become shorter.
Battery display (option)

As an option, more detailed monitoring of the battery charge level is
available. The battery display is connected to the hand-held terminal
connector [CONS] on the transistor regulator [A1].
The display (Fig. 16) has four green LEDs and a red LED that indicate
the battery charge level according to the table below.
Fig. 16 Battery display (option)
Table 15: Battery display LEDs

Energya Battery capacityb LEDs
100 % 100 % 4 green LEDs
60% 70% 3 green LEDs
45% 60% 2 green LEDs
30% 50% 1 green LED
15% 40% 1 green LED blinks (time for battery charging)
5% 35% 1 red LED
0% 30% 1 red LED + reduced speed
- 25% 1 red LED + extremely slow speed
a.Energy that can be consumed from the battery.
b.Battery capacity according to the hand-held terminal. If the battery capacity becomes less than 30%, the battery
service life will become shorter.
NOTE:
The battery display is only updated when the drive motor is operating.
This implies that the remaining charge level can be indicated as high
if only the lift motor has been used for some time (without the truck
moving).

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9.9.5 Built-in charger for charging on a lorry -

PP13
General
The truck can be fitted with an additional charger for charging the bat-
teries on a lorry with a 24 V electric system.
This means that it is not necessary to have access to a 230 V outlet
every day, since this charging on a lorry can boost the truck operating
time even if the travel time between different loading/unloading points is
only 15-20 minutes.
Keep in mind that this kind of charging is merely a supplement and
does not replace charging via the 230 V mains. The batteries should
be charged on the 230 V mains for minimum 10 hours at least once a
week or whenever the battery indicator indicates the need for charging.
The battery of the lorry is given highest priority during charging, and the
battery of the forklift truck is only charged while the lorry is driving.
The charger has a start limit switch that prevents operation of the forklift
truck while charging. To prevent overheating the batteries and in order
to optimise charging at varying environmental temperatures, the charg-
er features a temperature compensation circuit.
This option includes a connection cable for connection to the lorry's
rear platform lift.
NOTE:
For correct operation, it is important that the installation is made ac-
cording to the instructions of the supplier.
Installation recommendations for the “connection

point” on a lorry
• In order for this option to work, a connection point protected by a
fuse on the lorry is required.
• The connection point must be of high standard, e.g. voltage supply
to the rear platform lift or another connector with a min. cable dimen-
sion of 16 mm2.
• Be sure to connect a 20 A fuse for the voltage supply line of the con-
nection point, as close as possible to the lorry battery.
• Also ensure that the connection point and cable have sufficient me-
chanical protection.
• A sealed connection box or similar is ideal as a connection point, to
which the supplied cable can be connected.

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Installation on the truck

Install the lorry charger according to instruction drawing 219205. See
the pictures below.
23112 (2x)
218353
218856
29918 (2x)
218068
42322 (4x)
22006 (4x)
20235 (4x)
21307 (8x)

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Note: 1:
• Disconnect cable 23 from the start protection device and connect to
the contact housing on the harness from the lorry charger.
• Connect the cable with the 4.8 sleeve from the lorry charger to the
start prevention device.
• Strap the harness with the standard harness.
Note: 2:
• Disconnect the yellow rubber plug on the electric panel.
• Install the yellow indicator lamp on the electric panel, and connect
the red cable from the lorry charger to the brass coloured pin on the
indicator lamp.
Not. 2
Not. 1

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Charging
Connect the connection cable from the lorry to the terminal (A) on the
truck. Charging automatically starts when the voltage level from the lor-
ry reaches 25.5 V.
Troubleshooting
• Check whether the charger receives line voltage.
• Check the fuse on the charger's battery cable.
• Check whether the charger is overheated.
• If the charger still does not work, replace it.
Technical data
Charging voltage 28,4 V

Charging current 8 - 15 A
Temperature compensation YES
Start prevention device YES
Charging start point 25,5 V
Charging interruption point 24,8 V
Cable dimension 4 x 2.5 mm2

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9.9.6 Limiting the travel speed

The maximum travel speed of the truck is limited depending on several
different, interacting conditions:
• Load and remaining battery capacity.
• Whether or not the lifting function is used.
• The transistor regulator temperature.
• Too long use after receiving the service warning message.
• The parameter settings can also be used to affect the maximum
travel speed.
See Parameter list on page 48 for more information. The table below
summarises the travel speed limits. The values are presented on the
assumption that all relevant parameters have been set to 100%. Please
note that the indicated speeds are nominal. If a combination of limiting
conditions exists, the lowest speed will be applied.
Table 16: Summary of travel speed limits

Remaining energy in Lifting Transistor regula- Operating hours Max. speed km/h
battery [H81] status tor temperature °C after service
warning
>30% Off < 75 < 10 5.4
On 3.2
> 75 3.2
< 30% - - - 2.2
- - - >10 1.6 a
- - - > 20 0b
a.Depends on the parameter settings. See Select service warning type (CHECK UP TYPE) on page 49.
b.Depends on the parameter settings. See Select service warning type (CHECK UP TYPE) on page 49.
9.9.7 Hour meter modes

The truck controller stores the number of operating hours (drive motor).
Alternatively, a "time to next service" counter can be activated. When
this counter reaches the value for ”service required”, the transistor reg-
ulator sounds a signal and the battery status LED [H81] starts blinking
H continuously.
Fig. 17 Operating
The actual number of operating hours can be checked by connecting
the hand-held terminal. Operating hours are displayed as in Fig. 17 ”H”

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9.9.8 Hand-held terminal

General
The hand-held terminal is required for the following tasks:
• Changing parameters stored in the transistor regulator.
• Uploading and downloading parameter settings to or from the tran-
sistor regulator.
• Displaying errors and diagnostic information.
• Performing calibrations.
Fig. 18 Hand-held ter-
Connecting the hand-held terminal

Connect the hand-held terminal as follows:
• Check that the key switch has been switched off [S17].
• Swing out the main electric panel See “9.4 Access to the main elec-
tric panel” on page 7.
• Connect the hand-held terminal connector (Fig. 18 A) to the diag-
nostic connector on the transistor regulator (Fig. 15 B).
• Switch on the key switch [S17].
Hand-held terminal overview

The hand-held terminal uses an alphanumeric display (Fig. 19 A) and
six operation buttons.

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B E
C D
Fig. 19 Hand-held terminal overview
When the hand-held terminal is connected and the key switch is
switched on, the following is displayed:
First the hand-held terminal version is displayed.
Connection confirmation to a SEM-X transistor regulator and the

firmware version.
A
A - The transistor regulator's firmware version.
B - Voltage supply.
C - The transistor regulator's rated current.
B C D D - The hour meter.
• Press ENTER (Fig. 19 C) to display the first menu.
• It is possible to scroll through the menus by repeatedly pressing the
ROLL buttons (Fig. 19 B).
• Press OUT (Fig. 19 D) to leave the selected menu.
• The PARAM SET buttons (Fig. 19 E) are used to adjust the parame-
ter values.

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Hand-held terminal menus

Initial display on hand-held terminal
OUT SEM-X V..
24v 75A 00000
ENTER
* MAIN MENU * Menu to change or set parameters

PARAMETER CHANGE
ROLL
* MAIN MENU * This menu is not applicable

STEER TABLE
ROLL
* MAIN MENU *
PROGRAM VACC Menu for calibrating the speed controller potentiometer [R1]
ROLL
* MAIN MENU * Menu for displaying the error history

ALARMS
ROLL
Menu for downloading parameter settings from the hand-held ter-
* MAIN MENU * minal to the transistor regulator
RESTOR PARAM.
ROLL
* MAIN MENU * Menu for uploading parameter settings from the transistor regula-
SAVE PARAM. tor to the hand-held terminal
ROLL
* MAIN MENU * Menu for diagnostic functions

TESTER
ROLL
Proceed as follows to open one of the main menus:

• Press ENTER from the initial display and...
• Repeatedly press ROLL until the desired menu is displayed...
• then press ENTER
For more information about the various menu options, see the subse-
quent sections.

Troubleshooting
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9.10 Troubleshooting
9.10.1 General
The electronic control system of the truck features display of error
codes and stores errors in a log. These functions constitute powerful
support when troubleshooting and pinpointing faults on the truck. All
error conditions detected by the transistor regulator are displayed as a
blinking sequence via the status LED (Fig. 15 AL). The blinking
sequence always start with ”long” blinks followed by a number of ”short”
blinks. See table 17 on page 42.
The five error codes that have occurred last are stored in the error log
together with the hour meter reading, the number of occurrences and
the transistor regulator temperature when each error occurred.
The first time an error code is generated, it is recommended to check
whether the condition remains when the trucks is switched off and then
on again. Check to see if the error code is displayed again.
Used the TESTER function of the hand-held terminal to test basic truck
functions.
9.10.2 Displaying error codes

Direct error code display
Proceed as follows to check a possible error condition by observing the
status LED:
• Swing out the main electric panel See “9.4 Access to the main elec-
tric panel” on page 7.
Normally, the status LED should be extinguished. If not, an error has
occurred.
• Determine the error code by counting the number of ”long” (and
”short”) blinks in the sequence.
• See Table 17, “Error code list,” on page 42.
Displaying error code on the hand-held terminal

Proceed as follows to check an existing error condition or to check the
error history using the hand-held terminal:
• Check that the key switch has been switched off [S17].
• Swing out the main electric panel. See “9.4 Access to the main elec-
tric panel” on page 7..
• Connect the hand-held terminal connector (Fig. 18 A) to the diag-
* ALARM * nostic connector on the transistor regulator (Fig. 15 B).
INCORRECT START
• Switch on the key switch [S17].
Fig. 20 Typical error display If an error condition exists in the truck, it is displayed immediately.

Troubleshooting
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• See Table 17, “Error code list,” on page 42.

NOTE:
The status LED lights continuously when the hand-held terminal is
connected.
Error history
Proceed as follows to check the error code history log:
The hand-held terminal must have been connected as explained in the
previous section.
Navigate to the ALARM menu.
SEM-X V..
24v 75A 00000
ENTER
* MAIN MENU *
PARAMETER CHANGE
* MAIN MENU * CODE
ROLL STEER TABLE ROLL CODE
* MAIN MENU * OUT
PROGRAM VACC CODE
* MAIN MENU * ENTER CODE
ALARMS
00001 #01 20 C
OUT
ENTER
OUT
ENTER
OUT LOG BOOK CLEARED
G
(PRESS OUT)
Fig. 21 Menu tree for displaying the error history
The log shows the last five error types together with information about
each error.
A – Error code description.
A
B – Hour meter reading when the error occurred.
* VFIELD NOT OK *
00015h #01 27°C C – Number of occurrences for a specific error.
B C D D - Transistor regulator temperature when the error occurred.
As an alternative, the error code history log can be cleared when the
ALARM menu is closed.

Troubleshooting
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9.10.3 Error code list

NOTE:
It is important to know that some of the status LED codes can be
caused by different error codes. The hand-held terminal provides the
most reliable diagnoses.
Table 17: Error code list

Status Description of Possible cause / Hint or Solution
LED code error code
¤ Watch dog Defective logic card and/or firmware. / Replace the transistor
(1) regulator.
EEPROM KO Problem with EEPROM or logic. / Replace the transistor reg-
ulator.
¤¤ EB DRIVER Electromagnetic brake coil [Y1] output, short-circuit with -
(2) SHORT BATT. / Check the brake coil connecting lead.
EB DRIVER KO The electromagnetic brake coil [Y1] output does not oper-
ate. / Replace the transistor regulator.
¤ ¤¤ CONTACTOR The main contactor [K10] does not respond during operation.
(1+2) DRIVER / Check the main contactor coil and cabling.
DRIVER The main contactor coil has either short-circuited, the con-
SHORTED nection is defective or it is not connected. Main contactor,
connection fault or short-circuit with -BATT. / Check the main
contactor coil and cabling.
CONTACTOR The main contactor tips [K10] have melted away.
CLOSED Problem with the field circuit.
Problem detected by the safety microprocessor. / Check that
main contactor tips have not melted away. Check the field
winding connections. If the above are OK, then replace the
transistor regulator.
CONTACTOR Unexpected drop in battery voltage after the main contactor
OPEN has closed. / Check the main contactor cabling. Check the
battery charge level.
¤ ¤¤¤ POWER FAILURE Short-circuit detected on the drive unit output to the main
(1+3) #1 contactor [K10] or brake coil [Y1]. / Check whether the main
contactor or brake coil circuit has short-circuited. If the above
are OK, then replace the transistor regulator.

Troubleshooting
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LED code error code
¤¤ ¤ CAPACITOR The capacitors are charged within 500 ms after the key
(2+1) CHARGE switch has closed. / Check the PTC resistor circuit. / If the
above is OK, then replace the transistor regulator.
VMN NOT OK Problem in the VMN armature drive unit. Incorrect motor
connection, short-circuit between the motor windings and the
chassis.
Defective transistor regulator / Check that the armature con-
nections [M1] are correct and that an internal short-circuit
has not occurred. If the above are OK, then replace the tran-
sistor regulator.
VFIELD NOT OK Field voltage problem. Drive motor [M1] field winding, short-
circuit or connection fault.
The field winding has been incorrectly connected to the tran-
sistor regulator. Defective transistor regulator / Check that
the armature connections [M1] are correct and that a short-
circuit in the motor has not occurred. If the above are OK,
then replace the transistor regulator.
¤¤ ¤¤ NO FIELD CUR Field current abnormally low. Drive motor [M1] field winding,
(2+2) short-circuit or connection fault.
FW HIGH FIELD Field current abnormally high in the drive wheel direction.
CURR. Drive motor [M1] field winding, short-circuit or connection
fault.
BW HIGH FIELD Field current abnormally high in the fork direction. Drive
CURR. motor [M1] field winding, short-circuit or connection fault.

Troubleshooting
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040

LED code error code
¤¤ ¤¤¤ STBY I HIGH Armature current abnormally high in standby. Defective tran-
(2+3) sistor regulator / Replace the transistor regulator.
I=0 EVER Armature current abnormally low during truck travel. / Check
the armature connections, check or replace the carbon
brushes. If the above are OK, then replace the transistor reg-
ulator.
CURR. PROTEC- Armature current abnormally high during truck travel. /
TION Check the armature connections for short-circuits. If the
above is OK, then replace the transistor regulator.
¤¤¤ ¤ TH. PROTECTION The transistor regulator operating temperature is abnormally
(3+1) high or low (outside the range >70°C or <10°C). Defective
transistor regulator / First check that the operating environ-
ment of the truck and the operating conditions are normal!
Let the truck return to normal operating temperature and try
operating the truck normally. If the error remains, then
replace the transistor regulator.
¤¤¤ ¤¤¤ VACC NOT OK Incorrect voltage of the speed value signal from [A2] when
(3+3) the truck is switched on. / Check the cabling between [A1]
and [A2].
¤¤¤ ¤¤¤¤¤ INCORRECT Incorrect start sequence for truck travel. The emergency
(3+5) START reversing switch [A2:S317] is operated during the start
sequence. Faulty connection in the main contactor coil circuit
[K10]. The tiller arm switch [S10] is operated during the start
sequence. / Inspect the cabling to [S10] and [A2]. Adjust or
replace [S10]. Inspect the cabling to the coil [K10] and
replace [K10] if necessary.
¤¤¤ ¤¤¤¤¤¤ FORW+BACK Conflict between travel direction commands. / Inspect
(3+6) cabling to [A2], inspect operation of [A2:S300-S318].
¤¤¤ ¤¤¤¤¤¤¤ BELLY SW No connection to [A2:S317] on [A2]. / Inspect cabling to [A2],
(3+7) ERROR inspect operation of [A2:S317].
¤¤¤ CHECK UP Time for scheduled service!
¤¤¤¤¤¤¤¤ NEEDED Time since last service intervention > CHECK UP HOURS.
(3+8) The service counter may not have been reset at the last
service intervention. / Determine the service requirements
and the current situation. Perform scheduled service and
then reset the service counter according to the guidelines.
See Reset service counter (CHECK UP DONE) on page 49.
¤¤¤ ¤¤ BATTERY LOW The battery charge level is less than 50% of the nominal
(3+2) value. / Charge the batteries.

Troubleshooting
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9.10.4 TESTER function

The hand-held terminal can be used to test a number of basic truck
functions and features.
Proceed as follows to use the TESTER function:
• Connect the hand-held terminal. See “ Connecting the hand-held
terminal” on page 37.
SEM-X V..
24v 75A 00000 BATTERY CHARGE
BELLY SWITCH
ENTER
DIGITAL INPUT # 2
* MAIN MENU * HARD & SOFT

PARAMETER CHANGE BACKWARD SWITCH
* MAIN MENU * ROLL FORWARD SWITCH
STEER TABLE
* MAIN MENU * TILLER SWITCH
ROLL PROGRAM VACC ACCELERATOR
* MAIN MENU *
ALARMS TEMPERATURE OUT
* MAIN MENU * FIELD CURRENT
RESTOR PARAM.
MOTOR CURRENT
* MAIN MENU *
SAVE PARAM. VMN
* MAIN MENU * BATTERY VOLTAGE
TESTER ENTER
• Select TESTER on the menu and press ENTER.

• Scroll through the various test functions by pressing the ROLL but-
tons.

Troubleshooting
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Table 18: Hand-held terminal TESTER functions

Display Function Value(s), approx.
BATTERY VOLT- Battery voltage measured at key switch 24-26 V
AGE input.
VMN Voltage measured between VMN and B-. BATT.VOLTAGE - 0.1 at stand-
still
Max. speed - 0.3 V
MOTOR CURRENT Armature current, drive motor. Standstill – 0 A
Max. load and/or ramp – 75 A
FIELD CURRENT Field current, drive motor. Standstill (brake applied) – 0 A
Max. speed - 5 to 6 A
Motor braking - 6 to 10 A
TEMPERATURE Temperature measured on MOSFET tran- Depends on environment
sistor heat sink (transistor regulator).
ACCELERATOR Voltage on cable 51 from [A2] used to con- [L1] in neutral position – 0 V 0%
trol the truck travel speed. for both travel directions:
The voltage is displayed on the left, while min. speed - 0.5 V 1%
the value on the right is a percentage. max. speed - 10.1 V 100%
TILLER SWITCH Level on digital input pin A4 of tiller arm Tiller arm in vertical position -
switch [S10]: OFF
ON/+VB = active input, switch closed. Tiller arm in drive mode - ON
OFF/GND = inactive input, switch open.
FORWARD SWITCH Level on digital input pin A6 for travelling in [L1] in neutral position - OFF
(TRAVEL IN DRIVE the drive wheel direction: [L1] in drive wheel direction -
WHEEL ON/+VB = active input, switch closed. ON
DIR.SWITCH) OFF/GND = inactive input, switch open.
BACKWARD Level on digital input pin A7 for travelling in [L1] in neutral position - OFF
SWITCH the fork direction: [L1] in fork direction - ON
(TRAVEL IN FORKS ON/+VB = active input, switch closed.
DIR. SWITCH) OFF/GND = inactive input, switch open.
H&S Level on digital input pin A8: OFF
For future use (”turtle” function).
DIGITAL INPUT #2 Level on digital input for lifting/lowering the No lifting or lowering - OFF.
forks: Lifting or lowering operated -
ON/GND = active input, switch closed. ON.
OFF/+VB = inactive input, switch open.
BELLY SWITCH/ Level on digital input pin A5, safety revers- With tiller arm in travel position:
(SAFETY REVERS- ing switch: [A2:S317] not active -
ING) ON/+VB = active input, B SW closed. approx.12 V
OFF/GND = inactive input, B SW open. [A2:S317] active - >20 V
BATTERY CHARGE Battery charge level indicated as %. Depends on charge status

Parameters and settings
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9.11 Parameters and settings
9.11.1 General
A number of parameters are stored in the truck controller. These
parameters are used to configure the truck to adapt it for correct opera-
tion in the environment it has been designed for. The parameters can
be set using the hand-held terminal.
9.11.2 Setting the parameters

The parameters can be adjusted using the PARAMETER CHANGE
function of the hand-held terminal:
VALUE NOT CHANGE
CHANGED
ARE YOU SURE ? VALUE CHANGED

YES=ENTER NO= OUT
CHECK UP HOURS 0-9

CHECK UP TYPE 0-3
CHECK UP DONE OFF
ROLL
CUTBACK SPEED 3 0-9
SEM-X V.. OUT
24v 75A 00000 INVERSION BRAKING 0-9
RELEASE BRAKING 0-9
ENTER
DECELER DELAY 0-9 ROLL = CHOOSE PARAMETER
PARAM SET = CHANGE VALUE
* MAIN MENU * ENTER ACC.DELAY 0-9
PARAMETER CHANGE
• Select PARAMETER CHANGE on the menu and press ENTER.

• Display the desired parameters using the ROLL buttons.
• Adjust the parameter setting using the PARAM SET buttons.
• Press OUT and then ENTER to store the new parameter setting, or
• Press OUT and then OUT again to return to the main menu without
changing the existing parameter setting.
NOTE:
Truck handling.
When specific truck parameters are changed, truck handling will be
affected.
Do not change any parameters unless you are sure what results the
change will bring.

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9.11.3 Parameter list

NOTE:
Before changing any parameters, be sure you have read and under-
stood the instructions for displaying and changing parameters in the
section Setting the parameters on page 47.
See also section Limiting the travel speed on page 36 for information
regarding the maximum travel speeds of the truck.
Table 19: Parameter overview

Parameter Function Min. Max. Stand Remarks
name (display) ard
ACC.DELAY Determines accelera- 0 9 6
tion ramp time. A
9: 0:
A= acceleration
DECELER.DELAY Determines the ramp 0 9 5
time for braking when D
speed control actua-
tion is reduced. 9: 0:
D = deceleration (brak-
ing)
RELEASE BRAK- Determines braking 0 9 5
ING intensity. B
0: 9:
B = braking intensity
INVERSION BRAK- Determines inversion 0 9 9
ING braking intensity. B
0: 9:
B = braking intensity
CUTBACK SPEED Determines max. 0 9 9
3 travel speed S
0: 9:
S= maximum speed
CHECK UP DONE Resets the service - - OFF
counter.
CHECK UP TYPE Selects service warn- 0 3 NONE
ing type.
CHECK UP HOURS Determines ”Time to 0 9 2
next service”.

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9.11.4 Parameter description

Acceleration ramp time (ACC.DELAY)
Determines the acceleration ramp time. If this value is increased, the
speed increase will be slower, and acceleration as a result will be
smoother.
Deceleration ramp time (ACC.DELAY)

Determines the ramp time for braking when speed control [L1] actua-
tion is reduced. If this value is increased, deceleration will be slower,
and truck slowdown as a result will be smoother.
Adjustment of this parameter only has limited effect.
Release breaking intensity (RELEASE BRAKING)

When this parameter value is increased, braking becomes harder.
Release braking is defined as a reduction of the truck travel speed
using motor braking when the speed control [L1] is returned to the neu-
tral position.
Inversion braking intensity (INVERSION BRAKING)

When this parameter value is increased, braking becomes harder.
Inversion braking is defined as a reduction of the truck travel speed
using motor braking when the speed control [L1] is set to the opposite
travel direction.
Maximum speed (CUTBACK SPEED 3)

Determines the maximum travel speed. An increase in this parameter
value causes an increase in the maximum travel speed.
The maximum speed = 5.4 X (62 + (p X 4.2))% km/h, where p is the
parameter value.
Reset service counter (CHECK UP DONE)

When this parameter is set to ON, the service counter is reset. This is
done after each scheduled service intervention.
Select service warning type (CHECK UP TYPE)

Determines the warning type when the service counter reaches ”Time
for next service” according to the setting of CHECK UP HOURS.
Value NONE – No warning is made (standard setting).
Value 1 - Warning is made when the service counter reaches the value
CHECK UP HOURS.

795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
CHECK UP HOURS. After ten hours of continuous operation, the max-
imum speed is reduced.
CHECK UP HOURS. After ten hours of continuous operation, the max-
imum speed is reduced. After 20 hours of continuos operation, all truck
functions become blocked.
The ”Time for service” warning consists of:
• An acoustic signal from the transistor regulator.
• 3 long + 8 short blinks from the status LED on the transistor regula-
tor.
• The battery status LED [H81] blinks continuously.
”Time to next service” (CHECK UP HOURS)

Set this value to coincide with the increase in the number of operation
hours at which the next scheduled service intervention should be sig-
nalled.
Time to next service = 200 + (p X 50) hours, where p = parameter value.
9.11.5 Transferring parameter settings

General
The hand-held terminal can be used to download parameter settings
and configurations from the trucks. This is especially convenient in the
following situations:
• To reset the truck configuration to a known condition or following re-
placement of the transistor regulator.
• To transfer the configuration from one truck to a group of trucks that
will then receive identical configurations.
The hand-held terminal can store up to 32 unique parameter settings.

242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
From the truck to the hand-held terminal

To transfer the parameter setting from the truck to the hand-held termi-
nal, use the PARAMETER CHANGE function in the hand-held terminal:
SEM-X V..
24v 75A 00000
ENTER
* MAIN MENU *
PARAMETER CHANGE
* MAIN MENU *
STEER TABLE
* MAIN MENU * SELECT Mod 31
ROLL PROGRAM VACC SELECT Mod 03
ROLL
ALARMS
RESTOR PARAM. FREE ENTER
SAVE PARAM. ENTER SEM -X V
ENTER
Memory location
OUT OVERWRITE DATA? occupied
YES = ENTER NO = OUT
ENTER
READING Memory location
free
Run all parameters
• Select SAVE PARAM on the menu and press ENTER.

• Use the ROLL buttons to select one of the 32 memory positions
(mode 00 to mode 31).
FREE indicates an empty memory position. SEM-X V indicates
memory positions that contain a parameter setting.
• Press ENTER to download the truck's parameter setting.
NOTE:
It is recommended to keep a file of the trucks and their associated,
stored parameter setting. This will ensure that stored parameter set-
tings can be returned to the correct truck.

795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
From the hand-held terminal to the truck

To transfer a parameter setting from the hand-held terminal to the truck,
use the RESTOR PARAMETER function in the hand-held terminal:
SEM-X V..
24v 75A 00000
ENTER
* MAIN MENU *
PARAMETER CHANGE
* MAIN MENU *
STEER TABLE
ROLL * MAIN MENU * SELECT Mod 31
PROGRAM VACC ROLL SELECT Mod 02
* MAIN MENU * ENTER
ALARMS SELECT Mod 01
* MAIN MENU * ENTER SELECT Mod 00
RESTOR PARAM.
SEM-X V
NO DATA FOR THIS

CHOPPER! (OUT)
OUT ARE YOU SURE ?
ENTER
STORING
Run all parameters
• Select RESTOR PARAM on the menu and press ENTER.

• Use the ROLL buttons to select the correct memory position (mode
00 to mode 31).
• Press ENTER The parameter setting is restored in the transistor
regulator memory.
9.11.6 Speed potentiometer calibration

General
The transistor regulator [A1] can be calibrated so that the speed poten-
tiometer [R1] provides a smooth, symmetric response across the entire
operating range. Calibration should be used in the following cases:

242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
• If the speed control response is not uniform in both travel directions.

• If the VACC NOT OK error occurs.
• If [R1] has been disassembled, suffers from interference or has
been replaced.
Procedure
Use the PROGRAM VACC function in the hand-held terminal to cali-
brate the speed potentiometer:
SEM-X V..
24v 75A 00000
ENTER
* MAIN MENU *
PARAMETER CHANGE
ROLL * MAIN MENU *
STEER TABLE
* MAIN MENU * VACC SETTING ENTER
ENTER
PROGRAM VACC
0.4 4.7
OUT
MIN VACC MAX

0.0 - 0.0
Slowly move the speed control

towards max in both directions
MIN VACC MAX

0.5 4.8
OUT
OUT ARE YOU SURE ?

ENTER
• Select PROGRAM VACC on the menu, press ENTER and ENTER

once more.
• Set the tiller arm to the travel position.
• Slowly move the speed control [L1] from neutral position to the end
stop first in one direction, then in the other direction.
• Press OUT and then ENTER.
The transistor regulator and potentiometer have now been calibrated.
Technical data
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
9.12 Technical data
9.12.1 SEM-X transistor regulator
Table 20: SEM-X transistor regulator data

Feature Value Unit Description
Operating voltage 24 Volts
Overvoltage limit 33 Volts 28.8 V continuously
Undervoltage limit 16,8 Volts Minimum operating voltage
Electrical insulation towards cold 500 V AC Minimum
chassis
PWM frequency 16 kHz
Max. current of armature winding * 75 Amps for 2 minutes
40 Amps for 1 hour
Max. current of field winding 12 Amps for 2 minutes
6.6 Amps for 1 hour
Contactor voltage 24 Volts Same as battery voltage
Contactor current 3 Amps Max.
KSI input voltage, min. 16.8 Volts
Logic input voltage >9.; High Volts
<9.2; Low
Operating temperature -30 to +40 °C
Overtemperature, reduction 70 °C Reduced in proportion to the
temperature increase
Undertemperature, reduction to -10 °C
80%
Max. temperature limit 90

Hydraulic system – 6000
SP10, SP10S
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
10- Hydraulic system – 6000
10.1 SP10, SP10S

The hydraulic system consists of a compact hydraulic unit and has no
return filter. The system has a solenoid valve for lowering the forks and
a pressure limit valve.

Hydraulics diagram and main components SP10, SP10S
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
10.2 Hydraulics diagram and main

components SP10, SP10S
3
Y41
5 4
P M3
Pos. Name SP10, SP10S

1 Lift cylinder, forks
2 Hose breakage valve
3 Non-return valve
4 Flow regulation valve
5 Pressure limit valve
6 Intake filter (suction sieve)
M3 Pump motor
P Pump
Y41 Lowering valve

Hydraulics diagram and main components SP10, SP10S
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
Y41

Hydraulics diagram and components PP13
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
10.3 Hydraulics diagram and

components PP13
Y41
4
M3 P 5
Pos nr. Description main components PP13

1 Lift cylinder for the forks
2 Preasure relief valve
3 Flow control valve
4 Non-return valve
5 Filter
6 Filler tuber
M3 Pump motor
P Pump
T Tank
Y41 Lowering valve for the forks

Hydraulics diagram and components PP13
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
M3
Y41

Description SP10, SP10S, PP13
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
10.4 Description SP10, SP10S, PP13

Lift
The lifting motion occurs when the pump motor (M3) is run. Lift speed
depends on load weight.
The non-return valve prevents leakage through the pump. When the
load is in the lifted position, it is held in place by the non-return valve
and the closed electric lowering valve (Y41).
Lower
By opening the electric lowering valve (Y41), the load is lowered and
the maximum lowering speed of the forks is regulated by the flow con-
trol valve.
A pressure limit valve (overflow valve) prevents overload and protects
the pump motor from overpressure. A hose rupture valve is located at
the cylinder to prevent the load from falling uncontrollably in the event
of a hose rupturing.
Operating pressure and pressure limitation
SP10, SP10S PP13

Operating pressure at 190 bar 110 bar
rated load
The pressure limit valve 210 bar 130 bar
opens at

Adjustments
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
10.5 Adjustments
The pressure limit valve is set to the correct value at the factory, but
may need to be adjusted if the valve or complete hydraulic unit is
replaced.
• 1 = Lock nutLocking sleeve
• 2 = Adjuster screw, pressure limit
When the screw is turned clockwise pressure increases.
When the screw is turned counter clockwise pressure decreases.
10.5.1 Adjustment of the pressure limit valve

SP10, SP10S
The truck should be able to lift a load of between 1000 and 1100 kg on
the forks.
Place a load of 1000 kg on the forks and check that the truck can lift it.
If the truck cannot lift 1000 kg:
1. Loosen the lock nut (1) by turning it counter clockwise.
1 2. Turn the adjuster screw (2) clockwise until the truck is able to lift the
load without problems.
2
3. Tighten the lock nut (1) by turning it clockwise.
If the truck can lift 1000 kg, place a further 100 kg on the forks. Check
that the truck cannot lift the load.
If the truck can lift 1100 kg:
1. Loosen the lock nut (1) by turning it counter clockwise.
2. Turn the adjuster screw (2) counter clockwise until the truck is una-
ble to lift the load.
3. Tighten the lock nut (1) by turning it clockwise.
NOTE!
A special tool is required to adjust the lock nut and adjuster screw.
See the section on tools below.

Adjustments
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
10.5.2 Adjustment of the pressure limit valve

PP13
The truck should be able to lift a load of between 1300 and 1400 kg on
the forks.
Place a load of 1300 kg on the forks and check that the truck can lift it.
If the truck cannot lift 1300 kg:
1 2 1. Loosen the locking sleeve (1) by turning it counter clockwise.
2. Turn the adjuster screw (2) clockwise until the truck is able to lift the
load without problems.
3. Tighten the locking sleeve (1) by turning it clockwise.
If the truck can lift 1300 kg, place a further 100 kg on the forks. Check
that the truck cannot lift the load.
If the truck can lift 1400 kg:
1. Loosen the locking sleeve (1) by turning it counter clockwise.

2. Turn the adjuster screw (2) counter clockwise until the truck is una-
ble to lift the load.
3. Tighten the locking sleeve (1) by turning it clockwise.

Tools SP10, SP10S
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
10.6 Tools SP10, SP10S

Two special tools are required to adjust the pressure limit valve of the
hydraulic system.
A B
12
8
26,5 13,5
• A – Socket for loosening or tightening the adjuster screw for pres-

sure limitation (part number 0816530).
• B – Socket for loosening or tightening the lock nut (part number
0816530/1).

Tools SP10, SP10S
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040

Lift mast SP10, SP10S – 7000
Main mast
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
11- Lift mast SP10, SP10S – 7000
11.1 Main mast
11.1.1 Components
7
4
6
1
Pos. Name
1 Cover
2 Main lift cylinder
3 Plate (cylinder cover)
4 Lift chain
5 Roller
6 Mounting bolt
7 Plate (chain guide)
8 Mounting bolts

Main mast
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
11.1.2 Maintenance
Mounting
8
The maintenance schedule states that only a visual inspection of the
mast mounting bolts (8) must be carried out and that they must not be
tightened when they are checked. If the mast has to be replaced or if
the bolts have become loose, new bolts and washers must be used.
The tightening torque must be 150+/-15 Nm.
Lubrication
Lubricating the beam

1 The inner sides of
Fig. 22 Bolt joints the beam flanges
must be lubricated
with Q8 Rembrandt
EP2.
2
2 The inner sides of 1
the beam rib must
be lubricated with
Gleitmo 805.

Main mast
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
11.1.3 Cylinder
Disassembly
• Remove the mast cover.
• Lift the fork carriage so that the lift chain slackens.
• Unscrew the chain guide (Fig. 23).
• Remove the chain sprocket (Fig. 23).
Fig. 23 Removing the chain sprocket
• Undo the bolts on the cylinder mounting (Fig. 24).

• Lift the fork carriage up past the cylinder.
• Lift out the cylinder and unscrew the hose (Fig. 24).
Fig. 24 Removing the cylinder
NOTE:
If the hose is difficult to reach, remove one of the truck’s batteries and
loosen the other end of the hose.
Assembly
Assembly takes place in the reverse order.

Fork carriage
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
11.2 Fork carriage
11.2.1 Maintenance
• Check that the fork carriage’s play is not too great.

• Shim as illustrated (1) if necessary.

Main lift chain system
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
11.3 Main lift chain system
11.3.1 General
Applies to all machines with a mast.
VARNING!
When replacing the chain, be sure to also replace the anker bolt.
11.3.2 Checking the chain setting

The lift chains must be adjusted at regular periods due to stretching,
see below. The chain setting is checked during servicing as set out in
the maintenance schedule.
Any adjustment is made with the chain mounting bolts.
Adjust the fork height according to C code 7100, 7420, 7700 and 7800
as applicable.
11.3.3 Chain inspection

The chains are exposed to two types of wear, outline wear and stretch-
ing. Wear to the bolts and disc holes is caused by stretching. The
chains are also affected by the environment they are used in.
Noise
If lubrication has been insufficient there will be metallic friction on the
chain and this will result in noise.
The chain should be replaced.
Surface rust
Surface rust is easy to recognize as the chain will be reddish brown.
Deep-seated rust has generally started and the chain has impaired
strength.
The chain should be replaced
Rusty links
Fretting corrosion results in a reddish brown powder being visible by
the outer discs. It can also appear as if the chain is bleeding when lubri-
cated.

795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
Stiff links
If it is not possible to pull out the chain to its normal position this can be
because of link rust or seizing.
Bolt rotation
Bolt rotation can be a phenomenon of stiff links. The fault is easy to see
when comparing with a new chain.
The chain should be replaced
.
Loose bolts
If a bolt is loose it will protrude from the side of the chain, which is due
to a stiff link or bolt rotation.

242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
Outline wear
H2 H3
P = Pitch
H2 = Nominal disc height.
H3 = Minimum disc height.
A new lift chain has a specific nominal disc height, defined as H2 in the
figure. As the truck is used the lift chain wears radically, on the side that
runs over the chain sprocket. The minimum disc height is define as H3
in the figure and denotes the minimum permitted value of the disc
height.
Maximal permitted outline wear is 5% of the height H2. If a lift chain
reaches the maximum level of wear, the chain should be replaced.
The nominal and minimum disc heights for respective lift chains are
stated in the table in the chapter “Stretching”.

795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
Stretching
The amount of stretch on a lift chain is measured on the part of the
chain that runs over the chain sprocket. The amount of stretch may, at
the most, be 2% on the most worn section of the chain. Measurement is
suitably made over 300-1000 mm of the chain.
The nominal and maximum permitted chain lengths for lift chains are
stated in the table below.
Type of Nominal Minimum Pitch P Nominal chain Maximum permitted

chain disc height disc height (mm) length for 20/30/ chain length for 20/
H2 ( mm) H3 (mm) 50 discs (mm) 30/50 discs (mm)
3/4”, 2x3 17.8 16.9 19.05 381/572/953 389/583/972
3/4”, 3x4 17.8 16.9 19.05 381/572/953 389/583/972
3/4”, 4x6 17.8 16.9 19.05 381/572/953 389/583/972
1”, 4x4 23,6 22,4 25,4 508/762/1270 518/777/1295
1”, 6x6 23,6 22,4 25,4 508/762/1270 518/777/1295
Wear to the bolts and around the holes on the discs are a reason why
the chain stretches. The chain should be replaced if stretching is
more than 2%.

242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
Damage
The chain should be replaced if damaged in any way.
Damaged discs
If a disc has broken on the chain, this can be due to overloading or cor-
rosion.
Damaged bolts
It can be difficult to discover whether a bolt has broken. It can appear as
bolt rotation and/or that the outer disc is loose.
Dirty chain
If a chain is very dirty it is first and foremost recommended that it is
replaced. It can also be dismantled and cleaned as set out in the chap-
ter “Cleaning”.
11.3.4 Cleaning
If a chain is very dirty it is recommended that it is replaced.
Dirty chains should be cleaned before they are lubricated, e.g. by
washing with solvent such as diesel or petrol.
The chain should be blown dry using compressed air and lubricated
directly after cleaning
NOTE!
Exercise care with degreasing agent as these can contain abrasives.

795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
11.3.5 Lubrication
Mineral and synthetic oils can be used to relubricate Rexnord chains.
NOTE!
Lubricant must not contain substances such as molybdenum disul-
phide, PTFE or the like.
A lift chain should be offloaded from the weight of the fork carriage
(hanging free) when lubricated.
• Lubrication intervals:
- 500 hours with normal operations
- 100 hours when driving in rugged environments such as cold
stores and corrosive environments.
The chains are sprayed with lubricant. Note the entire chain must be
lubricated, even the fastening bolts. It is especially important that the
part of the chain which runs over the chain sprocket is well lubricated.
The lubricate must comply with the viscosity demands at respective
temperatures as set out in the table below. The following lubricants are
recommended:
Ambient Viscosity Recommended Products*
temperature class
> - 40°C VG 15 Klüberoil 4UH 1-15, Klüber Lubrica-
tion
< - 30°C
> - 30°C VG 68 Klüberoil 4UH 1-68N, Klüber Lubri-
cation
< + 5°C
Anticorit LBO 160 TT, Fuchs DEA
> + 5°C VG 150 Klüberoil 4UH 1-150N, Klüber
Lubrication
< + 45°C
Anticorit LBO 160, Fuchs DEA
Rexoil, Rexnord Kette
>+ 45°C VG 220 Klüberoil 4UH 1-220N, Klüber
Lubrication
<+ 80°C
* Equivalent products from another manufacturer may be used.
NOTE!
Do not use a special rust protective agent to prevent
rust on the lift chains.
These agents impair the lubrication of the chains. Regular lubrication
is the best method to prevent rust attack.

Accessories – 9000
Automatic height adjustment SP10, SP10S
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
12- Accessories – 9000
12.1 Automatic height adjustment

SP10, SP10S
12.1.1 General
The truck can be fitted with a photocell, which in the automatic mode
controls lifting and lowering of the forks to maintain a preset height
when the sensor detects the load.
The photocell is located in the holder (C) on the mast.

• Set an ergonomically correct work height by moving the holder up or
down to the desired height.

795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
The holder features an emergency stop switch (D) and an indicator

lamp (E), which lights when the function is active.
• Depress the emergency stop switch to switch off all truck functions.
The controls for automatic height adjustment are placed on the tiller
arm.
• Lift the forks by pressing A. They will then be lifted automatically until
the photocell detects the load.
• Lower the forks by pressing B. They will then be lowered automati-
cally until the photocell detects the load.
B
A
The truck has an end position switch that switches off the pump when
the forks reach the maximum lift height.
The truck has one more end position switch that detects when the forks
reach the safety clearance to the ground. To lower the forks further and
prevent crushing the operator's feet, further lowering must be per-
formed manually.
Lifting/lowering of the forks can also be done in the same way as on a
standard truck. When manual operation is switched on, automatic oper-
ation is cancelled.

1 2 3 4 5 6 7 8
ELECTRONIC CARD
A A1 A
© TIEE SARL
242330-040
5A
S21 G1 G2
F50
Order number
21 1 2 20 1 40
Sh. 4 - BATT INP. POWER SUPPLY 0VDC
10A
+ - + -
F51
9
Sh. 3 F1 R2
100A
PTC
2 3
Date
+ BATT INP. POWER SUPPLY 24VDC

B 1 2 B
PUMP MOTOR
M3 M1
2008-07-11
8 A1 A2 A1 A2 6
M M VMN ARMATURE WINDING
1 2
FIELD
40 4
Sh. 2 F1 FIELD WINDING
F2 F1
13
C S171 5 C
LOWER VALVE F2 FIELD WINDING
Service Manual
Y41 14
34 X61 X30 43 Y1
Sh. 4 2 1 X31 X31 41
1 2
31 31
Sh. 2 A4 INP, TILLER SWITCH
D 34 D
A13 INP, LOWER
K10
42
A1 A2
SP10, SP10S, PP13

23 23
Sh. 2 A15 IN, SUPPLY, MAIN CONTACTOR
K30
E 43 43 E
A2 OUT, NEG, PUMP CONTACTOR/LOWER
A1 A2
VALVE
12.1.2 Electrical wiring diagram
904526- (SP10, SP10S) 914369- (PP13)
35 X61 X30 35
Sh. 4 A10 INP, LIFT
F F
1/5 PROD A
T-code
218858
795, 675
1 2 3 4 5 6 7 8
12- 3
12- 4
1 2 3 4 5 6 7 8 T-code
22 ELECTRONIC CARD
795, 675
Sh. 4 A1
A A
KEY
START INTERLOCK S17
221 23 22
Sh. 4 A16 INP, 24VDC KEY SWITCH
S170 2 1
H81
59
PLUG:A
Sh. 3
PLUG:B
Sh. 3
B B
X30 50
A3 OUT, POS, SUPPLY DRIVE POT.
R1 1
23 X30 51
Sh. 1 A1 INP, WIPER, DRIVE POT.
2
H1
3
40 BK RD 57 X30 52
Sh. 1 3 A9 OUT, GND, SUPPLY DRIVE POT.
C C
TILLER SWITCH
Service Manual
X30
S10 S16
X30 53
A6 INP, DRIVE, STEERED WHEEL
COM NO COM NO
DIRECTION.
HORN SWITCH S15
X30 54
S18 A7 INP, DRIVE, FORK DIRECTION.
X30 COM NO
904526- (SP10, SP10S) 914369- (PP13)
COM NO
3K3
D D
S20
31 X30 X30 55
Sh. 1 4 A5 INP, BELLY BUTTON.
COM NO
FORK LIFT
SP10, SP10S, PP13

NC
S34
COM NO
135 X61
Date
Sh. 4
E FORK LOWER E
S41
X61
2008-07-11
COM NO
134
Sh. 4
F F
2/5 PROD A
218858
242330-040
1 2 3 4 5 6 7 8
Order number
© TIEE SARL
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
D
A
F
3/5 PROD A
218858
8
8
MAINS; EARTH
ONBOARD CHARGER
MAINS; VAC
MAINS; VAC
7
7
A30
40
9
6
6
5
5
4
4
3
3
2
2
PLUG:A
PLUG:B
40
9
1
1
Sh. 2
Sh. 2
Sh. 1
Sh. 2 4
D
A

12- 6
1 2 3 4 5 6 7 8 T-code
ELECTRONIC CARD
A40 795, 675
A A
22 22
Sh. 2 11 INP. 24VDC
31 31
Sh. 2 3 INP. TILLER ARM SWITCH
34 34
Sh. 1 15 OUT. LOWER VALVE
B B
35 35
Sh. 1 1 OUT. PUMP CONTACTOR
40 40
Sh. 3 14 INP. 0 VDC
134 134
Sh. 2 10 INP. LOWER FORKS
C C
Service Manual
135 135
Sh. 2 2 INP. LIFT FORKS
CONTROL BOX ON MAST

EMERGENCY SWITCH OFF S225
S22
21 X60 RD/YE 1 2 BN 201 1 4 BK X60 200
Sh. 1 13 INP. PHOTO CELL
AUTO ENABLED
3
904526- (SP10, SP10S) 914369- (PP13)
H97
221 X60 GN/WH X2 X1 BU 40 X60
Sh. 2
D D
X61 202
X60 12 OUT. 24VDC TO SWITCHES
SP10, SP10S, PP13

S226
X61 203
17 INP. AUTO UP REQ.
COM NO
MAST SWITCHES
NC
S32
X61 X62 204 1 2 X62 205
18 INP. FORKS < 150MM
Date
E E
S227
X61 206
8 INP. AUTO LOWER REQ.
2008-07-11
COM NO
NC
S33
X61 X62 207 1 2 X62 208
16 INP. LIFT LIMIT AUTO MODE
201
9 OUT. AUTO ENABLED
F F
4/5 PROD A
218858
242330-040
1 2 3 4 5 6 7 8
Order number
© TIEE SARL
1 2 3 4 5 6 7 8
A A
© TIEE SARL
242330-040
Order number
OPTION
DISPLAY; MDI ELECTRONIC CARD
A6 A1
Date
B B
101 101
PCLRXD 1 B1 PCLRXD
2008-07-11
102 102
GND 2 B5 GND
103 103
12VDC SUPPLY VOLTAGE 3 B6 +12VDC SUPPLY VOLTAGE
C C
104 104
NCLTXD 4 B4 NCLTXD
Service Manual
105 105
PCLTXD 5 B3 PCLTXD
106 106
NCLRXD 6 B2 NCLRXD
D D
SP10, SP10S, PP13

E E
904526- (SP10, SP10S) 914369- (PP13)
F F
5/5 PROD A
T-code
218858
795, 675
1 2 3 4 5 6 7 8
12- 7
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040

Destruction instructions
General
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
13- Destruction instructions
13.1 General
These instructions have been drawn up as part of the truck manufactur-
er’s environmental management program. An important motive is, by
taking nature into consideration, to economise with resources. In other
words, you should try to recycle all material as far as possible. This is to
minimise the discharge of environmentally-hazardous substances.
The dismantling instructions are divided into different C-codes (parts
and functions on the truck.) These C-codes are:
• 0000 Chassis
• 1000 Motors
• 2000 Transmission/drive transmission
• 3000 Brakes/belt/wheel system
• 4000 Steering system
• 5000 Electrical system
• 6000 Hydraulics/pneumatics
• 7000 Working function - lift mast
• 8000 Auxiliary/installation equipment
• 9000 Accessories/extra equipment
The instructions do not tell you the type of material the parts are made
of, but refer you to different material containers where the parts should
be collected. Some plastics are marked, which means some instruc-
tions refer to the marking to determine the collection container to use.
13.2 Procedure
When sorting a component part you must know what plastic parts, liq-
uids, environmentally-hazardous substances and metals it incorpo-
rates.

Abbreviations
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
13.3 Abbreviations
Abbreviations for Service Manuals and plastic materials are used in the
dismantling instructions. The abbreviations used are:
ABS = Acrylonitrile-butadiene-styrene
PA= Polyamide
PMMA = Plexiglass
PP = Polypropylene
SM = Service Manual
13.4 Sorting
The sorting method for component parts is based on how they can be
recycled and whether they must be handled in a special way.
• Plastics must first and foremost be sorted into recyclable and non
recyclable plastics. Plastics that can be recycled must be subdivided
to differentiate between the different types of plastic. Instructions ei-
ther indicate in which container the plastic should be placed or there
is a reference to the material marking on the plastic component. In
those cases where the container is indicated, the type of plastic is
shown by an abbreviation. Sorting is not necessary for non-recycla-
ble plastics. These are placed in containers intended for combusti-
ble material.
• Small plastic and rubber items are placed in the container intended
for combustible material.
• Iron and steel scrap are sorted separately.
• Composite scrap that is difficult to dismantle and which contains dif-
ferent metals such as steel, aluminium, copper and other materials,
for example, plastics, should be sorted separately.
• Oil is collected in the intended container.
• Oil filters are collected in the intended container.
• Parts contaminated by oil, such as hydraulic hoses, should be sort-
ed separately.
• Batteries should be returned to the manufacturer (manufacturer of
the battery or the truck).
• Electronic scrap should be sorted from other scrap.
• Cables should be removed and collected separately.
• Small parts, such as screws, bolts, nuts, washers, etc. are not in-
cluded in the dismantling instructions. These are placed in contain-
ers intended for iron and steel scrap.

Chassis (0300)
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
13.5 Chassis (0300)

Disassembly
• Remove the chassis from the truck.
Material handling
All parts are to be treated as iron and steel scrap.
13.6 Hoods, hatches (0340)

Disassembly
• Remove the hood.
Material handling
The hood is to be placed in a container intended for ABS.
13.7 Electric Pump Motor (1710)

Disassembly
• Remove the hydraulic unit.
• Remove hydraulic cables.
• Remove the pump motor including the pump.
Material handling
Oil should be treated as dangerous waste.
Hydraulic cables should be placed in a container for oil-contaminated
components.
The motor, together with the pump, should be placed in a container for
dangerous waste.

Drive assembly/drive motor (1760/2550)
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
13.8 Drive assembly/drive motor (1760/

2550)
Disassembly
• Remove the cables.
• Remove the drive motor including the electric parking brake (1) from
the gearbox.
• Empty the oil from the gearbox.
• Remove the drive wheel (2).
Material handling
Cables are to be placed in a container intended for cables. The motor
and electric parking brake should be placed in a container for danger-
ous waste.
The oil should be treated as dangerous waste.
The gearbox is to be placed in a container intended for iron and steel
scrap.

Wheels (3500)
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
13.9 Wheels (3500)
1
3
Disassembly
• Remove the castor wheel (1), drive wheel (2) and fork wheel (3).
Material handling
The vulcanised wheels should be placed in a container for vulcanised
wheels.

Tiller arm (4110)
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
13.10 Tiller arm (4110)

Disassembly
• Remove the gas dashpot (1) and cut it in half.
• Remove the switch (2).
Material handling
Cables are to be placed in a container intended for cables.
Metal parts and gas dashpots should be placed in a container for metal.
The switch should be placed in containers intended for electronic
1
scrap.

General electrical equipment (5100)
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
13.11 General electrical equipment

(5100)
+ - + -
Disassembly
• Remove batteries.
• Remove the electronic devices.
Material handling
Cables are to be placed in a container intended for cables.
The battery (classified as hazardous waste within the EU) should be
returned to the battery manufacturer or the manufacturer's representa-
tive (see the rating plate on the battery). The batteries can also be
handed in to a representative of the truck manufacturer, who bears
responsibility for returning it to the battery manufacturer.
The electronic units should be placed in a container intended for elec-
tronic scrap.

Hydraulic unit (6100)
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
13.12 Hydraulic unit (6100)
2
Disassembly
• Empty the oil from the hydraulics.
• Remove hydraulic cables.
• Remove the oil tank (1).
• Empty the oil from the tank.
• Remove the hydraulic unit (motor + pump) (2) (see 1710).
Material handling
Oil should be treated as dangerous waste.
Hydraulic cables should be placed in a container for oil-contaminated
components.
The tank should be placed in a container for PP.
The motor, together with the pump, should be placed in a container for
dangerous waste.

Hydraulic cables/cylinders (6230/6610)
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675
13.13 Hydraulic cables/cylinders (6230/

6610)
Disassembly
• Remove the cylinder (1).
• Empty the oil from the cylinder.
• Cut the cylinder in half
• Remove the hydraulic cables (2).
• Remove the hydraulic hoses.
1
2
Material handling
The oil should be treated as dangerous waste.
Cylinder and hydraulic pipes are to be placed in a container intended
for iron and steel scrap.
Hydraulic hoses should be placed in a container for oil-contaminated
components.

Main mast and fork carriage (7100)
795, 675 904526- (SP10, SP10S) 914369- (PP13) 2008-07-11 242330-040
13.14 Main mast and fork carriage

(7100)
Disassembly
• Remove the main mast. (For dismantling, see separate chapter on
masts.)
• Remove plastic components from the main mast.
Material handling
The mast and fork carriage should be treated as iron and steel scrap.
Plastic components are to be placed in the container intended for com-
bustible material.

Main mast and fork carriage (7100)
242330-040 2008-07-11 904526- (SP10, SP10S) 914369- (PP13) 795, 675

©TOYOTA Industrial Equipment
Europe SARL Ancenis, France

242330-040 pp13

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Service Manual

SP10, SP10S, PP13

Order number: 242330-040

©TOYOTA Industrial Equipment Europe SARL Ancenis, France

Issue date Order Changes

This manual covers following truck models:

T-code Model Serial number

© TIEE SARL Service Manual SP10, SP10S, PP13

3- Maintenance ........................................................................................ 3-1

4- Tools ..................................................................................................... 4-1

5- Chassis - 0000 ..................................................................................... 5-1

6- Drive unit/drive gear – 2000 ................................................................ 6-1

© TIEE SARL Service Manual SP10, SP10S, PP13 1- 1

7- Wheel system - 3000 ........................................................................... 7-1

8- Steering system – 4000 ....................................................................... 8-1

9- Electrical system – 5000 ..................................................................... 9-1

1- 2 Service Manual SP10, SP10S, PP13 © TIEE SARL

9.10 Troubleshooting ........................................................................... 9-40

10- Hydraulic system – 6000 ................................................................. 10-1

© TIEE SARL Service Manual SP10, SP10S, PP13 1- 3

11- Lift mast SP10, SP10S – 7000 ......................................................... 11-1

12- Accessories – 9000 ......................................................................... 12-1

1- 4 Service Manual SP10, SP10S, PP13 © TIEE SARL

13- Destruction instructions ................................................................. 13-1

© TIEE SARL Service Manual SP10, SP10S, PP13 1- 5

This page is intentionally left blank

1- 6 Service Manual SP10, SP10S, PP13 © TIEE SARL

Model SP10 SP10S PP13

© TIEE SARL Service Manual SP10, SP10S, PP13 2- 1

Model SP10 SP10S PP13

2- 2 Service Manual SP10, SP10S, PP13 © TIEE SARL

Model SP10 SP10S PP13

© TIEE SARL Service Manual SP10, SP10S, PP13 2- 3

2.1 General tightening torques

Table 1: General tightening torques [Nm]

2- 4 Service Manual SP10, SP10S, PP13 © TIEE SARL

© TIEE SARL Service Manual SP10, SP10S, PP13 3- 1

3.1 Safety regulations with

3- 2 Service Manual SP10, SP10S, PP13 © TIEE SARL

• Remove at least 100 mm of paint around the welding/grinding area

© TIEE SARL Service Manual SP10, SP10S, PP13 3- 3

3.2 Cleaning and washing

3.2.1 External cleaning

3.2.2 Cleaning the motor compartment

3.2.3 Electrical components

3- 4 Service Manual SP10, SP10S, PP13 © TIEE SARL

3.3 Safe lifting

© TIEE SARL Service Manual SP10, SP10S, PP13 3- 5

3.4 Lifting the truck SP10, SP10S

3- 6 Service Manual SP10, SP10S, PP13 © TIEE SARL

• Secure the truck to the lifting truck’s forks.

© TIEE SARL Service Manual SP10, SP10S, PP13 3- 7

3.5 Lifting the truck PP13

3.5.1 Using a lifting device

3.5.2 Lifting points, using another fork lift

3- 8 Service Manual SP10, SP10S, PP13 © TIEE SARL

3.6 Placing the truck on its side SP10,

Table 2: Placing the truck on its side

2 Loosen the battery cables and

3 Use the mast and lower the

© TIEE SARL Service Manual SP10, SP10S, PP13 3- 9

3.7 Maintenance Schedule

3- 10 Service Manual SP10, SP10S, PP13 © TIEE SARL

© TIEE SARL Service Manual SP10, SP10S, PP13 3- 11