Repair Manual 7660234 en

Repair manual 7660234 en
LWI160
Translation of the original instruction
Publication No.: 7660234-040

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

Table of contents

General introduction 1
1.1 Images and other information .......................................................................................................... 1 - 1
1.2 How to use this manual ................................................................................................................... 1 - 1
1.3 Warning levels and symbols ............................................................................................................ 1 - 2
1.4 Pictograms....................................................................................................................................... 1 - 2
1.5 Abbreviations ................................................................................................................................... 1 - 3
Repair manual 7660234-040

1 General introduction

Images and other information
Software: 7662518
1
General introduction
1
1.1 Images and other information

1.1
Images and other information
Images and other information used in this manual may differ from your truck depending on model or optional
equipment.
1.2 How to use this manual

1.2
How to use this manual
The repair manual is divided into chapters containing the following information:
• General safety rules.
• Operating principle
This chapter provides a basic description of the main functions and their interdependencies.
• Parameters
This chapter provides a basic description of the product parameters.
• Installation
This chapter describes the preparatory work that is to be done before the product is used for the first
time.
• Maintenance
This chapter provides an overview of periodic maintenance.
• Troubleshooting
The chapter describes the action you should take when the product is completely or partially out of
function. It also describes the cause of the problem together with suggested remedies.
• C codes
This chapter describes the various product systems, e.g. the hydraulic system and includes descrip-
tions of system parts and the necessary service procedures. These descriptions are divided according
to the manufacturer's C code system.
• Instructions for disposal
This chapter specifies the proper sorting categories for the materials used in the various product com-
ponents.
• Wiring diagram
This chapter provides information on electrical components and wiring diagrams.
• Hydraulics schematics
This chapter provides information on hydraulic components and diagrams.
• Tools
This chapter provides a list of the special tools required.
• Service data and grease specifications
This chapter contains information on general tightening torques and specifications for lubricants.
• Technical data.
1-1 Repair manual 7660234 en

Warning levels and symbols
1.3 Warning levels and symbols

1.3
Warning levels and symbols
The following warning levels and symbols are used in the repair manual:
DANGER
Indicates a dangerous situation that – if not avoided – will cause death or serious bodily injury.
WARNING
Indicates a dangerous situation that – if not avoided – could possibly cause death or serious bodily
injury.
CAUTION
Indicates a dangerous situation that – if not avoided – will cause a slight or minor bodily injury.
NOTICE
Used in connection with actions that can cause material damage but not bodily injury.
Used to attract attention and to give information about various actions.
1.4 Pictograms
1.4
Pictograms
Symbol Procedure Symbol Procedure

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

Checks for leaks.
to torque.
Listening for noise. Lubrication, application.
Check of functions. Calibration
Adjustment Welding
Disassembly/removal Assembly/installation
Open Close
Refilling Emptying
Update Charging
Lift Lower
An example of another type of pictogram is “Cut cable ties”:
Repair manual 7660234 en 1-2

Abbreviations
Additional information under the pictogram can, for example, indicate the number of cable ties to be cut.
1.5 Abbreviations
1.5
Abbreviations
Abbrevi- Meaning Explanation

ation
ACC Alternate Current Combi Motor control, hydraulics and drive.
ACH Alternate Current Hydraulic Motor control, hydraulics.
ACT Alternate Current Traction Motor control, drive.
ADU Automation Display Unit Display used for automated applications for control inputs and
visual feedback from the automatic system.
ACU Automation Camera Unit Camera equipment used for automatic applications in order to
identify empty places in racking, etc.
ACP Automation Control Panel Operating panel used for automated applications for control in-
puts and visual feedback from the automatic system.
AUX Auxiliary Outside equipment
BCU Onboard system
BDI Battery Discharge Indicator Unit indicating the state of battery charge.
BMS Battery Management System A interface for battery to truck communication.
CAN Controller Area Network A standardised interface that enable communication between
different electrical units.
CID Central Information Display Display with menu-based information system that is used as the
primary communication tool between operator and truck.
DHU Data Handling Unit
DX Duplex Mast with two sections.
EPS Electronic Power Steering Complete steering servo with its own motor control.
ESO Emergency Switch Off Emergency stop switch.
FCM Fuse Central Module Fuse panel.
FCU Fork Control Unit Unit for fork functions.
GFU General Function Unit Unit for general functions.
HPS Height Pre-Select Height preselector
ICH Integrated Control Handle
IPM Intelligent Power Module Power control unit
LID Load Information Display Display that provides the operator information such as lift height,
load weight and height preselection.
LGU Laser Guidance Unit Laser guidance unit
LSU Laser Scanner Unit Laser scanner that detects objects.
MC Main Contactor Main contactor
MCU Main Control Unit Main control unit.
MLD Multi Load Detection Sensor for automatic detection of loads, etc.
PDA Personal Digital Assistant A compact, portable handheld computer.
PPS Personal Protection System Personal Protection System.

Abbreviations
Abbrevi- Meaning Explanation

ation
PTC Positive Temperature Coeffi- Electrical property that causes resistance to increase with tem-
cient perature.
SAU Secondary Automation Unit Device used for automatic control in order to have enough I/O.
SCU Secondary Control Unit Secondary steering unit
SEU Spider Expansion Unit Expansion unit
SF Shuttle Forks Telescoping fork unit.
SR Safety Relay Relay to disconnect power to certain components in order to
stop all movements.
SPLC Safety PLC Device used in automation applications for control with SR and
UAC.
SSU Shock Sensor Unit Shock sensor that registers any collision.
TBD To Be Defined Means that the instruction/chapter will be added at a later date.
TCS Truck Control System The truck control system that communicates with units.
TH Turret Head Turret head fork unit
I_Site Toyota Wireless Information Wireless communication.
System
TX Triplex Mast with three sections.
UAC Unit for Automation Control Device used for automated control of an operator-less truck.
UAC will build an extra CAN and a power system for automation
by itself
VNA Very Narrow Aisle Narrow aisles
VRE Very narrow aisle Rider Electric

General safety regulations 2
2.1 Work safety...................................................................................................................................... 2 - 1
2.2 Authorised personnel....................................................................................................................... 2 - 2
2.3 Truck modifications.......................................................................................................................... 2 - 2
2.3.1 Responsible ........................................................................................................................ 2 - 2
2.3.2 What can be modified? ....................................................................................................... 2 - 2
2.4 Electrical system.............................................................................................................................. 2 - 4
2.4.1 Electrostatic risks ................................................................................................................ 2 - 4
2.4.2 Battery handling .................................................................................................................. 2 - 4
2.5 Safe lifting ........................................................................................................................................ 2 - 5
2.6 Software........................................................................................................................................... 2 - 5
2.7 Hydraulic system ............................................................................................................................. 2 - 6

2 General safety regulations

Work safety
Software: 7662518
2
General safety regulations
2
2.1 Work safety
2.1
Work safety
For safe work, always remember:
▷ Make sure that the work site is a safe place to perform the work. Follow local regulations.
▷ Make sure there is free space around and above the truck at the work site.
▷ Check that the underlying surface of the work site is suitable in terms of bearing capacity, flatness
and friction.
▷ Make sure barriers are in place to prevent unauthorised access. Follow local regulations.
▷ Always keep the work site clean. Oil and water on the floor will make it slippery.
▷ Always disconnect the battery when carrying out maintenance or repair work, unless otherwise stated
in this repair manual.
▷ Do not drive the truck in maintenance mode, as this entails risks.
▷ Use the correct working posture. The work often involves sitting on your knees or bending over for-
wards. Try sitting on a toolbox, for example, to relieve the strain on your knees and back.
▷ Loose items and jewellery may get caught in moving parts. So never wear loose articles or jewellery
when performing work.
▷ Exercise caution and always follow applicable local regulations when working at height.
▷ Use the correct tools for the work you are carrying out.
▷ Keep all tools well maintained.
▷ Make sure that all safety equipment including guards and covers are properly secured and that they
work as intended before starting the work. If a guard or cover must be removed in order to perform
the work, extra care must be taken, and when the work is finished the guard or cover must be refitted.
▷ Use some paper or a stiff piece of cardboard when checking for possible oil leaks. Do not use your
hands.
▷ The drive gear oil may be hot.
▷ Use only new and clean oil for the drive gear.
▷ Store and transport used oil in accordance with local regulations.
▷ Always keep fire-fighting equipment close at hand, and do not use an open fire to check fluid levels or
when searching for leaks
▷ Do not flush solvents, etc. down the drain unless they are intended to be disposed of in this way. Fol-
low local disposal regulations.
▷ Always disconnect the battery when performing welding work.
▷ Before welding or grinding painted surfaces on the truck, remove the paint within an area of at least
100 mm around the welding/grinding area by blasting or through use of paint remover.
▷ Always follow the relevant maintenance instructions in order to maintain a high level of safety on the
truck and minimise downtime.

Authorised personnel
2.2 Authorised personnel

2.2
Only personnel trained in servicing and repair of this type of product are authorised to carry out service and
repair activities.
2.3 Truck modifications

2.3
Truck modifications
Any modification of the truck must be approved in advance. No modification of truck may be performed that
may influence the capacity, stability and safety of the truck without prior written approval from the manufac-
turer, its representative or successor.
In the case of the manufacturer no longer being in business and there being no successor, the user of the
truck may arrange for modifications on the precondition that the user:
• makes sure that an engineer with expert knowledge of industrial trucks and their safety designs, tests
and implements the modification,
• files all documentation of the design, tests and implementation of the modification,
• approves and makes the applicable changes to the capacity plate (if present on the truck), adhesive
labels, markings and manuals
and
• affixes a permanent and well visible sign to the truck stating how the truck has been modified, together
with the date of the modification and the name and address of the company that carried out the modi-
fication work.
2.3.1 Responsible
2.3.1
Responsible
The one designated by the sales company or the supplier as being the person responsible for the trucks.
2.3.2 What can be modified?

2.3.2
What can be modified?
Any modification of the product must be approved beforehand. No modification of product may be performed
that may influence the capacity, stability and safety of the product without prior written approval from the
manufacturer, its representative or successor.
See the table below, types A, B and C.

• All sales companies and suppliers may perform modifications type A.
• All changes (adaptations) over and above those referred to in type A below must be ordered from the
manufacturer in accordance with standard procedures for customer adaptations (including software
changes).
• Type B and C modifications must only be carried out by the manufacturer.
Get in touch with our technical support for guidance and for any questions.

Truck modifications
Typ Description Examples of modifications

e
A Non safety-related modi- Please note that any additional equipment must have a CE declaration 2
fications and have the CE marking.
• Optional equipment, such as lamps, scales, scanners, writing pad

etc. to be installed according to service instructions.
• Forks for powered pallet trucks to existing standard lengths, widths
and load capacities.
Shortened forks, down to 800 mm for stackers.
• Adding smaller load carriers to forks.
• Adding load supports to fork carriages.
• Fitting a standard sideshift unit, requiring new plates for truck identi-
fication and capacity.
• Replacing the mast with one with lower standard lifting height, requir-
ing new plates for truck identification and capacity.
Note: If changing the mast to one with higher lifting height: Get
in touch with our technical support for approval.
• Wheels with brakes for powered pallet trucks.
• Assembly of load carrier and drive unit supplied by TMHE.
• Fitting of modification package for standard trucks purchased from
TMHE Parts.
B Safety-related modifica- • Fitting of non-standard equipment, e.g. clamping unit.
tions • Changes to load capacity or speed that are within the tested limits for
Changes the performance the truck.
(speed, capacity). • Installing load carriers other than those stated as type A.
Related to safety • Changes to equipment, or installing new equipment that are regu-
(sensors, electronic func- lated by norms and standards, e.g. radio equipment.
tions).
• New wheel types for wheels with brakes.
Only the manufacturer
is permitted to perform • Sensors connected to the truck’s control system.
these changes. • All electric equipment that is connected in any other way than what is
described as standard.
• New seat.
• Fitting of non-standard contactors, brushes.
• Limitation of personal protection, e.g. changing the protective scan-
ner area.
• Software changes, e.g. load types, loading operations and other ad-
aptations.
C The modification aims to • Increasing the maximum load or speed.
change the product into • Replacement of major electrical components, such as replacing a
something other than the motor or a steering unit with a non-standard unit.
basic specification states.
• The truck performs radically different tasks than stacking or trans-
Only the manufacturer porting loads.
is permitted to perform
these changes.

Electrical system
2.4 Electrical system

2.4
Electrical system
WARNING Short-circuiting/Burn injuries

Loose items and jewellery can get caught in moving parts. So never wear loose articles or jewellery
when performing maintenance or repairs.
► Remove any jewellery and loose items before starting work.
When working on the electrical system:
▷ Always disconnect the battery before starting work on the drive units and electrical systems.
▷ Use insulated tools.
▷ Always disconnect the battery prior to welding when using an electric welding unit. The welding cur-
rent may damage the battery.
▷ Never break the warranty seal on the electronic cards.
2.4.1 Electrostatic risks

2.4.1
Electrostatic risks
Purpose
These work instructions describe how to work in a safe manner with components that are sensitive to elec-
trostatic chocks.
Scope
These work instructions apply to all that work with component or units that are sensitive to electrostatic
chocks.
Procedure
Electrostatic discharges from people may destroy sensitive equipment. For this reason, one must follow the
instructions for packaging and earthing. Always pay attention to these precautionary instructions.
Electronic card are supplied in electrostatically protected packages or envelopes.
These packages carry the following symbol:
▷ Leave electrostatically sensitive equipment in their respective packaging until you can place them on
an electrostatically protected work area.
▷ Electrostatically sensitive equipment should only be handled when they are properly earthed.
▷ Use electrostatically protected footwear!
▷ Store electrostatically sensitive equipment in their protective packaging or on electrostatically protec-

ted surfaces.
▷ Use an antistatic surface: Anti-static carpet 148115, page 21 - 7.
2.4.2 Battery handling

2.4.2
Battery handling
When working on the battery, keep the following in mind:

Safe lifting
▷ Working with and charging batteries should always be performed in accordance with the safety in-
structions provided by the battery manufacturer.
▷ Do not place any electrically conductive items on the battery terminals or their connections. 2
▷ Ensure there is a shower and an eye bath nearby in case an accident happens.
▷ Do not place tools or other metal objects on the battery. This can cause a short-circuit and even an
explosion.
▷ The battery must be used according to the battery manufacturer's instructions regarding ambient and
working temperatures. Otherwise there is a large risk that the battery is damaged and that it will soon
have to be replaced.
2.5 Safe lifting

2.5
Safe lifting
When lifting the product, remember that:
▷ All lifting must be carried out on a level, non-slip and stable surface. Asphalt surfaces should be
avoided if possible.
▷ To prevent the truck moving while it is being lifted, it must not be lifted with anyone on the platform or
with the tiller arm in the lowered position.
▷ If the drive wheel which is braked, is being lifted, the other wheels must be blocked to stop the
product from moving.
▷ Select the lifting point so that the lift is as light as possible, for example one corner at a time. If there
are lifting points indicated on the lower part of the chassis, these must be used to ensure balanced
lifting.
▷ Make sure the surface where the jack is placed is clean and free of oil and grease.
▷ Make sure your hands and the jack lever are free of grease and oil.
▷ Only use the lever supplied with the jack. If the lever is too short, more exertion than is necessary will
be required. If the lever is too long, there is a risk that the jack will be overloaded.
▷ Never work under a truck that is not supported by trestles and secured by a lifting device.
▷ Never work under a raised truck without it being properly supported on trestles.
▷ Never add blocks under the jack in order to achieve a higher lifting height.
Put trestles:
▷ as close to the lifted part of the chassis as possible in order to reduce the falling height if the product
should collapse.
▷ so that no wheels may turn causing the product to move.
2.6 Software
2.6
Software
Erroneous handling of the product systems and/or the external systems of the product may affect the safety
of the product and the environment.
1. Always make sure that the correct software is downloaded to the product.
2. In case of parameter adjustments, the recommended values must be respected.
3. Only adjust one parameter at a time when making changes to the product. Check the function after
each adjustment.

Hydraulic system
4. Change the parameters in small increments.
2.7 Hydraulic system

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

Operating principle 3
3.1 Symbols on keypad and display ...................................................................................................... 3 - 1
3.2 Introductory description ................................................................................................................... 3 - 1
3.2.1 Start the battery .................................................................................................................. 3 - 1
3.2.2 Login via keypad ................................................................................................................. 3 - 2
3.2.3 Tiller arm lowered for driving............................................................................................... 3 - 2
3.2.4 Driving in fork direction ....................................................................................................... 3 - 2
3.2.5 Driving in the drive wheel direction ..................................................................................... 3 - 2
3.2.6 Braking in neutral ................................................................................................................ 3 - 3
3.2.7 Reverse braking.................................................................................................................. 3 - 3
3.2.8 Mechanical braking ............................................................................................................. 3 - 4
3.2.9 Emergency reversal ............................................................................................................ 3 - 4
3.2.10 Fork lifting ........................................................................................................................... 3 - 4
3.2.11 Turtle function (option) ........................................................................................................ 3 - 4
3.2.12 Click-2-Creep ...................................................................................................................... 3 - 5
3.2.13 Lowering limitation .............................................................................................................. 3 - 5

3 Operating principle

Symbols on keypad and display
Software: 7662518
3
Operating principle
3.1 Symbols on keypad and display 3

3.1
Symbols on keypad and display
Symbol Description
ON button
This switch is used to start the truck and confirm
entered settings during PIN code management
OFF button
Error code
Battery charge as a percentage
Parameter
Hour counter
3.2 Introductory description

3.2
Introductory description
This section provides a basic description of the main functions of the truck.
The terms below are used in the description of the truck’s main functions.
• Event – Use of one of the truck's main functions is referred to as an event.

• Prior event – Indicates an event which must have taken place immediately before the current event in
order for the latter to be performed correctly.
• Action(s) – An action that the driver must perform in order for an event to happen.
• Influencing elements – Conditions that must be fulfilled in order for an event to happen. Certain para-
meter settings may also affect the outcome of the event.
• Resulting conditions – Describe the key events that can be checked in order to confirm a function.
Note that resulting conditions indicate what is assumed to occur when there is no error state.
Text within square brackets [ ] refer to the electrical component names in the truck's electrical diagram.
{High} means ˜ 24 V and {low} means ˜ 0 V unless otherwise specified.
3.2.1 Start the battery

3.2.1
Start the battery
Event: 1 Start the battery

Previous event -
Action(s) Start the truck battery, C-Brix [G10] E-Brix [G1], with switch [S1].
Influencing elements Main contactor, C-Brix [Q10] E-Brix [Q50], from.
C-BRIX VBAT is activated.
E-BRIX VBAT_AUX2 is activated.
Main fuse OK [F1].
Operating circuit fuses OK [F50] [F51].
Resulting conditions For C-BRIX, LED [T12] will be lit continuously.
For E-BRIX, LED [T12] will be lit continuously after a number of flashing
sequences.

3.2.2 Login via keypad

3.2.2
Login via keypad
Event: 2 Login via keypad

Previous event Start the battery, page 3 - 1.
Action(s) Log in with a PIN code and press the ON button.
Influencing elements The emergency switch [S24] is not activated.
[T12:INP. SUPPLY +24V DC] {high}.
Drive mode switch set to operation.
Resulting conditions Battery indicator lamp is lit. The display shows the hour counter for 4
seconds, followed by battery status (% of full charge).
The mechanical brake must remain actuated.
[T12:OUT.BRAKE RELEASE] {high}.
3.2.3 Tiller arm lowered for driving

3.2.3
Tiller arm lowered for driving
Event: 3 Tiller arm lowered for driving

Previous event Login via keypad, page 3 - 2
Action(s) Lower the tiller arm.
Influencing elements Sensor [B60], page 19 - 2 for tiller arm in drive position.
Resulting conditions Sensor [B60], page 19 - 2 for tiller arm in drive position is activated.
[T12:INP.TILLER ARM IN DRIVE POS] {low}.
3.2.4 Driving in fork direction

3.2.4
Driving in fork direction
Event: 4 Driving in fork direction

Previous event Tiller arm lowered for driving, page 3 - 2.
Action(s) Turn the speed control in the fork direction.
Influencing elements Speed control with Hall sensor [A5:S310-318]
Settings of operator parameters 4, 5 and 6 determine truck travel perform-
ance.
Main fuse OK [F1].
Resulting conditions Main contactor output voltage [T12:OUT. MAIN CONTACTOR] becomes
{low}.
Main contactor [Q10] [Q50] closes.
[T12:OUT.BRAKE RELEASE] becomes {low}.
Brake coil [Q1] is activated, and the mechanical brake is released.
Pulsed current feed to drive motor rotor is proportional to speed control ac-
tuation.
3.2.5 Driving in the drive wheel direction

3.2.5
Driving in the drive wheel direction
Event: 5 Driving in the drive wheel direction

Action(s) Turn the speed control in the drive wheel direction.

Event: 5 Driving in the drive wheel direction

Influencing elements Speed control with Hall sensor [A5:S310-318]
Settings of operator parameters 4, 5 and 6 determine truck travel perform-
ance. 3
Main fuse OK [F1].
Resulting conditions Main contactor output voltage [T12:OUT. MAIN CONTACTOR] becomes
{low}.
Main contactor [Q10] [Q50] closes. [T12:OUT.BRAKE RELEASE] be-
comes {low}.
tuation.
3.2.6 Braking in neutral

3.2.6
Braking in neutral
Event: 6 Braking in neutral

Previous event Driving in the drive wheel direction, page 3 - 2.
Driving in fork direction, page 3 - 2.
Action(s) Allow the speed control to return to the neutral position.
Influencing elements Setting of operator parameter 5.
Resulting conditions The drive motor [M1] works as a generator and via the transistor regulator
[T12] it converts the truck's kinetic energy into electricity, thus reducing the
truck’s speed. The excess energy, in the form of electricity, is fed back to
the battery [G10] helping to recharge it. The mechanical brake [Q1] is ap-
plied when the truck stops.
[T12:OUT.BRAKE RELEASE] goes {high}.
3.2.7 Reverse braking

3.2.7
Reverse braking
Event: 7 Reverse braking

Driving in fork direction, page 3 - 2.
Action(s) Speed control turned to opposite travel direction.
Influencing elements Parameter 201.
Resulting conditions The drive motor [M1] works as a generator and via the transistor regulator
[T12] it converts the truck's kinetic energy into electricity, thus reducing the
truck’s speed. The excess energy, in the form of electricity, is fed back to
the battery [G10] helping to recharge it. The braking effect increases the
more the speed control is turned.
The mechanical brake [Q1] [T12:OUT. BRAKE RELEASE] is applied when
the truck stops.

3.2.8 Mechanical braking

3.2.8
Mechanical braking
Event: 8 Mechanical braking

Previous event Driving in fork direction, page 3 - 2.
Driving in the drive wheel direction, page 3 - 2.
Action(s) The tiller arm is folded completely up or down.
Influencing elements Tiller arm sensor in drive position [B60].
Resulting conditions Sensor for tiller arm in drive position [B60] is deactivated [T12: INP.
TILLER ARM IN DRIVE POS] {low}. When the tiller arm is completely
raised or lowered, maximum permitted brake reduction is applied for 200
ms or until the travel speed is lower than 0.8 m/s. After this, the mechan-
ical brake [Q1] is applied.
[T12:OUT.BRAKE RELEASE] {high}.
3.2.9 Emergency reversal

3.2.9
Emergency reversal
Event: 9 Emergency reversal

Action(s) When driving in the drive wheel direction, the emergency reversal button is
pressed.
Influencing elements Emergency reversal.
Resulting conditions The Hall sensor [A5:S317] is immediately activated. The card [A5] inter-
prets this signal as a command to the transistor regulator [T12] to run the
drive motor at a reduced speed in the fork direction as long as the button is
depressed. The normal drive command signal received from [L1] is
blocked until [L1] is released and returns to neutral position.
3.2.10 Fork lifting

3.2.10
Fork lifting
Event: 10 Fork lifting

Previous event Start the truck.
Action(s) Press the fork lift button [A5:S320].
Influencing elements Main contactor [Q10] [Q50].
Fuse [F1].
Lift forks button [A5:S320]
Battery status OK (battery discharge indicator > 0 or battery charge > 20
%).
Resulting conditions Pump motor [M3] starts.
3.2.11 Turtle function (option)

3.2.11
Turtle function (option)
Event: 11 Turtle function (option)

Action(s) Press [S206] to activate this function.
Turn the speed control in either direction.

Event: 11 Turtle function (option)

Option button 1 [S206].
Setting of operator parameter 7 and service parameter 202.
3
Main fuse OK [F1].
Resulting conditions [T12: OUT. BRAKE RELEASE] becomes {low}.
tuation.
The maximum travel speed is determined by operator parameter 7.
“SLO” is displayed (lit continuously).
3.2.12 Click-2-Creep
3.2.12
Click-2-Creep
Event: 12 Click-2-Creep
Previous event Start the truck.
Action(s) Quick double-actuation of the speed control to activate the function.
Put the tiller arm in the upright position and drive the truck at creep speed
(1.7 km/h).
Setting of factory parameter 1002.
Main fuse OK [F1].
Resulting conditions [T12:OUT.BRAKE RELEASE] becomes {low}.
tuation.
“SLO” is displayed (flashes).
3.2.13 Lowering limitation

3.2.13
Lowering limitation
Event: 13 Lowering limitation

Previous event Login via keypad
Fork lifting, page 3 - 4
Action(s) Turn tiller arm to the far right or left.
Press the fork lowering button [A5].
Influencing elements Fork lowering button [A5].
Main fuse OK [F1].
Resulting conditions [T12:OUT. LOWER VALVE] goes {high}.
*Turn* is shown on the display.
No fork lowering will take place.
This acts as foot protection when the operator gets very close to the truck.


Parameters 4
4.1 Software........................................................................................................................................... 4 - 1
4.2 Parameters in general ..................................................................................................................... 4 - 1
4.3 Parameter list................................................................................................................................... 4 - 1

4 Parameters

4 Parameters
Software
Software: 7662518
4 Parameters
4
Parameters
4.1 Software
4.1
Software
Erroneous handling of the product systems and/or the external systems of the product may affect the safety
4
of the product and the environment.
1. Always make sure that the correct software is downloaded to the product.
2. In case of parameter adjustments, the recommended values must be respected.
3. Only adjust one parameter at a time when making changes to the product. Check the function after
each adjustment.
4. Change the parameters in small increments.
4.2 Parameters in general

4.2
Parameters in general
The control system can store a number of different parameters. These are used to configure the product ac-
cording to the task to be performed. The parameters are divided into groups:
• Operator parameters (1-100)

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

4.3
Parameter list
Software: 7662518
4.3.1 Operator parameters
The operator parameters can be adjusted individually to the available log-in profiles. The parameter’s con-
nection to the operator is done by a combination of operator and parameter numbers where the single digit
always corresponds to the parameter.
For more information: PIN code defaults, page 5 - 4.
Operator profile Parameter range

4 Parameters
Parameter list
1 1-7
2 11-17
3 21-27
4 31-37
5 41-47
6 51-57
7 61-67
8 71-77
9 81-87
10 91-97
Tab. 1: Connection to logged-in operator
The maximum travel speed can also be limited by factory parameter 1044 and it is always the lowest speed
for a parameter that is the limiting one.
No. Designation See section Valid for

3 Acceleration, page 4 - 2 4.3.1.1 General,
page 4 - 2
6 Max. speed, walk-along mode, page 4 - 2 4.3.1.1 General,
page 4 - 2
7 Maximum speed, forks above 1.8 m, page 4 - 2 4.3.1.1 General,
page 4 - 2
4.3.1.1 General
No. Designation Min Std. Max Step Unit

3 Acceleration 10 80 100 5 %

6 Max. speed, walk-along mode 30 100 100 5 %
Adjusts the truck’s maximum speed when the operator is not on the platform, platform is up and the gates
down, i.e. when the operator walks alongside the truck.

7 Maximum speed, forks above 1.8 m 30 100 100 5 %
Adjusts the maximum speed of the truck when the forks are above 1.8 m
4.3.2 Service parameters

4.3.2.1 General

101 Service intervals 0 1000 2000 50 h
This parameter determines the time value (in hours) to the next service from 0 to 2000 hours in increments of
50 hours. Whenever this value is changed, the timer is reset and will start to count the truck activity time. On
reaching the set value, code “S - 0h” is shown on the display and the red LED flashes.
If the value is set as '0', no service interval is given.
The standard value 500 h applies to SWE120XR and SPE120XR/XRD.

4 Parameters
Parameter list

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

103 Start-up display 1 2 5 1
Sets which value is shown on the display when the truck is started.
When the truck is started, one of the truck's 5 values is shown on the hour meter display "H" (hour meter dis-
play) for 5 seconds. After the menu has disappeared, the battery capacity is continuously shown in the nu-
meric field at the same time as the battery indicator is lit.
The truck control system stores five different time values. "Value 2 - Operating time" is the default value on
the start-up display.
Hour meter values Display
Value 1 = (A) Key time
The total time the truck has been in use.
Value 2 = (B) Operating time
Combined time during which the pump or drive
motor has been in operation. Default display.
Value 3 = (C) Drive motor time
The total time the drive motor has been in opera-
tion.
Value 4 = (D) Pump motor time
Total time the pump motor has been in operation.
Value 5 = (S) Remaining time until next service.
Parameter 101 controls the initial value.

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

105 External shock sensor X-degree of sensitivity 0 0 100 1

4 Parameters
Parameter list
Indicates the degree of sensitivity for what should be interpreted as a frontal/rear-end impact. 0 = Shock
sensor not activated.
The external shock sensor can also be used in combination with DHU. In such cases, the parameters should
not be set in the truck. Collision monitoring is then administered via I_Site instead. This parameter must be
set during truck installation.

106 Impact sensor sensitivity for Y 0 0 100 1
Indicates the degree of sensitivity for what should be interpreted as a side impact. 0 = Shock sensor not ac-
tivated.
The shock sensor can also be used in combination with DHU. In such cases, the parameters should not be
set in the truck. Collision monitoring is instead administrated via I_Site.
This parameter must be set during truck installation.

109 Battery type, built-in charger 0 0 32766 1
Sets the type of battery in case of built-in charger. This parameter has no use unless there is a built-in char-
ger.
# 0 = No charging
# 1 = Lead/acid battery
# 2 = Hawker Evolution battery
# 3 = Exide gel battery
# 32766 = TMHMS Li-ion battery

110 Battery size, built-in charger (Option) 100 100 300 1 Ah
Not valid for LWI160.

Sets the battery size used with the built-in charger so the correct charging current is chosen. For Hawker
Evolution only the sizes 134 Ah, 174 Ah and 201 Ah are approved. This parameter has no use unless there
is a built-in charger.

111 Resetting procedure after collision (option) 0 0 3 1
Specifies the condition for how the truck is to be taken into operation again after the shock sensors have
been triggered.
Value Function
0 Not activated.
1 The operator can reset the truck.
2 Horn sounds once every 5 seconds.
3 Options 1 and 2 combined.
The PIN code to be activated for resetting can be found in operator profile 1 and special block 10.

112 Erase application data 0 0 2 1
Specifies whether information from the histogram/impact sensor is to be deleted at login.

4 Parameters
Parameter list
Value Function
0 Do not clear
1 Clear histogram at start-up
2 Clear collision log at start-up 4
The histogram data consists of the logged motor temperature, motor control and steering motor in the form
of a histogram. You clear this data by setting parameter 112 =1. This is useful when transferring the truck
from one client to another.
The collision log is a log with the 10 latest collisions are stored together with the operator PIN code. You
clear this data by setting parameter 112 =2.

201 Deceleration when reversing 70 100 100 5 %
Sets how hard the truck will brake when the speed control is turned in the opposite direction, and used to get
a smoother deceleration where the application requires this for all operator profiles.

202 Maximum speed Turtle mode activated 0.5 3.0 6.0 0.5 km/h
Sets the maximum speed when Turtle mode is activated.

203 Maximum speed, forks above 1.8 m 0.5 2.5 5.0 0.5 km/h
Sets the maximum speed when the forks are above 1.8 m.

204 Maximum acceleration, forks above 1.8 m 10 45 60 5 %
Sets the maximum acceleration when the forks are above 1.8 m. As a percentage of maximum acceleration
for this application.

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

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

209 Minimum fork/support arm lifting height to exit limited 10 10 50 1 ms
speed set with parameter 208
The required lifting time that the hydraulic pump must be active/lift the forks/support arms above the floor (in
increments of 20 ms) to exit limited speed set with parameter 208.

4 Parameters
Parameter list

220 Min. steering angle for initiation of speed limitation 0 0 100 5 %
Parameter 220 is used to adjust the maximum speed when cornering.

This parameter is used to set when speed reduction during cornering should begin. Set to between 0 and
100%, where 0% corresponds to 30° and 100% corresponds to 80°.
A lower angle produces a milder nature during cornering.

301 Lowering stop ramp 3 7 20 1 -

302 Fork lowering speed 70 190 255 5 -
Determines the maximum lowering speed of the forks. This parameter can be adjusted manually or can be
set by using the calibration function.

303 EVP startup mode 30 90 150 5 -
Determines the start position of the proportional valve. This parameter can be adjusted manually or can be
set by using the calibration function

304 EVP support arms, lowering speed 50 130 220 5 %
Specifies the lowering speed of the support arms. This parameter can be adjusted manually or can be set by
using the calibration function.

305 EVP slow lowering speed 40 150 220 5 -
Determines the slow lowering speed when using "Click-2-Creep”. This parameter can be adjusted manually
or can be set by using the calibration function.

306 Activate “Click-2-Creep” lifting/lowering 0 1 1 1 -
Value Function
0 Off
1 On

307 Automatic support arm lowering (On/Off) 0 1 1 1
Controls whether the support arms should be lowered automatically when the forks reach the 1.8 m sensor.
Value Function
0 Off
1 On

4 Parameters
Parameter list

310 Reduce speed 5 100 100 5 %
Valid for special trucks only.
No. Designation Min Std. Max Step Unit 4

311 Indication of load weight 0 0 1 1 -
Indication of load weight in kg, based on hydraulic pressure.

0 = The parameter is not active.
1 = The parameter is active and the weight of the load is shown in the display.

316 Silent pump motor 0 1 1 1 -
The parameter indicates whether or not the truck is equipped with a silent pump motor.
0 = The truck is not equipped with a silent pump motor.
1 = The truck is equipped with a silent pump motor.

334 Automatic shutdown for AUX 0 0 1 1 -
The parameter specifies how long the truck can be inactive for before automatic shutdown occurs for AUX.
0 = 30 seconds
1 = 20 minutes

342 Calibration of straight tiller arm 200 600 1000 1 mV
The parameter is set at the factory and does not need to be adjusted after delivery to the customer.

499 License key
Used only for field testing software.

4.3.2.1.1 Low speed with low forks

208 Limitation of max. speed with forks fully lowered 5 25 60 5 km/h ×
10
Limits the maximum speed when the forks are fully lowered. This option requires that a pressure sensor
Load detection is installed.
This function is helpful when you are operating on uneven floors and do not want excessive wear to the
forks.
4.3.2.1.2 Optimized corner control (OCC)

222 Maximum speed during cornering, walking trucks 35 35 45 5 km/h ×
10

4 Parameters
Parameter list
This parameter is used to determine the speed when full speed reduction is achieved during cornering.
A higher speed here produces gentler braking, but a higher curve speed.

315 Speed reduction during cornering 0 0 3 1 -
The truck's speed will be reduced when the steering angle is so great that the steering angle sensor is
passed.
0 = Steering angle sensor is not activated.
1 = Digital steering angle sensor is activated. (This value is not valid for LWI160.)
2 = Analogue steering angle sensor is activated.
3 = Analogue steering angle sensor with lowering restriction is activated.
4.3.2.1.3 Silent pump motor

316 Silent pump motor 0 1 1 1 -
The parameter indicates whether or not the truck is equipped with a silent pump motor.
0 = The truck is not equipped with a silent pump motor.
1 = The truck is equipped with a silent pump motor.
4.3.3 Factory parameters

4.3.3.1 Configurable optional functions
Parameters #1003 to #1042 are reserved in the truck’s control system for additional truck options and/or
special product modifications. The parameters configure and control the Spider expansion unit (SEU) that
must be fitted to the truck, in some cases it is enough to have an empty I/0 in the motor control. This method
of implementation enables use of the standard program. This eliminates the need for any special program.
Normally, these parameters are configured by the manufacturer when the truck is modified or customised. It
is advisable to upload the parameter settings from the truck when carrying out any modification. If the main
control unit [A2] has been replaced, the original parameter settings can be transferred to the new unit, thus
ensuring that special options function correctly. Factory parameter no. #1003, #1008, #1013, #1018, #1023,
#1028, #1033 and #1038 can be adjusted to allow up to a maximum of 8 pre-programmed "Basic options" to
be activated and configured to suit a specific special option or customisation.
Activation of optional functions
The system can use up to eight configurable optional functions simultaneously. Each configurable function is
controlled by five factory parameters. During activation, an index parameter (#1003, #1008, #1013, #1018,
#1023, #1028, #1033, #1038) must first be set to a value equivalent to an optional function. Four parameters
that can be modified to configure the optional function are linked to each index parameter. The index para-
meter is allocated one optional function (optional function is determined).
Each optional function can have up to 4 arguments associated with it. Each argument holds a value which
can be changed to configure the function (optional function is configured). If the value of an argument is out-
side of the highest or lowest permitted value, an error code is generated and the option cannot be used. The
error code cannot be eliminated until the argument is given a permissible value.
See the additional explanation of the optional functions after the table.

4 Parameters
Parameter list
No. Description Argument 1 Argument 2 Argument 3 Argument 4 Comments

1 The option but- 0=SEU 0 0-3 0-7 0=Activated A number of pos-
ton controls the 1=SEU 1 Digital outputs 0=Option but- 1=Deactivated sible options are per-
SEU output 1-4 ton 2 or 5 mitted for this altern-
ative. Each occur-
Option buttons rence must use a 4
1-6 unique digital output.
7=Option but-
ton 3 or 4
2 Reduced 0=SEU 0 0-7 0-125 [km/ 0=High speed If argument 3 is
speed con- 1=SEU 1 Digital inputs h/10] range zero, driving will not
trolled by di- 1-8 1=Low speed be possible and the
gital input 2=ACT/ACC brake will not re-
range
lease.
2 = Both
ranges
3 Activate the 0=SEU 0 0-3 1=Driving in Output mode: A number of pos-
SEU output in 1=SEU 1 Digital outputs fork direction 0=Activated sible options are per-
connection with 1-4 2=Driving in 1=flashing 1 Hz mitted for this altern-
certain ma- drive wheel dir- ative. Each occur-
chine move- ection 2=flashing 2 Hz rence must use a
ments unique digital output.
4=Fork lifting
‘Braking’ means:
8=Fork lower-
ing Tiller arm in its upper
and lower position
16=Braking respectively.
Rocker is moved in
the opposite direc-
tion
Rocker returns to its
neutral position.
4 Activate the 0=SEU 0 0-7 Main contactor,
main contactor, 1=SEU 1 Digital inputs activated in
controlled by 1-8 minutes (0-30)
SEU digital in- 2=ACT/ACC
put.
5 Lift/lower, con- 0=SEU 0 I/O...Lift, lower, Foot guard 0= lift/lower When the foot guard
trolled by SEU 1=SEU 1 foot guard 0= deactivate forks is deactivated, the
digital input. 0=Digital inputs 1= activate 1=lift/lower corresponding digital
1,2,3 support arm input is free to be
used by other op-
1=Digital inputs tional functions.
2,3,4
2=Digital inputs
3,4,5
3=Digital inputs
4,5,6
4=Digital inputs
5,6,7
5=Digital inputs
6,7,8

4 Parameters
Parameter list

6 Lift height re- 0=SEU 0 0-7 Override 0-7= 1-8 lifting If several lifting
striction 1=SEU 1 Digital inputs 0-8 heights heights are used, all
1-8 heights must be re-
2=ACT/ACC 0=option button If argument 1 = set by pressing the
2 or 5 2, argument 4
must be 0. override button.
Option buttons When you press the
1-6 button, the override
function will be activ-
7=option button
ated for 15 seconds
3 or 4
or for as long as lift-
8=no override ing remains active.
The reset will be
cancelled as soon as
the lifting height is
reached.
Repair manual 7660234 en 4 - 10

4 Parameters
Parameter list

7 Single-acting SEU 0 must al- 0-39 50-255 max. 50-255 max- If the value of argu-
hydraulic func- ways be used 0=option button speed of pump imum propor- ment 2 is greater
tion controlled for this altern- 2 or 5 tional lowering than 7, pressing only
by SEU. ative command. one option button
Option buttons
0=digital output 1-6 will result in hy- 4
1 draulic control.
7=option button A number of pos-
1=digital output 3 or 4
3 sible options are per-
8=N/A mitted for this altern-
ative. Each occur-
9=option but-
rence must use a
tons 1 & 2
unique digital output.
10=option but-
Values 14-39 are
tons 2 & 3
available for argu-
11=option but- ment 2 from default
tons 3 & 4 program
12=option but- 7528678-018 on-
tons 4 & 5 wards.
13=option but-
tons 5 & 6
14-16 = N/A
17=Spider in 1
(lift) & 2 (lower)
18=Spider in 2
(lift) & 3 (lower)
19=Spider in 3
(lift) & 4 (lower)
20=Spider in 4
(lift) & 5 (lower)
21=Spider in 5
(lift) & 6 (lower)
22=Spider in 6
(lift) & 7 (lower)
23=Spider in 7
(lift) & 8 (lower)
24-32= N/A
33=Spider in 1
(lift) & 2 (lower)
or option but-
ton 1 + actu-
ator
34=Spider in 2
(lift) & 3 (lower)
or option but-
ton 2 + actu-
ator
35=Spider in 3
(lift) & 4 (lower)
or option but-
ton 3 + actu-
ator
36=Spider in 4
(lift) & 5 (lower)
or option but-
ton 4 + actu- 4 - 11 Repair manual 7660234 en
ator
37=Spider in 5
4 Parameters
Parameter list

8 Double-acting SEU 0 must al- 0-39 50-255 max. 50-255 max. If the value of argu-
hydraulic func- ways be used 0=option button speed of pump speed of pump ment 2 is greater
tion controlled for this altern- 2 or 5 when lift com- when lower than 7, pressing only
by SEU. ative mand is given. command is one option button
Option buttons given. will result in hy-
0=digital out- 1-6
puts 1 & 2 draulic control.
7=option button Two possible options
1=digital out- 3 or 4
puts 3 & 4 are permitted for this
8=N/A alternative. Each oc-
2=digital out- currence must use a
puts 3 & 4 on 9=option but- unique digital output.
spider 0 and di- tons 1 & 2
gital output 1 10=option but- Values 14-39 are
on spider 1 available for argu-
tons 2 & 3
ment 2 from default
11=option but- program
tons 3 & 4 7528678-018 on-
12=option but- wards.
tons 4 & 5
13=option but-
tons 5 & 6
14-16 = N/A
17=Spider in 1
(lift) & 2 (lower)
18=Spider in 2
(lift) & 3 (lower)
19=Spider in 3
(lift) & 4 (lower)
20=Spider in 4
(lift) & 5 (lower)
21=Spider in 5
(lift) & 6 (lower)
22=Spider in 6
(lift) & 7 (lower)
23=Spider in 7
(lift) & 8 (lower)
24-32= N/A
33=Spider in 1
(lift) & 2 (lower)
or option but-
ton 1 + actu-
ator
34=Spider in 2
(lift) & 3 (lower)
or option but-
ton 2 + actu-
ator
35=Spider in 3
(lift) & 4 (lower)
or option but-
ton 3 + actu-
ator
36=Spider in 4
(lift) & 5 (lower)
or option but-
Repair manual 7660234 en ton 4 + actu- 4 - 12
ator
37=Spider in 5
4 Parameters
Parameter list

9 Single-acting TBD
hydraulic func-
tion controlled
by ACT/ACC.
10 Double-acting TBD 4
hydraulic func-
tion controlled
by ACT/ACC.
11 Automatic lift/ 0=SEU 0 0-7 Inputs....photo- External lift/ Valid for mast trucks
lower 1=SEU 1 Automatic lift/ cell, top/bottom lower button When external lift/
lower sensor, ex- 0= deactivate lower buttons are
ternal lift/lower deactivated, the cor-
0=No option button 1= activate
buttons responding digital in-
0=digital inputs puts can be freely
1=option but- 1,2,3 (4,5) used by other op-
tons 1 and 2 tional functions.
1=digital inputs
2=option but- 2,3,4 (5,6)
tons 2 and 3
2=digital inputs
3=option but- 3,4,5 (6,7)
tons 3 and 4
3=digital inputs
4=option but- 4,5,6 (7,8)
tons 4 and 5
Out-
5=option but- puts....Auto.
tons 5 and 6 light
6=option but- 0=digital output
tons 1.6 and 1
2.5
1=digital output
7=option but- 2
tons 2.5 and
3.4 2=digital output
3
3=digital output
4
12 Speed 0=SEU 0 0-7 0-125 [km/ 0=High speed If argument 3 is set
1=SEU 1 Digital inputs h/10] range to 0, driving will not
2=ACT/ACC 1-8 1=Low speed be possible and the

range brake will not re-
lease.
2 = Both
ranges
13 Activate SEU 0=SEU 0 0-3 Not used Output mode: A number of pos-
output when 1=SEU 1 Digital outputs 0=Activated sible options are per-
the truck is 1-4 mitted for this altern-
logged on 1=flashing 1 Hz ative. Each occur-
2=flashing 2 Hz rence must use a
unique digital output.
4 - 13 Repair manual 7660234 en

4 Parameters
Parameter list

14 Hydraulic re- Not used 1=profile 1 1 = Pump 1st Not used No SEU needed
striction con- 2=profile 1-2 hydr.
trolled by oper- 2 = Rel. 1st
ator profile 3=profile 1-3
hydr.
4=profile 1-4
4 = Pump 2nd
5=profile 1-5 hydr.
6=profile 1-6 8 = Rel. 2nd
7=profile 1-7 hydr.
8=profile 1-8 16 = Pump 3rd
hydr.
9=profile 1-9
32 = Rel. 3rd
10=profile 1-10
hydr.
64 = Pump 4th
hydr.
128 = Rel. 4th
hydr.
15 Hydraulic re- 0=SEU 0 0-7 1 = Pump 1st 0-8
striction con- 1=SEU 1 Digital inputs hydr. 0=option button
trolled by SEU 1-8 2 = Rel. 1st 2 or 5
digital input 2=ACT/ACC
hydr. Option buttons
4 = Pump 2nd 1-6
hydr. 7=option button
8 = Rel. 2nd 4-4
hydr. 8=no override
16 = Pump 3rd
hydr.
32 = Rel. 3rd
hydr.
64 = Pump 4th
hydr.
128 = Rel. 4th
hydr.
16 Switch for 0=SEU 0 0-7 Not used Not used
safety revers- 1=SEU 1 Digital inputs Default time 5
ing, emergency 1-8 seconds
reversal, con- 2=ACT/ACC
trolled by SEU
digital input
17 Not used Not used
18 Reach sensor 0=SEU 0 SEU 0-8 Not used Used for special
1=SEU 1 0-7 0=option button software only
2=ACT/ACC Digital inputs 2 or 5

1-8 Option buttons
ACT/ACC 1-6
0-11 7=option button

4-4
Digital inputs
1-12 8=no override

4 Parameters
Parameter list

19 Direction indic- 0=SEU 0 Output Option button 0 = Direction
ators 1=SEU 1 0 = digital out- 0 = option but- indicators auto-
put 1 (left) and ton 1 (left) and matically
2 (right) 6 (right) switched off
after turn 4
1 = digital out- 1 = option but-
put 2 (left) and ton 2 (left) and 1 = Direction
3 (right) 5 (right) indicators must
be switched off
2 = digital out- 2 = option but- manually
put 3 (left) and ton 3 (left) and
4 (right) 4 (right) 2 = Activate
direction indic-
ators for as
long as the op-
tion button is
pressed
20 Hydraulic func- 0=SEU 0 Option button Hydraulic func- Stop the hy- If argument 4 is
tion controlled 1=SEU 1 0-7 tion draulic function used, digital input
by SEU digital must be “high” in or-
input with op- 0=option button 1 = Pump 1st 0-8 der to activate the
2 or 5 hydr. 0 = No input hydraulic function.
tion button
Option buttons 2 = Rel. 1st limitation hy-
1-6 hydr. draulic function
7=option button 4 = Pump 2nd 1-8 = digital in-

3 or 4 hydr. puts 1 - 8
8 = Rel. 2nd
hydr.
21 Activate the 0=SEU 0 0-7 Activate the Max command
function con- 1=SEU 1 Digital inputs function 50-255
trolled by SEU 1-8 0 = Pump mo- Speed of the
digital input tor pump or open-
1 = Propor- ing of propor-
tional valve tional valve
22 Activate the 0=SEU 0 0-3 0-7 Output mode:
SEU output 1=SEU 1 Digital outputs Digital inputs 0=Activated
with a digital
signal 2 = ACT / ACC, 1-4 1-8 1=flashing 1 Hz
digital input 2=flashing 2 Hz
from ACT /
ACC, always
use SEU 0
23 Activate the Not used 1 = lift button 1 0-7 Not used
horn 2 = Lower but- 0=option button
ton 1 2 or 5
4 = Lift button 2 Option buttons
8 = Lower but- 1-6
ton 2 7=option button
3 or 4

4 Parameters
Parameter list

24 Fork spread Not used Option button 50-255 max. 50-255 max. If SEU 0 digital out-
and sideshift 0 = 1 and 2 speed of pump speed of pump puts 1, 2 and 3 are
upon lift com- upon lower used, it cannot be
1 = 2 and 3 mand command combined with op-
2 = 3 and 4 tional function 7 or 8.
3 = 4 and 5 For special trucks
only
4 = 5 and 6
25 Activate the 0=SEU 0 0-3 Weight limit 50 Not used
SEU output de- 1=SEU 1 Digital outputs kg
pending on the 1-4 0-255
weight of the
load on the 50 kg Weight
forks limit 50 kg
26 Activate the 0=SEU 0 0-3 Battery charge Output mode: For special trucks
SEU output de- 1=SEU 1 Digital outputs level 0=Activated only
pending on the 1-4 10-100%
battery status 1=flashing 1 Hz
2=flashing 2 Hz
Description of optional functions.
1) A digital output from the SEU can be activated from any option button on the tiller arm handle. When
the button is pressed, the output signal can be either activated temporarily or deactivated.
2) An unactivated (active low) digital input on SEU or ACT / ACC will reduce the maximum travel speed.
The programmable speed is reduced to 0 - 12.5 km/h. Platform trucks with two speed ranges, high
speed and low speed, can have the reduction programmed for a chosen range.
3) A digital SEU output is activated when a specific truck movement occurs.
The movements which can be selected are:
Driving in fork direction
Driving in drive wheel direction
Fork lifting
Fork lowering
One of the four digital outputs from SEU can be assigned this alternative and one of the following
activities can be selected:
Activated
Flashing, 1 Hz
Flashing, 2 Hz
4) An activated (active high) digital input on an SEU or ACT / ACC activates the main contactor with a
selected time in minutes.
5) Two external switches connected to a SEU digital input for monitoring fork and support arm lift/lower
function when the input is activated (active high). A foot guard function can be added with a third ex-
ternal switch. When this switch is deactivated (active low), the lowering function will be deactivated.
6) The lifting function is limited by default. When an external switch, connected to an SEU or ACT / ACC
digital input, is activated (active high), the limitation will be cancelled. If you press an option button on
the handle, you will override the limitation for 15 seconds.
7) The function is activated by pressing and holding down an option button while giving the command
(using the sensilift potentiometer or the digital rocker). SEU digital output 1-4 must be connected to the
3rd or 4th hydraulic function valves (Q33-Q36). The output combination can be selected with a para-
meter argument. On a standard truck with two hydraulic functions, where Q23 is used for the other hy-
draulic function, this valve is replaced with a cavity plug and Q23 is moved to the new hydraulic unit.

4 Parameters
Parameter list
This will not result in a software change for the other hydraulic function. The maximum speed of the
pump and the maximum command for the proportional lowering valve can be set using a parameter
argument.
Description of functions: Press and hold down the selected option button (and/or spindle inputs de-
pending on the parameter values). Give the command using the sensilift potentiometer or the digital
rocker. The pump command starts the pump and activates ACT digital output 3 and the selected SEU 4
output. If the lower command is given, the proportional lowering valve and the ACT digital output 3 and
selected SEU output will open.
8) The function is activated by pressing and holding down an option button (selectable via a parameter
argument) while giving the command (using the sensilift potentiometer or the digital rocker). SEU di-
gital output 1-4 must be connected to the 3rd or 4th hydraulic function valves (Q33-Q36). The output
combination can be selected with a parameter argument. On a standard truck with two hydraulic func-
tions, where Q23 is used for the other hydraulic function, this valve is replaced with a cavity plug and
Q23 is moved to the new hydraulic unit. This will not result in a software change for the other hydraulic
function. The maximum speed of the pump can be set using a parameter argument.
Description of functions: Press and hold down the selected option button (and/or spindle inputs de-
pending on the parameter values). Give the command using the sensilift potentiometer or the digital
rocker. The pump command starts the pump and activates ACT digital output 3 and the selected SEU
output. If the lower command is given, the pump will start and ACT digital output 3 and the other selec-
ted SEU output will be activated.
9) TBD
10) TBD
11) TBD
12) This alternative is similar to “Reduced speed controlled by digital input”. The digital input is intended to
be connected to a “Rabbit” button, which is used to switch between normal speed and reduced speed.
The alternative works in the same way in both fork and drive wheel directions. Reduced speed will be
selected upon start-up. The rocker must first be applied in order to permit switching. When the “Rabbit”
button is pressed and released (digital input must go high and low again), the speed will change to
normal. Pressing and releasing again will switch to reduced speed and so on. Reduced speed will be
selected automatically if the rocker is released or turned (reversal) if the switch for safety reversing is
pressed or the brake is activated. The programmable speed is reduced to 0 - 12.5 km/h. Platform
trucks with two speed ranges, high speed (>6km/h) and low speed (6km/h), can reduce the program-
ming for a selected range. If the speed reduction is set to 0 km/h, driving will not be possible. In this
case, the parking brake will never release.
13) A digital SEU output will be activated when the machine is logged in. One of the four digital outputs
from SEU can be assigned this alternative and one of the following activities can be selected:
Activated
Flashing, 1 Hz
Flashing, 2 Hz
14) Hydraulic function selected by argument 3 is limited if the operator profile that is selected by argument
2 is logged in.
15) Hydraulic function selected by argument 3 is limited by default. When an external switch, connected to
an SEU or ACT / ACC digital input, is activated (active high), the limitation will be cancelled. If you
press an alternative button on the handle, you will override the limitation for 15 seconds. It is possible
to use a combination of argument 3 by adding the values
16) An activated digital input on an SEU or ACT / ACC will activate the function for safety reversing, emer-
gency reversal.
17) Reserved for future use
18) An external switch, connected to SEU or ACT/ACC.
19) The output signal will flash on the selected SEU when the selected option button has been pressed. It
is possible to choose whether the direction indicators will be automatically switched off when the truck
has turned.

4 Parameters
Parameter list
20) The selected hydraulic function will start if the selected option button is pressed. The hydraulic func-
tion will operate until the option button is released or the selected SEU digital input becomes low.
21) An activated (active high) digital input on an SEU will activate the pump motor or the proportional
valve.
22) An activated (active high) digital input on an SEU or ACT / ACC will activate a digital output on SEU.
One of the four digital outputs from SEU can be assigned this alternative and one of the following
activities can be selected:
Activated
Flashing, 1 Hz
Flashing, 2 Hz
23) The horn can be activated using the lift/lower buttons and/or option buttons on the operating panel.
24) Two option buttons located next to each are used to select sideshift or fork spreading. The lower
numbered option button (the left-hand button from the operator's perspective) is used for fork spread-
ing and the higher numbered option button (the right-hand button from the operator’s perspective) is
used for sideshift. When one of the option buttons is pressed and the lift or lower command is given,
the selected movement will be executed. Can only be used on SEU 0. Use digital outputs 1, 2 and 3
as described in the table below.
Hydraulic
Option button command SEU 0 output 1 SEU 0 output 2 SEU 0 output 3
Spread Lift 1 0 1
Spread Lower 0 1 1
Sideshift Lift 1 0 0
Sideshift Lower 0 1 0
25) A digital output on SEU will be activated depending on the weight of the load on the forks.
26) A digital output on SEU will be activated depending on the battery status. If the battery level is below
the chosen level, the output will be activated.
4.3.3.2 General

1001 Truck type 0 0 108 1
This parameter is used to set which truck type the program is to adapt operational data for.
Value Function
0 Unknown truck type
1 LWE140
2 LWE160
3 LWE180
4 LWE200
5 LWE250
101 SWE100
102 SWE120
103 SWE140
104 SWE120L
105 SWE140L
106 SWE200D
107 SWE080L
108 SWE120S

4 Parameters
Parameter list

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

1003 Optional function 1 0 0 23 1
For further information, see the text for factory-standard

1004 Optional function 1 Arg1 0 0 255 1








4 Parameters
Parameter list
















4 Parameters
Parameter list


4














4 Parameters
Parameter list



1044 Master maximum speed 0.5 6.0 6.0 0.5 km/h
Sets the maximum speed for the application. The speed can never exceed the value of this parameter, re-
gardless of the settings of the other parameters.

1045 Type of battery in the truck 0 0 1 1
Specifies the type of battery that is fitted to the truck

Value Function
0 Lead/acid or gel battery
1 Li-ion battery

1046 Adaptation to special trucks 0 0 4 1

1080 Battery system 0 0 1 1
0 = Battery system 50Ah

1 = Battery systems 105Ah and 150Ah

1101 Built-in battery charger 0 1 2 1
Indicates if there is a battery charger on the application. If there is a battery charger, parameters 109 and
110 must also be set. (Parameter 110 is not valid for LWI160.)
Battery charger, special version with extra sensor:
Some countries have a switch for each socket. If it is not switched on, the BCU will not detect whether it is
connected or not. To prevent the risk of the truck being started and driven off with the mains cable connected
to the wall, the "UK" version has an extra sensor that measures whether the mains cable is in its parked pos-
ition in the battery compartment.
Value Function
0 No battery charger
1 Battery charger present
2 Battery charger, special version with extra sensor.

1101 Built-in battery charger 0 1 2 1

4 Parameters
Parameter list
Indicates if there is a battery charger on the application. If there is a battery charger, parameters 109 and
110 must also be set.
Battery charger, special version with extra sensor:
Some countries have a breaker for each socket. If it is not switched on, the BCU will not detect whether it is
connected or not. To prevent the risk of the truck being started and driven off with the mains cable connected 4
to the wall, the "UK" version has an extra sensor that measures whether the mains cable is in its parked pos-
ition in the battery compartment.
Value Function
0 No battery charger
1 Battery charger present
2 Battery charger, special version with extra sensor in
truck:

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

1110 Reset voltage for BDI 24.8 25.2 27.0 0.1 V
After the battery is charged to full capacity, BDI is reset to 100% provided that battery voltage comes up to
the pre-programmed reset value. If the reset voltage value is not reached, it could be due to a voltage drop
between the battery and the logic card.
In case of reset problems:
• Charge the battery to full capacity following the instructions in the operator's manual.
• Then drive the truck for at least 25 seconds before logging out.
• BDI will only set to 100% if the battery has been disconnected/reconnected.
• Check the battery voltage and compare with the voltage between wires 20 and 40 on the tiller arm logic
card (A5)
• A voltage drop between the battery and the logic card (A5) could be caused by poor contacts/connections
or a loose connection in the battery connector.

1118 Hardware version 0 1 1 1
Determines the [T1] ACT version on the truck.

Value Function
0 Before 2010-03-22

4 Parameters
Parameter list
Value Function
1 After 2010-03-22
* Matrix for compatibility of hardware and software. See the matrix below for the correct setting of factory
parameter 1118. The setting depends on which version of motor control is installed on the truck. • Value 0 =
1.5 kHz (default value) • Value 1=8kHz
Factory parameter 1118
Motor controller Value = 0 Value = 1
243428/-001/-002 OK Not permitted
246889/-001/-002
246890/-001/-002
7513528-001/ or later Not recommended OK
7513526-001/ or later
7513527-001/ or later

1140 Motor controller: 0 0 1 1
The parameter indicates what type of motor control unit the truck is fitted with.
The parameter is only used for trucks which are normally equipped with ACT, but which have been ticked
with an option which requires ACC. On these trucks, the parameter is set to 1.
0 ACT
1 ACC
4.3.4 Calibration parameters

These parameters manage calibration for the various truck functions. Based on the truck configuration, only
those parameters that are valid for the truck model will be visible in the calibration menu..
No. Designation See section Valid for

340 Initial lift starting value, page 4 - 24 4.3.4.1 Auto, page
4 - 24
341 Initial lift final value, page 4 - 24 4.3.4.1 Auto, page
4 - 24
4.3.4.1 Auto

340 Initial lift starting value 500 500 1499 1 mV
Pressure sensor voltage, zeroed for free lift. For weight indication

341 Initial lift final value 1500 1500 4200 1 mV
Pressure sensor voltage, zeroed at maximum load on initial lift. For weight indication

Installation 5
5.1 Transport ......................................................................................................................................... 5 - 1
5.1.1 Transporting the Truck........................................................................................................ 5 - 1
5.1.2 Transporting the fork carriage............................................................................................. 5 - 1
5.2 Lifting the truck ................................................................................................................................ 5 - 2
5.2.1 Lifting the truck.................................................................................................................... 5 - 2
5.3 Commissioning ................................................................................................................................ 5 - 3
5.3.1 General information regarding PIN codes........................................................................... 5 - 3
5.3.1.1 PIN code at delivery .............................................................................................. 5 - 3
5.3.1.2 Programming PIN codes ....................................................................................... 5 - 3
5.3.1.3 PIN code defaults.................................................................................................. 5 - 4
5.3.1.4 PIN code for resetting after a collision .................................................................. 5 - 5
5.3.2 Setting parameters.............................................................................................................. 5 - 5
5.3.3 Function and safety checks ................................................................................................ 5 - 6

5 Installation

5 Installation
Transport
Software: 7662518
5 Installation
5
Installation
5.1 Transport
5.1
Transport
5.1.1 Transporting the Truck

5.1.1
Transporting the Truck
1. When transporting the truck on a lorry or similar, the

truck must be properly anchored with suitable straps (A).
Use inserts and sheets of shock-absorbing material to
prevent damage to the truck during lashing and trans-
port.
5.1.2 Transporting the fork carriage

5.1.2
Transporting the fork carriage
Preparations
1. Cables and hoses must be secured so they cannot come loose or be damaged.
2. The entire fork carriage must then be anchored on a pallet or some other suitable support for trans-
port.

5 Installation
Lifting the truck
5.2 Lifting the truck

5.2
Lifting the truck
5.2.1 Lifting the truck

5.2.1
Lifting the truck
WARNING Risk of tipping

The truck may tip over if it is lifted incorrectly.
► Always lift the truck secured on, and with the centre of gravity between, the lifting
truck's forks.
WARNING Risk of tipping

The truck may tip over if it is lifted in the wrong places.
► Always lift the truck from the marked lifting points.
1. Lift the truck at its centre of gravity using another fork lift truck.
2. Secure the truck to the forks of the lifting truck.
3. Lift it very carefully.

5 Installation
Commissioning
5.3 Commissioning
5.3
Commissioning
5.3.1 General information regarding PIN codes

5.3.1
General information regarding PIN codes
5.3.1.1 PIN code at delivery

5.3.1.1
PIN code at delivery
Trucks that normally require a PIN code to start are delivered with a four-number delivery code, which is in-
dicated by a protective film covering the keypad.
Remove the protective film when supplying the truck to the customer, and change the PIN codes for the
5
truck.
Trucks with Smart Access are instead delivered with a transport key card.
All trucks are delivered with the same set of PIN codes: Three (3) codes for manual trucks and four (4) codes
for auto trucks.
5.3.1.2 Programming PIN codes

5.3.1.2
Programming PIN codes
Note: There are two possible methods for programming PIN codes. The first and the simplest is to
use TruckCom, which provides clear instructions. The other alternative is to use the truck keypad.
If the truck is configured to handle PIN codes, 100 different PIN codes can be programmed.
The first time a block is activated, all PIN codes in the block are set to “0000”. If a block with PIN codes not
set to “0000”, is deactivated and later reactivated, the PIN codes with other values than “0000” will again be
valid.
Use of PIN code “0000” is permitted, but it means that the position is deactivated. It is never possible to log
in with PIN code “0”.
The truck program stores a standard set of PIN codes as indicated in the table in the section PIN code de-
faults, page 5 - 4.
Note: The truck program will not accept attempts to program PIN codes that have already been set.
The previous code will be restored.
When a PIN code is programmed, there is a check to ensure that it is not used elsewhere in the table, re-
gardless of whether the block is active or inactive.
The PIN code setting menu is used to manage PIN codes. The menu can only be accessed when a service
key is connected.
Change the PIN code with the truck keypad
1. Make sure that the truck is switched off. Connect the CAN service key to connector [X41]. Enter the
PIN code.
2. Press and then release the horn button. “Info“ is shown on the display.
3. Turn the speed control several times until “Pin” is shown on the display.
4. Press and then release the horn button to select.
5. Select programming commands from the table below.
6. Switch off the truck by pressing the OFF button. PIN code programming is now complete. Verify that
programming has been done correctly by logging in using one of the new PIN codes.
Function Programming Comments

Reset the settings for PIN codes. Press 1 + ON button. Blocks 0-9 are deactivated, and all
PIN codes are reset to 0000.
Activate a new PIN code block. Press 2 + b + ON button. b = Block 0-9. When activating a
PIN code block, the codes already
saved become available again.

5 Installation
Commissioning

Deactivate a PIN code block. Press 3 + b + ON button. b = Block 0-9. No codes will be de-
leted. They will be available again
when the PIN code block is reactiv-
ated.
Programming a new PIN code Press 4 + b + P + NNNN + ON but- b = Block 0-9. P = Driver profile
ton. 1-10. NNNN = PIN code.
Note: The block that should apply Note: It is only possible to assign
must first be activated (see function one digit to an operator profile. As
2 in the table above). a result, operator profile 10 should
If the PIN code is correct, the code be assigned as 0 (zero).
is shown for 3 seconds, followed by
the text “donE” for 2 seconds. It is
possible to enter a new PIN code
within these 5 seconds by pressing
a key on the keyboard.
If the PIN code is wrong, the dis-
play shows “Err”. If the red button
is pressed, the new PIN code is not
saved.
PIN code programming for truck re- Press 6 + NNNN + ON button. The NNNN = PIN code.
set after collision. PIN code that is activated can be
found in Operator profile 1 and
special block 10. The default value
of the PIN code is 0000. This must
be changed to the PIN code selec-
ted by the service technician.
Change the PIN code with the TruckCom
For PIN code management via TruckCom, see the TruckCom Manual.
Note: It is important to ensure the correct operator profile is activated when a specific PIN code is
entered. This is especially important when an operator profile has been set to apply for a specific
truck application.
5.3.1.3 PIN code defaults

5.3.1.3
PIN code defaults
The PIN codes are factory set so that only block 1/operator profiles 1-10 are activated.
It is only possible to assign one digit to an operator profile. The operator profile 10 should be set to 0 (zero).
Block 10 and operator profile 1 are only used for PIN code programming for truck reset after collision, the re-
maining operator profiles in block 10 are not used.
Service personnel are urged to keep notes on activated blocks, changed PIN codes and special operator
profile settings.
Oper- 1 2 3 4 5 6 7 8 9 0
ator
profile
number
Block 0 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 1 1258 2258 3258 0000 0000 0000 0000 0000 9258 0000
Block 2 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 3 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 4 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 5 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 6 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000

5 Installation
Commissioning
Oper- 1 2 3 4 5 6 7 8 9 0
ator
profile
number
Block 7 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 8 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 9 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 5
Block 10 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Tab. 2: PIN code defaults
The factory-set operator profiles are classified as follows:
Profile Characteristic Remarks
1 Standard profile Transport PIN code for all trucks,
as indicated on the transport
sticker (1258)
2 Beginner profile Factory pre-set PIN code at the
time of delivery (2258).
3 Advanced profile Factory pre-set PIN code at the
time of delivery (3258). Operator
parameters set to max. values
4 Standard profile -
9 Standard profile Factory pre-set PIN code at the
time of delivery (9258), only for
automatic trucks.
5.3.1.4 PIN code for resetting after a collision

5.3.1.4
PIN code for resetting after a collision
If the truck has stopped as a result of a collision, it needs to be reset by entering a special PIN code. This
PIN code must be programmed by a service technician during installation. .
The PIN code to be activated can be found in operator profile 1 and special block 10. The default value of
the PIN code is 0000. This must be changed to the PIN code selected by the service technician.
Note: The PIN code cannot contain the same combination of digits as any of the other programmed
PIN codes.
With parameter #111, it is possible to change how reset after collision is carried out. Resetting procedure
after collision.
5.3.2 Setting parameters

5.3.2
Setting parameters
This chapter covers only those parameters that need to be set upon commissioning of the truck and which
require detailed descriptions. Fore more information on the parameters, please refer to the Parameters
chapter.
Check to make sure all parameters are set to the desired values in terms of
• maximum speed, operator parameters - Parameter list, page 4 - 1 Operator parameters

• acceleration, operator parameters - Operator parameters
• deceleration, operator parameters - Operator parameters
• collision sensor (option) - Impact sensor sensitivity for X

5 Installation
Commissioning
• battery - Battery size

• battery charger (option) - Battery type, built-in charger Built-in battery charger
Note:When checking or setting parameters, be sure to keep written records, e.g. in a truck report, of
the truck's specific parameter values. This separate information on truck-specific parameters can
come in handy, e.g. in case of downtime, since the information is not available elsewhere.
5.3.3 Function and safety checks

5.3.3
Function and safety checks
Position Checkpoint Procedure

1 Driving control Check the function
2 Switch for safety reversing Check the function
3 Sound signal Check the function
4 Steering Check the function
5 Brake Check the function
6 Emergency switch off Check the function
7 Hydraulic system Check all components
8 Power pack Check for any noise or oil leakage
9 Wheels Check for damage and remove dirt
10 Chassis Check for damage and remove dirt
11 Battery cover and lock Check the function
12 Battery Inspect the battery acid level and
charge level
13 Fork carriage Check for damage and remove dirt

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

6 Maintenance

6 Maintenance
Introduction
Software: 7662518
6 Maintenance
6
Maintenance
6.1 Introduction
6.1
Introduction
Follow the general safety regulations when performing maintenance work. General safety regulations, page
2-1
6
▷ To maintain a high level of safety and to minimise downtime, all the points specified in the service
programme must be carried out.
▷ The set intervals of 1000 operating hours/12 months (whichever comes first) are those that meet the
manufacturer's requirements for a product in standard applications. The local operating environment
may require service intervals that differ from those specified.
▷ The first service may occur after x operating hours to reduce wear during the run-in period. See the
maintenance schedule.
▷ Once the service intervals have been determined, the hour counter is primarily used for determining
when servicing is to be carried out.
▷ To maintain safety, only spare parts approved by the manufacturer may be used for servicing and re-
pairs.
▷ Worn components on the truck must be replaced when discovered.

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

6.2
Maintenance instructions
6.2.1 Cleaning
6.2.1
Cleaning
Cleaning is an important factor in maintaining product service life.
▷ Always clean the product when servicing it.
NOTICE Risk of short-circuiting

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

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

6 Maintenance
Maintenance instructions
▷ After performing a high-pressure wash, all bearings and chains must be lubricated/greased as spe-
cified in the maintenance instructions.

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

6.2.3
Degreasing agents
NOTICE Risk of material damage

Sensors and safety equipment may be damaged by degreasers.
► Protect sensors and safety equipment so that they are not exposed to degreasers.
When using degreasing agents, only environmentally-friendly cold degreasing agents may be used, such as
those that are designed for general vehicle cleaning and do not damage paintwork, plastic components,
cables, hydraulic hoses or decals.
6.2.4 Cleaning the exterior

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

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

6.2.5
Cleaning the motor compartment
Always clean the motor compartment when servicing it.
▷ Cleaning is most suitably done using compressed air and/or a vacuum cleaner.

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

6.2.6
Electric components

Risk of damage to electrical components.
► Do not break off any warranty seals on the logic cards.
Always clean electrical components of the product when servicing it.
▷ Clean electric motors using vacuum cleaner or a rag.
▷ Clean electrical panels, electronic cards, contactors, connectors, solenoid valves, etc. with a
dampened cloth and a cleaning agent that will not damage the part.

6 Maintenance
Periodic maintenance
6.2.7 Optical sensors and reflectors

6.2.7
Optical sensors and reflectors
▷ Use a soft brush to remove dust from the units. Wipe the glass with a clean cloth moistened with an
alcohol-free fluid.
Note: Use an alcohol-free product.
6.2.8 Hydraulic system

6.2.8
Hydraulic system
6
Follow the regulations concerning work with hydraulics when performing maintenance work. See Hydraulics/
Pneumatics C6000, page 14 - 1
6.2.9 Signs, warnings and adhesive labels

6.2.9
Signs, warnings and adhesive labels
Inspect all signs and labels when performing service on the truck.
6.3 Periodic maintenance

6.3

6 Maintenance

Interval - Usage
Pos. Type Point Instruction Measure 250 500 750 1000 1500 2000 3000 4000 5000
1 Tiller arm Check the steering and tiller arm. X
Link target missing for title:
Checking steering and tiller arm
[ID: 23520139019]
2 Travel brake Check the parking brake, service X
function brake and switch for safety re-
versing.
Checking the parking brake, ser-
vice brake and switch for safety
reversing, page 11 - 3
3 The fork carriage Check the lifting and lowering X
function.
Checking the lifting and lowering
function, page 8 - 5
4 The function of Press the horn buttons to pro- X
6-5
the horn duce a sound signal.
Checking the horn function, page
13 - 93
5 The emergency Check the function of the emer- X
switch function gency switch off.
Checking the emergency switch
Preparations Raise the forks off the ground a
little and switch off the truck.
Disconnect or switch off the bat-
tery.
Remove the service cover.
Raise the truck onto blocks (x4).
6 Maintenance

6
Interval - Usage
6 The drive motor Clean the drive motor. X
Cleaning the drive motor [ID:
9007210190893963]
6 Maintenance
7 The parking Clean the brake using com- X

brake pressed air.

Cleaning the parking brake, page
11 - 3
8 The fork wheels Clean the fork wheels from X
strings and other dirt.
Cleaning the fork wheels, page
11 - 13
9 The chassis Inspect the chassis for cracks X
and other damage.
Checking the chassis, page
6-6
8-1
10 The battery lock Inspect the battery locking sys- X
tem.
Inspecting the battery locking
system, page 13 - 92
11 The fork carriage Inspect bushings and links for X
possible play.
Inspection of bushings and links,
page 8 - 5
12 The fork carriage Inspect the chassis for fork car- X
riage and other damage.
Inspect fork carriage, page
8-5
13 The fork wheels Inspect the fork wheels X
Inspect fork wheels, page
11 - 14
Interval - Usage
14 The drive motor Check for oil leaks and damage X
to the drive and hydraulic units.
Check for leaks in the drive mo-
tor, page 9 - 2
15 The drive motor Check the drive motor for signs of X
damage.
Checking the drive motor [ID:
23549528331]
16 Drive wheel Inspect the drive wheel for wear. Replacing the drive X
For a wheel with a diameter of D wheel, page 11 - 7
= 230, the tread must be ≥ 15
mm.
Inspect drive wheel, page
11 - 6
6-7
17 Drive wheel at- Check-tighten the drive wheel at- X
tachment tachment.
Check-tightening the drive wheel
attachment [ID: 23550064395]
18 The caster wheel Check the castor wheels for Replacing the castor X
wear. Measure the castor wheel wheel, page 11 - 10
tread. The tread should be ≥ 10
mm.
Inspect castor wheels, page
11 - 10
19 The caster wheel Check that the castor wheel is Replacing the castor X
properly attached and that it ro- wheel, page 11 - 10
tates and pivots freely.
Checking the castor wheels, page
11 - 10
6 Maintenance

6
Interval - Usage
20 The parking Use a feeler gauge to measure Replacing the parking X
brake gap the air gap between the brake brake, page 11 - 4
unit's magnet housing and the
movable pressure disc. Make
sure the air gap is =0.2-0.7 mm.
6 Maintenance
Adjusting the parking brake gap,

page 11 - 3

21 Hydraulic system Inspect the hydraulic system for X
damage and leaks, and that it is
properly attached.
Inspecting the hydraulic system,
page 14 - 2
22 Wiring harness Inspect electrical system, page X
13 - 1
Preparations Position the truck on the floor and
6-8
reconnect the battery.
Lower the forks completely and
release the hydraulic pressure.
Disconnect the battery.
23 Breather filter, Check the operation of the
hydraulic tank breather filter.
Inspecting the breather filter,
page 14 - 9
24 Oil level Checking the hydraulic oil level Topping up with oil, X
Checking the hydraulic oil level, page 14 - 9Topping
page 14 - 8 up with oil, page
14 - 9
Preparations Connect the battery and start the
truck.
Interval - Usage
25 Tiller arm Check the steering and tiller arm. X
[ID: 23520139019]
26 Travel brake Check the function of the travel X
function brake
Checking the function of the
travel brake, page 11 - 2
27 The drive motor Listen for abnormal noise in the X
drive motor
Listen for any abnormal noise in
the drive motor bearings and in
the drive gear, page 9 - 2
28 Travel brake Check the parking brake, service X
function brake and switch for safety re-
6-9
versing.
Checking the parking brake, ser-
vice brake and switch for safety
reversing, page 11 - 3
29 The fork carriage Check the lifting and lowering X
function.
Checking the lifting and lowering
30 The function of Press the horn buttons to pro- X
the horn duce a sound signal.
Checking the horn function, page
13 - 93
Preparations Refit the service cover.
6 Maintenance

6
Interval - Usage
31 The emergency Check the function of the emer- X
switch function gency switch off.
Checking the emergency switch
6 Maintenance
32 The chassis Inspect the signs and labels X

Inspect signs and labels, page

8-6
33 Operating hours Inspect the error log and operat- X
ing hours.
Checking error log and operating
hours, page 13 - 112
34 Fire extinguisher If the truck is equipped with a fire X
extinguisher, its status must be
inspected.
Inspection of fire extinguisher,
6 - 10
page 17 - 2
Troubleshooting 7
7.1 Initial troubleshooting....................................................................................................................... 7 - 1
7.2 Concluding troubleshooting ............................................................................................................. 7 - 2
7.3 Auxiliary functions............................................................................................................................ 7 - 3
7.3.1 Hydraulic pressure .............................................................................................................. 7 - 3
7.3.1.1 Erroneous hydraulic system pressure................................................................... 7 - 3
7.4 Troubleshooting using error codes .................................................................................................. 7 - 3
7.4.1 First actions when an error code is displayed..................................................................... 7 - 3
7.4.2 List of error codes ............................................................................................................... 7 - 3

7 Troubleshooting

7 Troubleshooting
Initial troubleshooting
Software: 7662518
7 Troubleshooting
7
Troubleshooting
7.1 Initial troubleshooting

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

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

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

the problem?

7 Troubleshooting
Concluding troubleshooting
7.2 Concluding troubleshooting

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

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

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

7 Troubleshooting
Auxiliary functions
7.3 Auxiliary functions

7.3
Auxiliary functions
7.3.1 Hydraulic pressure

7.3.1
Hydraulic pressure
7.3.1.1 Erroneous hydraulic system pressure

7.3.1.1
Erroneous hydraulic system pressure
Required special tools

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

7.4
Troubleshooting using error codes
7.4.1 First actions when an error code is displayed

7.4.1
First actions when an error code is displayed
Perform these actions before doing anything else.

1) Restart the truck by logging out and logging back in.
2) Disconnect the power supply for a while, and then reconnect it again.
7.4.2 List of error codes

7.4.2
List of error codes
Software: 7662518
7.4.2.1 Error codes
No. Description Error cause(s) Action

2:002 Parameters set to standard • New software has 1) Check parameters:
values been loaded in the - Check that factory
At start-up, it was detected truck, adding a new parameters are set ac-
that one or more parameters parameter, or it has cording to the truck’s
were not within acceptable changed the para- configuration.
intervals; they have therefore meter limit values - Check that other
been reset to default values. • Corrupt memory ICH parameters are set
correctly.
Truck behaviour
Unaffected 2) Replace A5, page
19 - 2 (ICH).
2:004 Backup copies do not • Hardware (T12 or 1) Copy the truck's con-
match. ICH) has been re- figuration via Truck-
Backup copy in secondary placed on the truck. Com
unit (T12) does not match • Software has been up- See separate manual
data in primary unit (ICH) dated to an older ver- for TruckCom
Truck behaviour sion 2) Copy the truck's con-

Unaffected • Corrupt memory T12 figuration via Truck-
Com
• Corrupt memory ICH See separate manual
for TruckCom
3) Replace T12
See Replacing the
motor control panel,
page 13 - 116
4) Replace the ICH.
See Replacing the lo-
gic card, page
12 - 4

7 Troubleshooting

2:005 Internal program error • Internal program error 1) Create a truck report.
Internal program error ICH Send a report to the
manufacturer.
Truck behaviour
Everything is stopped imme- 2) Update the truck soft-
diately, the parking brake is ware to the latest ver-
activated and the main con- sion.
tactor opens.
2:006 Saving to memory failed • Battery wiring harness 1) Check that the battery
Saving to memory failed be- inadequately attached wiring harness is se-
cause of low battery voltage. or loose. curely attached.
Battery voltage below 15 V • Voltage loss in power 2) Check battery voltage:
at the time of saving. supply to ICH. - Check the voltage
Truck behaviour • The battery is defect- using the built-in test
Unaffected. ive. procedure and com-
pare with the value
• Battery parameter from an external volt
#107 has an erro- meter.
neous value. - Check connectors,
joints and splices for
damage or corrosion.
- Check fuses F1 and
F50.
3) Check the battery.
4) Check parameters:
- Check that factory
parameters are set ac-
cording to the truck
configuration.
- Check that other
parameters are set
correctly.
2:007 Internal program error ICH • Internal program error 1) Create a truck report.
manufacturer.
Truck behaviour
Not influenced 2) Update the truck soft-
ware to the latest ver-
sion.
manufacturer.
Truck behaviour
sion.
manufacturer.
Truck behaviour
sion.

7 Troubleshooting

2:010 CAN communication warn- • Error on CAN bus wir- 1) Check the CAN bus:
ing ing or connections. - Check that the CAN
ICH has received too many • Loose connections bus is intact in terms
erroneous messages. of wiring harness, res-
• CAN node defective istance and connect-
Truck behaviour • Software failure ors. Disconnect the
Unaffected. battery. Check that the
resistance between 7
(X41:3) and (X41:4) is
54 - 66 ohms; see
X41, page 19 - 3.
- Check that the CAN
wiring harness is not
pinched. Measure res-
istance between the
chassis and CAN con-
nector. Limit value
>24kOhm.
2) Check for loose con-
nections:
- Switch on the truck,
and pull carefully in
the branches of the
wiring harness to find
any loose connec-
tions, and note when/if
the error code ap-
pears.
3) Check the CAN node:
- Deactivate and dis-
connect the option unit
connected to the CAN
wiring harness. Activ-
ate and then connect
them one by one to
identify which unit pro-
duces the communica-
tion error.
4) Update the truck soft-
sion.
2:011 New software • New software in- 1) Information concern-
New software has been installed. ing when software is
stalled on the truck. updated is saved in
the error log.
Truck performance
Not influenced.
Internal program error. • ICH manufacturing de- Send a report to the
fect manufacturer.
Truck performance
Creep speed, blocked lifting/ 2) Update the truck soft-
lowering movement. ware to the latest ver-
sion.

7 Troubleshooting

2:080 Internal program error 3) Replace the ICH
Internal program error. See section Removing
the logic card, page
Truck performance 12 - 4.
Creep speed, blocked lifting/
lowering movement.
2:102 Configuration error • Incorrect value for 1) Check parameters:
Truck configuration does not parameter 1102. - Check that factory
match parameter 1102. parameters are set ac-
Truck performance configuration.
Creep speed, blocked lifting/ - Check that other
lowering movement. parameters are set
correctly.
Internal program error. Send a report to the
manufacturer.
Truck behaviour
sion.
2:285 Incorrect signal combina- • High signal from both 1) Check the sensor sig-
tion from the support arm B62 and B65 nal.
position sensor • Constantly high signal Check that the dis-
at input (T12) tance between the
sensor and the oppos-
Truck behaviour ite part is correct.
Creep speed, blocked lift- Check that there is no
ing-/lowering movements dirt or foreign objects
on the sensor.
Inspect cabling.
Measure the signals
from the sensor with a
volt meter and verify
using TruckCom or
the built-in test that
the signal is correct.
2) Check the signal to
the unit.
Compare the signals
from the sensor with
the input signal (use a
volt meter and verify
using TruckCom or
the built-in test that
the signals are the
same).
Check the pins on the
unit and in the con-
nector.
Replace the unit if you
cannot get it to work
properly.

7 Troubleshooting

2:501 Low battery voltage • The battery is dis- 1) Charge the battery.
Low battery voltage below charged. 2) Check battery voltage:
16.8 Volts for more than 2 • Voltage loss in power - Check the voltage
seconds. supply to ICH. using the built-in test
Truck performance • The battery is defect- procedure and com-
Everything is stopped at ive. paring with value from
once, the parking brake is external volt meter.
activated, and the main con-
• Battery parameter - Check connectors, 7
#107 has an erro- joints and splices for
tactor opens. neous value. damage or corrosion.
F50.
configuration.
- Check that other
parameters are set
correctly.
2:502 Truck type not set • ICH is replaced and/or 1) Copy the truck config-
Parameter 1001 is incor- erroneous value for uration using Truck-
rectly set. factory parameters. Com:
• Incorrect value for - See the separate
Truck performance manual for TruckCom.
Everything is stopped imme- parameter 1001.
diately. The parking brake is 2) Check parameters:
activated and the main con- - Check that factory
tactor opens. parameters are set ac-
configuration.
- Check that other
parameters are set
correctly.
2:503 Wrong truck model set. • ICH is replaced and/or 1) Copy the truck's con-
Parameter 1108 is wrongly erroneous value for figuration via Truck-
set in combination with 1001 factory parameters Com
• Wrong value for para- See separate manual
Truck behaviour for TruckCom
Everything is stopped imme- meter 1108 and/or
diately, the parking brake is 1001 2) Check parameters.
activated and the main con- Check that factory
tactor opens parameters are set ac-
configuration.
Check that other para-
meters are set cor-
rectly.

7 Troubleshooting

2:511 ICH has received too many • Error on CAN bus wir- 1) Check the CAN bus:
erroneous messages ing harness or con- - Check that the CAN
Truck behaviour nection. bus is intact in terms
Everything stops immedi- • Loose connections of wiring harness, res-
ately. The parking brake is istance and connect-
• CAN node defective ors. Disconnect the
activated and the main con-
tactor opens. • Software failure battery. Check that the
resistance between
X41:3 and X41:4 is 54
- 66 ohms; see X41,
page 19 - 3.
istance between the
nector. Limit value
>24kOhm.
nections:
and pull carefully in
the branches of the
any loose connec-
the error code ap-
pears.
3) Check the CAN node:
- Deactivate and dis-
connect the option unit
connected to the CAN
wiring harness. Activ-
ate and then connect
them one by one to
identify which unit pro-
duces the communica-
tion error.
sion.
2:515 No response is received • Error on CAN bus wir- 1) Check the CAN bus:
from K110 (DHU/I_Site) ing harness or con- - Check that the CAN
No return signal from K110 nection. bus is intact in terms
(DHU/I_Site) within 0.6 • Parameter 102 set in- of wiring harness, res-
seconds after logging on. correctly. istance and connect-
ors. Disconnect the
Truck behaviour • No connection with battery. Check that the
Everything is stopped imme- K110. resistance between
diately. The parking brake is • Loose connections X41:3 and X41:4 is 54
activated and the main con- - 66 ohms; see X41,
tactor opens. • Software failure
page 19 - 3.

7 Troubleshooting

2:515 No response is received istance between the
from K110 (DHU/I_Site) chassis and CAN con-
No return signal from K110 nector. Limit value
(DHU/I_Site) within 0.6 >24kOhm.
seconds after logging on. 2) Check parameters:
Truck behaviour - Check that factory
Everything is stopped imme- parameters are set ac-
diately. The parking brake is cording to the truck 7
activated and the main con- configuration.
tactor opens. - Check that other
parameters are set
correctly.
3) Check X5:1 (DHU/
I_Site):
- Check that the
DHU's green LED is
lit. If the LED is not lit:
Check that the DHU's
feed voltage = battery
voltage.
- Make sure it is pos-
sible to connect Truck-
Com to the DHU. If it
is possible to connect
them, check the
DHU's configuration. If
there is a power sup-
ply but no communica-
tion, check the CAN
bus.
- If it is still not pos-
sible to communicate
with X5:1 (DHU) - re-
place the unit.
nections:
and tug carefully on
the branches of the
any loose connec-
the error code ap-
pears.
sion.

7 Troubleshooting

2:516 ICH has an incorrect box • Box address error on 1) Remove the jumper in
address ICH. X203, if there is one.
There is a jumper/short cir- 2) Check if there is a
cuit in connection X203. In- short circuit in the
ternally on the ICH card X203 connector.
(between pins 1 and 0). 3) Replace the ICH: See
Truck performance section Replacing the
Everything is stopped at logic card, page
once, the parking brake is 12 - 4.
tactor opens.
2:520 Parameter values do not • Checksum error 1) Set new checksum:
match • New software has - If the problem with
The checksum of the para- been loaded in the the check sum occurs
meter values does not match truck, adding a new directly in connection
the parameter values. parameter, or it has with the software up-
changed the para- date, proceed as fol-
Truck performance lows:
Everything is stopped at meter limit values.
- Change the value of
once, the parking brake is • Corrupt memory cir- one parameter in each
activated, and the main con- cuit category, operator
tactor opens. parameters, service
parameters and calib-
ration parameters.
- Save the changes
and restart the truck.
- Reset the values you
changed in the previ-
ous step back to their
original values.
- Restart the truck.
- The program will
have performed a new
checksum calculation.
configuration.
- Check that other
parameters are set
correctly.
3) Replace the ICH:
- See section Repla-
cing the logic card,
page 12 - 4.

7 Troubleshooting

2:522 Incorrect power supply to • Incorrect power supply Check the Hall sensors:
Hall sensors to the Hall sensors. - Check with TruckCom or
High (or low) signal from all the built-in test that the Hall
Hall sensors ICH:S300- sensors work the way they
S318. should.
- A Hall sensor that is being
Truck performance influenced should give a low
Plug braking to stop, then
the parking brake is activ-
signal. 7
- Replace ICH if the Hall
ated and the main contactor sensors have an error func-
opens. tion. See section Replacing
the logic card, page
12 - 4.
2:523 Internal memory (FRAM or • Corrupt memory cir- 1) Replace the ICH:
RAM) is faulty cuit. - See section Repla-
Reading from or writing to cing the logic card,
memory failed. page 12 - 4.
Truck performance
Everything is stopped at
once, the parking brake is
tactor opens.
2:580 Signal from Hall element • ICH defective. 1) Check the Hall
The Hall element for the sensors:
throttle control gives a signal - Check with Truck-
(active low) when it should Com or the built-in test
not. for the Hall sensors
that they work the way
Truck performance they should. A Hall
Plug braking to stop, then sensor that is being in-
the parking brake is activ- fluenced should give a
ated and the main contactor low signal.
opens. - Replace ICH if the
Hall sensors have an
error function. See
section Replacing the
logic card, page
12 - 4.
3:001 The speed control was not • Control manipulated. 1) Let go of the control,
in the neutral position at • The speed control and wait for four
start-up does not spring back seconds.
One or more Hall elements to neutral position. 2) Check the speed con-
for the speed control give an • ICH defective. trol:
active signal at start. - Check the spring
Truck performance function.
The truck cannot be driven, - Check that the speed
other functions are OK. control is not seized.
- Check that the
plastic cover where
the spring is attached
is intact.
3) Check the Hall
sensors:
- Check with Truck-

7 Troubleshooting

3:001 The speed control was not Com or the built-in test
in the neutral position at for the Hall sensors
start-up that they work the way
One or more Hall elements they should. A Hall
for the speed control give an sensor that is being in-
active signal at start. fluenced should give a
low signal.
Truck performance - Replace ICH if the
The truck cannot be driven, Hall sensors have an
other functions are OK. error function. See
section Replacing the
logic card, page
12 - 4.
3:002 The motor control unit • Reduced cooling or 1) Check the cooling.
temperature exceeds defective temperature
+85°C. sensor • Check the transistor
regulator, motor,
steering motor heat
Truck behaviour sink and the battery
The motor control is limiting charger for dirt and
the voltage. dust. Too much dust
and dirt causes the
cooling not to work
properly.
• Check that the char-
ger works when char-
ging starts, i.e. when
the mains cable is
connected. Check the
signal from B1 and the
temperature sensors
for T12 and EPS, us-
ing the integrated test
or TruckCom. Determ-
ine if the temperature
signals are plausible
relative to the real
temperatures of the
components. If not, re-
place T12, EPS or re-
place B1 with a repair
kit.
3:040 Incorrect power saving • Internal error in T12 1) Restart the truck.
function in standby mode. 2) If the error persists,
Truck behaviour replace the motor con-
Not influenced trol T12.

7 Troubleshooting

3:080 Temperature sensor out of • Reduced cooling or 1) Check the cooling
range defective temperature Check the transistor
The temperature sensor in sensor. regulator, motor,
the motor control power steering motor heat
stage is outside the limit sink and the battery
value. Above 130°C charger for dirt and
dust. Too much dust
Truck behaviour
The motor control is limiting
and dirt causes the 7
cooling not to work
the voltage. properly.
Check that the char-
ger BCU works when
the charging starts,
i.e. when the mains
cable is connected
Check the signal from
the temperature
sensors for T12 and
EPS and from B1 via
the integrated test or
TruckCom. Determine
if the temperature sig-
nals are plausible rel-
ative to the real tem-
peratures of the com-
ponents. If not, re-
kit.
3:081 The motor temperature • Reduced cooling or 1) Check the cooling
sensor is outside of limit defective temperature Check the transistor
values. sensor. regulator, motor,
Above 210°C. steering motor heat
sink and the battery
Truck behaviour charger for dirt and
Creep speed, motor control dust. Too much dust
limits the current. and dirt causes the
cooling not to work
properly.
Check that the char-
ger BCU works when
the charging starts,
i.e. when the mains
cable is connected.
the temperature
sensors for T12 and
EPS and from B1 via
TruckCom. Determine

7 Troubleshooting

3:081 The motor temperature place T12, EPS or re-
sensor is outside of limit place B1 with a repair
values. kit.
Above 210°C.
Truck behaviour
Creep speed, motor control
limits the current.
3:100 Motor control warning. • Internal program error 1) Create a truck report.
Unknown warning • Software failure Send a report to the
manufacturer.
Truck behaviour
sion.
3:101 Internal error in T12. • The motor control is 1) Restart the truck.
Truck behaviour using pre-set power 2) If the error persists,
amplification. Internal replace the motor con-
Creep speed, blocked lifting/ error
lowering movement. trol T12.
3:120 Incorrect checksum for the • Motor control corrupt 1) Update the truck soft-
motor control parameters ware to the latest ver-
Truck behaviour sion.
Creep speed, blocked lifting/ 2) If the error persists,

lowering movement. replace T12.
3:121 The motor control T12 can- • Internal error in T12 1) Restart the truck.
not use internal memory. 2) Update the truck soft-
Truck behaviour ware.
Creep speed, blocked lifting/ • Update the en-
lowering movement. tire truck soft-
ware package
to the latest
available ver-
sion.
3) If the error persists,
replace T12.
3:140 Short circuit in horn out- • High power consump- 1) Check for overcurrent
put tion or short circuit or short circuit:
Hardware protection in T12 Check the ohms and
detects a short circuit in the the amperes of the
output for the horn. The cur- component, compare
rent through the horn is them to the setpoint
above the valid limit value. values if they outside
Maximum value = 500mA, the accepted range.
continuous value = 300mA 2) Check the connec-
Truck behaviour tions and wiring har-
Unaffected ness for short-circuit-
ing.
3) Check that the com-
ponent does not seize
or is jammed.

7 Troubleshooting

3:140 Short circuit in horn out- If points 1-3 are OK, it indic-
put ates that the output stage is
Hardware protection in T12 short circuited - Replace the
detects a short circuit in the power-supplying component
output for the horn. The cur-
rent through the horn is
above the valid limit value.
Maximum value = 500mA, 7
continuous value = 300mA
Truck behaviour
Unaffected
3:303 Motor control start-up • Error on CAN bus wir- 1) Check the CAN bus
failed ing harness or con- Check that the CAN
nection bus is intact in terms
• Incorrect value for of wiring harness, res-
Truck behaviour istance and connect-
The truck cannot be started. parameter 1001
ors. Disconnect the
• No power supply battery. Check that the
• Wrong kind of motor resistance between
control (X41:3) and (X41:4) is
54 - 66 ohms.
Check that the CAN
istance between the
nector. Limit value >24
kOhm
2) Check parameters.
Check that factory
configuration.
meters are set cor-
rectly.
3) Check the wiring for
any breaks, damage
or short-circuiting.
Cut the power to the
truck
Using instruments,
check that there is no
break in any wire
Measure and check
the current for the ac-
tivated functions
4) Replace T12.
See Replacing the
page 13 - 116.

7 Troubleshooting

3:303 Motor control start-up • Error on CAN bus wir- 1) Check the CAN bus
failed ing harness or con- Check that CAN bus is
nection intact in terms of wir-
• Incorrect value for ing harness, resist-
Truck performance ance and connectors.
The truck cannot be started. parameter 1001
Disconnect the bat-
• No power supply tery. Check that the
• Wrong kind of motor resistance between
control (X41:3) and (X41:4) is
54 - 66 ohms.
Check that the CAN
istance between the
kOhm
2) Check parameters.
Check that factory
configuration.
meters are set cor-
rectly.
3) Check the wiring har-
ness for any discon-
nection.
Cut off power to the
truck
Using instruments,
break in any wire.
Measure and check
the voltage for the ac-
tivated functions
4) Replace T1.
See Replacing the
page 13 - 116.
3:501 Defective motor controller • Defective motor con- Check:
Truck behaviour trol 1) T12.
Everything is stopped imme- 2) Factory parameter
diately, the parking brake is 1001 (Truck type).
If the error persists, replace
tactor opens.
T12.

7 Troubleshooting

3:502 Error in T12 • Internal program error 1) Update the truck’s
Error in T12 when saving • Defective motor con- software to the latest
parameters. trol available version.
Truck behaviour 2) Replace T12 (motor

Everything is stopped imme- control).
diately. The parking brake is
tactor opens.
7
3:505 Unknown error in T12 • No software compatib- 1) Update the truck soft-
ility ware
Update the truck en-
Truck behaviour tire software package
Everything is stopped at to the latest available
once, the parking brake is version.
tactor opens
3:507 Internal error in T12 • Defective motor con- 1) Replace T12 (motor
trol control).
Truck behaviour
Everything is stopped imme-
tactor opens.
3:511 CAN communication prob- • Error on CAN bus wir- 1) Check the CAN bus
lem ing harness or con- Check that the CAN
CAN communication prob- nection bus is intact in terms
lem between T12 and ICH, • CAN module in ICH of wiring harness, res-
ICH gets no signals from defective istance and connect-
T12 ors. Disconnect the
battery. Check that the
Truck behaviour resistance between
Everything is stopped imme- (X41:3) and (X41:4) is
diately, the parking brake is 54 - 66 ohms.
activated and the main con- Check that the CAN
tactor opens wiring harness is not
istance between the
kOhm
2) Replace the ICH
3) Check the connection
point (T12:84). (by
checking that the LED
is illuminated or meas-
uring that, between B+
and B- on the motor
control, the voltage is
slightly lower than the
battery voltage.

7 Troubleshooting

lem between ICH and T12, of wiring harness, res-
T12 gets no signals from istance and connect-
ICH ors. Disconnect the
Truck behaviour resistance between
Everything is stopped imme- (X41:3) and (X41:4) is
diately, the parking brake is 54 - 66 ohms.
activated and the main con- Check that the CAN
tactor opens wiring harness is not
istance between the
kOhm
lem, ICH cannot send to T12 • CAN module in ICH of wiring harness, res-
defective istance and connect-
Truck behaviour ors. Disconnect the
Everything is stopped imme- battery. Check that the
diately, the parking brake is resistance between
activated and the main con- (X41:3) and (X41:4) is
tactor opens 54 - 66 ohms.
Check that the CAN
istance between the
kOhm
2) Replace ICH
See section “13.1.6
Replacing the logic
card”.
3:515 Motor control receives in- • Short circuit in motor 1) Check the motor:
correct data from ICH. • Short circuit in motor - Disconnect the motor
Truck behaviour wiring harness cables and the sensor
Everything is stopped imme- • Short circuit in power wires.
diately, the parking brake is stage - Perform an insulation
activated and the main con- • test: Check that the
tactor opens. coils are not electric-
ally connected to the
chassis. Replace M1 if
the motor is not isol-
ated
2) Check the motor wir-
ing harness
- Visual check of the
motor wiring harness.
Check that there is no

7 Troubleshooting

3:515 Motor control receives in- connection between
correct data from ICH. the terminal connec-
Truck behaviour tions on the motor/mo-
tor control. Search for
Everything is stopped imme- contact and damaged
diately, the parking brake is insulation on the wir-
activated and the main con- ing harness.
tactor opens.
- Disconnect the motor 7
wiring harness at the
motor control and on
the motor and meas-
ure the Ohms of the
wiring harness
between the phases
and verify that there is
no connection.
3) Check the CAN wiring
harness.
4) Replace T12.
3:521 The motor control has de- • Short circuit in motor 1) Check the motor:
tected low motor voltage. • Short circuit in motor - Disconnect the motor
Error in the motor’s power wiring harness cables and the sensor
circuit. Motor control T12 de- • Short circuit in power wires.
tects short-circuit or low mo- stage - Perform an insulation
tor voltage. test: Check that the
Truck behaviour coils are not electric-
Everything is stopped imme- ally connected to the
diately, the parking brake is chassis. Replace M1 if
activated and the main con- the motor is not isol-
tactor opens. ated.
ing harness:
connection between
the terminal connec-
tions on the motor/mo-
contact and damaged
insulation on the wir-
ing harness.
- Disconnect the motor
the motor and meas-
ure the Ohms of the
wiring harness
between the phases
no connection.
3) Replace T12.

7 Troubleshooting

3:522 The motor control has de- • Short circuit in motor 1) Check the motor:
tected high motor voltage. • Short-circuit in motor - Disconnect the motor
Error in the motor’s power wiring harness cables and the sensor
circuit. Motor control T12 de- • Short circuit in power wires.
tects short-circuit or a high stage - Perform an insulation
motor voltage. test: Check that the
Truck behaviour coils are not electric-
Everything is stopped imme- ally connected to the
diately. The parking brake is chassis. Replace M1 if
activated and the main con- the motor is not isol-
tactor opens. ated.
ing harness:
connection between
the terminal connec-
tions on the motor/mo-
contact and damaged
insulation on the wir-
ing harness.
the motor and meas-
ure the Ohms of the
wiring harness
between the phases
no connection.
3) Replace T12.
3:526 Internal error in T12 • Software failure 1) Update the truck soft-
Truck behaviour • Defective motor con- ware to the latest ver-
trol sion.
diately, the parking brake is 2) Replace T12.
tactor opens.
3:527 Blown fuse • 1) Check that the wiring
Low voltage level on motor harness and fuses are
control (ACT). intact and functioning.
Truck behaviour 2) Check whether there

Everything is stopped imme- is an external load on
diately. The parking brake is B+.
tactor opens.

7 Troubleshooting

trol sion.
tactor opens.
3:530 Internal error in T12 • Software failure 1) Update the truck soft- 7
trol sion.
tactor opens.
trol sion.
tactor opens.
3:532 Internal error in T12. • The motor control has 1) Replace T12.
Truck behaviour detected an internal
problem in the AD
Everything is stopped imme- converter
diately, the parking brake is
tactor opens.
3:533 The charging voltage for • The charging voltage 1) Check:
the motor control capa- for the motor control - Connections and wir-
citor indicates abnormal capacitor indicates ab- ing harness
values. normal values
- Wire 22
Truck behaviour
- The connection point
Everything is stopped imme- (T12:84) must be 24 V
diately, the parking brake is
activated and the main con- - Motor control
tactor opens 2) If the problem per-
sists, replace T12.
3:535 Incorrect checksum for the • Incorrect checksum 1) Update the truck soft-
motor control parameters. for the motor control ware.
Truck performance parameters. 2) Update the entire
Everything is stopped at truck software pack-
once, the parking brake is age to the latest avail-
activated, and the main con- able version.
tactor opens.
3:537 Internal error in ICH. • Multi-direction com- 1) Check the signals
Truck performance mand issued by from the ICH Hall ele-
handle ment.
Everything is stopped at
once, the parking brake is 2) Check the motor con-
activated, and the main control.
tactor opens.

7 Troubleshooting

3:539 Motor control detects • The battery is dis- 1) Ensure that the
T12 (the motor control) de- charged. voltage is within the
tects that the battery voltage • The battery is defect- approved range.
is not between 16.8 V and ive. 2) Charge the battery.
30 V on output 91. • The wiring harness is 3) Check the battery.
Truck behaviour defective. 4) Check the wiring har-
Everything is stopped imme- ness and fuses.
tactor opens.
3:540 Short circuit in power • Short circuit in motor 1) Check the motor:
stage • Short circuit in motor Disconnect motor wir-
Hardware in T12 detects a wiring harness ing including sensor
short circuit in the power wires. Insulation test.
• Short circuit in power Check that the coils
stage and a phase-to-phase stage
short circuit, phase B- and are not electrically
phase B+. connected to the
Truck behaviour the motor is not isol-
Everything is stopped imme- ated.
activated and the main con- 2) Check the motor wir-
tactor opens. ing harness:
Visual check of the
contact between the
pole connections on
the motor/motor con-
trol. Search for contact
and damaged insula-
tion on the wiring har-
ness.
Disconnect the motor
motor control and the
motor and measure
the ohms of the wiring
harness between the
phases and verify that
there is no contact.
3) Replace T12.
See Replacing the
page 13 - 116.

7 Troubleshooting

3:545 Output short circuit • High power consump- 1) Check for overcurrent
Hardware protection unit in tion or short circuit or short circuit:
T12 detects a short circuit in Check the ohms and
the output to brake (Q1). The the amperes of the
current through the brake is component, compare
above the valid limit value. them to the setpoint
Maximum value = 5.95A, values if they outside
continuous value = 3A the accepted range. 7
Check the connec-
Truck behaviour tions and wiring har-
Everything is stopped imme- ness for short-circuit-
diately, the parking brake is ing.
activated and the main con- Check that the com-
tactor opens ponent does not seize
or is jammed.
If points 1-3 are OK, it
indicates that the out-
put stage is short cir-
cuited - Replace the
power-supplying com-
ponent
3:546 Short circuit or current in • High power consump- 1) Check for overcurrent
main contactor tion or short circuit or short circuit:
Hardware protection unit in Check the ohms and
T12 detects a short circuit or the amperes of the
that the current through the component, compare
main contactor (Q10) ex- them to the setpoint
ceeds valid limit values. values if they outside
Maximum value = 2.5A, con- the accepted range.
tinuous value = 1.5A Check the connec-
tions and wiring har-
Truck behaviour ness for short-circuit-
Everything is stopped imme- ing.
diately, the parking brake is Check that the com-
activated and the main con- ponent does not seize
tactor opens or is jammed.
If points 1-3 are OK, it
indicates that the out-
ponent.
3:547 Output short circuit • Components are using 1) Check the compon-
Hardware protection unit in too much power or ents that are supplied
T12 detects a short circuit in wiring is short cir- with power from the
the output “High Side driver” cuited. High Side Out (Main
• No software compatib- contactor, brake coil
Truck behaviour and lowering valve).
Everything is stopped imme- ility
diately, the parking brake is • Short circuit in power Check the ohms and
activated and the main con- stage the amperes of the
tactor opens component, compare
them to the setpoint
values if they outside
the accepted range.

7 Troubleshooting

3:547 Output short circuit Check the connec-
Hardware protection unit in tions and wiring har-
T12 detects a short circuit in ness for short-circuit-
the output “High Side driver” ing.
Truck behaviour Check that the com-

Everything is stopped imme- ponent does not seize
diately, the parking brake is or is jammed.
activated and the main con- If points 1-3 are OK, it
tactor opens indicates that the out-
ponent
ware
Update the truck soft-
sion.
3) Replace T12.
3:548 Hardware protection unit • High power consump- Check for overcurrent or
in T12 detects a short cir- tion or short circuit short circuit:
cuit or that the current 1) Check the ohms and
through the main con- the amperes of the
tactor (Q10) exceeds valid component, compare
limit values. Maximum them to the setpoint
value = 2.5A, continuous values if they outside
value = 1.5A. the accepted range.
Truck behaviour 2) Check the connec-
Everything is stopped imme- tions and wiring har-
diately, the parking brake is ness for short-circuit-
activated and the main con- ing. Check the battery.
tactor opens. 3) Check that the com-
ponent does not seize
or is jammed. Check
the parameters.
• If items 1-3 are
OK, it indicates
that the output
stage is short
circuited. Re-
place the com-
ponent that sup-
plies the power.
3:549 The motor control detects • Short circuit in motor 1) Have the engine over-
missing phases to the mo- • Low power consump- hauled.
tor. tion or break - Disconnect the motor
Truck behaviour • Short circuit in power cables and the sensor
Everything is stopped imme- stage wires.
diately, the parking brake is - Perform an insulation
activated and the main con- test: Check that the
tactor opens. coils are not electric-

7 Troubleshooting

3:549 The motor control detects ally connected to the
missing phases to the mo- chassis. Replace M1 if
tor. the motor is not isol-
Truck behaviour ated.
Everything is stopped imme- 2) Check wiring and

diately, the parking brake is component for a dis-
activated and the main con- connection.
tactor opens. - Cut the power to the
7
truck
- Visually check the
wiring harness.
- Using instruments,
break in any wire.
- Check the Ohms and
the Amperes of the
component, compare
them to the set values,
and replace the unit if
they are outside the
accepted range.
- Restore power to the
truck. Measure and
check the current for
the activated func-
tions.
3) Replace T12.
3:563 Low current • Low power consump- 1) Check wiring and
The amperage is below the tion or break component for a dis-
limit value 100mA on the connection
output to Brake (Q1). Switch off the power
supply to the truck
Truck behaviour Visually check the wir-
Everything is stopped imme- ing harness
diately, the parking brake is Using instruments,
activated and the main con- check that there is no
tactor opens break in any wire
Check the Ohms and
the Amperes of the
component, compare
accepted range.
Restore power to the
truck. Measure and
the activated func-
tions.

7 Troubleshooting

3:564 Low current • Low power consump- 1) Check wiring and
The amperage is below the tion or break component for a dis-
limit value 100mA on the connection
output to main contactor Switch off the power
(Q10). supply to the truck
Visually check the wir-
Truck behaviour ing harness
Everything is stopped imme- Using instruments,
diately, the parking brake is check that there is no
activated and the main con- break in any wire
tactor opens Check the Ohms and
the Amperes of the
component, compare
accepted range.
Restore power to the
truck. Measure and
the activated func-
tions.
3:582 The transistor regulator's • Low power consump- 1) Check wiring and
output for power supply tion or break component for a dis-
has the wrong voltage • Short circuit in power connection (main con-
level. stage tactor, lowering valve,
Truck behaviour brake, pump con-
Everything is stopped imme- tactor).
diately, the parking brake is - Cut the power to the
activated and the main con- truck.
tactor opens - Visually check the
wiring harness.
- Using instruments,
break in any wire.
- Check the Ohms and
the Amperes of the
component, compare
accepted range.
- Restore power to the
truck. Measure and
the activated func-
tions.
2) If the error persists,
replace T12.

7 Troubleshooting

3:583 Internal transistor regu- • Defective RPM sensor 1) Defective RPM
lator voltage supply has • Defective motor con- sensor.
not been switched on. trol - Check wiring and
Truck behaviour connectors for a dis-
Everything is stopped imme- connection.
diately, the parking brake is - Replace the RPM
activated and the main con- sensor.
tactor opens.
7
2) Replace T12.
3:590 Change in rpms • Broken wiring 1) Check wiring after the
The change exceeds 1000 • Defective component break.
rpm in 20 ms Cut the power to the
• Change in surface fric- truck
Truck behaviour tion combined with Using instruments,
The drive is stopped immedi- slippage check that there is no
ately with the parking brake break in any wire
Measure and check
the voltage with the
functions activated
2) Check the rotational
speed sensor
Disconnect the rota-
tional speed sensor
(B11/B12). Check that
there are no metal
fragments on the tip of
the sensor (B11/B12).
Check that the toothed
wheel on the motor
axle is clean, intact
and properly mounted.
3) Drive carefully if there
is a risk of slipping
3:592 Internal current error • Defective motor con- 1) Replace T12.
Sensor offset is too high. trol
Truck behaviour
Truck travel is stopped im-
mediately with the parking
brake.
3:597 High temperature • Intensive use of the 1) Intensive use of the
The motor temperature ex- truck truck. Let the truck
ceeds +180°C. • Reduced cooling or cool down.
Truck behaviour defective temperature 2) Check the cooling

- sensor. Check the transistor
regulator, motor,
steering motor heat
charger for dirt and
dust. Too much dust
and dirt causes the
cooling not to work
properly.

7 Troubleshooting

3:597 High temperature Check that the fans
The motor temperature ex- work when the speed
ceeds +180°C. control is activated
(fans behind T12 and
Truck behaviour motor fan)
- Check that the fan on
charger BCU works
when the charging
starts, i.e. when the
mains cable is con-
nected
the temperature
sensors for T12 and
EPS and from B1 via
TruckCom. Determine
kit.
4:001 Lifting/lowering control is • Control manipulated 1) Let go of the control,
not in neutral position at and wait for four
start-up. seconds.
Lifting is prevented until the 2) Check.
lifting/lowering controller is
back in the neutral position. • wiring in the handle.
Truck performance • the potentiometer. If
Blocked lifting/lowering defective, replace the
movement potentiometer.
4:101 Signal from the sensilift • Control manipulated 1) Let go of the control,
potentiometer detects ab- and wait for four
normal values. seconds.
Truck behaviour 2) Check:
Blocked lifting/lowering • wiring in the
movement handle.
• the poten-
tiometer. If de-
fective, replace
the poten-
tiometer.

7 Troubleshooting

4:102 Signal error • Incorrect value for 1) Check parameters:
Signal from the sensilift po- parameter 1102. - Check that factory
tentiometer detected even • Error in hydraulic con- parameters are set ac-
though parameter 1102 does trols. cording to the truck
not have the value 4. configuration.
- Check that other
Truck performance parameters are set
Blocked lifting/lowering
movement.
correctly. 7
2) Replacement of the
hydraulic control:
- See section Steering
arm/wheel/lever
C4110, page 12 - 1.
4:125 Pump motor current feed- • Defective power sup- 1) Replace T12.
back remains zero when ply to the motor con- 2) Replace the wiring
the pump motor operates. trol harness between T12
Truck behaviour and pump motor.
lowering movement.
4:126 Excessive pump motor • Defective power sup- 1) Replace T12.
current feedback at start- ply to the motor con- 2) Replace the wiring
up and in the standby trol harness between T12
mode. and pump motor.
Truck behaviour
lowering movement.
4:521 Pump motor voltage too • Wire break between 1) Check the wiring har-
low. T12 and the pump ness for any discon-
Truck behaviour motor nection.
Everything is stopped imme- • The pump motor - Cut the power to the
diately, the parking brake is truck.
activated and the main con- - Using instruments,
tactor opens. check that there is no
break in any wire.
- Measure and check
tivated functions.
2) Check the pump mo-
tor.
cables and the sensor
wires.
- Perform an insulation
test: Check that the
coils are not electric-
ated.

7 Troubleshooting

4:522 Pump motor voltage too • Wire break between 1) Check the wiring har-
high. T12 and the pump ness for any discon-
Truck behaviour motor nection.
Everything is stopped imme- • The pump motor - Cut the power to the
diately, the parking brake is truck.
activated and the main con- - Using instruments,
tactor opens. check that there is no
break in any wire.
- Measure and check
tivated functions.
2) Check the pump mo-

tor.
cables and the sensor
wires.
- Perform an insulation
test: Check that the
coils are not electric-
ated.
4:540 The transistor regulator • The transistor regu-
output to the lowering lator output to the 1) Check the connec-
valve has short-circuited. lowering valve has a tions and the wiring
Truck behaviour short-circuit harness.
Everything is stopped imme- • Internal short-circuit in • Disconnect the
diately, the parking brake is the motor control lowering valve
activated and the main con- and try restart-
tactor opens. ing the truck.
2) Replace the lowering
valve or T12 if the er-
ror persists.
4:541 The transistor regulator • Broken wiring 1) Check the wiring har-
output to the lowering ness for any discon-
valve has short-circuited nection.
with B-. • Cut off power to
Truck performance the truck.
Everything is stopped at • Using instru-
once, the parking brake is ments, check
activated, and the main con- that there is no
tactor opens break in any
wire.
• Measure and
check the
voltage for the
activated func-
tions.

7 Troubleshooting

4:560 The transistor regulator • Broken wiring 1) Check the wiring har-
output to the lowering • Lowering valve ness for any discon-
valve is open. nection.
Truck performance - Cut the power to the
Everything is stopped at truck.
once, the parking brake is - Using instruments,
activated, and the main con- check that there is no
tactor opens disconnection in any
7
wire.
- Measure and check
the voltage for the ac-
tivated functions.
2) Check the lowering
valve solenoid.
5:180 Steering angle signal is • Defective component, Check the analogue sensor:
outside the valid range short circuit or wire cut 1) Start the truck and
(applies only to mechanical off drive without the arm
steering, not power steering) • Truck logged on with fully engaged for 1
Valid range: 0.18V - 4.86V large steering angle minute; this is not a
Truck behaviour and not moved for 20+ component fault if the
Creep speed seconds with the arm fault does not occur.
lowered. 2) Check that no foreign
objects, rubbish or
shavings are affecting
the sensor.
3) Check that the sensor
has a 5V or 24V
power supply (de-
pending on the com-
ponent).
4) Compare the meas-
ured output from the
sensor with the cor-
responding value in
TruckCom or built-in
test. If the values are
the same and are out
of the valid range, it
indicates an error in
the sensor or the wir-
ing harness. Repair or
replace the compon-
ent.
5) If the values are not
the same, this indic-
ates an error in T12.
Replace the T12. See
Replacing the motor
control panel, page
13 - 116.

7 Troubleshooting

8:001 The shock sensor has re- • Collision 1) Resetting truck after
gistered a collision • Parameters 105 and collision.
Shock sensor has registered 106 set too low. 2) Check parameters:
impact levels above the set - Check that factory
limit values as defined by parameters are set ac-
parameters 105 and 106. cording to the truck
Truck behaviour configuration.
Creep speed, blocked lifting - Check that other
movement. parameters are set
correctly.
8:002 The truck was intentionally • The truck was inten- No action.
taken out of service via tionally taken out of
I_Site service via I_Site.
Truck behaviour
Creep speed, blocked lifting
movement.
8:003 Argument error in option. • Option argument er- 1) Check parameters
Invalid configuration in one ror, parameters 1003 - Check that factory
or more options. 1042 parameters are set ac-
Truck behaviour configuration.
Not influenced Check that other para-
meters are set cor-
rectly.
8:004 Option buttons activated • Option button pressed 1) Check the option but-
One or more option buttons during start-up tons
on ICH is activated at start- Check the function of
up. the option buttons via
the built-in test mode,
Truck behaviour Service Information
All option buttons are non- mode 9 or TruckCom.
functional until the option If there is still a signal
button that is influenced is from a seemingly un-
not influenced any more. influenced button, the
button must be
checked for jamming
or unwanted connec-
tion.
8:010 CAN communication prob- • Error on CAN bus wir- 1) Check the CAN bus:
lem ing or connections. - Check that the CAN
With the built-in charger A30, bus is intact in terms
A31 at start-up. of wiring harness, res-
istance and connect-
resistance between
X41:3 and X41:4 is 54
- 66 ohms; see X41,
page 19 - 3.

7 Troubleshooting

8:010 CAN communication prob- istance between the
lem chassis and CAN con-
With the built-in charger A30, nector. Limit value
A31 at start-up. >24kOhm.
Truck behaviour 2) - Check A30, A31 if

Unaffected. the error is recurring.
8:021 Low voltage • The battery is defect- 1) Check the battery. 7

A30, A31 detects low battery ive.
voltage when charging.
Voltage below valid level:
19.8V.
Truck behaviour
Unaffected.
8:022 High voltage • The battery is defect- 1) Check the battery.
A30, A31 detects high bat- ive.
tery voltage when charging.
Voltage above valid level:
34.8V.
Truck behaviour
Unaffected.
8:023 Low temperature • Truck used in cold en- 1) Inform the client that
A30, A31 detects low tem- vironments. the truck should be
perature when charging. stored in normal ambi-
ent temperatures to
Truck behaviour avoid unnecessary
Unaffected. wear and tear of the
battery and other com-
ponents.
8:024 High temperature • Reduced cooling or 1) Check the cooling
A30, A31 has reduced the defective temperature Check the transistor
charging current to 0A be- sensor. regulator, motor,
cause of high temperature. steering motor heat
Truck behaviour charger for dirt and
Unaffected dust. Too much dust
and dirt causes the
cooling not to work
properly.
Check that the fans
work when the speed
control is activated
(fans behind T12 and
motor fan)
Check that the fan on
the charger works
when the charging
starts, i.e. when the
mains cable is con-
nected
the temperature
sensors for T12 and

7 Troubleshooting

8:024 High temperature from B1 via the integ-
A30, A31 has reduced the rated test or Truck-
charging current to 0A be- Com. Determine if the
cause of high temperature. temperature signals
are plausible relative
Truck behaviour to the real temperat-
Unaffected ures of the compon-
ents. If not, replace
T12 or replace B1 with
a repair kit.
8:028 Charging time • Battery parameters 1) Check parameters:
The main charging time is 109 and 110 incor- - Check that factory
exceeded by 5-11 hours de- rectly set. parameters are set ac-
pending of battery capacity. • The battery is defect- cording to the truck
ive. configuration.
Truck performance - Check that other
Not influenced. parameters are set
correctly.
8:029 Charged capacity exceeds • Battery parameters 1) Check parameters:
battery capacity 109 and 110 incor- - Check that factory
rectly set. parameters are set ac-
• The battery is defect- cording to the truck
Not influenced. ive.
- Check that other
parameters are set
correctly.
8:030 Parameter 1101 not activ- • Incorrect value for 1) Check parameters:
ated parameter 1101. - Check that factory
Communication with charger parameters are set ac-
A30, A31 exists, but factory cording to the truck
parameter 1101 is not activ- configuration.
ated. - Check that other
parameters are set
Truck behaviour correctly.
Unaffected.
8:031 Saving parameter in A30, • No software compatib- 1) Update the truck soft-
A31 failed ility. ware to the latest ver-
sion.
Truck performance
Not influenced.
8:032 Wrong battery type selec- • Battery parameters 1) Check parameters:
ted via parameters 109 and 109 and 110 incor- - Check that factory
110 rectly set. parameters are set ac-
configuration.
Truck performance - Check that other
Not influenced. parameters are set
correctly.

7 Troubleshooting

8:033 CAN communication prob- • Error on CAN bus wir- 1) Check the CAN bus.
lems between BMS and ing or connections • Check that CAN
BCU (A30, A31). bus is intact in
Truck behaviour terms of wiring
Unaffected. harness, resist-
ance and con-
nectors. Discon-
nect the battery. 7
Check that the
resistance
between
(X41:3) and
(X41:4) is 54 -
66 ohms.
• Check that the
CAN wiring har-
ness is not
pinched. Meas-
ure resistance
between the
chassis and
CAN connector.
Limit value
>24kOhm.
Communication problem at bus is intact in terms
start-up between ICH and of wiring harness, res-
A36/A37. istance and connect-
ors. Disconnect the
Truck behaviour battery. Check that the
Creep speed. Blocked lifting/ resistance between
lowering movement. X41:3 and X41:4 is 54
- 66 ohms; see X41,
page 19 - 3.
istance between the
nector. Limit value
>24kOhm.
Communication problem bus is intact in terms
between ICH and A36/A37. of wiring harness, res-
Creep speed. Blocked lifting/ battery. Check that the
lowering movement. resistance between
X41:3 and X41:4 is 54
- 66 ohms; see X41,
page 19 - 3.

7 Troubleshooting

8:111 CAN communication prob- pinched. Measure res-
lem istance between the
Communication problem chassis and CAN con-
between ICH and A36/A37. nector. Limit value
>24kOhm.
Truck behaviour
Creep speed. Blocked lifting/
lowering movement.
Communication problem bus is intact in terms
between ICH and B90. of wiring harness, res-
resistance between
X41:3 and X41:4 is 54
- 66 ohms; see X41,
page 19 - 3.
istance between the
nector. Limit value
>24kOhm.
8:123 Argument error in option • Argument error option. 1) Check parameters:
Invalid configuration in one - Check that factory
or more options. parameters are set ac-
Creep speed. Blocked lifting/ - Check that other
lowering movement. parameters are set
correctly.
8:126 BMS: unexpected charging • Charging current de- 1) Check the charger:
current tected where this - Check that the char-
Truck behaviour should not be present. ger is not damaged.
Creep speed. Blocked lifting/ - Check that the char-
lowering movement. ger is configured cor-
rectly.
8:127 BMS: The charge level is • The current charge • Check the connection
too low. level is too low. between the charger
and the battery.
8:128 BMS: The charge level is • The current charge
too high. level is too high.
8:129 BMS: Charger cannot be • The truck cannot find 1) Check that the battery
found the charger. is connected to an ap-
Truck behaviour • The truck detects a PI- proved charger.
Creep speed. Blocked lifting/ LOT signal where this 2) Check that the char-
lowering movement. should not be present. ger has the correct
settings.

7 Troubleshooting

8:129 BMS: Charger cannot be 3) Check whether the
found charger wiring har-
Truck behaviour ness is damaged.
Creep speed. Blocked lifting/ 4) Restart the truck.
lowering movement.
8:130 CAN - communication er- • Error on CAN bus wir- 1) Check the CAN bus:
ror ing or connections. - Check that the CAN 7
with lithium-ion battery. bus is intact in terms
of wiring harness, res-
Truck behaviour istance and connect-
Creep speed, blocked lifting ors. Disconnect the
movement. If CAN key con- battery. Check that the
nected - creep speed. resistance between
X41:3 and X41:4 is 54
- 66 ohms; see X41,
page 19 - 3.
istance between the
nector. Limit value
>24kOhm.
8:131 Temperature in the li-ion 1) Let the battery cool
battery is too high down.
Truck performance
movement.
8:132 Current in the li-ion battery • Regenerative braking 1) Check battery voltage:
is too high with fully-charged bat- - Check the voltage
tery. using the built-in test
procedure and com-
Truck behaviour paring with value from
Creep speed, blocked lifting an external volt meter.
movement. - Check connectors,
- Check fuse F8 F51.
- Check the paramet-
ers and software on
the truck/BMS.
8:133 Li-ion battery temperature 1) Move the truck to a
below permitted level warmer area.
Truck performance
movement.

7 Troubleshooting

8:134 Defective hardware in the • Defective sensor in 1) Contact the battery
li-ion battery the module. manufacturer.
Truck performance
movement.
8:135 Internal CAN problem • Communication prob- 1) Contact the battery
CAN communication problem between modules manufacturer.
lem in the lithium-ion battery. in the battery.
Truck performance
movement.
8:136 Battery voltage too high • A module in the bat- 1) Restart the truck.
Voltage load on the truck’s tery has been
battery too high - the truck switched off because
stops. the voltage load is too
high.
Truck behaviour
Motor braking to a complete
stop, then the parking brake
is activated and the main
contactor opens.
8:137 Battery cells deactivated • Some battery func- 1) Let the battery rest
by internal monitoring tions are not working. and then restart the
Overvoltage, undervoltage, battery.
temperature too high or tem-
perature too low.
Truck performance
movement.
8:138 Low battery voltage • Battery discharged. 1) Charge the battery.
Low battery voltage in the • Voltage drop. 2) Check battery voltage:
lithium-ion battery. - Check the voltage
Truck behaviour using the built-in test
Creep speed, blocked lifting procedure and com-
movement. paring with value from
an external volt meter.
- Check connectors,
F51.
8:139 Wrong type of battery • Battery parameter 1) Check parameters:
Incorrect battery type selec- 1045 has incorrect - Check that factory
ted in parameter 1045. setting. parameters are set ac-
Creep speed, blocked lifting - Check that other
movement. parameters are set
correctly.

7 Troubleshooting

8:140 Start-up problem • Internal program error. 1) Create a truck report.
Start-up problem between Send a report to the
truck and lithium-ion battery manufacturer.
during start. 2) Update the truck soft-
Truck performance ware to the latest ver-
Creep speed, blocked lifting sion.
movement.
7
8:141 Communication problem • Internal program error 1) Update the truck soft-
The truck does not have ware.
contact with the battery. 2) Update the battery
Truck behaviour software.
Creep speed, blocked lifting 3) Check the CAN bus:
movement. If CAN key con- - Check that the CAN
nected - creep speed. bus is intact in terms
of wiring harness, res-
ors. Disconnect the
resistance between
X41:3 and X41:4 is 54
- 66 ohms.
istance between the
nector. Limit value
>24kOhm.
4) Check the signal wir-
ing harness for the
battery for any dam-
age.
5) Create a truck report.
6) Send a report to the
manufacturer.
8:200 No charging current • Defective current 1) Update the truck soft-
The charger is connected sensor does not de- ware.
without a charging current tect a charging cur- 2) Update the battery
entering the battery. rent. software.
Truck behaviour • Charger detected but 3) Check that the BMS
Creep speed, blocked lifting no charging current. charging capacity has
movement. not been reset.
4) Check the charger for
damage.
5) Check the wiring har-
ness for damage.
6) Use an external cur-
rent measurement to
determine whether the

7 Troubleshooting

8:200 No charging current desired charging cur-
The charger is connected rent is entering the
without a charging current battery.
entering the battery. 7) Contact a service
Truck behaviour technician.
movement.
8:201 High current lock • - 1) Update the truck soft-
The charger is connected ware.
without a charging current 2) Update the battery
entering the battery. software.
Truck behaviour 3) Contact a service
Creep speed, blocked lifting technician.
movement.
8:202 Low SOC • The battery has been 1) Connect the battery to
Low SOC. discharged well bey- an approved charger.
ond the warning level 2) Check if error code
Truck behaviour for low SOC.
Creep speed, blocked lifting 0xX004 has occurred
movement. and act accordingly.
8:203 Unknown • Defective battery 1) Update BMS.

- 2) Update the battery
Truck behaviour software.
movement.
ESO Emergency stop circuit • Emergency stop activ- 1) Return the emergency
open. ated stop switch to the nor-
Low voltage on T12:83 • Open electrical circuit mal position and re-
start the truck.
Truck behaviour
Everything is stopped imme- 2) Check the circuit of
diately, the parking brake is the emergency stop
activated and the main con- switch.
tactor opens • Check that the
emergency stop
switch is in the
normal position.
• Check fuse
F51.
• Check the wir-
ing and S24 for
a disconnection.

7 Troubleshooting

HOT High temperature. • Intensive use of the 1) Intensive use of the
The power stage in T12 truck truck. Let the truck
shows a high temperature. • Reduced cooling or cool down.
The temperature is above defective temperature 2) Check the cooling:
85°C. The motor temperat- sensor • Check the tran-
ure sensor detects a high sistor regulator,
temperature. The motor tem- motor, steering
perature exceeds +145°C. motor heat sink
7
Truck behaviour and the battery
The motor control reduces charger for dirt
the maximum accelerating and dust. Too
voltage linearly much dust and
dirt causes the
cooling not to
work properly.
• Check the sig-
nals from the T1
temperature
sensor and from
B1 using the
built-in test fea-
ture or Truck-
Com.
• Determine if the
temperature
signals are
plausible relat-
ive to the real
temperatures of
the compon-
ents. If not, re-
place T12 or re-
place B1 with a
repair kit.
LiFt Limited travel speed • Forks fully lowered Raise the forks in order to
drive at maximum speed.
Truck behaviour
Limited travel speed
Plug Built-in charger • The plug of the char- Place the plug in the sensor
The plug of the charger is ger is not placed in the bracket.
not placed in the sensor sensor bracket when
bracket when charging is fin- charging is finished
ished.
Truck behaviour
Truck will not start.
Only available in certain
markets.
S-0h Time for service • Time for service 1) After service is com-
plete, enter a new or
the same value in
Truck behaviour parameter 101
Not influenced

7 Troubleshooting

SLO Reduced travel speed • Travel speed reduced
because of activated
Click-2-Creep, turtle or
Truck behaviour emergency drive
Reduced speed and acceler- mode.
ation
StOP Forks or support arms in- • The forks cannot be
terlocks. lifted above 1.8
meters if the support
arms are raised
Truck performance
Blocked lifting movement • The support arms can-
not be raised if the
forks are ≥ 1.8 meters
turn Forks or support arms in- • The forks cannot be Turn the steering arm back
terlocks. lowered to lower the forks.
Truck behaviour
The forks cannot be lowered

Chassis C0000 8
8.1 Inspect hood mounts ....................................................................................................................... 8 - 1
8.2 Frame, chassis C0300..................................................................................................................... 8 - 1
8.2.1 Checking the chassis .......................................................................................................... 8 - 1
8.2.2 Inspection covers C0340 .................................................................................................... 8 - 1
8.2.2.1 Motor compartment covers ................................................................................... 8 - 1
8.2.3 Support arms, stabilizers C0350......................................................................................... 8 - 5
8.2.3.1 Inspection of push rods ......................................................................................... 8 - 5
8.2.3.2 Inspection of bushings and links ........................................................................... 8 - 5
8.2.4 Fork structure (low-lifter) C0380 ......................................................................................... 8 - 5
8.2.4.1 Inspect fork carriage.............................................................................................. 8 - 5
8.2.4.2 Checking the lifting and lowering function............................................................. 8 - 5
8.3 Safety equipment C0800 ................................................................................................................. 8 - 6
8.3.1 Signs, warnings, labels C0850............................................................................................ 8 - 6
8.3.1.1 Inspect signs and labels........................................................................................ 8 - 6
8.3.1.2 Placement of plates and symbols ......................................................................... 8 - 6

8 Chassis C0000

8 Chassis C0000
Inspect hood mounts
Software: 7662518
8 Chassis C0000
8
Chassis C0000
8.1 Inspect hood mounts

8.1
Inspect hood mounts
1. Make sure that the hood mounts are not broken.
8.2 Frame, chassis C0300

8.2
Frame, chassis C0300
8
8.2.1 Checking the chassis
8.2.1
Checking the chassis
1. Make sure that the chassis has no cracks or any other damage. Contact the truck manufacturer if you
find any cracks or other damage.
8.2.2 Inspection covers C0340

8.2.2
Inspection covers C0340
8.2.2.1 Motor compartment covers

8.2.2.1
Motor compartment covers
8.2.2.1.1 Motor compartment covers Overview

8.2.2.1.1
Motor compartment covers Overview
Pos. Designation
a Top cover
b Front cover
c Motor cover

8 Chassis C0000
8.2.2.1.2 Replacing the top cover

8.2.2.1.2
Replacing the top cover
8.2.2.1.2.1 Removing the top cover

8.2.2.1.2.1
Removing the top cover
1. Undo and remove the four screws holding the top cover
to the motor cover.
2. Remove the top cover.
8.2.2.1.2.2 Installing the top cover

8.2.2.1.2.2
Installing the top cover
1. Fit the top cover and secure using the four screws.
8.2.2.1.3 Replacing the motor cover

8.2.2.1.3
Replacing the motor cover
8.2.2.1.3.1 Removing the motor cover

8.2.2.1.3.1
Removing the motor cover
Preparations
Removing the top cover, page 8 - 2

8 Chassis C0000
1. Detach the motor cover from the chassis.
8.2.2.1.3.2 Installing the motor cover

8.2.2.1.3.2
Installing the motor cover
1. Snap in the motor cover to the chassis.
8.2.2.1.4 Replacing the chassis front plate

8.2.2.1.4
Replacing the chassis front plate
8.2.2.1.4.1 Removing front plates

8.2.2.1.4.1
Removing front plates
Preparations
Removing the motor cover, page 8 - 2

8 Chassis C0000
1. Undo and remove the 4 screws securing the front plates

to the chassis. Then remove the front plates.
8.2.2.1.4.2 Installing front plates

8.2.2.1.4.2
Installing front plates
1. Fit the front plates and secure it to the chassis using the
four screws.
8.2.2.1.5 Replacing the cylinder cover

8.2.2.1.5
Replacing the cylinder cover
8.2.2.1.5.1 Removing the cylinder cover

8.2.2.1.5.1
Removing the cylinder cover
Preparations
Removing front plates, page 8 - 3

8 Chassis C0000
1. Loosen and remove the 2 screws (a).

a b
2. Remove the two pieces of the cylinder cover, (b) and (c).
c
8.2.2.1.5.2 Installing the cylinder cover

8.2.2.1.5.2
Installing the cylinder cover
1. Fit the two parts of the cylinder cover (b) and (c) in the
a b truck.
c 2. Secure the parts using the two screws (a).
8.2.3 Support arms, stabilizers C0350

8.2.3
Support arms, stabilizers C0350
8.2.3.1 Inspection of push rods

8.2.3.1
Inspection of push rods
1. Make sure there are no cracks or other damage on the push rods.
8.2.3.2 Inspection of bushings and links

8.2.3.2
Inspection of bushings and links
1. Make sure there is no play in bushings and links.
8.2.4 Fork structure (low-lifter) C0380

8.2.4
Fork structure (low-lifter) C0380
8.2.4.1 Inspect fork carriage

8.2.4.1
Inspect fork carriage
1. Make sure the fork carriage has no cracks or any other damage.
8.2.4.2 Checking the lifting and lowering function

8.2.4.2
Checking the lifting and lowering function
1. Check the lifting and lower function by lifting and lowering the forks.

8 Chassis C0000
Safety equipment C0800
8.3 Safety equipment C0800

8.3
8.3.1 Signs, warnings, labels C0850

8.3.1
Signs, warnings, labels C0850
8.3.1.1 Inspect signs and labels

8.3.1.1
Inspect signs and labels
1. Inspect all signs and adhesive labels to ensure they are intact. Replace any sign or label that is dam-
aged or cannot be read.
8.3.1.2 Placement of plates and symbols

8.3.1.2
Placement of plates and symbols
WARNING Illegible warning and information signs

The warning and information signs on the truck contain important information about the truck and
for personal safety. If a warning and information sign is missing there is a risk of danger. The signs
must always be legible.
► Replace broken or missing warning and information signs
The picture shows the location and meaning of the plates attached to the truck.
i j k
M-PLATE Qmax XXXX kg a
a a
b b
c c
d
d e
l
e
f
g
h
i
j
k
l
h b
g
c
f
d
j e
a) Identification plate
b) Radio transmitter
c) Adapted for cold store environments (option)
d) Do not step here
e) Gearbox oil filler; only oil adapted for the food industry (option)
f) Hydraulic oil filler; only oil adapted for the food industry (option)

8 Chassis C0000
g) Hydraulic oil filler

h) Hydraulic oil filler; only oil adapted for cold storage environments (option)
i) Modification plate, (applicable only for customer or application adapted trucks)
j) SMART plate - indicates that the truck can be connected to Toyota I_Site
k) Maximum capacity
l) Lifting points

8 Chassis C0000

Motors C1000 9
9.1 Electric motors C1700 ..................................................................................................................... 9 - 1
9.1.1 Electric drive motor C1760.................................................................................................. 9 - 1
9.1.1.1 Overview ............................................................................................................... 9 - 1
9.1.1.2 Cleaning the drive motor ....................................................................................... 9 - 2
9.1.1.3 Checking the drive motor ...................................................................................... 9 - 2
9.1.1.4 Checking the drive motor ...................................................................................... 9 - 2
9.1.1.5 Listen for any abnormal noise in the drive motor bearings and in the drive gear..... 9 -
2
9.1.1.6 Control tightening of drive motor mountings ......................................................... 9 - 2
9.1.1.7 Check for leaks in the drive motor......................................................................... 9 - 2
9.1.1.8 Replacing the drive motor ..................................................................................... 9 - 2
9.1.1.9 Replacing the temperature sensor ........................................................................ 9 - 3
9.1.1.10 Replacing the rotational speed sensor.................................................................. 9 - 4
9.1.1.11 Replacing the bearing ........................................................................................... 9 - 4
9.1.1.12 Replacing the toothed wheel................................................................................. 9 - 7
9.1.1.13 Drive motor tightening torques ............................................................................ 9 - 10
9.1.1.14 Drive motor tightening torques ............................................................................ 9 - 10

9 Motors C1000

9 Motors C1000
Electric motors C1700
Software: 7662518
9 Motors C1000
9
Motors C1000
9.1 Electric motors C1700

9.1
9.1.1 Electric drive motor C1760

9.1.1
Electric drive motor C1760
9.1.1.1 Overview
9.1.1.1
Overview
Pos. Designation
a Speed sensor
b Cover
c Motor
d Lift cylinder
e Temperature sensor

9 Motors C1000
9.1.1.2 Cleaning the drive motor

9.1.1.2
Cleaning the drive motor
1. Keep the motor as clean as possible since this is a decisive factor for correct operation. Regularly in-
spect the motor and motor compartment for build-up of dust, oil and other contaminants.
Dirty and/or greasy components should be cleaned with a rag moistened with solvent. Use a rag of
lint-free cloth material. Do not use too much solvent as it could penetrate into the motor parts.
After cleaning, dry the components thoroughly. The easiest way is by heating.
NOTE! Windings and insulation must not be heated over 125°C and for no longer than 6 hours.
9.1.1.3 Checking the drive motor

9.1.1.3
Checking the drive motor
1. Check the drive motor for signs of damage.

If there is visible damage: --- MISSING LINK ---.
9.1.1.4 Checking the drive motor

9.1.1.4
Checking the drive motor
1. Check the drive motor for signs of damage.

If there is visible damage: --- MISSING LINK ---.
9.1.1.5 Listen for any abnormal noise in the drive motor bearings and in the drive gear
9.1.1.5
Listen for any abnormal noise in the drive motor bearings and in the drive gear
1. Listen for any abnormal noise in the drive motor bearings.
2. Listen for abnormal noise in the drive gear bearing.
9.1.1.6 Control tightening of drive motor mountings

9.1.1.6
Control tightening of drive motor mountings
1. Control tighten the screws to the drive motor, torque the screws in two stages crosswise, tightening
torque 10±1.5 N·m.
9.1.1.7 Check for leaks in the drive motor

9.1.1.7
Check for leaks in the drive motor
1. Place a piece of cardboard under the drive unit and use a cloth to check for leaks.
9.1.1.8 Replacing the drive motor

9.1.1.8
Replacing the drive motor
9.1.1.8.1 Removing the drive motor

9.1.1.8.1
Removing the drive motor
1. Remove the covers.
2. Lift the drive unit using a jack and secure the truck with trestles placed under the drive unit so that the
drive wheel is freely suspended.
3. Cut off the cable ties of the cable duct on the transistor regulator side and disconnect cable connec-
tions X5 and X65.
4. Unscrew the retaining screws of the operating console and remove the operating console and the
tiller arm.
5. Unscrew the retaining screws of the brake and disconnect cable connection Q1.

9 Motors C1000
6. Remove the brake.
7. Remove the rotational speed sensor. Removing a RPM sensor, page 9 - 4.
8. Loosen cable connection B1.
9. Disconnect the motor cables and unscrew the motor retaining screws.
10. Lift out the motor from the truck.

Note! Cover the drive gear to prevent loose items from falling into the drive gear after the drive
motor has been removed. 9
9.1.1.8.2 Installing the drive motor

9.1.1.8.2
Installing the drive motor
1. Lift the motor into the truck.
2. Mount the motor cables and screw the motor in position.
3. Mount cable connection B1.
4. Mount the RPM sensor connector B11.
5. Mount the brake.
6. Mount the brake retaining screws and connect Q1.
7. Mount the operating console and tiller arm using the retaining screws.
8. Attach cable connectors X5 and X65.
9. Lift up the truck and remove the block.
10. Install the covers.
9.1.1.9 Replacing the temperature sensor

9.1.1.9
Replacing the temperature sensor
9.1.1.9.1 Installing the temperature sensor

9.1.1.9.1
Installing the temperature sensor
1. Cut off the cable of the broken temperature sensor, and splice on the cable of the new one.
2. Position the new temperature sensor on the motor.
3. Carefully clean the area and make sure all surfaces are dry.
4. Apply plastic steel by pushing out a string that is half the length of the curing agent compared to the
putty, then carefully mix the two (be careful not to mix a larger amount than will be used in 5 minutes).
5. Apply a layer of plastic steel, at least 4 mm thick, and make sure the repaired surface has an overlap
of at least 2 cm.
6. Secure the steel plastic with masking tape and allow it to cure.
7. Remove the masking tape.

The temperature sensor should now be completely covered by plastic steel.

9 Motors C1000
8. Following curing it is recommended to apply another layer of plastic steel.
9.1.1.10 Replacing the rotational speed sensor

9.1.1.10
Replacing the rotational speed sensor
9.1.1.10.1 Removing a RPM sensor

9.1.1.10.1
Removing a RPM sensor
Preparations
1. Undo the screw and pull the RPM sensor straight out.
Disconnect connector B11.
9.1.1.10.2 Installing a RPM sensor

9.1.1.10.2
Installing a RPM sensor
1. Fit the speed sensor. Connect contact B11.
2. Tighten the screw.

Reinstall the cover.
9.1.1.11 Replacing the bearing

9.1.1.11
Replacing the bearing
9.1.1.11.1 Removing the motor bearings

9.1.1.11.1
Removing the motor bearings
Preparations
Removing a toothed wheel, page 9 - 7
1. Remove the circlip from above.

9 Motors C1000
9
2. Carefully knock out the stator.
3. Remove the circlip inside the motor.
4. Knock out the bearing.
9.1.1.11.2 Removing the motor bearings

9.1.1.11.2
Removing the motor bearings
Preparations
Removing a toothed wheel, page 9 - 7

9 Motors C1000
1. Remove the circlip from above.
2. Carefully knock out the stator.
3. Remove the circlip inside the motor.
4. Knock out the bearing.

9 Motors C1000
9.1.1.11.3 Installing motor bearings

9.1.1.11.3
Installing motor bearings
1. Install the bearing.
2. Install the circlip inside the motor.
3. Carefully install the stator.
4. Install the circlip from above.

Resetting
Installing a toothed wheel, page 9 - 9
9.1.1.12 Replacing the toothed wheel

9.1.1.12
Replacing the toothed wheel
9.1.1.12.1 Removing a toothed wheel

9.1.1.12.1
Removing a toothed wheel
Preparations
Removing the drive motor, page 9 - 2

9 Motors C1000
1. Remove the circlip.
2. Remove the brake hub.
3. Remove the wedge.
4. Remove the toothed wheel.

9 Motors C1000
9.1.1.12.2 Installing a toothed wheel

9.1.1.12.2
Installing a toothed wheel
1. Install the toothed wheel.
2. Install the wedge.
3. Install the brake hub.
4. Install the circlip
Resetting
Installing the drive motor, page 9 - 3

9 Motors C1000
9.1.1.13 Drive motor tightening torques

9.1.1.13
Drive motor tightening torques
The drive motor tightening torques are depicted in the figure below:
9.1.1.14 Drive motor tightening torques

9.1.1.14
Drive motor tightening torques
The drive motor tightening torques are depicted in the figure below:
Note! Safety critical when torque tightening wiring harness to 4.5 Nm – risk of overheating. Ensure good
electrical contact by keeping contact surfaces clean and free of damage.

Transmission/Drive gear C2000 10
10.1 Drive unit, final gear C2500 ........................................................................................................... 10 - 1
10.1.1 Drive unit/gear C2550 ...................................................................................................... 10 - 1
10.1.1.1 Overview ............................................................................................................. 10 - 1
10.1.1.2 Inspect drive gear................................................................................................ 10 - 1
10.1.1.3 Drive gear oil change ......................................................................................... 10 - 2
10.1.1.4 Replacing the drive gear .................................................................................... 10 - 2
10.1.1.5 Replacing the wheel hub seal ............................................................................ 10 - 3
10.1.1.6 Stud replacement ............................................................................................... 10 - 5
10.1.1.7 Fit grease nipples, steering bearing .................................................................... 10 - 6
10.1.1.8 Lubricate steering bearings (Option)................................................................... 10 - 7

10 Transmission/Drive gear C2000

Drive unit, final gear C2500
Software: 7662518
10
Transmission/Drive gear C2000
10.1 Drive unit, final gear C2500

10.1
10.1.1 Drive unit/gear C2550

10.1.1
Drive unit/gear C2550
10.1.1.1 Overview
10.1.1.1
Overview
Pos. Designation
a Ratio 29.85
b Oil quantity 0.8 litres
c Drive wheel Ø 230 10
Pos. Designation
a Transmission housing
b Motor bearing and packing box
c Steering bearings
d Seal and cover ring
e Pin bolt M12x1,5
10.1.1.2 Inspect drive gear

10.1.1.2
Inspect drive gear
1. Make sure there is no play in the drive gear steering bearing.

10.1.1.3 Drive gear oil change

10.1.1.3
Drive gear oil change
10.1.1.3.1 Empty the drive gear oil

10.1.1.3.1
Empty the drive gear oil
1. Undo and remove the oil plug on the lower part of the
gear housing.
2. Drain all old oil into a suitable receptacle.
3. Clean the oil plug of any dirt and shavings. Reinstall the
oil plug.
10.1.1.4 Replacing the drive gear

10.1.1.4
Replacing the drive gear
10.1.1.4.1 Removing the drive gear

10.1.1.4.1
Removing the drive gear
1. Raise the support arms and place blocks under the drive unit at approx. 190 mm.

2. Loosen the drive wheel.
3. Remove the covers.
tions X5 and X65.
5. Unscrew the retaining screws of the operating console and remove the operating console and the
tiller arm.
6. Disassemble the speed sensor and disconnect the cable connections Q1 and B1.
7. Disconnect the motor cables and unscrew the motor re- 10

taining screws.
8. Lift out the motor from the truck.
9. Insert a plug in the hole in the gear housing to prevent oil

leakage when the gear is removed from the truck.
10. Unscrew the retaining screws of the gear box.
11. Lay down the gear and move it out under the forks.
10.1.1.4.2 Installing the drive gear

10.1.1.4.2
Installing the drive gear
1. Move the gear into position.
2. Install the gear retaining screws.
3. Lift the motor into the truck.
4. Connect the motor cables and the motor retaining screws.
5. Connect the speed sensor and the cable connections Q1 and B1.
6. Install the operating console retaining screws and install operating console and tiller arm.
7. Install cable duct cable ties on the transistor regulator side and connect cable connections X5 and
X65.
8. Install the covers.
9. Fit the drive wheel.
10.1.1.5 Replacing the wheel hub seal

10.1.1.5
Replacing the wheel hub seal
10.1.1.5.1 Removing the wheel hub seal

10.1.1.5.1
Removing the wheel hub seal
Disassembling the drive wheel, page 11 - 7

1. Remove the cover ring using a screwdriver or similar to

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

move the seal.

10
10.1.1.5.2 Installing the wheel hub seal

10.1.1.5.2
Installing the wheel hub seal
1. Fit the seal. Tap lightly to get it into the right position.
2. Fit the cover ring. Tap it lightly into place.
Installing a drive wheel, page 11 - 7
10.1.1.6 Stud replacement

10.1.1.6
Stud replacement
10.1.1.6.1 Removing a stud

10.1.1.6.1
Removing a stud
Disassembling the drive wheel, page 11 - 7

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

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

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

10.1.1.6.2
Installing a stud
1. Apply Loctite 270 to the stud threads.

Loctite XXX
2. Use the stud tool to fit the new stud and tighten to 35
N·m.
Installing a drive wheel, page 11 - 7
10.1.1.7 Fit grease nipples, steering bearing

10.1.1.7
Fit grease nipples, steering bearing
1. Clean the surface, remove all dirt from the recess for the
grease nipples.

10
2. Unscrew the stop screws.
3. Screw in the grease nipples using an extension piece, 2

each.
10.1.1.8 Lubricate steering bearings (Option)

10.1.1.8
Lubricate steering bearings (Option)

1. Turn the steering wheel to the end position.
2. Press in a little grease, but not so much that the seal

lifts. Check the sealing at the grease nipple position.
3. Steer approximately 15 degrees and apply a little

grease. Continue to the other end position.
4. Do the same with the other grease nipple to lubricate the

entire bearing.

Brake/wheel/track system C3000 11
11.1 Travel brake system C3100........................................................................................................... 11 - 1
11.1.1 Description ........................................................................................................................ 11 - 1
11.1.1.1 Brake types ......................................................................................................... 11 - 1
11.1.2 Electrically controlled service brake C3180 ...................................................................... 11 - 2
11.1.2.1 Overview ............................................................................................................. 11 - 2
11.1.3 Checking the function of the travel brake.......................................................................... 11 - 2
11.1.4 Checking the parking brake, service brake and switch for safety reversing ..................... 11 - 3
11.2 Parking brake details C3300.......................................................................................................... 11 - 3
11.2.1 Electrical parking brake, magnet brake C3370 ................................................................. 11 - 3
11.2.1.1 Cleaning the parking brake ................................................................................. 11 - 3
11.2.1.2 Adjusting the parking brake gap.......................................................................... 11 - 3
11.2.1.3 Emergency release of the parking brake ............................................................ 11 - 4
11.2.1.4 Replacing the parking brake ............................................................................... 11 - 4
11.3 Wheels C3500 ............................................................................................................................... 11 - 6
11.3.1 Drive wheel C3530............................................................................................................ 11 - 6
11.3.1.1 Check-tightening the drive wheel attachment ..................................................... 11 - 6
11.3.1.2 Inspect drive wheel ............................................................................................. 11 - 6
11.3.1.3 Replacing the drive wheel ................................................................................... 11 - 7
11.3.2 Support arm wheels/castor wheels C3540 ....................................................................... 11 - 8
11.3.2.1 Overview ............................................................................................................. 11 - 8
11.3.2.2 Overview, Wheel cradle in chassis ..................................................................... 11 - 8
11.3.2.3 Castor wheel suspension C-brix, 50 Ah system.................................................. 11 - 9
11.3.2.4 Castor suspension E-brix, 105/150 Ah system ................................................... 11 - 9
11.3.2.5 Inspect castor wheels........................................................................................ 11 - 10
11.3.2.6 Checking the castor wheels .............................................................................. 11 - 10
11.3.2.7 Replacing the castor wheel ............................................................................... 11 - 10
11.3.3 Fork wheels/support arm wheels C3550......................................................................... 11 - 11
11.3.3.1 Overview ........................................................................................................... 11 - 11
11.3.3.2 Overview ........................................................................................................... 11 - 12
11.3.3.3 Overview 2 ........................................................................................................ 11 - 13
11.3.3.4 Cleaning the fork wheels................................................................................... 11 - 13

11 Brake/wheel/track system C3000
11.3.3.5 Inspect fork wheels ........................................................................................... 11 - 14
11.3.4 Side guide wheels C3580 ............................................................................................... 11 - 14
11.3.4.1 Overview ........................................................................................................... 11 - 14

Travel brake system C3100
Software: 7662518
11
Brake/wheel/track system C3000
11.1 Travel brake system C3100

11.1
11.1.1 Description
11.1.1
Description
11.1.1.1 Brake types

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

- Service brake
- Emergency brake.
- Parking brake
11
11.1.1.1.1 Travel brake
11.1.1.1.1
Travel brake
The travel brake is designed as a system:

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

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

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

11.1.2 Electrically controlled service brake C3180

11.1.2
Electrically controlled service brake C3180
11.1.2.1 Overview
11.1.2.1
Overview
Pos. Designation
a Dust seal
b O-ring
c Dust seal
d Wiring harness
e Magnet housing
f Dust seal
g Friction disc
h Hub
i Pressure disc
j Mounting plate
11.1.3 Checking the function of the travel brake

11.1.3
Checking the function of the travel brake
1. Check the function by releasing the speed control to the centre position while driving or moving the
speed control to the opposite travel direction..

Parking brake details C3300
11.1.4 Checking the parking brake, service brake and switch for safety reversing
11.1.4
Checking the parking brake, service brake and switch for safety reversing
B1
11
B2
1. Check the parking brake and service brake by pressing

the tiller arm up and pulling it down.
In position B1 and B2, the truck should brake.
2. Check that the switch for safety reversing operates prop-

erly when activated.
11.2 Parking brake details C3300

11.2
11.2.1 Electrical parking brake, magnet brake C3370

11.2.1
Electrical parking brake, magnet brake C3370
11.2.1.1 Cleaning the parking brake

11.2.1.1
Cleaning the parking brake
1. Place the parking brake on a workbench with the magnet

housing facing downwards.
2. Clean the brake using compressed air. Clean from the

inside outwards.
3. If there are particles that cannot be cleared away with

compressed air, these may be carefully scraped away.
11.2.1.2 Adjusting the parking brake gap

11.2.1.2
Adjusting the parking brake gap
Removing the parking brake, page 11 - 4

Cleaning the parking brake, page 11 - 3
1. Measure the air gap between the magnet housing of the brake unit and the movable pressure disc.
Measurement must be done around the entire pressure disc, both on the inside and the outside.

2. Make sure that the brake air gap is =0.2-0.7mm.

If the air gap cannot be maintained, see Replacing the parking brake, page 11 - 4.
Resetting
Fitting the parking brake, page 11 - 5
11.2.1.3 Emergency release of the parking brake

11.2.1.3
Emergency release of the parking brake
1. Note:An emergency release of the brakes should

only be performed when the truck needs to be
moved for service and repairs.
The brakes on the truck can be manually released by
screwing two screws (M5) into the holes (A). The screws
should be 30-35 mm long.
Note:Remember to remove the screws before oper-
ating the truck again.
11.2.1.4 Replacing the parking brake

11.2.1.4
Replacing the parking brake
11.2.1.4.1 Removing the parking brake

11.2.1.4.1
Removing the parking brake
WARNING Working with the parking brake

Risk of brake function being lost.
When work is done in the brake system, there is a risk of brake function being partly or com-
pletely lost.
Only the actions described in this section may be carried out on the parking brake.
Preparations
1. Remove the steering yoke together with the tiller arm.

Note the position of the conduit entry so that reinstalla-
tion is done correctly.
See:Removing the tiller arm, page 12 - 11.

2. Remove the brake and the cable connector Q1.
11
3. Remove the brake unit from the truck. Note the position
of the brake so that refitting is done correctly.
11.2.1.4.2 Fitting the parking brake

11.2.1.4.2
Fitting the parking brake
1. Torque tighten the brake retaining screws to 5N·m.
2. Fit the connector Q1.

Wheels C3500
3. Install the dust caps.
4. Reinstall the tiller arm and steering yoke and torque

tighten their retaining screws to 23N·m.
See:Fitting tiller arm,Fitting the steering yoke..
Fit the wire grommet on the brake, position according to
instructions. Make sure that it is properly attached.
5. Close the motor compartment.
6. Start the truck and check that the brake works correctly.
11.3 Wheels C3500

11.3
Wheels C3500
11.3.1 Drive wheel C3530

11.3.1
Drive wheel C3530
11.3.1.1 Check-tightening the drive wheel attachment

11.3.1.1
Check-tightening the drive wheel attachment
1. Check-tighten the drive wheel attachment. For diameter D = 230, the tightening torque should be 78
Nm.
11.3.1.2 Inspect drive wheel

11.3.1.2
Inspect drive wheel
1. Inspect the drive wheel for wear.
2. For a wheel with a diameter of D = 230, the tread must be ≥ 15 mm. If the drive wheel is worn: Repla-
cing the drive wheel, page 11 - 7.

Wheels C3500
11.3.1.3 Replacing the drive wheel

11.3.1.3
Replacing the drive wheel
11.3.1.3.1 Disassembling the drive wheel

11.3.1.3.1
Disassembling the drive wheel
1. Raise the forks and support the truck in a heightened po-

sition (approx. 100 mm).
2. Disassemble the drive wheel (A).

It is easiest to remove the drive wheel between the forks.
Angle the wheel to the side in order to work more easily
under the truck.
11
11.3.1.3.2 Installing a drive wheel

11.3.1.3.2
Installing a drive wheel
1. Install the new wheel (A) and tighten the nuts (B) with
torque 81±19 N·m.

Wheels C3500
11.3.2 Support arm wheels/castor wheels C3540

11.3.2
Support arm wheels/castor wheels C3540
11.3.2.1 Overview
A
11.3.2.1
Overview
a
b
d
e
Pos. Designation
a Screw
b Washer
c Wheel bracket
d Axel (kit)
e Castor wheels
11.3.2.2 Overview, Wheel cradle in chassis

11.3.2.2
Overview, Wheel cradle in chassis
a
b
Pos. Designation
a Screw
b Bracket

Wheels C3500
11.3.2.3 Castor wheel suspension C-brix, 50 Ah system

11.3.2.3
Castor wheel suspension C-brix, 50 Ah system
a
c
b
d
e
f
g
h
i j
k 11
Pos. Designation Pos. Designation

a Bracket b Shaft
c Spring pin d Steering
e Spring f Shaft
g Bracket h Nut, torque 3 Nm
i Block j Washer
k Nut, torque 10 Nm.
11.3.2.4 Castor suspension E-brix, 105/150 Ah system

11.3.2.4
Castor suspension E-brix, 105/150 Ah system
bb c
d
e
f
g
h
i
j
Pos. Designation
a Bracket
b Shaft
c Spring pin
d Steering
e Spring
f Shaft
g Bracket
h Nut, torque 3 Nm
i Washer
j Nut, torque 10 Nm

Wheels C3500
11.3.2.5 Inspect castor wheels

11.3.2.5
Inspect castor wheels
1. Check the castor wheels for wear. Measure the castor wheel tread. The tread should be ≥ 10 mm.
Replace castor wheels if required. Replacing the castor wheel, page 11 - 10.
11.3.2.6 Checking the castor wheels

11.3.2.6
Checking the castor wheels
1. Check that the castor wheel is properly attached and

that it rotates and pivots freely. In case of faults, replace
the castor wheel; see Replacing the castor wheel, page
11 - 10.
11.3.2.7 Replacing the castor wheel

11.3.2.7
Replacing the castor wheel
11.3.2.7.1 Disassembling the castor wheel cradle

11.3.2.7.1
Disassembling the castor wheel cradle
1. Raise the forks.
2. Remove the inspection cover.
3. Loosen the spring fasteners.
4. Loosen the bracket for the castor wheel mounting.
5. Lift the drive unit so that the cradle is free.
11.3.2.7.2 Installing castor wheel cradle

11.3.2.7.2
Installing castor wheel cradle
1. Lower the drive unit.
2. Install the castor wheel mounting bracket.
3. Install the spring fasteners.
4. Reinstall the cover.
5. Lower the forks.

Wheels C3500
11.3.3 Fork wheels/support arm wheels C3550

11.3.3
Fork wheels/support arm wheels C3550
11.3.3.1 Overview
11.3.3.1
Overview
11
Pos. Designation
a Screw
b Bracket
c Bogie wheel
d Single wheel
e Shaft
f Circlip
g Nut
h Screw
i Bracket

Wheels C3500
11.3.3.2 Overview
11.3.3.2
Overview
d
h
b
i
g
d
Pos. Designation
a Boogie wheels
b Link
c Screw
d Single wheel
e Shaft
f Circlip
g Nut
h Screw
i Bracket

Wheels C3500
11.3.3.3 Overview 2
11.3.3.3
Overview 2
b
a
11
a b
c b
Pos. Designation
a Shaft
b Pin
c Shaft
11.3.3.4 Cleaning the fork wheels

11.3.3.4
Cleaning the fork wheels
1. Clean the fork wheels from strings and other dirt.

Wheels C3500
11.3.3.5 Inspect fork wheels

11.3.3.5
Inspect fork wheels
1. Inspect the fork wheels for wear.

Replace fork wheels if required.
11.3.4 Side guide wheels C3580

11.3.4
Side guide wheels C3580
11.3.4.1 Overview
11.3.4.1
Overview

a Screw, K6S 8x12 b Screw, MF6S 8x35
c Sleeve d Climber wheels
e Slide pad f Lock nut, M8
g Wheel, assy h Wheel bracket
i Shaft j Wheels
k Spring pin

Steering system C4000 12
12.1 Mechanical steering system C4100............................................................................................... 12 - 1
12.1.1 Steering arm/wheel/lever C4110....................................................................................... 12 - 1
12.1.1.1 Operating panel................................................................................................... 12 - 1
12.1.1.2 Tiller arm handle ................................................................................................. 12 - 7
12.1.1.3 Tiller arm ........................................................................................................... 12 - 10
12.1.1.4 Checking steering and tiller arm........................................................................ 12 - 15

12 Steering system C4000

Mechanical steering system C4100
Software: 7662518
12
Steering system C4000
12.1 Mechanical steering system C4100

12.1
12.1.1 Steering arm/wheel/lever C4110

12.1.1
Steering arm/wheel/lever C4110
12.1.1.1 Operating panel

12.1.1.1
Operating panel
12.1.1.1.1 Controls
12.1.1.1.1
Controls
12.1.1.1.1.1 Replacing the safety reversing switch

12.1.1.1.1.1
Replacing the safety reversing switch
12.1.1.1.1.1.1 Removing the safety reversing switch

12.1.1.1.1.1.1
Removing the safety reversing switch
Preparations
1. Undo and remove the screws holding the cover/switch 12

for safety reversing over the logic card and carefully lift
away the cover.
Keep a finger between the cover and the shaft for the
speed control buttons to prevent the speed control as-
sembly from falling down.
The switch for safety reversing must not be replaced by
itself; the complete cover and button must be replaced
as a unit.
12.1.1.1.1.1.2 Fitting the safety reversing switch

12.1.1.1.1.1.2
Fitting the safety reversing switch
1. Install the cover/switch for safety reversing over the logic

card.
Fasten the screws.
Resetting
12.1.1.1.1.2 Replacing the sensilift

12.1.1.1.1.2
Replacing the sensilift
12.1.1.1.1.2.1 Removing the sensilift

12.1.1.1.1.2.1
Removing the sensilift
Preparations
Removing the safety reversing switch, page 12 - 1

1. Remove the button, use a screwdriver to carefully prise it

loose
2. Pull it straight up
12.1.1.1.1.2.2 Installing sensilift

12.1.1.1.1.2.2
Installing sensilift
1. Fit the button, compress the spring when installing it

2. Make sure the button is properly installed
12
Resetting
Fitting the safety reversing switch, page 12 - 1
12.1.1.1.1.3 Changing the position of the controls - support arm lift/fork lift
12.1.1.1.1.3
Changing the position of the controls - support arm lift/fork lift
1. Pry off the lift control buttons using a thin screwdriver

and switch the positions with the rear buttons.
2. Make sure that the lugs hook on when the new buttons
are fitted in place.
3. See parameter Optional function 5 for more information.
4. Start the truck and make sure the change is correct.
12.1.1.1.1.4 Replacing the keypad

12.1.1.1.1.4
Replacing the keypad
12.1.1.1.1.4.1 Removing the keypad

12.1.1.1.1.4.1
Removing the keypad
1. Remove the keypad and disconnect it from the logic

card.

12.1.1.1.1.4.2 Installing a keypad

12.1.1.1.1.4.2
Installing a keypad
1. Connect the keypad and screw it in position.
12.1.1.1.2 Replacing the logic card

12.1.1.1.2
Replacing the logic card
12.1.1.1.2.1 Removing the logic card

12.1.1.1.2.1
Removing the logic card
WARNING Static electricity

Risk of static discharge that can damage the electronics.
► Make sure you take the necessary steps to prevent static electricity, ESD protection, be-
fore starting work on the steering module.
Preparations
1. Remove the screws holding the cover for the logic card
and carefully lift away the cover.
Keep a finger between the cover and the shaft for the
speed control buttons to prevent the speed control as-
sembly from falling down.

12
2. Pull out the logic card, and pull off the connectors.
12.1.1.1.2.2 Installing a logic card

12.1.1.1.2.2
Installing a logic card
1. Install the new logic card and connect it.
2. Check the cable connection to the logic card and that the
connectors are correctly connected.

3. Fit the cover, and make sure the conduit grommet is in-
tact and correctly positioned.

Resetting
12.1.1.2 Tiller arm handle

12.1.1.2
Tiller arm handle
12.1.1.2.1 Overview, tiller arm handle

12.1.1.2.1
Overview, tiller arm handle
12

a Cover b Plug
c Wiring harness d Cover
e Toggle switch f “Horn” button


g “Lifting/lowering” push button h Display
i “Horn” button j “Horn” switch
k Display l Electronic card “A5”
m Safety switch n Speed control
12.1.1.2.2 Replacing the handle to the tiller arm

12.1.1.2.2
Replacing the handle to the tiller arm
12.1.1.2.2.1 Removing the tiller arm handle

12.1.1.2.2.1
Removing the tiller arm handle
Removing the tiller arm cover, page 12 - 12.
1. Remove the cable bracket/handle in the tiller arm.

12.1.1.2.2.2 Fitting the handle to the tiller arm

12.1.1.2.2.2
Fitting the handle to the tiller arm
1. Fit the handle/cable bracket with 12N·m.

Note: Mount the wiring harness so that it does not
get pinched.
12
Resetting
Installing the tiller arm cover, page 12 - 13

12.1.1.3 Tiller arm

12.1.1.3
Tiller arm
12.1.1.3.1 Overview tiller arm

12.1.1.3.1
Overview tiller arm
a
b
ac
ab
d
aa
z
y
e
x
u v
w
t f
s
r
q h
i
p
j
o
n
k
m l

a Wiring harness b Guard
c Screw d Tiller arm
e Retaining ring f Cable clamp
g Screw h Shaft
i Indicator sleeve j Stop screw


k Sensor l Nut
m Sensor bracket n Cable clamp
o Screw p Cable clamp
q Spring hollow pin r Screw
s Steering link with cover t Screw
u Oil well bearing v Cover
w Rubber damper x Gas strut
y Locking pin z Rubber stop
aa Cover ab Screw
ac Contact bracket
12.1.1.3.2 Replacing the tiller arm

12.1.1.3.2
Replacing the tiller arm
12
12.1.1.3.2.1 Removing the tiller arm
12.1.1.3.2.1
Removing the tiller arm
1. Remove the inspection cover.
2. Remove the cover (T).
3. Unscrew the retaining screws of the yoke (R).
4. Detach the cable clamp (P) by pressing on the clamp with your thumbs and lifting it upwards. Pull the
cable clamp out through the hole in the operating console.
Note! Do not try to prise away the cable clamp with a screwdriver.
tions X5 and X65.
12.1.1.3.3 Replacing a gas strut

12.1.1.3.3
Replacing a gas strut
12.1.1.3.3.1 Removing a gas strut

12.1.1.3.3.1
Removing a gas strut
1. Remove the cover (T).
2. Remove the cable clamp retaining screw (W).
3. Unscrew the adjusting screw (Q).
4. Remove the lock (E) from the gas strut locking axle (C).
5. Detach the gas strut locking shaft (C).
6. Remove the gas strut.
12.1.1.3.3.2 Installing a gas strut

12.1.1.3.3.2
Installing a gas strut
1. Install the gas strut.
2. Install the gas strut locking shaft.
3. Install the lock on the gas strut locking shaft.

4. Install the adjusting screw.
5. Install the cable clamp retaining screw.
6. Refit the cover.
12.1.1.3.4 Replacing the tiller arm cover

12.1.1.3.4
Replacing the tiller arm cover
12.1.1.3.4.1 Removing the tiller arm cover

12.1.1.3.4.1
Removing the tiller arm cover
Removing the keypad, page 12 - 3.
1. Remove the screws holding the upper cover and keep

hold of the upper cover to prevent damage to the cable
to the logic board
2. Disconnect the CAN connection to the logic card

12.1.1.3.4.2 Installing the tiller arm cover

12.1.1.3.4.2
Installing the tiller arm cover
1. Connect the CAN bus connection to the logic card.
12
2. Press together the upper and the lower parts, and turn
the screws five complete turns. Start with the left side,
and then proceed with the right side.
3. Turn the screws a further four complete turns (a total of

nine turns, which corresponds to 1 Nm).

4. Check that there is no space between the handle and

the steering head.
5. Make sure that the control can be moved back and forth
without difficulty, and that the control returns to the neut-
ral position. Adjust the screws as explained in step 3 if
the control is difficult to move.
Installing a keypad, page 12 - 4.
12.1.1.3.5 Replacing the tiller arm housing

12.1.1.3.5
Replacing the tiller arm housing
12.1.1.3.5.1 Removing the tiller arm housing

12.1.1.3.5.1
Removing the tiller arm housing
Preparations
Removing front plates, page 8 - 3
1. Remove the screws to the tiller arm housing.

2. Remove the two pieces of the tiller arm housing.
12
12.1.1.3.5.2 Fitting the tiller arm housing
12.1.1.3.5.2
Fitting the tiller arm housing
1. Install the two pieces of the tiller arm housing.

Make sure that the rubber gasket between the housing
pieces and tiller arm are properly mounted.
2. Fit the screws of the tiller arm housing.
12.1.1.4 Checking steering and tiller arm

12.1.1.4
1. Use the tiller arm to check for correct operation.
2. Verify that the tiller arm rotates correctly at the maximum angle to the right and left. .

3. Check that the tiller arm returns to the upright position.

13.1 Using the anti-static carpet ............................................................................................................ 13 - 1
13.2 Inspect electrical system................................................................................................................ 13 - 1
13.3 Programming tools......................................................................................................................... 13 - 1
13.3.1 TruckCom ......................................................................................................................... 13 - 1
13.3.1.1 Connect the CAN interface to the truck............................................................... 13 - 1
13.3.2 Software............................................................................................................................ 13 - 2
13.3.2.1 Software update .................................................................................................. 13 - 2
13.4 General electric equipment C5100 ................................................................................................ 13 - 2
13.4.1 Battery lithium-ion TMHMS C5110 ................................................................................... 13 - 2
13.4.1.1 Authorised personnel .......................................................................................... 13 - 2
13.4.1.2 Disconnecting the battery.................................................................................... 13 - 3
13.4.1.3 Using the charging/discharging unit (CDU)......................................................... 13 - 3
13.4.1.4 Battery system overview ..................................................................................... 13 - 4
13.4.1.5 Description of the battery system...................................................................... 13 - 10
13.4.1.6 The battery system............................................................................................ 13 - 10
13.4.1.7 Troubleshooting ................................................................................................ 13 - 12
13.4.1.8 Battery Management System, BMS .................................................................. 13 - 34
13.4.1.9 Battery replacement .......................................................................................... 13 - 34
13.4.1.10Battery module .................................................................................................. 13 - 36
13.4.1.11Power Module Unit (PMU) ................................................................................ 13 - 48
13.4.1.12TruckCom lithium-ion TMHMS .......................................................................... 13 - 64
13.4.1.13Maintenance...................................................................................................... 13 - 91
13.4.1.14Recycling and transport .................................................................................... 13 - 92
13.4.1.15Technical data................................................................................................... 13 - 92
13.4.2 General alarm signals (audible/visual) C5160 ................................................................ 13 - 93
13.4.2.1 Horn .................................................................................................................. 13 - 93
13.4.3 Battery charger (built-in) C5170...................................................................................... 13 - 97
13.4.3.1 Battery charger overview .................................................................................. 13 - 97
13.4.3.2 Description ........................................................................................................ 13 - 97
13.4.3.3 Replacing the battery charger (onboard) .......................................................... 13 - 98
13.4.4 Battery cut out switch, main contactor C5190............................................................... 13 - 100

13 Electrical system C5000
13.4.4.1 Overview, main contactor................................................................................ 13 - 100
13.4.4.2 Main contactor................................................................................................. 13 - 101
13.5 Instrument panel, display C5200 ............................................................................................... 13 - 104
13.5.1 Menu ............................................................................................................................. 13 - 104
13.5.1.1 Menus ............................................................................................................. 13 - 104
13.5.1.2 Menu navigation.............................................................................................. 13 - 104
13.5.1.3 Menu overview ................................................................................................ 13 - 105
13.5.1.4 Menu information ............................................................................................ 13 - 105
13.5.1.5 Show hour meter values ................................................................................. 13 - 105
13.5.1.6 Show error codes ............................................................................................ 13 - 106
13.5.1.7 Show part numbers for software/hardware ..................................................... 13 - 106
13.5.1.8 Built-in test ICH ............................................................................................... 13 - 107
13.5.1.9 Show collisions................................................................................................ 13 - 107
13.5.1.10Show/change parameters ............................................................................... 13 - 107
13.5.1.11Emergency driving mode ................................................................................ 13 - 107
13.5.1.12Calibration ....................................................................................................... 13 - 107
13.5.1.13Show/change PIN code................................................................................... 13 - 107
13.5.1.14PIN codes........................................................................................................ 13 - 108
13.5.2 Hour counter, tachograph C5290.................................................................................. 13 - 112
13.5.2.1 Checking error log and operating hours.......................................................... 13 - 112
13.6 Power system travel function C5400 ......................................................................................... 13 - 112
13.6.1 Drive motor cables/resistors/fuses C5430 .................................................................... 13 - 112
13.6.1.1 Overview, drive motor wiring harness ............................................................. 13 - 112
13.6.1.2 List of fuses ..................................................................................................... 13 - 113
13.6.2 Motor control C5460 ..................................................................................................... 13 - 114
13.6.2.1 Overview, motor control panel ........................................................................ 13 - 114
13.6.2.2 Checking the cable connections ..................................................................... 13 - 115
13.6.2.3 Checking the transistor panel mounting.......................................................... 13 - 115
13.6.2.4 Replacing the motor control panel .................................................................. 13 - 116
13.7 Control system, working function C5500 ................................................................................... 13 - 122
13.7.1 Work function harnesses/fuse C5590 ........................................................................... 13 - 122

13.7.1.1 Overview, main wiring harness 50 Ah............................................................. 13 - 122
13.7.1.2 Overview, main wiring harness 150 Ah........................................................... 13 - 123
13.7.1.3 BMS overview ................................................................................................. 13 - 124
13.7.1.4 Inspecting the wiring harnesses...................................................................... 13 - 124
13.8 Power system working function C5600...................................................................................... 13 - 125
13.8.1 Battery/motor cables, fuse C5680................................................................................. 13 - 125
13.8.1.1 Overview, battery 105/150 Ah with wiring harness ......................................... 13 - 125
13.8.1.2 Overview, battery charger wiring harness, external ........................................ 13 - 125
13.8.1.3 Overview, battery charger wiring harness, external with heater ..................... 13 - 126
13.8.1.4 Overview, battery charger wiring harness, truck ............................................. 13 - 126
13.8.1.5 Overview, pump motor wiring harness............................................................ 13 - 127
13.8.1.6 Overview, battery lock..................................................................................... 13 - 127
13.8.1.7 Overview, battery wiring harness 50 Ah.......................................................... 13 - 128
13.8.1.8 Replacing the battery cables........................................................................... 13 - 128
13.8.1.9 Inspecting the wiring harnesses...................................................................... 13 - 128
13.9 Control/protection electronics C5700......................................................................................... 13 - 129
13.9.1 Transmitting/receiving equipment C5760 ..................................................................... 13 - 129
13.9.1.1 I_Site ............................................................................................................... 13 - 129
13.10 Protective sensors, position sensors C5800.............................................................................. 13 - 133
13.10.1 Overview, OCC ............................................................................................................. 13 - 133
13.10.2 Maximum speed during cornering (OCC) ..................................................................... 13 - 134
13.10.3 Lift/lowering/reach movement sensor C5820................................................................ 13 - 135
13.10.3.1Height sensor .................................................................................................. 13 - 135
13.10.3.2Low Speed when Low Forks (LSwLF) sensors............................................... 13 - 138
13.10.4 Safety probes/sensors C5830....................................................................................... 13 - 140
13.10.4.1Emergency switch off ...................................................................................... 13 - 140


Using the anti-static carpet
Software: 7662518
13
Electrical system C5000
13.1 Using the anti-static carpet

13.1
Using the anti-static carpet
Preparations
Electrostatic risks, page 2 - 4
• Anti-static carpet 148115
1. Disconnect the power source.
2. Attach the clamp to the area that is to be protected, and

the other end to the wrist. Anti-static carpet 148115,
page 21 - 7.
13
13.2 Inspect electrical system

13.2
Inspect electrical system
1. Make sure the connectors to the battery, electric panel and the battery charger are undamaged.
If any connectors are damaged, the wiring harness must be replaced.
2. Tighten all wire connectors.
3. Make sure the battery cables are not damaged. Replace the battery cables if they are damaged in
any way.
4. Make sure that contactors work.
5. Make sure that all switches and sensors work.
6. Clean and make sure that there is no play between the steering box and the heat dissipation plate.
13.3 Programming tools

13.3
Programming tools
13.3.1 TruckCom
13.3.1
TruckCom
13.3.1.1 Connect the CAN interface to the truck

13.3.1.1
Connect the CAN interface to the truck
See the separate TruckCom manual to see the various connection alternatives available.
• PC to CAN cable 163793

General electric equipment C5100
• CASTOR USB 7521083
1. Ensure that the truck is switched off before making the

connection
2. Connect the PC to CAN cable 163793, page 21 - 7

and CASTOR USB 7521083, page 21 - 7 cables.
3. Connect the CAN connector to the truck
4. Connect the USB to the TruckCom equipment.
13.3.2 Software
13.3.2
Software
13.3.2.1 Software update

13.3.2.1
Software update
See the TruckCom manual.

Preparations
Connect the CAN interface to the truck, page 13 - 1
CAN key 7516707, page - 7
• CAN key 7516707
1. Connect the CAN connector to X41.
2. Create truck report before updating. This can be used if the parameter values are corrupted during
updating.
3. Download the new software package.
4. Compare the old parameter values in the truck report with the new ones, and adjust if needed.
5. Copy the truck configuration to a secondary unit (from ICH to ACT/ACC). If this is not done, the truck
will generate error code 2.004 at startup.
13.4 General electric equipment C5100

13.4
13.4.1 Battery lithium-ion TMHMS C5110

13.4.1
Battery lithium-ion TMHMS C5110
13.4.1.1 Authorised personnel

13.4.1.1
WARNING Service/diagnostics work and repairs on the truck may only be performed by author-
ised personnel
Serious risk of injuries
► Only personnel trained to work on TMHMS AB lithium-ion battery systems are authorized to
perform service/diagnostic work and repairs on the battery and its components.

13.4.1.2 Disconnecting the battery

13.4.1.2
Disconnecting the battery
WARNING Risk of short-circuiting.

Short circuit
► When working with 105 or 150 Ah battery systems, it is important to disconnect the battery on
the left side of the truck first.
If the right side is connected first, there is a risk of short-circuiting.
105 or 150 Ah battery system
1. Disconnect the power cables from the battery on the left side of the truck. Insulate the cable with elec-
trical tape. Fit the terminal bolts.
50 Ah battery system
2. Remove the power cables from the battery on the truck. Insulate the cable with electrical tape. Fit the 13
terminal bolts.
13.4.1.3 Using the charging/discharging unit (CDU)

13.4.1.3
Using the charging/discharging unit (CDU)
WARNING Risk of short-circuiting

The lithium-ion battery module is always electrically live.
► Always take appropriate precautions when handling the lithium-ion battery modules.
The charging/discharging unit is only intended for the TMHMS Lithium-ion battery module.
Charger CDU 7661401, page 21 - 8
• Only charge/discharge one module at a time.
• The voltage range for the modules is: 2.5 - 4.2V.
• Use the charging/discharging unit in the temperature range 0-45°.
It is very important to read the user manual enclosed with the CDU unit. Follow the safety instruc-
tions in the user manual.
Charging/discharging unit for TMHMS Lithium-ion battery module.

13.4.1.4 Battery system overview

13.4.1.4
Battery system overview
13.4.1.4.1 Overview 50 Ah
13.4.1.4.1
Overview 50 Ah
i
h
j
k
f
c
d
e g
a
b

a Battery b Protective plate
c Screw d Washer
e Nut f Screw
g Washer h Signal cable connection
i Power cable connection + j Power cable connection -
k On/off button

13.4.1.4.2 Overview 105/150 Ah Right

13.4.1.4.2
Overview 105/150 Ah Right
Pos. Designation Pos. Designation 13

a Screw, torque 5+/-0.5 Nm b Washer
c Plate d Screw, torque 3.5+/-0.5 Nm
e Cover f Insulation bushing
g Screw, torque 22+/-2.2 Nm h Copper bar
i PMU (Power Modul Unit) j Holder
k Screw, torque 2.5+/-0.5 Nm l Battery module type A
m Plate n Battery module type B
o Stay p Signal cable
q Copper bar r Copper bar
13.4.1.4.3 Overview 105/150 Ah Left

13.4.1.4.3
Overview 105/150 Ah Left

a Screw, torque 5+/-0.5 Nm b Washer
c Plate d Screw, torque 3.5+/-0.5 Nm
e Cover f Plug
g Insulation bushing h Screw, torque 22+/-2.2 Nm
i Copper bar j Battery module type A
k Plate l Stay
m Battery module type B n Signal cable
o Copper bar

13.4.1.4.4 Overview 150 Ah, right heater

13.4.1.4.4
Overview 150 Ah, right heater
a
i
h
c
g
d
f
e
Pos. Designation
a Cover
b PMU 24V
c Spacer
d Battery module
e Plate
f Battery module

Pos. Designation
g Stay
h Wiring harness
i Plate
13.4.1.4.5 Overview 150 Ah, left heater

13.4.1.4.5
Overview 150 Ah, left heater
13
h
i a
b
g c
Pos. Designation
a Insulation bushing

Pos. Designation
b Screw
c Copper bar
d Battery module
e Plate
f Battery module
g Wiring harness
h Plug
i Copper bar

13.4.1.4.6 Overview of wiring harness, heater 105, 150 Ah

13.4.1.4.6
Overview of wiring harness, heater 105, 150 Ah
a b
c
d
13
e
n
m
j i
l h
k g f

a Ring cable terminal, [40:2] b Pipe cable terminal, [42]
c Ring cable terminal, [40:1] d Ring cable terminal, [6:2]
e Fuse f Connector, [E32]
g Connector, [E33] h Connector, [E34]
i Connector, [X31] j Connector, [E36]
k Connector, [E37] l Connector, [E38]


m Connector, [E35] n Connector, [X31]
13.4.1.5 Description of the battery system

13.4.1.5
Description of the battery system
WARNING Risk of personal injury and material and property damage

No modifications must be carried out to the battery.
► Two versions of battery system are available: The 50Ah system is an integrated battery sys-
tem consisting of a complete package of seven modules and a battery management system
(BMS). May only be exchanged for a complete package. 105Ah/150Ah is a battery system
made up of separate modules and a separate battery management system (BMS). Individual
modules and the BMS are replaceable.
13.4.1.6 The battery system

13.4.1.6
The battery system
13.4.1.6.1 On/off button

13.4.1.6.1
On/off button
a b
The battery system can be started or shut down using the on/off button.
Batteries with 105/150 Ah have a button (a) for the battery system.
Batteries with 50 Ah have two On/Off buttons for the battery system, one on the truck (a) and one on the bat-
tery (b). These two buttons perform an identical function.
• Start the battery system: Press the on/off button ~ 0.5s

• Shutting down the battery system: Press the button twice ~ 0.5s with an interval of ~ 0.5s.
The On/Off button on the battery will flash and continue to flash until the battery is activated, after which the
button will remain lit as long as the battery is active. In the event of a fault in the battery system, the on/off
button of the battery system will flash. The on/off button will illuminate for ~ 0.5 seconds, and then extinguish
for ~ 0.5 seconds.
To check the status of the battery system, see Status check on the battery system, page 13 - 10, Keypad
status check, page 13 - 11.
13.4.1.6.2 Status check on the battery system

13.4.1.6.2
Status check on the battery system
LED Event Status

LED On The battery system is OK

LED Event Status

LED extinguished The battery system is:
1) In sleep mode
2) Off
LED lit 0.5s The battery system is:

LED extinguished 0.5s 1) not ready
2) incorrectly configured
3) faulty
LED lit 1.5s Charging in process
LED extinguished 1.5s
13
13.4.1.6.3 Keypad status check
13.4.1.6.3
Keypad status check
a b
O I
Indicator (b) lights green when the truck is logged in.

Indicator (a) lights red when the truck is logged out and goes out after 1 second.
If neither indicator is lit, the truck is logged out. To log in, the battery system must be active and the On/Off
button constantly lit.
13.4.1.6.4 Sleep mode

13.4.1.6.4
Sleep mode
After the battery system has been inactive for a certain period of time, which depends on the battery’s capa-
city and charging status, it will enter sleep mode. The battery system will show no voltage because the
power supply to the terminals will be disconnected.
The table below shows some examples of how long the battery can be inactive before it enters sleep mode.
The greater the battery capacity, the longer the battery can remain inactive before sleep mode is activated.
Battery capacity Voltage Charging status Time until sleep mode
105 Ah 24V 30% 9 hours
105 Ah 24V 50% 30 hours
420 Ah 48V 30% 36 hours
420 Ah 48V 50% 120 hours
The battery system can be restarted in the following ways:

• Press the battery system’s start button. See On/off button, page 13 - 10, Link target missing for title:
[ID: 15180250635].
• Charge the battery system.
13.4.1.6.5 Sleep mode

13.4.1.6.5
Sleep mode
After the battery system has been inactive for a certain period of time, which depends on the battery’s char-
ging status, it will enter sleep mode. The battery system will show no voltage because the power supply to
the terminals will be disconnected.
The table below shows some examples of how long the battery can be inactive before it enters sleep mode.
Battery capacity Charging status Time until sleep mode
50 Ah 30% 2 hours
50 Ah 50% 14 hours
The battery system can be reset by pressing the battery system's on/off button. See On/off button, page
13 - 10.
13.4.1.6.6 Battery charger safety switch-off

13.4.1.6.6
Battery charger safety switch-off
Charging will be terminated if:
• The battery system is disconnected without first switching off the battery charger.
• The E-box switches off the battery charger via the CAN bus.
• CAN communication with the battery system is interrupted.
Charging is temporarily interrupted or reduced if:
• The charging temperature exceeds the limit values.

• The E-box interrupts or reduces charging via the CAN bus
• The E-box interrupts or reduces charging if the temperature is too high. High ambient temperatures
will prolong the charging time.
13.4.1.6.7 Balancing the battery system

13.4.1.6.7
Balancing the battery system
The battery management system automatically manages the balancing. The truck must be charged after one
or more modules have been replaced. The battery management system will then charge and balance the
system for optimal function. The time taken for the balancing procedure depends on how much the voltage
differs.
Note: Do not charge a battery module by itself. There is a risk of damaging the battery module, as the
battery management system does not monitor the charging process.
13.4.1.7 Troubleshooting
13.4.1.7
Troubleshooting
13.4.1.7.1 Initial troubleshooting

13.4.1.7.1

The modules are always active, and the terminals and must be protected against short-circuits.
• Check that the battery system is properly connected to the truck.

• Check that the battery system is activated and has not entered sleep mode; see Status check on the
battery system, page 13 - 10. If the battery system is not active, start the battery system by pressing
the on/off button; see On/off button, page 13 - 10.
• Restart the battery system; see On/off button, page 13 - 10.

• Check the status of the battery system in TruckCom, see Connecting to the battery system, page
13 - 64.
• Check that the battery system is not still in protective mode; see Protective mode, page
13 - 83.
• Check that the configuration, voltage and temperature (master/slave) correspond; see Informa-
tion about the battery system, page 13 - 69.
• Generate a truck report with a battery log; see Truck report with battery log, page 13 - 73.
• Update to the latest software; see Software update, page 13 - 82.
• Check that the battery charger is not visibly damaged and that it is the correct kind of charger.
• Check that the mains power supply to the battery charger is correct.
• Check all wiring harnesses, contactors and connectors in the battery system.
• See error codes and proposed measures; see List of error codes, page 13 - 13.
13.4.1.7.2 Troubleshooting using error codes

13.4.1.7.2
13
13.4.1.7.2.1 List of error codes
13.4.1.7.2.1
List of error codes
Software: 7623820-XXX
13.4.1.7.2.1.1 Error codes

200F Low SOC error. • The battery has been • Connect the battery to
discharged beyond an approved charger.
the warning level for • Check if the error
low SOC. code 4004 exists and
correct the error if this
is the case.
2A80 Low SOC error • • Check error codes in
the event log.
is the case.
the event log.
400A Error on HSW1. • Component fault. • Check the heater
switch and wiring har-
ness.
• Replace if necessary.
400B Overcurrent fault. • Deficient accuracy for • Make sure the battery
current sensor > 5 % is configured correctly.
(only applicable during • Check electrical and
charging). electromechanical
• Error with current components, espe-
sensor or wiring har- cially contactors,
ness. which may have been
• BMS defective. damaged by the high
current.


400B Overcurrent fault. • Check that the current
measured in Truck-
Com gives a reason-
able value.
• Replace faulty com-
ponents.
400C Invalid charging current • The battery has been • Make sure that only
The battery has been charged with a non- approved chargers are
charged, but no approved approved charger or used to charge the
charger has been detected. non-approved char- battery.
ging method. • Check that the current
• Deficient accuracy for measured in Truck-
current sensor > 5 % Com gives a reason-
(only applicable during able value.
charging). • Measure the resist-
• Error with current ance in the contactor
sensor or wiring har- for the broken circuit.
ness. Replace the contactor
• BMS defective. if it is < 1 MΩ.
• Replace defective
components.
400D The contactor is stuck in • The contactor has re- • Measure the resist-
the closed position / fused peatedly tripped at ance in the circuit
contactors. high load. breaker for the broken
Detected by current meas- • The truck side will still circuit. Replace the
urement or CAN identifica- be live after the con- circuit breaker if it is <
tion. tactor has tripped. 1 MΩ.
• Deficient accuracy for • Measure the voltage

current sensor > 5 % on the truck side while
(only applicable during shutting down the bat-
charging). tery using the on/off
button.
• Error with current
sensor or wiring har- • Make sure that com-
ness. ponents that are not
intended for the ma-
• BMS defective. chine system are re-
moved.
• Check that the current
measured in Truck-
Com gives a reason-
able value.
components.
400E High pulse currents. • The battery has been • Let the battery cool
used with pulse cur- down.
rents that are too high. • Inspect all wiring har-
nesses and connec-
tions.


is the case.
40FF Unknown error. • The error code is re- • Update the BMS soft-
ported when the bat- ware to the latest ver-
tery has an error that sion and check for er-
is not supported by ror codes.
the software.
4A00 HCUNLOCK error • The CAN communica- • Check that the truck
tion between the ma- parameters are con-
chine and the battery figured for lithium-ion. 13
does not work cor- • Inspect all wiring har-
rectly. nesses and connec-
• HCUNLOCK has been tions.
triggered incorrectly, • Check the CAN com-
e.g. due to faulty cur- munication between
rent sensor. the machine and the
• Error with current battery: – Check that
sensor or wiring har- the signal connection
ness. between the machine
• BMS defective. and the battery is cor-
rect and intact.
• Check the configura-
tion: Check that the
values for HCUN-
LOCKTRIGGER and
HCUNLOCKRE-
LEASE.
measured in Truck-
Com gives a reason-
able value.
components.
the event log.
4F00 Limit value exceeded. • • Check error codes in
the event log.
4F01 Limit value exceeded. • • Check error codes in
the event log.
4F03 Emergency switch off ac- • The emergency switch • Reset the emergency
tivated. off (ESO) has been switch off,
activated. • Inspect all wiring har-
nesses and connec-
tions.


4F04 Protective mode. • The battery is in pro- • Check error messages
Reported only at battery tective mode due to in TruckCom.
start. hardware error. • Check protective
mode ID/cause ID.
4F05 Configuration error. • The BMS configura- • Check that the BMS
tion contains conflicts configuration corres-
or parameters outside ponds to the physical
the limits. configuration and that
the configured para-
meters are within the
limits.
4F08 Internal error, BMS • Resetting of monitor- • Replace the BMS if
ing timer may be due this occurs
to the processor be-
coming stuck.
4F09 The most recent shutdown • Unexpected power • Inspect all wiring har-
was uncontrolled. failure may be due to nesses and connec-
wiring harness error or tions.
component error. • Replace the BMS if
this occurs
4FFF Unknown error. • The error code is re- • Update the BMS soft-
ported when the bat- ware to the latest ver-
tery has an error that sion and check for er-
is not supported by ror codes.
the software.
1005 Shutdown due to sleep • For information only. • Update to the latest
mode or external shut- software.
down.
2003 Overvoltage error • The battery/module • Leave the battery to
has been charged stand for about 5
without BMS monitor- minutes. Check the
ing. measured voltages in
• The battery has been the modules/cell in
charged with a non- TruckCom. Attempt to
approved charger and restart the battery if
the contactor has these are below the
fused contactors. E1 threshold.
• Allow the battery to
rest under observation
for 24 hours due to
balancing. Measure
the voltage across the
poles of the affected
module with a volt-
meter. Attempt to re-
start the battery if
these are below the
E1 threshold.
• Check that an ap-
proved charger with
the correct settings is
being used.


2003 Overvoltage error • Check whether there
are other error codes.
BMS: E1=4,17 V/module
50Ah battery system: E1=
4,15 V/cell (29.05 V on com-
plete battery system).
BMS protective mode: Dis-
connect the modules in the
battery system. Use insu-
lated tools.
Use a service charger (CDU)
to bring the affected module
to the same voltage level as
the other modules in the sys- 13
tem under observation.
50 Ah battery system pro-
tective mode: Remove the
protective mode. Replace
the battery system if the er-
ror persists.
2004 Undervoltage error • The battery has been • Check the voltages
discharged beyond measured in the mod-
the warning level. ules/cells in TruckCom
• The battery has been or measure the
discharged with too voltage across the
high a current at low poles of the affected
voltage. module with a volt-
meter. If the voltage is
above the E3 level,
use an approved char-
ger to charge the af-
fected BRIX module to
a voltage above the
E1 limit.
proved charger with
being used.
BMS: E1=2.5 V E3=2 V
50 Ah battery pack: E1= 2,6
V (18.2 V on complete bat-
tery pack) E3=2.3 V (16.1 V
on complete battery pack)
Protective mode: Remove
protective mode if the above
does not rectify the problem.
Replace the module/battery
system if the error persists.
2006 Over-temperature error. • The battery has been • Make sure that the ter-
used at a high ambi- minal connections are
ent temperature. not contaminated and


2006 Over-temperature error. • The battery has been that they are tightened
used with a high cur- with the correct
rent. torque.
• The terminal connec- • Allow the battery to
tions have low con- cool to room temperat-
ductivity. ure. Then, check if the
battery starts again.
• Protective mode: Re-
move protective mode
if the above does not
rectify the problem.
Replace the module/
battery system if the
error persists.
2007 Under-temperature error • The battery has been • Move the battery
used at an ambient somewhere warmer
temperature that is too where it can warm up
low. to room temperature.
Then, check if the bat-
tery starts again.
Replace the module/
error persists.
• The battery has been that they are tightened
rent. torque.

Replace the module/
error persists.
tery starts again.


2400 Under-temperature error rectify the problem.
Replace the module/
error persists.
above the E3 level,
ger to charge the af- 13
a voltage above the
E1 limit.
proved charger with
being used.
BMS: E1=2.5 V E3=2 V
for 24 hours due to
balancing. Measure
module with a volt-
these are below the
E1 threshold.


2600 Overvoltage error • Check that an ap-
proved charger with
being used.
• Check whether there
4,15 V/cell (29.05 V on com-
lated tools.
the other modules in the sys-
ror persists.
2702 Overcurrent detected on • The load on the output • Inspect all wiring har-
output AUX 1 on BMS. is too high. nesses and connec-
tions.
• Restart the battery
system to reactivate
the output.
2703 Overcurrent detected on • The load on the output • Inspect all wiring har-
output AUX 2 on BMS. is too high. nesses and connec-
tions.
• Restart the battery
system to reactivate
the output.
for 24 hours due to
balancing. Measure


3003 Overvoltage error module with a volt-
these are below the
E1 threshold.
proved charger with
being used.
50 Ah battery system: E1=
4,15 V/cell (29.05 V on com- 13
lated tools.
ror persists.
above the E3 level,
a voltage above the
E1 limit.
proved charger with
being used.
BMS: E1=2.5 V E3=2 V


3004 Undervoltage error 50 Ah battery pack: E1= 2,6
rent. torque.

Replace the module/
error persists.
tery starts again.
Replace the module/
error persists.
rent. torque.



3300 Over-temperature error. Replace the module/
error persists.
tery starts again.
Replace the module/
battery system if the 13
error persists.
above the E3 level,
a voltage above the
E1 limit.
proved charger with
being used.
BMS: E1=2.5 V E3=2 V
the modules/cell in
TruckCom. Attempt to
restart the battery if
these are below the
E1 threshold.


3600 Overvoltage error • The battery has been • Allow the battery to
charged with a non- rest under observation
approved charger and for 24 hours due to
the contactor has balancing. Measure
fused contactors. the voltage across the
module with a volt-
these are below the
E1 threshold.
proved charger with
being used.
4,15 V/cell (29.05 V on com-
lated tools.
ror persists.
4002 Internal communication er- • Internal communica- • Inspect all wiring har-
ror tion error in the battery nesses and connec-
system. tions. Replace if ne-
cessary.
• The BMS must be re-
placed if none of the
measures above re-
solve the problem.


4003 Overvoltage error • Allow the battery to
for 24 hours due to
balancing. Measure
module with a volt-
these are below the
E1 threshold.
proved charger with
being used. 13
4,15 V/cell (29.05 V on com-
lated tools.
ror persists.
above the E3 level,
a voltage above the
E1 limit.


4004 Undervoltage error • Check that an ap-
proved charger with
being used.
BMS: E1=2.5 V E3=2 V
4005 The battery voltage is in- • The number of con- • Create a battery report
correct. figured battery mod- and ensure the
The sum of the module ules does not corres- voltage for all mod-
voltages does not correspond to the number of ules.
pond to the total battery electrically connected • Make sure that the
voltage. battery modules. electrical connection
of the battery modules
conforms to the BMS
configuration.
4005 Error on current sensor • Component fault. • Replace the current
Only available for VCE. sensor.
4005 Configuration error. • The BMS configura- • Check that the BMS
tion contains conflicts configuration corres-
or parameters outside ponds to the physical
the limits. configuration and that
the configured para-
meters are within the
limits.
4005 The voltage difference on • The voltage difference • Disconnect from paral-
the parallel battery system measured by BMS is lel batteries. Reconfig-
is too great for the con- greater than 1000 mV. ure the batteries as a
tactor to close. single unit. Charge
Only available for parallel 50 each battery separ-
Ah battery system. ately on the machine.
4005 Protective mode. • The battery is in pro- • Check error messages

Reported only at battery tective mode due to in TruckCom.
start. hardware error. • Check protective
mode ID/cause ID.
rent. torque.


4006 Over-temperature error. • The terminal connec- • Allow the battery to
Replace the module/
error persists.
low. to room temperature. 13
tery starts again.
Replace the module/
error persists.
4009 High BMS temperature • The battery has been • Let the battery cool
Only applies to 50 Ah battery used with pulse cur- down.
systems. rents that are too high.
4011 Limit value exceeded. • • Check error codes in

the event log.
4012 Limit value exceeded. • • Check error codes in
the event log.
4013 Error on HSW2. • Component fault. • Check the heater
ness.
ness.
4030 "PILOT" signal was detec- • The battery is connec- • Check that the battery
ted when not expected. ted to a charger that is connected to an ap-
does not communicate proved charger.
according to the cor- • Check that the char-
rect CAN protocol ger has the correct
after "PILOT" has settings.
been connected.
• Inspect all wiring har-
nesses and connec-
tions.


4031 Charging current is too • The battery has been • Ensure an approved
high. charged using a cur- charger is used.
rent higher than the • Check that the char-
configured maximum ger has the correct
"C-rate". settings.
• Deficient accuracy for • Check that the current
current sensor > 5 % measured in Truck-
(only applicable during Com gives a reason-
charging). able value.
• Error with current • Replace faulty com-
sensor or wiring har- ponents.
ness.
• BMS defective.
4100 Charging current is too • The battery has been • Ensure an approved
high. charged using a cur- charger is used.
rent higher than the • Check that the char-
configured maximum ger has the correct
"C-rate". settings.
• Deficient accuracy for • Check that the current
current sensor > 5 % measured in Truck-
(only applicable during Com gives a reason-
charging). able value.
• Error with current • Replace faulty com-
sensor or wiring har- ponents.
ness.
• BMS defective.
4101 Invalid charging current • The battery has been • Make sure that only
The battery has been charged with a non- approved chargers are
charged, but no approved approved charger or used to charge the
charger has been detected. non-approved char- battery.
ging method. • Check that the current
• Deficient accuracy for measured in Truck-
current sensor > 5 % Com gives a reason-
(only applicable during able value.
charging). • Measure the resist-
• Error with current ance in the contactor
sensor or wiring har- for the broken circuit.
ness. Replace the contactor
• BMS defective. if it is < 1 MΩ.
components.
4102 Low SOC error during • Defective current • Inspect all wiring har-
charging. sensor that does not nesses and connec-
The charger is connected detect any charging tions.
but no charging current is current.
being fed to the battery. • The charger has been
detected, but the de-
fective charger does
not supply power.


4200 Internal communication er- • Internal communica- • Inspect all wiring har-
ror tion error in the battery nesses and connec-
system. tions. Replace if ne-
cessary.
• The BMS must be re-
placed if none of the
measures above re-
solve the problem.
4201 Internal communication er- • Internal communica- • Replace BMS.
ror in BMS tion in BMS is incor-
rect.
ent temperature. not contaminated and 13
rent. torque.

Replace the module/
error persists.
4301 High BMS temperature • The battery has been • Let the battery cool
Only applies to 50 Ah battery used with pulse cur- down.
systems. rents that are too high.
tery starts again.
Replace the module/
error persists.


4501 Undervoltage error above the E3 level,
a voltage above the
E1 limit.
proved charger with
being used.
BMS: E1=2.5 V E3=2 V
for 24 hours due to
balancing. Measure
module with a volt-
these are below the
E1 threshold.
proved charger with
being used.
4,15 V/cell (29.05 V on com-


4600 Overvoltage error BMS protective mode: Dis-
lated tools.
ror persists.
13
4700 Overcurrent fault. • Deficient accuracy for • Make sure the battery
current sensor > 5 % is configured correctly.
(only applicable during • Check electrical and
charging). electromechanical
• Error with current components, espe-
sensor or wiring har- cially contactors,
ness. which may have been
• BMS defective. damaged by the high
current.
measured in Truck-
Com gives a reason-
able value.
• Replace faulty com-
ponents.
4701 High pulse currents. • The battery has been • Let the battery cool
used with pulse cur- down.
rents that are too high. • Inspect all wiring har-
nesses and connec-
tions.
4800 Error on current sensor • Component fault. • Replace the current
Only available for VCE. sensor.
4801 The battery voltage is in- • The number of con- • Create a battery report
correct. figured battery mod- and ensure the
The sum of the module ules does not corres- voltage for all mod-
voltages does not correspond to the number of ules.
pond to the total battery electrically connected • Make sure that the
voltage. battery modules. electrical connection
of the battery modules
conforms to the BMS
configuration.
4802 "PILOT" signal was detec- • The battery is connec- • Check that the battery
ted when not expected. ted to a charger that is connected to an ap-
does not communicate proved charger.
according to the cor- • Check that the char-
ger has the correct
settings.


4802 "PILOT" signal was detec- rect CAN protocol • Inspect all wiring har-
ted when not expected. after "PILOT" has nesses and connec-
been connected. tions.
4803 Error on emergency switch • Emergency switch off • Inspect all wiring har-
off. (ESO) does not work nesses and connec-
Not available for all systems. as intended. tions
Only applies to E-box Lite.
4804 The contactor is stuck in • The contactor has re- • Measure the resist-

button.
moved.
measured in Truck-
Com gives a reason-
able value.
components.
4805 The contactor is stuck in • The contactor has re- • Measure the resist-

button.
moved.
measured in Truck-
Com gives a reason-
able value.
components.


4806 The voltage difference on • The voltage difference • Disconnect from paral-
the parallel battery system measured by BMS is lel batteries. Reconfig-
is too great for the con- greater than 1000 mV. ure the batteries as a
tactor to close. single unit. Charge
Only available for parallel 50 each battery separ-
Ah battery system. ately on the machine.

ness.
ness.
• Replace if necessary. 13
ness.
5001 HCUNLOCK error • The CAN communica- • Check that the truck
tion between the ma- parameters are con-
chine and the battery figured for lithium-ion.
does not work cor- • Inspect all wiring har-
rectly. nesses and connec-
• HCUNLOCK has been tions.
triggered incorrectly, • Check the CAN com-
e.g. due to faulty cur- munication between
rent sensor. the machine and the
• Error with current battery: – Check that
sensor or wiring har- the signal connection
ness. between the machine
• BMS defective. and the battery is cor-
rect and intact.
• Check the configura-
tion: Check that the
values for HCUN-
LOCKTRIGGER and
HCUNLOCKRE-
LEASE.
measured in Truck-
Com gives a reason-
able value.
components.
13.4.1.7.2.2 Protective modeID

13.4.1.7.2.2
Protective modeID
Software: 7623820-XXX
ID Description Measure, see error code:

3 Overvoltage error 4003

ID Description Measure, see error code:

4 Undervoltage error 4004
5 Hardware error 4005
6 High temperature 4006
7 Low temperature 4007
9 High BMS temperature 4009
10 Error on "HeaterSwitch" (HSW1) 400A
11 Overcurrent fault 400B
13 The contactor is stuck in the closed 400D
position/fused contactors
14 High pulse currents 400E
18 Limit value exceeded 4012
19 Error on "HeaterSwitch" (HSW2) 4013
20 Error on "HeaterSwitch" (HSW3) 4014
49 Charging current is too high. 4031
Tab. 3: Protective mode ID
13.4.1.8 Battery Management System, BMS

13.4.1.8
Battery Management System, BMS
13.4.1.8.1 Battery Management System, BMS

13.4.1.8.1
Battery Management System, BMS
The battery management system controls the charging process based on the modules’ temperature, voltage
and current. Statistical information about charging and discharging processes, system status and deviations
is saved internally in the unit.
The battery management system monitors and controls cell balancing, voltage and temperature, amongst
other things. It also protects the modules by preventing them from operating outside their operating range,
for example in the event of:
• Overcurrent (may differ in different charging and discharging modes)

• Overvoltage (while charging)
• Undervoltage (while discharging)
• Over and under temperatures
13.4.1.9 Battery replacement

13.4.1.9
Battery replacement
13.4.1.9.1 Removing the 50 Ah battery

13.4.1.9.1
Removing the 50 Ah battery
WARNING Sparks formation

Sparks may be formed during installation/removal of the power cables.
► Take care when working on the battery system.

The lithium-ion battery is always electrically live.
► Always take appropriate precautions when handling the lithium-ion battery.
Preparations
Removing the main contactor, page 13 - 101
1. Switch off the battery by using the truck’s On/off button.

2. Disconnect the battery wiring harness. See Disconnect the battery wiring harnesses, page 13 - 128.
3. Undo the protective plate by undoing the two screws.
13
4. Lift the battery out of the truck using the protective plate.
13.4.1.9.2 Installing the 50 Ah battery

13.4.1.9.2
Installing the 50 Ah battery
WARNING Sparks formation

Sparks may be formed during installation/removal of the power cables.

The lithium-ion battery is always electrically live.
► Always take appropriate precautions when handling the lithium-ion battery.

1. Lift the battery into position in the truck.
2. Install the protective plate using the two screws. Tighten-

ing torque 9.5N·m.
3. Mount the signal cables (X90) on the battery.
4. Mount the positive power cable on the battery with

washer and nut. Tightening torque 8N·m.
5. Mount the negative power cable on the battery with

washer and nut. Tightening torque 3.4N·m.
6. Start the battery system using the On/Off buttonStart the

battery, page 3 - 1.
7. Make sure the correct software is installed in the battery

system. See Software update, page 13 - 82.
Resetting
Installing the motor cover, page 8 - 3
Fitting the main contactor, page 13 - 103
13.4.1.10 Battery module

13.4.1.10
Battery module
13.4.1.10.1 Battery module

13.4.1.10.1
Battery module

The modules are always active, and the terminals and must be protected against short-circuits.

a b
13
The lithium-ion battery module has a 3.7-volt output and is available in two versions. Module (a) for battery
system without heater and module (b) for battery system with heater.
The modules are available in the following sizes:
• 105 Ah
• 150 Ah

a b
1 2
There are two versions for each size:
• Type A (1).
• Type B (2), which is a mirror-image of type A.
a) Label with requirements symbols.
b) Label with product information.
The two types of modules make it possible to flexibly combine modules to achieve the desired capacity and
voltage.
Information about the product's part number, serial number and labelling can be found on the top.
Modules sent as spare parts are only charged to 30%, and the system must be balanced/charged before use
after a module replacement.
The original module has part numbers ending in -001 or -002, while the spare parts module has part num-
bers ending in -101 or -102.
13.4.1.10.2 Cleaning and protective grease application

13.4.1.10.2
Cleaning and protective grease application
Always carry out this process when handling battery modules.

NOTE! Steps 1–5 concern aluminium modules; steps 4–5 concern brand new modules.
1. Grind the top and bottom of the connector strip and

around the holes using fine abrasive paper to remove
any contaminants.

2. Grind the positive and negative terminals of the module

using fine abrasive paper to remove any contaminants.
3. Clean the ground surfaces.
4. Apply a thin layer of protective grease, so that it covers

the contact surface of the positive and negative termin-
als of the module; see Lubricants specification, page
22 - 2.
5. Ensure that good contact is achieved between all con-

tact surfaces.
13
13.4.1.10.3 Replacing a battery module
13.4.1.10.3
Replacing a battery module
13.4.1.10.3.1 Removing the battery module, right-hand side (105/150 Ah)

13.4.1.10.3.1
Removing the battery module, right-hand side (105/150 Ah)
WARNING Warning for sparkovers

A difference in voltage between the battery modules of more than 500 mV may cause sparks
to form when removing or fitting the connector strips.

1. Log the truck out via the keypad.
2. Shut down the battery system using the button (on/off button).
3. It is important to always disconnect the power cables on

the left side of the battery system first. Disconnect the
negative and positive power cables from the battery
module respectively. Refit the terminal poles. Label the
cables and isolate the cable clips with electrical
tape.

b 4. Refit the negative power cable from the battery module

(a); refit the terminal pole and label the cables and isol-
a
ate the cable clips with electrical tape. Disconnect
cable 10, connection X3 on the PMU (b). Refit the ter-
minal pole and label the cables and isolate the cable
clips with electrical tape.
5. This step is only performed when the truck has a

heater wiring harness. Disconnect the signal cable for
the heater wiring harness. Remember the respective po-
sitions of E32 (a), E33 (b) and E34 (c).
c b
6. Disconnect signal cables X1 and X2. (Use a screwdriver

to loosen these).

7. Remove the fuse holder.
8. Remove the collision protection. 13
9. Remove the bracket for the battery lock.
10. Attach a lifting hook or cable tie to the plastic cover on

the battery system.
11. Tilt the battery system forwards in order to access Q50.

12. Disconnect connector Q50 by pulling the lock (a) up-

wards and then holding in the catch (b) and pulling care-
fully.
a
13. Move the cables, wiring harness and connectors to one

side. Then lift the battery system out of the truck.
14. Remove the cover according to the overview on the bat-

tery system. Note that the terminal poles must be un-
screwed in order to remove the cover.

15. Unscrew the terminal pillars that hold the copper rails
and loosen the cables that are on the modules.
16. Lift out the battery module to be replaced. 13
13.4.1.10.3.2 Fitting the battery module (105/150 Ah)

13.4.1.10.3.2
Fitting the battery module (105/150 Ah)



1. Lift the new battery module into place.
2. Fit the screws for the copper bar. Tighten to 22±2.2N·m
3. Fit the cover. Note that the bolts must be loosened in or-
der to fit the cover and then be refitted, as there must be
no open terminals. Make sure that the side supports are
fitted correctly in the recesses in the bottom plate.

4. Lift the battery system into the truck and then check that
no cables are trapped.
5. Fit the collision protection. 13
6. Fit the locking bracket for the battery pack.

7. Connect connector Q50. Push in the connector until you

hear a click (b). Then press down the lock (a).
8. Connect signal cables X1 and X2.
9. This step is only performed when the truck has a

heater wiring harness. Connect the signal cables for
the heater wiring harness E32 (a), E33 (b) and E34 (c).
c b

10. Fit the fuse holder.
b 11. Connect cable 10 in X3 on the PMU (b). Check that the 13

spacer is in position. Tighten to 22±2.2N·m
a
Connect the negative power cable to the module (a).
Check that the spacer is in position. Tighten to
22±2.2N·m
12. Connect the positive and negative power cables to the

battery system on the left side. Tighten to 22±2.2N·m
13. Start up the battery system using the button.
14. Log in via the keypad.
15. Perform a function check.

13.4.1.11 Power Module Unit (PMU)

13.4.1.11
Power Module Unit (PMU)
13.4.1.11.1 Replacing the PMU (105 Ah)

13.4.1.11.1
Replacing the PMU (105 Ah)
13.4.1.11.1.1 Removing the PMU (105/150 Ah)

13.4.1.11.1.1
Removing the PMU (105/150 Ah)


2. Shut down the battery system using the on/off button.
3. It is important to disconnect the power cables on the left

side of the battery before removing the PMU. Disconnect
the negative and positive power cables from the battery
tape.

a

5. Disconnect the signal cable for the heater wiring har-

ness. Remember the respective positions of E32 (a),
E33 (b) and E34 (c).
c b
6. Disconnect signal cables X1 and X2. (Use a screwdriver 13

to loosen these).

8. Remove the collision protection.
10. Attach a lifting hook or cable tie to the cover on the bat-
tery system.

fully.
a


14. Remove the cover from the battery system. Note that the 13
terminal poles must be unscrewed in order to remove
the cover.
15. Unscrew the terminal pole which secures the copper bar
to the PMU and then lift out the PMU.

16. Remove the PMU from the spacer.
13.4.1.11.1.2 Removing the PMU (105/150 Ah) without Heater

13.4.1.11.1.2
Removing the PMU (105/150 Ah) without Heater


2. Shut down the battery system using the on/off button.
3. It is important to disconnect the power cables on the left

side of the battery before removing the PMU. Disconnect
the negative and positive power cables from the battery
tape.


a
5. Disconnect signal cables X1 and X2. Use a screwdriver 13

to loosen these.

7. Remove the collision protection.
9. Attach a lifting hook or cable tie to the plastic cover on

the battery system.

fully.
a


13. Remove the cover from the battery system. Note that the 13
terminal poles must be unscrewed in order to remove
the cover.
14. Unscrew the screw which secures the copper bar to the
PMU and then lift out the PMU.

15. Remove the PMU from the spacer.
13.4.1.11.1.3 Fitting the PMU (105/150 Ah) without Heater

13.4.1.11.1.3
Fitting the PMU (105/150 Ah) without Heater


1. Mount the new PMU on the spacer and then lift into posi-
tion.

3. Fit the cover. Note that the bolts must be loosened in or- 13

5. Fit the collision protection.
6. Fit the lock yoke for the battery pack.


9. Fit the fuse holder. 13
b 10. Connect cable 10 in X3 on the PMU (b). Check that the

a
22±2.2N·m


12. Start up the battery system using the on/off button.
13.4.1.11.1.4 Fitting the PMU (105/150 Ah)

13.4.1.11.1.4
Fitting the PMU (105/150 Ah)


1. Mount the new PMU on the spacer and then lift into posi-
tion.

3. Fit the cover. Note that the bolts must be loosened in or- 13

5. Fit the collision protection.
6. Fit the locking bracket for the battery pack.


9. Connect the signal cables for the heater wiring harness 13

E32 (a), E33 (b) and E34 (c).
c b
10. Fit the fuse holder.

b 11. Connect cable 10 in X3 on the PMU (b). Check that the

a
22±2.2N·m

13. Start up the battery system using the on/off button.
13.4.1.12 TruckCom lithium-ion TMHMS

13.4.1.12
TruckCom lithium-ion TMHMS
13.4.1.12.1 Connecting to the battery system

13.4.1.12.1
Connecting to the battery system
To connect directly to the 105Ah battery system and higher capacities (BMS), use PC CAN cable
7561869, page 21 - 8.
To connect directly to the 105Ah battery system and higher capacities (BMS-Lite), use PC CAN cable
7652381, page 21 - 8.
To connect directly to the 50Ah and 100Ah battery systems, use PC CAN cable 7671692, page
21 - 8.
• PC CAN cable 7561869
1. Make sure the latest version of TruckCom is being used.
2. Connect the CAN connector and start the TruckCom program.

Make sure that the battery system is switched on.
3. Make sure that the latest version of Power Package LIB/BCU is used.

13
4. Press “Connect”. The information is downloaded from

the system.

5. If "Truck model" displays "Power package LIB/BCU", the

connection to the truck's battery system is ready. If
"Truck model" displays the truck model instead, go to
step 7.
6. If TruckCom shows a list with a generic software pack-

age, select “Generic BMS”.

13
7. Select "Open Package" under "Action". Go to step 8.
8. Select "Open Package" under "Action".

9. Enter "LIB" in the box for "Package search" and click on

"Search".
10. Click on the most recent version.

13
11. When "Truck model" displays "Power package LIB/

BCU", the connection to the truck’s battery system is
ready.
13.4.1.12.2 Information about the battery system

13.4.1.12.2
Information about the battery system
Preparations
Connecting to the battery system, page 13 - 64

1. Select BMSoptxxxxxxx from the list under "Node". Select

the version that has the status “OK”.
2. Select "Configuration" under "Action".

13
3. Select "Read battery information".

BMS
• The battery system's total capacity
• The battery system’s serial number
Module status
• Battery module's serial number
• The battery module’s serial number in the latest configuration
• Temperature [°C] Master and Slave
• Volt [V] Master and Slave
• Capacity [Ah]
• TMHMS part number (PN) - the value shows "NOT OK" if the battery module’s part number
cannot be retrieved. This value is not an indication of the battery module's status.

13.4.1.12.3 Truck report with battery log

13.4.1.12.3
Truck report with battery log
Preparations
13
1. Select "Truck report" under "Action".

2. Enter the "Machine no" and also check the box for "In-
clude battery log". Then press "Generate".
3. The truck report will then be generated. Save it for the

configuration.
13.4.1.12.4 Configuring the battery system

13.4.1.12.4
Configuring the battery system
Preparations
Information about the battery system, page 13 - 69
Truck report with battery log, page 13 - 73

13
1. Select the "Set configuration" tab.

2. The following menu will appear.

Configuration can be filled in using one of the following
ways:
Load the configuration from the battery system

13
3. Click on “Load configuration”.

4. Click on “From BMS”. The information is filled in auto-

matically.
Enter the data manually

Software Package Number=7623820-014
[BMS3opt CONFIGURATION]
Configuration PN=7623507-080
System serial NO=6753689
Status of last configuration=2 OK
Total capacity [Ah]=150
Serial size=7
Parallel size=1
C-rate=0,8C
Truck type=3 (ToyotaGen2)
Charger type=2 (External access charger (Slave CAN with Pilot))
Cell type=0 (29E7)
External Equipment=2 (Heater)
Charger Strategy=0 (Unknown charger strategy)
Type=ManufacturedByTMHMS
HCUnlock Trigger=15
HCUnlock Release=5
Signature [user]=bt3586
Signature [date]=2020-09-09 09:53:40
Protective fault=ID: 0, Description: 0x0000 (No fault)
Max auxiliary hardware current charge [A]=260
13
Max auxiliary hardware current discharge/regen [A]=325
Max hardware current charge [A]=325
Max hardware current discharge/regen [A]=325
Heater threshold max [degC]=20
Heater threshold min [degC]=15
Heater temp set [degC]=18
Primary Contactor Type=0 (Unknown contactor type)
Secondary Contactor Type=0 (Unknown contactor type)

5. Enter the data according to the saved truck report with

battery log.
• System serial no.

• Configuration Part Number
• Total capacity
• Serial size
• Parallel size
• SW package Part Number
• C-rate:
Entered without decimals. If the truck report
shows the value “0.8", “8” must be entered in the
configuration field.
• HC Unlock trigger:
50 Ah and 100 Ah battery system: "10"
105 Ah battery system and higher capacities: "15"
Autotruck battery system: "15"
• HC Unlock release:
105 Ah battery system and higher capacities: "5"
Autotruck battery system: "5"
• Type:
Enter "ManufacturedByTMHMS" in the free text
field.
• Charger type:
Select the type based on the type of charger that
the truck uses: "Onboard (1)","External (2)" or
"Master CAN charger (4)".
Autotruck battery system: "Auto-charging (3)".
• Cell type:
50 Ah and 100 Ah battery system: "48X (2)".
105 Ah battery system and higher capacities:
"29E7 (0)”
"M50 (1)" not used.
• Truck type:
LWI160 105 Ah and 150 Ah battery system:
"ToyotaGen2 (3)" .
Other battery system: "Integrated (0)". Other value
not used.
• Charger strategy:
"SW default". Other value not used.
• Primary contactor:
"NO PWM" (default). Other value not used.
• Secondary contactor type:
"NO PWM" (default). Other value not used.
• Heater enable:
Select "Heater enable" if the battery is equipped
with a heater.
6. • QSense (precharge)/Precharge enable:

QSense (precharge)/Precharge enable must be
selected depending on the generation of external
charger being used.
Generation 1 charging socket selected.
Generation 2 charging socket not selected. 13
• Can Current Sensors S:

Used for CAN-based current sensor. Only for VCE
battery systems at present.
• Aux. hardware current charge [A]:
Sets a limit on charging current due to hardware
restrictions outside BMS.Important to follow
this!
105 Ah battery system and higher capacities:
"260"
Autotruck battery system: “200"
• Dual contactor dedicated:
Used when there are two contactors in the system
that BMS controls - one for the battery and one for
charging. Only for VCE at present.
• Detect modules automatically:
Must be marked.
7. Create text fields for modules:

A function that is used if you have not selected "Detect
modules automatically". The function allows you to enter
the serial numbers of the modules, instead of it being ex-
ported automatically.

8. Make sure all of the values have been entered cor-

rectly!
Press "Configure".
9. Check the new configuration by reading the battery sys-

tem information. Make sure that the battery system is
communicating. See Information about the battery sys-
tem, page 13 - 69.
13.4.1.12.5 Software update

13.4.1.12.5
Software update
Use TruckCom to upgrade the software in the E-box.

The firmware package file consists of a configuration file, with the .xml format, which describes the
various applications for each electronic card.
Preparations
1. Select "Download software" under "Action".

13
2. Select the package that is to be updated and click on

"Update".
13.4.1.12.6 Protective mode

13.4.1.12.6
Protective mode
WARNING Serious error

An error which switches the battery system to protective mode is very serious and can cause
personal injury or material damage. The cause of the error must be identified before the bat-
tery can be used again.
► If the cause of the error cannot be identified, TMH support must be contacted for further
troubleshooting.
Preparations

1. Click on the "Protective mode” tab.

13
2. Click on "Detect fault".
3. The fault which caused the protective mode will be

shown.
4. Investigate the fault carefully. See Protective modeID,

page 13 - 33.

5. Confirm that the fault has been rectified by pressing

“Clear fault”.
NOTE! Faults cannot be cleared without a thorough
investigation.
13.4.1.12.7 Diagnostics
13.4.1.12.7
Diagnostics
Preparations

13
1. Click on the “Diagnostics” tab.

2. Click on “Read diagnostic data” to start loading informa-

tion.

13

3. The information is downloaded from the system.

Name Data Description Comments
Current Average cur-
rent in the
last second.
Primary Con- 0: Open Battery con-
tactor tactor
1: Time up
Secondary 0: Open. Charging Not used on
Contractor contactor all battery
1 Time up.
systems.
Precharge/ 0: Not active Output Not used on
AUX all battery
1: Active
systems.
Pilot 0: No Charger con-
nected
1: Yes
Q-sense 0: No Battery con- Not used on
nector/oper- all battery
1: Yes
ating clamp systems.
connected.
Enable 0: Not activ- Test of the
ated battery’s on/
off button.
1: Activated
ESO 0: Not activ- Test of the Not used on
ated emergency all truck mod-
switch off. els.
1: Activated
AUX2 0: Not activ- Not used on
ated all battery
systems.
1: Output
active
Tab. 4: Information read from the system

13
4. Click “Stop” to stop the diagnostics before further action.
13.4.1.13 Maintenance
13.4.1.13
Maintenance
13.4.1.13.1 Storing the battery system

13.4.1.13.1
Storing the battery system
The battery slowly discharges itself. This is partly due to the built-in battery management system. To protect
and save the battery capacity, the battery will enter sleep mode. To start the battery, see Sleep mode, page
13 - 11, Sleep mode, page 13 - 12.
Always charge a battery that warns for low battery charge before putting it in storage.
For storage temperature, see Technical data, page 23 - 1, Truck data, page 23 - 2.
If storing for less than two weeks
• No particular action is required.

If storing for longer than two weeks
• The battery will enter sleep mode after it has not been used for an extended period of time. To restart
the battery, see Sleep mode, page 13 - 11, Sleep mode, page 13 - 12.
• Charge the battery if required before using it.
If storing for more than six months
• Charge the battery fully before putting it in storage.

• Charge the battery fully every six months.

• Charge the battery fully before using it.
13.4.1.13.2 Inspecting the battery locking system

13.4.1.13.2
Inspecting the battery locking system
1. Inspect the battery’s protective plates.
2. Check the mounting of the lock yokes.
13.4.1.14 Recycling and transport

13.4.1.14
Recycling and transport
13.4.1.14.1 Recycling and transport

13.4.1.14.1
Recycling
Lithium-ion battery modules must be considered to be hazardous waste and must be handed in for recycling
at approved plants. Used lithium-ion batteries are covered by the EU’s Battery Directive (2006/66/EC) and
must be disposed of in accordance with national laws. Follow local regulations. Cleaned packaging must be
recycled in accordance with the applicable national regulations.
Transport
Lithium-ion battery modules are approved for transport according to test UL 38.3.
A lithium-ion battery module that is being transported is considered to be dangerous goods, UN3480
class 9. Only personnel trained in handling dangerous goods are permitted to mark and transport the
batteries.
• The battery terminals must be protected against accidental short-circuits.

• Normal and used lithium-ion battery modules must be packaged according to P903.
• Damaged lithium-ion battery modules must be packaged according to P908 or LP904.
13.4.1.15 Technical data

13.4.1.15
Technical data
13.4.1.15.1 Technical data

13.4.1.15.1
Technical data
Ambient temperature 0-40°C

Storage temperature -25-60°C
Voltage See data plate
Result See the battery charger data plate
Protection class: IP20
Approvals: CE and /or UL. See data plate
Tab. 5: Battery system
Product no.: See the marking on the top.
Battery type: See the marking on the top.
Voltage: 3.70 V
Capacity: 50 Ah
Energy content: See the marking on the bottom.
Ambient temperature: 0 - 45°C
Storage temperature: -30°C to +45°C
Tab. 6: Battery module

13.4.2 General alarm signals (audible/visual) C5160

13.4.2
General alarm signals (audible/visual) C5160
13.4.2.1 Horn
13.4.2.1
Horn
13.4.2.1.1 Overview, horn

13.4.2.1.1
Overview, horn
13
Pos. Designation
a Horn
13.4.2.1.2 Checking the horn function

13.4.2.1.2
Checking the horn function
1. Press the horn button to produce a sound signal. Check

both buttons.
Check connectors and fuses if there is no sound signal.
Replace the horn if the error persists.
13.4.2.1.3 Replacing the horn

13.4.2.1.3
Replacing the horn
13.4.2.1.3.1 Removing the horn

13.4.2.1.3.1
Removing the horn
Preparations

1. Disconnect the wiring harness from the horn (P4).
2. Unscrew the two screws to remove the mounting plate

and horn.
3. Disconnect the wiring harness from the horn.

4. Detach the horn from the mounting plate by undoing the

stop ring.
13
13.4.2.1.3.2 Fitting a horn
13.4.2.1.3.2
Fitting a horn
1. Fit the horn (P4) to the mounting plate. Tightening torque

1.7±0.5 Nm.
2. Connect the wiring harness to the horn.

3. Fit the mounting plate and the horn using the two
screws.
4. Connect the wiring harness to the horn.

13.4.3 Battery charger (built-in) C5170

13.4.3
Battery charger (built-in) C5170
13.4.3.1 Battery charger overview

13.4.3.1
Battery charger overview
c 13
Pos. Designation
a Battery charger connector for truck on lorry
b CAN connector
c Battery charger
d Charger connector
13.4.3.2 Description
13.4.3.2
Description
13.4.3.2.1 Installation recommendations for the “connection point” on a lorry

13.4.3.2.1
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 dimension of 16 mm2.
• Be sure to connect a 20 A fuse for the voltage supply line of the connection point, as close as possible
to the lorry battery's positive terminal.
• Another 20 A fuse should be mounted on the negative feed as close as possible to the charging cable
socket.
• Also ensure that the connection point and cable have sufficient mechanical protection. (e.g. double in-
sulated wire and/or protective tube)

• A sealed connection box or similar is ideal as a connection point, to which the supplied cable can be
connected.
13.4.3.3 Replacing the battery charger (onboard)

13.4.3.3
Replacing the battery charger (onboard)
13.4.3.3.1 Removing the battery charger (onboard)

13.4.3.3.1
Removing the battery charger (onboard)
Preparations
1. Undo the four screws.
2. Disconnect the wiring harness.
3. Remove the battery charger.

13.4.3.3.2 Fitting the battery charger (onboard)

13.4.3.3.2
Fitting the battery charger (onboard)
1. Install the battery charger in the truck and connect the

wiring harness.
13
2. Screw the four screws into place.

Resetting
13.4.4 Battery cut out switch, main contactor C5190

13.4.4
Battery cut out switch, main contactor C5190
13.4.4.1 Overview, main contactor

13.4.4.1
Overview, main contactor
i
h
e g
Pos. Designation
a Battery cBrix 50Ah
b Protective plate
c Main contactor
d Fuse
e Power cable -
f Power cable +
g Washer
h Seal
i Nut

13.4.4.2 Main contactor

13.4.4.2
Main contactor
13.4.4.2.1 Tighten the connections of the contactor

13.4.4.2.1
Tighten the connections of the contactor
Link target missing for title: [ID: 2177978123], Opening the electric panel
1. Tighten the connections of the contactor. Make sure that

the torque is within the given interval, 8.75 0.7⁄0.7 N·m.
Tighten if needed.
13
13.4.4.2.2 Replacing the main contactor

13.4.4.2.2
Replacing the main contactor
13.4.4.2.2.1 Removing the main contactor

13.4.4.2.2.1
Removing the main contactor
Link shutdown? Link target missing for title: [ID: 2177978123]
1. Disconnect the battery from the main contactor by un-

screwing the nuts, washers and wiring harness.

2. Remove the fuse by unscrewing its nuts and washers.
3. Disconnect the wiring harness from the underside of the

main contactor by pulling it downwards.
4. Remove the main contactor from the protective plate by

undoing the two screws.

13.4.4.2.2.2 Fitting the main contactor

13.4.4.2.2.2
Fitting the main contactor
1. Install the main contactor at the protective plate and se-

cure it using the two screws.
13
2. Connect the wiring harness.
3. Install the fuse, washers and nuts with 8.75 0.7⁄0.7N·m.

Instrument panel, display C5200
4. Install the wiring harness, washers and nuts with 8.75

0.7
⁄0.7N·m.
Link target missing for title: [ID: 2177980939]
13.5 Instrument panel, display C5200

13.5
13.5.1 Menu
13.5.1
Menu
13.5.1.1 Menus
13.5.1.1
Menus
The speed control is used for menu navigation.

To select a menu item, press and release the horn button.
Menu item "ESC" always returns you to the previous menu.
If logged in without CAN key or TruckCom, only a limited number of menus are available.
13.5.1.2 Menu navigation

13.5.1.2
Menu navigation
Proceed as follows if you only want to view the different truck settings:
1. Ensure that the truck is switched off. Connect CAN key or enter the PIN code. Note: Do not press the ON
button.
3. Move between menus by turning the speed control several times.
4. Press and release the horn button to select which menu to view.
5. Turn the speed control several times to move between the different positions in the selected menu.
6. If logged in without CAN key or TruckCom, only a limited number of menus are available and unavailable
menus are not shown.
The following are not shown:
- Calibration (CAL)
- PIN code menu (Pin)
- Collision sensor log (c)
- Service mode (Ser)
7. Switch off the truck by pressing the OFF button or return to the previous menu by selecting "ESC".

13.5.1.3 Menu overview

13.5.1.3
Menu overview
Log on using horn
Parameter set/ Calibrate PIN code menu Escape

Info menu view Emergency drive
“CAL”
“Cal” “Pin” “ESC”
“InFo” “PAr” “Ed”
Truck resets
Starts truck in
First parameter emergency drive 1st calibrate Enter PIN code
“1” mode. All LEDs function edit function
are flashing “1”
Last parameter Last calibrate

“XXXX” function
“X”
Escape Escape
“ESC”
Back to prev menu
“ESC”
Back to prev menu
13
Part number Build in test ICH Escape

Hour meter display Error log display Shock lockout log
display “tESt” “ESC”
“H” “E” “c”
“Pn” Back to prev menu
A time “A” Software part no Display test Latest shock PIN

Latest error “1”
Total key on time “SPn” Walking 8 “1”
B time “b” Oldest error “XX” Hardware part no Oldest shock PIN
Throttle
Active time (XX max 50) “HPn” “10”
Accessible to
the operator
C time “c” Escape Escape
Machine no Emergency
Drive avtive time “ESC” “ESC”
“no” Reverese
Back to prev menu Back to prev menu
D time “d” Only accessible

Hydraulic active Hardware serial no Lift/Lower with the CAN key,
time “HSn” operator
S time “S” Escape

“ESC” Sensilift
Time to service
Back to prev menu
Escape
“ESC” Keyboard
Back to prev menu
Escape by
pressing horn
13.5.1.4 Menu information

13.5.1.4
Menu information
An explanation/description of the various menus is found below.

For access and navigation among the menus. Menu navigation, page 13 - 104.
13.5.1.5 Show hour meter values

13.5.1.5
Show hour meter values
“H” is shown on the display.
1. Press the horn button to select. The hour counter symbol is lit.

2. You can obtain the following information by pressing the speed control repeatedly:
- Total time (A)
- Total operating time (b)
- Total operating time drive motor (c)
- Total operating time hydraulic motor (c)
- Time until service (S)
3. To show an hour meter value, release the speed control when the required hour meter symbol is
shown on the display. The hour meter value in question is shown on the display.
13.5.1.6 Show error codes

13.5.1.6
Show error codes
“E” is shown on the display.

A maximum of 50 error codes are stored.
1. Press the horn button to select.
- Latest error code (1)
Next error code, etc. (2)
Last error code (XX, max 50)
3. To show an error code, release the speed control when the required error code is shown on the dis-
play.
13.5.1.7 Show part numbers for software/hardware

13.5.1.7
Show part numbers for software/hardware
“Pn” is shown on the display.
1. Press the horn button to select.
SPn - Software package
HPn - Logic card
no - Machine number
HSn . Logic card serial number
3. To show a part number, release the speed control when the required part number is shown on the
display.

13.5.1.8 Built-in test ICH

13.5.1.8
Built-in test ICH
“tESt" is shown on the display.
1. See section Link target missing for title: [ID: 2668805771]
13.5.1.9 Show collisions

13.5.1.9
Show collisions
If there is a collision sensor installed on the CAN bus, it registers when the truck bumps into some-
thing. Information about the collision is stored in the truck's internal memory. The last ten registered
collisions can be read directly from the display together with operator identity via the PIN code. Addi-
tional information is available via TruckCom, where collision levels and time indications can also be
read.
“c” is shown on the display.
1. Press the horn button to select. 13

2. By pressing the speed control repeatedly, you can see the last 10 collisions.
3. If a 5-digit PIN code is shown, the first digit is shown and then the other 4 digits are shown.
13.5.1.10 Show/change parameters

13.5.1.10
Show/change parameters
“Par” is shown on the display.
1. Press the horn button to select. The parameter symbol lights up.
2. By pressing the speed control repeatedly, you can move through the parameter list. Parameter list,
page 4 - 1
3. To show a parameter, release the speed control when the required parameter is shown on the dis-
play. Press the horn button to change the parameter.
13.5.1.11 Emergency driving mode

13.5.1.11
Emergency driving mode
“Ed" is shown on the display.

Link target missing for title: [ID: 2668665227]
13.5.1.12 Calibration
13.5.1.12
Calibration
“Cal" is shown on the display.

Link target missing for title: Kalibreringar [ID: 2175729547]
13.5.1.13 Show/change PIN code

13.5.1.13
Show/change PIN code
“Par” is shown on the display.
1. Press the horn button to select. The parameter symbol lights up.

2. By pressing the speed control repeatedly, you can move through the parameter list. Parameter list,
page 4 - 1
3. To show a parameter, release the speed control when the required parameter is shown on the dis-
play. Press the horn button to change the parameter.
13.5.1.14 PIN codes

13.5.1.14
PIN codes
13.5.1.14.1 General
13.5.1.14.1
General
1. The PIN codes can be used e.g. to link different operator experience levels to specific truck character-
istics – Operator profiles.
Operator parameters can be adjusted individually for up to ten different operator profiles.
The PIN codes are organised in blocks and profiles. Each block can hold ten operator profiles, each
with its own PIN code.
In order to use the PIN codes in a block, the block must first be activated.
By default, block one (1) is activated, which means that initially the truck has three ready-to-use oper-
ator profiles. PIN code defaults, page 13 - 111
PIN codes can be activated or changed according to the preferences of the operator. An operator pro-
file is activated upon normal log-in by all PIN codes whose block number is activated.
13.5.1.14.2 PIN code for resetting the truck

13.5.1.14.2
PIN code for resetting the truck
1. If the truck has stopped as a result of a collision, it needs to be reset using a PIN code. The PIN code
must be programmed by a service technician during installation, see section Programming PIN codes,
page 13 - 109
The PIN code to be activated can be found in operator profile 1 and special block 10. The default
value of the PIN code is 0000. This must be changed to the PIN code selected by the service techni-
cian.
The PIN code cannot contain the same combination of digits as any of the other programmed PIN
codes.
With parameter Resetting procedure after collision, it is possible to change how reset after collision is
carried out.

13.5.1.14.3 Programming PIN codes

13.5.1.14.3
Programming PIN codes
If the truck is configured to handle PIN codes, 100 different PIN codes can be programmed.
There are two possible methods for programming PIN codes. TruckCom or the truck's keypad.
The first time a block is activated, all PIN codes in the block are set to “0000”. If a block with PIN
codes not set to “0000”, is deactivated and later reactivated, the PIN codes with other values than
“0000” will again be valid.
Use of PIN code “0000” is permitted, but it means that the position is deactivated. It is never possible
to log in with PIN code “0”.
The truck firmware stores the standard PIN-code set according to the table, see PIN code defaults,
page 13 - 111.
The truck program will not accept attempts to program a PIN code that has already been set. The pre-
vious code will be restored.
When a PIN code is programmed, there is a check to ensure that it is not used elsewhere in the table,
regardless of whether the block is active or inactive. 13
The PIN code setting menu is used for managing PIN codes; the menu can only be accessed when a
service key is connected.
1. Make sure that the truck is switched off.
2. Connect CAN keyCAN key 7516707, page 21 - 7 to connector [X41]. Enter the PIN code.
4. Turn the speed control several times until “Pin” is shown on the display.

5. Press the horn button. Select programming commands according to the following table:
Restore factory settings Press 1 + ON button Blocks 0-9 are deactivated, and
all PIN codes are reset to 0000.
Activate a new PIN code block Press 2 + b + ON button b = Block 0-9
Upon activation of a PIN code
block, the codes already saved
become available again.
Deactivate a PIN code block Press 3 + b + ON button b = Block 0-9
No codes will be deleted. They
will be available again when the
PIN code's block is reactivated.
Programming a new PIN code Press 4 + b + P + NNNN + ON b = Block 0-9
button
P = Operator profile 1-10
Note: The block in question must
NNNN = PIN code
first be activated.
Note: It is only possible to assign
If the PIN code is correct, the
one digit to an operator profile.
code is shown for 3 seconds, fol-
As a result, operator profile 10
lowed by the text "donE" for 2
should be assigned as 0 (zero).
seconds. It is possible to enter a
new PIN code within these 5
seconds by pressing a key on
the keyboard. If the PIN code is
wrong, the display shows “Err”. If
you press the red button, the
new PIN code is not saved.
PIN code programming for truck Press 6 + NNNN + ON button NNNN = PIN code
reset after collision
The PIN code that is activated
can be found in operator profile 1
and special block 10. The default
value of the PIN code is 0000.
This must be changed to the PIN
code selected by the service
technician.
6. Switch off the truck by pressing the OFF switch. Programming of PIN codes is now complete. Verify
that programming has been done correctly by logging in using one of the new PIN codes.
For PIN code management via TruckCom, see the TruckCom Manual.
It is important to ensure the correct operator profile is activated when a specific PIN code is entered.
This is especially important when an operator profile has been set to apply for a specific truck applica-
tion.
13.5.1.14.4 PIN code at delivery

13.5.1.14.4
PIN code at delivery
Trucks that normally require a PIN code to start are delivered with a four-number delivery code, which is in-
dicated by a protective film covering the keypad.
Remove the protective film when supplying the truck to the customer, and change the PIN codes for the
truck.
(Trucks with Smart Access are delivered with a transport key card)
All truck are delivered with the same set of PIN codes: Three (3) codes for manual trucks and one (1) code
for auto trucks. PIN code defaults, page 13 - 111

13.5.1.14.5 PIN code defaults

13.5.1.14.5
PIN code defaults
1. When replacing an electronic unit (main computer), all PIN codes will be set as 0 (zero). This
means that the PIN codes must be configured in the truck using TruckCom.
Log-in with PIN codes will not be affected if you are only updating the truck software.
Service personnel are urged to keep notes on activated blocks, changed PIN codes and spe-
cial operator profile settings.
The PIN codes are factory set so that only block 1/operator profiles 1-10 are activated. Note: It is only
possible to assign one digit to an operator profile. The operator profile 10 should be set to 0 (zero).
Block 10 and operator profile 1 are only used for PIN code programming for truck reset after collision,
the remaining operator profiles in block 10 are not used.
PIN code defaults
Operator pro- 1 2 3 4 5 6 7 8 9 10
file no.
Block 0 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 1 1258 2258 3258 0000 0000 0000 0000 0000 9258 0000 13
Block 2 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 3 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 4 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 5 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 6 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 7 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 8 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 9 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 10 0000
2. The factory-set operator profiles are classified as follows:

Operator profile Characteristic Remarks
1 Standard profile Transport PIN code for all trucks, as indicated on the
transport sticker (1258)
2 Beginner profile Factory pre-set PIN code at the time of delivery (2258).
3 Advanced profile Factory pre-set PIN code at the time of delivery (3258).
Operator parameters set to max. values
9 Standard profile Factory pre-set PIN code at the time of delivery (9258),
only for automatic trucks.

Power system travel function C5400
13.5.2 Hour counter, tachograph C5290

13.5.2
Hour counter, tachograph C5290
13.5.2.1 Checking error log and operating hours

13.5.2.1
Checking error log and operating hours
1. Inspect the error log and operating hours.
13.6 Power system travel function C5400

13.6
13.6.1 Drive motor cables/resistors/fuses C5430

13.6.1
Drive motor cables/resistors/fuses C5430
13.6.1.1 Overview, drive motor wiring harness

13.6.1.1
Overview, drive motor wiring harness
b
c
f
e
d
Pos. Designation
a Connection to motor control panel [W]
b Connection to motor control panel [U]
c Connection to motor control panel [V]
d Connection to drive motor [2]
e Connection to drive motor [3]
f Connection to drive motor [4]

13.6.1.2 List of fuses

13.6.1.2
List of fuses
The fuses are of the type "FKS" flat pin fuses. The rated current is printed on the top of the fuses and is also
indicated by the colour coding of the fuse body.
a
3.6
19 5
(13.2)
19.7
6.5
5.2 0.62
(4.1) 3.5
14.5 3.8
17
The fuses' measurements, in mm, without given tolerances a = rated current. 13

Rated current (A) Colour Remarks
1 Black -
3 Violet -
5 Light brown -
7.5 Brown -
10 Red -
15 Blue -
20 Yellow -
25 White Brown print
30 Light green -

13.6.2 Motor control C5460

13.6.2
Motor control C5460
13.6.2.1 Overview, motor control panel

13.6.2.1
Overview, motor control panel
Pos. Designation
a Motor control panel

13.6.2.2 Checking the cable connections

13.6.2.2
Checking the cable connections
1. Make sure that the wire connections to the transistor

panel are correctly fitted.
13
13.6.2.3 Checking the transistor panel mounting

13.6.2.3
Checking the transistor panel mounting
Preparations
1. Make sure the transistor panel mounting is correct and

undamaged.

13.6.2.4 Replacing the motor control panel

13.6.2.4
Replacing the motor control panel
13.6.2.4.1 Removing the motor control panel

13.6.2.4.1
Removing the motor control panel
Preparations
1. Undo and remove the screws and washers at the B+ and

P- terminals on the motor control panel.
2. Remove the wiring harness to the pump motor and the

main contactor.
3. Undo and remove the screws and washers at the U, V

and W terminals on the motor control panel.

4. Remove the wiring harness for the drive motor.
5. Undo and remove the screws and washers at the B- ter- 13

minal on the motor control panel.
6. Remove the main wiring harness and the battery cables.

7. Disconnect the main wiring harness connector.
8. Undo and remove the four screws holding the motor

control panel to the electric board.
9. Remove the motor control panel.

13.6.2.4.2 Installing the motor control panel

13.6.2.4.2
Installing the motor control panel
1. Install the motor control panel and fix in place to the

electric board using the four screws.
13
2. Connect the main wiring harness connector.
3. Connect the main wiring harness and the battery cables

to the B- terminal on the motor control panel.

4. Fit the screws and washers at the B- terminal on the mo-

tor control panel. Tightening torque: 7 1.4⁄1.4N·m.
5. Install the drive motor cables to the U, V and W termin-

als of the motor control panel.
6. Fit the screws and washers at the U, V and W terminals

on the motor control panel. Tightening torque: 7
1.4
⁄1.4N·m.

7. Connect the pump motor and the main contactor cables

to the B + and the P- terminals on the motor control
panel.
8. Fit the screws and washers at the B + and the P- termin- 13

als on the motor control panel. Tightening torque: 7
1.4
⁄1.4N·m.

Control system, working function C5500
Resetting
13.7 Control system, working function C5500

13.7
13.7.1 Work function harnesses/fuse C5590

13.7.1
Work function harnesses/fuse C5590
13.7.1.1 Overview, main wiring harness 50 Ah

13.7.1.1
Overview, main wiring harness 50 Ah
n
i m
a d l
b k
c h
e j o
f
p
g
y
q
s
x w r
t
v

a Fuse 15 A, [F3] b Fuse 7.5 A, [F51]
c Fuse 7.5 A, [F50] d Connection to main switch for
the battery, [S1]
e Connection to B+ f Connection to B- [cable 40:1]
g Connection to external char- h Steering angle sensor (OCC),
ger, [X1] [B13]
i Data Handling Unit (DHU), j Speed sensor, [B11]
[K110]
k Connection to parking brake, l Connection to horn, [P4]
[Q1]
m Connection to USB socket, n Connection to emergency
[X25] switch off, [S24]
o Temperature sensor, [B1] p Solenoid valve for fork lower-
ing, [Q4]
q Connection to tiller arm, [X5] r Connection to tiller arm, [X65]
s Sensor for support arm in top t Sensor for support arm in bot-
position, [B65] tom position, (Low Speed
when Low Forks), [B62]
u Contact, [X40] v Connection to battery [X1]
w Connection to battery [X2] x BCU, [A31]
y Connection to main contactor’s
fuse holder [cable 7]

13.7.1.2 Overview, main wiring harness 150 Ah

13.7.1.2
Overview, main wiring harness 150 Ah
e 13
a f g r s
q t
b p
c
d h o
n u
i k
l m
j v
w
a Connection to horn, [P4] b Temperature sensor, [B1]
c Speed sensor, [B11] d Connection to parking brake,
[Q1]
e Connection to USB socket, f Solenoid valve for fork lower-
[X25] ing, [Q4]
g Data Handling Unit (DHU), h Connection to emergency
[K110] switch off, [S24]
i Sensor for support arm in bot- j Sensor for support arm in top
tom position, (Low Speed position, [B65]
when Low Forks), [B62]
k Connection to tiller arm, [X5] l Connection to tiller arm, [X65]
m Steering angle sensor (OCC), n Signal cable, [J2]
[B13]
o Signal cable, [J1] p Connection to B- [cable 40:1]
q Connection to B+ [cable 6] r Connection to motor control,
[T12]
s Fuse 7.5A [F51] t Fuse 7.5A [F50]
u Connection to external char- v Main contactor, [Q10]
ger, [X1]


w Connection to CAN, [X40]
13.7.1.3 BMS overview

13.7.1.3
BMS overview
a) BMS
13.7.1.4 Inspecting the wiring harnesses

13.7.1.4
Inspecting the wiring harnesses
1. Inspecting all wiring harnesses. Replace any that is damaged.

Power system working function C5600
13.8 Power system working function C5600

13.8
13.8.1 Battery/motor cables, fuse C5680

13.8.1
Battery/motor cables, fuse C5680
13.8.1.1 Overview, battery 105/150 Ah with wiring harness

13.8.1.1
Overview, battery 105/150 Ah with wiring harness
g
h
f i
j
13

a Terminal pole (-), torque 22 b Terminal pole (+), torque 22
Nm Nm
c B(-) on battery d B(+) on battery
e Signal cable f Spacer
g Terminal pole PMU (+) h Connection PMU (+), torque 22
Nm
i Terminal pole battery (-), j Connection battery (-)
torque 22 Nm
k Fuse 150 A l B(-) on motor control
m B(+) on motor control
13.8.1.2 Overview, battery charger wiring harness, external

13.8.1.2
Overview, battery charger wiring harness, external
Pos. Designation
a X40
b K4

13.8.1.3 Overview, battery charger wiring harness, external with heater

13.8.1.3
Overview, battery charger wiring harness, external with heater
Pos. Designation
a X40
b K4
c K11
13.8.1.4 Overview, battery charger wiring harness, truck

13.8.1.4
Overview, battery charger wiring harness, truck
a
b c d
e
g
h
i
Pos. Designation
a EU charging connector, UK version also
available,
b Truck charger (option)
c Connector 22:1, only for UK and Jpm
d Connector 51:1, only for UK and Jpm
e A31 charger
f Fuse F3 (15 Amp)
g 40 motor controller
h No. 7, F1, 150 A fuse. Located above con-
tactor.
i X40

13.8.1.5 Overview, pump motor wiring harness

13.8.1.5
Overview, pump motor wiring harness
a b
c
13
Pos. Designation
a Connection to pump motor (+), tightening
torque 4 ± 1 Nm
b Connection to pump motor (-), tightening
torque 4 ± 1 Nm
c Connection to motor control (B+)
d Connection to motor control (P-)
13.8.1.6 Overview, battery lock

13.8.1.6
Overview, battery lock
a
c
b
Pos. Designation
a Screw, torque 2 Nm
b Nut
c Plate

13.8.1.7 Overview, battery wiring harness 50 Ah

13.8.1.7
Overview, battery wiring harness 50 Ah
c e
f
d
Pos. Designation
a Connection to motor control (B-), [cable 40],
7±4.1 Nm
b Connection to motor control (B+), [cable 6],
7±4.1 Nm
c Connection to battery, [cable +]
d Connection to battery, [cable 40]
e Connection to main contactor, [cable 6]
f Connection to fuse 150 A, [cable +]
13.8.1.8 Replacing the battery cables

13.8.1.8
Replacing the battery cables
13.8.1.8.1 Disconnect the battery wiring harnesses

13.8.1.8.1
Disconnect the battery wiring harnesses
Preparations
1. Mark each wiring harness connected to the battery.
2. Detach the wiring harnesses and wrap each cable lug with electrical tape.
13.8.1.9 Inspecting the wiring harnesses

13.8.1.9
Inspecting the wiring harnesses
1. Inspecting all wiring harnesses. Replace any that is damaged.

Control/protection electronics C5700
13.9 Control/protection electronics C5700

13.9
13.9.1 Transmitting/receiving equipment C5760

13.9.1
Transmitting/receiving equipment C5760
13.9.1.1 I_Site
13.9.1.1
I_Site
13.9.1.1.1 Overview
13.9.1.1.1
Overview
a
b
13
Pos. Designation
a I_Site antenna
b DHU
13.9.1.1.2 I_Site
13.9.1.1.2
I_Site
I_Site is a system that collects data from the trucks.

I_Site is available in three different hardware versions:
• DHU/DHU2 with external antenna and shock sensor

• DHU2+ with external antenna and shock sensor
• DHU2+ with integrated shock sensor and external antenna for cellular communication plus GNSS
The data handling unit (DHU) receives data from the truck and transfers it to a central server at a set interval.
The data is then accessible to users with an authorised code via a website. No hardware installation is re-
quired at the customer site.
The communication can take place via different protocols depending on the version of DHU that is being
used:
• DHU - GPRS (2G)

• DHU2 - GPRS (2G) and UMTS (3G)
• DHU2+ - GPRS (2G), UMTS (3G) and LTE (4G)
Reports can be viewed showing information such as the following:
• Truck usage
• Operator utilisation
• Battery consumption and charging behaviour
• Hour meter readings
If the system includes a shock sensor, the following collision data will also be provided:
• Operator involved in collision

• Severity of collision

• Error codes generated by a collision

• When the collision occurred and how long the truck had been in use before the collision
Collision sensitivity and the post-collision resetting procedure can be programmed separately for each indi-
vidual truck.
For instructions on installation, configuration, set-up and troubleshooting, see the separate manual for I_Site.
13.9.1.1.3 Replacing the DHU

13.9.1.1.3
Replacing the DHU
13.9.1.1.3.1 Removing the DHU

13.9.1.1.3.1
Removing the DHU
1. Disconnect signal cables [K110] and [T20] from the

DHU.
2. Disconnect the DHU from the truck by unscrewing the

two screws with washers.

3. Pull the plug out of the DHU.
13
13.9.1.1.3.2 Installing the DHU
13.9.1.1.3.2
Installing the DHU
1. Attach the plug to the DHU.
2. Fit the DHU using the two washers and screws.

3. Connect signal cables [K110] and [T20] to the DHU.
4. Start by pressing the battery system'sOn/off button.
5. Check that the LED on the DHU illuminates with a

steady green light.
13.9.1.1.4 Checking DHU/I-site [K110]

13.9.1.1.4
Checking DHU/I-site [K110]
1. Check that the DHU's green LED is lit. If the LED is not lit: Check that the DHU's feed voltage = bat-
tery voltage.
2. Make sure it is possible to connect TruckCom to the DHU. If it is possible to connect them, check the
DHU's configuration. If there is a power supply, but no communication, check the CAN bus.
3. If it is still not possible to establish communication with the DHU, replace the unit.

Protective sensors, position sensors C5800
13.10 Protective sensors, position sensors C5800

13.10
13.10.1 Overview, OCC

13.10.1
Overview, OCC
c
13
Pos. Designation
a Screw
b Upper sensor holder
c Sensor
d Lower sensor holder
e Screw, 3.5±0.5 Nm

13.10.2 Maximum speed during cornering (OCC)

13.10.2
Maximum speed during cornering (OCC)
OCC sets the maximum speed when turning. An automatic reduction in speed occurs when the angle of the
steering arm is greater than 35 degrees. The speed reduction is adjusted using parameters 222 and 315,
see Parameter list, page 4 - 1.

13.10.3 Lift/lowering/reach movement sensor C5820

13.10.3
Lift/lowering/reach movement sensor C5820
13.10.3.1 Height sensor

13.10.3.1
Height sensor
13.10.3.1.1 Overview, height sensor

13.10.3.1.1
Overview, height sensor
a
c
13
d
Pos. Designation
a Locking nut
b Bracket
c Height sensor
d Screw

13.10.3.1.2 Replacing the height sensor

13.10.3.1.2
Replacing the height sensor
13.10.3.1.2.1 Removing the height sensor

13.10.3.1.2.1
Removing the height sensor
a
d
1. Disconnect the truck battery.
2. Disconnect the electrical connection of the height sensor

d (d).
3. Disconnect the electrical connection of the LSwLF (Low

Speed when Low Forks) sensor.Removing LSwLF
sensor, LSwLF option, page 13 - 139.

4. Undo the screws (b) of the sensor bracket and lift it off
b the truck.
13
5. Remove the sensor by undoing the screws (e) from the
locking nuts (a).
a 6. Discard the locking nuts (a).
13.10.3.1.2.2 Installing a height sensor

13.10.3.1.2.2
Installing a height sensor
1. Mount the height sensor on the bracket with the screws

(e) and new locking nuts (a).
2. Mount the bracket on the truck with the screws (b).

b

3. Connect the electrical connection of the height sensor

d (d).
4. Connect the truck battery.
13.10.3.2 Low Speed when Low Forks (LSwLF) sensors

13.10.3.2
Low Speed when Low Forks (LSwLF) sensors
13.10.3.2.1 Overview, LSwLF sensor

13.10.3.2.1
Overview, LSwLF sensor
a
c
Pos. Designation
a Locking nut
b Bracket
c LSwLF sensor
d Screw

13.10.3.2.2 Replacing LSwLF sensors

13.10.3.2.2
Replacing LSwLF sensors
13.10.3.2.2.1 Removing LSwLF sensor, LSwLF option

13.10.3.2.2.1
Removing LSwLF sensor, LSwLF option
1. Disconnect the truck battery.
2. Disconnect the electrical connection of the height sensor. See Removing the height sensor, page
13 - 136.
3. Disconnect the electrical connection of the LSwLF (Low

d Speed when Low Forks) sensor (d).
13
4. Remove the bracket (c), together with the sensors, by

b undoing the screws (b)
5. Unscrew the sensor and discard the locking nuts.
13.10.3.2.2.2 Installing LSwLF sensor, LSwLF option

13.10.3.2.2.2
Installing LSwLF sensor, LSwLF option
1. Mount the LSwLF sensor on the bracket with the screws (e) and new locking nuts (a).
2. Mount the bracket (c) with the screws (b).
3. Connect the electrical connection of the LSwLF sensor (d).
4. Connect the electrical connection of the height sensor.
5. Connect the truck battery.

13.10.4 Safety probes/sensors C5830

13.10.4
Safety probes/sensors C5830
13.10.4.1 Emergency switch off

13.10.4.1
Emergency switch off
13.10.4.1.1 Overview
13.10.4.1.1
Overview
Pos. Designation
a Emergency switch off
13.10.4.1.2 Checking the emergency stop switch

13.10.4.1.2
Checking the emergency stop switch
1. Make sure the emergency off switch does not have any
cracks or other damage.
Replace the emergency off switch if necessary, see Re-
moving the safety switch.

13.10.4.1.3 Checking the emergency switch function

13.10.4.1.3
Checking the emergency switch function
1. Drive the truck carefully and press the emergency switch

off button. Make sure that the truck cannot be driven
when the emergency switch off is activated.
If it is still possible to drive the truck: Troubleshoot the
wiring harness, replace the emergency switch off.
13
13.10.4.1.4 Replacing the emergency stop switch

13.10.4.1.4
Replacing the emergency stop switch
13.10.4.1.4.1 Removing the emergency off switch

13.10.4.1.4.1
Removing the emergency off switch
Serial number: 6659479-

Preparations
1. Disconnect the connector (S21) from the emergency off

switch.
2. Loosen the threaded ring holding the emergency off

switch.

3. Remove the emergency off switch.
13.10.4.1.4.2 Installing the emergency off switch

13.10.4.1.4.2
Installing the emergency off switch
Serial number: 6659479-
1. Install the emergency off switch.
2. Install the threaded ring holding the emergency switch

off.

3. Connect the contact (S21) of the emergency switch off.
Resetting 13
Installing the top cover, page 8 - 2


Hydraulics/Pneumatics C6000 14
14.1 Description..................................................................................................................................... 14 - 1
14.1.1 Hydraulic hygiene ............................................................................................................. 14 - 1
14.1.1.1 Definitions – hydraulic parts ................................................................................ 14 - 1
14.1.1.2 Inside cleaning .................................................................................................... 14 - 1
14.1.1.3 Packaging ........................................................................................................... 14 - 1
14.1.1.4 Handling .............................................................................................................. 14 - 1
14.1.1.5 Storage................................................................................................................ 14 - 1
14.1.1.6 Work procedures................................................................................................. 14 - 1
14.2 Inspecting the hydraulic system..................................................................................................... 14 - 2
14.3 Quick change connectors .............................................................................................................. 14 - 2
14.3.1 Overview quick change connectors .................................................................................. 14 - 2
14.3.2 Removing female quick change connectors ..................................................................... 14 - 3
14.3.3 Removing female quick change connectors ..................................................................... 14 - 4
14.3.4 Installing female quick change connectors ....................................................................... 14 - 5
14.3.5 Removing a quick change connector (male)..................................................................... 14 - 6
14.3.6 Installing a quick change connector (male)....................................................................... 14 - 7
14.4 Hydraulic unit C6100 ..................................................................................................................... 14 - 8
14.4.1 Overview ........................................................................................................................... 14 - 8
14.4.2 Hydraulic oil tank C6110 ................................................................................................... 14 - 8
14.4.2.1 Checking the hydraulic oil level........................................................................... 14 - 8
14.4.2.2 Oil change ........................................................................................................... 14 - 9
14.4.3 Filter, filter housing C6130 ................................................................................................ 14 - 9
14.4.3.1 Air filter ................................................................................................................ 14 - 9
14.4.4 Pressure/flow/lowering valve C6170............................................................................... 14 - 10
14.4.4.1 Adjusting the pressure limiting valve................................................................. 14 - 10
14.4.5 Replacing the hydraulic unit............................................................................................ 14 - 11
14.4.5.1 Removing the hydraulic unit.............................................................................. 14 - 11
14.4.5.2 Installing the hydraulic unit................................................................................ 14 - 11
14.5 Hydraulic cylinder C6600............................................................................................................. 14 - 12
14.5.1 Main lift cylinders C6610................................................................................................. 14 - 12
14.5.1.1 Inspect lifting cylinder........................................................................................ 14 - 12

14 Hydraulics/Pneumatics C6000
14.6 Hydraulic unit tightening torques ................................................................................................. 14 - 12
14.6.1 Hydraulic unit tightening torques..................................................................................... 14 - 12

Description
Software: 7662518
14
Hydraulics/Pneumatics C6000
14.1 Description
14.1
Description
14.1.1 Hydraulic hygiene

14.1.1
Hydraulic hygiene
14.1.1.1 Definitions – hydraulic parts

14.1.1.1
Definitions – hydraulic parts
• "Clean oil" is defined by the purity code 19/16/13 according to ISO4406:1999 or better.
• When hydraulic components are replaced (valves, wires, etc.), original spare parts specified by the
manufacturer must be used. This is necessary in order to guarantee the safety and function of the
truck.
14.1.1.2 Inside cleaning

14.1.1.2
Inside cleaning
If new, genuine components specified by the manufacturer are used, they do not normally require cleaning.
These are cleaned to a sufficiently high level for the hydraulic system. New, individual components such as 14
hydraulic couplings must be blown clean with dry, filtered air since they have been stored in a service
vehicle. All genuine hoses specified by the manufacturer are washed internally to the right level of cleanli-
ness.
If the technician intends to reuse the truck's hydraulic parts in the same truck they came from after removal
and servicing, these may requiring cleaning; see Work procedures, page 14 - 1.
14.1.1.3 Packaging
14.1.1.3
Packaging
All genuine spare parts specified by the manufacturer are packaged in a manner that ensures cleanliness,
e.g. with a protective bag or a plug to prevent contamination.
As a minimum, loose hydraulic parts must be stored in a clean box with a closed lid.
The packaging (protective plugs, masking, plastic bag, etc.) must not be removed until immediately before
the component is to be fitted in a workplace suitable for handling hydraulic parts. All protective materials
must be discarded after use.
14.1.1.4 Handling
14.1.1.4
Handling
Hydraulic parts must be handled and transported with the greatest care. The transport packaging must be
used throughout the entire handling chain and only opened when it is time for installation in the truck.
Make sure that no contamination, like dust and dirt, is found on the packaging before it is opened.
14.1.1.5 Storage
14.1.1.5
Storage
Hydraulic components must be handled and stored so that:
• no rusting can occur.

• they are protected against dust and dirt particles, e.g. through storage in clean boxes with lids.
• no mechanical deformation can occur.
14.1.1.6 Work procedures

14.1.1.6
Work procedures
When working on the hydraulic system, a clean environment must be created so that no impurities can enter
the system.
No work that generates particles may be carried out in the same workplace or close to where work is being
carried out on the hydraulic system.

Inspecting the hydraulic system
The service technician must ensure that the hydraulic parts used are undamaged and that the cleanliness for
genuine spare parts specified by the manufacturer is maintained.
Couplings for pipe ends or other openings must never be removed until the part is to be fitted to the receiving
component.
Before you start the job:

• Remove all dirt in the area in which the work will be performed. Clean around the various hydraulic
parts if you intend to remove them.
• All hydraulic parts, like pipe couplings and unions, must be blown clean with dry, filtered air prior to fit-
ting.
• If the hydraulic tank is removed, protect it with e.g. a large bag to prevent dust from entering the tank.
If the inside of the hydraulic tank must be cleaned, agitate with new hydraulic oil and then drain the oil.
Do not use cloths or the like inside the tank. Fill new oil via the tank's oil filter.
• Sealing material like flax, caulking compounds or Teflon are not permitted.
When the job is done:

• Check components and connections for leaks.
• Listen for abnormal noise when starting the hydraulic system.
• Tighten all screwed joints, plugs and screws in the system after releasing the pressure.
• Check the oil level with the cylinders retracted after purging the system, top up if needed.
14.2 Inspecting the hydraulic system

14.2
Inspecting the hydraulic system
1. Check hydraulic hoses and hose couplings for cracks or any other damage.
If necessary, replace the hydraulic hoses or the couplings.
2. Make sure that the hydraulic unit is properly connected.
3. Make sure that there are no leaks in the hydraulic system.
14.3 Quick change connectors

14.3
Quick change connectors
14.3.1 Overview quick change connectors

14.3.1
Overview quick change connectors
a b c
Pos. Designation
a WEO insert (female)
b Disassembly ring
c Assembly stop

14.3.2 Removing female quick change connectors

14.3.2
Removing female quick change connectors

• 19mm WEO insert removal 7539594
• Plug 10 mm / 1/4" (male) 254526
• Plug 13 mm / 3/8" (male) 254527
• Plug 16 mm / 1/2" (male) 254528
• Plug 10 mm / 1/4" (female) 254529
• Plug 13 mm / 3/8" (female) 254530
• Plug 16 mm / 1/2" (female) 254531
1. Place the removal tool up against the WEO insert

19mm WEO insert removal 7539594, page 21 - 9
14
2. Remove the WEO insert

3. Fit protective plugs to the insert and the male connector

in order to avoid oil spills. Plug 19 mm / 1/4" (male)
Plug 23 mm / 3/8" (male)
Plug 19 mm / 1/4" (female)
14.3.3 Removing female quick change connectors

14.3.3
Removing female quick change connectors
1. Place the removal tool up against the WEO insert

2. Remove the WEO insert


in order to avoid oil spills. Plug 19 mm / 1/4" (male)
14.3.4 Installing female quick change connectors

14.3.4
Installing female quick change connectors
14
1. Clean the threads.
2. Screw the WEO insert into the threads.
3. Place the fitting tool against the WEO insert.

Installing 19mm WEO insert
Installing 23 mm WEO insert
Installing 26 mm WEO insert
4. Fit the WEO insert. (See table for the correct torque)
Size Tightening torque
1/4" (19mm) 30 +5⁄-5 N·m
3/8" (23mm) 35 +5⁄-5 N·m
1/2" (26mm) 45 +5⁄-5 N·m
Resetting
Installing a quick change connector (male), page 14 - 7

14.3.5 Removing a quick change connector (male)

14.3.5
Removing a quick change connector (male)
Preparations
• Plug 10 mm / 1/4" (male) 254526
• Plug 13 mm / 3/8" (male) 254527
• Plug 16 mm / 1/2" (male) 254528
• Plug 10 mm / 1/4" (female) 254529
• Plug 13 mm / 3/8" (female) 254530
• Plug 16 mm / 1/2" (female) 254531
1. Use a screwdriver or similar tool to remove the assembly

stop.
2. Push the male fitting all the way into the fitting.
3. Pull the male fitting out of the insert.
4. Refit the assembly stop in the male fitting.

in order to avoid oil spills.
Plug 10 mm / 1/4" (male) 254526, page 21 - 10
Plug 13 mm / 3/8" (male) 254527, page 21 - 10
Plug 16 mm / 1/2" (male) 254528, page 21 - 10
Plug 10 mm / 1/4" (female) 254529, page 21 - 11

14.3.6 Installing a quick change connector (male)

14.3.6
Installing a quick change connector (male)
It is important that the instructions for fitting quick change connectors are followed. Otherwise, both
the hose and the WEO insert must be replaced.
1. Make sure that the assembly stop is correctly in place.

Check that the disassembly ring runs freely in the
groove.
2. Push the male fitting into the female fitting until the as-
sembly stop makes contact with the female fitting.
14
3. The coupling is now made and locked.

Check that the male connector is correctly assembled by
pulling on the connector.

Hydraulic unit C6100
14.4 Hydraulic unit C6100

14.4
14.4.1 Overview
14.4.1
Overview
Pos. Designation
a Pump motor
b Screw
c Pressure limiting valve
d Magnetic valve, fork lowering
e Tank (suitable oil volume 0.8 l)
f Filler pipe
14.4.2 Hydraulic oil tank C6110

14.4.2
Hydraulic oil tank C6110
14.4.2.1 Checking the hydraulic oil level

14.4.2.1
Checking the hydraulic oil level
1. Check the oil level in the hydraulic oil reservoir.

If the oil level is close to the minimum level: Topping up with oil, page 14 - 9, Topping up with oil,
page 14 - 9.

14.4.2.2 Oil change

14.4.2.2
Oil change
14.4.2.2.1 Topping up with oil

14.4.2.2.1
Topping up with oil
1. Unscrew the top-up lid (a).
2. Fill with oil to the line for max oil level.
3. Put the top-up lid (a) back and tighten.
14
14.4.2.2.2 Topping up with oil

14.4.2.2.2
Topping up with oil
1. Unscrew the top-up lid (a).
2. Fill with oil to the line for max oil level (b).
3. Put the top-up lid (a) back and tighten.
a
b
14.4.3 Filter, filter housing C6130

14.4.3
Filter, filter housing C6130
14.4.3.1 Air filter

14.4.3.1
Air filter
14.4.3.1.1 Inspecting the breather filter

14.4.3.1.1
Inspecting the breather filter
1. Check the operation of the breather filter.

14.4.4 Pressure/flow/lowering valve C6170

14.4.4
Pressure/flow/lowering valve C6170
14.4.4.1 Adjusting the pressure limiting valve

14.4.4.1
Adjusting the pressure limiting valve
The truck must be able to handle the rated load on the forks.
Place a rated load on the forks and verify that the truck is able to lift it.
If the truck cannot lift the rated load:
Note: It is not necessary to restore the closing seal after adjustment.
1. a) Pry off the white sealing cap (1) attached to the pressure limiting valve using a screwdriver. No
longer used.
b) Scrape away the marking paint sealing the valve.
2. Loosen the locking nut (2) by screwing it anticlockwise.
3. Adjust the adjusting screw (3) clockwise until the truck is able to lift the load without problems.
4. Screw the locking nut (2) clockwise.
Once the truck manages to lift the rated load, apply an additional 100 kg on the forks. Verify that the
truck cannot lift the load.
If the truck is able to lift 100 kg more than its rated load:
1. a) Pry off the white sealing cap (1) attached to the pressure limiting valve using a screwdriver.
b) Scrape away the marking paint sealing the valve.
2. Loosen the locking nut (2) by screwing it anticlockwise.
3. Screw the adjusting screw (3) anticlockwise until the truck cannot lift the load.
4. Screw the locking nut (2) clockwise.

14.4.5 Replacing the hydraulic unit

14.4.5
Replacing the hydraulic unit
14.4.5.1 Removing the hydraulic unit

14.4.5.1
Removing the hydraulic unit
Before commencing any work on the hydraulic unit, make sure the forks have been fully lowered.
1. Disconnect the hydraulic hose (1). Quick change con-

nectors, page 14 - 2.
2. Disconnect the motor cables (2) using a wrench, no. 13.
3. Disconnect the lowering valve connector (3).
4. Loosen the hydraulic unit bracket (4) and lift out the unit
from the truck.
14
5. Loosen the screw (5) to be able to disassemble the tank

from the motor and lift the motor away from the tank.
6. Loosen the locking ring (6) attached to the oil strainer

(7).
7. Remove and clean the strainer, then reattach it in the

correct position.
8. Change the oil and clean the tank.
14.4.5.2 Installing the hydraulic unit

14.4.5.2
Installing the hydraulic unit
1. Assemble the motor and the tank. Make sure that the clamp is fitted.
2. Lift the unit into the truck and fit the clamp.
3. Fit the electrical connector to the lowering valve.
4. Fit the motor cables. For torque, see Hydraulic unit tightening torques, page 14 - 12.
5. Fit the hydraulic hoses.
6. Top up with oil; see Topping up with oil, page 14 - 9

Hydraulic cylinder C6600
14.5 Hydraulic cylinder C6600

14.5
Hydraulic cylinder C6600
14.5.1 Main lift cylinders C6610

14.5.1
Main lift cylinders C6610
14.5.1.1 Inspect lifting cylinder

14.5.1.1
Inspect lifting cylinder
1. Make sure that there are no leaks from the lifting cylinder.
14.6 Hydraulic unit tightening torques

14.6
Hydraulic unit tightening torques
14.6.1 Hydraulic unit tightening torques

14.6.1
Hydraulic unit tightening torques
The hydraulic unit tightening torques applies as follows:

Work function - lifting mast C7000 15

15 Work function - lifting mast C7000

Software: 7662518
15
Work function - lifting mast C7000
15


Auxiliary equipment, installation
equipment C8000
16

Auxiliary equipment, installation
16 equipment C8000

16 Auxiliary equipment, installation equipment C8000
Software: 7662518
16
Auxiliary equipment, installation equipment C8000
16


Optional equipment/Extra equip-
ment C9000
17
17.1 Other extra equipment C9500 ....................................................................................................... 17 - 1
17.1.1 Low speed with low forks (LSwLF) ................................................................................... 17 - 1
17.1.2 Fire extinguisher ............................................................................................................... 17 - 2
17.1.2.1 Inspection of fire extinguisher ............................................................................. 17 - 2
17.1.3 Spider expansion unit ....................................................................................................... 17 - 2
17.1.3.1 Description .......................................................................................................... 17 - 2

Optional equipment/Extra equip-
17 ment C9000

17 Optional equipment/Extra equipment C9000
Other extra equipment C9500
Software: 7662518
17
Optional equipment/Extra equipment C9000
17.1 Other extra equipment C9500

17.1
17.1.1 Low speed with low forks (LSwLF)

17.1.1
Low speed with low forks (LSwLF)
The truck speed is reduced when the forks are in their lowermost position. The speed reduction is deactiv-
ated when the forks are raised 10-15 mm. Adjust using parameters 208 and 209, see Parameter list, page
4 - 1.
With the LSwLF option, an extra sensor is fitted that detects when the forks are in their lowest position.
17
a
c
a) Locking nut
b) Bracket
c) LSwLF sensor
d) Screw

17.1.2 Fire extinguisher

17.1.2
Fire extinguisher
17.1.2.1 Inspection of fire extinguisher

17.1.2.1
Inspection of fire extinguisher
1. Check that the fire extinguisher is intact, undamaged

and properly mounted on the truck.
If the fire extinguisher does not seem to be operational,
replace it.
2. Check that the pressure gauge indicator is in the green

field.
If the indicator is in the red field, the fire extinguisher is
not fit for use and must be recharged.
17.1.3 Spider expansion unit

17.1.3
Spider expansion unit
17.1.3.1 Description
17.1.3.1
Description
17.1.3.1.1 Spider expansion unit

17.1.3.1.1
Spider expansion unit
The spider expansion unit, called SEU, allows the main logic card to handle a greater number of inputs and
outputs. The SEU does not have its own truck controller logic, which means that a defective SEU can be re-
placed without the replacement affecting any truck functions.
The SEU is used for modification of the truck to meet special customer requirements.

Electronic
card
Truck Log
System
Spider
Extra/Customised
Expansion
function(s)
Unit
CAN bus
Pump
controller
CAN service
connector 17
Motor
Controller
The picture shows how the SEU is used to allow a greater number of functions to be controlled via the CAN
bus. SEU has a 42-pin, multi-pin contact that manages all inputs, outputs, CAN and power supply signals.


Instructions for disposal 18
18.1 Recycling and transport ................................................................................................................. 18 - 1
18.2 Marking of plastics ......................................................................................................................... 18 - 1
18.2.1 General marking of products and packaging .................................................................... 18 - 1
18.2.2 Marking according to the manufacturer’s standards ......................................................... 18 - 1
18.2.2.1 Abbreviations ...................................................................................................... 18 - 2
18.2.2.2 Marking examples ............................................................................................... 18 - 2
18.3 Pressure vessels ........................................................................................................................... 18 - 3
18.3.1 Gas struts.......................................................................................................................... 18 - 3
18.4 Sorting categories.......................................................................................................................... 18 - 3

18 Instructions for disposal

Software: 7662518
18
Instructions for disposal
18.1 Recycling and transport

18.1
Recycling
Lithium-ion battery modules must be considered to be hazardous waste and must be handed in for recycling
at approved plants. Used lithium-ion batteries are covered by the EU’s Battery Directive (2006/66/EC) and
must be disposed of in accordance with national laws. Follow local regulations. Cleaned packaging must be
recycled in accordance with the applicable national regulations.
Transport
Lithium-ion battery modules are approved for transport according to test UL 38.3.
A lithium-ion battery module that is being transported is considered to be dangerous goods, UN3480
class 9. Only personnel trained in handling dangerous goods are permitted to mark and transport the
batteries.
• The battery terminals must be protected against accidental short-circuits.

• Normal and used lithium-ion battery modules must be packaged according to P903.
• Damaged lithium-ion battery modules must be packaged according to P908 or LP904.
18
18.2 Marking of plastics
18.2
Marking of plastics
18.2.1 General marking of products and packaging

18.2.1
General marking of products and packaging
Markings on plastics consist of three arrows, a number and usually also a designation of the plastic material
used. This example shows the marking for polypropylene.
• 01: PET – Polyethylene terephthalate

• 02: PE-HD – Polyethylene with high density
• 03: PVC – Polyvinyl chloride
• 04: PE-LD – Polyethylene with low density
• 05: PP - Polypropylene
• 06: PS – Polystyrene
• 07: O – Other
18.2.2 Marking according to the manufacturer’s standards

18.2.2
Marking according to the manufacturer’s standards
Standards: 58-02-001, 58-02-003 and 58-02-004.

A few examples of markings are given here. For more information, please refer to the standards above.

Marking of plastics
The product material and trade name of each item are indicated between arrows. Example: >PP<.
18.2.2.1 Abbreviations
18.2.2.1
Abbreviations
ABS
Acrylonitrile/butadiene/styrene
HDPE
High Density Polyethylene
LDPE
Low Density Polyethylene
PA
Polyamide
PA6
Amide resin 6
PA66
Amide resin 66
PBT
Polybutylene terephtalate
PC
Polycarbonate
PET
Polyethylene terephtalate
PMMA
Plexiglas
POM
Polyoxymethylene, Polyformaldehyde
PP
Polypropylene
PUR
Polyurethane
18.2.2.2 Marking examples

18.2.2.2
Marking examples
Products made from a single substance

ABS (acrylonitrile/butadiene/polystyrene):
>ABS<
Polyurethane:
>PUR<
Plastic compounds
A compound based on acrylonitrile/butadiene/polystyrene and carbonate plastic:
>ABS+PC<
Filled or reinforced materials
Polypropylene with 30% mineral powder:
>PP-MD30<

Pressure vessels
18.3 Pressure vessels

18.3
Pressure vessels
Pressure vessels sent for recycling/destruction must have been depressurised beforehand and, if possible,
opened.
Examples of existing pressure vessels are gas struts and accumulators used in hydraulic systems.
18.3.1 Gas struts

18.3.1
Gas struts
WARNING High interior pressure

Gas struts have extremely high internal pressure.
► Always follow the manufacturer's recommendations.
► Always use protective goggles when dismantling struts.
To allow the gas to escape, only open and disassemble gas struts as recommended by the manufacturer. An
example of how to perform this is given for "Stabilus Lift-O-Mat/Inter-stop":
2 1
18
m1
m1 = approx. 20 mm
1. Drill or cut a hole in the cylinders, approximately 20 mm from the bottom.
2. Drill or cut a hole in the recess at the piston rod end.
18.4 Sorting categories

18.4
Sorting categories
• Plastic and rubber material

• Iron/steel (including bolts, washers and nuts)
• Oils
• Oil filters
• Oil-polluted material
• Electronic parts (including switches and sensors)
• Wires
• Hazardous waste
• Complex materials - large amounts in several categories but non-combustible and not hazardous
• Combustible material, including small plastic and rubber parts
• Please return batteries to the manufacturer.
Component Category Comments
Chassis Iron/steel

Sorting categories
Component Category Comments

Inspection covers, sheet metal Iron/steel
Handle: >ABS<
Inspection covers, plastic Plastic Sort according to the material
marking
Forks and frames Iron/steel
Operator's platforms Iron/steel, including any gas struts Be sure to depressurise struts
Mats, cushions: combustible
Roofs and overhead guards Iron/steel
Gates and operator protective Iron/steel
devices Plastic handles: >PA<
Crush protectors: >PMMA<
Hydraulic unit Oil Ensure that the system has been
Hydraulic hoses: Oil-polluted ma- depressurised. Carefully drain all
terial oil. Any accumulators should be
Oil tank: >PP< emptied of gas and if possible
Motor, valves: Electronic compon- opened.
ents
Pump: Iron/steel
Accumulator: Iron/steel
Travel motors Motor: Electronic components
Wires
Parking brake: Hazardous waste
Drive gears Iron/steel Carefully drain all oil
Oil Hazardous waste
Wheels Tread: Plastic according to marking If the tread and hub cannot be sep-
Hub: Iron/steel arated, then sort the wheel as com-
plex material
Tiller arms Electronic parts, wires, iron/steel, Be sure to depressurise struts
also gas struts
Electrical system PCBs, transistor regulators, Expan- Hazardous waste
sion unit SEU, contactors: Elec-
tronic components
Wires
Small batteries Hazardous waste
Fluorescent tubes Hazardous waste.
Because of the chemical content in
fluorescent tubes, do not break
them. Obsolete fluorescent tubes
must be packaged and transported
according to local regulations.
Mast Mast beams, rollers, cylinders, hy- Oil-polluted components should be
draulic pipes: handled as hazardous waste
Iron/steel
Hydraulic hoses: Oil-polluted ()
Wires
Sensors/switches: Electronic com-
ponents
Plastic components: According to
marking or as combustible waste
Chargers and connectors Electronic components
Wires

Wiring diagram 19
19.1 Colour code table........................................................................................................................... 19 - 1
19.2 List of fuses.................................................................................................................................... 19 - 1
19.3 Diagram [7654485 D - LWI160.1056] ............................................................................................ 19 - 2
19.3.1 Component list .................................................................................................................. 19 - 2
19.3.2 General diagram ............................................................................................................... 19 - 5
19.3.3 Detailed diagrams ............................................................................................................. 19 - 6
19.4 Diagram [7654487 D - LWI160.1056] .......................................................................................... 19 - 20
19.4.1 Component list ................................................................................................................ 19 - 20
19.4.2 General diagram ............................................................................................................. 19 - 22
19.4.3 Detailed diagrams ........................................................................................................... 19 - 23

19 Wiring diagram

19 Wiring diagram
Colour code table
Software: 7662518
19 Wiring diagram
19
Wiring diagram
19.1 Colour code table

19.1
Colour code table
Abbreviation Colour
RD Red
BK Black
BU Blue
BN Brown
YE Yellow
GY Grey
GN Green
OG Orange
PK Pink
VT Violet
WH White
TQ Turquoise
SCR Shielded
19
19.2 List of fuses
19.2
List of fuses
The fuses are of the type "FKS" flat pin fuses. The rated current is printed on the top of the fuses and is also
indicated by the colour coding of the fuse body.
a
3.6
19 5
(13.2)
19.7
6.5
5.2 0.62
(4.1) 3.5
14.5 3.8
17
The fuses' measurements, in mm, without given tolerances a = rated current.

Rated current (A) Colour Remarks
1 Black -
3 Violet -
5 Light brown -
7.5 Brown -
10 Red -
15 Blue -
20 Yellow -
25 White Brown print
30 Light green -

19 Wiring diagram
Diagram [7654485 D - LWI160.1056]
19.3 Diagram [7654485 D - LWI160.1056]

19.3
Diagram [7654485 D - LWI160.1056]
19.3.1 Component list

19.3.1
Component list
Des. Function Component type Other Image Sheet

A1 Electronic card Electronic card
A5 Electronics card Electronic circuit
(ICH) board
A30 Onboard charger Charger
B1 Drive motor tem- Temperature
perature sensor sensor
B11 Motor speed Speed sensor
sensor
B13 Steering angle Analogue, induct-
sensor (OCC) ive sensor
B60 Drive position Inductive switch
sensor
B62 Support arm in sensor
bottom position
top position
F1 Main fuse 150 A Fuse
F2 Fuse 500 A Fuse
F4 Fuse 40 A Fuse
F5 Fuse 40A Fuse
F50 Fuse 7.5 A Fuse
F51 Fuse 7.5 A Fuse
F52 Fuse 5 A Fuse
G1 E-BRIX Battery
G10 C-BRIX Battery
K11 Heater Switch Connector
K25 Relay Relay
M1 Truck traction Motor
M3 Pump motor Motor
M6 Connection Connection
P4 Horn Horn
P6 Display of truck Display
functions
Q1 Parking brake Electromagnetic
Q4 Fork lowering Solenoid valve
Q50 PMU PMU
R68 Resistor Resistor

19 Wiring diagram
Diagram [7654485 D - LWI160.1056]

S1 Switch for the bat- Main switch
tery
S18: Horn button (left) Switch
1
S18: Horn button (right) Switch
2
S24 Emergency switch Emergency switch
off off
S206 Creep function Switch
T0 Connector Connector
T7 DC/DC converter, Circuit board
24V/12V
24V/24V
T9 USB socket Printed circuit
card
T12 Motor controller Motor Controller 19
T20 Antenna Antenna
X1 Connector Connector
X5 Tiller arm Port
X23 Socket, DC/DC Port
converter
X25 Sheet 10 Terminal
X40 CAN communica- Terminal
tion (Extra I/O)
X41 External CAN Port
communication
X2:1/ Turtle switch Terminal
2
X2:1/ Low speed switch Terminal
3

19 Wiring diagram
Diagram [7654485 D - LWI160.1056]

19.3.2 General diagram
19.3.2
General diagram
K25
25 (83) IN+24V "HIGH SIDE DRIVER" 6 F52 52 53
B+ 6 1 2 IN +24VDC X23
B62 12VDC/24VDC 26
25
OPTION 74 B- 40 36
4 3 ENABLE
94 INP. SUPPORT ARM, IN LOWEST POS. OVCD 41
OUT. ENABLE AUXILIARY EQUIPMENT (111) 36

D1
40 0VDC T7/T8
B60 U
40
22 72 6
95 TILLER ARM IN DRIVE POS.
V M1
2 INP. 0VDC
T12 T9
40 W INP. +24VDC 1
25
B65 MAIN CONTACTOR (106)
31 OPTION
22 73
87 INP. SUPPORT ARM. AT TOP POS. F51
23 S1
OUT. P- 5 M3 J1:2 INP. ENABLE AUX ENABLE_A J1:13
80
B13 40 7 F50 23
INP. VBAT+
22 76 91 INP. CORNER CONTROL SENSOR
Q1 ENABLE_B J1:14 81
34
30 J2: 8 OUT. CONTACTOR
BRAKE RELESE (90) 32 OUT. MAIN SWITCH 4
7 X4
40 3 OUT. VBAT+ 82
+ 6 KeyLED J1:15
Q4 IN 24V+
B11
61 33
Q50 - 40 IN 24V-
(104) INP CH A, SPEED SENSOR LOWER VALVE (108) 1 KeyLEDRtn J1:12 83
P4 IN B+ (X2)
1 219
62 (103) INP CH B, SPEED SENSOR X2:3 CANB_H
OUT. +24V (82) 30
R68
OUT. SHUNT BAT+ 2 2 220
X2:4 CANB_L G1
63 SIGNAL HORN (112) 50 R69 OUT. SHUNT LOAD+ 1 3 217
X2:6 DETECT
X40
(92) THERMAL SENSOR
57 55 N
Lb La 25 6 F1 10 OUT B+ (X3) 118
X1:2 CAN_GND
B1 ENABLE/PRE-CHARGE (84) 22 218
65 J1:16 INP. I1_BAT+ X2:2 CANB_GND
MAINS CONNECTOR SENSE 66 J1:17 INP. I1_LOAD+

64
105 OUT. NEGATIV SPEED/ THERMAL SENSOR
51 20 J1:18 OUT. VBAT_AUX2
INP. MAINS CONNECTOR DETECT (96) 24
60
ACCESS POWER OUT ESO J1:19
(85) +5 SPEED SENSOR
OPTION
CAN HIGH/LOW (99/100)
22 22
J2:11 OUT. VBAT_AUX1 OUT
S24
119/120
84 217
J1:7 BMU_5V
85 DETECT X2:6
J1:8 BMU_A
86 VBAT J1:11
J1:9 BMU_B
87 40
22 J1:10 BMU_GND CAN HIGH/LOW
X1:3/X1:4
22
119/120 119/120
(X3/X3) 20 20
CAN HIGH/LOW +24V DC (X3)
0V DC (X3) 40
A2: S17
SAFETY
eԹll 119/120
REVERSE (2/3) 6 F5
A2: S19 CAN HIGH/LOW 119/120
eՅll FORK LIFT 20 (3/4)
(X1 1) HORN 2 +24V DC (1) CAN HIGH/LOW
A2: S120
8
0V DC (8) + OUT. POSITIV CHARGER VOLTAGE
(X4 1) HORN 1 eНll FORK
LOWER
K110 40
1
S18:2 B+
A2: S1-S9 A2: S10-S18
ANTENNA
T20 BK
- OUT. NEGATIVE CHARGER VOLTAGE
S18:1 eНll eНll SPEED REF. 6
F4 54 40
E32-E38:1 HEATER VDD
VALUE
(X4 2) X41 OPTION 42
E32-E38:2 HEATER GND
MAINS CONNECTOR
A30 DETECT .INP 1
217
(X1 2) +24V DC (X3) 22
(X2:1/2) TURTLE
A5 0V DC (X3) 40 G10 MAINS, VAC
MAINS, VAC
CAN HIGH (X3) 119 85 X:2 RS485-A
CAN LOW (X3) 120 MAINS, EARTH
KEYBOARD/ 22
1 +V (HEATER LOGIC) M6
86 X:3 RS485-B
S206 84 X:1 +5V_BMU
OPTION 40
SMARTCARD (X2:1/3) TURTLE
K11 87 X:4 +5V_GND
B-
S223 (X11)
(X12) DISPLAY 119/120
(3/4) CAN HIGH/LOW
42 40
M8 HSW -
P6
OPTION
7654485-D-0
19.3.3 Detailed diagrams
19.3.3
Detailed diagrams
J2:3 DETECT-J2:4 CANB_H 02-8

E-BRIX LITE
[S1] [G1]
1 80
J1:13 ENABLE_A
2 81
J1:14 ENABLE_B
3 82
J1:15 KeyLED
19 Wiring diagram

4 83
J1:12 KeyLEDRtn
84
09-2 J1:7 BMU_5V
85
09-2 J1:8 BMU_A
86
09-2 J1:9 BMU_B
Diagram [7654485 D - LWI160.1056]
87
09-2 J1:10 BMU_GND
20
08-2 J1:18 OUT. VBAT_AUX2 ACCESS POWER OUT
06-2 22
04-1 J2:11 OUT. VBAT_AUX1 OUT
05-2
19 - 6
[S24]
14-1 118 11 12 24
02-2 J1:19 ESO
13-2
04-1
65
03-2 J1:16 INP. I1_BAT+
66
03-2 J1:17 INP. I1_LOAD+
34
03-2 J2:8 OUT. CONTACTOR
23
7,5A J1:2 INP. ENABLE AUX
[F50]
7 23
03-2 J1:1 INP. VBAT+
40
09-1 J1:11 VBAT-
7654485-D-1
01-8
E-BRIX LITE
[G1]
217
11-2 J2:3 DETECT
10-2 219
11-2 J2:4 CANB_H
13-2 220
11-2 J2:5 CANB_L
13-2 118
01-2
19 - 7
[X40]
118
J1:6 CAN_GND
5
218
J2:6 CANB_GND
9
119/RD
05-1 J1:4 CAN_H
120/WH
05-1 J1:5 CAN_L
216
J2:13 VBAT-
216
J2:14 PILOT-
Diagram [7654485 D - LWI160.1056]
19 Wiring diagram
7654485-D-2

19
PMU
[Q50]
SHUNT
1 1 2
09-1 IN B+ (X2)
19 Wiring diagram

03-11
A1
Q
Q
a
03-8
A2
Diagram [7654485 D - LWI160.1056]
[X1]
34
01-1 4 OUT. MAIN SWITCH
19 - 8
7
01-2 3 OUT. VBAT+
65
01-1 2 OUT. SHUNT BAT+
66
01-1 1 OUT. SHUNT LOAD+
7,5A 150A 500A
[F51] [F1] [F2]
25 6 6 10
12-1 OUT B+ (X3)
04-1
05-2
6
10-2
04-1
12-1
11-2
09-2
7654485-D-3
100 INP. CAN LOW-95 INP.TILLER ARM IN DRIVER POS 05-7
94 INP. SUPPORT ARM, IN LOWEST POS.- 14-7

MOTOR CONTROLLER
[T12]
40
09-1 INP. B-
22
01-1 84 INP. ENABLE / PRE-CHARGE
PUMP MOTOR
6 6 A2 [M3] A1 5
03-2 OUT. P-
6
INP. B+
25
03-2 83 INP. +24V. "HIGH SIDE DRIVER"
36
12-1 111 OUT. ENABLE AUXILIARY EQUIPMENT
22 51
01-1 96 INP. MAINS CONNECTOR DETECT
OPTION DRIVE MOTOR U 2
MAINS CONNECTOR SENSE OUT. U
19 - 9
[M1] V 3
OUT. V
W 4
OUT.W
B11 60
85 OUT. +5V SPEED SENSOR
1
[B11]
RD BU B11 61
2 104 INP CH A, SPEED SENSOR
BK WH B11 62
103 INP. CH B, SPEED SENSOR
3
B1 GN B1 63
1 92 INP. THERMAL SENSOR
TEMP. DRIVE MOTOR
RD B1
2
B11 64
105 OUT. NEGATIVE SPEED / THERMAL SENSOR
4
7654485-D-4
Diagram [7654485 D - LWI160.1056]
19 Wiring diagram

19
04-7
MOTOR CONTROLLER
[T12]
119/RD 119/RD
02-1 99 INP. CAN HIGH
10-2 120/WH 120/WH
08-2 02-1 100 INP. CAN LOW
06-2 10-2 [B60]
08-2 22 1 2 72
95 INP.TILLER ARM IN DRIVER POS
19 Wiring diagram

06-2
3
40
[B65]
Diagram [7654485 D - LWI160.1056]
22 1 2 73
87 INP. SUPPORT ARM, AT TOP POS.
3
40
[B13]
22 22 + A 76
19 - 10
01-1 91 INP. CORNER CONTROL SENSOR
-
40 40
09-1
68Ohm 68Ohm
[P4] [R68] [R69]
55 57 50 P4 50
112 OUT. SIGNAL HORN
3
La N 30
Lb 82 OUT. +24V, HIGH SIDE DRIVER
25 P4 56
03-2 [Q1]
1
1 2 32
90 BRAKE RELEASE
[Q4]
1 2 33
108 OUT. LOWER VALVE
7654485-D-5
ELECTRONIC CARD TILLER ARM
[A1]
120/WH X5 OG A5 120
05-1 X3 CAN LOW
4 3
119/RD X5 RD A5 119
05-1 X3 CAN HIGH
3 7
40 X5 BN A5 40
09-1 X3 INP.0V DC
2 2
20 X5 BK A5 20
01-1 X3 INP. +24V DC
1 6
CAN, SERVICE CONNECTOR
[X41]
19 - 11
VT A5
1 X3 OUT. +24V DC
5
GY A5
2 X3 OUT. 0V DC
1
WH A5
3 X3 CAN HIGH
8
PK A5
4 X3 CAN LOW
4
7654485-D-6
Diagram [7654485 D - LWI160.1056]
19 Wiring diagram

19
DISPLAY ELECTRONIC CARD TILLER ARM
[P6] [A5]
X1 1 X12 1 +5V DC
DISPLAY X1 2 X12 2 SI
[P6]
19 Wiring diagram

8 8 8 8 X1 3 X12 3 SCK
X1 4 X12 4 ENABLE
X1 5 X12 5 LCLK
Diagram [7654485 D - LWI160.1056]
X1 6 X12 6 0V DC
19 - 12
S18:1
1 2
X4 1 INP. HORN 1
X4 2 OUT. 0V DC HORN 1
S18:2
1 2
X1 1 INP. HORN 2
S206
1 2
X2: 1/2 TURTLE
OPTION
X2 :1/3 TURTLE
7654485-D-7
DHU
[K110]
20
01-1 1 INP. +24V DC
119/RD
05-1 2 CAN HIGH
120/WH
05-1 3 CAN LOW
40
09-1 8 INP. 0V DC
19 - 13
[T20]
INP. LTE ANTENNA (Violet)
INP. GNS ANTENNA (Blue)
7654485-D-8
Diagram [7654485 D - LWI160.1056]
19 Wiring diagram

19
LI-ION BATTERY
[G10]
1
03-2 B+
19 Wiring diagram

*
+
-
Diagram [7654485 D - LWI160.1056]
40
01-2 B-
10-2
08-2
19 - 14
04-1 * LINKCABLE COLOR
05-2 85
01-1 X:2 RS485-A GN
11-2
06-2 86
01-1 X:3 RS485-B YE
14-1
12-1 84
01-1 X:1 +5V_BMU RD
13-2
87
01-1 X:4 +5V_GND BK
40A
[F4]
6 54
03-2 E32-E38:1 HEATER VDD
OPTION
COLD STORE 13-2 42
E32-E38:2 HEATER GND
7654485-D-9
ONBOARD CHARGER BCU
[A30]
40A
X30 [F5]
6 RD 8
03-2 + OUT. POSITIVE CHARGER VOLTAGE
BK 40 BK
09-1 - OUT. NEGATIVE CHARGER VOLTAGE
X40 120/WH
05-1 4 INP. CAN LOW
7
X40 119/RD
6
X40 217
19 - 15
02-1 1 INP. PILOT
8
MAINS CONNECTOR
MAINS. VAC
MAINS. VAC
MAINS. EARTH
7654485-D-10
Diagram [7654485 D - LWI160.1056]
19 Wiring diagram

19
EXTERNAL CHARGER
19 Wiring diagram

CHARGER CONNECTOR
[X4]
Diagram [7654485 D - LWI160.1056]
6 +
03-2
40 -
09-1
19 - 16
X40 1
219
02-2 10
X40 220 2
02-2
11
X40 217 3
02-1 8
7654485-D-11
USB POWER SOCKET
[T9]
1
25
1 INP. +24VDC
36
2 INP. 0VDC
5A
[F52]
6
03-2 DC/DC 24/12
52
[T7]
SSR
25 X25 25 3 [K25] 1 53 T0 ENABLE
03-2 1 ENABLE
1
36 X25 36 4 2 53 53 53 T0 IN +
04-1 2 IN +24VDC OPTION
2
40 T0 IN - 12VDC OUTLET
3 IN 0VDC
[D1] 1
26 T0 OUT +
40 OUT +12VDC
09-1 4
41 T0 OUT -
OUT 0VDC
19 - 17
5
[X23]
DC/DC 24/24
[T8]
53 T0 ENABLE
1 ENABLE
53 T0 IN +
2 IN +24VDC OPTION
IN 0VDC
3
1
26 T0 OUT +
4 OUT +24VDC
41 T0 OUT -
OUT 0VDC
5
[X23] 1 Depending on configuration
7654485-D-12
Diagram [7654485 D - LWI160.1056]
19 Wiring diagram

19
19 Wiring diagram

OPTION
COLD STORE
HEATER SWITCH
[K11]
Diagram [7654485 D - LWI160.1056]
40
09-1 M6 BAT-
X40 22
01-1 1 +V (HEATER LOGIC)
1
19 - 18
2 GND
X40 219
02-2 3 CANB_H
10
X40 220
02-2 4 CANB_L
11
42
09-2 M8 HSW-
7654485-D-13
OPTION MOTOR CONTROLLER
LOWER SPEED WHEN LOWERED FORKS [T12]
04-7
[B62]
22 1 2 74
01-1 94 INP. SUPPORT ARM, IN LOWEST POS.
3
40
09-1
19 - 19
7654485-D-14
Diagram [7654485 D - LWI160.1056]
19 Wiring diagram

19
19 Wiring diagram
Diagram [7654487 D - LWI160.1056]
19.4 Diagram [7654487 D - LWI160.1056]

19.4
Diagram [7654487 D - LWI160.1056]
19.4.1 Component list

19.4.1
Component list

A1 Electronic card Electronic card
A5 Electronics card Electronic circuit
(ICH) board
A30 Onboard charger Charger
A31 BCU Electronic module
B1 Drive motor tem- Temperature
perature sensor sensor
B11 Motor speed Speed sensor
sensor
B13 Steering angle Analogue, induct-
sensor (OCC) ive sensor
B60 Drive position Inductive switch
sensor
bottom position
top position
F1 Main fuse 150 A Fuse
F3 Fuse 15A Fuse
F5 Fuse 40A Fuse
F50 Fuse 7.5 A Fuse
F51 Fuse 7.5 A Fuse
F52 Fuse 7.5 A Fuse
F52 Fuse 5 A Fuse
G1 E-BRIX Battery
G10 C-BRIX Battery
K11 Heater Switch Connector
K25 Relay Relay
M1 Truck traction Motor
M3 Pump motor Motor
P4 Horn Horn
P6 Display of truck Display
functions
Q1 Parking brake Electromagnetic
Q4 Fork lowering Solenoid valve
Q10 Main contactor Contactor

19 Wiring diagram
Diagram [7654487 D - LWI160.1056]

Q50 PMU PMU
S1 Switch for the bat- Main switch
tery
S18: Horn button (left) Switch
1
S18: Horn button (right) Switch
2
S24 Emergency switch Emergency switch
off off
S206 Creep function Switch
T0 Connector Connector
24V/12V
24V/24V
T9 USB socket Printed circuit 19
card
T12 Motor controller Motor Controller
T20 Antenna Antenna
X1 External charging Connection
connection
X5 Tiller arm Port
X23 Socket, DC/DC Port
converter
X40 CAN communica- Terminal
tion (Extra I/O)
X41 External CAN Port
communication
X2:1/ Turtle switch Terminal
2
X2:1/ Low speed switch Terminal
3

19.4.2 General diagram
19.4.2
General diagram
K25
24 (83) IN+24V "HIGH SIDE DRIVER"
6
F52 52 53
1 2 IN +24VDC X23
B62 B+
12VDC/24VDC 26
25
24 OPTION 74 B- 40 36
4 3 ENABLE
94 INP. SUPPORT ARM, IN LOWEST POS. OVCD 41
F51 25
OUT. ENABLE AUXILIARY EQUIPMENT (111) 36
24 D1
40 0VDC T7/T8
B60 U S24
40
24 72 6
95 TILLER ARM IN DRIVE POS.
V M1
2 INP. 0VDC
T12 T9
40 W INP. +24VDC 1
Q10
B65 MAIN CONTACTOR (106)
31 OPTION
24 73 30
87 INP. SUPPORT ARM. AT TOP POS.
25
S1
OUT. P- 5 M3
80
B13 40 7 7 F1 10
ENABLE+ X1:7
24 76
VBAT+
G10 81
91 INP. CORNER CONTROL SENSOR Q1 ENABLE- X1:8
30
BRAKE RELESE (90) 32
40 X4 82
KeyLED X1:6
B11 Q4 + 7
IN 24V+
61 - 40 IN 24V- 40
(104) INP CH A, SPEED SENSOR LOWER VALVE (108) 33
P4
62 (103) INP CH B, SPEED SENSOR 1 219 X40
X2:3 CANB_H
OUT. +24V (82) 30
2 220
SIGNAL HORN (112) R69 R68 X2:4 CANB_L X1:2 CAN_GND
63 50 57 55 N 3 217
(92) THERMAL SENSOR Lb La X2:6 DETECT X2:2 CANB_GND
B1 ENABLE/PRE-CHARGE (84)
22
DETECT X2:6
64 MAINS CONNECTOR SENSE
105 OUT. NEGATIV SPEED/ THERMAL SENSOR CAN HIGH/LOW
X1:3/X1:4
INP. MAINS CONNECTOR DETECT (96) 51
60 (85) +5 SPEED SENSOR 119/120
OPTION 22 22 F50 7
CAN HIGH/LOW (99/100)
119/120
24
119/120
(X3/X3)
CAN HIGH/LOW +24V DC (X3) 22
0V DC (X3) 40
A2: S17 119/120
SAFETY (3/4)
eНll 119/120
REVERSE 7 CAN HIGH/LOW
(2/3)
A2: S19 CAN HIGH/LOW
22 7 F5 8
eНll FORK LIFT +24V DC (1) + OUT. POSITIV CHARGER VOLTAGE
(X1 1) HORN 2 119/120 40
(X4 1) HORN 1
A2: S120
eНll FORK K110 0V DC (8)

40
(5/4) INP. CAN LOW/HIGH
BK
- OUT. NEGATIVE CHARGER VOLTAGE
S18:2
LOWER F3 9
A2: S1-S9 A2: S10-S18
ANTENNA
T20 1 OUT. POSITIV CHARGER VOLTAGE
A30 217
S18:1 SPEED REF. MAINS CONNECTOR DETECT .INP 1
e㠮ll eНll 2 OUT. NEGATIVE CHARGER VOLTAGE
VALUE 40 MAINS, VAC
(X4 2) X41 OPTION MAINS, VAC
(X1 2) +24V DC (X3) 22 MAINS, EARTH
(X2:1/2) TURTLE
A5 0V DC (X3) 40 A31
CAN HIGH (X3) 119 MAINS CONNECTOR
CAN LOW (X3) 120
KEYBOARD/ MAINS, VAC
217
S206 MAINS, VAC INP. PILOT 1
OPTION
SMARTCARD (X2:1/3) TURTLE MAINS, EARTH DC INPUT OPTION
(X11) (X12) DISPLAY INPUT +24V DC

BN +1
S223 P6 INPUT 0V DC BU -2
7654487-C-0
19.4.3
Detailed diagrams
cBRIX
[S1] [G10]
1 80
X1:7 ENABLE+
2 81
X1:8 ENABLE-
3 82
X1:6 KeyLED
4
40 40
07-2 VBAT-
06-2 7
02-1 09-2
08-2 7,5A
03-2 [F50]
09-2 07-2 22 7
06-2 150A
04-2 02-1 [F1]
6 6 7 7 10
08-2 04-2 02-1 VBAT+
11-1 02-1 10-1
7.5A
10-1 [F51]
25
02-1
10-1 30
19 - 23
03-2 1 2
31 [Q10]
03-2
217
09-2 X2:6 DETECT
07-2 219
08-1 09-2 X2:3 CANB_H
220
09-2 X2:4 CANB_L
[X40]
118
X1:2 CAN_GND
5
218
X2:2 CANB_GND
9
119/RD
03-1 X1:3 CAN_H
120/WH
03-1 X1:4 CAN_L
Diagram [7654487 D - LWI160.1056]
19 Wiring diagram

19
7654487-D-1
100 INP. CAN LOW-95 INP.TILLER ARM IN DRIVER POS 03-7
94 INP. SUPPORT ARM, IN LOWEST POS.- 11-7
MOTOR CONTROLLER
[T12]
40
01-1 INP. B-
22
01-1 84 INP. ENABLE / PRE-CHARGE
19 Wiring diagram

PUMP MOTOR
6 6 A2 [M3] A1 5
01-2 OUT. P-
6
INP. B+
36
10-1 111 OUT. ENABLE AUXILIARY EQUIPMENT
Diagram [7654487 D - LWI160.1056]
[S24]
25 11 12 24 24
01-1 83 INP. +24V. "HIGH SIDE DRIVER"
24
03-2 DRIVE MOTOR U 2
03-2 OUT. U
19 - 24
11-1 V 3
[M1] OUT. V
OPTION W 4
OUT.W
MAINS CONNECTOR SENSE
22 51
01-1 96 INP. MAINS CONNECTOR DETECT
B11 60
85 OUT. +5V SPEED SENSOR
1
[B11]
RD BU B11 61
2 104 INP CH A, SPEED SENSOR
BK WH B11 62
103 INP. CH B, SPEED SENSOR
3
B1 GN B1 63
1
92 INP. THERMAL SENSOR
TEMP. DRIVE MOTOR
RD B1
2
B11 64
105 OUT. NEGATIVE SPEED / THERMAL SENSOR
4
7654487-D-2
MOTOR CONTROLLER
[T12]
02-7
119/RD 119/RD
06-2 120/WH 120/WH
04-2 07-2 100 INP. CAN LOW
08-2 06-2 [B60]
01-2 04-2 24 1 2 72
95 INP.TILLER ARM IN DRIVER POS
08-2
01-2 3
40
[B65]
24 1 2 73
87 INP. SUPPORT ARM, AT TOP POS.
3
40
[B13]
24 24 1 4 73
02-1 91 INP. CORNER CONTROL SENSOR
3
40 40
01-1
19 - 25
31
01-2 106 OUT. MAIN CONTACTOR
68Ohm 68Ohm
[P4] [R68] [R69]
55 57 50 P4 50
112 OUT. SIGNAL HORN
3
La N 30
Lb 82 OUT. +24V, HIGH SIDE DRIVER
24 P4 56
02-1 [Q1]
1
30 1 2 32
90 BRAKE RELEASE
[Q4]
30 30 1 2 33
01-2 108 OUT. LOWER VALVE
7654487-D-3
Diagram [7654487 D - LWI160.1056]
19 Wiring diagram

19
ELECTRONIC CARD TILLER ARM
[A1]
120/WH X5 OG A5 120
03-1 4 X3 CAN LOW
3
19 Wiring diagram

119/RD X5 RD A5 119
03-1 3 X3 CAN HIGH
7
40 X5 BN A5 40
01-1 2 X3 INP.0V DC
2
Diagram [7654487 D - LWI160.1056]
22 X5 BK A5 22
01-1 X3 INP. +24V DC
1 6
CAN, SERVICE CONNECTOR
[X41]
19 - 26
VT A5
1 X3 OUT. +24V DC
5
GY A5
2 X3 OUT. 0V DC
1
WH A5
3 X3 CAN HIGH
8
PK A5
4 X3 CAN LOW
4
7654487-D-4
DISPLAY ELECTRONIC CARD TILLER ARM
[P6] [A5]
X1 1 X12 1 +5V DC
DISPLAY X1 2 X12 2 SI
P6
8 8 8 8 X1 3 X12 3 SCK
X1 4 X12 4 ENABLE
X1 5 X12 5 LCLK
X1 6 X12 6 0V DC
19 - 27
S18:1
1 2
X4 1 INP. HORN 1
S18:2
1 2
X1 1 INP. HORN 2
S206
1 2
X2: 1/2 TURTLE
OPTION
X2 :1/3 TURTLE
7654487-D-5
Diagram [7654487 D - LWI160.1056]
19 Wiring diagram

19
DHU
[K110]
22
01-1 1 INP. +24V DC
19 Wiring diagram

119/RD
03-1 2 CAN HIGH
120/WH
03-1 3 CAN LOW
Diagram [7654487 D - LWI160.1056]
40
01-1 8 INP. 0V DC
19 - 28
[T20]
INP. LTE ANTENNA (Violet)
INP. GNS ANTENNA (Blue)
7654487-D-6
ONBOARD CHARGER BCU
[A30]
40A
X30 RD [F5]
7 8
01-1 + OUT. POSITIVE CHARGER VOLTAGE
BK 40 BK
01-1 - OUT. NEGATIVE CHARGER VOLTAGE
X40 120/WH
03-1 4 INP. CAN LOW
7
X40 119/RD
6
X40 217
19 - 29
01-1 1 INP. PILOT
8
MAINS CONNECTOR
MAINS. VAC
MAINS. VAC
MAINS. EARTH
7654487-D-7
Diagram [7654487 D - LWI160.1056]
19 Wiring diagram

19
LORRY CHARGER BCU
[A31]
15A
[F3]
7 1 2 9
01-1 1 OUT. POSITIVE CHARGER VOLTAGE
40
01-1 2 OUT. NEGATIVE CHARGER VOLTAGE
19 Wiring diagram

X40 217
01-1
8
X40 120/WH
03-1 5 INP. CAN LOW
7
Diagram [7654487 D - LWI160.1056]
X40 119/RD
6
+ 1
DC INPUT BN
19 - 30
INPUT +24V DC
- 2 BU
INPUT 0V DC
MAINS CONNECTOR
MAINS. VAC
MAINS. VAC
MAINS. EARTH
7654487-D-8
EXTERNAL CHARGER
CHARGER CONNECTOR
X30 [X4]
7 +
01-1
40 -
01-1 -
19 - 31
X40 219 1
01-2
10
X40 220 2
01-2 11
X40 217 3
01-1
8
7654487-D-9
Diagram [7654487 D - LWI160.1056]
19 Wiring diagram

19
USB POWER SOCKET
[T9]
1
25
1 INP. +24VDC
36
2 INP. 0VDC
5A
[F52]
6
01-2
19 Wiring diagram

DC/DC 24/12
52
[T7]
SSR
25 X25 25 3 [K25] 1 53 T0 ENABLE
01-1 1 ENABLE
1
36 X25 36 4 2 53 53 53 T0 IN +
02-1 2 IN +24VDC OPTION
2
40 T0 IN -
Diagram [7654487 D - LWI160.1056]
3 IN 0VDC 12VDC OUTLET

[D1] 1
26 T0 OUT +
40 4 OUT +12VDC
01-1 T0 OUT -
41
OUT 0VDC
19 - 32
5
[X23]
DC/DC 24/24
[T8]
T0 53 ENABLE
1 ENABLE
53 T0 IN +
2 IN +24VDC OPTION
IN 0VDC
3
1
26 T0 OUT +
4 OUT +24VDC
41 T0 OUT -
OUT 0VDC
5
[X23] 1 Depending on configuration
7654487-D-10
OPTION MOTOR CONTROLLER
LOWER SPEED WHEN LOWERED FORKS [T12]
02-7
[B62]
24 1 2 74
02-1 94 INP. SUPPORT ARM, IN LOWEST POS.
3
40
01-1
19 - 33
7654487-D-11
Diagram [7654487 D - LWI160.1056]
19 Wiring diagram

19
19 Wiring diagram
Diagram [7654487 D - LWI160.1056]

Hydraulic diagrams 20
20.1 List of symbols ............................................................................................................................... 20 - 1
20.2 Component list............................................................................................................................... 20 - 3
20.3 Diagram ......................................................................................................................................... 20 - 4
20.3.1 Detailed diagrams ............................................................................................................. 20 - 5

20 Hydraulic diagrams

List of symbols
Software: 7662518
20
Hydraulic diagrams
20.1 List of symbols

20.1
List of symbols
The list explains the various symbols that are used in the hydraulic flow diagram.
Symbols
Symbol Description Symbol Description

Accumulator: Operational conduit
Operational conduit, connection Operational conduit, cross-opera-

tion
Needle valve (manual lowering Non-return valve 20

valve)
Non-return valve, spring-loaded Double-acting hydraulic cylinder

(hose rupture valve) with damper (reducer)
Electric motor and pump Single-acting hydraulic cylinder

With fixed displacement
Bi-directional flow
Single-acting hydraulic cylinder Filter

with purging

List of symbols

Flow control valve Hydraulic lock
Hydraulic motor Framing of two or more functions

concentrated in one single unit
With fixed displacement
Bi-directional flow
Counter-balance valve Counter balance valve (above

centre valve)
Air drier Back-pressure valve, with integ-

rated non-return valve
Pilot pipe PowerTrak
Proportional valve, controlled by Proportional valve, controlled by

solenoid solenoid
Proportional valve, controlled by Proportional valve, controlled by

solenoid solenoid
Proportional valve, auto-controlling Directional valve 2/2

of proportional type
Two ports
Two distinct positions
Controlled by solenoid

Component list

Directional valve 2/2 Directional valve 4/2
Two ports Two distinct positions
Draining Spring-back
Two distinct positions Controlled by solenoid
Directional valve 4/3 Directional valve 6/2
Four ports
Three distinct positions
Directional valve 6/3 Shuttle valve
Throttling Tank
20
Pressure limiting valve Pressure compensating valve,

closing action
Pressure sensor, analogue
20.2 Component list

20.2
Component list
Position Description
a Lift cylinder
b Magnetic valve, fork lowering
c Flow regulator valve
d Air filter
e Filter
f Tank
g Pump

Diagram
Position Description
M3 Pump motor
h Pressure limiting valve, max. 230 Bar
i Non-return valve
20.3 Diagram
20.3
Diagram

20.3.1
Detailed diagrams
Only for trucks with Power Link
20 - 5
[M]
b
i
Max 230 Bar
[M3]
d
g
e
f
Diagram

20
Diagram
256719-B-1

Tools 21
21.1 Tools for electric connectors.......................................................................................................... 21 - 1
21.1.1 AMP connectors................................................................................................................ 21 - 1
21.1.2 MQS connectors ............................................................................................................... 21 - 2
21.1.3 CPC connectors................................................................................................................ 21 - 3
21.1.4 AMP Seal connectors ....................................................................................................... 21 - 3
21.1.5 Molex connectors.............................................................................................................. 21 - 4
21.1.6 Super Seal connectors...................................................................................................... 21 - 4
21.2 Lubricating tool .............................................................................................................................. 21 - 5
21.3 Special tools .................................................................................................................................. 21 - 6

21 Tools

21 Tools
Tools for electric connectors
Software: 7662518
21 Tools
21
Tools
21.1 Tools for electric connectors

21.1
21.1.1 AMP connectors

21.1.1
AMP connectors
PT = Power Timer (4.8; 5.8; 6.3 mm).

JPT = Junior Power Timer (2.8 mm).
MPT = Micro Power Timer (1.5 mm).
Tools Number Usage

21
213296 Removal of pins/sleeves (JPT, PT)
213298 Removal of pins/sleeves (MPT)
1=163787 (JPT) Crimping sleeves

2=163788 (JPT)
1 1=213336 (MPT)
2 2=213337 (MPT)
1=213336 (JPT) Crimping 0.5-2.5mm² pins
2=213549 (JPT)
1
2

21 Tools
21.1.2 MQS connectors

21.1.2
MQS connectors
Tools Number Usage

257841 MQS Basic toolbox.
The box contains:
1 pair crimping pliers
1 pair stripping pliers
25x splicing sleeves 0.5–1.5 mm2
2x complete 2, 3, 4, 6, 8 and 12-pin
connectors (male and female) with
prewired cables and splicing
sleeves.
Please use to replace damaged
connectors on the truck.
257842 MQS refill box.

Use to refill the “MQS 257843
Complete toolbox”.
The refill box contains:
200x splicing sleeves 0.2–0.5 mm2
200x splicing sleeves SWS 0.2-0.5
mm2
400x splicing sleeves SWS
0.5-0.75 mm2
100x splicing sleeves "Clean body"
0.5-0.75 mm2
200x pins SWS 0.2–0.5 mm2 400x
pins SWS 0.5–0.75 mm2 1200x
seals
200x plugs and connectors
257843 MQS Complete toolbox.
The tool box contains four pli-
ers:
MQS SWS 0.25–0.5 mm2
MQS SWS 0.5-0.75 mm2
MQS Std&”Clean body” 0.25–0.5
mm2,
MQS Std&”Clean body” 0.5–0.75
mm2
Puller for 2, 3, 4, 6, 8 and 12-pin
male and female connectors.

21 Tools
21.1.3 CPC connectors

21.1.3
CPC connectors
Tools Number Usage

1=163787 Application of sleeve (CPC)
2=163788
1
2
183593 Removal of pins/sleeves (CPC)
21.1.4 AMP Seal connectors

21.1.4
AMP Seal connectors
21
Tools Number Use

1=261599 Application of sleeve
2=261600
1
2

21 Tools
21.1.5 Molex connectors

21.1.5
Molex connectors
Tools Number Usage

156936 Crimping tool for fitting sleeves/
pins
156937 Removal tool for pins/sleeves
21.1.6 Super Seal connectors

21.1.6
Super Seal connectors
Tools Number Usage

159232 Crimping tool for fitting sleeves/
pins

21 Tools
Lubricating tool
Tools Number Usage

159228 Removal tool for pins/sleeves
159229 Tool for removing lock
159230 Tool for fitting secondary locking,

1-2 pins
159231 Tool for fitting secondary locking,

3-6 pins
21.2 Lubricating tool

21.2
Lubricating tool
21
Tools Number Usage
24981 Tool with a pointed nozzle used to
apply grease. Length 170 mm.
202154PM Pointed nozzle for grease guns

used to apply grease in recessed
nipples. Fits grease guns with hose
and discharge pipe. Length 125
mm.
755132 Single-hand grease gun with

straight discharge pipe and nozzle.

21 Tools
Special tools
Tools Number Usage

755142 Two-handed grease gun with
angled discharge pipe and nozzle.
755152 Two-handed grease gun with hose

and nozzle.
755145 Lubricating hose 450 mm.

755140 Nozzle for necked nipples. Fits

grease guns with hose and dis-
charge pipe.
21.3 Special tools

21.3
Special tools
Tools No. Use Classification /

Inspection interval
Hydraulic pressure -/
219730
gauge (Manometer) -

21 Tools
Special tools

Inspection interval
Anti-static carpet
148115 Anti-static carpet with - /
armband and spiral -
cable.
PC to CAN cable
PC to CAN cable for -/
163793
programming in -
TruckCom.
21
CASTOR USB
7521083 Service instrument for - /
programming in -
TruckCom.
CAN key
-/
7516707 Used for for setting -
parameters

21 Tools
Special tools

Inspection interval
Charger CDU
Charging/discharging - /
7661401 unit for TMHMS Lith- -
ium-ion battery mod-
ule.
PC CAN cable
PC CAN cable for -/
7561869 connection to Li-Ion -
battery system via E-
box.
PC CAN cable
PC CAN cable for -/
7652381 connection to Li-Ion -
battery system via E-
box.
PC CAN cable
PC CAN cable for -/
7671692 connection to lithium- -
ion battery system
with E-box Lite.

21 Tools
Special tools

Inspection interval
19mm WEO insert re-

moval
Tool for the removing - /
7539594 of WEO connectors -
(female). With 1/2”
connector. Size: 19
mm / 1/4”.
23mm WEO insert re-

moval
connector. Size: 23 21
mm / 3/8”.
26mm WEO insert re-

moval
connector. Size: 23
mm / 1/2”.

21 Tools
Special tools

Inspection interval
Plug 10 mm /
1/4" (male)
Plug for quick change - /
254526
connectors type WEO -
(male).
Size: 19 mm / 1/4”.
Plug 13 mm /
3/8" (male)
254527
(male).
Size: 23 mm / 3/8".
Plug 16 mm /
1/2" (male)
Plug for quick change
-/
254528 connectors type WEO
-
(male). With 1/2” con-
nector.
Size: 26 mm / 1/2”.

21 Tools
Special tools

Inspection interval
Plug 10 mm / 1/4" (fe-

male)
254529
(female).
Size: 19 mm / 1/4”.
Plug 13 mm / 3/8" (fe-

male)
254530
(female).
Size: 23 mm / 3/8".
21
Plug 16 mm / 1/2" (fe-

male)
Plug for quick change
-/
254531 connectors type WEO
-
connector.
Size: 26 mm / 1/2”.

21 Tools
Special tools

Service data and grease specifica-
tions
22
22.1 General tightening torques ............................................................................................................ 22 - 1
22.1.1 Galvanised, non-oiled screws ........................................................................................... 22 - 1
22.1.2 Untreated, oiled screws .................................................................................................... 22 - 1
22.2 Lubricants specification ................................................................................................................. 22 - 2

Service data and grease specifica-
22 tions

22 Service data and grease specifications
General tightening torques
Software: 7662518
22
Service data and grease specifications
22.1 General tightening torques

22.1
General tightening torques
Millimetre threads M3 to M24. The following applies in the case of good conditions, e.g. steel against steel.
NOTICE General tightening torques

Experience has shown that if you adjust the torque wrench to the values for untreated bolts, you
will also get the correct torque value for galvanised bolts.
► Do not tighten more than the values indicated in the table; otherwise the bolts could be dam-
aged.
22.1.1 Galvanised, non-oiled screws

22.1.1
Galvanised, non-oiled screws
Dimension Strength class

8.8 10.9 12.9
M3 1.1 1.6 2.0
M4 2.8 3.8 4.7
M5 5.5 7.7 9.3
M6 9.5 13 16
M8 23 32 38
M10 45 62 76
M12 78 109 130
M14 123 174 208
22
M16 189 266 320
M20 370 519 623
M24 638 898 1075
Tightening torque ‘T’ (Nm)
22.1.2 Untreated, oiled screws

22.1.2
Untreated, oiled screws
Dimension Strength class

8.8 10.9 12.9
M3 1, 2 1.7 2.1
M4 2.9 4.0 4.9
M5 5.7 8.1 9.7
M6 9.8 14 17
M8 24 33 40
M10 47 65 79
M12 81 114 136
M14 128 181 217
M16 197 277 333
M20 385 541 649
M24 665 935 1120
Tightening torque ‘T’ (Nm)

Lubricants specification
22.2 Lubricants specification

22.2
Lubricants specification
Pos. Lubricant type Specification Usage

A Grease S213366, Q8 Rubens WB Bearings and
bushes
B Hydraulic oil See table below Hydraulic system
C Grease ESSO Unirex N2 Gears
D Grease See table below Chains
F Grease Gletmo 805 Beams, rib
F Grease Rembrandt EP2 Beams, flanges
Grease Q8 Rembrandt EP2 Mast
G Grease Staburags, NBU 8EP Steering bearings
Pos. Ambient temperature Viscosity class Usage

B 0°C - 40°C ISO VG 32 Hydraulic system
ISO 6743-4 category HM
DIN 51524 part 2 = HLP
B -35°C - 40°C ISO VG 27.5 Hydraulic system
ISO 6743-4 category HV
DIN 51524 part 3 = HVLP
Pos. Ambient temper- Viscosity class Recommended products*

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

Technical data 23
23.1 Truck Dimensions .......................................................................................................................... 23 - 1
23.2 Truck data...................................................................................................................................... 23 - 2

23 Technical data

23 Technical data
Truck Dimensions
Software: 7662518
23 Technical data
23
Technical data
23.1 Truck Dimensions

23.1
Truck Dimensions
The images show the outer dimensions of the truck with standard specifications.
h14
h14
h3
h23
s
h13
m2
m
y
l1
23
°
93
e
b10
b1
b5
b11
Wa
l2 l

23 Technical data
Truck data
23.2 Truck data

23.2
Truck data
Software: 7662518
Specifications LWI160
Brand name Toyota
1.2 Model LWI160
1.3 Drive unit Electric
1.4 Driving mode Walking
Identification
1.5 Lifting capacity Q kg 1600

1.6 Distance to centre of gravity c mm 600
1.8 Distance (raised forks for handling pallets), centre of x mm 922
support arm wheel to fork back
1.8 Distance (lowered forks), centre of support arm x mm 970
wheel to fork back
1.9 Wheelbase (raised forks for handling pallets) y mm 1192
1.9 Wheelbase (lowered forks) y mm 1240
2.1 Truck weight including battery kg 267
(weight)
Mass
2.2 Axle load, with load, drive/caster/fork wheels kg 578/61/1228

2.3 Axle load, without load, drive/caster/fork wheels kg 159/48/60
3.1 Drive/caster/fork wheels Vulkollan®/Polyurethane/Vulkollan®
3.2 Wheel size, front mm Ø 85
Wheels
3.3 Wheel size, rear mm Ø 230/96

3.5 Wheels, number front/rear (x=drive wheels) 1x + 2/2 or 4
3.6 Track, front b10 mm 502
3.7 Track width, rear b11 mm 370
4.4 Lifting h3 mm 125
Lifting height h23 mm 210
4.9 Tiller arm height in driving position, min/max h14 mm 865/1235
4.15 Height, lowered forks h13 mm 85
4.19 Total length l1 mm 1569
4.20 Length to fork back l2 mm 419
Dimensions
4.21 Overall width b1 mm 730

4.22 Fork dimensions s/e/l mm 50/180/1150
4.25 Width across fork b5 mm 550
4.32 Floor clearance, track centre m2 mm 33
4.33 Path requirements for pallet size 1000x1200, long Ast mm 2157
side handling
4.34 Path requirements for pallet size 800x1200, short Ast mm 2039
side handling
4.35 Turning radius (raised forks) Wa mm 1352
4.35 Turning radius (lowered forks) Wa mm 1400
5.1 Speed with/without load km/h 6/6
Performance
5.2 Lifting speed with/without load m/s 0.047/0.056

5.3 Lowering speed with/without load m/s 0.012/0.04
5.8 Max. gradient capability, with/without load % 10/18
5.9 Acceleration time without load (10 m) s 6.3
5.10 Travel brake Electromagnetic
6.1 Drive motor S2 @ 60 min kW 1.0
Electric motor
6.2 Lifting motor S3 15% kW 1.0

6.4 Battery voltage/nominal capacity K5 V/Ah 24/105
6.5 Battery weight kg 6.4
6.6 Energy consumption according to VDI cycle kWh/h 0.29
8.1 Type of steering device BT Powerdrive
Other
10.7 Sound pressure level, average value over time ac- dB(A) 59
cording to EN 12053 [dBA], margin of error 4 dB

24 Index
24 Index
24
Index
24

24 Index

Optimised Periodical Maintenance
LWI160
The OPM checklist below is intended as a support tool and does not replace the maintenance points specified in the table
in the “Periodic maintenance” section
F: C: I: O: T: Every Every Check- Service points
12 36 point from Mainten-
mths/1,0 mths/3,0 ance schedule
M: N:
00 h 00 h
Initial checks
1 F Steering, tiller arm X 1
2 F Function of the safety switch X 2
3 F Lifting, height limit X 3
4 F Horn X 4
5 F Emergency switch off X 5
Cleaning
◦ Raise the forks off the ground a little and switch off the truck.
◦ Disconnect or switch off the battery.
◦ Remove the service cover.
◦ Raise the truck onto blocks (x4).
6 C Cleaning the electrical compartment, drive motor, brake, etc. X 6, 7

7 C Cleaning the forks and fork wheels X 8
General checks
8 I Cracks or damage X 9
Battery
9 I Battery locking system X 10
Fork carriage
10 I Bushings, links, ball bearings and fork wheels X 11, 12
11 I Fork wheel thickness X 13
Motor compartment
12 O Oil leakage or damage to the drive unit or hydraulics X 14
13 I Any cracks or damage to the drive unit X 15
14 I Drive wheel condition X 16
15 T Drive wheel assembly X 17
16 I/F Castor wheel condition X 18, 19
17 M Parking brake X 20
18 I Steering motor and drive motor X 21
19 I Condition of main wiring harness and connectors X 22
◦ Position the truck on the floor and reconnect the battery.

◦ Lower the forks completely and release the hydraulic pressure.
◦ Disconnect the battery.
20 I Hydraulic oil and filters X 23, 24
◦ Connect the battery and start the truck.

Final checks
21 F Steering, tiller arm X 25
22 F/N Driving, action of service brake and parking brake X 26, 27
23 F Function of emergency brake (tiller arm up/down) and switch X 28
for safely reversing
24 F Lifting, height limit and lowering X 29
25 F Horn X 30
◦ Refit the service cover.
26 F Emergency stop X 31
27 I Signs and adhesive labels X 32
28 I Driving hours/service hours and reset X 33
29 I Inspecting fire extinguisher status X 34
TOYOTA Material Handling Group

Repair Manual 7660234 en

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Repair Manual 7660234 en

Uploaded by

Copyright:

Available Formats

Repair manual 7660234 en

Publication No.: 7660234-040

Repair manual 7660234 en

Repair manual 7660234 en

1.1 Images and other information .......................................................................................................... 1 - 1

1.2 How to use this manual ................................................................................................................... 1 - 1

1.3 Warning levels and symbols ............................................................................................................ 1 - 2

1.5 Abbreviations ................................................................................................................................... 1 - 3

Repair manual 7660234-040

Repair manual 7660234-040

1.1 Images and other information

1.2 How to use this manual

1-1 Repair manual 7660234 en

1.3 Warning levels and symbols

Used to attract attention and to give information about various actions.

Symbol Procedure Symbol Procedure

Check that screws, nuts, etc. are tightened

Listening for noise. Lubrication, application.

Check of functions. Calibration

An example of another type of pictogram is “Cut cable ties”:

Repair manual 7660234 en 1-2

Abbrevi- Meaning Explanation

1-3 Repair manual 7660234 en

Abbrevi- Meaning Explanation

Repair manual 7660234 en 1-4

2.1 Work safety...................................................................................................................................... 2 - 1

2.2 Authorised personnel....................................................................................................................... 2 - 2

2.3 Truck modifications.......................................................................................................................... 2 - 2

2.3.1 Responsible ........................................................................................................................ 2 - 2

2.3.2 What can be modified? ....................................................................................................... 2 - 2

2.4 Electrical system.............................................................................................................................. 2 - 4

2.4.1 Electrostatic risks ................................................................................................................ 2 - 4

2.4.2 Battery handling .................................................................................................................. 2 - 4

2.5 Safe lifting ........................................................................................................................................ 2 - 5

2.7 Hydraulic system ............................................................................................................................. 2 - 6

Repair manual 7660234-040

Repair manual 7660234-040

For safe work, always remember:

▷ Do not drive the truck in maintenance mode, as this entails risks.

▷ Keep all tools well maintained.

▷ The drive gear oil may be hot.

▷ Store and transport used oil in accordance with local regulations.

▷ Always disconnect the battery when performing welding work.

2-1 Repair manual 7660234 en

2.2 Authorised personnel

2.3 Truck modifications

2.3.2 What can be modified?

See the table below, types A, B and C.

Repair manual 7660234 en 2-2

Typ Description Examples of modifications

• Optional equipment, such as lamps, scales, scanners, writing pad

2-3 Repair manual 7660234 en

2.4 Electrical system

WARNING Short-circuiting/Burn injuries

When working on the electrical system:

▷ Use insulated tools.

▷ Never break the warranty seal on the electronic cards.

2.4.1 Electrostatic risks

▷ Use electrostatically protected footwear!

▷ Store electrostatically sensitive equipment in their protective packaging or on electrostatically protec-

▷ Use an antistatic surface: Anti-static carpet 148115, page 21 - 7.

2.4.2 Battery handling

When working on the battery, keep the following in mind: